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SERVICE MANUAL TC5040 / TC5050 / TC5060 TC5070 / TC5080 / TC5080 Hillside Combines

SERVICE MANUAL TC5040 TC5050 TC5060 TC5070 TC5080 TC5080 Hillside Combines

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Print No. 87734472B

Print No. 87734472B


SERVICE MANUAL

TC5040 , TC5050 , TC5060 , TC5070 , TC5080 Hillside , TC5080

87734472B 05/05/2009


Contents INTRODUCTION DISTRIBUTION SYSTEMS............................................................. A PRIMARY HYDRAULIC POWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.A ELECTRICAL POWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.30.A ELECTRONIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.50.A FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.50.A

POWER TRAIN .............................................................................C POWER COUPLING Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.10.C TRANSMISSION Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.20.B TRANSMISSION Hydrostatic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.20.F

TRAVELLING................................................................................D FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.10.A REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.12.A STEERING Hydraulic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.20.C SERVICE BRAKE Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.30.B SERVICE BRAKE Hydraulic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.30.C PARKING BRAKE Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.32.B

BODY AND STRUCTURE .............................................................. E USER PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.34.A ENVIRONMENT CONTROL Air-conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.40.C

FRAME POSITIONING .................................................................. F FRAME LEVELLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F.30.A

TOOL POSITIONING .................................................................... G LEVELLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G.30.A

CROP PROCESSING .................................................................... K FEEDING Feeder housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K.25.E THRESHING Conventional threshing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K.40.B SEPARATING Beating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K.42.B 87734472B 05/05/2009


SEPARATING Straw walker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K.42.E STORING AND HANDLING Grain storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K.60.B CLEANING Primary cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K.62.B CLEANING Tailings return system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K.62.C RESIDUE HANDLING Straw chopper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K.64.C

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INTRODUCTION

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INTRODUCTION

Foreword TC5000

IMPORTANT INFORMATION All repair and maintenance works listed in this manual must be carried out only by staff belonging to the NEW HOLLAND Service network, strictly complying with the instructions given and using, whenever required, the special tools. Anyone who carries out the above operations without complying with the prescriptions shall be responsible for the subsequent damages. The manufacturer and all the organizations of its distribution chain, including - without limitation - national, regional or local dealers, reject any responsibility for damages due to the anomalous behavior of parts and/or components not approved by the manufacturer himself, including those used for the servicing or repair of the product manufactured or marketed by the Manufacturer. In any case, no warranty is given or attributed on the product manufactured or marketed by the Manufacturer in case of damages due to an anomalous behavior of parts and/or components not approved by the Manufacturer. No reproduction, though partial of text and illustrations allowed

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INTRODUCTION

Foreword TC5000

Technical Information This manual has been produced by a new technical information system. This new system is designed to deliver technical information electronically through CD-ROM and in paper manuals. A coding system called ICE has been developed to link the technical information to other Product Support functions e.g. Warranty. Technical information is written to support the maintenance and service of the functions or systems on a customers machine. When a customer has a concern on his machine it is usually because a function or system on his machine is not working at all, is not working efficiently, or is not responding correctly to his commands. When you refer to the technical information in this manual to resolve that customers concern, you will find all the information classified using the new ICE coding, according to the functions or systems on that machine. Once you have located the technical information for that function or system then you will find all the mechanical, electrical or hydraulic devices, components, assemblies and sub assemblies for that function or system. You will also find all the types of information that have been written for that function or system, the technical data (specifications), the functional data (how it works), the diagnostic data (fault codes and troubleshooting) and the service data (remove, install adjust, etc.). By integrating this new ICE coding into technical information , you will be able to search and retrieve just the right piece of technical information you need to resolve that customers concern on his machine. This is made possible by attaching 3 categories to each piece of technical information during the authoring process. The first category is the Location, the second category is the Information Type and the third category is the Product: •

LOCATION - is the component or function on the machine, that the piece of technical information is going to describe e.g. Fuel tank.

INFORMATION TYPE - is the piece of technical information that has been written for a particular component or function on the machine e.g. Capacity would be a type of Technical Data that would describe the amount of fuel held by the Fuel tank.

PRODUCT - is the model that the piece of technical information is written for.

Every piece of technical information will have those 3 categories attached to it. You will be able to use any combination of those categories to find the right piece of technical information you need to resolve that customers concern on his machine. That information could be: •

the description of how to remove the cylinder head

a table of specifications for a hydraulic pump

a fault code

a troubleshooting table

a special tool

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INTRODUCTION

How to Use this Manual This manual is divided into Sections. Each Section is then divided into Chapters. Contents pages are included at the beginning of the manual, then inside every Section and inside every Chapter. An alphabetical Index is included at the end of a Chapter. Page number references are included for every piece of technical information listed in the Chapter Contents or Chapter Index. Each Chapter is divided into four Information types: •

Technical Data (specifications) for all the mechanical, electrical or hydraulic devices, components and, assemblies.

Functional Data (how it works) for all the mechanical, electrical or hydraulic devices, components and assemblies.

Diagnostic Data (fault codes, electrical and hydraulic troubleshooting) for all the mechanical, electrical or hydraulic devices, components and assemblies.

Service data (remove disassembly, assemble, install) for all the mechanical, electrical or hydraulic devices, components and assemblies.

Sections Sections are grouped according to the main functions or a systems on the machine. Each Section is identified by a letter A, B, C etc. The amount of Sections included in the manual will depend on the type and function of the machine that the manual is written for. Each Section has a Contents page listed in alphabetic/numeric order. This table illustrates which Sections could be included in a manual for a particular product. SECTION A - Distribution Systems B - Power Production C - Power Train D - Travelling E - Body and Structure F - Frame Positioning G - Tool Positioning H - Working Arm J - Tools and Couplers K - Crop Processing L - Field Processing PRODUCT Tractors Vehicles with working arms: backhoes, excavators, skid steers, ..... Combines, forage harvesters, balers, .... Seeding, planting, floating, spraying equipment, .... Mounted equipment and tools, .....

X X X X X X X X

X X X X X

X X

X X

X X X X X X X X

X X X X X X

X

X X

X X X

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X

X X


INTRODUCTION

This manual contains these Sections. The contents of each Section are explained over the following pages. Contents INTRODUCTION DISTRIBUTION SYSTEMS POWER PRODUCTION POWER TRAIN TRAVELLING BODY AND STRUCTURE TOOL POSITIONING CROP PROCESSING

A B C D E G K

Section Contents SECTION A, DISTRIBUTION SYSTEMS This Section covers the main systems that interact with most of the functions of the product. It includes the central parts of the hydraulic, electrical, electronic, pneumatic, lighting and grease lubrication systems. The components that are dedicated to a specific function are listed in the Chapter where all the technical information for that function is included. SECTION B, POWER PRODUCTION This Section covers all the functions related to the production of power to move the machine and to drive various devices. SECTION C, POWER TRAIN This Section covers all the functions related to the transmission of power from the engine to the axles and to internal or external devices and additional Process Drive functions. SECTION D, TRAVELLING This Section covers all the functions related to moving the machine, including tracks, wheels, steering and braking. It covers all the axles both driven axles and non-driven axles, including any axle suspension. SECTION E, BODY AND STRUCTURE This Section covers all the main functions and systems related to the structure and body of the machine. Including the frame, the shields, the operator’s cab and the platform. SECTION G, TOOL POSITIONING This Section covers all the functions related to the final and/or automatic positioning of the tool once the tool is positioned using the Working Arm or the machine frame. SECTION K, CROP PROCESSING This Section covers all the functions related to crop processing.

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SERVICE MANUAL DISTRIBUTION SYSTEMS

TC5000

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A


DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Torque TC5000

Union nuts

55009

1

Ferrules The ferrule must be pre-assembled on the tube. Tighten the union nut as specified in the table below. The ferrule and screw thread are greased. Tube outer diameter mm (inch) 8 (0.32) 10 (0.4) 12 (0.47) 16 (0.63) 18 (0.71) 22 (0.87) 28 (1.10)

Torque Nm (lb.ft) Minimum 15 (11) 25 (18) 35 (26) 50 (37) 60 (44) 100 (74) 110 (81)

Metric fittings Unions Are suitable for use with union nuts and ferrules and ball-type nipples.

55011

2

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Maximum 20 (15) 30 (22) 40 (29) 55 (40) 70 (51) 110 (81) 120 (88)


DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Connections Are screwed in ISO metric thread - tolerance class 6H - with a tightening torque as specified in the table below.

55012

3

Tube outer diameter mm (inch)

Torque Nm (lb.ft) Minimum

8 (0,32) 10 (0,40) 12 (0,47) 16 (0,63) 18 (0,71) 22 (0,87) 28 (1,10)

40 (29) 65 (48) 80 (59) 100 (74) 120 (88) 200 (147) 350 (257)

Maximum 45 (33) 70 (51) 85 (63) 120 (88) 140 (103) 220 (164) 380 (280)

Swivel nut with ball-type nipple Are suitable for use with female unions

55013

D1 6H M14 x 1.5 M16 x 1.5 M18 x 1.5 M24 x 1.5 M26 x 1.5 M30 x 2 M36 x 2

4

Torque Nm (lb.ft) Minimum 15 (11) 20 (15) 30 (22) -

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Maximum 20 (15) 25 (18) 35 (26) -


DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Hydraulic pump - General specification TC5000

The hydraulic system is equipped with two pumps for models without lateral flotation, and with three pumps for models with lateral flotation.

RNIL08TC0014F0C

Main hydraulic pump (2) Type Direction of rotation Maximum pressure Maximum speed Output per revolution Maximum oil flow

Silence gear type Right -hand rotation 280 bar ( 4061 psi) 3000 rpm 16 cc/rev. 48 l/min ( 10.5 gal/min)

Hydraulic pump (steering circuit) (3) Type Direction of rotation Maximum pressure Maximum speed Output per revolution Maximum oil flow

Silence gear type Right-hand rotation 280 bar ( 4061 psi) 3000 rpm 5.5 cc/rev. 16.5 l/min ( 3.6 gal/min)

Hydraulic pump (lateral flotation circuit) (4) Type: Direction of rotation Maximum pressure Maximum speed Output per revolution Maximum oil flow

Gear type Right-hand rotation 230 bar ( 3336 psi) 3000 rpm 2 cc/rev. 6 l/min ( 1.3 gal/min)

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Overview TC5000

RNIL08TC004G0B

1

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

RNIL08TC003G0B

2

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

PRIMARY HYDRAULIC POWER SYSTEM - Component localisation TC5000

NOTE: To find the location of those components, refer to PRIMARY HYDRAULIC POWER SYSTEM - Overview (A.10.A).

For units without lateral flotation: Main hydraulic pump (2), steering circuit pump (3).

ZEIL08TC0006A0B

1

ZEIL08TC0033A0C

2

ZEIL08TC0004A0B

3

For units with lateral flotation (optional): Main hydraulic pump (2), steering circuit pump (3), lateral flotation pump (4).

Oil tank (5), filler cap with filter (6), breather with filter and non−return valve (33), low pressure filter (32).

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Valve stack Hydrostatic drive unit without lateral flotation: Header height control valve (8), pilot valve (42), unloading tube valve (13), reel vertical adjustment valve (15), reel horizontal adjustment valve (17).

RNIL08TC0128A0A

4

RNIL08TC0127A0A

5

ZEIL08TC0297A0B

6

ZEIL08TC0010A0B

7

Hydrostatic drive with lateral flotation: Header height control valve (8), pilot valve (42), unloading tube control valve (13), reel vertical adjustment valve (15), reel horizontal adjustment valve (17), lateral flotation control valve (28), load sensing valve (27).

Mechanical drive unit without lateral flotation: Header height control valve (8), pilot valve (42), unloading tube valve (13), reel vertical adjustment valve (15), reel horizontal adjustment valve (17), drive variator valve (47).

Header lift cylinders (9).

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Accumulator control valve (10), header suspension accumulator (11), pressure sensor (12).

ZEIL08TC0005A0A

8

ZEIL08TC0003A0B

9

Unload tube cylinder (14).

Header quick release coupler (18) (or screw couplers).

ZEIL08TC0001A0B

10

ZEIL08TC0002A0B

11

Steering valve (24).

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Steering cylinder(s) (25).

ZEIL08TC0011A0B

12

ZEIL08TC0018A0B

13

ZEIL08TC0008A0B

14

ZEIL08TC0012A0B

15

Lateral float cylinder (29) (optional).

Drain hose (31).

Rotary union (34), straw chopper clutch (35).

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Header engaging cylinder (37).

ZEIL08TC0298A0B

16

ZEIL08TC0032A0B

17

ZEIL08TC0299A0B

18

ZEIL08TC0019A0B

19

Hydraulic remote control valves: Straw elevator and header engaging control valve (38), threshing engaging control valve (39), unloading engaging control valve (40).

Unloading engaging cylinder (41), threshing engagement cylinder (46).

Lateral float accumulator ( 120 bar (1740.0 psi)) (43), lateral float accumulator ( 85 bar (1232.5 psi)) (44) (optional).

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Straw chopper clutch valve (45).

ZEIL08TC0300A0B

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Stack valve - Dynamic description TC5000

If all valves are in the "0" position, then: The valves (13), (15), (17) and (47), (Refer to Stack valve - Static description (A.10.A)) are closed, which means that the oil can not flow through these valves. The pressure raises at (7b), (27b), (Refer to Remote valve - Hydraulic schema (A.10.A)), until the load sensing spool is pushed open against spring pressure (delta P= 3 bar (43.5 psi)) and the return pressure in the pilot line (7a), (27a). Now pump oil flows into the return line at standby pressure. When activating the lateral float control spools (optional), the hydraulic cylinder pressure (pump pressure measured after the spool restriction) is present in the pilot line (7a), (27a) and closes the load sensing spool. The oil pressure is available for the activated control spool(s). When the pump pressure reaches the cylinder pressure (+ 3 bar (43.500 psi)), the load sensing spool is pushed open. The necessary amount of oil will flow to the control spool at the needed pressure. Excess oil is dumped into the return line. When activating valves without direct load sensing, (13), (15) and (17), the pilot valve (42) is activated to connect the pressure line with the load sensing line. This closes the load spooling line. Because the pilot valve (42) connects the pressure line directly with the load sensing line, the pressure rises up to relief pressure. Then the relief valve is pushed open and system pressure is limited to 210 bar (3045.0 psi) ( 207+3 bar). The load sense shuttle valve ensures the pilot pressure cannot escape into the return line.

ZEIL08TC0297A0B

1

Operation of the reel vertical adjustment valve (15) When switching the valve, the pilot valve (42) (refer to Hydraulic schema − Models with lateral flotation and Hydraulic schema − Models without lateral flotation − A.10.A) is activated as well to connect the pressure line with the load sensing line and closes the load sensing spool. Full oil flow is available towards the hydraulic cylinder. Only the lockout valve is provided in the connection towards the cylinder.

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Operation of the unloading tube valve (13) and the reel horizontal adjustment valve (17) When switching one of these valves, the pilot valve is activated as well to connect the pressure line with the load sensing line and close the load sensing spool. Full oil flow is available towards the hydraulic cylinder. Lockout valves are installed in the connections towards the cylinder.

ZEIL08TC0297A0B

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Stack valve - Static description TC5000

See also the hydraulic schemes. The main hydraulic system will be an open centre load sensing system that controls all high pressure functions of the header and unloading auger swing. The hydraulic system contains one main stack valve.

ZEIL08TC0297A0B

1

The stack valve consists of: •

Control valves for oil supply and load sensing. Refer to PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schema (A.10.A). Load sensing is a system which avoids high pressure when the valves are in neutral position and consequently, less heating up of oil and creating load-independent flow rate control.

Control valves with load sensing and optional lateral flotation valve - not shown.

Control valves which need the activation through the pilot valve (42), (13), (15), (17).

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Hydraulic pump - Exploded view TC5000

RNIL08TC0017F0B

1. 2. 3. 4. 5. 6. 7. 8. 9.

Pump housing Housing cover Bearing end plate Radial-lip-type oil seal Retaining ring Spring lock washer Hexagon nut Set of seals Bushing

10. 11. 12. 13. 14. 15. 16. 17. 18.

1

Bushing Straight pin Protective cap Protective cap Screw Radial-lip-type of seal Toothed washer Toothed gear Toothed gear

NOTE: Tighten the screw (5) with a torque of 12 - 16 Nm ( 9 - 12 lb ft).

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Filter - Static description TC5040, TC5050, TC5060, TC5070, TC5080

The low pressure filter (32) are installed on top of the hydraulic tank (5) and has a bypass (non-return) valve set to 1.15 bar ( 17 psi). The return oil from the hydraulics system is flowing through the low pressure filter before entering the hydraulic oil tank.

ZEIL08TC0004A0B

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DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM

Filter - Static description TC5080 Hillside

The low pressure filters (32) are installed on top of the hydraulic tank (5) and has a bypass (non-return) valve set to 1.15 bar ( 17 psi). The return oil from the hydraulics system is flowing through the low pressure filter before entering the hydraulic oil tank.

ZEIL08TC0004A0B

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