Service Manual: Loader Control System
Service Manual: Loader Control System
Service Manual: Loader Control System
2013-04
EN
Original instructions
Caution!
Read through the entire instruction manual before you begin to use the product.
x
Content
CONTENT 8 TROUBLESHOOTING............................ 27
8.1 No function.......................................................27
1 PREFACE.................................................. 3 8.2 No pressure......................................................27
1.1 Necessary and supplementary 8.3 Low working pressure.................................... 28
documentation......................................................... 3 8.4 Low working pressure during loader arm
1.2 Identification...................................................... 3 lowering movement...............................................28
1.2.1 Model and part-number.................................. 3 8.5 Low working pressure during bucket tilting
1.3 Alignment reference..........................................3 movement............................................................... 29
1.4 Definitions.......................................................... 4 8.6 Low lifting force/working pressure during
1.4.1 3rd service...................................................... 4 loader arm lifting movement................................ 29
1.4.2 4th service.......................................................4 8.7 High oil temperature....................................... 29
1.4.3 Multi Coupling MC4........................................ 4 8.8 Tractor's hydraulic functions do not work but
1.4.4 Loader Control System (LCS).........................4 the loader valve is working.................................. 29
1.4.5 ErgoDrive LCS................................................ 4 8.9 Hydraulic pump does not relieve pressure –
1.4.6 ElectroDrive LCS............................................ 4 high standby pressure..........................................30
2 SAFETY INSTRUCTIONS.........................5 8.10 Float position does not work....................... 31
8.11 Slow loader movement................................. 31
2.1 General information.......................................... 5
2.1.1 Guards.............................................................5 9 LIVE3 (ONLY AVAILABLE IN CERTAIN
2.1.2 Explanation of warning levels......................... 5 MARKETS)................................................. 32
2.1.3 Explanation of symbols................................... 5
9.1 Description....................................................... 32
2.1.4 Responsibility.................................................. 6
9.1.1 Features........................................................ 32
2.2 Installing the loader.......................................... 7
9.2 Structure........................................................... 33
2.2.1 Tether stop...................................................... 7
9.2.1 Exploded view Live3 (with quick
2.3 Protection equipment........................................8
couplings)............................................................... 33
2.3.1 Roll Over Protective Structure (ROPS)........... 8
9.2.2 Exploded view Live3 (with JIC adapters)...... 34
2.3.2 Counterweight and track................................. 9
9.3 Tightening torques Live3................................35
2.4 Operation............................................................ 9
9.4 Troubleshooting...............................................35
2.4.1 User's position.................................................9
9.4.1 No Live3 function.......................................... 35
2.4.2 Workplace..................................................... 10
9.4.2 Live3 only works in one direction..................36
2.4.3 Load stability................................................. 12
2.5 Risk factors during work................................ 14 10 MULTI COUPLING MC4....................... 38
2.5.1 During transport............................................ 14 10.1 Exploded view................................................38
2.5.2 Spare parts................................................... 17 10.2 Replacing the WEO Plug-In coupling.......... 39
10.3 Replacing the lock lever............................... 39
3 DESCRIPTION AND FUNCTION............18
10.4 Troubleshooting.............................................40
3.1 Mechanically controlled valve........................19
3.1.1 Features........................................................ 19 11 DIAGRAMS............................................42
3.1.2 Hydraulic features......................................... 19 11.1 Wiring diagram...............................................42
3.2 Open Center valve...........................................19 11.2 Hydraulic diagram OC...................................42
3.2.1 Features........................................................ 19 11.3 Hydraulic diagram OC - Shock valve A1......43
11.4 Hydraulic diagram Live3, serial number
4 STRUCTURE...........................................21
-037747....................................................................44
4.1 Connectors....................................................... 21
11.5 Hydraulic diagram Live3, serial number
4.1.1 Upper interface - valve..................................21
037747-....................................................................44
4.1.2 Lower interface - valve..................................21
5 TIGHTENING TORQUES........................22
6 TECHNICAL DATA................................. 23
6.1 Pressure........................................................... 23
6.2 Temperature range.......................................... 23
6.3 Environment..................................................... 23
7 SERVICE................................................. 24
7.1 Removing a valve from the tractor................ 24
7.2 Disassembly of a valve on the
workbench.............................................................. 24
7.2.1 General information...................................... 24
7.2.2 Tools.............................................................. 24
7.2.3 Removal........................................................ 25
7.3 Reinstalling a valve......................................... 25
7.4 Replacing a seal in a quick coupling.............26
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Content
125786
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Preface
1 PREFACE
This service manual describes service, repair and
troubleshooting work on the LCS control system together
with front loaders manufactured by ÅLÖ AB.
The service manual is aimed at professional service
technicians specializing in agricultural machinery and
heavy machinery.
Read and study the text in the instruction manual for the
control system, loader and tractor thoroughly before using
the machine. If you are not an experienced driver, study the
instruction manual and ask an experienced driver to explain
things to you.
Warning!
Read through the entire instruction manual
before you start to use the product.
1.2 Identification
1.2.1 Model and part-number
Each valve has a decal with an identification number. A
decal is placed on one side of the valve.
3
Preface
1.4 Definitions
1.4.1 3rd service
Optional hydraulic function for operating the implement's
hydraulics.
0418
4
Safety instructions
2 SAFETY INSTRUCTIONS
2.1 General information
Driver safety is one of the most important matters when
a new loader is designed. The designer builds in as many
safety functions as possible. However, several accidents
occur every year which could have been avoided by a few
seconds of reflection and more careful operation of the
machine.
Avoid personal injury. Read the following personal safety
instructions and insist that everybody who works with you,
or for you, also complies with the instructions.
Only use implements which have been approved by the
manufacturer for use with the loader.
2.1.1 Guards
This instruction manuals contains a number of illustrations
which show the guards removed, to give a better picture.
Never use the machine with the guards removed. If a guard
has been removed for service/repairs, re-install the guard
before the machine is taken back into service.
5
Safety instructions
2.1.4 Responsibility
• If there is no instruction manual included with the
tractor then obtain one from the dealer before fitting
and using the loader.
• Read through all material carefully and learn how to
use the equipment in a safe and correct manner.
• Only qualified individuals are permitted to operate the
machine.
Warning!
Only use the loader in the intended area of
application.
Warning!
Do not grip objects that extend the centre of
gravity to a significant extent. This can lead to
instability.
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Safety instructions
Caution!
The tractor and loader use fluids under high
pressure when working. Check all components
and keep them in good condition.
Make sure that no hydraulic components,
especially hoses, are damaged in contact with
moving components.
Warning!
The loader must not be operated with a
programmable joystick or other equipment that
enables automatic loader movements.
7
Safety instructions
Caution!
Always wear eye protection when cleaning
components with compressed air.
Fig.9 Use suitable protection equipment.
Caution!
Always wear appropriate protective equipment
for welding jobs as safety shoes, gloves, welding
helmet with approved eye protection. NEVER
look directly at the arc without approved eye
protection.
Warning!
If the tractor is equipped with a seatbelt, it must
be used and be correctly adjusted during work.
Change damaged seat belts before the machine is
used.
8
Safety instructions
Caution!
Check that the machine has ballast
(counterweight) at the rear to stabilise
the machine's load-carrying ability. The
counterweight is essential for maintaining control
of the machine.
2.4 Operation
2.4.1 User's position
Caution!
Only operate the machine when sitting in the
driver's seat.
9
Safety instructions
2.4.2 Workplace
Always check the machine's surroundings and ensure
that all individuals, especially children, and animals have
moved away before starting or driving the machine.
You may not hear any shouting to attract your attention
from individuals on the outside when you are sitting in the
cab with the door closed.
10
Safety instructions
Warning!
Do NOT use the loader or the bucket as a
working platform.
Warning!
Do NOT use the loader to lift or transport people.
11
Safety instructions
Warning!
Always look at the implement. Objects can fall or
roll backwards onto the driver when the loader is
raised.
Only lift loads that fit and are designed for that
specific implement.
Some implements should be equipped with a
collapse protector. Fig.21 Pay attention to the implement, objects may fall off.
Warning!
If the tractor is only equipped with Roll Over
Protective Structure (ROPS), and does not have
a Falling Objects Protective Structure (FOPS),
there is only limited protection against falling
loads. The driver risks injury if the load falls
when the loader is operated at height.
FOPS is not designed to protect against all falling
loads. It is therefore critical to use an implement
that prevents the load from falling.
Exercise caution when working with raised loads.
The tractor may not be operated on public roads
with a load in the implement.
Fig.22 Only lift loads that fit and are designed for that specific
implement.
• Adjust the tilt angle of the implement when the load is
raised so that the load is not aimed at the driver.
12
Safety instructions
Warning!
Reduce speed before cornering to avoid
overturning the machine.
Avoid sudden turns when driving down slopes.
Warning!
Do NOT work on or close to steep slopes.
The distance from a slope must be as far or
further than the height of the slope.
Open
Lock 0136-b
13
Safety instructions
Warning!
Never stand between the front of the tractor and
the loader's cross tubes.
Fig.28 Never stand between the front of the tractor and the
loader's cross tubes.
Caution!
When the machine is used for carrying or
transporting loads on public roads, by day or
at night, the warning signs may not be visible.
When this occurs, make sure that extra warning
material is used.
Warning!
Only use the attachment for the intended
application area. Do not grip objects that extend
the centre of gravity by a significant extent.
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Safety instructions
Warning!
Always look at the implement. Objects can fall or
roll backwards onto the driver when the loader is
raised. Only lift loads that are designed for each
specific implement.
Warning!
Always look at the implement. Objects can fall
out during transport. Only transport loads that
are designed for each specific implement.
15
Safety instructions
0361
16
Safety instructions
2.5.1.2 Welding
Caution!
Always wear appropriate protective equipment
for welding jobs as safety shoes, gloves, welding
helmet with approved eye protection. NEVER
look directly at the arc without approved eye
protection.
Warning!
Avoid heat near pressurized pipes by soldering,
welding, gas cutting, etc. Pressurized flammable
liquid can be sprayed out due to heat and cause
severe burns to yourself and bystanders. Use fire
sheets to protect the cables or other materials.
Warning!
Remove all paint before welding. Vapours and
gases released from the paint or other materials
on heating can be hazardous. Ensure good
ventilation. Fig.40 Avoid heat near pressurized pipes.
Remove the LCS system plus (+) and negative (-) from the
tractor's electrical system before welding begins.
17
Description and function
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Description and function
3.1.1 Features
• Durable installation of valve spool control cables with
lock screw
• Installation between valve spool and control cable that
prevents loose connections
• Simple and quick control cable installation Fig.43 Installation of control cable for mechanically controlled
LCS valve
3.2.1 Features
• Open Center valves have internal load sensing
functionality.
• Provides a flow to the loader that is proportional
to lever movement with little influence from load/
pressure.
• The feel of the lever is the same as that of a Load
Sensing system.
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Description and function
Pump Flow
Pump pressurized oil
Return to reservoir PB Flow
Internal load signal
Trapped oil
Fig.44 Valve spool in neutral position. OC shunt open - flow P-PB. The oil flow circulation pressure keep the OC-shunt open
and the oil flow is directed to the PB-port.
Port B1
Port A1
Tank
Pump pressurized oil Pump Flow
Return to reservoir
Internal load signal
Drilling Trapped oil
Fig.45 Valve spool in boom lift position. OC shunt closed - flow P-A1. Load signal pressure forces the OC-shunt to close,
oil flow is directed to the lift cylinder via port A1. The pressure generated in the P-line is corresponding to the load. Only the
required flow (lever stroke) goes to the lift cylinder, the remaining flow will go to port PB.
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Structure
4 STRUCTURE
4.1 Connectors
4.1.1 Upper interface - valve
Version with quick couplings ISO16028 Version with adapters JIC 7/8"
P P
PB T
Live3 Live3
Connection P, PB, T: adapters - JIC 1 1/16 "(external thread), Connection P, T: adapters - JIC 1 1/16 "(external thread),
valve ports - BSP 3/4" (internal thread). valve ports - BSP 3/4" (internal thread).
Connection Live3: BSP 1/8" Connection Live3: BSP 1/8"
NOTE! Dismount the heating cartridge when the valve is not
series connected.
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Tightening torques
5 TIGHTENING TORQUES
40Nm
10Nm
24Nm
10Nm
40Nm
6Nm
10Nm
80Nm
24Nm
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Technical data
6 TECHNICAL DATA
6.1 Pressure
Working pressure at 60L/min (valve serial number 034098-): 200 bar -5+10 bar
Working pressure at 60L/min (valve serial number -034098): 190 bar -5+10 bar
Max. system pressure 250 bar
Max. tank pressure 20 bar
Choke valve port A1 (if installed) 225 bar
6.3 Environment
Max. permitted contamination level in the hydraulic system Better than or equal to 19/16
fluid as per ISO4406
Viscosity range during operation 10-400 cSt
Weight (mechanically controlled valve) ~15 kg
Dimensions (mm)
281
201 147
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Service
7 SERVICE
7.1 Removing a valve from the tractor
Warning!
Relieve pressure before performing service work.
1. Stop the engine and relieve the pressure from the loader
and LCS valve.
2. Place a container under the valve to collect spilled oil
when the hoses are detached.
Fig.46 Relieve pressure before performing service work to
3. Clean around all hydraulic and electrical connections
prevent the risk of serious injury.
before disassembly.
4. Detach the hydraulic and electrical connection to the
loader.
Important! There may still be pressure in the valve.
7.2.2 Tools
• Allen key 3 mm, 4 mm
• Combination spanner 25 mm, 32 mm
• Hex socket 26 mm, 32 mm
• Hex socket, long 13 mm
• Hex socket, long 25 mm
• Hex socket, long 25 mm, internal depth: min. 36 mm
(loader interface with JIC adapter)
• Slotted screwdriver 8 mm
• Torx spanner TX45
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Service
7.2.3 Removal
1. Place the valve in a container to collect spilled oil.
2. Remove all JIC adapters (16, 17, 18) for connection to
the tractor's hydraulic system.
3. Remove the heating valve (15) that is mounted in the
channel above the PB connection. 1
4. Remove the covers (19, 20) over the valve's actuator 3
spools.
5. Detach the connector and remove the plastic cover over 4
the quick couplings/JIC adapters.
6. Clean the area around the quick couplers/JIC adapters.
7. Remove the quick couplings/JIC adapters (4). 5
NOTE! The socket for removing JIC adapters must
have an internal depth of min. 36 mm.
8. Lift the anti-cavitation valves (8) out of ports A2 and
B1. 2
9. Lift the choke valve (7) (if installed) out of port A1.
10. Remove the cover from over the actuator spools.
11. Lift out the actuator spools for the bucket (13) and
loader arm (12). 6
Important: Note the position of the respective actuator 8
spool. Handle with care. Make sure the spool surfaces 7
are not damaged! 8
12. Lift out the shunt spool valve. 9
10
Important: Handle with care. Make sure the spool
13
surfaces are not damaged! 9
14
13. Remove the check valves (9).
14. Fit an M5 threaded screw in the threaded hole on 11
holder for the check-valves (10, 11). Use a suitable tool
to pull out the check valve holders. Disassemble the 12
check valves (qty 2).
15. Remove the cover plate (5).
16. Lift away the multi coupling post (if installed) (3).
17. Remove the check valve (14). 16
15
17 18
19 20
25
Service
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Troubleshooting
8 TROUBLESHOOTING
8.1 No function
1. Check:
A. Hydraulic oil level
B. That the system has the right oil
C. That there are no limitations in the hydraulic
pump's suction line, filter or strainer
D. Whether the tractor's other hydraulic functions are
working
2. Check:
A. Ensure that spool valves move unhindered.
B. Check the joystick, wires and adjustments.
Replace worn or broken parts and test the system again.
3. Check:
A. Remove the shunt valve mounted in the centre.
Check the spool for seizing and for loose or
missing parts.
If necessary, replace the shunt valve and test run
the system again.
Check (OC valve, not connected in series):
B. Measure and check whether the circulation
pressure at valve port P is correct (normally 3-7bar,
depending on the flow).
• Yes) Go to step 3a Fig.49 Shunt valve, Open Center
• No) Check that the pressure line from the
tractor is not blocked or leaking. Repair if
necessary. See chapter 8.2 No pressure.
8.2 No pressure
1. Check and correct:
A. Hydraulic oil level
B. That the system has the right oil
C. That there are no limitations in the hydraulic
pump's suction line, filter or strainer
D. Whether the tractor's other hydraulic functions are
working
E. That the tractors hydraulic system performs
normally. Perform a performance test, pressure/
flow.
2. Check:
A. That the standby pressure in the LCS valve at port
P is in line with the specification from the tractor
manufacturer (normally 3-7 bar, depending on the
flow).
B. That the pressure lines and hydraulic pump are not
damaged or blocked. Remedy if necessary.
P
Fig.50 Install a pressure gauge to the line at port P on the LCS
valve.
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Troubleshooting
28
Troubleshooting
29
Troubleshooting
30
Troubleshooting
Fig.60 Spool valves lift and bucket (1,2) and check valve seat
for LS signal (3).
31
Live3 (only available in certain markets)
9.1.1 Features
• Electronic control function on/off
• Enables operation of three functions simultaneously
• Servo-operated spool
• Heating function to prevent thermal shock
• Regulated hydraulic flow
• Prepared for connection to loader with multi coupling Fig.63 Add-on valve Live3
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Live3 (only available in certain markets)
9.2 Structure
14
2
6
15
9
10
12 5
1
7
3
11
16
13 8
1. Harness
2. Cap
3. Check valve
4. Multi coupling post
5. Quick coupling
6. Cover plate
7. Adapter with sealing
8. Spool control unit
9. Sealing sleeve
10. Sealing sleeve
11. Adapter with sealing
12. Connecting pipe
13. Solenoid
14. Cover
15. Cable tie
16. Spool valve
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Live3 (only available in certain markets)
6
9 10
12 5
1
7
3
11
14
13 8
1. Harness
2. Cap
3. Check valve
4. Plug with sealing
5. Coupling JIC
6. Cover plate
7. Adapter with sealing
8. Spool control unit
9. Sealing sleeve
10. Sealing sleeve
11. Adapter with sealing
12. Connecting pipe
13. Solenoid
14. Spool valve
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Live3 (only available in certain markets)
40Nm
24Nm
30Nm
80Nm
25Nm
4Nm
9.4 Troubleshooting
9.4.1 No Live3 function
1. Check:
A. Hydraulic oil level
B. That the system has the right oil
C. That there are no limitations in the hydraulic
pump's suction line, filter or strainer
D. That the other functions of the LCS valve work
• Yes) Go to step 2
• No) See chapter 8.1 No function.
2. Check:
A. That the power supply and ground to the system is
OK.
B. Measure the voltage and ground to the solenoid
valve while manoeuvring the Live3 valve. The
solenoid must be connected during measurement.
Is the voltage over 12 V?
• Yes) Go to step 2C
• No) Check the cable harness and the switches
in the lever
C. Measure the magnetic coil's resistance in the
solenoid valves. Is the resistance 8 Ohm at +20°C?
• Yes) Go to step 3
• No) Replace the solenoid valve
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Live3 (only available in certain markets)
3. Check:
A. Remove and check the check-valve for foreign
objects, damage, etc.
B. Remove actuator spool and check the spool and
bore for scratches and damage. Replace damaged
components.
36
Live3 (only available in certain markets)
2. Check:
A. Remove actuator spool and check the spool and
bore for scratches and damage. Replace damaged
components.
37
Multi Coupling MC4
3 2
1. Locking pin
2. Lever set
3. Locking knob
4. Cover
5. Plug-in coupling
6. Valve kit
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Multi Coupling MC4
1. Stop the engine and relieve the pressure from the loader
and LCS valve.
2. Remove the quick couplings/multi coupling from the
loader valve.
3. Place a container under the valve to collect spilled oil
when the hoses are detached.
4. Remove the lock clip from the WEO plug-in coupling.
Detach the hose by pressing it into the coupling. Then
pull out the hose.
5. Remove the quick coupling (use a 26 mm socket).
6. Install a new quick coupling (tightening torque Fig.67 Remove the lock clip and detach the hose.
40-50 Nm).
7. Remove the plastic holder from the quick coupling.
8. Refit the lock clip on the WEO plug-in coupling.
Attach the hose by pressing it into the coupling. Twist
and pull on the hose to check that it is attached.
Fig.69 Press out the bayonet sleeve and remove the old support
ring.
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Multi Coupling MC4
Fig.70 Fit the new bayonet sleeve and support ring and insert
the new lever.
7. Place a drill bit (2.5 mm) in one of the holes to centre 2,5mm
the hole in the lever and sleeve. Then fit the tenter pin
using a mandrel and hammer.
8. Fit the retainer ball using lubrication grease.
9. Place the spring in the hole in the plastic cover and then
lock the cover to the multi-connection using the torx
screw. Note that the control on the lid and the groove in
the multi-connection housing must line up.
Fig.71 Centre the hole in the lever and sleeve with a drill or
similar tool, then place the tenter pins.
Fig.72 Fit the tenter pins and retainer ball. Refit spring and
plastic cover.
10.4 Troubleshooting
40
Multi Coupling MC4
Fig.73 Seal in male quick coupling. See chapter 7.4 Replacing a seal in a quick coupling.
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Diagrams
11 DIAGRAMS
11.1 Wiring diagram
DEUTCH
1 6 6 1 1 8
SD GND 4TH OC
2 5 5 2 2 7
3 4 4TH 3RD SD
4 3 3 6
4 5
DT04-08P
Part number
10570112 10570112-18
10570114 10570114-18
10570040 10570040-18
10570046 10570046-18
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Diagrams
Part number
10570113
10570115 10570115-18
10570141
10570147 10570147-18
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Diagrams
b3 a3
P T
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