Hydraulic System

CVS FERRARI S.r.l.
Società con socio unico e soggetta a direzione e controllo di Manitex International Inc.
Via Emilia - 29010 Roveleto di Cadeo (PC) - Italy
Tel: +39.0523.503511 - Fax: +39.0523.500439 - E-mail: info.mktg@cvsferrari.com - Web site: www.cvsferrari.com
REACH STACKER
F500
Hydraulic System
Index
Hydraulic system decriptino
1 Description
1.1 Components Position
2 Hydraulic oil Tank
2.1 Hydraulic Oil
2-2 Hydraulic Filter
3 Piston Rexroth Pump
3.1 Pump Function
3.3 Load Sensive ( LS ) Function
3.3.1 CVS Load Sensing line ( LS )
3.3.2 CVS Load Sensing Valve Electronic control
4 Distributor Rexroth
4.1 Hydraulic functoon
4,2 Hydraulic Distributor Oil pressure
4.3 Hydraulic Distributor Rele Valve
4.4 . Hydraulic Distributor Pilot pressure
4.4.1 . Hydraulic Distributor Pilot pressure Accumulator
4.4.2 . Hydraulic Distributor Pilot pressure Safety System
4,4.3 Operation of movements
a division of MANITEX INTERNATIONAL Inc.
Capitale Sociale Euro 1.271.000,00 i.v. - Registro Imprese, Codice Fiscale, Partita IVA 01579310333 – R.E.A. PC-174530
CVS FERRARI S.r.l.
1 Hydraulic System Description
The hydraulic system, used on F500 is made in collaboration between CVS and Bosch Rexroth
This system was created in 1999 with the series F200
So , this last generation It is the fourth generation of a long history
The system has always been updated, but maintained its characteristics of:
- Simplicity,
- Reliability
- Performance
All the material that composes the hydraulic system is of Bosch Rexroth
The system was created to work in harmony with the rest of the machine, in particular with the engine
The hydraulic system will put never , in crisis the engine
Its maximum operating pressure is 320 bar with a lifting capacity of 56 tons in weight
All this with :
- 800 rpm diesel engine
- 20% of engine power
So in the life of the machine , means that the hydraulic system will use only, about 40% of the power of the
diesel engine
Then :
- Long service life of the mechanical parts
- Long service life of the diesel engine
- Low fuel consumption (standard of 13/14 liters / hour)
- Safety in the work
CVS FERRARI S.r.l.
The Hydraulic system composes by :

1. Oil Tank
2. Oil tank filter ( return )
3. Piston oil pump,( item 1 ) which supplies all the hydraulic movement function
4. Hydraulic oil distributor ( item 3 )
5. Lift cylinder valve (item 2 ) located to the lift cylinder
6. Extension cylinder Valve (item 8 ) located to the extension cylinder of boom t
7. A filter ( item 5 ) on the return line of the lubrication circuit / cooling of the brake discs
8. An accumulator ( item 7 ) , with hydrogen inside , that
Hydraulic filter 2x
Hydraulic Oil Tank
Piston Piston
Pump Pump
P2 P1
Cooling system
Hydraulic Distributor
Steering movement
Boom extension retraction movement
Boom lift movement

Full Spreader movement
CVS FERRARI S.r.l.
CVS FERRARI S.r.l.
1.2 Components Position
Boom Cylinder Valve 1716076
Main piston Pump code 622789-622780
Oil tank and return Filter
Main Distributor 622787

Lift cylinder valve
606766
CVS FERRARI S.r.l.
Cooling radiator code 618754
CVS FERRARI S.r.l.
2 - Hydraulic Oil Tank

The machine is provide with only one oil tank .
This oil is used for the hydraulic system of the boom movements , spreader, steering and brake system
Hydraulic oil Tank
2.1 Hydraulic Oil

The first filling of the hydraulic system is made with oil "ENI MULTITECH JD/F SAE10W-30 (80W)", an oil with
additives compliant with the following specifications:
* ALLISON C-4, * API GL-4, * CAT TO-2, * FORD ESN-M2C 86-B, C & 134D,
* CASE MS 1207/1210, * JOHN DEER JDM J20C, * MASSEY FERGUSON M1135-1141-1143
With temperature from 0°C up to -10°C, use oils VG22, mixing them with additive "LUBRIZOL" type 6270 or
9990A in the proportion of 3%  6%.
With temperature from 0°C up to -20°C, use oils VG10, mixing them with additive "LUBRIZOL" type 6270 or
9990A in the proportion of 3%  6%.
NOTE:
 With temperatures of -15 °C, the automatic pre-heating of the hydraulic oil is necessary.
 With temperatures up to -40°C, the first filling of the hydraulic system is made with oil "ENI ROTRA A/R
75W-90".
CVS FERRARI S.r.l.
2.3 - Hydraulic Oil Tank Filter

The hydraulic tank is provide with two filter ( Filter Cartridge code 555775 )
These two filters are positioned in the oil return line to the tank from hydraulic system
Their function is to filter the oil before it enters the tank
Oil to filter  The tank is divided into two distinct

Hydraulic Tank section sections between them
 A section collects all the oil return from
the hydraulic system of the machine
 A section collects the filtered oil and so
Hydraulic Filter 2x clean, that will serve to supply the two
bumps
 Between these , we have the two filters
Oil From system
Oil to Pump
Safety switch
 The tank is provided with an electrical switch ( item 42 ) which indicates a possible anomaly in the filter
element
 This switch is activated when the pressure inside the tank is higher than 2 bar
 This electrical signal is sent to the electronic control unit MASTER
 The control unit MASTER in case of signalling , sends an alarm “ 3216 “ , that is shown on the display
VCU area ( see VCU Alarm list )

This alarm is only showing not intervene or change, the operating mode of the vehicle
When appears the alarm , the drive operator must stop the vehicle immediately and call the workshop ,
Then check
1. The filter element
2. The switch sensor and electrical connection
CVS FERRARI S.r.l.
3 - Pump Rexroth
The system uses two hydraulic pumps
These pumps are piston type
These pump are make by Rexroth Bosch Germany
The two Pump P1 and P2 are located on the gear box

 P1 code 622789 ( 145 CC ) in the left side
 P2 code 622790 ( 95 CC ) in the right side
CVS FERRARI S.r.l.
3.1 - Pump Function

This is variabil pump
This type of pump is a piston type
The pump is composed of
 Power regulator (capacity)
 Feed pump oil
 Group the pumping elements
CVS FERRARI S.r.l.
3.1 - Pump Function

This type of pump is piston The compression chamber
These piston B compresses the oil in a the
cylindrical chamber A
This cylindrical chamber can change its size The piston B
(capacity) Power regulator
So this type of pump has the ability to system of adjustment of
change its capacity internal the cylindrical chamber
In this way you can adjust the flow rate and
power in function of the working pressure
So , most cylinder capacity ,equal big flow

of oil and lower pressure
Max Power
Flow litres/min ( Kw )
 • Cubic capacity Highest = Highest oil flow rate - Minimum power of operating pressure
 • Cubic capacity Minimum = Minimum oil flow rate - Maximum power of operating pressure
CVS FERRARI S.r.l.
3.3 - Load Sensive ( LS ) Function

The pump is adjusted through the system Load Sensitive (LS)
The load sensing valve S is used to change the pump displacement,
using the pressure signal that arrives directly from the distributor
through the input X
This Allows a better and rapid response of the pump that adapt quickly to pressure variation due to the application
 The LS regulator pump is ready adjust at 25 bar

 So , the Delta P between Pump and Distributor is 25 bar ( + - 5 bar )
 Standby pressure equal at 25 bar ( + - 5 bar ) Distributor = 0 bar , Pump = 25 bar ( + - 5 bar )
LS Valve
WARNING
The CVS pumps are already calibrated and ready to operate. They do not need any adjustment
Do not modify or tamper with the original settings
CVS FERRARI S.r.l.
3.3.1 - CVS Load Sensing line

( LS )
The vehicles CVS are provided with a LS
line that joins the distributor to the two
pumps used
In this way, the distributor can
"converse" with the two pumps
So, according to its needs the distributor
can ask:
 Quantity of oil ( flow – speed )
 Oil pressure ( power )
Important
This line LS is very important for the
system
Without this line the pump don’t feel with
the distributor
Therefore , the two pumps , don’t can
send oil and pressure to the distributor
In this case we don't have any type of

movement from hydraulic system
LS Line
LS Line LS Line P1
CVS FERRARI S.r.l.
3.3.2 - CVS Load Sensing Valve Electronic control

The LS line that joins the distributor to the two pumps used is provide also of a solenoid unit
This solenoid valve
this valve allows to electronically control the signal LS
The command is made with a current signal
This signal comes from the control MASTER
The system evaluates the condition of stress of the diesel engine, and then provides to limit the power of
the pump
The most critical situation is when there are several hydraulic movements and the travel movement of the
machine
In this case the transmission requires the full power of the diesel engine
With the controlling the hydraulic power you can copy the curve of engine power
so allow
 Low consumption of fuel
 Prevent overheating of the components
 Long life to the engine and hydraulic components
Important
The control system is negative
The current signal closes the passage, while the lack of signal leaves the passage
So in case of any electrical problem, disconnect the electrical outlet
In this case the hydraulic pump will work normally

Its variation is controlled exclusively by the distributor
CVS FERRARI S.r.l.
4. Hydraulic Distributor
The distributor code 622787 provides the oil to all the functions of the hydraulic system
 Steering
 The Movements of boom
 The movements of Equipment ( spreader )
Important
The primary function is the steering system
Door side Distributor Engine side
Steering
Boom movemnt
Equipment –
Spreader
Flow control
 This distributor also divides the flow
of hydraulic oil
 Some internal Valves, named
compensators, regulating the flow of
oil directed to various users
 Therefore, the oil supplied from the
pumps has the ability to power all
functions at the same time
 This way, you can use various
functions at the same time
WARNING
The CVS Distributor is already calibrated and ready to operate. They do not need any adjustment
CVS FERRARI S.r.l.
4.1 Hydraulic Distributor Connection to function

The distributor code 622787 provides the oil to all the functions of the
hydraulic system
Function Pressure out Return in

Steering S Tank
Boom Lift A1 – A2 B2
Boom Levering B2 A2
Boom extension A1 – B3 B1
Boom retraction B1 A1
Spreader movement S Tank
SLS Steering LS
line from
steering
Return to Tank direction unit
LS line to Pump P2-P1
Return to tank
From Pump P1
From Pump P2 Steering system Main pressure

To steering direction unit
Pilot pressure To Dead man Valve

and Accumulator
WARNING
CVS FERRARI S.r.l.
4.2 Hydraulic Distributor oil Pressure

The distributor code 622787 provides the oil to all the functions of
the hydraulic system Pressure check point MLS
The pressure in each movements is like a “ analogical signal “
Based on the request of the distributor
Pump Power pressure Bar
Pump delivery Max 320 bar
Zone A
Working Pressure
Distributor Power pressure request (Bar)
Distributor Max request 320 bar

Zone A
In this area we have the working pressure
Check oil pressure Point

With the check point MLS , we can see the distributor job
So can see , all the oil pressure of system
Important
Like explain in the point of Pump function . The Pump have a standby pressure of 25 bar ( + - 5 bar )
So , in this case we consider that the pressure in the Pump is 320 bar +25 bar of standby pressure
Then , for any type of functions , we consider a different pressure between pump and distributor of 25 bar
Distributor Out Distributor Pump Safety Valve of

Function
point Pressure Pressure component ( Rele Valve )
Main Pressure 320 bar 345 bar 370 bar
Steering S 220 bar 245 bar 240 bar
Boom lift A2 – A3 320 bar 345 bar 350 bar
Boom levering B2 40 bar 65 bar 40 bar
Boom extension A1 – B3 320 bar 345 bar 350 bar
Boom Retraction B1 320 bar 345 bar 350 bar
Spreader side shift Left-right B4 160 bar 185 bar 210 bar
Spreader open/close 20-30-40 B4 160 bar 185 bar 180 bar
Spreader Rotation B4 140 bar 165 bar 140 bar
Spreader twist lock B4 160 bar 185 bar 210 bar
WARNING
CVS FERRARI S.r.l.
4.3 Hydraulic Distributor Rele Valve

The distributor code 622787 for each users components is provides with a Safety Valve
This valve is a Rele Valve
General safety valve
Boom Retraction valve

SLS valve Boom Levering valve
Spreader MLS
Valve Valve
Door side B4 B3 B2 B1
Engine side
S
A3 A2 A1
Boom Lift valve
Boom Extension valve
WARNING
CVS FERRARI S.r.l.
4.4 . Hydraulic Distributor Pilot pressure

The distributor code 622787 provides with an internal oil pressure “ Pilot Pressure “
This pressure provide to move the internal spool
 The Movements of boom
 The movements of Equipment ( spreader )
Important
The primary function is the steering system
C ) Proportional A ) Screw for adjust the spool ( and-stroke )

electrical valve
Spool
B ) Pilot oil pressure

for the proportional
electrical valve
This pressure is for
move the spool
Pressare to
movement
 The pilot pressure is regulated

by an internal valve to the
distributor
 The pressure is 40 bar and can
not be changed
 A small accumulator maintains
constant the value of this
pressure to 40 bar
 In this way, it is easy, safe and
accurate regulate the
movement of the spool
CVS FERRARI S.r.l.
4.4.1 . Hydraulic Distributor Pilot pressure Accumulator

This accumulator is connected with the distributor
When the vehicle is running, the oil arrives from the pumps
This oil feeds the piloting line
The accumulator maintains always this constant pressureImportant
Important
A variable pressure, causes an abnormal operating and inconsistent movements
 The pilot pressure is regulated

by an internal valve to the
distributor
 The pressure is 40 bars and
can not be changed
 A small accumulator item 95
maintains constant the value
of this pressure
 In this way, it is easy, safe and
accurate regulate the
movement of the spool
CVS FERRARI S.r.l.
4.4.2 . Hydraulic Distributor Pilot pressure Safety System

The vehicle is provided with a security system that protects the components
This protects the components , from eventually anomalies in the hydraulic system
A solenoid valve item 154 is inserted in the line of the pilot pressure of the distributor
When this solenoid valve is activated ( 24 volt ) , opens the oil circuit of the piloting and sends it in
draining the tank
In this way, you can no longer have any hydraulic function
When the valve is off,( 0 volt ) the circuit is closed
In this way the driving circuit maintains the pressure of 40 bar and therefore can move the spools and
having hydraulic functions
From the check point item 91 , is possible check the pilot pressure
Important
A abnormal function of this valve , causes an operating and inconsistent movements
CVS FERRARI S.r.l.
5. Operation of movements
The motion functions of boom and spreader are controlled electrically
Each function of the distributor is provided with a solenoid
The MASTER control unit receives the command and sends a current signal to the solenoid
This signal is variable (PWM)
This signal varies according to the demands of the movement
The solenoid, according to the signal it receives, opens the passage. to the pilot pressure to the spools
This pilot pressure moves back and forth, and then sends the main pressure to the various functions
Important
This electric signal before arriving to the solenoids of the distributor, pass through the control unit “
Interblocchi “
This unit checks whether there are anomalies in the machine
and then only if there are no problems, it allows the signal to reach the solenoid and thus have the desired
movement
B ) Pilot oil pressure

for the proportional
electrical valve
This pressure is for
move the spool
PWM Signal
Pressare to
movement
CVS FERRARI S.r.l.
5.1 Boom movements

The functions of boom are controlled by electrical mode
This function ( lift , lowering , extension and retraction ) depends also from the LMI
and from the Spreader condition
Important
Only if all functions is ok , we can have all the functions
Joystick and button Spreader Card ( Spreader conditions )

function
Angle and length transducers ( container position )
Electronic Card Cabin 0

Cylinder pressure transducers ( container weight )
Electronic Card Master Load Table ( lifting capacity of machine )
Electronic Card MIDAC Hydraulic filter x2 Cooling radiator

PLUS
Electronic Card Oil Tank

“Interblocchi “
Pump P2 Pump P1
Solenoid Valve Hydraulic Distributor
Boom function
CVS FERRARI S.r.l.
Boom mouvement
Electrical function
Cab 0
Cab 1
CAN BUS Line

Electrical line 24 volt
Electrical line PWM
CVS FERRARI S.r.l.
5.2 Spreader movements

The functions of boom are controlled by electrical mode
This function ( lift , lowering , extension and retraction ) depends also from the LMI
and from the Spreader condition
Important
Only if all functions is ok , we can have all the functions
Joystick botton function
Angle and length transducers ( container position )
Electronic Card Cabin 0

Cylinder pressure transducers ( container weight )
Electronic Card Master Load Table ( lifting capacity of machine )
Electronic Card MIDAC Hydraulic filter x2 Cooling radiator

PLUS
Electronic Card Oil Tank

“Interblocchi “
Pump P2 Pump P1
Solenoid Valve SP Hydraulic Distributor
Spreader Card Solenoid Valve Spreader Distributor valve
Spreader Function
CVS FERRARI S.r.l.
Spreader mouvement
Electrical function
152
151
158
150 "100" [Joystick]
154
157
156
Cab 0
153
155
Cab 1
Spreader mouvement
CAN BUS Line

Electrical line 24 volt
Electrical line PWM
CVS FERRARI S.r.l.

Hydraulic System

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Hydraulic System

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CVS FERRARI S.r.l.

a division of MANITEX INTERNATIONAL Inc.

1 Hydraulic System Description

a division of MANITEX INTERNATIONAL Inc.

The Hydraulic system composes by :

Boom extension retraction movement

Boom lift movement

a division of MANITEX INTERNATIONAL Inc.

a division of MANITEX INTERNATIONAL Inc.

1.2 Components Position

Boom Cylinder Valve 1716076

Main piston Pump code 622789-622780

Oil tank and return Filter

Main Distributor 622787

a division of MANITEX INTERNATIONAL Inc.

Cooling radiator code 618754

a division of MANITEX INTERNATIONAL Inc.

2 - Hydraulic Oil Tank

Hydraulic oil Tank

2.1 Hydraulic Oil

a division of MANITEX INTERNATIONAL Inc.

2.3 - Hydraulic Oil Tank Filter

Oil to filter  The tank is divided into two distinct

Oil From system

a division of MANITEX INTERNATIONAL Inc.

The two Pump P1 and P2 are located on the gear box

a division of MANITEX INTERNATIONAL Inc.

3.1 - Pump Function

a division of MANITEX INTERNATIONAL Inc.

3.1 - Pump Function

So , most cylinder capacity ,equal big flow

a division of MANITEX INTERNATIONAL Inc.

3.3 - Load Sensive ( LS ) Function

 The LS regulator pump is ready adjust at 25 bar

a division of MANITEX INTERNATIONAL Inc.

3.3.1 - CVS Load Sensing line

In this case we don't have any type of

a division of MANITEX INTERNATIONAL Inc.

3.3.2 - CVS Load Sensing Valve Electronic control

In this case the hydraulic pump will work normally

a division of MANITEX INTERNATIONAL Inc.

Door side Distributor Engine side

a division of MANITEX INTERNATIONAL Inc.

4.1 Hydraulic Distributor Connection to function

Function Pressure out Return in

LS line to Pump P2-P1

From Pump P2 Steering system Main pressure

Pilot pressure To Dead man Valve

a division of MANITEX INTERNATIONAL Inc.

4.2 Hydraulic Distributor oil Pressure

Pump Power pressure Bar

Pump delivery Max 320 bar

Distributor Power pressure request (Bar)

Distributor Max request 320 bar

Check oil pressure Point

Distributor Out Distributor Pump Safety Valve of

a division of MANITEX INTERNATIONAL Inc.

4.3 Hydraulic Distributor Rele Valve

General safety valve

Boom Retraction valve

Boom Lift valve

Boom Extension valve

a division of MANITEX INTERNATIONAL Inc.