Working Hydraulic - Xps

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Service manual

SUBGROUP - INDEX

Section Group Type

Overview of hydraulic symbols 060.005.1 R 920 - R 924

Colour code for lines in hydraulic schematics 060.007.1 R 920 - R 924

Description of the Positive Control system 060.010.1 R 920 - R 924

Description of the hydraulic system 060.100.1 R 920 - R 924

Components list 060.110.1 R 920 - R 924

Hydraulic schematic 060.120.1 R 920 - R 924

060.000.1

MJFCIFSS
Service manual

060.000.2
MJFCIFSS
Service manual Overview of hydraulic symbols

Overview of hydraulic symbols


Note!
See also the components list of the hydraulic schematic.

R 920 - R 924 060.005.1


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Overview of hydraulic symbols Service manual

060.005.2 R 920 - R 924


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Service manual Overview of hydraulic symbols

R 920 - R 924 060.005.3


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Overview of hydraulic symbols Service manual

Symbol Symbol designation Symbol Symbol designation

Quick coupling Pressure sensor


With two check valves, Analog output signal
uncoupled

060.005.4 R 920 - R 924


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Service manual Colour code for lines in hydraulic schematics

Colour code for lines in hydraulic schematics

Colour Line width Description

Thick or thin High pressure

Thick Tank channel

Thin Leak oil

Thin Replenishing pressure


or
servo pressure until pilot
control unit

Thin Control pressure


or
servo pressure from pilot
control unit

Thick Closed loop oil

Thick Working pressure

Thin Load Sensing pressure

R 920 - R 924 060.007.1


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Colour code for lines in hydraulic schematics Service manual

060.007.2 R 920 - R 924


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Service manual Description of the Positive Control system
Design

Description of the Positive Control system

1 Design

Fig. 1 Design

2010 Pump unit BXXX Pressure transmitter


3300 Servo pump YR5X Regulation solenoid valve
4XXX Pilot control unit Master Master module
5100 Control valve block Module CAN-module
5101 Primary pressure relief valve REG Pump regulator
6XXX User

Basic principle of a Positive Control system is to increase flow rate of working pumps when output
pressures of pilot control units increase.
During actuation of a pilot control unit 4XXX, its output pressure feeds the control valve block 5100
and works at the same time on a pressure transmitter BXXX.
This pressure transmitter informs the Master of the value of the control pressure.
The Master sends an output signal to the regulation solenoid valve YR5X. The latter generates a
control pressure sent to the pump regulator which changes the flow rate of the working pump.
At the control valve block 5100, the spool valve is moved proportionally to the control pressure.
Setting the Positive Control circuit allows a correlation between the flow rate of the pump unit 2010
and the opening of the spool valves of the control valve block 5100, which keeps the hydraulic
pressure losses in the circuit at a minimum value.
The valve 5101 limits the high pressure between the pump outlet and the control valve block
inlet 5100.

R 920 - R 924 060.010.1


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Description of the Positive Control system Service manual
Function

2 Function

The Positive Control system impacts the flow regulation (SD) and the power summation (SL) of each
working pump.

2.1 Flow regulation

Fig. 2 Flow regulation

1000 Diesel engine BXXX Pressure transmitter


2010 Pump unit Master Master module
2130 Regulator of pump P1 Module CAN-module
2230 Regulator of pump P2 PSD1 Flow regulation pressure on P1
3300 Servo pump PSD2 Flow regulation pressure on P2
3310 Servo oil unit Pst Servo pressure
4XXX Pilot control unit YR51 Regulation solenoid valve / flow
regulation P1 (SD1)
5100 Control valve block YR52 Regulation solenoid valve / flow
regulation P2 (SD2)
6XXX User

The Master transmits an electric signal to the solenoid valves YR51 and YR52 that depends on the
different pressures measured by the pressure transmitters BXXX.
The regulation solenoid valves YR51 and YR52 are pressure-reducing valves that let change the
regulation pressure according to the received electrical signal.
The flow regulation pressure supplied by YR51 (YR52) to the regulator of the pump P1 (P2) is called
PSD1 (PSD2).

060.010.2 R 920 - R 924


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Service manual Description of the Positive Control system
Function

This control pressure PSD1 (PSD2) defines the flow of the pump P1 (P2) during the feeding of the
different users (see 080.050 SL-SD regulator).

2.2 Power regulation

Fig. 3 Regulation by power summation

1000 Diesel engine 5100 Control valve block


2010 Pump unit 6XXX User
2130 Pump regulator of pump P1 A_CumminsEngine control unit
2230 Pump regulator of pump P2 Master Master module
3300 Servo pump PLR Power regulation pressure
3310 Servo oil unit Pst Servo pressure
4XXX Pilot control unit YR50 Power regulation solenoid valve

The engine control unit A_Cummins informs the Master of the instant engine speed. The Master
compares this value to the set value selected by the operator.
Difference between the two values shows the engine load.
The Master supplies an electric signal to the solenoid valve YR50, related to this difference.
The regulation solenoid valve YR50 is a pressure-reducing valve that let the regulation pressure
change according to the electrical signal received.
The output pressure supplied by YR50 to the regulator of the pumps P1 and P2 is called power
regulation pressure.
This regulation pressure PLR specifies the summation of the hydraulic pressures supplied by the
pumps P1 and P2 during the feeding of other users (see 080.050 Regulator SL - SD).

R 920 - R 924 060.010.3


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Description of the Positive Control system Service manual
Function

2.3 Piloting table

2.3.1 Legend
– L = left
– R = right
– FO = forwards
– BA = backwards
Concerned input
Possible input in case of combined movements
Concerned output

2.3.2 Inputs
– Inputs low pressure: from 7 -0,5 to 27,5 +2 bar, from 7.7 to 18.7 mA
– Inputs high pressure: from 0 to 380 bar, from 4 to 19.2 mA
– Input frequency: from 0 to 9.5 rpm, from 0 to 900 Hz

2.3.3 Outputs
– Pumps: from 9.5 to 26 bar, from 460 to 890 mA
– Spools: from 5.6 to 28 bar, from 350 to 750 mA

060.010.4 R 920 - R 924


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Service manual Description of the Positive Control system
Function

R 920 - R 924 060.010.5


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Description of the Positive Control system Service manual
Adjustment

3 Adjustment

(see 030 Adjustment protocol and guidelines)

060.010.6 R 920 - R 924


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Service manual Description of the hydraulic system

Description of the hydraulic system

1 Overview

Fig. 1 Overview

1000 Diesel engine


1500 Hydraulic tank
2010 Pump unit
3160 Fan motor
3170 Hydraulic oil cooler
3310 Servo oil unit
4850 Regulation solenoid valves block
5100 Control valve block
6100 Hoist cylinder
6200 Stick cylinder
6300 Bucket or grapple cylinder
6500 Slewing motor
6600 Travel motor left
6690 Travel gear left

R 920 - R 924 060.100.1


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Description of the hydraulic system Service manual

7100 Rotary connection / high pressure

2 Hydraulic tank 1500

Fig. 2 Hydraulic tank 1500

1510 Breather filter


1520 Return filter
1530 Leak oil filter
B8/B14 Control pressure transmitter / hydraulic oil temperature and level

060.100.2 R 920 - R 924


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Service manual Description of the hydraulic system

3 Hydraulic pumps

Fig. 3 Hydraulic pumps

2010 Pump unit


2130 Regulator complete
2230 Regulator complete
3300 Servo pump
M21 Measuring point / positioning pressure P1 (p pos1)
M22 Measuring point / positioning pressure P2 (p pos2)
M25 Measuring point / high pressure pump P1 (p HP1)
M26 Measuring point / high pressure pump P2 (p HP2)

R 920 - R 924 060.100.3


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Description of the hydraulic system Service manual
Hydraulic cooling system

4 Hydraulic cooling system

Fig. 4 Hydraulic cooling system

3100 Cooler fan pump

Fig. 5 Hydraulic cooling system

3160 Fan motor


3170 Hydraulic oil cooler
YR347 Regulation solenoid valve / cooler fan RPM

060.100.4 R 920 - R 924


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Service manual Description of the hydraulic system
Control oil system

5 Control oil system

5.1 Control oil unit 3310

Fig. 6 Control oil unit 3310

3311 Pressure-relief valve


3312 Servo oil filter
3314 Pressure accumulator
M33 Measuring point / servo pressure (pSt)
M34 Measuring point / flow limitation pressure P1 (p SD1)
M35 Measuring point / flow limitation pressure P2 (p SD2)
M39 Measuring point / power regulation pressure (p LR)
Y3 Solenoid valve / servo control
Y7 Solenoid valve / slewing brake
Y24 Solenoid valve / travel speed increase
YR50 Regulation solenoid valve / power regulation (LR)
YR51 Regulation solenoid valve / flow regulation P1 (SD1)
YR52 Regulation solenoid valve / flow regulation P2 (SD2)

R 920 - R 924 060.100.5


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Description of the hydraulic system Service manual

5.2 Operating elements in the cab

Fig. 7 Operating elements in the cab

4000 Pilot control unit / joystick left


4100 Pilot control unit / joystick right
4200 Pilot control unit / travel pedals
S7 Safety lever

060.100.6 R 920 - R 924


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Service manual Description of the hydraulic system

6 Control valve block entity

6.1 Regulation solenoid valves block 4850

Fig. 8 Regulation solenoid valves block 4850

4850 Regulation solenoid valves block


M91 Measuring point / travel straight
M92 Measuring point / summation stick cylinder
M93 Measuring point / Cut 2
M94 Measuring point / stick regeneration
M95 Measuring point / Cut 1
M96 Measuring point / summation hoist cylinders
M97 Measuring point / option
YR415 Regulation solenoid valve / straight travel
YR417 Regulation solenoid valve / Cut 1
YR418 Regulation solenoid valve / Cut 2
YR419 Regulation solenoid valve / summation stick cylinder
YR420 Regulation solenoid valve / summation hoist cylinder
YR421 Regulation solenoid valve / regeneration stick cylinder
YR421 Regulation solenoid valve / bypass stick cylinder

R 920 - R 924 060.100.7


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Description of the hydraulic system Service manual

6.2 Control valve block 5100

Fig. 9 Control valve block 5100

4850 Regulation solenoid valves block


5053 Spool / priority selection
5101 Primary pressure-relief valve
5104 Spool Cut 1
5106 Spool Cut 2
5113 Spool / hoist cylinders
5114 Summation piston for hoist cylinders
5121 Secondary pressure-relief valve / extending stick cylinder
5122 Secondary pressure-relief valve / retracting stick cylinder

060.100.8 R 920 - R 924


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Service manual Description of the hydraulic system

5123 Spool / stick cylinder


5124 Summation piston / stick cylinder
5128 Switching valve / cancellation of stick regeneration
5131 Secondary pressure-relief valve / extending bucket or grapple cylinder
5132 Secondary pressure-relief valve / retracting bucket or grapple cylinder
5133 Spool / bucket or grapple cylinder
5141 Secondary pressure relief valve / high pressure circuit 1
5142 Secondary pressure relief valve / high pressure circuit 1
5143 Spool / high pressure circuit 1
5153 Spool / slewing
5163 Spool / travel left
5173 Spool / travel right
5313 Spool / regeneration and bypass stick cylinder

Fig. 10 Control valve block 5100

B159 High pressure transmitter P1


B160 High pressure transmitter P2
B161 Control pressure transmitter / stick extension
B162 Control pressure transmitter / stick retraction
B163 Control pressure transmitter / boom up
B164 Control pressure transmitter / boom down
B165 Control pressure transmitter / bucket extension
B167 Control pressure transmitter / slewing left
B168 Control pressure transmitter / slewing right

R 920 - R 924 060.100.9


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Description of the hydraulic system Service manual

7 Hydraulic users

7.1 Working attachment

Fig. 11 Working attachment

6100 Hoist cylinder


6200 Stick cylinder
6300 Bucket or grapple cylinder
B190 High pressure transmitter / hoist cylinders piston side

7.2 Travel gear mechanism

Fig. 12 Travel gear mechanism

6600 Travel motor left


6690 Travel gear left

060.100.10 R 920 - R 924


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Service manual Description of the hydraulic system

6700 Travel motor right


6790 Travel gear right

7.3 Slewing gear mechanism

Fig. 13 Slewing gear mechanism

6500 Slewing motor


6502 Suction valve
6504 Secondary pressure relief valve / slewing left
6505 Secondary pressure relief valve / slewing right

R 920 - R 924 060.100.11


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Description of the hydraulic system Service manual
Hydraulic users

6510 Rotary group


6530 Drainage valve
6550 Slewing gear
6560 Slewing brake
6565 Valve / slewing brake valve
B53 RPM transmitter / slewing drive

7.4 Rotary connection 7100

Fig. 14 Rotary connection

060.100.12 R 920 - R 924


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Service manual Components list

Components list
Notice!
The arrangement of the main components of the hydraulic installation is detailed in the chapter
060.100.

Positions
1000 Diesel engine
1500 Hydraulic tank
1510 Breather filter
1520 Return filter
1521 Bypass valve
1530 Leak oil filter
1600 Distribution block / control pressure
1610 Collector / control pressure
1620 Collector / return oil
1621 Collector / return oil
2000 Pump distribution gear
2010 Pump unit
2108 Shuttle valve
2110 Rotary group P1
2120 Positioning piston
2130 Regulator complete
2150 Flow regulator SD
2170 Power summation regulator SL
2208 Shuttle valve
2210 Rotary group P2
2220 Positioning piston
2230 Regulator, complete
2250 Flow regulator SD
2270 Power summation regulator SL
3100 Cooler fan pump
3160 Fan motor
3161 Rotary group
3162 Suction valve
3170 Hydraulic oil cooler
3300 Servo pump
3310 Servo oil unit
3311 Pressure-relief valve
3312 Servo oil filter
3314 Pressure accumulator
4000 Pilot control unit / joystick left
4100 Pilot control unit / joystick right

R 920 - R 924 060.110.1


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Components list Service manual

Positions
4200 Pilot control unit / travel pedals
4850 Regulation solenoid valves block
5050 Input block
5051 Preload valve cooling circuit / port K
5052 Preload valve tank circuit / port T
5053 Spool / priority selection
5054 Check valve
5055 Check valve
5100 Control valve block
5101 Primary pressure-relief valve P1+P2
5104 Spool Cut1
5106 Spool Cut2
5111 Secondary pressure-relief valve / extending hoist
cylinders
5112 Secondary pressure-relief valve / retracting hoist
cylinders
5113 Spool / hoist cylinders
5114 Summation spool / hoist cylinders
5115 Throttle check valve / actuation of hoist cylinders
5116 Load holding valve / hoist cylinders
5117 Check valve / hoist cylinders summation
5118 Load holding valve / hoist cylinders
5121 Secondary pressure-relief valve / extending stick
cylinder
5122 Secondary pressure-relief valve / retracting stick
cylinder
5123 Spool / stick cylinder
5124 Summation spool / stick cylinder
5125 Throttle check valve / actuation of stick cylinder
5126 Load holding valve / stick cylinder
5127 Check valve / stick cylinder
5128 Switching valve / cancellation of stick regeneration
5129 Load holding valve / stick cylinder
5131 Secondary pressure-relief valve / extending bucket or
grapple cylinder
5132 Secondary pressure-relief valve / retracting bucket or
grapple cylinder
5133 Spool / bucket or grapple cylinder
5136 Load holding valve / bucket or grapple cylinder
5138 Load holding valve / bucket or grapple cylinder
5141 Secondary pressure relief valve / high pressure
circuit 1
5142 Secondary pressure relief valve / high pressure
circuit 1

060.110.2 R 920 - R 924


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Service manual Components list

Positions
5143 Spool / high pressure circuit 1
5146 Load holding valve / high pressure circuit 1
5153 Spool / slewing
5155 Throttle check valve / actuation of slewing
5156 Load holding valve / slewing
5163 Spool / travel left
5165 Throttle check valve / actuation of travel left
5173 Spool / travel right
5175 Throttle check valve / actuation of travel right
5300 Additional block
5313 Spool / regeneration and bypass stick cylinder
6100 Hoist cylinder
6200 Stick cylinder
6300 Bucket or grapple cylinder
6500 Slewing motor
6502 Suction valve
6503 Suction valve
6504 Secondary pressure relief valve / slewing left
6505 Secondary pressure relief valve / slewing right
6510 Rotary group
6530 Drainage valve
6550 Slewing gear
6560 Slewing brake
6565 Valve / slewing brake valve
6600 Travel motor left
6604 Secondary pressure-relief valve / travel left forward
6605 Secondary pressure-relief valve / travel left backward
6610 Rotary group
6620 Positioning piston / maximum motor displacement
6625 Positioning piston / minimum motor displacement
6630 Switching valve / motor displacement
6660 Hydraulic braking piston
6670 Shuttle valve
6675 Switching valve
6680 Pressure reduction valve
6690 Travel gear left
6692 Travel brake left
6700 Travel motor right
6704 Secondary pressure-relief valve / travel right forward
6705 Secondary pressure-relief valve / travel right backward
6710 Rotary group
6720 Positioning piston / maximum motor displacement

R 920 - R 924 060.110.3


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Components list Service manual

Positions
6725 Positioning piston / minimum motor displacement
6730 Switching valve / motor displacement
6760 Hydraulic braking piston
6770 Shuttle valve
6775 Switching valve
6780 Pressure reduction valve
6790 Travel gear right
6792 Travel brake right
7100 Rotary connection / high pressure

B159 High pressure transmitter P1


B160 High pressure transmitter P2
B161 Control pressure transmitter / stick extension
B162 Control pressure transmitter / stick retraction
B163 Control pressure transmitter / boom up
B164 Control pressure transmitter / boom down
B165 Control pressure transmitter / movement bucket
B167 Control pressure transmitter / slewing left
B168 Control pressure transmitter / slewing right
B170 Control pressure transmitter / travel left
B171 Control pressure transmitter / travel right
B190 High pressure transmitter / hoist cylinders piston side

M21 Measuring point / positioning pressure P1 (p pos1)


M22 Measuring point / positioning pressure P2 (p pos2)
M25 Measuring point / high pressure pump P1 (p HP1)
M26 Measuring point / high pressure pump P2 (p HP2)
M31 Measuring point / fan drive 1
M33 Measuring point / servo pressure (p St )
M34 Measuring point / flow limitation pressure P1 (p SD1)
M35 Measuring point / flow limitation pressure P2 (p SD2)
M39 Measuring point / power regulation pressure (p LR)
M91 Measuring point / travel straight
M92 Measuring point / summation stick cylinder
M93 Measuring point / Cut 2
M94 Measuring point / stick regeneration
M95 Measuring point / Cut 1
M96 Measuring point / summation hoist cylinders
M97 Measuring point / option
M3160 Measuring point / fan motor

060.110.4 R 920 - R 924


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Service manual Components list

Positions
Y3 Solenoid valve / servo control
Y7 Solenoid valve / slewing brake
Y24 Solenoid valve / travel speed increase
Y50 Regulation solenoid valve / pumps power (LR)
Y51 Regulation solenoid valve / flow regulation P1 (SD1)
Y52 Regulation solenoid valve / flow regulation P2 (SD2)
Y347 Regulation solenoid valve / cooler fan RPM
Y415 Regulation solenoid valve / straight travel
Y417 Regulation solenoid valve / Cut 1
Y418 Regulation solenoid valve / Cut 2
Y419 Regulation solenoid valve / summation stick cylinder
Y420 Regulation solenoid valve / summation hoist cylinders
Y421 Regulation solenoid valve / regeneration stick cylinder
Y450 Regulation solenoid valve / bypass stick cylinder

R 920 - R 924 060.110.5


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Components list Service manual

060.110.6 R 920 - R 924


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M39

M34

M35

0,8 mm
0,8 mm

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