DF05 - J06 - Electro Hydraulic - Agrovector 29.6 29.6Lp 35.7

CENTRO ADDESTRAMENTO TECNICO 2009-2010
TECHNICAL TRAINING CENTRE PHONE: +39/0363/421.486

CENTRE DE FORMATION SAME DEUTZ–FAHR ITALIA FAX: +39/0363/423.486
Electro - Hydraulic System

29.6 - 29.6LP & 35.7
DF05_J06_ Updated: 18- January - 2010
1
Hydraulic tank
1)Increased capacity = 120 lts..
2)Larger top opening for improved access.
3)Removable inner baffle plate.
4)Cleaned and treated in production
REMOVABLE BAFFLE
PLATE
REMOVABLE BAFFLE
PLATE
2
Two versions of hydraulic system

GEAR PUMP VERSION
P/N 0.900.1305.9 LS type

CONTROL VALVE with
DUMP VALVE
PISTON PUMP VERSION
P/N 0.900.1308.2 LS type CONTROL VALVE

3
Two types of main valve block
TELESCOPIC
TILT + COMP.
EXIT BLOCK
AUXILIARY
INLET BLOCK
BOOM LIFT
GEAR PUMP VERSION: 0.900.1305.9
PISTON PUMP VERSION: 0.900.1308.2
4
Main valve block– Schematics Gear pump version
INLET BOOM LIFT AUX TELE EXIT

TILT
BLOCK BLOCK
5
Main valve block– Schematics Piston pump version
INLET BLOCK BOOM LIFT TILT AUX TELE
6
GEAR PUMP
VERSION
7
Implement pump – GEAR
Casappa Pump 45cc

1
4
3 Delivery port
3
4 Suction port
4 3
8
Oil supply to control valve
9
Main control valve – Inlet block
LS relief
Steering priority valve
LS Bleed
10
Main control valve ( GEAR PUMP ) – Inlet block connections

PORT D – Oil supply to
steer orbital unit ( after
PRIORITY valve) PORT LS –
pressure port
fitted T
PORT T – Oil return

to tank
PORT P - Oil delivery

from implement pump
P
PORT DLS – LS signal

from steer orbital unit
PORT M – Pressure gauge
M
11
Main control valve (GEAR PUMP) Steer priority valve

LS Relief
L.S. Bleed
T
P
D
M
Priority valve spool
12
Main control valve – LS Bleed
After controls have returned to

neutral, the residual pressure in
the LS line, is quickly discharged
through the calibrated orifice of
the LS bleed valve.
13
Main control valve – LS relief
When pressure in the LS line

reaches 2 bar , LS relief valve
opens to tank, limiting the max
pressure in the system.
14
Main control valve – Spool section

SPOOL
COMPENSATOR
SPOOL
15
Main control valve – Compensated flow

2 simultaneous movements: M1 and M2 ; M1 is demanding more pressure than M2 ( P1 is higher than P2)
M2 P2 M1
P1
P1 Higher than P2
Q1 Higher than Q2
Q = Flow ( lts/min)
P = Pressure ( bar )
PILOT PRESSURE LS
LOW PRESSURE
HIGH PRESSURE
16
Main control valve ( GEAR PUMP) – End block DUMP

VALVE
17
Main control valve – operation of dump valve

( only Gear pump )
With controls and spools in neutral position, When a spool is moved as a consequence of a
the dump valve opens as a consequence of the commanded movement, the pilot pressure in
stand by pressure ( at least 22 bar needed ) in the LS line, locks the dump valve in closed
the system and dumps oil to tank. The control position. Oil is therefore available for the
valve works as an open center. function.
18
LS relief pressure – Dump valve function
M = 250 bar
LS = 225 bar
LS relief valve limiting

the LS pressure LS line LS port P ( bar ) = 225
P line main pressure M port P ( bar ) = 250
T return to tank Dump valve balanced opens
passage to tank.
19
Main control valve - Exit block
DUMP VALVE
20
Main control valve (GEAR PUMP) – End block connections
IMPORTANT NOTE: In
absence of CHARGE
pressure servo controls
are non operational !!!
PORT Pr – CHARGE pressure from G port hydrostatic pump
To Pr
Tpr
Pr PORT Tpr –
Pilot oil
G port TANK
return to
tank
Hydrostatic pump 21
Pressure check points (Gear pump)
Located on main control valve. Accessible from rear

chassis opening.
PORT D
MAIN
IMPLEMENT
+ STEERING
PRESSURE
PORT M
PORT LS
22
PISTON PUMP
VERSION
23
Implement pump - LS
LS Pilot
SUCTION
DELIVERY
CASE DRAIN
PUMP CONNECTIONS
45 cc Max displacement
24
Main control valve (PISTON PUMP) – Inlet block connections

PORT D – Oil supply to
steer orbital unit ( after
PRIORITY valve) PORT LS –
connected to
port X on T
Piston pump
PORT T – Oil return

to tank
PORT P - Oil
delivery from
implement P
pump
PORT DLS – LS signal

from steer orbital unit
PORT M – Pressure gauge
M
25
Main control valve – LS Bleed
After controls have returned to

neutral, the residual pressure in
the LS line, is quickly discharged
through the calibrated orifice of
the LS bleed valve.
26
Main control valve (PISTON PUMP) – Steer priority valve
LS Relief
L.S. Bleed
T
P
D
M
Priority valve spool
27
Main control valve – LS relief
When pressure in the LS line

reaches 2 bar , LS relief valve
opens to tank, limiting the max
pressure in the system.
28
Main control valve ( PISTON PUMP) – End block connections

IMPORTANT NOTE: In
absence of CHARGE
pressure servo controls
are non operational !!!
PORT Pr – CHARGE pressure from G port hydrostatic pump
To Pr
Tpr
Pr PORT Tpr –
Pilot oil
G port TANK
return to
tank
29
Pressure check points (Piston pump)

Located on main control valve. Accessible from rear
chassis opening.
MAIN
IMPLEMENT
+ STEERING
PRESSURE
PORT M
PORT LS
30
Main return line and filter

Filter
Breather
Return Filter
31
Hydraulic return filter
Filter breather
32
Hydraulic filter clogging indicator switch

ERROR CODE
2332 -
HYDRAULIC
FILTER
RESTRICTION
UGM
J2(24)
Normally the contacts of the switch are closed ( Input is grounded) to indicate filter is
clean. When the filter differential pressure rises above 1,2 bar the pressure switch
contact will open indicating a filter restriction.
33
ELECTRO
HYDRAULIC
SYSTEM
34
Joystick
P/N 0.900.1321.4
+
XG ( 8 )
Power from fuse F22 After ignition
J7 CAN 1
35
Joystick switches
AUXILIARY ELECTRIC
AUXILIARY SWITCH
CONTINOUS
36
Servo controls electric circuit
X2
37
Servo controls
MAX CURRENT : 1.7 A ( 1700 mA)
Coil resistance at 20°C = 3.5 Ohms
Integrated protection diode = NONE
38
Lift Cylinder
39
P Return
Lift Up
2)
DIAGNOSTICS / CABIN FUNCTIONS /

)
(
11
J3
MAIN LIFT COMMANDED: 1500 mA

(
J2
MAIN LIFT ACTUAL :1500 mA
UGM
CAN - BUS
JOYSTICK
40
2)
Lift Down
(
J3
)
22
(
J2

UGM MAIN LIFT COMMANDED: 1500 mA
MAIN LIFT ACTUAL:1500 mA
CAN - BUS
JOYSTICK P Return
41
Boom angle sensor
Lowest position Highest position
42
Boom angle sensor installation 29.6
43
Boom angle sensor installation 35.7
44
Telescopic cylinder
45
JOYSTICK Telescopic extend
CAN - BUS
UGM
)
4)
35
(
J3
(
J2

TELESCOPE COMMANDED: 1500 mA
TELESCOPE ACTUAL :1500 mA
P Return
46
P Return
Telescopic retract
TELESCOPE COMMANDED: 1500 mA
TELESCOPE ACTUAL :1500 mA
4)
(
J3
)
34
(
J2
UGM
CAN - BUS
47
JOYSTICK
Tilt Up
CAN - BUS
COMP
CYLINDER
DIAGNOSTICS / CABIN
FUNCTIONS /
TILT COMMANDED: 1500 mA
TILT ACTUAL:1500 mA TILT
CYLINDER
UGM
8)
6)
(
J2
(
J3
P Return
48
JOYSTICK
Tilt Down
CAN - BUS COMP
CYLINDER
DIAGNOSTICS / CABIN
FUNCTIONS /
TILT COMMANDED: 1500 mA
TILT ACTUAL:1500 mA
TILT
CYLINDER
UGM
6)
)
19
(
J3
(
J2
P Return
49
Compensation circuit
Kg
0 Degrees
Kg
0 Degrees
COMPENSATION
Compensation cylinder on side of boom connected to tilt cylinder through main control valve,
works to maintain level of forks all along the boom lift and lower arc.
50
Compensation cylinder
Improved boom hinge fixation. Two
bolts on a mobile plate. Fixation moved
on right side of boom ( opposite to the
compensation cylinder.
One compensation cylinder on left side of boom.
51
Anti kick valve
Anti kick valve helps to reduce stress on boom

base while the tilt circuit is operating at high
pressure ( example = bucket work ).
52
Compensation – Boom Lift Up
Boom Lift Up results in the

Comp cylinder extending, there
fore pressurizing its rod side.
Oil is transferred to the TILT cylinder

rod side, resulting in the same to
retract ( TILT DOWN).
Lines connected to Port A2 on main control

valve are pressurized. TILT Spool remains in
neutral position ( closing A2 and B2 ports).
Overpressure is discharged through port relief
valve set at 280 bar.
53
Port relief valve A2
Pressure relief at 280 bar
54
Compensation – Boom Lift Down
Boom Lift Down results in the

Comp cylinder retracting, there
fore pressurizing its piston side.
Oil is transferred to the TILT cylinder

piston side, resulting in the same to
extend ( TILT UP).
Lines connected to Port B2 on main control

valve are pressurized. TILT Spool remains in
neutral position ( closing A2 and B2 ports).
Overpressure is discharged through port relief
valve set at 280 bar.
55
Port relief valve B2
Pressure relief at 280 bar
56
Operation of the anti kick valve

TILT CYLINDER
COMPENSATION
ANTI KICK CYLINDER
VALVE
During heavy bucket work, pressure in the piston side of the tilt cylinder operates almost
constantly to the maximum spec ( 250 bar ) with possible peaks of higher pressure. The Anti
kick valve isolates the piston side of the COMPENSATION cylinder in order to reduce stress
transferred to the boom base.
57
Operation of the Anti kick valve_2

TILT CYLINDER BOOM LIFT UP
COMPENSATION
ANTI KICK CYLINDER
VALVE
Example shows compensation circuit at work when the boom is LIFT UP. The anti kick
valve is piloted open to allow flow of oil from the tilt cylinder piston side to the
compensation cylinder piston side.
58
Front auxiliary
CLOSE CENTER FUNCTION. When

command is released, residual
pressure can be discharged by
using the CONTINOUS AUXILIARY
SWITCH ( see next page).
2nd auxiliary hydraulic + electric

( Option ) shown here.
59
JOYSTICK Aux B
CAN - BUS DIAGNOSTICS / CABIN FUNCTIONS /

AUXILIARY COMMANDED: 1500 mA
AUXILIARY ACTUAL:1500 mA
UGM
)
14
(
)
J3
20
(
J2
P Return
60
JOYSTICK
Aux A
CAN - BUS
AUXILIARY COMMANDED: 1500 mA
AUXILIARY ACTUAL:1500 mA
UGM
)
14
(
9)
J3
(
J2
P Return
61
Auxiliary residual pressure dump

In order to dump any residual pressure trapped in the auxiliary lines, the operator has to:
-Push and release two times the shown switch
-Then push and hold for at least 30 seconds until the pressure is released.
• IMPORTANT: Engine must be running
P (Bar)
250
T ( sec)
HOLD
Minimum 30 seconds
PUSH Release PUSH Release PUSH Release

62
STEERING
63
Orbital – steering pump

ORBITAL CONNECTIONS
LS Pilot line to DLS

port on entry block
From priority valve – Entry

block port D
Steering pressure switch Return to tank
Left Right
L R
Bar 170
+/- 10
P
T
R
L
P T
64
Steer pressure switch

ERROR CODE - 8638 –
LOW STEER PRESSURE
Steer pressure J1(35)

switch Setting
5 Bar
Under normal conditions pressure switch contact is closed ( input is grounded).

If steer pressure drops below 5 bar, contact will open, indicating low steer pressure.
65
Steering priority valve
Steering priority
valve
66
Delivery to port P of Steering orbitrol unit
Pilot signal
form
Orbitrol
Less than Less than

12 bar 12 bar
Pilot signal to pump
Phase 1 –
Delivery from
LS PUMP
engine starting – no
steering
67
Pilot signal
form
Orbitrol
12 bar 20 bar
Phase 2 –
Delivery from
LS PUMP
engine started – no steering -
stand by pressure
68
Pilot signal
form
Orbitrol
P= More
P – 12 bar than 20 bar
Delivery from
LS PUMP
Phase 3 – boom movement

69
Pilot signal
form
Orbitrol
More than More than

20 bar 20 bar
Delivery from
LS PUMP Phase 4 - steering
70
Steer select valve
71
2 Wheel steer
72
4 Wheel steer
73
Crab Steer
74
Complete hydraulic schematics – Gear pump
DWG.1001109615
75
Complete hydraulic schematics – Piston pump
DWG.1001110010
76
PRESSURE
CHECKS AND
ADJUSTMENTS
77
Stand by pressure check ( GEAR PUMP )

1) Fit 0- 40 bar range pressure gauge fitted on port M of main control valve.
When controls are left in NEUTRAL,

DUMP VALVE begins to open at 20-22
bar allowing oil flow to tank.
Port M
2) Start engine, low idle, all controls in NEUTRAL.
3) Pressure should be 20-22 bar

DUMP
VALVE
MAIN CONTROL VALVE

78
Stand by pressure check ( PISTON PUMP)

1) Fit 0-40 bar range pressure gauge fitted on port M of main control valve
This valve block is NOT fitted

28-30 bar with a dump valve, therefore
the circuit is closed ( closed
center spools)
Port M
2) Start engine, low idle, all controls in NEUTRAL.
3) Pressure should be 28- 30 bar
Stand by pressure can be adjusted

here. Turn clockwise to increase MAIN CONTROL VALVE
pressure.
79
Max Implement pressure check (GEAR & PISTON PUMP)

1) Connect a 0- 600 bar range pressure gauge to port M of Main control valve.
2) Start engine, low idle, in this example, engaging TELE IN function to end stroke.
3) Max pressure should be 260 bar.
To LIFT cylinder
Port M
PUMP
MAIN CONTROL VALVE

LS Relief valve
80
Max steer pressure check ( GEAR & PISTON PUMP)

1) Connect gauge on port D, Engine running , low idle, leave joystick controls in NEUTRAL,
activate steering full stroke.
NOTE: 2WS mode shown here.
180 - 190 bar
MAIN
CONTROL
STEER ORBITAL
VALVE
UNIT PRIORITY
VALVE
PUMP
81
RESUME OF PRESSURE CHECKS

Valid only for GEAR pump version.
Engine =
DEUTZ Low Idle speed = 950 rpm High Idle speed = 2350 rpm
TCD2012
HYDRAULIC PRESSURE READINGS ( Bar )
Low Idle Neutral High Idle Neutral Steer to end stroke Low Idle Steer to end stroke High Idle Tele IN Low Idle Tele IN High Idle
Port M 22 29 185 194 250 250
Port D 18 18.5 180 180 21 22
Port LS 5.5 6 168 168 225 225
D
LS
M
Ports M & D Port LS
Use 0- 40 bar gauge for pressure checks in NEUTRAL.

Change to 0- 600 bar gauge for checks while commanding a function.
Alternatively use a digital pressure gauge ( 0- 700 bar range).
82
RESUME OF PRESSURE CHECKS

Valid only for PISTON pump version.
Engine =
DEUTZ Low Idle speed = 950 rpm High Idle speed = 2350 rpm
TCD2012
HYDRAULIC PRESSURE READINGS ( Bar )
Low Idle Neutral High Idle Neutral Steer to end stroke Low Idle Steer to end stroke High Idle Tele IN Low Idle Tele IN High Idle
Port M 28-30 28-30 200 200 260 260
Port D 20-22 20-22 190 190 20-22 20-22
Port LS 8-9 8-9 175 175 240 240
D
LS
M
Ports M & D Port LS
Use 0- 40 bar gauge for pressure checks in NEUTRAL.

Change to 0- 600 bar gauge for checks while commanding a function.
Alternatively use a digital pressure gauge ( 0- 700 bar range).
83
HYDRAULIC STALL TEST

1) Start engine, accelerate to high idle ( 2350 rpm).
2) Stall each hydraulic function (end stroke) and note the engine
rpm drop.
3) Compare the results to the standard.
GEAR PUMP VERSION PISTON PUMP VERSION
Hydraulic stall test Hydraulic stall test

Throttle set ( rpm ) Throttle set ( rpm )
Function STD Function STD
NEUTRAL 2350 NEUTRAL 2350
Boom lift up 2300 Boom lift up 2325
Boom lift down 2250 Boom lift down 2325
Tele in 2250 Tele in 2325
Tele out 2250 Tele out 2325
Combined Tele in + Boom lift down 2250 Combined Tele in + Boom lift down 2325
Combined Tele out + Boom lift up 2250 Combined Tele out + Boom lift up 2325
Tilt up 2250 Tilt up 2325
Tilt down 2250 Tilt down 2325
Aux A 2250 Aux A 2325
Aux B 2250 Aux B 2325
Steer left 2WS 2275 Steer left 2WS 2325
Steer right 2WS 2275 Steer right 2WS 2325
Steer left 4WS 2275 Steer left 4WS 2325
84

DF05 - J06 - Electro Hydraulic - Agrovector 29.6 29.6Lp 35.7

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DF05 - J06 - Electro Hydraulic - Agrovector 29.6 29.6Lp 35.7

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Available Formats

CENTRO ADDESTRAMENTO TECNICO 2009-2010

TECHNICAL TRAINING CENTRE PHONE: +39/0363/421.486

Electro - Hydraulic System

DF05_J06_ Updated: 18- January - 2010

Two versions of hydraulic system

P/N 0.900.1305.9 LS type

PISTON PUMP VERSION

P/N 0.900.1308.2 LS type CONTROL VALVE

Two types of main valve block

PISTON PUMP VERSION: 0.900.1308.2

Main valve block– Schematics Gear pump version

INLET BOOM LIFT AUX TELE EXIT

Main valve block– Schematics Piston pump version

INLET BLOCK BOOM LIFT TILT AUX TELE

Implement pump – GEAR

Casappa Pump 45cc

Oil supply to control valve

Main control valve – Inlet block

Steering priority valve

Main control valve ( GEAR PUMP ) – Inlet block connections

PORT T – Oil return

PORT P - Oil delivery

PORT DLS – LS signal

PORT M – Pressure gauge

Main control valve (GEAR PUMP) Steer priority valve

Priority valve spool

Main control valve – LS Bleed

After controls have returned to

Main control valve – LS relief

When pressure in the LS line

Main control valve – Spool section

Main control valve – Compensated flow

Main control valve ( GEAR PUMP) – End block DUMP

Main control valve – operation of dump valve

LS relief pressure – Dump valve function

LS relief valve limiting

Main control valve - Exit block

Main control valve (GEAR PUMP) – End block connections

PORT Pr – CHARGE pressure from G port hydrostatic pump

Pressure check points (Gear pump)

Located on main control valve. Accessible from rear

Main control valve (PISTON PUMP) – Inlet block connections

PORT T – Oil return

PORT DLS – LS signal

PORT M – Pressure gauge

Main control valve – LS Bleed

After controls have returned to

Main control valve (PISTON PUMP) – Steer priority valve

Priority valve spool

Main control valve – LS relief

When pressure in the LS line

Main control valve ( PISTON PUMP) – End block connections

PORT Pr – CHARGE pressure from G port hydrostatic pump

Pressure check points (Piston pump)

Main return line and filter

Hydraulic return filter

Hydraulic filter clogging indicator switch

Power from fuse F22 After ignition