section 6 - timberpro inca11vlo series 40 hydraulic pump. this is a variable displacement piston...

Implement Circuit - General6.1.1Form T011

Section 6.1

Implement Circuit - General System

General: Implement Circuit .............................. 6.1.3

Implement Pump Breakdown ................. 6.1.4

Operational Description: General ............................................. 6.1.5 Compensator Control ........................ 6.1.6 Standby Condition............................. 6.1.6 On-Stroke Condition ......................... 6.1.7 Pressure Compensation ................... 6.1.8

Implement Control Valve: Description ........................................ 6.1.9 LS90 Operation ................................. 6.1.9 L90LS Valve Cross-Section .............. 6.1.10 K220 Valve Cross-Section ................ 6.1.11

Operational Description: Swing System .............................. 6.1.5

Implement Circuit - General 6.1.2 Form T011

Trac

k M

achi

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Impl

emen

t Circ

uit

CA

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EVEL

CA

B L

EVEL

LATE

RA

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LT

AC

CU

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CLA

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1 3 5 7 9 11 13 15

2 4 6 8 10 12 14

Low

er F

ram

e

12

Figure 1: Simplified Implement Circuit Diagram (Typical)

T0892


General - Configurations (See Figure 1)

The TimberPro implement circuit is a “closed center” hydraulic system.

The system uses state-of-the-art components such as a load sensing axial piston pump, radial piston motors, and pressure compensated (electric-controlled-pilot operated) control valves.

The main components in the system are:

1) 60 gal. (227 litre) hydraulic oil tank for storage and cooling of the hydraulic oil. See Section 3.2 in this manual for important information on the hydraulic tank and its components.

2) 100-mesh implement suction strainer w/magnetic stem.

3) Suction line shut-off valve.

4) Rexroth AA11VO145 95 gpm (360 litres) variable displacement axial piston implement pump with pressure flow compensating capabilities.

5) VOAC main control valve with load sensing and flow compensation capabilities. All sections are electric-controlled-pilot operated.

6) Load sense orifice (.024). This orfice is located in the #6 connector turned into the “PL” port on the mid inlet section of the control valve.

7) High pressure, double acting cylinders

8) 15-port rotary manifold for 360° continuous rotation swing. In the implement circuit it provides the hydraulic link to the steer cylinders located in the rear frame.

9) Rexroth AA2FE series fixed displacement, bi-directional, piston motor mated to a Lohamnn GFB-72 planetary reduction gearbox with a wet mult-disc brake.

10) 130 psi (1,03 Mpa) return line check valve. To create back pressure in the system. This check valve is located inside the end cap of the Voac control valve.

11) High capacity oil cooler with a 120°-140°F (49°-60°C) thermal bypass and 50 psi (3,45 kPa) back pressure bypass.

12) Return and case drain filters in the hydraulic tank. See Section 3.2 in this manual for important information on the hydraulic tank and its components.

13) Fixed displacement, bi-directional, gear motors that turn the cooling fans for the engine radiator and hydraulic oil cooler. This motor also has built in valving to control fan speed and fan reversing.

14) Charge and Fan Drive Manifold. This manifold is supplied oil from the charge pump and regulates and filters the charge oil being supplied to the track drive pump.

15) Charge pump piggy-back mounted to the implement pump. The charge pump is a 52cc gear pump that supplies oil to the wheel drive pump charge circuit and supplies oil for the radiator and cooler fan.

16) Rexroth variable displacement, over-center, axial piston swing pump.


Figure 3: Implement Pump Breakdown

00702

“P” Pressure Manifold (Connection for “P” port pressure to control valve

& optional clam bunk, and mono-block brake

manifold)

Suction Inlet

Case Drain

Rexroth Series 40 Pump

Pump Compensator

POR Pressure Adjustment

Standby Pressure Adjustment

Load Sense From Valve


Operational Description GeneralThe implement hydraulic system uses a Rexroth A11VLO Series 40 hydraulic pump. This is a variable displacement piston pump with L4 – Power controller / electric-proportional override.

Compensator Control (See Figure 4)

The compensator control has three main oil galleries that connect to the pump at its mounting base. The first gallery vents to tank via the pump case. The second gallery connects to the pump’s large control piston. The third gallery is the “P” pressure connection. “P” pressure is the pressure seen at the outlet of the pump and at the pumps’ small control piston (bias stem).

Inside the compensator control are two spools; stand-by, and pressure limiting,.

Each spool has a mechanical spring force applied at one end. The amount of spring force can be changed by turning an adjustment setscrew IN or OUT to preload the spring. Turning the adjustment screw IN increases spring preload, requiring more force at the opposite end of the spool to overcome the spring. Turning the adjustment screw OUT decreases spring preload, requiring less force at the opposite end of the spool to overcome the spring.

Both spools are open on the opposite end to “P” pressure. “P” pressure” provides the hydraulic force used to overcome the mechanical spring force.

Figure 4: Pump Compensator Control

00705

Load Sense From Valve


Figure 5: Implement Pump Compensator Control - Standby Condition

00706

Sta

ndby

Con

ditio

nW

hen

all f

unct

ions

are

in n

eutra

l, oi

l flo

w t

o th

e m

ain

cont

rol v

alve

por

t “P

” is

bloc

ked.

In

this

“pum

p st

andb

y”

cond

ition

“P” p

ress

ure

on o

ne s

ide

of th

e st

andb

y (lo

ad

sens

ing)

spo

ol o

verc

omes

the

mec

hani

cal s

prin

g fo

rce

on th

e ot

her s

ide

of th

e sp

ool.

Thi

s fo

rces

the

spoo

l to

shift

thu

s al

low

ing

“P”

pres

sure

pas

t th

e sp

ool t

o th

e la

rge

cont

rol p

isto

n. T

he p

ress

ure

on th

e la

rge

cont

rol

pist

on f

orce

s it

to s

hift,

ove

rcom

ing

the

smal

l con

trol

pist

on (

bias

ste

m)

and

mov

ing

the

swas

h pl

ate

to th

e de

-stro

ke p

ositi

on.

By

adju

stin

g th

e sp

ring

tens

ion

exer

ted

agai

nst

the

stan

dby

spoo

l, th

e st

andb

y pr

essu

re w

ill b

e in

crea

sed

or

decr

ease

d.

S

tand

by

pres

sure

is

th

e m

inim

um

pres

sure

requ

ired

to m

aint

ain

cont

rol o

f the

pum

p.


Figure 6: Implement Pump Compensator Control - On-Stroke Condition

00707

On-

Stro

ke C

ondi

tion

The

mai

n co

ntro

l val

ve a

nd im

plem

ent

pum

p ar

e tie

d to

geth

er w

ith a

“loa

d se

nse”

sig

nal l

ine.

Whe

n a

func

tion

is a

ctiv

ated

the

cont

rol v

alve

indu

ces

a lo

ad s

ense

sig

nal t

o th

e sp

ring

side

of

the

stan

dby

(load

sen

sing

) sp

ool.

The

load

sen

se p

ress

ure

adds

to

the

exis

ting

sprin

g fo

rce

whi

ch in

turn

ove

rcom

es “P

” pr

essu

re o

n th

e ot

her

side

of

the

spoo

l. T

his

for

ces

the

stan

dby

spoo

l to

shift

thus

ven

ting

the

larg

e co

ntro

l pi

ston

to

the

hydr

aulic

tan

k th

roug

h th

e pu

mp

case

dr

ain.

With

the

larg

e co

ntro

l pis

ton

vent

ed to

tank

, “P

” pr

essu

re o

n th

e sm

all c

ontro

l pis

ton

(bia

s st

em) m

oves

th

e sw

ash

plat

e to

it’s

on-

stro

ke p

ositi

on.

The

stre

ngth

of t

he lo

ad s

ense

sig

nal f

rom

the

cont

rol

valv

e de

term

ines

how

muc

h pr

essu

re w

ill b

e re

quire

d to

do

the

wor

k.


Figure 7: Implement Pump Compensator Control - Pressure Compensation

00708

Pre

ssur

e C

ompe

nsat

ion

To

limit

max

imum

im

plem

ent

syst

em

pres

sure

th

e pu

mp

uses

an

adju

stab

le p

ress

ure

com

pens

ator

(al

so

calle

d “p

ress

ure

limiti

ng” o

r “pr

essu

re o

verr

ide<

PO

R>)

. P

OR

pre

ssur

e is

set

at 3

800

PS

I (26

,2 M

pa) f

or th

e TB

co

nfig

urat

ion.

Pre

ssur

e co

mpe

nsat

ion

is

done

at

th

e pu

mp

com

pens

ator

with

a p

ress

ure

limiti

ng (P

OR

) spo

ol.

On

one

side

of

the

pres

sure

lim

iting

spo

ol i

s ad

just

able

sp

ring

forc

e.

On

the

othe

r si

de o

f th

e sp

ool

is “

P”

pres

sure

. W

hen

“P”

pres

sure

ove

rcom

es t

he s

prin

g fo

rce

the

spoo

l sh

ifts,

rou

ting

“P”

pres

sure

pas

t th

e sp

ool t

o th

e la

rge

cont

rol p

isto

n. T

his

pres

sure

on

the

larg

e co

ntro

l pi

ston

for

ces

it to

shi

ft, o

verc

omin

g th

e sm

all c

ontro

l pis

ton

(bia

s st

em) a

nd m

ovin

g th

e sw

ash

plat

e to

the

min

imum

dis

plac

emen

t pos

ition

. Th

e pu

mp

in t

his

posi

tion

wou

ld p

rodu

ce o

nly

enou

gh f

low

to

mai

ntai

n th

e m

axim

um s

yste

m p

ress

ure.


Implement Control Valve DescriptionThe Timberpro T800 utilizes a VOAC L90LS or K220 series directional control valve. The valve is a stackable proportional, load sensing and flow compensated, closed center valve. The valve is controlled with proportional, electric-over-hydraulic controls.

L90LS Operation NOTE: Operation of the K220 valve used on the TB configuration is very similar in operation to the L90LS valve used on the TF and TB configurations.

By breaking the VOAC valve down into its three major components (Mid inlet section, end section, and spool section) it will be easier to understand.

Inlet Section

The inlet section is where the pump connections are made. These connections are the load sense line and pump pressure line and tank.

A direct acting main safety relief is also incorporated into the inlet section to protect the valve and pump from pressure spikes. This relief is a cartridge style relief that is factory preset at 4350 PSI (300 bar) and is not adjustable.

End Section

Internal pilot pressure supply is a valve function built into the end section. The end section is fitted with a non-adjustable pilot pressure reducing valve factory preset at 320 PSI (22 bar). This gives an internal pilot supply for the electro-hydraulic pilot caps to shift the main valve spools. For safety reasons, the pilot pressure reducing valve is equipped with a separate non-adjustable safety relief factory preset at 500 PSI (35 bar).

Also incorporated into the end section is a pilot oil filter equipped with a bypass. The filter protects internal pilot circuit from contamination.

Four ports are used in the end section.

1) T2B - Return oil to tank. 2) T3B - Oil supply for the frame lock circuit 3) LSP - Load sense drain 4) P2 - Auxiliary pressure port that supplies

the mono-block valve

Spool Section (See Figure 8)

The spool section consists of a body, 4-way main spool, compensator spool, port relief valves, and electric proportional solenoids.

The electric proportional solenoids (Ref #6 & #7) are controlled by a proportional current signal from the IQAN digital control system. As the current to the solenoids changes, the valve produces a pilot signal proportional to the current supplied. This changing pilot pressure pushes the 4-way main spool (Ref #2) in either the “A” or “B” direction. Not only is direction determined, but also how far the spool travels.

Primary load sense is connected through the timed drillings in the main spool (Ref #4). When the main spool shifts the load sense will communicate with the work ports. The load sense signal travels to the pump control through the section shuttle valve (not shown). These shuttles are hardened seats located between each section. The series of shuttles allow only the load sense signal from the section with the highest pressure to reach the pump.

The load sense signal also travels into the spring chamber (Ref #9) of the section compensator spool (Ref #10). The compensator spool spring and the section’s load sense pressure maintain a constant pressure across the main spool. Having a constant pressure drop across the main spool allows the section to deliver oil flow that is proportional to the main spool position.

Port reliefs (Ref #3 & #5) are also used on all sections. The port reliefs on standard machines are set at 4060PSI (280 bar). All port reliefs have an anti-cavitation feature. The system tank line has a 130 PSI (9 bar) back pressure check valve. The back pressure check valve causes the oil flow through the anti-cavitation checks to maintain back pressure on all components.


Figure 8: Implement Control Valve Spool Section Cut-Away - LS90

00601 1)

Spo

ol S

top

2)

4-W

ay M

ain

Spo

ol

3)

“A” P

ort R

elie

f 4

) Lo

ad S

ense

Com

mun

icat

ion

Hol

e 5

) “B

” Por

t Rel

ief

6)

“A” S

olen

oid

Coi

l 7

) “B

” Sol

enoi

d C

oil

8)

LS D

ampe

ning

Orif

ice

9)

Com

pens

ator

Spr

ing

10)

Com

pens

ator

Spo

ol

11)

Cen

terin

g S

prin

g 12

) C

over

13

) P

ropo

rtion

al S

olen

oid

Orif

ice


Figure 9: Implement Control Valve Spool Section Cut-Away - K220

T0837 1)

Spo

ol S

top

2)

Mai

n W

ork

Spo

ol

3)

“A” P

ort R

elie

f 4

) Lo

ad S

ense

Com

mun

icat

ion

Hol

e 5

) “B

” Por

t Rel

ief

6)

“A” S

olen

oid

Coi

l 7

) “B

” Sol

enoi

d C

oil

8)

Pro

porti

onal

Sol

enoi

d O

rific

e 9

) C

ompe

nsat

or S

pool

10

) C

over


Swing Circuit GeneralThe circuit type is a closed loop hydrostatic system. The directional changes in machine movement are controlled by swiveling the pump rotating group from a centered, neutral position to either forward or reverse. This is controlled by an electrical signal sent from a control pedal actuated by the operator to the Iqan control system where the signal from the foot control is converted to a current output that conrtrols the coils on the track drive pumps.

DescriptionA Rexroth pump is used on all configurations. These pumps are referred to as a over-center pump. This means that the rotary group, which provides oil flow around the hydrostatic loop, can travel over-center on either side of the neutral swash plate position. This allows oil flow to be reversed in the hydrostatic loop. The direction of cabin swing travel is controlled by the angle of the pump swash plate to either side of neutral.

The swing drive pump is driven through a gearbox with a speed increaser. Doing so allows the top engine RPM to be reduced from 2200 to 1800 (which is the peak torque level of the Cummins engine). This is being done to reduce the fuel required and reduce the noise level in the cab.

The pumps then feeds pressure to a variable displacement Rexroth motor.

MechanicsWhen the operator activates the swing joystick an electrical signal is sent to the pump controller via the IQAN digital control system.

The electrical signal activates the solenoid on the pump controller, which in turn moves a small control spool that allows command oil to the pump servo. The pump servo is connected directly to the swash plate in the pump and when it is shifted, strokes up the pump in the desired direction and forces the pump to produce flow to the motor. When changing directions, the swash plate goes to the opposite side of neutral to change the direction of oil flow.

The oil returning from the motors is then routed to the opposite work port on the pump. This oil is then reused by the pump and sent to the motor.

Charge PumpThe pump and motors have a natural manufacturing leakage which cannot be eliminated. This leakage must be made up or the closed loop system would run dry of oil. The charge system continually feeds oil into the low pressure side of the closed hydrostatic loop.

The maximum pressure setting of the charge circuit is regulated by a charge sequence valve. (see section 7.1) Charge pressure is set at 400-425 PSI (27.6-29 bar) at 1400 RPM with a screw-type adjustment cartridge. Charge pressure also is used to release the swing brake, supply the pilot pressure manifold, and as make-up oil for the implement valve to prevent cavitation.

Swing Pump POR (Pressure Override)The pressure override valve is unique in that it can limit the maximum allowed pump pressure without putting high pressure oil over a relief. See Figure 10 - item 7.

When the machine encounters a condition where the drive pressure starts to exceed the maximum setting, the POR valve senses this. The POR valve then dumps the command oil that controls the pump servo to case. This allows the swash plate to move back towards the neutral position and reduce the pump flow to an amount that is enough to maintain the maximum allowed pressure.

The POR valve is adjustable and is set at 3600 PSI (248 bar) at 1400 RPM. See Section 6.2 in this manual for adjustment procedures.

High Pressure Relief ValvesThe high pressure reliefs perform two important functions:

1) Prevent system or machine damage by venting oil from the hydrostatic loop should the machine stall against an immovable object. In this situation, a pressure spike is created in the circuit which could damage components. The high pressure reliefs sense this pressure spike and, if it exceeds the relief setting, vents oil from the hydrostatic loop into the charge system. This allows the pressure spike to dissipate without causing damage. Venting oil through a high pressure relief also generates an excessive amount of heat, so it is


important that they are adjusted properly. The high pressure reliefs are like a safety relief and are seldom active in a properly designed and adjusted circuit. The high pressure reliefs are not adjustable and are set at 4000 PSI (276 bar) at 1400 RPM.

2) A high pressure relief, when located on the low pressure side of the hydrostatic loop, also acts as a check valve to allow charge oil to replenish the hydrostatic loop oil volume. This is required because of internal leakage in the pump and motors. If the leakage oil is not replaced, the hydrostatic loop would run low on oil and component damage would occur.

Parts T4036 05/1550.00

Figure 10: Swing Pump

Implement Circuit - Tests & Adjustments6.2.1Form T012

Section 6.2

Implement Circuit - Tests & Adjustments

Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.2 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.2

Implement Pump: Implement Pump Stand-by Pressure . . . . . . . . . . . . . . . . . . . . . . . 6.2.3 Implement Pump POR Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.5 Implement Pump Case Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.6 Implement Pump Case Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.7

Disc Saw Pump: Disc Saw Pump Stand-by Pressure . . . . . . . . . . . . . . . . . . . . . . . . 6.2.8 Disc Saw Pump POR Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.9

Swing Pump: Swing Pump POR Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.10

Implement Circuit - Tests & Adjustments 6.2.2 Form T012

Safety information

You must read and understand the warnings and basic safety rules, found in Group-1 of the Operation & Maintenance manual, before performing any operation, test or adjustment procedures.

Tools Required• Tachometer • 0 - 60 psi (0 - 1000 kPa) pressure gauge • 0 - 600 psi (0 - 5 Mpa) pressure gauge • 0 - 10,000 psi (0 - 80 Mpa) pressure gauge • 9/16”, 11/16”, 3/4”, 13/16”, 1-1/4”, & 1-3/8” wrenches • 13mm wrench • 4mm allen wrench • PN# 15437, #12 ORS cap • PN# 15869, quick-couple adapter • PN# 18838, #6 ORS plug • PN# 18839, #6 ORS cap • Gauge test hose • #12 ORBM - #4 JICM adapter • Calibrated container - 10 gallons (38 litres) • Stop watch

• The operator or another mechanic may be required to operate a control while a pressure reading is being taken.

NOTE: Each machine is shipped from the factory with at least one 600 psi and one 10,000 psi gauge with quick-couple adapters. The gauges can be found in the machine Up-Time Kit.

At operating temperature, the engine, exhaust system components, cooling system components and hydraulic system components are HOT. Any contact can cause severe burns.

00017

Diesel exhaust fumes contain elements that are hazardous to your health. Always run engine in a well ventilated area. If in an enclosed space, vent exhaust to the outside.

00015


Implement Pump Stand-By Pressure Specification:

525 psi (36 bar) LS line disconnected

Test Standards:

• Hydraulics at operating temperature of 140°F (60°C) or greater.

• Engine operating at idle

Procedure:

1. Ensure the hydraulics are at correct operating temperature.

2. Access the implement pump behind the swing-out guard located below the hydraulic tank.

3. Use the 13/16” wrench to disconnect the implement pump’s load sense line were it connects to the load sense shuttle valve. See Figure 1.

NOTE: The load sense must be disconnected before testing or adjusting the implement pump stand-by pressure. This prevents false readings from the control valve interacting with the pump.

3. Plug the Hose, but leave the pump open to atmosphere.

4. Start the engine and run at idle.

5. Connect the 600 psi pressure gauge, with the quick-couple adapter attached, to the gauge port tap provided on the centralized pressure check manifold. See Figure 2.

NOTE: Only install a 600 psi pressure gauge after the engine is running. If the gauge is installed before the engine is started it can be damaged.

6. Read the pressure gauge, the implement pump stand-by pressure should be set at

525 psi (36 bar)

If implement pump stand-by pressure setting is correct, go to step #11. If adjustment is required, continue with step #7.

7. Use the 13mm wrench to loosen the jam nut on the stand-by pressure adjustment setscrew. See Figure 3.

8. Use the 4mm allen wrench to turn the adjustment setscrew.

Turning the adjustment setscrew CLOCKWISE increases the pressure setting. Turning the setscrew COUNTER-CLOCKWISE decreases the pressure setting.

Figure 1: Disconnect Load Sense Line (Typical)

00589

Figure 2: Implement Pump Pressure Gauge Port Tap

T0026


9. Read the pressure gauge and adjust pressure setting as required.

10. After the correct pressure setting is made, tighten the jam nut to lock the setscrew.

11. Remove the pressure gauge and shut down the engine.

12. Re-connect the load sense line removed in step #3.

NOTE: It is not necessary to bleed the load sense line because the pump is vented internally.

13. Close and secure the rear engine guard.

Figure 3: Implement Pump Stand-By Pressure Adjustment

Stand-By Pressure00676


Implement Pump POR Pressure Specification:

3800 +/- 50 psi (262 +/- 3.5 bar)

NOTE: The settings listed above are standard settings for most TimberPro machines. Some specialized machines with special attachments can require these settings to be different. Please contact your TimberPro dealer if you have any question on the setting of your machine.

Test Standards:


• Engine operating at high idle (approx. 1200 RPM).

Procedure:


2. Access the implement pump behind the operator’s cab in front of the hydraulic tank.

3. Connect the 10,000 psi pressure gauge, with the quick-couple adapter attached, to the gauge port tap provided on the centralized pressure check manifold. See Figure 2.

4. Start engine and increase engine throttle to high idle (approx. 1200 RPM).

5. Instruct the operator or another mechanic to bottom out an implement function while you read the pressure gauge, implement pump POR pressure should be set at specification. (Because different function have different pressure settings make sure and select a function (stick boom) that has a main relief setting higher than the implement pump POR.)

6. If implement pump POR pressure setting is correct, go to step #10. If adjustment is required, continue with step #7.

7. Use the 13 mm wrench to loosen the jam nut on the POR pressure adjustment setscrew. See Figure 5.

8. Use the 4 mm allen wrench to turn the adjustment setscrew.


9. Instruct the operator or another mechanic to bottom out an implement function while you read the pressure gauge, implement pump POR pressure should be set at specification. (Because different function have different pressure settings make sure and select a function (stick boom) that has a main relief setting higher than the implement pump POR.)

10. After the correct pressure setting is made, tighten the jam nut to lock the setscrew.

11. Shut down the engine.

12. Remove the pressure gauge then close and secure all access panels and guards.

Figure 5: Implement Pump POR Pressure Adjustment

00676

POR Pressure


Implement Pump Case Drain Pressure Specification:

Maximum 35 psig (2.4 bar) allowed.

Test Standards:


• Engine operating at full throttle (approx. 1800 RPM).

• Implement pump pressure at specification.

Procedure:

1. Produce a gauge test hose that will allow you to tee in a 60 psi (4 bar) gauge to the #12 ORFS connector that will be installed into the implement pump case drain port.


3. Access the implement pump behind the operator’s cab next to the hydraulic tank.

4. Locate and remove the implement pump case drain hose and connector and tee in a fitting and 60 psi (4 bar) gauge.

5. Install the gauge test hose and pressure gauge to the case drain port adapter.

Be sure the pump case is full of oil before starting the machine otherwise catastrophic damage to the pump will occur.

6. Start engine and run at full throttle.

7. Instruct the operator or another mechanic to bottom out an implement function and hold it for a full minute while you observe the pressure gauge.

The implement pump case drain pressure should not exceed specification. If the specification is exceeded, look for conditions that would increase backpressure in the case drain circuit such as a plugged case drain filter element, failing component, etc.

8. After completing the test, cycle all implement functions for a least 2-minutes to cool the hydraulics down.

9. Shutdown the engine and remove the adapter tee that was installed for testing.



Implement Pump Case Drain Flow Specification:

• New or rebuilt - Maximum 4.6 gpm (17,5 litres) allowed.

• Used - Maximum 5.8 gpm (22 litres) allowed.

Test Standards:


• Engine operating at full throttle (approx 1800RPM).

• Implement pump pressure at specification.

Procedure:


2. Access the implement pump behind the operator’s cab in front of the hydraulic tank.

3. Use the 1-1/4” and 1-3/8” wrenches to remove the implement pump case drain line at the hydraulic tank. Cap the fitting to prevent contaminates from entering the hydraulic system.

4. Place the open end of the case drain hose into the calibrated container.

Be sure the pump case is full of oil before starting the machine otherwise catastrophic damage to the pump will occur.

5. Start engine and run at full throttle. Immediately have the operator or another mechanic bottom out an implement function and hold it for a full minute.

6. After one minute, deactivate the implement function and shutdown the engine.

7. Remove implement pump case drain hose from the container and re-connect it to the hydraulic tank.

8. Cycle all implement functions for a least 2-minutes to cool the hydraulics down.

9. Measure the oil in the container. If the amount exceeds specification, the implement pump is worn or failing and may have to be replaced.



Disc Saw Pump Stand-By Pressure (optional) Specification:

145 - 200 psig (10 - 13.8 bar)

Test Standards:• Hydraulics at operating temperature of

140°F (60°C) or greater.

• Engine operating at idle

Tools Required:

• 17 mm wrench

• 3/16” Allen wrench

• 3 mm Allen wrench

• 0 - 600 psi (0 - 41.37 bar) pressure gauge

Procedure:

1. Be sure the disc saw circuit switch on the right Joystick Pod is in the OFF position so that the disc saw blade does not start during the procedure. See Figure 6.

2. Open the rear gullwing guard to access the disc saw pump.

3. Install the gauge at the disc saw pump pressure output block See Figure 7.

4. Start the engine and run at low idle.


6. Connect the 600 PSI pressure gauge to the gauge test hose.

7. Increase engine throttle to 1500 RPM.

8. Read the pressure gauge. The disc saw stand-by pressure should be set at

145 - 200 psig (10 - 13.8 bar).

If the disc saw stand-by pressure setting

is correct, go to step #12. If adjustment is required, continue with step #9.

9. Locate the stand-by pressure adjustment setscrew on the disc saw pump compensator. See Figure 7.

10. Use the 17 mm wrench to remove the protective acorn nut. Use the 3 mm Allen wrench to hold the adjustment setscrew stationary while loosening the jamnut with the 17 mm wrench.

11. Turn the adjustment setscrew out COUNTERCLOCKWISE until the gauge reads about 100 psig (690 kPa), then in CLOCKWISE until the gauge reads the correct pressure of 145 - 200 psig (10 - 13.8 bar).

Figure 6: Disc Saw Circuit “ON and OFF” Switch

T00051

Figure 7: Stand-by Pressure Gauge Installation (Typical)

00531

Gauge Port

Stand-By Pressure


Disc Saw Pump POR PressureTools Required:

• 17 mm wrench

• 3 mm Allen wrench

Specification: 4500 psig (310 bar)

Test Standards:

• Hydraulics at operating temperature of 140° F (60° C) or greater.

• Engine operating at 1250 - 1500 RPM.

Procedure:

1. Be sure the disc saw circuit switch on the right Joystick Pod is in the OFF position so that the disc saw blade does not start during the procedure. See Figure 8.

2. Open the rear gullwing guard to access the disc saw pump.

3. Start the engine and run at low idle.


5. In order to get an accurate compensator pressure reading, the cutting disc must be pinned to prevent rotation. See the disc saw attachment manual for this procedure.

6. Increase engine speed to full throttle.

Flying objects and moving parts can cause serious personal injury or death. Keep clear of disc saw cutting attachment when in operation.

7. Turn the disc saw circuit “ON” to signal the disc saw to come on-stroke. See Figure 8.

8. Read the pressure gauge mounted in the cab on the front left dash panel. See Figure

9. The disc saw POR pressure should be set at 3800 psig (262 bar). If the disc saw POR pressure setting is correct, go to step #13. If

Tighten the jamnut to lock in the adjustment. See Figure 7.

12. Shut-down the engine and remove the gauge test hose and pressure gauge.

13. Close and secure the rear gullwing guard.

14. Procedure complete.

Figure 9: POR Pressure Gauge Installation (Typical)

00531

Gauge Port

Figure 8: Disc Saw Circuit “ON and OFF” Switch

T00051

POR Pressure


adjustment is required, continue with step #9.

10. Locate the compensator pressure adjustment setscrew on the disc saw pump compensator. See Figure 9.

11. Use the 17 mm wrench to remove the protective acorn nut. Use the 3 mm Allen wrench to hold the adjustment setscrew stationary while loosening the jamnut with the 17 mm wrench.

12. Turn the adjustment setscrew out COUNTERCLOCKWISE until the gauge reads about 3200 psig (220.6 bar), then in CLOCKWISE until the gauge reads the correct pressure of 3950 psig (272 bar). Tighten the jamnut to lock in the adjustment. See Figure 9.

13. Shut-down the engine.

14. Close and secure the swing-out pump access guard.

15. Procedure complete.

Swing Pump POR Pressure Specification:

3800 PSI (262 bar) 725,735,745 5300 PSI (365 bar) 755 (56cc motor only)

Test Standards:


• Engine at high idle (approx. 1800 RPM).

• Swing pump charge pressure and charge spike relief set to specification.

Procedure:

Operating the swing pump over relief produces extreme heat that can damage hydraulic system components. Expedite all pressure readings and adjustments.


2. Connect the 10,000 psi pressure gauge, with the quick-couple adapter attached, to the gauge port tap provided on the centralized pressure check manifold. See Figure 8.

3. Instruct the operator or another mechanic to start the engine and run at high idle (approx. 1800 RPM).

4. On your signal, have the operator or another mechanic move the swing joystick function while you take a pressure reading. Swing pump POR pressure should be set at 3600 PSI (248 bar) .

If Swing pump POR pressure is correct, go to step #11. If an adjustment is required, continue with step #7.

6. Locate the POR relief on the swing drive pump. See Figure 10. Use the 13mm wrench and 4mm allen wrench to loosen the jam nut on the POR relief adjustment setscrew.

7. On your signal, have the operator or another mechanic move the swing joystick function while you take a pressure reading. Swing pump POR pressure should be set at 3600 PSI (248 bar) .


8. After the correct pressure setting is made, hold the adjustment setscrew stationary and tighten the jamnut to hold the pressure setting.

9. Shut down the engine and remove the pressure gauge.

10. Shut down the engine.


Parts T4036 05/1550.00

Figure 10: Swing Pump

POR Adjustment

section 6 - timberpro inca11vlo series 40 hydraulic pump. this is a variable displacement piston...

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