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Contents and 00_Foreworda_15031.doc

06.10.05

SERVICE MANUAL

PC5500 MACHINE MODEL

SERIAL NUMBER

PC5500-6 Diesel

15031 and up

This service manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice.

Contents and 00_Foreworda_15031.doc

06.10.05

Contents and 00_Foreworda_15031.doc

06.10.05

CONTENTS TABLE OF CONTENTS

00 01 02

Safety - Foreword Technical DATA (Leaflet) Assembly PROCEDURE (Brochure)

Section 1. Main assembly groups 2. Drive. 3. Hydraulic oil tank. 4. Hydraulic oil cooling. 5. Controlling. 6. Components 7. Main hydraulic pumps and pump regulation. 8. Operating hydraulic. 9. Hydraulic track tensioning system. 10. Hydraulic operated access ladder 11. 12. Hints for the hydraulic circuit diagram 13. Hints for the electric circuit diagram 14. ECS-T 15. Lubrication Systems

APPENDIX

)

• Each section includes a detailed table of contents.

Contents and 00_Foreworda_15031.doc

06.10.05

SAFTEY

SAFTEY NOTICE

SAFETY SAFETY NOTICE • IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. The following Symbols are used in this Manual to designate Instructions of particular Importance.

WARNING -

Serious personal injury or extensive property damage can result if the warning instructions are not followed. To prevent injury to workers, this symbol is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.

)

CAUTION -

Minor personal injury can result or a part, an assembly, or the shovel can be damaged if the caution instructions are not followed.

NOTE -

Refers to special information

GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • Always wear safety glasses when hitting parts with a hammer. • Always wear safety glasses when grinding parts with a grinder, etc. continued 00-1

SAFTEY

SAFTEY NOTICE

Cont'd: GENERAL PRECAUTIONS 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them. 6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK 7. Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower bucket, hammer or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out work on the oil or water circuits. continued 00-2

SAFTEY

SAFTEY NOTICE

Cont'd: PRECAUTIONS DURING WORK 13. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first. 14. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16. When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires. 17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18. As a general rule, do not use gasoline to wash parts. 19. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts. • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed. 21. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.

00-3

SAFTEY

SAFTEY NOTICE

FOREWORD GENERAL With this SERVICE MANUAL KOMATSU provides you with the description of the construction and the function of the major systems of the Hydraulic Excavator PC5500-E. We describe for you all functions and how to carry out the inspections and adjustments. How do you find "your" desired information? In the table of CONTENT all the functions and components are shown in their sequence of the description. If after reading this SERVICE MANUAL you can give us suggestions and comments for improvements - please do not hesitate to contact us. Komatsu Mining Germany GmbH - Service Training Postfach 180361 40570 Düsseldorf Tel.:0211 / 7109 - 206 Fax.:0211 / 74 33 07 The editorial staff will be pleased about your co-operation. - FROM THE PRACTICE - FOR THE PRACTICE -

)

• This service manual corresponds to the state of development of the machine at the time the manual was produced. Variations based on special customers request and special equipment are not included in this manual

00-4

FOREWORD

HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS HOISTING • Heavy parts (25 kg or more) must be lifted with a hoist etc.

)

• If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1. Check for removal of all bolts fastening the part to the relative parts. 2. Check for existence of another part causing interface with the part to be removed.

WIRE ROPES 1. Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "Z" or "S" twist ropes without galvanizing) Rope diameter [mm]

10,0

11,2 12,5 14,0 16,0 18,0 20,0 22,4 30,0 40,0 50,0 60,0

Allowable load [tons]

1,0

1,4

)

1,6

2,2

2,8

3,6

4,4

5,6

10,0 18,0 28,0 40,0

• The allowable load value is estimated to be 1/6 or 1/7 of the breaking strength of the rope used.

2. Sling wire ropes from the middle portion of the hook. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.

continued Cont'd: 00-5

FOREWORD

HOISTING INSTRUCTIONS

WIRE ROPES 3. Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load. • Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 4. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes make a 120° hanging angle. On the other hand, two ropes are subject to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150.

00-6

FOREWORD

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE (1Kgm = 9,806Nm) STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS

Bolt dia.

Wrench size [mm]

Tightening torque [Nm] Quality grades 8.8

10.9

12.9

M 8

M 10

M 12

108

127

M 14

118

173

202

M 16

179

265

310

M 18

255

360

425

M 20

360

510

600

M 22

485

690

810

M 24

620

880

1030

M 27

920

1310

1530

M 30

1250

1770

2080

M 33

1690

2400

2800

M 36

2170

3100

3600

M 39

2800

4000

4700

M 42

3500

4950

5800

M 45

4350

6200

7200

M 48

5200

7500

8700

M 52

6700

9600

11200

M 56

8400

12000

14000

M 60

10400

14800

17400

M 64

12600

17900

20900

M 68

100

15200

21600

25500

32 35 41 46

Insert all bolts lubricated with MPG, KP2K

00-7

FOREWORD

CONVERSION TABLE

CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. EXAMPLE Method of using the Conversion Table to convert from millimeters to inches. 1. Convert 55 mm into inches. (a) Locate the number 5 in the vertical column at the left side, take this as (A), then draw a horizontal line from (A). (b) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). (c) Take the point where the two lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 millimeters = 2.165 inches. 2. Convert 550 mm into inches. (a) The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to convert it to 55 mm. (b) Carry out the same procedure as above to convert 55 mm to 2.165 inches. (c) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

00-8

FOREWORD

00-9

CONVERSION TABLE

FOREWORD

CONVERSION TABLE

00-10

FOREWORD

00-11

CONVERSION TABLE

FOREWORD

CONVERSION TABLE

00-12

FOREWORD

CONVERSION TABLE

Basic Values in Ohm according to DIN 43 76 For Measuring Resistor PT100

°C

-0

-1

-2

-3

-4

-5

-6

-7

-8

-9

-50

80,31

79,91

79,51

79,11

78,72

78,32

77,92

77,52

77,13

76,73

-40

84,27

83,88

83,48

83,08

82,69

82,29

81,89

81,50

81,10

80,70

-30

88,22

87,83

87,43

87,04

86,64

86,25

85,85

85,46

85,06

84,67

-20

92,16

91,77

91,37

90,98

90,59

90,19

89,80

89,40

89,01

88,62

-10

96,09

95,69

95,30

94,91

94,52

94,12

93,73

93,34

92,95

92,55

100,00

99,61

99,22

98,83

98,44

98,04

97,65

97,26

96,87

96,48

°C

100,00

100,39

100,78

101,17

101,56

101,95

102,34

102,73

103,12

103,51

103,90

104,29

104,68

105,07

105,46

105,85

106,24

106,63

107,02

107,40

107,79

108,18

108,57

108,96

109,35

109,73

110,12

110,51

110,90

111,28

111,67

112,06

112,45

112,83

113,22

113,61

113,99

114,38

114,77

115,15

115,54

115,93

116,31

116,70

117,08

117,47

117,85

118,24

118,62

119,01

119,40

119,78

120,16

120,55

120,93

121,32

121,70

122,09

122,47

122,86

123,24

123,62 124,01, 124,39

124,77

125,16

125,54

125,92

126,31

126,69

127,07

127,45

127,84

128,22

128,60

128,98

129,37

129,75

130,13

130,51

130,89

131,27

131,66

132,04

132,42

132,80

133,18

133,56

133,94

134,32

134,70

135,08

135,46

135,84

136,22

136,60

136,98

137,36

137,47

138,12

100

138,50

138,88

139,26

139,64

140,02

140,39

140,77

141,15

141,53

141,91

110

142,29

142,66

143,04

143,42

143,80

144,17

144,55

144,93

145,31

145,68

120

146,06

146,44

146,81

147,19

147,57

147,94

148,32

148,70

149,07

149,45

130

149,82

150,20

150,57

150,95

151,33

151,70

152,08

152,45

152,83

153,20

140

153,58

153,95

154,32

154,70

155,07

155,45

155,82

156,19

156,57

156,94

150

157,31

157,69

158,06

158,43

158,81

159,18

159,55

159,93

160,30

16067

00-13

FOREWORD

CONVERSION TABLE

TEMPERATURE Fahrenheit – Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.

00-14

Main Assembly Groups

Section 1.0 Page 1

Table of contents section 1.0

Section 1.0

06.10.05

Page Main assembly groups General lay out

1.1

Superstructure

1.1.1

Machine house

1.1.2

Hydraulic Oil Reservoir

1.1.3

Hydraulic Oil Cooler

1.1.4

Fuel Tank

1.1.5

Counter weight

1.1.6

Cab support

1.1.7

Operators cab

1.1.8

Control Blocks

1.1.9

Swing gears

1.2

Under carriage

1.3

Attachment

1.3.1.

Backhoe Attachment (BHA)

1.3.2.

Front Shovel Attachment (FSA)

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1.0 2

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Main Assembly Groups

Section 1.0 Page 2

General layout Legend for illustration (Z 22387): (1) Superstructure (2) Under carriage (3) Front Shovel Attachment (FSA) (4) Backhoe Attachment (BHA)

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1.0 3

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Section 1.0 Page 3

Main Assembly Groups

1.1

Superstructure Legend for illustration (Z 22386): (1) Operators Cab with integrated FOPS. (2) Exhaust (3) Air cleaner (4) Cab support (contains the electrical switch board) (5) Swing ring connection (6) Fuel reservoir (7) Hydraulic ladder (8) Counter weight (9) Hydraulic oil cooler with hydraulic driven fans (10) Hydraulic oil reservoir (11) Batteries (12) Swing Gear (13) Grease pump of the Central Lubrication System (14) Grease pump of the Swing gear pinion Lubrication System (15) Main Control blocks with high pressure filters

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(16) (17) (18) (19) (20)

Engine 1 Flexible coupling, oil filled PTO gear with hydraulic pumps Main hydraulic pumps 1, 2 and 3 Radiator for the engine cooling system

(21) (22) (23) (24) (25)

Engine 2 Flexible coupling, oil filled PTO gear with hydraulic pumps Main hydraulic pumps 4, 5 and 6 Radiator for the engine cooling system

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1.0 4

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Main Assembly Groups

1.1

Section 1.0 Page 4

Superstructure 1.1.1

Machine house

Legend for illustration (Z 22390): (1) Roof mounted exhaust (2) Roof mounted air cleaners with restriction switches (3) Expansion tank of the radiator for the engine cooling system (4) Hydraulic control and filter panel (5) PTO gear box (6) Main hydraulic pumps (7) Auxiliary pumps, installed at the drive through shaft of the main hydraulic pumps (piggyback pumps) (8) Hydraulic pump for radiator fan drive (9) Hydraulic pump for the hydraulic oil cooler fan drive (10) Suction oil reservoir (11) Flexible coupling, oil filled (12) Batteries (13) Engine 1 (14) Engine 2 (15) Hydraulic motor for the radiator fan drive (16) Radiator for the engine cooling system

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1.0 5

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Main Assembly Groups

1.1

Section 1.0 Page 5

Superstructure 1.1.2

Hydraulic Oil Reservoir

Legend for illustration (Z 22391): (1) Breather filter (2) Temperature controlled back pressure valve (3) Drain coupling of the hydraulic oil reservoir (4) Return oil filter (5) Case drain (leak oil) filter (6) Main shut-off valve (Gate valve) with compensator (7) Return oil collector tube (8) Drain coupling of the Return oil collector tube (9) Back pressure valves for swing motors

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Main Assembly Groups

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Section 1.0 Page 6

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Main Assembly Groups

1.1

Section 1.0 Page 6

Superstructure 1.1.3

Hydraulic Oil Cooler

Legend for illustration (Z 22392): (1) Cooler frame with swing out facility (2) Hydraulic motor of upper fan (3) Upper fan (4) Fan guard (5) Outer part of the upper radiator set (6) Inner part of the upper radiator set (7) Hydraulic motor of lower fan (8) Lower fan (9) Fan guard (10) Outer part of the lower radiator set (11) Inner part of the lower radiator (12) Swing out doors (13) Locking bars to secure the swing out doors

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1.0 7

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Main Assembly Groups

1.1

Section 1.0 Page 7

Superstructure 1.1.4

Fuel tank (Fuel reservoir)

Legend for illustration (Z 21473): (1) Fuel tank (2) Fuel tank breather valve (3) Main shut-off solenoid valves (4) Drain coupling with protection cap (5) Shut-off cock for fuel pressure transducer (6) Fuel pressure transducer

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1.0 8

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Section 1.0 Page 8

Main Assembly Groups

1.1

Superstructure 1.1.5

Counter weight

Legend for illustration (Z 21474): (1) Counter weight Total weight 40000 kg (2)

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Mounting bolts Quantity

Bolt size (mm)

Grade

SW* (mm)

Tightening torque (Nm)

M 48 x 380

10.9

7500

SW = Wrench size

(3)

Lifting points

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1.0 9

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Section 1.0 Page 9

Main Assembly Groups

1.1

Superstructure 1.1.6

Cab support

Legend for illustration (Z 21475): (1) Cab support (Location of electrical switch board “X2”) (2) Mounting bolts Quantity Bolt size Grade SW* Tightening (mm) (mm) torque (Nm) 6

M 36 x 320

10.9

3100

Grade

SW* (mm)

Tightening torque (Nm)

10.9

3100

* SW = Wrench size (3)

Mounting bolts Quantity Bolt size (mm) 6

M 36 x 160

* SW = Wrench size (4) (5) (6)

06.10.05

Door Gasket Door handle (adjustable)

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1.0 10

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Main Assembly Groups

1.1

Section 1.0 Page 10

Superstructure 1.1.7

Operators cab

Legend for illustration (Z 21476): (1) (2) (3) (E19)

Monitor panel Switch panel Operators seat Control lever – EURO Control

– KMG Control

(E20)

Control lever – EURO Control

– KMG Control

(E21a)

Control pedal

A - forward Left track B - reverse

(E21b)

Control pedal

A - forward Right track B - reverse

(E22) (E23) (E24)

06.10.05

Control pedal - Swing brake Control pedal (left) Control pedal (right)

Clam closing Clam opening

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1.0 11

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Main Assembly Groups

1.1

Section 1.0 Page 11

Superstructure 1.1.8

Control blocks

Legend for illustration (Z 21477a): (1) Control block carrier (2) Remote control valves (3) Main control blocks (4) High pressure filter

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1.0 12

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Main Assembly Groups

1.1

Section 1.0 Page 12

Superstructure 1.1.9

Swing gears

Legend for illustration (Z 22395): (1) Swing gear box (2) Swing parking brake (3) (4) (5) (6) (7) (8) (9) (10) (20.1 + 20.2) (49.1 + 49.2)

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– Spring loaded multi disk brake (Released by oil pressure) Parking brake Control port (X) Oil level gauge - gear box Breather – gear box Oil filling plug – gear box Oil level gauge – motor adapter housing Breather – motor adapter housing Oil drain plug – motor adapter housing Oil drain plug - gear box Swing motor Swing brake valve block

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1.0 13

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Main Assembly Groups

1.2

Section 1.0 Page 13

Under carriage Legend for illustration (Z 21481): (1) Undercarriage center body (2) Crawler carrier R.H.-side (3) Crawler carrier L.H.-side (4) Connecting bolts, between center body and crawler carriers (5) Crawler tracks (6) Rotary distributor (7) Brake valves (8) Travel motors (9) Parking brakes, spring loaded disk type brakes (10) Travel gear (11) Sprocket (12) Track rollers (13) Carrier rollers (14) Guide wheel (Idler)

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1.0 14

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Main Assembly Groups

1.3

Section 1.0 Page 14

Attachment 1.3.1

Backhoe attachment (BHA)

Legend for illustration (Z 21482): (1) Boom (2) Boom Cylinders (3) Stick (4) Stick Cylinders (5) Bucket (6) Bucket Cylinders (7) Control arm (8) Linkage

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Main Assembly Groups

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Section 1.0 Page 15

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Main Assembly Groups

1.3

Section 1.0 Page 15

Attachment 1.3.2

Front Shovel Attachment (FSA)

Legend for illustration (Z 21483): (1) Boom (2) Boom Cylinders (3) Stick (4) Stick Cylinders (5) Bucket back wall (6) Bucket Cylinders (7) Bullclam (8) Bucket Clam cylinders

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Drive

Section 2.0 Page 1

Table of contents section 2.0

Section 2.0

Page Prime drive assembly General lay out

2.1

Engine and PTO mounts

3+4

2.2

Coupling

2.3

Air filter

2.4

Fan drive and radiator assembly

7+8

2.5

Radiator fan drive speed adjustment

9 + 10

2.6

Pump distributor gearbox (PTO)

2.7

Pump-spline lubrication

2.8

PTO Lubrication and cooling

13 + 14

2.9

Hydraulic pumps – location, drive speed and flow rates

2.0 2

Drive

2.0

Section 2.0 Page 2

Prime drive assembly Legend for illustration (Z 22395): (1) Engine 1 (2) Torsion type coupling (2) Pump distributor gear (PTO) (6) (7) (8)

Engine 2 Torsion type coupling Pump distributor gear (PTO)

(5)

Power frame

General The drive unit, consists of the two PTO gear and the two engines, are bolted to the power frame. The connection between engine and PTO gear is a flexible coupling.

2.0 3

Section 2.0 Page 3

Drive

2.1

Engine and PTO mounts Legend for illustration (Z 21601): (1) Flexible bearing (2) Bolt with self locking nut

(3)

Quantity

Bolt size (mm)

4 per mount

M 10 x35

Bolt size (mm)

Grade

SW* (mm)

Tightening torque (Nm)

M 24 x420

10.9

snugly

Bolt size (mm)

Grade

SW* (mm)

Tightening torque (Nm)

M 16x 80

10.9

265

Bolt size (mm)

Grade

SW* (mm)

Tightening torque (Nm)

M 36 x250

10.9

Not specified

Bolt size (mm)

Grade

SW* (mm)

Tightening torque (Nm)

M 24 x 230

10.9

880

Grade

SW* (mm)

Tightening torque (Nm)

10.9

510

Grade

SW* (mm)

Tightening torque (Nm)

10.9

1770

Bolt Quantity 16

(12) (13)

Nut Bolt Quantity

(11)

8.8

Cup springs, seven per bolt Stop bolt Quantity

(9) (10)

Tightening torque (Nm)

Rubber-bounded metal bar Self locking nut M24 Bolt M16 with self locking nut Quantity

(7) (8)

SW* (mm)

Tie bolt Quantity

(4) (5) (6)

Grade

Bolt size (mm) M 20 x 120

Resilient sleeve Bolt Quantity 4

Bolt size (mm) M 30 x 200

(14)

Resilient sleeve

SW = Wrench size continued

2.0 4

Drive

Section 2.0 Page 4

Cont'd 2.1

Engine and PTO mounts General The flexible bearings are installed to take the vibrations and the torsion forces and they carry the total weight of the engine, the pump distributor gear with all hydraulic pumps. Check mounting and security of Diesel engine and pump distributor gear, illustration (Z 21601) •

Check all flexible bearings (1) for engine and pump distributor gear. Check the flexible bearings for damage and signs of fatigue. Make sure that there is no contact between the upper and lower metal brackets of the flexible bearings (1). Replace the bearings if necessary. Use new bolts and self locking nuts (2). After new flexible bearings have been installed, check distance (B) on both torque supports.

)

• All flexible bearings (1) and all rubber-bounded metal bars (4) should be replaced during engine overhaul.

•

Check distance (B) between torque support and stop bolt (8). With setting of the flexible engine bearings (1) the distance (B) increases and must be readjusted. To do this, loosen lock nut (9) and tighten stop bolt (8) until the correct distance (B) is obtained. Tighten lock nut (9) and recheck distance (B). If new flexible engine bearings (1) have been installed, replace also cup springs (7) and adjust distance (B) to 29 mm.

•

Check tie bolts (3) on front and rear carrier units for looseness. (four tie bolts) Check to make sure that the self locking retainer nuts (5) are tight and that there is no gap between nut and rubber-bounded metal bar (4). If necessary retighten retainer nuts (5) snugly. Check rubber-bounded metal bars (4) for signs of fatigue and damage. Replace as necessary.

)

• Check all bolt connections for correct tightening torque. • Check condition of engine carrier and brackets. If any damages, failures or wrong condition are found, corrective action must be taken. • For more information, refer to Parts & Service News REF NO AH01521.

2.0 5

Drive

2.2

Section 2.0 Page 5

Coupling Legend for illustration (Z 21602): (1) Coupling Assy. (2) Input drive flange (3) Leave spring assy. (4) Output drive flange (5) Dip stick (6) Bleeder plug (7) O-Rings (8) Spacers E Engine side G Gearbox side (PTO-side) Task: The coupling is the connecting link between the engine and the PTO Function: "GEISLINGER COUPLING" The combination of the high elasticity of its leaf springs with complimentary viscous damping by oil displacement, ensures that the coupling reduces the intensity of torsional vibrations effectively. The widest engine speed range free of vibration periods and dangerous resonance’s is thus obtained. The springs (3) together with the inner driving and outer driven member form chambers A and B which are filled with oil. If the outer member is displaced in relation to the inner member, the deflection of the leaf springs displaces oil from one chamber to the next, by this action the relative movements of the two members of the coupling are braked and the vibrations are dampened. The spacers (8) limits the movement of the leaf springs.

2.0 6

Drive

2.3

Section 2.0 Page 6

Air Filter Legend for illustration (Z 22396): (1) Wing nut (2) Washer (3) Seal ring (4) Main filter element (5) Cotter pin (6) Wing nut with service indicator (7) Safety element (8) Maintenance switch (9) Flap for pre-separator (10) Air intake with pre-separation The air is filtered by a dry-air-filter with pre-separator for coarse impurities. One filter housing includes 2 filter sets. Each one consists of a main filter element (4) and a safety element (7). The filter condition is monitored by the maintenance switch (8). A fault message like „Engine air filter restricted“ is displayed at the operator's dash board as soon as the restriction is too high. The wing nut (6) incorporates a service indicator. Green indication = O.K. Red indication = safety element (7) needs maintenance. The indication mark must be re-set by blowing through the nut opposite to the normal air flow or by sucking at the other end, this can be done with the mouth.

)

• For service intervals and procedure refer to the OPERATION AND MAINTENANCE MANUAL of the corresponding machine.

2.0 7

Drive

2.4

Section 2.0 Page 7

Fan drive and radiator assembly

Legend for illustration (Z 22398): (1) Radiator (2) Fan motor (Axial piston motor) (3) Intake air fan (4) Bearing group carrier (5) Ball bearings (6) Breather filter (7) Oil level plug (8) Check valve (Anti-cavitation valve)

)

• For service intervals and procedure refer to the OPERATION AND MAINTENANCE MANUAL of the corresponding machine.

continued

2.0 8

Drive

Section 2.0 Page 8

Cont'd 2.4

Fan drive and radiator assembly Legend for illustration (Z 22399): (1) Radiator (2) Intake air fan (10.1) Axial piston pump Engine 1 (fixed displacement pump, with variable setting) (10.3) Axial piston pump Engine 2 (fixed displacement pump, with variable setting) (23.1) Fan motor (Axial piston motor) (23.2) Fan motor (Axial piston motor) (41) Main oil reservoir (168.3) Pressure relief valve – Engine 1 radiator fan drive (168.4) Pressure relief valve – Engine 2 radiator fan drive (68.3) Pressure filter with pressure differential switch B21-1 (Engine 1) (68.5) Pressure filter with pressure differential switch B21-2 (Engine 2) (103.3) Check valve engine 1– (Anti cavitation valve for fan drive motor) (103.4) Check valve engine 2– (Anti cavitation valve for fan drive motor) (148.13) 4/3 direction flow valve – Engine 1 radiator fan speed (stop, low and high speed) (148.14) 4/3 direction flow valve – Engine 2 radiator fan speed (stop, low and high speed) (169.3) pressure reduction valve (low fan speed adjusting) engine 1 (169.4) pressure reduction valve (low fan speed adjusting) engine 2 (L) Leak oil (case drain) to tank (P) Pressure to motor (R) Return oil to tank Function: From pump (10.1 / 10.3) flows the oil through the filter (68.3 / 68.5) to the fan motor (23.1 / 23.2) and then back to the tank. The check valve (103.3 / 103.4) act as an anti cavitation valve and is installed, because the fan motor -driven by inertial force- is running for a short period after the engine has been switched off. The hydraulic circuit "Fan drive" is secured by the pilot controlled pressure relief valve (168.3 / 168.4). This valve works together with the 4/3 direction flow valve continued

2.0 9

Drive

Section 2.0 Page 9

Cont'd

(148.13 / 148.14) and the pressure reduction valve (169.1 / 169.4). The 4/3 direction flow valve (148.13 / 148.14) with the solenoids (Y14A-1 and Y14B-1 / Y14A-2 and Y14B-2) operates depending on engine coolant temperature. The PLC (Programmable Logic Control) in the cab support controls the 4/3 direction valve (148.13 / 148.14) by activating the solenoids (Y14A-1 and Y14B-1 / Y14A-2 and Y14B-2), depending on the engine coolant temperature. With de-energized solenoids the fan turn with max. speed. With activated solenoid (Y14A-1 / Y14A2) the fan is running with a very low speed, caused by the flow resistance only. With activated solenoid (Y14B-1 / Y14B2) the fan is running with middle setted speed, caused by the reduced pilot pressure on port X of pressure relief valve (168.3 / 168.4) with the pressure reduction valve (169.1 / 169.4).

2.0 10

Drive

2.5

Section 2.0 Page 10

Radiator fan drive speed adjustment Basic Adjustment Legend for illustration (Z 22400): (1) Dust cap (2) Lock nut (3) Set screw (P) Axial piston pump (fixed displacement pump, with variable setting) (6) Qmin stop bolt (6.1) Lock nut (7) Qmax stop bolt (7.1) Lock nut (10) Positioning pin (mover) (168.3) Pressure relief valve - Engine radiator fan drive (Engine 1) (168.4) Pressure relief valve - Engine radiator fan drive (Engine 2) (169.3) pressure reduction valve - Engine radiator fan drive (Engine 1) (169.4) pressure reduction valve - Engine radiator fan drive (Engine 2) (Y14A-1 /Y14B-1)) 4/3 direction flow valve – Engine 1 (Y14A-2 /Y14B-2)) 4/3 direction flow valve – Engine 2 (L1) Measurement of Qmin stop bolt (L2) Measurement of Qmax stop bolt (M19-1) Pressure check points - Engine 1 radiator fan drive operating pressure (M19-2) Pressure check points - Engine 2 radiator fan drive operating pressure

)

• Basic adjustment has to be carried out whenever one of the following components has been replaced: - pump - relief valve - hydraulic motor continued

2.0 11

Drive

Section 2.0 Page 11

Cont'd 2.5

Radiator fan drive speed adjustment Basic Adjustment max fan speed 1. Reduce the output flow of the respective pump (P),by adjusting the minimum possible swivel angle, to avoid over speeding the fan: To do this, loosen both lock nuts (6.1 + 7.1) and turn out bolt (6) and turn in bolt (7) the same length. This is necessary to avoid a loose positioning pin (10), resulting in oscillating of the cylinder barrel. Tighten the lock nuts. 2. Remove protection cap (1) from relief valve (168.x), loosen lock nut (2) and turn set screw (3) fully clockwise and then a half turn counter clockwise. 3. Disconnect the plug connectors (Y14A-x and Y14B-x) of the 4/3 direction flow valve, to ensure that the full flow of pump P will be delivered to the fan motor. The valve is in neutral position and all ports are blocked. 4. Connect a pressure gauge to check point (M19-x). 5. Start the engine and let it run with max. speed. 6. Check the fan speed with a non-contact rev counter Required fan speed: 1250 min-1 • Be careful not to get caught in the fan or other rotating parts 7.

)

Increase the output flow of pump P ,by adjusting the swivel angle, until the fan speed will be 20 min-1 higher than required: To do this, loosen both lock nuts (6.1 + 7.1) and turn in bolt (6) and turn out bolt (7) the same length. This is necessary to avoid a loose positioning pin (10), resulting in oscillating of the cylinder barrel. Tighten the lock nuts (6.1 + 7.1). • Do not exceed the maximum permissible operating pressure of 230 bar

• Note down the lengths ”L1” and ”L2” as reference measurements.

continued

2.0 12

Drive

Section 2.0 Page 12

Cont'd

8. 9.

Loosen lock nut (2) of the relief valve (168.x), and decrease the pressure with set screw (3) until the correct fan speed is obtained. Tighten lock nut (2) and fix protection cap (3).

Basic Adjustment middle fan speed 10. Activate the 4/3 direction flow valve (Y14B-x), by connecting the solenoid plug (Y14B-x ) to permanent 24 V. Use the 24V socket at the PTO *). 11. Check the fan speed with a non-contact rev counter Required fan speed: 1000 min-1 12. If adjustment is necessary loosen lock nut (5) of the relief valve (169.x), and decrease the pressure with set screw (4) until the correct fan speed is obtained. 13. Stop engine and reconnect the plugs to the correct positions. 14. Disconnect the pressure gauge from check point (M7). Fan speed check If the maximum fan speed is out of adjustment, increase or decrease first the pressure at relief valve (168.x), to change the speed. • Do not exceed the maximum permissible operating pressure of 230 bar

If the speed can not be raised by increasing the pressure then increase the output flow of pump (10.x).

Prepare a test wire with a plug ET-No. 891 039 40, and a plug ET-No. 440 305 99. Connect terminal 1 to positive (+) (center off plug 440 305 99) and terminal 2 to ground (-).

2.0 13

Drive

2.6

Section 2.0 Page 13

Pump distributor gearbox (PTO) Legend for illustration (Z 22409): (1) Oil level gauge (2) Oil filler plug (3) Breather filter (4) Oil collector reservoir for auxiliary pump drive shaft housing (5) Breather filter with oil level gauge (drive shaft housing) (6) Main pump drive shaft housings (7) Oil level plug of main pump drive shaft housing (8) Oil filler plug with breather pipe of main pump drive shaft housing (9) Oil drain plug of main pump drive shaft housing (10) Oil drain plug of PTO gear (11) Flange for heater studs (12) Gear oil temperature probe mounting bore (13) Thermostat switch mounting bore cover plate (14) Suction line connection for gear oil cooling (15) Return line connection from gear oil cooler (D) Drive flange (M) Power take off for main pumps (R) Power take off for engine radiator fan drive pump (C) Power take off for hydraulic oil cooler fan drive pump Description The pump distribution gear (PTO gear) is a spur gear design and driven by an diesel engine. The PTO gear runs in anti friction bearings and has been provided with a splash lubrication system. The oil supply of the bearings and tooth contacts takes place by an injection. The gearwheels are of case-hardened steel. The hydraulic pumps are directly attached to the gearbox. O-rings included in the supply enable the unit to be reliably sealed statically. The gearbox housing is a one-piece design and made of Grey cast iron. Gearbox design allows a direct attachment to the engine via connection flange. The gearbox has been provided with connections for a separate cooling system resp. for heating rods. For more information refer to the REPAIR MANUAL Description for the lubrication see next pages.

2.0 14

Drive

2.7

Section 2.0 Page 14

Pump-spline lubrication Drive shaft housings Legend for illustration (Z 21608): (1) Oil filler plug with breather pipe of main pump drive shaft housing (2) Oil collector reservoir for auxiliary pump drive shaft housing (M) Configuration, main pump drives (A) Configuration, auxiliary pump drives All drive shaft housings are filled with the same gear oil as the pump distributor gear. This is done for two reasons: 1. To lubricate the multi-spline connections, to prevent wear and corrosion. 2. It makes it easier to determine a seal ring leak at one of the drive shaft connections. Function: M If the oil level increases the oil drops out of the breather pipe (1). If this oil is gear oil it indicates a possible leak at the gearbox side. If the oil is a mixture of gear oil and hydraulic oil it shows a possible leak at the pump side. If at an oil level check a loss of oil is found it may be due to worn or defective radial seal rings. Function: A The oil is filled in via the oil collector reservoir (2). All auxiliary drive shaft housings are connected by pipes with the reservoir. The reservoir is filled approx. one half with oil. If the oil level in the reservoir increases due to leakage the oil drops out from the breather filter (with oil level gauge) on top of the reservoir. Now a check has to be done to find out which one of the drive shafts seals is damaged. It can be done by disconnecting temporary the pipe to the reservoir. Disconnect the pipe at the drive shaft housing, plug the pipe and leave the union open. If now at operation the oil still comes out of the union, this drive shaft seal is gone. Otherwise check sequential all auxiliary drives.

2.0 15

Drive

2.8

Section 2.0 Page 15

PTO Lubrication and cooling Legend for illustration (Z 22410e): The machine is equipped with two engines and gearboxes. The engine close to the counter weight is called engine 1 and the engine to the front is called engine 2. The extension of the component designation shows the mounted position. Example: Pressure filter (69.1) is the pressure filter for the PTO lubrication of engine 1 and (69.2) for engine 2. (1) Line to the cooler (hot oil) (2) Return line from the cooler (cooled oil) (3) Return line from valve to PTO (relief line) (4) Suction line from PTO oil pan to the pump (P) Connections to spray nozzles (8.1)(8.4) Gear pump PTO-gearbox lubrication (69.1)(69.2) Pressure filter - PTO gear lubrication (74.1)(74.2) Pressure relief valve, 7,5 bar (78.14)(78.15) Solenoid valve (Y53-x), (reduction of relief valve pressure) (105.3+105.4) Oil cooler, part of hydraulic oil cooler engine 1 (105.1+105.2) Oil cooler, part of hydraulic oil cooler engine 2 (M1-1)(M1-2) Pressure check point (B17-1)(B17-2) Pressure switch, 0,5 bar (B27-1)(B27-2) Maintenance switch, 5 bar (B49-1) Temperature sensor Function: Pump (8.1)/(8.4) forces the gear oil from the gear oil pan through filter (69.1)/(69.2)) to pressure relief valve (74.1/74.2). This pressure relief valve acts as a back pressure valve causing that most of the oil passes through the gear oil coolers (105.3+105.4)/(105.1+105.2). The gear oil coolers are a small part of the hydraulic oil coolers, thus the gear oil gets cooled by the same air stream as the hydraulic oil. From the coolers the oil flows to the port (P) of the gear and internally via a system of pipes to the several spray nozzles. The spray nozzles in the gear case ensure proper and adequate distribution of the lube oil. The circuit is monitored by the pressure switches (B17-1). At too low lube oil pressure (0.5 bar), a fault message will be displayed on the monitor at the dash board. The gear oil temperature is monitored by the sensor unit (B49-1) (B49-2). At too high oil temperature a fault message will be displayed on the monitor at the dash board. If the oil temperature is to low, solenoid valve (Y53-1) (Y53-2) energized and opened port X of the pressure relive valve (74.1) (74.2). This reduced the relieve valve pressure setting. The main gear oil flow direct back to the PTO to quick warm up of the gear oil. continued

2.0 16

Section 2.0 Page 16

Drive

Cont’d.: 2.8

PTO Lubrication and cooling Legend for illustration (Z 22414) (1) Pilot operated relief valve (2) Plug screw (3) Valve piston (4) Port for pressure switch B17-1 (6) Port for pressure check stud (7) Jet bore

(8) (9) (B27-x) (74.x) (A) (T)

Valve spring Seal rings Maintenance switch Pressure relief valve Pressure port Return from valve

Adjustments: • The adjustment of the maximum permissible PTO lube pressure, has to be carried out with cold oil to avoid serious damages to the coolers. • The check for a sufficient PTO lube pressure has to be carried out with warm oil to avoid serious damages gearbox. Setting the pressure relief valve (74.x) at cold oil. 1. Connect a pressure gauge to check point (M1.x). 2. Disconnect plug of solenoid valve Y53-1/ Y53-2 3. Start the engine and let it run with max. speed. 4. Maximum pressure: 7,5 bar. If adjustment is required: 5. Remove protection cap (1a). 6. Loosen lock nut (1b). 7. Set the pressure with set screw (1c). 8. Tighten lock nut (1b) and re-install protection cap (1a) 9. Reconnect plug of Y53-1/ Y53-2

)

• If the pressure of 7,5 bar cannot be adj. 100 %, adj. to the highest visible pressure.

Checking the PTO lube pressure at operating temperature (warm oil) 1. Connect a pressure gauge to check point (M1.x). 2. Start the engine and let it run with max. speed. 3. Required pressure: 2-7,5 bar.

2.0 17

Section 2.0 Page 17

Drive

2.9

Hydraulic pumps – location, drive speed and flow rates Legend for illustration (Z 22415a): (1 - 6)

Axial piston pump (swash plate type) Vg max theoretical flow rate, each Qmax Drive speed* n for all working motions

= 500 cm³/rev = 700 Liter/min = 1400 min-1

(10.1), (10.3) Axial piston pump theoretical flow rate Drive speed* for radiator fan drive

Vg max Qmax n

= 80 cm³/rev = 158 Liter/min = 1973 min-1

(10.2), (10.4) Axial piston pump theoretical flow rate Drive speed* for oil cooler fan drive

Vg max Qmax n

= 80 cm³/rev = 142 Liter/min = 1770 min-1

(8.1), (8.4)

Gear pump theoretical flow rate Drive speed* for PTO gear lubrication

Vg Qmax n

= 58,7 cm³/rev = 82,2 Liter/min = 1400 min-1

(8.2), (8.5)

Gear pump theoretical flow rate Drive speed*

Vg Qmax n

= 58,7 cm³/rev = 82,2 Liter/min = 1400 min-1

Vg Qmax n

= 85,7 cm³/rev = 120 Liter/min = 1400 min-1

for hydraulic oil circulation (7.1), (7.2)

)

Gear pump theoretical flow rate Drive speed* for pilot pressure supply

• * at 1800 min-1 input drive speed

Hydraulic Oil Reservoir

Section 3.0 Page 1

Table of contents section 3.0 Section 3.0

Page Hydraulic oil reservoir General lay out

3.1

Main oil tank, location of switches, sensors etc.

3.2

Suction oil tank with strainers

3.3

Return oil collector tube with strainer

3.4

Back pressure valve

3.6

Return and Leak Oil Filter

3.7

Breather Filter

3.5

04.01.07

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3.0 2

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Hydraulic Oil Reservoir

Section 3.0 Page 2

General lay out Legend for illustration (Z 22416b): (1) Filter cover retainer (2) Filter cover (3) (A) – Return oil filter – 10 µm (4x) (B) – Case drain filter – 3 µm (1x) (4) Man hole cover (5) Hydraulic oil filler plug (6) Differential pressure switch, screen filter monitoring (7) Test port, back pressure 8 bar (8) Test port, back pressure swing motor 15 bar (24) Pressure switch B24 – monitors item (132.1+132.2) (39) Hydraulic oil level gauge (41) Main oil reservoir (114) Return oil collector tube with pressure check point M10 (115) Back pressure valve (118) Oil drain, quick release coupling (128) Shut off valve (Gate valve) with monitoring switch S31 (129) Compensator (132.1 + 132.2) Breather filter (178) Oil cooler filter (screen filter) The hydraulic oil tank is a welded sheet-metal construction. The filling capacity is about 3800 litres. The tank contains four return oil filters (3-A) and one case drain filter (3-B). The breather filter (132.1 + 132.2) cleans the air that streams into the tank. The back pressure valve (115) and the pressure check point (M10) are located at the collector tube (114) for return oil. The connection to the suction tank can be closed with the shut- off valve (118) to prevent oil flow during repairs on the hydraulic pumps. This unit is controlled by the switch S31, to prevent a motor start with closed shut-off valve. Fault message ”Start blocked because of main Shut-Off (gate) valve” is displayed at the operators dash board. The screen filter (178) protect the oil cooler for internal contamination, the filter is monitored by differential pressure switch (178). The back pressure valves (8) increase the circulation pump pressure to 15 bar for cavitation protection of the swing motors.

04.01.07

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3.0 3

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Hydraulic Oil Reservoir

3.1

Section 3.0 Page 3

Main oil tank, location of switches, sensors etc. Legend for illustration (Z 21495a): (B4) Oil level sensor “Hydraulic oil level too low” (B15) Hydraulic oil temperature probe “Hydraulic oil temperature below: too hot” (B24) Breather filter pressure switch (B25) Pressure switch – Pressure leak oil chamber (B26) Pressure switch – Pressure return oil chamber (B32) Hydraulic oil temperature probe “Temp. gauge cabin” (B42) Oil level sensor “Oil level maximum” (B50) Oil level sensor “Hydraulic oil refill level” (Y101) Solenoid valve “Back pressure reduction”

04.01.07

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3.0 4

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Hydraulic Oil Reservoir

3.2

Section 3.0 Page 4

Suction oil tank with strainers Legend for illustration (Z 22418): (1) Suction oil reservoir (2) Drain coupling (3) Bolt (4) Gaskets (5) Main suction oil strainer (6) Gaskets (7) Intermediate pipe (8) Nut (9) Bolt (10) Compensator (11) Suction strainer – one for each main pump (12) Suction hose connection pipe The suction oil tank (1) is a welded sheet-metal construction. The capacity is 187 liters. The suction lines of all hydraulic pumps are connected to the suction tank.

04.01.07

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3.0 5

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Hydraulic Oil Reservoir

Section 3.0 Page 5

3.3 Return oil collector tube with strainer Legend for illustration (Z 21497a): (1) Return oil collector tube - Part 1 (2) Return oil collector tube - Part 2 (3) Return oil collector tube - Part 3 (4) Strainer (5) Bolt (6) Self locking nut (7) Gasket (8) Differential pressure switch B165

Task: The strainer is installed to prevent the hydraulic oil coolers from getting clogged up in case of contamination in the main return oil circuit. Excessive increase of the hydraulic oil temperature can be an indication for a restricted strainer, i.e. bad cooling performance due to insufficient oil flow through the coolers. In case that main components such as cylinders or motors are internal fragmentary damaged, the strainer should be inspected for metal chips.

04.01.07

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3.0 6

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Hydraulic Oil Reservoir

3.4

Section 3.0 Page 6

Back pressure valve Legend for illustration (Z 21498): (1) Back pressure valve assembly (2) Solenoid valve (Y101)

Task: The back pressure valve has to fulfill two functions in the hydraulic system: 1. To ensure a sufficient pressure within the return oil circuit, i.e. to supply oil via the anticavitaton valves to the low pressure side of cylinders, respectively motors. 2. To force the return oil through the coolers depending on the present hydraulic oil temperature, controlled by solenoid valve Y101. - Low temperature ⇒ low volume through the coolers - High temperature ⇒ high volume through the coolers

)

04.01.07

• Further information about the function principle and adjustments, refer to Section 4.0 this Manual.

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Hydraulic Oil Reservoir

3.6

Section 3.0 Page 7

Return and Leak Oil Filter Legend for illustration (Z 21500): (1) Filter cover retainer (2) Filter cover with o-ring (3) Pre-tensioning spring (4) Retainer (5) Filter assembly (6) Filter pot with machined cover (7) Main filter element, 10 micron absolute (8) Safety filter element (200 micron strainer) (9) By pass-valve, 2.3bar (9.1) Valve cone (9.2) Valve spring (9.3) O-ring (10) Profile gasket (11) Seal ring (12) Self locking nut (13) Self locking nut Function: The returning oil flows into the filter chamber (A) of the hydraulic tank. (The sketch shows one section only). The chamber is split into two sections; one sections with 4 filters for the return oil and one for the leak oil. But the five filters are all the same. The hydraulic oil enters the filter at the top and passes then on its way to the entire tank the filterelement (7). "Inside to outside filtration." The filter element condition is monitored by a pressure switch (B25, 0.5 bar for the leak oil filter) and (B26, 2 bar for the return oil filter). As soon as the pressure inside the filter chamber reaches the set pressure of those switches due to the restriction of the filter-element which is caused by foreign matters, the fault message ”Return oil filter restricted" or ”Leak oil filter restricted” is displayed at the operator's dash board The filter elements must be replaced. For safety pre-cautions the filter is equipped with a by-pass valve. As the filter chamber pressure increases the by-pass valve opens at 2.3 bar and protects the element from bursting. But the oil flows not totally unfiltered into the tank because it must flow through the strainer (8).

)

•

04.01.07

The switch point of the pressure switch for the leak oil has been chosen so low with best intention to protect first of all the radial seal rings of the hydraulic motors. Because the filter is oversized for this purpose, the message ”Leak oil filter restricted” is displayed very seldom under normal circumstances. Maintenance see MAINTENANCE MANUAL

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Hydraulic Oil Reservoir

3.7

Section 3.0 Page 8

Breather filter Legend for illustration (Z 21501a): (1) Nut (2) Cover (3) Filter element (4) Filter pot A breather filter is installed to clean the air that streams into the tank any time the oil level decreases while extending attachment cylinders The filter element condition is monitored by a vacuum type pressure switch (B24, 80mbar). Maintenance see MAINTENANCE MANUAL

04.01.07

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25.03.03

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Hydraulic Oil Cooling

Section 4.0 Page 1

Table of contents section 4.0

Section 4.0

06.10.05

Page Hydraulic oil cooling 4.1

General

4.2

Function of the hydraulic oil cooling circuit

4.3

Adjustment of the Back Pressure Valve

4.4

Fan drive (Two stage cooler fan RPM control)

5+6

4.5

Pressure relief valves and solenoid valve

7+8

4.6

Fixed Displacement Pump, with variable setting

4.7

Radiator fan drive speed adjustment

9 10 – 12

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Hydraulic Oil Cooling

4.1

Section 4.0 Page 2

General The hydraulic oil cooling system maintains the hydraulic oil at a normal operating temperature. Legend for illustration (Z 21594) (1) Noise shield (1) Cooler (Radiator) (2) Cooler frame (3) Fan (4) Fan motor (Axial piston motor) (5) Bolt (6) Bolt (7) Drive shaft (8) Shaft protecting Sleeve (9) Drive shaft seal (10) Ball bearings (11) Seeger clip ring (12) Bearing group carrier (13) Oil level plug (14) Breather filter Design: There are four* hydraulic oil coolers in front of the hydraulic tank on the R.H. side of the platform. They are in pairs mounted in one frame, one above the other. The air stream needed for the cooling is produced by hydraulic driven fans. The air flows from inside to outside through the coolers. For a better cleaning, the coolers can be moved to the side. (“Swing out cooler”) The bearing group carrier is filled with oil to lubricate the bearings.

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Hydraulic Oil Cooling

4.2

Section 4.0 Page 3

Function of the hydraulic oil cooling circuit Legend for illustration (Z 22419) (107.1-107.4) Restrictor, shock absorbers for the hydraulic oil cooler (106.1-106.4) Hydraulic oil cooler (41) Main oil reservoir (114) Return oil collector tube (115) Back pressure valve (L6 + L7) Return line from control blocks (L8 + L9) Supply line for the anticavitation circuit of the swing motors (M10) Pressure check point (Y101) Solenoid valve – 4/2-directional control valve (H) Lines to cooler (hot oil) (C) Lines to tank (cold oil) Function: The returning oil from the system flows via the lines (L6 - L7) into the collector tube (114). On the top of it is the Back Pressure Valve (115) installed. The back pressure valve (115) causes a back pressure which forces most of the relative hot oil through the lines (H) to the cooler (106.1-106.4). On its flow through the cooler the hydraulic oil gets cooled and flows than through the restrictors (107.1-107.4) and the lines (C) into the filter chamber of the main oil reservoir (41). The restrictors are acting like shock absorbers to prevent cooler cracking at pressure peaks. Besides the back pressure valve acts as an oil flow control valve as far as the oil temperature has not reached its steady temperature. During the warm up period (1/2 Qmax) the back pressure valve (115) is wide open, because solenoid valve Y101 is energized, which results in less oil flows through the cooler which causes that the oil gets quicker its optimum operating temperature. With increasing oil temperature the oil gets thinner, so that the main pumps can be shifted to Qmax position and simultaneously solenoid valve Y101 will be de-energized, so that the valve piston will be more closed by the force of the spring thus that more oil passes the cooler. (See sectional drawing on next page.)

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Section 4.0 Page 4

Hydraulic Oil Cooling

4.3

Adjustment of the Back Pressure Valve Checks and settings only at normal operating temperature of the hydraulic oil, main pumps in maximum flow position and "Idle Time" control eliminated (service switch S151 actuated)! 1. Connect a pressure gauge to check point (M10). 2. Disconnect plug connector (13) of solenoid valve Y101. 3. Actuate service switch S151 (). 4. Start the engine and let it run with maximum speed. 5. Required pressure: 8 ±0,5 bar If adjustment is required: a) Take off protective cap (12). b) Loosen lock nut (5). c) Adjust the pressure with the set screw (6). d) Tighten lock nut (5) and refit protective cap (12). 6. Disconnect the pressure gauge, reconnect solenoid valve Y101 and switch back service switch S151. Legend for illustration (Z 21596): (1) Control oil port (2) "Y"- port (external return to tank) (2a) "X"- port (external return to tank via solenoid valve Y101) (3) Poppet (4) Valve spring (5) Lock nut (6) Set screw (7) Jet bore (large) (8) Valve spring (9) Valve piston (10) Jet bore (small) (11) Plug screw (12) Protective cap (13) Plug connector (A) Return to tank (Filter chamber) (Z) Pressure oil to valve

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Hydraulic Oil Cooling

4.4

Section 4.0 Page 5

Fan drive (Two stage cooler fan RPM control) Legend for illustration (Z 22420) (10.2) Axial piston pump Engine 1 (fixed displacement pump, with variable setting) (10.4) Axial piston pump Engine 2 (fixed displacement pump, with variable setting) (22.1) Fan motor (Axial piston motor) (22.2) Fan motor (Axial piston motor) (41) Main oil reservoir (168.1) Pressure relief valve – Engine 1 radiator fan drive (168.2) Pressure relief valve – Engine 2 radiator fan drive (68.1) Pressure filter with pressure differential switch B28-1 (Engine 1) (68.2) Pressure filter with pressure differential switch B28-2 (Engine 2) (103.1) Check valve engine 1– (Anti cavitation valve for fan drive motor) (103.2) Check valve engine 2– (Anti cavitation valve for fan drive motor) (148.11) 4/3 direction flow valve – Engine 1 radiator fan speed (stop, low and high speed), solenoid Y6A-1 + Y6B-1 (148.12) 4/3 direction flow valve – Engine 2 radiator fan speed (stop, low and high speed), solenoid Y6A-2 + Y6B-2 (169.1) pressure reduction valve (low fan speed adjusting) engine 1 (169.2) pressure reduction valve (low fan speed adjusting) engine 2 (L) Leak oil (case drain) to tank (P) Pressure to motor (R) Return oil to tank 1 Engine 1 2 Engine 2

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Hydraulic Oil Cooling

Section 4.0 Page 6

Function: From pump (10.x) flows the oil through the filter (68.x) to the fan motor (22.x) and then back to the tank. The check valve (103.x) act as an anti cavitation valve and is installed, because the fan motor -driven by inertial force- is running for a short period after the oil flow is interrupted by solenoid valve (Y6A-x/Y6B-x) or if the engine has been switched off. The hydraulic circuit "Fan drive" is secured by the pilot controlled pressure relief valves (168.x) and (169.x). These valves are working together with the solenoid valve (Y6A-x/Y6B-x), controlled by the PLC, depending on the hydraulic oil temperature: • With de-energized solenoids Y6A-x and Y6B-x the relief valve (168.x) is functioning and the fans are running with max. adjusted speed (1300 RPM) • With solenoid Y6A-x energized the relief valve (168.x) is not functioning and the fans are running with a very low speed caused by the flow resistance only. • With solenoid Y6b energized the relief valve (169.x) is controlling the relief valve (168.x) and the fans are running with 1000 RPM only. (See also description on next page)

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Hydraulic Oil Cooling

4.5

Section 4.0 Page 7

Pressure relief valves and solenoid valves Pressure relief valves (168.x) Legend for illustration (Z 21598b) (1) Valve cartridge (2) Spring (3) Spring chamber (4) "X" port (5) Jet bore, Pilot poppet (6) Jet bore, Main piston (7) Main piston (8) Valve housing (9) Pilot poppet (Y) (A) (B)

External leak oil port Pressure port Return oil port

Function: Pressure in line A affects the main piston (7). At the same time there is pressure via the jet bore (6) on the spring-loaded side of the main piston and via jet bore (5) at the pilot poppet (9) of the relief valve cartridge (1). If system pressure in line A exceeds the value set at the spring (2), pilot poppet (9) opens. The signal for this comes from line A via the jet bores (6) and (5). The oil on the spring-loaded side of the main piston (7) now flows via the jet bore (5) and poppet (9) into the spring chamber (3). From here it is fed internally by means of the control line (Y) to tank (port B). Due to the state of equilibrium at the main piston (7), oil flows from line A to line B, while the set operating pressure is maintained. The pressure relief valve can be changed (Remote controlled) by means of the port "X" and the function of the solenoid valve Y6A-x / Y6B-x and pressure reduction valve 169.x. .( Function see next page)

continued

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Section 4.0 Page 8

Hydraulic Oil Cooling

Cont’d. 4.5

Pressure relief valves and solenoid valve, illustration (Z 21599c)

Function: With de-energized solenoids (Y6A-x and Y6B-x), the spool (3) of the 4/3 direction flow valve 148.x keeps the "X" connection of valve (168.x) and port “B“ to port “P“ closed. The pressure relief valve (168.x) operates normal with the max. adjusted pressure. The fan turn with maximum speed. The energized solenoid Y6B, operate the spool (3) of the 4/3 direction flow valve 148.x and a connection is made between port “P“ , port “B“ and port "X" of valve (168.x) The system pressure now opens main piston (7) of valve (168.x), because via solenoid Y6B (P to B) the oil from the rear side of piston (7) flows from the "X"-port to the “P“ port of valve (169.x). This valve (169.x) reduce now the max. adjusted pressure of valve (168.x) to a lower value. The fan turn with reduced speed. The energized solenoid Y6A, operate the spool (3) of the 4/3 direction flow valve (148.x) and a connection is made between port “P“ and port “A” and port "X" of relief valve (168.x). The system pressure now opens the main piston (7) of valve (168.x) because via the "X"-port the oil from the rear side of piston (7) flows to tank. The normal relief valve function is eliminated. The fan turn with minimum speed, nearly stand still.

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Hydraulic Oil Cooling

4.6

Section 4.0 Page 9

Fixed Displacement Pump, with variable setting

Legend for illustration (Z 21852) (1) Drive shaft (2) Bearings (3) Cylinder with pistons (4) Center pin (5) Control lens (6) Q-min adjustment bolt (7) Q-max adjustment bolt (8) Pressure port (9) Tank port Description. Pump type A7F0 is a variable displacement pump, designed to operate in open circuits. It has an internal case drain return. The rotary group is a robust self aspirating unit. External forces may be applied to the drive shaft. Changing the swivel angle of the rotary group is achieved by sliding the control lens along a cylindrical formed track by means of an adjusting screw. • With an increase in the swivel angel, the pump output increase together with necessary drive torque. • With an decrease in the swivel angel, the pump output decreases together with the necessary drive torque. • When increasing to maximum swivel angle, there is a danger of cavitation and over-speeding the hydraulic motor!

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Hydraulic Oil Cooling

4.7

Section 4.0 Page 10

Radiator fan drive speed adjustment Basic Adjustment Legend for illustration (Z 22400a): (1) Dust cap (2) Lock nut (3) Set screw (P) Axial piston pump (fixed displacement pump, with variable setting) (6) Qmin stop bolt (6.1) Lock nut (7) Qmax stop bolt (7.1) Lock nut (10) Positioning pin (mover) (168.1) Pressure relief valve – bottom oil cooler fan (Motor 1) (168.4) Pressure relief valve – top oil cooler fan (Motor 2) (169.1) pressure reduction valve – bottom oil cooler fan (Motor 1) (169.2) pressure reduction valve – top oil cooler fan (Motor 2) (Y6A-1 /Y6B-1)) 4/3 direction flow valve – Motor 1 (Y6A-2 /Y6B-2)) 4/3 direction flow valve – Motor 2 (L1) Measurement of Qmin stop bolt (L2) Measurement of Qmax stop bolt (M5-1) Pressure check points - Motor 1 oil cooler fan drive operating pressure (M5-2) Pressure check points - Motor 2 oil cooler fan drive operating pressure

)

• A blocked cooler, restricted air flow, defect cooler seal or bend fan influence the fan RPM and air volume. • Basic adjustment has to be carried out whenever one of the following components has been replaced: - pump - relief valve - hydraulic motor continued

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Hydraulic Oil Cooling

Section 4.0 Page 11

Cont'd 4.7

Radiator fan drive speed adjustment Basic Adjustment max fan speed 1. Reduce the output flow of the respective pump (P),by adjusting the minimum possible swivel angle, to avoid over speeding the fan: To do this, loosen both lock nuts (6.1 + 7.1) and turn out bolt (6)and turn in bolt (7) up to final stop. This is necessary to avoid a loose positioning pin (10), resulting in oscillating of the cylinder barrel. Tighten the lock nuts. 2. Remove protection cap (1) from relief valve (168.x), loosen lock nut (2) and turn set screw (3) fully clockwise and then a half turn counter clockwise. 3. Disconnect the plug connectors (Y6A-x and Y6B-x) of the 4/3 direction flow valve, to ensure that the full flow of pump P will be delivered to the fan motor. The valve is in neutral position and all ports are blocked. 4. Connect a pressure gauge to check point (M5-x). 5. Start the respective engine and let it run in high idle. 6. Check the fan speed with a non-contact rev counter Required fan speed: 1250 min-1 • Be careful not to get caught in the fan or other rotating parts 7.

)

continued

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Section 4.0 Page 12

Hydraulic Oil Cooling

Cont'd 8. 9.

Loosen lock nut (2) of the relief valve (168.x), and decrease the pressure with set screw (3) until the correct fan speed is obtained. Tighten lock nut (2) and fix protection cap (3).

Basic Adjustment middle fan speed 10. Activate the 4/3 direction flow valve (Y6B-x), by connecting the solenoid plug (Y6B-x ) to permanent 24 V. Use the 24V socket at the PTO *). 11. Check the fan speed with a non-contact rev counter Required fan speed: 1000 min-1 12. If adjustment is necessary loosen lock nut (5) of the relief valve (169.x), and decrease the pressure with set screw (4) until the correct fan speed is obtained. 13. Stop engine and reconnect the plugs to the correct positions. 14. Disconnect the pressure gauge from check point (M5-x). Fan speed check If the maximum fan speed is out of adjustment, increase or decrease first the pressure at relief valve (168.x), to change the speed. • Do not exceed the maximum permissible operating pressure of 230 bar

If the speed can not be raised by increasing the pressure then increase the output flow of pump (10.x). *)

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Prepare a test wire with a plug ET-No. 891 039 40, and a plug ET-No. 440 305 99. Connect terminal 1 to positive (+) (center off plug 440 305 99) and terminal 2 to ground (-).

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Controlling

Section 5.0 Page 1

Table of contents section 5.0

Section 5.0

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Page Controlling General lay out

5.1

Control and filter panel location of components (valves, switches, sensors etc.)

5.2

Pilot Pressure Supply and Adjustments

4–7

5.3

Remote control valves arrangement

5.4

Function principle of the Electro-Hydraulic- Proportional Control

9 + 10

5.5

Potentiometer Control (Lever, Joy Stick)

5.6

Potentiometer Control (Pedal)

5.7

Proportional amplifier module, Type A (for swing brake only)

5.8

Proportional amplifier module, Type B (for Boom, Stick, Bucket, Swing and Travel)

5.9

Ramp Time Module (Analogue command value module for Boom, Stick, Travel and Swing function)

5.10

Adjustments of Amplifier Modules (General)

5.11

Adjusting the Amplifiers Type B

17 + 18

5.12

Adjusting the Amplifiers Type A

19 + 20

5.13

Adjusting the Ramp Time Module

21 + 23

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5.0 2

X4 - pump support pressure

X2 pilot pressure

X3 – remote control pressure (1/2Qmax; Qmin) pump regulation

X1 - pump regulation pressure

to (45.2); (45.3) and (43)

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Controlling

5.0

Section 5.0 Page 2

General lay out Legend for illustration (Z 21631): (7.1 / (7.2) Pumps for pilot pressure and pump regulation system (84.1 / 84.2) Check valve (for combined operation) (68.1) Filter (70.1) Pressure relief valve (X4 – pressure) (70.2) Pressure relief valve (X2 – pressure) (85) Pressure accumulator (10 Liter, 10 bar pre-charge pressure) (91) Check valve (45.1; 45.2 ;45.3, 43) Remote control valves (14; 15; 16; 13)) Control blocks General The controlling includes the pilot pressure system and the pump regulation system. The pumps (7.1 / 7.2) forcing the oil through the filter (68.1) to all involved valves. The pressure accumulator ensures that under any circumstances enough pilot pressure oil is available. The accumulator (85) is also functioning as a hydraulic battery for a certain time when the engine was shut down or to pressure relive the system for repair works. When the operator is using his controls an electrical signal causes energizing of the selected solenoid valve of the remote control valves(14). By the function of the remote control valves pilot pressure oil is send to the relevant control block spools which in turn allows operating hydraulic oil to the users.

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Section 5.0 Page 3

Controlling

5.1

Control and filter panel location of components Legend for illustration (Z 22497): Solenoid valves

Engine 1

Engine 2 (Y5)

(Y6A-1) (Y6A-2) (Y14A-1) (Y14B-1)

(Y6B-1) (Y6B-2) (Y14A-2) (Y14B-2) (Y16) (Y17) (Y17a) (Y127)

(Y61.1) (Y61.2) (Y102.1) (Y102.2) (Y124A/B) (Y124c) (Y48) (Y120) (Y123A/B) (Y125)

Swing gear house brake Oil cooler fan RPM control Oil cooler fan RPM control Radiator fan RPM control, low speed (only with diesel engines) Radiator fan RPM control, middle speed (only with diesel engines) Travel gear house brake Idle time“ control ½ Q-max (reduced oil flow at too cold oil) Swing foot brake pressure „XLR“ pressure, pumps 1+2, „XLR“ pressure, pumps 4 - 6 „X4“ pressure, pumps 1 - 3, „X4“ pressure, pumps 4 - 6 Refilling arm – up and down (only with diesel engines) Refilling arm on and out (only with diesel engines) Swing gear – pressure controlled turn Swing brake – enable valve ladder up and down ladder fast movement

Pressure switches: (B16) (B21.1)

(B21.2) (B22)

(B27.1) (B28.1)

(B27.2) (B28.2) (B48)

(B97.1) (B85.1)

(B97.2) (B85.2) (B86)

Pilot pressure for Swing gear house brake (24 bar) Radiator fan drive filter differential switch (filters 68.3+5) (only diesel) Differential pressure switch, pilot pressure system filter Differential pressure switch, PTO gear oil filter Pressure switch, cooler fan drive filter Pilot pressure for travel gear house brake (24 bar) „X4.1“ pressure, pumps 1 - 3, „X4.2“ pressure, pumps 4 - 6 “X1.1” pressure, pumps 1+2; “X1.2” pressure pumps 4 - 6 X2 pressure sensor

Pressure check points: (M1.1)

(M1.2) (M2) (M3)

(M5.1)

(M5.2) (M6) (M7) (M11) (M18)

(M19.1) (M20.1)

(M19.2) (M20.2) (M30) (M32) (M40)

Pressure PTO gear lubrication X4 - pressure X2 - pressure Cooler fan drive pressure Pressure travel gear house brake Pressure Swing gear house brake Pressure swing brake (safety circuit ) Pressure for hydraulic pump regulation (electronic out) Radiator fan drive pressure (only with diesel engines) X1 pressure pumps 1, 2, 4, 5, 6 X3 pressure for pumps at ½ flow position X3 pressure for pumps at ½ flow position Pilot pressure, X-2

Filter: (68.1) (68.2) (68.3) (69.1)

(68.4) (68.5) (69.2)

Pilot pressure and pump regulation Oil cooler fan drive Engine radiator fan drive (only with diesel engines) PTO gear lubrication

continued

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Controlling

5.2

Section 5.0 Page 4

Pilot Pressure Supply and Adjustments Pilot Pressure Circuit The pilot pressure oil is used for the following functions. To move the control block spools, to supply the main pump regulation system, to lubricate the main pump bearings, to release the travel- and swing gear house brakes (spring loaded multi disk brakes), to drive the Lincoln Lubrication pumps, to move the hydraulic operated ladder, to move the hydraulic operated refilling arm and to supply the hydraulic track tensioning system. Legend for illustration (Z 22498): (7.1 / 7.2) Pilot pressure pumps (84.1 / 84.2) Check valve (for combined operation) (68.1) Filter (70.1) Pressure relief valve 60 bar (70.2) Pressure relief valve 35 bar (85) Pressure accumulator (43 + 45.x) Remote control valves (M2) 60 bar pressure check point (X4-Pressure) (M3) 35 bar pressure check point (X2-Pressure) (M40) 35 bar pres. check point (X2-Pressure in front of accumulator) Function: Study together with the hydraulic circuit diagram The pumps (7.1 and 7.2) are delivering the oil through the filter (68.1) to port A of the pressure relief valve (70.1) and the pressure relief valve (70.2) port A. The pressure relief valve (70.1) maintains the adjusted pressure of 60 bar it is called X4-pressure. X4 - pressure: Pump support pressure Pump bearing lubrication Actuation of refilling arm and ladder Lubrication system Track tensioning system continued

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Controlling

Section 5.0 Page 5

Cont’d.: The pressure relief valve (70.2) maintains the adjusted pressure of 35 bar it is the X2-pressure. X2 – pressure: Pilot pressure system Pump regulation system Capacity regulation swing motors Travel- and Swing gear house brakes (spring loaded multi disk brakes) The pressure accumulator (85) holds an amount of oil under pressure to ensure sufficient pilot pressure during normal operations and a limited number of operations without engine power. The check valves (91) prevents return flow of the pilot pressure oil.

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Controlling

Section 5.0 Page 6

Cont'd: 5.2

Pilot Pressure Supply and Adjustments Pilot Pressure Circuit Legend for illustration (Z 22500): (41) Main oil reservoir (91) Check valve (85) Bladder Accumulator – 10 liter, 10 bar (located behind the filter and valve panel of engine 2 on top of the PTO) (PX2) Pilot pressure line (LX2) Leak / return oil line from the remote control blocks Function: The pilot pressure oil flows via line (PX2) to port (P) of each remote control block and is present via a gallery at all proportional and directional solenoid valves. These solenoid valves are energized by the function of the Electro proportional controls (Joy sticks or pedals) and direct the pilot pressure oil to the respective spools of the main control blocks with a variable pilot pressure proportional to the deflection of the controls.

)

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• For the location and designation of the proportional and directional solenoid valves of the remote control blocks see “5.3 Remote control valves arrangement” in this section.

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Controlling

Section 5.0 Page 7

5.2

Pilot Pressure Supply and Adjustments

)

Checks and Adjustment of Pilot Pressure Legend for illustration (Z 21635a): (85) Bladder Accumulator – 10 liter, 10 bar pre-charge pressure (located underneath the catwalk in front of the PTO) (70.1) Pressure relief valve for pump support pressure X4 (60 bar) (70.2) Pressure relief valve for pilot pressure X2 (35 bar) (M2) Pressure check point X4, pump support pressure (60 bar) (M3) Pressure check point X2 pressure, pilot pressure (35 bar) (M40) Pressure check point for accumulator (If not factory installed, fit a T-union with test connector as shown in illustration Z 21635a) • Since the “X2” and the “X4” pressure are influencing each other it is always necessary to adjust both valves 70.1+70.2 alternately. 60 bar pressure „X4“, valve 70.1: 1. Connect pressure gauge to check point (M2) 2. Start engine and let it run with max. speed 3. Read pressure, required = 60 -2 bar If readjustment is required *: 35 bar pressure „X2“, valve 70.2: 1. Connect pressure gauge to check point (M3) 2. Start engine and let it run with max. speed 3. Read pressure, required = 35+3 bar If readjustment is required *: * Valve adjustment: a Remove dust cap (1). b. Loosen lock nut (2). c. Set pressure with set screw (3). d. Tighten lock nut (2) and re-fit dust cap (1). Checking of Accumulator Function 1. Connect pressure gauge to check point (M40). 2. Start one engine and let it run with maximum speed. 3. After build-up of pressure stop the engine, but do not turn the key switch to zero position. 4. Watch pressure gauge. Pressure should remain constant for at least 5 minutes.

)

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• If the pressure droops the system must be checked for leakage’s. • To check the accumulator charging pressure refer to SERVICE BULLETIN AH01531a latest edition.

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Section 5.0 Page 8

Controlling

5.3

Remote control valves arrangement Legend for illustration (Z 21636)

No.

45.1

45.2

45.3

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Solenoid Proportional valve valve

Function FSA

BHA

Y20a Y20b

Y20

L.H. Crawler forward L.H. Crawler reverse

Y21a Y21b

Y21

Stick extending Stick retracting

Y22a Y22b

Y22

Bucket filling (curl) Bucket emptying (dump)

Y23a Y23b

Y23

Boom raising Boom lowering

Y24a X24b

Y24

Clam closing Clam opening

Bucket filling (curl) Bucket emptying (dump)

Y25a Y25b

Y25

Bucket filling (curl) Bucket emptying (dump)

Boom raising Boom lowering

Y26a Y26b

Y26

Boom raising Boom lowering

Reserved Reserved

Y27a Y27b

Y27

Stick extending Stick retracting

Y28a Y28b

Y28

R.H. Crawler reverse R.H. Crawler forward

Y29a Y29b

Y29

Boom raising Boom lowering

Y30a Y30b

Y30

Bucket filling (curl) Bucket emptying (dump)

Y31a Y31b

Y31

Stick extending Stick retracting

Y32a Y32b

Y32

R.H. Swing L.H. Swing

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Controlling

5.4

Section 5.0 Page 9

Function principle of the Electro-Hydraulic- Proportional Control Legend for illustration (Z 21637) (1) Pump (2) Filter (3) Pressure relief valve (4) Check valve (5) Pressure Accumulator (6) Directional Solenoid valve, a side (7) Directional Solenoid valve, b side (8) Proportional Solenoid valve (9) Control valve block (10) Battery (11) Electronic units with amplifiers etc. (12) Control lever Function: The electric-hydraulic control system is used to control the direction and volume of oil flow to the operating cylinders and motors via the control valve blocks. Hydraulically: The oil volume of pump (1) flows through filter (2) into the pilot pressure system. The pressure is limited by the pressure relief valve (3). With the pressurized oil stored in accumulator (5), a limited number of spool movements can be carried out with the engines at standstill. When a lever (or pedal) is actuated, proportional solenoid valve (8) and one of the directional solenoid valves (either 6 or 7) are energized, and allows the pilot pressure oil to flow to the spools of the control blocks. Electrical Whenever a lever or a pedal is moved out of its neutral position, an amplifier will created a current between 0 and 1000 mA. (For detailed information refer to page 10 in this section) Depending on the lever direction, simultaneously one of the directional solenoid valves (either 6 or 7) is energized. The proportional solenoid valve alters the pilot pressure, proportional to the lever deflection, this results a spool movement between neutral and full stroke position. continued

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Controlling

Section 5.0 Page 10

Cont'd: 5.4

Function principle of the Electro-Hydraulic- Proportional Control (Exemplary illustration of the function of two axis with one Amplifier only) Legend for illustration (Z 21638a) (1) Control lever (joystick) (2) Capacitor-Module (3) Ramp time module (4) Proportional-Amplifier-Module (5) Relay (Supply Voltage) (6) Proportional solenoid valve-(Pressure-Reducing Valve) (7) Directional solenoid valve (8) Control block spool General Function Control lever (1) is supplied with 24 VDC battery voltage for the switch contacts and for the internal electronics to create the signal voltage. When moving lever (1) out of its neutral position, 24 VDC battery voltage arrives at relay (5) and energizes the Proportional Amplifier (4) with capacitor supported 24 VDC via terminal 1. Depending on the function of the control lever, 1 to 4 Amplifiers can be involved for the „Y-axis“ (forward/ backwards direction) and 1 to 4 Amplifiers for the „Xaxis“ (left/right direction.) The polarity of the Output Signal from joystick (1), either positive or negative, between 0 and 10 VDC indicates the direction of the lever movement and is proportional to the lever deflection. This is the Input Signal to the ramp time module (3) at terminal 5 which will arrive after the adjusted ramp time delay via terminal 7 to the proportional amplifier (4) at terminal 5. This Input Signal (between 0 and 10 VDC) is amplified to an Output Signal between 0 to 1000 mA and is simultaneously send via terminal 7 (negative) or terminal 8 (positive) to the Proportional Solenoid valve (6) and to the Directional solenoid valve (7) via terminal 3 (negative) or terminal 9 (positive) to the “a” or “b”-side. The proportional Solenoid valve (6) alters the pilot pressure (“X2”) of 35 bar to a value proportional to the Current Signal. This pressure controls the movement of the control block spool (8) between neutral and full stroke position.

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Controlling

5.5

Section 5.0 Page 11

Potentiometer Control (Lever, Joy Stick) Legend for illustration (Z 21639b) (1) Push button * (2) Toggle switch * (3) Inductive linear transmitter (4) Universal joint (5) Electronics (6) Push pin (7) Shaft seal (8) Reset spring (9) Coil core (10) Coil * Alternative application The non-contacting lever control (inductive linear transmitter) contains both the electronic and mechanical components which converts the lever movement into a proportional electrical voltage. The lever can be operate in two axes: Axis "Y", splitted into the half axis Y- and Y + (backward and forward) Axis "X", splitted into the half axis X- and X + (left and right) Of course the lever can be moved in any other direction (Joy stick function) In order to be able to monitor the direction of the lever movement and the neutral position, the electronics (8) sends a 24V signal as soon as the lever gets moved out of its neutral position. For one axis are used two inductive linear transmitter (3). The motion of the coil core (9) connected to the push pin (6) causes a variation of the induction in the coils (10). The electronics convert this inductive signal into a proportional output signal of –10...0...+10 V for the amplifiers. The electronic part of the lever is equipped with a internal fault detector. In case of a internal electronic fault the electronic send a 24V signal to the test output. The test input is used for a lever system check before engine start. The inductive system is designed as a redundant system with two separate coils.

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Section 5.0 Page 12

Controlling

5.6

Potentiometer Control (Pedal) Legend for illustration (Z 21300) (1) Potentiometer Control Unit (2) Pedal (3) Standard cable (4) Connection cable for combined operation Application for: (A) Swing foot brake (B) Clam Opening/closing, (only face shovel attachment) (C) Travelling The Potentiometer Control (inductive linear transmitter) contains both the electronic and mechanical components which converts the pedal movement into a proportional electrical voltage. In order to be able to electrically monitor the pedal (2) action a neutral position switch is fitted. This switch closes when the pedal is moved out of the rest position. When using the double unit (B) (combined operation) only the signal output from one unit is used for the Clam Operation. Due to the cross lined connection via the connection cable (4) the signal is once positive and once negative (inverted), depending on the Pedal used.

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Controlling

5.7

Section 5.0 Page 13

Proportional Amplifier Module, Type A Legend for illustration (Z 21516) Type A (for swing brake only) (LED) LED for Solenoid A or B (P) Set Potentiometer R1 for the lowest current value R2 for the highest current value The amplifier module is snapped onto mounting rails inside the X2-box. The amplifier module contains the necessary electronics for the control of two proportional solenoids. Depending on the input polarity, either solenoid A or solenoid B is operated. The solenoid current (solenoid A - solenoid B) is measured and compared with the external input value. Differences between feed-back and input values, for example caused by changes in solenoid temperature or supply voltage, are compensated. The module also generates a direction-dependent voltage signal (solenoid A solenoid B) as soon as the solenoid current reaches the lowest set value. The lowest and highest values are set externally via the potentiometer R1 + R2. The brightness of the LED's changes with the current. This function should not be used for setting.

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Controlling

5.8

Section 5.0 Page 14

Proportional Amplifier Module, Type B Legend for illustration (Z 21640) Type B (for Boom, Stick, Bucket, Clam, Swing and Travel) (LED) (P) Set Potentiometer: AX: Proportional output AX active - 10% for the lowest current value AS: Switched output AS active - J2 for the highest current value BX: Proportional output BX active (Pt) Set Potentiometer for the „Ramp BS: Switched output BS active Time“ Power: Internal supply voltage Fault: Fault indication The amplifier module is snapped onto mounting rails inside the X2-box. The amplifier module contains the necessary electronics for the control of two proportional solenoids and two directional solenoids. The outputs for proportional solenoids Ax and Bx and the switched outputs As and Bs are activated by connecting a minimum of approx. 10 % signal voltage at the amplifier input. A positive signal voltage controls outputs A, a negative signal voltage controls output B. A signal voltage of approx. 10% with respect to +/- 10 V input voltage at the amplifier, produces a stepped output voltage. The height of this 10% jump may be set separately for proportional outputs Ax and Bx via external potentiometer. As the signal voltage rises the solenoid current for the proportional outputs increases linearly. A further step in output current occurs at approx. 90% signal voltage. The maximum current or the 90% jump may be set separately for outputs Ax and Bx via external potentiometers and hence the gradient of the output curve may be influenced. LED’s indicate the current output to each proportional and switched output, whereby the brightness is approx. proportional to the solenoid current in Ax and Bx. This function should not be used for setting. A Ramp Time function is included in the amplifier which may be externally changed by a set potentiometer. The setting range for the ramp time is approx. from 80 ms to 1s. The time setting applies to both up and down ramps and to both proportional solenoids. A fault is indicated by the LED „Fault“.

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5.9

Section 5.0 Page 15

Ramp Time Module (Analogue command value module for Boom, Stick, Travel and Swing function) Legend for illustration (Z 21518) Potentiometer: "t1" to "t5" ⇒ Ramp times "w1" to "w4" ⇒ Command value call-ups "G" ⇒ Zero point matching "Z" ⇒ Amplitude attenuation for the differential input LED displays: (1) green ⇒ Operational power (2) "4-Q" ⇒ Quadrant recognition (3) "INV" ⇒ Inversion active (4) yellow ⇒ display for potentiometer t1 to t4 (5) yellow ⇒ display for potentiometer w1 to w4 (6) Measurement sockets: "t" ⇒ Actual ramp time "w" ⇒ Internal adjustment variable "⊥" ⇒ Reference potential / GND General The Ramp Time Module is snapped onto mounting rails inside the X2-box. The electrical connection is done via screw terminals. The module is operated with 24 VDC. A power supply provides the internally required positive and negative supply voltages. As soon as the power supply is in operation the green LED (power) lights up. Internal command values The internal command value signal is generated from the external command value signal which is being applied to the differential input, a called-up signal and an offset signal (zero point potentiometer "Z"). The external command value signal can, via potentiometer "G", changed from 0 % to approx. 110 %. Command value call-ups The call-up signals w1 to w4 also have an adjustment range of 0 % to 110 %. No settings required. (factory set to 100 %). Ramp time call up If the quadrant recognition is not activated, then each command value call-up "w1" to "w4" is allocated its own ramp time "t1" to "t4". As long as there is a signal change, the LED allocated to the actual ramp time is alight.

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Controlling

5.10

Adjustments of Amplifier Modules (General) Legend for illustration (Z 21641) (1) Potentiometer control (2) Terminal with a separating possibility (3) Ramp time module (4) Amplifier (5) Solenoid valve (6) Service module Introduction: The illustration shows simplified the route of the signal voltage from Potentiometer Control (1) to Solenoid-Valve (5): A. With ramp time module, i.e. Boom,- Stick,- Travel,- and Swing Function. B. Without ramp time module, i.e. Bucket and Clam Function. The ramp time modules (3) and the amplifiers (4) are adjustable. Adjustments are required: Ramp time modules

Amplifiers

• When commissioning the machine • When replacing a module

• When replacing a solenoid valve • When replacing an amplifier

For Checking and Setting the Signal Current at the Proportional-Amplifier (4), both separating terminal (2) before and behind the Amplifier (4) must be opened. For the setting procedure the signal voltage from the potentiometer control (1) can be simulated with the potentiometer of Service-Module (6),which is installed on the X2-panel. Accessories required for the adjustments: a) A multimeter, good readable for values between 0 and 1000 mA. b) More convenient is a second meter for reading voltage simultaneously. c) A simple wire, 1m length, or better a prepared test lead same length d) Four test leads, 1m length, with banana type connectors on each end.

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"a"

"b"

VDC

"c" "d"

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5.11

Section 5.0 Page 17

Adjusting the Amplifiers Type B, illustration (Z 21642a) Procedure applicable for all amplifiers except the one for the swing brake: (Do not start the engines turn only the key switch in ON – position.) 1. Open* the respective separating terminal (T1) between the lever unit and the amplifier module to be set. 2. Open* the respective separating terminal (T2) between the amplifier module to be set and the proportional solenoid valve. 3. Disconnect the wire from terminal five. 4. Connect the positive output of the service module with terminal five of the amplifier module, using test lead (2). 5. Attach a multimeter for voltage reading to the service module, using test lead (3). 6. Attach a multimeter (in series) for Amp reading to the terminal between amplifier module and solenoid valve, using test leads (3). 7. Move the lever of the Potentiometer Control into its final position; or override manual the relay which allows 24 V operating voltage to the amplifier module; thus the amplifier gets 24 V operating voltage. The power LED and simultaneously LED A(+) or B(-) lights up, depending on the polarity. 8. Turn the potentiometer (P) of the Service-Module until the multimeter shows 1 VDC (it may be either positive or negative); the multimeter for the current reading will show a value which should correspond to the value giving in the circuit diagram e.g. 330 mA. (The first step (10 %) value) If necessary correct the value with potentiometer (R1). 9. Turn the potentiometer (P) of the Service-Module further until the multimeter shows 9 VDC; the multimeter for the current reading will show a value which should correspond to the value giving in the circuit diagram e.g. 660 mA. (The second step (90 %) value). If necessary correct the value with potentiometer (R2). 10. Repeat settings of item 8 and 9 until both mA values are stabilized, because R1 and R2 influence each other. * How to open and close the terminal: Push the yellow stud (1) down with a screw driver and turn it 90° to the left to open or to the right to close the terminal. A spring pushes then the stud outwards and the contacts are either open or closed. continued

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Controlling

Section 5.0 Page 18

Cont'd: 5.11

Adjusting the Amplifiers Type B, illustration (Z 21642) 11.

12. 13.

If the setting with either positive or negative potential was successful, turn the potentiometer (P) of the service module into the opposite direction and check the settings with the other polarity i.e. if the first setting was done with positive potential then turn the pot into negative direction; otherwise vice versa. Repeat the setting as described under item 7 to 10. Remove multimeter, test wire, close* the terminals and reconnect the wire to terminal 5 of the amplifier module.

Adjusting the Ramp Time 1. 2.

Turn potentiometer (Rt) 30 revolutions counter clockwise, to guarantee the correct start position at the complete left side. Turn potentiometer (Rt) so many revolutions clockwise as shown in the table below (part of the electrical circuit diagram).

* How to open and close the terminal: Push the yellow stud (1) down with a screw driver and turn it 90° to the left to open or to the right to close the terminal. A spring pushes then the stud outwards and the contacts are either open or closed.

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Controlling

5.12

Section 5.0 Page 19

Adjusting the Amplifiers Type B, illustration (Z 21643) The amplifiers for the crawler foot pedals are adjustable in the same way as the amplifiers for the joy sticks.(refer to page 17 and 18 in this section) The amplifier for the swing foot brake is similar. Procedure for the swing foot brake: 1. Open* the respective separating terminal (T1) between the pedal unit and the amplifier module to be set. 2. Open* the respective separating terminal (T2) between the amplifier module to be set and the proportional solenoid valve. 3. Disconnect the wire from terminal five. 4. Connect the positive output of the service module with terminal five of the amplifier module, using test lead (2). 5. Attach a multimeter for voltage reading to the service module, using test lead (3). 6. Attach a multimeter (in series) for Amp reading to the terminal between amplifier module and solenoid valve, using test lead (3). 7. Press the pedal fully down ; or manual override the relay which allows 24 V operating voltage to the amplifier module; thus the amplifier gets 24 V operating voltage. 8. Turn the potentiometer (P) of the Service-Module until the multimeter shows 1 VDC ; the multimeter for the current reading will show a value which should correspond to the value giving in the circuit diagram e.g. 10 mA. (10 % value) If necessary correct the value with potentiometer (R1). * How to open and close the terminal: Push the yellow stud (1) down with a screw driver and turn it 90° to the left to open or to the right to close the terminal. A spring pushes then the stud outwards and the contacts are either open or closed. continued

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Controlling

Section 5.0 Page 20

Cont'd: 5.12

Adjusting the Amplifiers Type B, illustration (Z 21643) 9.

) 10. 11.

Turn the potentiometer (P) of the Service-Module further until the multimeter shows 10 VDC; the multimeter for the current reading will show a value which should correspond to the value giving in the circuit diagram e.g. 500 mA. (100 % value). If necessary correct the value with potentiometer (R2). • It is important that the pilot pressure for the pressure increasing valve is 19± 1 bar. For more information refer to section 8.2 „Swing Circuit“ Repeat settings of item 8 and 9 until both mA values are stabilized, because R1 and R2 influence each other. Remove multimeter, test wire, close* the terminals and reconnect the wire to terminal 5 of the amplifier module.

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Controlling

5.13

Section 5.0 Page 21

Adjusting the Ramp Time Module Legend for illustration (Z 21644) (2) Capacitor-Module (3) Ramp time module (6) Service module (P) Potentiometer

)

• The following adjustments have to be done when commissioning the machine and whenever the Ramp Time Module has been replaced. • Do not start the engines turn only the key switch in ON – position.

Basic Adjustment: 1. Connect 0 VDC with a test lead from the red positive terminal of the service module (6) to terminal 5 of the Ramp Time Module (3) and adjust with "Pot Z" a value of 0 VDC measured at terminal 7. Disconnect the test lead after the setting is done. 2. Connect +10 VDC with a test lead from the red positive terminal of the service module (6) to terminal 5 of the Ramp Time Module (3) and adjust with "Pot G" a value of 10 VDC measured at terminal 7. Check the negative voltage as well(- 10 VDC). Disconnect the test lead after the setting is done.

)

• Repeat settings of item 1 and 2 until both values are stabilized, because "Pot Z" and "Pot G" influence each other. • The factory setting of potentiometer "w1" to "w4" for the command value call-ups must not be adjusted.

continued

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Controlling

Cont'd: 5.13

Adjusting the Ramp Time Module Legend for illustration (Z 21645) (1) Control lever (joystick) (2) Capacitor-Module (3) Ramp time module (4) Proportional-Amplifier-Module (5) Relay (Supply Voltage) Ramp time adjustment in relation to the operating movements: 3.

Disconnect the cables at terminal 3 and terminal 5 of the respective module. Connect 24 Volt with a test lead to terminal 9, 10, 11 and 12 one after another and adjust with the respective "Pot t1, t2, t3 and t4" the values giving in the table on the next page. (Measure the voltage only at the Measurement socket "t" of the ramp time module)

To check the adjustments under operating conditions reconnect terminal 3 and terminal 5 and measure the ramp time with a stopwatch.

If the above mentioned values are not suitable for the local working conditions, for example due to, different Attachments or different operation feeling of the operator, the ramp time can be changed according to the NOTE on illustration Z 21645, to ensure smooth and efficient working cycles.

continued

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Section 5.0 Page 23

Controlling

Cont'd: 5.13

Adjusting the Ramp Time Module

E48 Stick 24 Volt at

Joy stick Signal

Pot

Value to be measured at socket "t"

Terminal 9

Neutral ⇒ Stick out

0V to +10V

0,10 Volt = 1000 ms

Terminal 10

Stick out ⇒ Neutral

+10V to 0V

5,00 Volt = 20 ms

Terminal 11

Neutral ⇒ Stick in

0V to -10V

0,10 Volt = 1000 ms

Terminal 12

Stick in ⇒ Neutral

-10V to 0V

5,00 Volt = 20 ms

Pot

Value to be measured at socket "t"

E49 Boom 24 Volt at

Joy stick Signal

Terminal 9

Neutral ⇒ Lower

0V to +10V

0,10 Volt = 1000 ms

Terminal 10

Lower ⇒ Neutral

+10V to 0V

5,00 Volt = 20 ms

Terminal 11

Neutral ⇒ Lift

0V to -10V

0,10 Volt = 1000 ms

Terminal 12

Lift ⇒ Neutral

-10V to 0V

5,00 Volt = 20 ms

Pot

Value to be measured at socket "t"

E50 Swing 24 Volt at

Joy stick Signal

Terminal 9

Neutral ⇒ Swing R

0V to +10V

0,10 Volt = 1000 ms

Terminal 10

Swing R ⇒ Neutral

+10V to 0V

0,10 Volt = 1000 ms

Terminal 11

Neutral ⇒ Swing L

0V to -10V

0,10 Volt = 1000 ms

Terminal 12

Swing L ⇒ Neutral

-10V to 0V

0,10 Volt = 1000 ms

Pot

Value to be measured at socket "t"

E50B Swing brake 24 Volt at

Joy stick Signal

Terminal 9

Neutral ⇒ counter swing right

0V to +10V

0,067 Volt ≈ 1500 ms

Terminal 10

Counter swing right +10V to 0V ⇒ Neutral

5,000 Volt = 20 ms

Terminal 11

Neutral ⇒ counter swing left

0V to -10V

0,067 Volt ≈ 1500 ms

Terminal 12

Counter swing left ⇒ Neutral

-10V to 0V

5,000 Volt = 20 ms

continued

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Section 5.0 Page 24

Controlling

E51 Left crawler 24 Volt at

Joy stick Signal

Pot

Value to be measured at socket "t"

Terminal 9

Neutral ⇒ Forward

0V to +10V

0,10 Volt = 1000 ms

Terminal 10

Forward ⇒ Neutral

+10V to 0V

0,10 Volt = 1000 ms

Terminal 11

Neutral ⇒ Backward

0V to -10V

0,10 Volt = 1000 ms

Terminal 12

Backward ⇒ Neutral

-10V to 0V

0,10 Volt = 1000 ms

Pot

Value to be measured at socket "t"

E52 Right crawler 24 Volt at

Joy stick Signal

Terminal 9

Neutral ⇒ Backward

0V to +10V

0,10 Volt = 1000 ms

Terminal 10

Backward ⇒ Neutral

+10V to 0V

0,10 Volt = 1000 ms

Terminal 11

Neutral ⇒ Forward

0V to -10V

0,10 Volt = 1000 ms

Terminal 12

Forward ⇒ Neutral

-10V to 0V

0,10 Volt = 1000 ms

Pot

Value to be measured at socket "t"

E59 Bucket (only BHA) 24 Volt at

Joy stick Signal

Terminal 9

Neutral ⇒ Fill

0V to +10V

0,10 Volt = 1000 ms

Terminal 10

Fill ⇒ Neutral

+10V to 0V

5,00 Volt = 20 ms

Terminal 11

Neutral ⇒ Dump

0V to -10V

0,10 Volt = 1000 ms

Terminal 12

Dump ⇒ Neutral

-10V to 0V

5,00 Volt = 20 ms

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Section 6.0 Page 1

Components

Table of contents section 6.0

Section 6.0

Page Components 6.1

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Hydraulic 6.1.1 Main Control Blocks and High Pressure Filter FSA

2-3

6.1.2

Main Control Blocks and High Pressure Filter BHA

4-5

6.1.3

Distributor Manifold – Restrictor blocks FSA

6.1.4

Distributor Manifold – Restrictor blocks BHA

6.1.5

Restrictor Block with Pressure Relief Valve

6.1.6

Anti Cavitation Valve Block

6.1.7

Remote Control Valves

6.1.8

Directional Solenoid Valves (4 way / 3 positions)

6.1.9

Proportional Solenoid Valves

6.1.10

High Pressure Filter

6.1.11

Control Blocks and Valves

6.1.12

Load Holding Valve

6.1.13

Travel Brake Valve

6.1.14

Pressure Reducing Valve

6.1.15

Directional Solenoid Valves (2 positions / 4-ways)

6.1.16

Pressure Increasing Valve

14-17

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Section 6.0 Page 2

Components

6.1.1

Main Control Blocks and High Pressure Filter Front Shovel Attachment FSA Legend for illustration (Z 22566): Pump circuit No. I (14 / I ) Control block I (L.H. Travel, Stick, Bucket, Boom,) (46.1) High pressure filter, Pump 2 and 5 (31.01) SRV Travel motors left backward (32.01) ACV Travel motors left backward (31.02) SRV Travel motors left forward (32.02) ACV Travel motors left forward (33.1) SRV Stick cylinder piston side (32.3) ACV Stick cylinder piston side (32.4) ACV Stick cylinder rod side (32.5) ACV Bucket cylinder rod side (33.2) SRV Bucket cylinder rod side (32.6) ACV Bucket cylinder piston side (32.7) ACV Boom cylinder rod side (32.8) ACV Boom cylinder piston side Pump circuit No. II (15 / II) Control block II (Bucket, Boom, Reserved, Stick) (44.2) High pressure filter, Pump4 (32.9) ACV Bucket cylinder rod side (32.10) ACV Bucket piston side (30) SRV Clam cylinder piston side (33.06) SRV Bucket cylinder rod side (32.11) ACV Bucket cylinder rod side (32.12) ACV Bucket cylinder piston side (32.13) ACV Boom cylinder rod side (33.4) SRV Bucket cylinder rod side (32.14) ACV Boom cylinder piston side (32.15) ACV Stick cylinder piston side (191) SRV (pressure increasing valve) Stick cylinder rod side (32.16) ACV Stick cylinder piston side continue

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Section 6.0 Page 3

Components

Pump circuit No. III (176 / III) Control block (R. H. Travel, Boom, Bucket, Stick) (46.2) High pressure filter, Pump 1 and 6 (31.03) SRV Travel motors right forward (32.17) ACV Travel motors right forward (31.04) SRV Travel motors right backward (32.18) ACV Travel motors right backward (32.19) ACV Boom cylinder rod side (32.20) ACV Boom cylinder piston side (32.21) ACV Bucket cylinder rod side (32.22) ACV Bucket cylinder piston side (32.23) ACV Stick cylinder rod side (32.24) ACV Stick cylinder piston side Pump circuit No. IV (13 / IV) Control block IV (Single spool for swing) (44.1) High pressure filter, Pump 3

)

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• There is one MRV in each control block.

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Section 6.0 Page 4

Components

6.1.2

Main Control Blocks and High Pressure Filter Backhoe Attachment Legend for illustration (Z 22433): Pump circuit No. I (175 / I ) Control block I (L.H. Travel, Stick, Bucket, Boom,) (46.1) High pressure filter, Pump 2 and 5 (31.01) SRV Travel motors left backward (32.01) ACV Travel motors left backward (31.02) SRV Travel motors left forward (32.02) ACV Travel motors left forward (33.1) SRV Stick cylinder piston side (32.3) ACV Stick cylinder piston side (32.4) ACV Stick cylinder rod side (32.5) ACV Bucket cylinder rod side (32.11) ACV Bucket cylinder piston side (32.12) ACV Boom cylinder rod side (32.13) ACV Boom cylinder piston side Pump circuit No. II (15 / II) Control block II (Bucket, Boom, Reserved, Stick) (44.2) High pressure filter, Pump4 (32.14) ACV Bucket cylinder rod side (32.15) ACV Bucket piston side (33.06) SRV Boom cylinder rod side (32.11) ACV Boom cylinder rod side (33.05) SRV Stick cylinder piston side (32.15) ACV Stick cylinder piston side (32.16) ACV Stick cylinder rod side continue

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Section 6.0 Page 5

Components

Cont’d Main Control Blocks and High Pressure Filter BHA Pump circuit No. III (176 / III) Control block (R. H. Travel, Boom, Bucket, Stick) (46.2) High pressure filter, Pump 1 and 6 (31.03) SRV Travel motors right backward (32.17) ACV Travel motors right backward (31.04) SRV Travel motors right forward (32.18) ACV Travel motors right forward (32.19) ACV Boom cylinder rod side (32.20) ACV Boom cylinder piston side (32.21) ACV Bucket cylinder rod side (32.22) ACV Bucket cylinder piston side (32.23) ACV Stick cylinder rod side (32.25) ACV Stick cylinder piston side Pump circuit No. IV (13 / IV) Control block IV (Single spool for swing) (44.1) High pressure filter, Pump 3

)

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• There is one MRV in each control block.

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Components

6.1.3

Section 6.0 Page 6

Distributor Manifold - Location of restrictor blocks and anti cavitation valves Front Shovel Attachment (FSA) Legend for illustration (Z 22434): (1) Distributor manifold (2) Synchronization (Equalization) lines (3) Synchronization (Equalization) lines (4) Anti Cavitation Valve Block (ACV) (5) Restrictor Block (Throttle valve) (6) Restrictor Block (Throttle valve) (7) Service-line Relief Valve

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Components

6.1.4

Section 6.0 Page 7

Distributor Manifold - Location of restrictor blocks and anti cavitation valves Backhoe Attachment Legend for illustration (Z 22434): (1) Distributor manifold (2) Synchronization (Equalization) lines (3) Synchronization (Equalization) lines (5) Service-line Relief Valve (4) ACV Block Section A ,Boom cylinder rod side (6) Service-line Relief Valve Pressure check point (7) Restrictor blocks

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Components

6.1.5

Section 6.0 Page 8

Restrictor Block with Pressure Relief Valve

)

• A restrictor block is used for limiting cylinder lowering speeds. • A Service Line Relief Valve is installed to limit the maximum system pressure due to external forces.

Legend for illustration (Z 21834): (1) (2 + 3) (4) (5 + 6) (7) (8) (9) (10) (11 (12) (13) (14) (15) (16) A+B M Y

Adjustment spindle O-ring with back-up ring Retainer O-ring with back-up ring Spring Spring cup Throttle sleeve O-ring Housing Return line port, T Pressure relief valve Allen bolt Clip ring Lock nut Line ports Pressure check point Control oil drain port

Function: Setting of the maximum permissible cylinder speed (flow B to A) is carried out by spindle (1). Depending on the spindle setting, the radial holes (9.1) in the valve poppet (9) will be partially opened to achieve the required throttling of the oil flow. The extra holes (fixed throttle 9.2) prevents the valve from becoming completely closed. For the lifting operation (flow A to B), the valve poppet (9), which is guided by the spindle (1), is pressed against spring (7) so that the valve will be completely open.

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Components

6.1.6

Section 6.0 Page 9

Anti Cavitation Valve Block

)

• ACVs are installed to avoid cavitation damages on users (hydraulic cylinders), by compensating a possible lack of oil, when the SRV at the opposite side of the cylinder opens (see circuit diagram).

Legend for illustration (Z 21835): (Type 64.1 to 64.9 of the hydraulic circuit diagram) (1) Housing (2) Valve cone (3) Spring (4) O-ring (5) Control and leak oil bore (6) Cap screw (torque 900 Nm) S Supply line (Return oil pressurized to approximately 10 bar by back pressure valve) A and B Line connections Function: The circuit pressure in the line A and B hold the valve cone (2) closed. The pressure of the supply line S forces onto the valve cone. The valve cone opens, whenever the pressure at the A and B side is lower than the back pressure at return oil port S, to allow necessary oil supply into the circuit.

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Components

6.1.7

Section 6.0 Page 10

Remote control valves

)

• Remote control valves are part of the electric-hydraulic control system

Legend for illustration (Z 21838): (1 - 8) (9) (10) (11) (12) (13)

Pilot pressure lines to the control block Pilot pressure supply port Return to tank port Manifold block Double directional solenoid valve Single proportional solenoid valve

Function: The electric-hydraulic control system is used to control the direction and volume of oil flow to the operating cylinders and motors via the main control valve blocks. When a lever (or pedal) is actuated, a proportional solenoid valve (13) and one of the directional solenoid valves (12 either a or b) are energized, and allows the pilot pressure oil to flow to the spools of the main control blocks. The proportional solenoid valve alters the pilot pressure, proportional to the lever deflection, this results a spool movement between neutral and full stroke position.

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Components

6.1.8

Section 6.0 Page 11

Directional Solenoid Valves (4/3 direction flow valve = 4 way / 3 positions)

)

• This solenoid operated directional spool valves are installed to control the start, stop and direction of an oil flow.

Legend for illustration (Z 21839): (1) Housing (2) Solenoids (3) Control spool (4) Reset springs (5) Plunger (6) End cover Function: In un-operated condition the control spool (3) is held in the neutral or starting position by the reset springs (4). Operation of the control spool is by means of oil immersed solenoids (2). The force of the solenoid (2) acts via the plunger (5) on the control spool (3) and pushes its from its resting position into the required end position. This results in the required free flow from P to A and B to T or from P to B and A to T. When the solenoid (2) is de-energised, the control spool (3) is returned to its original position by the reset springs (4).

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Components

6.1.9

Section 6.0 Page 12

Proportional Solenoid Valve

)

• This valves are responsible for the creation of a variable control pressure proportional to the electrical signal output of an amplifier.

Legend for illustration (Z 21697): (1) Proportional solenoid (2) Control piston (3) Valve housing (4) Pressure measuring spool

(5) (6) (7) (8)

Pressure measuring spool Connection plug Return spring Bleed screw

Function: In un-operated condition the control spool (2) is held in the neutral or starting position by reset springs. The control spool (2) is directly operated by the proportional solenoid (1). If the solenoid is energized, it produces a force to operate the control spool (2) via the pressure measuring spool (4) and moves the spool to the left. Oil flows from P to A. As pressure in A increases, it passes via the radial borings in the control spool (2) to the inner end of the pressure measuring spool (2). The force generated by the pressure now works against the solenoid force and pushes the control spool (2) to the right (closing direction) until a balance is achieved between the two forces. In order to achieve this, the pressure measuring spool (2) moves to the left until it is supported by the pin (5). When the force balance is achieved, the connection between P and A is interrupted and the pressure in line A is held constant. Any reduction in the solenoid force leads to the pressure force exceeding the solenoid force on the control spool (2). The control spool is then moved to the right causing a connection from A to T allowing the pressure to fall until a balance is reestablished at a lower level. At rest, when the solenoid is de-energized, ports A and B are open to tank, whilst port P is blocked from both ports A and B.

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• In order to achieve optimum functioning of the valve, it must be bleed when commissioning: - Supply pressure to the valve - Remove plug 8 - When no more air bubbles appear screw in plug 8.

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Components

6.1.10

Section 6.0 Page 13

High Pressure Filter

)

• There is one filter in each pump line installed.

Legend for illustration (Z 21696): (1) Filter head (2) Drain plug (3) Filter case (4) Hexagon (5) Filter element (6) Seal (7) O-ring (8) Back-up ring (9) O-ring (10) Spring (11) Differential pressure switch P1 Input pressure P2 Output pressure a Electrical connection b REED contact c Permanent magnet piston d Spring e Plug screw Function: High-pressure in-line filters prevent contamination from entering the hydraulic circuits. The high pressure filters are installed between the main hydraulic pumps and main control blocks. All hydraulic components, behind the pumps, are effectively protected from damage and undue wear. Each filter is equipped with a differential pressure switch to monitor the filter flow restriction. If the pressure reaches an unsafe difference of 8.5 bar, a visual/acoustic warning appears on the display in the cab and the engines will be shifted automatically to low idle.

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Components

6.1.11

Section 6.0 Page 14

Control Blocks and Valves

)

• This is a principle drawing, showing valve block I, II and III.

Legend for illustration (Z 22436): (1) Control block housing (2) Cab ("A side) (3) Cap ("B" side) (4) Solid spool (5) "B" side service line ports (6) Centering springs (7) MRV, main relief valve (8) Port A, to cylinder/motor (9) Port B, to cylinder / motor (10) Fine controlling grooves (11) Port P, from pumps (12) Port T, to tank (13) Load holding valves Control blocks with "Open Center and Closed Ports". Control blocks I, II and III are 4 spool blocks and IV is a 1 spool block. See hydraulic circuit diagram for spool details. Each spool is provided with "Fine Controlling Grooves" and ring grooves for hydraulically centering of the spool. Between 8 and 19 bar pilot pressure the spools are moved in their fine control range. Spool number 4 of block I, 2 of block II and 4 of block III are special designed, to keep the pressure channel connected to the center channel during the floating function is activated, so that pump flow is available for other functions. This spools are marked in the hydraulic diagram with (# or $) symbol. The Load Holding Valves are installed inside of the spool, for each port to the cylinder or motor one valve. The hydraulic diagram shows only one. The MRV is a pilot operated pressure relief valve.

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Components

6.1.11

Section 6.0 Page 15

Control Blocks and Valves Legend for illustration (Z 22440): (1) Main relief valve (MRV)Control block housing (2) Load holding valve (3) Anti cavitation valve (ACV) (4) Service line relief valve (SRV) Explanation of the schematic drawing of the control block: The hydraulic oil flows through the control block from port P to T, if all spools are in neutral position ("pressure-less circuit" or “Free circulation“).

(A) 4 valve block E.g. the spools moves up when pilot pressure is build up in the control pipe line a1. (Imagine the lower symbol box moves to the center position.) Now pump oil flows through holding valve (2) to the user port A1 because the free flow circulation to the hydraulic reservoir is closed. The main relief valve (1) limits the maximum operation pressure in this circuit. Via port B1 the return oil from the user is flowing back to the hydraulic reservoir. During down hill travelling motion and stopping procedure (e.g. travel motors) the anti cavitation valves (3) prevents cavitation on the hydraulic motors. Because during these short periods of time the hydraulic motor needs a higher oil supply than the pump can deliver. E.g. the spool (4) moves up when pilot pressure is build up in the control pipe A4. Now the user port A4 is connected to the pump pressure line and the free circulation to the tank. There is no high pressure build up only 8 bar from the back pressure valve and line resistance. Via port B4 the return oil from the user is flowing back to the hydraulic reservoir. Service line relief valve (4) is additional installed in this circuit to protect the circuit for extreme pressure. The shortly extreme pressure closes also the holding valve (2) which secures the hydraulic pump from extreme pressure peaks.

(B)

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The holding valves (2) have also the function of load holding valves because during the fine controlling period all lines are connected together (negative over-lapping). The load pressure is for a moment higher than the pump pressure. single valve block

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Components

6.1.11

Section 6.0 Page 16

Control Blocks and Valves Legend for illustration (Z 22441): (1) Spool (2) Reset springs (3) Load holding valve Function: Reset springs (2) moves the spool (1) in neutral position. Fine control grooves provide for sensitive controlling, because a motion is started always while the pressure oil and the return oil first passes this fine control grooves before spool (1) is inter connecting the entire groove to the user channel. In neutral position of spool (1) the pump oil is flowing back via port PU to the tank. Lower picture: Example. The spool is moved by pilot pressure on the left spool side to right position: Port PU is closed and the connection through the holding valve (3) to the user (port A) is open. Also the connection from the other user side (port B return)is connected to the port T (return line to tank).

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Components

6.1.11

Section 6.0 Page 17

Control Blocks and Valves Legend for illustration (Z 21705): (01) Service -Line Relief Valve (02) Anti Cavitation Valve (03) Main Relief Valve (04) Closing plate (5) Plug screw (6) Spring (7) Valve cone (8) Dust cap

(9) (10 (11) (12) (13) + 16) (14) (15) (17)

Set screw Lock nut Spring, pilot part Poppet Jet bore Spring, main cone Main valve cone Pilot oil dump line to tank

MRVs and SRVs are pilot operated relief valves. The MRV limits the max. Pump supply line pressure. The SRV limits the max. possible pressure peak in the service-line. The valves have an „opening characteristic“. That means, that in case of contamination after the response procedure no further pressure increasing is possible and damages are avoided. Function: The circuit pressure P forces with the force F1 on the piston surface A of the main valve cone (15). Because there is via the jet bore (16) the same pressure on the back side of the main cone, this results together with the spring (14) force in a force F2 that keeps the main cone closed. Via the jet bore (13) the circuit pressure is in front of the poppet (12). Exceeds the circuit pressure the setting value of the spring (11), the poppet opens against the force of the spring (11). This causes that the force F2 decreases and there is no more balance condition between F1 and F2. Valve cone (15) is moved upwards by the greater force F1. That means there is now a direct connection from port P to T (tank). ACVs serve for compensation possible lack of feed when the SRV at the opposite port is actuated (see circuit diagram) and for avoiding cavitation damages. In addition, to supply a user in case it is continuously moved by acceleration forces at zero position of the control spool. Function: The circuit pressure inside the spring chamber closes the valve cone (7). The back pressure of the return line acts on the surface of the valve cone (7). Whenever the pressure in the service-line is lower than the springs force the valve cone opens by the force of the back pressure and hydraulic oil is additional supplied.

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Components

6.1.12

Section 6.0 Page 18

Load Holding Valve Legend for illustration (Z 22441): (1) Spool (2) Reset springs (3) Load holding valve Control Blocks I to IV (4 spool blocks and single spool block) Two load holding valves are fitted into each spool of the control blocks, one valve for each port (A and B). They have three tasks: 1. When circuit pressure due to attachment weight is higher than pump pressure these valves prevent dropping of the attachment, within their sensitive (fine controlling) range. 2.

Due suddenly pressure peaks in the service lines the valves also protect the pump. 3. When two pumps flows are used for one user they ensure that at least the flow of one pump reaches the user in case one MRV is defect or not more correct adjusted. That means: Up to the max. Pressure of the defective valve both load holding valves are open allowing the flow of both pumps to the user, then one valve will be closed by the higher pressure and the flow of one pump only flows to the user. Function: The system pressure forces onto the front area of the valve cone (1). This force moves the valve cone against the spring and allows the oil to flow from the pump through the spool centre to the port. In neutral position of the spool no further flow is possible. (see circuit diagram) If the spool is not more in neutral the flow continues to the user. If due to an external force the pressure directed to the pump overcomes the pump line pressure, this pressure forces the valve onto its seat (closed position)

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Components

6.1.13

Section 6.0 Page 19

Travel Brake Valve Illustration Z 21695 Task: Travel brake valves control the oil flow from the hydraulic motor to the tank depending on operating pressure. This braking action prevents the motors from over speeding. Function: Spring force keeps the spool in the lowest flow position. with increasing operating pressure the opening for the return oil flow becomes larger. On its way to the hydraulic motor the oil flows from A to A1 respectively from B to B1 depending on the selected travel motion. Example: Operating pressure at port A moves spool (1) against the force of the spring (2) and opens the way for the return oil (B1 to B). Holding valve (3) prevents a direct oil flow from B1 to B. If the operating pressure decreases to such an extend that the spring force overcomes the pressure, the flow to the tank becomes restricted, resulting in braking of the machine. For more information and adjustment see section 8.3.

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Components

6.1.14

Section 6.0 Page 20

Pressure Reducing Valve

)

• Pressure reducing valves are installed to reduce the common 35 bar pilot pressure to a lower pressure for other systems, e.g. the pump regulation system.

Legend for illustration (Z 21844): (1) Set screw (2) Spool (3) Compression spring (4) Threaded sleeve (5) Non return valve (6) Boring (7) Spring chamber (8) Control land Function: Pressure reducing valves type DR & DP are direct operated valves of 3 way design, e.g. with a pressure relief function on the reduced pressure side. At rest, the valve is normally open, and fluid can flow unhindered from port P to A. Pressure in port A is also present on the end of the spool (2), via control line (6), opposing the compression spring (3). When the pressure in port A reaches the pressure level set at spring (3), spool (2) moves to the control position and holds the pressure in port A constant. Fluid to control the valve is taken from port A via the boring (6). If the pressure in port A rises still further due to external forces, the spool (2) is moved still further towards the compression spring (3). This causes a flow path to be opened over control land (8) in the control spool (2) to tank. Sufficient fluid then flows to tank to prevent any further rise in pressure. An optional non return valve (5) is available to allow free flow from A to P.

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Components

6.1.15

Section 6.0 Page 21

Directional Solenoid Valves (2 positions / 4-ways)

)

• This solenoid operated directional spool valves are installed to control the start, stop or direction of an oil flow.

Legend for illustration (Z 21845): (1) Housing (2) Solenoid (3) Control spool (4) Return spring (5) Plunger (6) Dust cap with stem for manual operation Function: When there is no flow through the valve, control spool (3) is held in neutral or output position by means of the return springs (4). The control spool (3) is operated by means of oil immersed solenoid (2). The force of the solenoid (2) effects control spool (3) by means of the plunger (5) and pushes it from its resting position to the required end position. This results in free flow from P to B and A to T. When solenoid (2) is de-energized, control spool (3) is moved back to its resting position by means of return springs (4). An optional hand emergency (6) allows movement of the control spool (3) without energizing the solenoid.

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Components

6.1.16

Section 6.0 Page 22

Pressure Increasing Valve

)

• The pressure increasing valve is a remote controlled pressure relief valve, actuated by hydraulic pressure. The individual pressure is in such a way determined by the pilot pressure.

Legend for illustration (Z 21846): (1) Pilot valve with valve seat (2) Valve poppet (3) Compression spring (4) Main valve with sleeve (5) Main piston (6) Closing spring (7+8) Set screws (9) Piston (10) Pin (11+12) Jet bore (13+14) Lock nut Function: The valve poppet (2) is connected via the jet bores (11) and (12) with the pressure port (P). If static pressure increase above the set pressure value, the valve poppet (2) opens and allows oil to flow freely via port (T1) to tank. This out flowing oil generates a pressure drop in the spring chamber of the main spool (5). The closing force of the spring (6) is now lower as the oil pressure from the pressure port (P) and the main piston (5) opens to release pressurized oil to the tank via port (T2). Damped opening and closing is obtained by the throttled volumetric change. By applying external pressure of Pst max = 35 bar to the main spool (9) via port X, the pre-tensioning of the pressure spring (3) is increased by the amount of the piston stroke "S" and system pressure is increased correspondingly. The maximal possible pressure (P) adjustment is 440 bar with max. control pressure at port X. The lower setting is fixed by means of the setting screw (7) and lock nut (13); 1 turn of setting screw reduce or increase the pressure about ~150 bar.

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Main Hydraulic Pumps and Pump Regulation System

Section 7.0 Page 1

Table of contents section 7.0 Section 7.0

Page Main hydraulic pumps and pump regulation system General 7.1

7.2

7.3

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2–5

Main Pumps 7.1.1 Location of Pumps

7.1.2

Pump bearing flushing / lubrication

7.1.3

Operating Principles

8 – 15

7.1.4

Checks and Adjustments

16 – 20

Electronic Pump Regulation System 7.2.1 Electronic load limiting control - General

7.2.2

Micro controller MC7

7.2.3

Checks and adjustments - General

Method A -

X1-pressure adjustment with 24V supply to separating terminals at the X2-switch board.

Method B - With the electronic service tool BB-3 - Language selection

25 + 26

- Excavator Type selection

27 + 28

- X1-pressure (max. current) adjust.

29 + 30

Method C - With a laptop and BODEM software - Starting the program

31 + 32

- Language selection

- Excavator Type selection

- X1-pressure (max. current) adjust.

Hydraulic Constant Regulation System 7.3.1 General

7.3.2

X1-pressure adjustment (constant-pressure)

7.4

Determination of the Peak point

38+39

7.5

Engine speed sensor (pick up) 7.5.1 Engine speed sensor (pick up) adjustment

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Main Hydraulic Pumps and Pump Regulation System 7.0

Section 7.0 Page 2

Main hydraulic pumps and pump regulation system General layout (Hydraulic only) Legend for illustration (Z 22442a): (1 - 6) Main hydraulic pumps (7.1) Pilot pressure pumps, engine 1 (7.2) Pilot pressure pumps, engine 2 (68.1) Pilot pressure filter unit (70.1) 60 bar pressure relief valve (70.2) 35 bar pressure relief valve (81.1) Pressure reducing valve: "Remote control pressure" ½ Q-max flow reduction for the warming-up period (81.2) Pressure reducing valve: "Pump regulation pressure X1 at hydraulic pump regulation" (Hydraulic constant regulation mode) (Y17) Solenoid valve: "Idle time control and low hydraulic oil temperature" Q-min flow for all main pumps (Y17a) Solenoid valve: "Remote control pressure" ½ Q-max flow reduction for all main pumps (low hydraulic oil temperature) (Y61-1) Proportional solenoid valve: "Pump regulation pressure X1 at electronic pump regulation, engine 1" (Standard operation mode) (Y61-2) Proportional solenoid valve: "Pump regulation pressure X1 at electronic pump regulation, engine 1" (Standard operation mode) (79.1) Change over valve: "Electronic or Hydraulic pump regulation", engine 1 (79.2) Change over valve: "Electronic or Hydraulic pump regulation", engine 2 (Y102-1) Solenoid valve: "Pump regulation support pressure and pump bearing lubrication" (Y102-2) Solenoid valve: "Pump regulation support pressure and pump bearing lubrication"

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Main Hydraulic Pumps and Pump Regulation System 7.0

Section 7.0 Page 3

Main hydraulic pumps and pump regulation system Pump regulation system General Controlled output flow of the main pumps is necessary: • To utilize the available engine power most efficiently in every operating mode. • To limit the power consumption of the hydraulic pumps depending of the load of the engine. (Electronic pump regulation with micro-controller MC7) • For additional functions, such as swing dependent or temperaturedependent flow control. Function: X1 – pump regulation pressure (0 – 25 bar): The power controller of the main pumps can be remotely controlled by applying an external pilot pressure (X1 ) at port X LR to the spring chamber of the power control valve. The start of destroking can be varied in proportion to the applied X1 - pressure. X2 – pilot pressure (35 bar): Constant pilot pressure to regulate the main pumps at special circumstances, e.g. to fix pump 3 in Q-max position activated by the swing control (pump for swinging controlled by Y48) . X3 – remote control pressure (0 / 16 / 35 bar): Basic setting Q-min (0 bar), the flow rate increases with the pilot pressure X3 at port Pst, up to Q-max (35 bar). The hyperbolic power control is superimposed on the pilot pressure signal and keeps the specified drive power constant. (px Vg = constant). The flow rates are: Q-min.: X3 = 0 bar ½ Q-max.: X3 = 16 bar Q-max.: X3 = 35 bar X4 – pump support pressure (60 bar): Constant pilot pressure to support the regulation function at low operating pressure and to lubricate the main pump bearings.

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Main Hydraulic Pumps and Pump Regulation System 7.0

Section 7.0 Page 4

Main hydraulic pumps and pump regulation system Pump regulation system general Function: Solenoid valve Y17: (33/7)* If solenoid valve Y17 is de-energized pumps (1-6) are in Q-min position. It gets energized as soon as one of the control levers/pedals has been operated and de-energized when ever all controls are in neutral position for more than 20 seconds (exception: high oil temperature >T3). Solenoid valve Y17a: (33/5)* The solenoid is de-energized as long the hydraulic oil temperature is below the values of temperature range „T2“ (depending on the filled in hydraulic oil) shown in the table. ( pumps (1-6) are in ½ Q-max. position)

)

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Electric circuit diagram page / column (based on id # 897 889 40)

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Main Hydraulic Pumps and Pump Regulation System 7.0

Section 7.0 Page 5

Main hydraulic pumps and pump regulation system Pump regulation system general Function: Proportional Solenoid valve Y61-1 and Y61-2: (49/2)* This valves, connected to the MC7 micro-controller E32 (electronic pump regulation), creates a X1-pressure depending on the load of the engine. This X1-pressure is the pumps regulation signal to de-stroke from Q-max. into Q-min. – position, to keep the engine at rated speed of approx. 1800 RPM. Pressure reducing valve 81.1: "Remote control pressure" (X3) ½ Q-max flow reduction during the warming-up period for all pumps by the function of solenoid valve Y17a. Pressure reducing valve 81.2: Pump regulation pressure X1 at "hydraulic pump regulation" (Hydraulic constant regulation mode) by the function of change over valve (79.1 / 79.2). One valve for both engines. This valve create a constant X1 pressure, the pressure can be change for different pump regulation checks and adjustments. Change over valve 79.1 and 79.2: Change over three way cock valve to select "Electronic or constant regulation mode", one for each engine.

Note:

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* Electric circuit diagram page / column (based on Id # 897 889 40)

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Main Hydraulic Pumps and Pump Regulation System 7.1

Section 7.0 Page 6

Main Pumps 7.1.1. Location of Pumps Legend for illustration (Z 22415a): (1 - 6)

= 500 cm³/rev = 700 Liter/min = 1400 min-1

(10.1), (10.3) Axial piston pump pump volume theoretical flow rate Drive speed* for radiator fan drive

Vg max Qmax n

= 80 cm³/rev = 158 Liter/min = 1973 min-1

(10.2), (10.4) Axial piston pump pump volume theoretical flow rate Drive speed* for oil cooler fan drive

Vg max Qmax n

= 80 cm³/rev = 142 Liter/min = 1770 min-1

Gear pump pump volume theoretical flow rate Drive speed* for PTO gear lubrication

Vg Qmax n

= 58,7 cm³/rev = 82,2 Liter/min = 1400 min-1

Gear pump pump volume theoretical flow rate Drive speed* for hydraulic oil circulation

Vg Qmax n

= 58,7 cm³/rev = 82,2 Liter/min = 1400 min-1

Gear pump pump volume theoretical flow rate Drive speed* for pilot pressure supply

Vg Qmax n

= 85,7 cm³/rev = 120 Liter/min = 1400 min-1

(8.1), (8.4)

(8.2), (8.5)

(7.1), (7.2)

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Axial piston pump (swash plate type) pump volume Vg max theoretical flow rate, each Qmax Drive speed* n for all working motions

• * at 1800 min-1 input drive speed

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Main Hydraulic Pumps and Pump Regulation System

7.1

Section 7.0 Page 7

Main Pumps 7.1.2. Pump bearing flushing / lubrication The installed main pumps are provided with an external cooling and lubrication system for flushing of drive shaft bearing and shaft seal. Oil supply is provided from the X4-pressure circuit. To reach the restricted guidance of the coolant for external bearing flushing, the throttle screw (located behind the union at port U) must screwed in all the way. An information sign is fixed at the pump. Legend for illustration (Z 22443): (1 – 4) Main pumps (147.1-147.6) Orifice (one for each main pump) (33) Filter for pilot pressure (P) Ports for X4-pressure (pump support pressure) (U) Port for the pump bearing flushing / lubrication

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Main Hydraulic Pumps and Pump Regulation System 7.1

Section 7.0 Page 8

Main Pumps 7.1.3 Operating Principles Main hydraulic pump A4VSO 500 LR3DN / 30L Type code explanation: A4VSO 500 LR 3 D N / 30 L Rotation Series Basic adjustment for minimum displacement With pressure control Hydraulic remote adjustment facility Constant power with hyperbolic curve Max displacement in cm3 at one (1) revolution Axial piston pump series 4, variable displacement ,swash plate design for open circuits

Function and characteristics: • The A4VSO variable displacement axial piston pump in swash plate design is intended for drives in open circuit operation. • The flow volume is proportional to the drive speed and the displacement. By adjusting the swash plate a infinitely variable flow adjustment is possible. • Pumps of the same nominal size can be built onto the trough drive. Combinations with gear pumps are also possible. Legend for illustration (Z 22446): The lower illustration shows only a principle pump construction (1) Drive shaft (2) Cylindrical roller bearing (3) Slipper pad (4) Swivel angle indicator (5) Positioning piston (6) Swivel pin (7) Cylinder with pistons (8) Final connecting plate (9) Cylindrical roller bearing (10) Splints for the through drive coupling (Aux. pump drive) (11) Swivel cradle (12) Q-min stop bolt (13) Power control valve (14) Pressure balance valve (15) Power curve correction (16) Pressure cut off valve (17) Q-max. stop bolt (18) Remote control valve continued

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Main Hydraulic Pumps and Pump Regulation System

Section 7.0 Page 9

Cont'd: 7.1 Main Pumps 7.1.3 Operating Principles Symbol of main hydraulic pump A4VSLO 750 LR3DN / 30L Legend for illustration (Z 22447): (1) Main pump (swash plate pump, variable displacement) (2) Pump bearing group (3) Drive shaft (4) Non return valves (5) Remote control valve (5.1) Mechanical stroke limitation* (5.2) Remote pressure (PST) operated piston for item 6 (5.3) Mechanical stroke limitation* (6) Spool valve (pressure balance valve) (7) Nozzle (8) Power control valve (9) Nozzle (10) Pressure cut-off valve (11) Auxiliary pump (Gear pump, fixed displacement (12) Positioning piston (13) Slipper pad piston (14) Lever (15) Cam (16) Through drive shaft

)

• * Factory side adjusted, no field adjustment required

B/B1 S MB Mst R(L) T, K1, K2 P Pst U XLR

Pressure port Oil intake (suction port) Operating pressure check point Control pressure check point Filler and bleeder port Connection port for chip indicator Pump support pressure (”X4”-pressure) Remote control pressure port (”X3”-pressure) Bearing flushing port Regulating pressure port (”X1”-pressure) continued

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Main Hydraulic Pumps and Pump Regulation System

Section 7.0 Page 10

Cont'd: 7.1 Main Pumps 7.1.3

Operating Principles

Sectional drawing of Power Controller LR3DN / 30L Legend for illustration (Z 21551a): (5) Remote control valve (5.1) Mechanical stroke limitation (5.2) Remote pressure (PST) operated piston for item 6 (5.3) Mechanical stroke limitation (6) Spool valve (pressure balance valve) (8) Power control valve (10) Pressure cut-off valve (12) Positioning piston (13) Slipper pad piston (14) Lever

)

• Refer also to illustration Z 22447 on the previous page.

continued

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Main Hydraulic Pumps and Pump Regulation System

Section 7.0 Page 11

Cont'd: 7.1 Main Pumps 7.1.3

Operating Principles, illustration (Z 21552a)

Q-min position: (remember Q means volume) When are the pumps in Q-min position? A: Engine at standstill B: Engine running and the controls are not used for 20 sec. or longer at normal operating temperature C: Engine running and service switch S150 activated Example C with the following conditions: • Engine running (high idle) • Pump pressure smaller than X4 = 60 bar (pump support pressure) • X1 = 24 bar (pump regulation pressure), this pressure will not influence the Q-min position under these conditions. • X3 = 0 bar (remote control pressure); Y17 de-energized (S150 activated) for pumps (1, 2,4, 5 and 6). Pump #3 is not connected in the regulation circuit its port XLR is permanent charged with X2-pressure • X4 = 60 bar (pump support pressure) Pump support pressure is present at valve (6), the slipper pad of piston (13) and the small area side of the positioning piston (12). Response of pump control mechanism: Valve (6) moves to position "b" because the X4-pressure will overcome the spring force, since the oil behind nozzle (7) flows through valve (5) (which is in position "a", due to the missing remote control pressure X3) back to tank. Pump support pressure X4 passes valve (6) position "b" and flows via power control valve (8) position "a" to the large area side of positioning piston (12). Because the large area side of positioning piston (12) is approximately three times larger as the small area side, the pump support pressure X4 of 60 bar present on both sides, resulting in stronger force at the large area side, keeps the pump in Q-min position. The pump remains in Q-min position continued

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Main Hydraulic Pumps and Pump Regulation System

Section 7.0 Page 12

Cont'd: 7.1 Main Pumps 7.1.3 Operating Principles, illustration (Z 21553a) Q-max position: (remember Q means volume) When does the pumps move into Q-max position? and and and

Engine running hydraulic oil at normal operating temperature (> T2) the controls frequently used within 20 sec. (or Service switch S151 activated) a pump pressure below start of de-stroking.

Example with the following conditions: • Engine running (> 1800 min-1) • Pump pressure between 60 bar and 300 bar, present at the slipper pad of piston (13) and the small area side of the positioning piston (12) • X1 = 24 bar (pump regulation pressure) • X3 = 35 bar (remote control pressure); Y17 and Y17a energized for all six pumps. • X4 = 60 bar (pump support pressure), present at valve (6). Response of pump control mechanism: Valve (6) moves to position "a" because the spring force is supported by the X4-pressure, since the oil flow back to tank is blocked at valve (5) (which is in position "b", due to the 35 bar remote control pressure X3). The large area side of positioning piston (12) is connected, via power control valve (8) position "a" and pressure balance valve (6) position "a", to the return oil line. The pump moves into Q-max position, because the pump pressure acts only at the small area side of positioning piston (12). The pump moves into Q-max position continued

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Main Hydraulic Pumps and Pump Regulation System

Section 7.0 Page 13

Cont'd: 7.1 Main Pumps 7.1.3 Operating Principles, illustration (Z 21554a) ½ Q-max position: (remember Q means volume) When does the pumps move into half Q-max position? and and and

Engine running hydraulic oil below normal operating temperature (< T2) the controls frequently used within 20 sec. (or Service switch S151 activated) a pump pressure below start of de-stroking.

Example with the following conditions: • Engine running (> 1800 min-1) • Pump pressure between 60 bar and 300 bar, present at the slipper pad of piston #14 and the small area side of the positioning piston #13 • X1 = 24 bar (pump regulation pressure) • X3 = 16 bar (remote control pressure); Y17 energized and Y17a deenergized for all six pumps. • X4 = 60 bar (pump support pressure), present at valve #6. Response of pump control mechanism: Valve (6) moves to an intermediate position (in-between "a" and "b"), since a certain amount of oil behind nozzle (7) flows through valve (5) (which is also in an intermediate position, due to the 16 bar remote control pressure X3) back to tank. The large area side of positioning piston (12) is connected, via power control valve (8) position "a" and pressure balance valve (6), to the return oil line. The pump moves into ½ Q-max position, because the return oil flow through pressure balance valve (6) is restricted (due to its intermediate position), resulting in a pressure at the large area side of the positioning piston (12). The pump moves into ½ Q-max position continued

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Main Hydraulic Pumps and Pump Regulation System

Section 7.0 Page 14

Cont'd: 7.1 Main Pumps 7.1.3 Operating Principles, illustration (Z 21555a) De-stroking: (Pump moves from Q-max. into of Q-min. direction) When does the pumps start to de-stroke Engine running and hydraulic at normal operating temperature (> T2) and Service switch S150 deactivated and The load stalls the engine RPM below 1800 min-1 ⇒ (The electronic pump regulation system will reduce the X1-pressure) or With pump pressure above ≈ 150 bar (Hydraulic constant regulation) (Constant X1-pressure of approximately 8 bar) Example with the following conditions: • Engine running (> 1800 min-1) • Pump pressure 260 bar adjustable at main relief valve, present at the slipper pad of piston (13) and the small area side of the positioning piston (12) • X1 = 12 bar (constant regulation pressure adjustable at pressure reducing valve 81.2) Change over valve (79.1 / 73.2) switched to hydraulic mode • X3 = 35 bar (remote control pressure); Y17 energized and Y17a energized • X4 = 60 bar (pump support pressure), present at valve (7). Response of pump control mechanism: Valve (6) moves to position "a" because the spring force is supported by the X4-pressure, since the oil flow back to tank is blocked at valve (5) (which is in position "b", due to the 35 bar remote control pressure X3). The operating pressure (with the value for start of de-stroking) at the slipper pad of piston (13) moves the power control valve (8) into position "b" (against the spring force supported by the X1-pressure). This in turn connects the operating pressure to the large area side of positioning piston (12). Because the large area side of positioning piston (12) is approximately three times larger as the small area side, the operating pressure present on both sides, resulting in stronger force at the large area side, moving the pump in Q-min direction. The pump de-strokes until the forces at positioning piston (12) are balanced continued

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Main Hydraulic Pumps and Pump Regulation System

Section 7.0 Page 15

Cont'd: 7.1 Main Pumps 7.1.3

Operating Principles, illustration (Z 21556a)

Pressure cut-off valve: (DR control valve, Pump moves into Q-min. position) When is the pressure cut-off valve active? Engine running and With pump pressure above ≈ 300 bar Example with the following conditions: Engine running (> 1800 min-1) Pump pressure 300 bar X1 = 24 bar (pump regulation pressure) X3 = 35 bar (remote control pressure) X4 = 60 bar (pump support pressure) Response of pump control mechanism: Independent of the position of power control valve (8) the pressure cut-off valve (10) causes the pump to de-stroke to the pre-adjusted Q-min position. The operating pressure moves the pressure cut-off valve (10) (at set pressure) into position "b" and flows to the large area side of positioning piston (12). Because the large area side of positioning piston (12) is approximately three times larger as the small area side, the operating pressure present on both sides, resulting in stronger force at the large area side, moving the pump in Qmin position. The pump moves into Q-min position

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Main Hydraulic Pumps and Pump Regulation System 7.1

Section 7.0 Page 16

Main Pumps 7.1.4

Checks / Adjustments

Location of Adjustments Legend for , illustration (Z21557) (1) Remote control valve (2) Q-min. stop bolt (3) Pressure balance valve (4) Start of de-stroking (5) Power curve correction (6) Pressure cut-off valve (7) Q-max. stop bolt (8) Angle indicator The average length of the measurement "L" is: set crews (bolts )

)

location

length L (mm)

13.4

21.9

7.6

8.1

----

6.0

27.6

• The measurement "L" is an orientation only if the adjustment is totally out of requirements. They must not be used for final adjustments. The detail for (5) shows the position of the housing edge and the edge of the eccentric set bolt. The example shows them in parallel position which is mostly not the case. The adjustment should never be altered.

Further information see next pages

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Main Hydraulic Pumps and Pump Regulation System 7.1

Section 7.0 Page 17

Main Pumps 7.1.4

Checks / Adjustments

Pressure balance valve, illustration (Z 21558b)

• The pressure balance valve is bench adjusted. There is no field setting with a sufficient result possible.

continued

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Main Hydraulic Pumps and Pump Regulation System

Section 7.0 Page 18

Cont'd: 7.1 Main Pumps 7.1.4

Checks / Adjustments

Start of de-stroking(LR valve), illustration (Z21559) The reason of this check is to make sure, the pump starts de-stroking at an operating pressure of 150 bar with a pump regulation pressure X1 = 0 bar. 1. 2. 3. 4. 5. 6. 7.

Connect a 400 bar pressure gauge to the pressure check point at the respective high pressure filter for the pumps being checked. Connect a 25 bar pressure gauge to respective pressure check point M20-1 or M20-2 at the control and filter panel (X1-pressure). Change over the respective three way cock to electronic regulation. Unplug the respective proportional valve Y61.1 / Y61.2. Insert an Allen key into the angle indicator bolt (see illustration) for better visibility of the start of. Start the respective engine, let it run with max. speed. The X1pressure should be 0 bar. Stall the hydraulic for the pump to be checked and alter the operating pressure with the MRV between 140 and 160 bar. Start of de-stroking should be at an operating pressure of 150 bar, shown at the gauge connected to the high pressure filter.

If readjustment is required proceed as follow: a) Adjust with the MRV an operating pressure of 150 bar. b) Loosen lock nut (6) (Power control valve). c) Turn set bolt (7), so that the pump is still in Q-max. position, but just at the beginning of de-stroking. d) Tighten lock nut (6). 8.

Re-adjust the operating pressure at the MRV to 310+10 bar and plug on the Y61.1 resp. Y61.2 (For exact values refer to the final test report.) Remove Allen key and gauges. continued

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Main Hydraulic Pumps and Pump Regulation System

Section 7.0 Page 19

Cont'd: 7.1 Main Pumps 7.1.4

Checks / Adjustments

Pressure cut-off valve (DR control valve), illustration (Z21560) The sense of this check is to make sure that the pump is in Q-min. position at an operating pressure between 300 bar and 310 bar. 1. 2. 3.

Connect a 400 bar pressure gauge to the pressure check point at the respective high pressure filter for the pumps being checked. Insert an Allen key into the angle indicator bolt (see illustration) for better visibility of the start of destroking. Start the respective engine, let it run with max. speed, stall the hydraulic for the pump to be checked and alter the operating pressure with the MRV between 280 and 310 bar. The angle indicator must indicate Q-min. position at a pressure of 300 bar shown at the gauge connected to the high pressure filter.

If readjustment is required proceed as follow: a) Loosen lock nut (8). b) Turn set bolt (9), so that the pump is in Q-min. position at the required value. c) Tighten lock nut (8). 5. 6.

Re-adjust the operating pressure at the MRV to 310+10 bar Remove Allen key and gauges.

continued

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Main Hydraulic Pumps and Pump Regulation System

Section 7.0 Page 20

Cont'd: 7.1 Main Pumps 7.1.4

Checks / Adjustments

Q-max. and Q-min. stop bolt, illustration (Z21561) 1. 2. 3. 5.

Unscrew box nut (10 or 14). Loosen the lock nut (11 or 13) Turn the stop (12 or 15) in or out until required length Length "X" or "Y" Tighten the lock nut and screw on box nut (12).

• Turning the Q-min. stop bolt too much out can cause serious damage to the pump. The pump moves over 0 (zero) position into the opposite drive direction: (suction line becomes pressure line and pressure line becomes suction line)

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Main Hydraulic Pumps and Pump Regulation System 7.2

Section 7.0 Page 21

Electronic Pump Regulation System 7.2.1

Electronic load limiting control - general, illustration (Z 22448)

The drive train of the excavator consists of two diesel engine, several hydraulic pumps, which supply cylinders and hydraulic motors. The load limiting control ensures optimum use of the power required for the excavator under varying operating conditions and avoiding overload of the diesel engine. Illustration Z22448 shows the principle of the electronic load limiting control. The MC7 (E32) processes the following input signals: • Diesel engine speed (Pin 52, 53 and 54) from magnetic pick-up (B64-1 and B64-2), adjustment see at the end of this section. • Switch signal (Pin 35) from engine control (3E14-1), 24V if n > 300 min-1 The MC7 (E32) processes the following output signals: • Signal value to control the proportional solenoid valve Y61-1 (Pin 28) and Y61-2 (Pin 30). • Switch signals (Pin 32 and 33), diagnostic of the MC7 (E32-1) The diesel engine drives three variable displacement pumps by means of a PTO-gearbox. Each pump is equipped with a hydraulic power controller (HPC). This controller limits the input torque of the pump to an adjusted command value (X1-pressure, for start of de-stroking). The command value (X1-pressure) is present via proportional solenoid valve Y61-1 and Y61-2 at the hydraulic power controllers of each pump. The actual speed of the engine is measured with a speed sensor at the flywheel.

)

• The auxiliary hydraulic pumps and other consumers can be operated without being directly affected by the load limiting control.

The control algorithm of the load limiting control always compares the actual engine speed with the rated load speed. With increasing load the engine torque will rise and the engine speed will drop. For this reason the electronic load limiting control will be initiated when the load speed falls below 1800 min-1 , i.e. the torque of the main pumps will be lowered (by reducing the X1-pressure) until the rated speed of 1800 min-1 is attained again.

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Main Hydraulic Pumps and Pump Regulation System 7.2

Section 7.0 Page 22

Electronic Pump Regulation System 7.2.2 Micro controller MC7, illustration (Z 21716) The MC7 micro controller is used for the programmable control of a maximum of four proportional solenoids and two additional switching functions. As input signals, the microprocessor processes analog voltages in the 0V to 5V range and switching information. All inputs are protected against over voltage and electrical interference. As output signals, the output stages of the MC7 deliver closed loop controlled currents for the connection of proportional solenoids. The analog voltage output is suitable for the simple forwarding of analog information to other electronic circuits. Characteristics • Closed loop control of solenoid currents, i.e. independent of voltage and temperature. • Pulse width modulated (PWM) solenoid currents for minimal hysteresis. • Internal buzzer for programmable monitoring of functions or errors.

Setting and Display Facilities All calibration operations and the display of functions, faults and system variables are connected via the serial interface to the BB-3 control panel or to a PC running the BODEM software. MC7 - Unit Dimensions

Plug Contacts

MC7 - Block Circuit Diagram

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Main Hydraulic Pumps and Pump Regulation System 7.2

Section 7.0 Page 23

Electronic Pump Regulation System 7.2.3 Checks and adjustments Micro controller MC7, illustration (Z 21714a) The adjustment of the X1-pressure can be done with three different methods: A. With 24V supply to separating terminals at the X2-switch board or B. With the electronic service tool (EST) BB-3 connected to the serial interface X13-1 (located in the operators cab) or C. With a laptop, running the BODEM software, connected to the serial interface X13-1 (located in the operators cab)

)

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• Procedure B and C should only be carried out by authorized personnel. [ Dealer or KMG-factory staff ] Because it is possible to influence the behavior of the pump regulation system. On the following pages are only the necessary setups described. If additional information is required, please contact KMG-Service department.

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Main Hydraulic Pumps and Pump Regulation System 7.2

Section 7.0 Page 24

Electronic Pump Regulation System 7.2.3

Checks and adjustments Micro controller MC7, illustration (Z 21717a)

Method A - X1-pressure with 24V supply to separating terminals at the X2switch board Pre-conditions: Normal operating temperature, correct pilot pressure setting and the system must be free of air. 1. Make sure the change over valves is in position “Electronic Pump Regulation” 2. Connect a pressure gauge to the respective check point (M20-1 or M20-2), using a long pressure gauge hose to be able reading the pressure in front of the X2panel. 3. Selection of adjusting mode: Turn the main key switch in on position, and activate the adjusting mode as follows: Connect 24V, simultaneously to terminal 127 and 128 for 10 seconds, using two test leads and disconnect the voltage thereafter. 4. Selection of the required proportional solenoid valve: With the main key switch still in on position, select the applying terminal (X2board) for proportional solenoid valve Y61-1 (engine1) or Y61-2 (engine2) as follows: Y 61-1 →No connections at selecting terminals required. Y 61-2 →Connect 24V, to terminal 126, using one test lead. 5. Adjusting the X1-pressure: Start the engine, let it run with maximum speed. Read the pressure, required = 24± 0,5 bar If necessary increase the X1-pressure as follows: Connect 24V temporarily to terminal 127. • As long as voltage is supplied, the X1-pressure drops to zero. After interrupting the voltage supply, the gauge pointer will move slowly to the new present X1-pressure. • Example: Keeping voltage supply for two seconds , will increase the X1-pressure of approximately 1 bar.

)

6. To decrease the X1-pressure connect 24V to terminal 128 and proceed as described under item 5, keeping voltage supply for two seconds , will decrease the X1-pressure of approximately 1 bar. 7. After the adjustment is finished, remove the test leads and pressure gauge and turn the main key switch in OFF position to deactivate the adjusting mode.

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Main Hydraulic Pumps and Pump Regulation System 7.2

Section 7.0 Page 25

Electronic Pump Regulation System 7.2.3

Checks and adjustments Micro controller MC7, illustration (Z 22357a)

Method B -

With the electronic service tool (EST) BB-3 connected to the serial interface X13-1 (located in the operators cab) Pre-conditions: Normal operating temperature, correct pilot pressure setting and the system must be free of air. 1. Make sure the respective change over valve is in position “Electronic Pump Regulation” 2. Connect a pressure gauge to check point (respective M20-1, M20-2 ), using a long pressure gauge hose to be able reading the pressure inside the operators cab. 3. Connect the electronic service tool (BB-3) to the data link adapter X13, with key switch (S1) in OFF position. 4. Turn key switch (S1) in ON position: After switching on the power for the Control panel BB-3 the following functions are carried out and shown on the display: 4.1 Self-test and baud rate recognition: The BB-3 automatically recognizes the rate of data transmission from the MC electronics. 4.2 Identification: On recognition of the MC electronics the relevant software in the BB-3 will be started up. 4.3 Main menu: Initialization of remote control unit BB-3 is complete. One of the four main menu items can be selected using the given keys. First screen (main menu) after connection and Key switch turned ON in German.

Language selection To change the language press simultaneously the buttons ALT + Clear

The language selection menu appears

continued

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Main Hydraulic Pumps and Pump Regulation System 7.2

Section 7.0 Page 26

Electronic Pump Regulation System 7.2.3

Checks and adjustments Micro controller MC7, illustration (Z 22357)

Method B Cont'd: Language selection Press button 2

The language will change to English

One of the four main menu items can be selected using the given keys. (Fig. 1)

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Main Hydraulic Pumps and Pump Regulation System 7.2

Section 7.0 Page 27

Electronic Pump Regulation System 7.2.3

Checks and adjustments Micro controller MC7, illustration (Z 22357)

Method B Excavator Type selection: Press F1 Config/Cal.

Press 4 Device List.

Press 1 Device List.

Select the excavator type by pressing Ï or Ð. PC4000/5500/8000

Press ENTER . Accept value/condition

Press MENU . Return to sub menu.

continued

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Main Hydraulic Pumps and Pump Regulation System 7.2

Section 7.0 Page 28

Electronic Pump Regulation System 7.2.3

Checks and adjustments Micro controller MC7, illustration (Z 22357)

Method B Cont'd: Excavator Type selection: Press MENU . Return to main menu.

Press TEACH . Activate storage menu.

Press 1 . Save Params. This menu item permits storage of all edited parameters in the EEPROM of the MC electronics.

Press ENTER . Store parameters.

Press MENU .Abort.

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Main Hydraulic Pumps and Pump Regulation System 7.2

Section 7.0 Page 29

Electronic Pump Regulation System 7.2.3

Checks and adjustments Micro controller MC7, illustration (Z 22357)

Method B X1-Pressure (maximum current) Adjustment: Press F1 Config/Cal.

Press 2 Max current

Start the respective diesel engine and let it run with maximum speed. (high free idle) Do not load the diesel engine. Press 1 Valve 1. (Engine 1) or Press 2 Valve 2 (Engine 2)

Check the X1-pressure with a pressure gauge and set it to the desired value by pressing Ï or Ð.

Press ENTER . Acceptance of new value

Press MENU . Return to sub menu.

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Main Hydraulic Pumps and Pump Regulation System 7.2

Section 7.0 Page 30

Electronic Pump Regulation System 7.2.3

Checks and adjustments Micro controller MC7, illustration (Z 22357)

Method B Cont'd: X1-Pressure (maximum current) Adjustment: Press MENU . Return to main menu.

Press TEACH . Activate storage menu.

Press 1 . Save Params. This menu item permits storage of all edited parameters in the EEPROM of the MC electronics.

Press ENTER . Store parameters.

Press MENU .Abort.

If all adjustments are correct and stored in the MC7, proceed as follow: • Stop the engine and turn key switch (S1) in OFF position • Disconnect the electronic service tool (BB-3) and the pressure gauge.

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Main Hydraulic Pumps and Pump Regulation System 7.2

Section 7.0 Page 31

Electronic Pump Regulation System

7.2.3 Checks and adjustments Micro controller MC7, illustration (Z 22358) Method C - With a laptop computer and BODEM software connected to the serial interface X13 (located in the operators cab) Pre-conditions: Normal operating temperature, correct pilot pressure setting and the system must be free of air. 1. Make sure the change over valve is in position “Electronic Pump Regulation” 2. Connect a pressure gauge to the respective check point (M20-x), using a long pressure gauge hose to be able reading the pressure inside the operators cab. 3. Connect the laptop computer to the data link adapter X13, with key switch (S1) in OFF position. 4. Make sure that the dongle is connected to the laptop computer. If not

5. Turn key switch (S1) in ON position. 6. Start the computer. 7. Click on the Bodem - icon to start the program.

continued

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Main Hydraulic Pumps and Pump Regulation System 7.2

Section 7.0 Page 32

Electronic Pump Regulation System 7.2.3

Checks and adjustments Micro controller MC7, illustration (Z 22358)

Method C Cont'd: 8. The program starts (only) the first time with the Demo Version.

9. Open menu FILE → INTERFACE , select the required interface connection (Standard COM1), confirm with OK and leave the program.

10. Start the program again. Now the computer is connected to the Micro controller.

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Main Hydraulic Pumps and Pump Regulation System 7.2

Section 7.0 Page 33

Electronic Pump Regulation System 7.2.3

Checks and adjustments Micro controller MC7, illustration (Z 22358)

Method C Language selection Open menu FILE → Language , select the required language and confirm with OK .

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Main Hydraulic Pumps and Pump Regulation System 7.2

Section 7.0 Page 34

Electronic Pump Regulation System 7.2.3

Checks and adjustments Micro controller MC7, illustration (Z 22358)

Method C Excavator Type selection: Open menu Display/Edit parameters → Device list , select the required Excavator type and confirm with OK .

After confirming the Excavator type, confirm saving the parameters with OK.

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Main Hydraulic Pumps and Pump Regulation System 7.2

Section 7.0 Page 35

Electronic Pump Regulation System 7.2.3

Checks and adjustments Micro controller MC7, illustration (Z 22358)

Method C X1-Pressure (maximum current) Adjustment: Display/Edit parameters → Max current , adjust the required pressure with the Open menu slide bar and confirm with OK .

After adjusting the pressure, confirm saving the parameters with OK.

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Main Hydraulic Pumps and Pump Regulation System 7.3

Section 7.0 Page 36

Hydraulic Constant Regulation System 7.3.1. General The pilot pressure pump (7.1 and 7.2) delivers the oil through the pressure filter (68.1) to port A of the pressure relief valve (70.1) for limiting the pilot pressure (X2). The 35 bar limited pilot pressure oil flows through the solenoid manifold to the pressure reducing valve (81.2), which reduces the X2 pressure to the necessary constant X1 pressure, to prevent the engine from overloading.

)

• For testing purposes the pump regulation system can be changed to the hydraulic operation mode. In case of a failure in the electronic regulation system the hydraulic operation mode can also be used for emergency operation. • The standard operation mode of the pump regulation system is the Electronic Operation Mode.

Legend for illustration (Z 22449): (1 - 6) Main hydraulic pumps (7.1) Pilot pressure pump, engine 1 (7.2) Pilot pressure pump, engine 2 (68.1) Pilot pressure filter unit (70.1) 60 bar pressure relief valve (70.2) 35 bar pressure relief valve (81.1) Pressure reducing valve: "Remote control pressure" ½ Q-max flow reduction for the warming-up period. (81.2) Pressure reducing valve: " Pump regulation pressure X1 at hydraulic pump regulation" (Hydraulic constant regulation mode) (Y61.1) Proportional solenoid valve: "Pump regulation pressure X1.1 at electronic pump regulation " (Standard operation mode), pump 1 and 2. (Y61.2) Proportional solenoid valve: "Pump regulation pressure X1.2 at electronic pump regulation " (Standard operation mode), pump 4, 5 and 6. (79.1) Change over valve engine 1: "Electronic or Hydraulic pump regulation" (79.2) Change over valve engine 1: "Electronic or Hydraulic pump regulation" (Y102-1) Solenoid valve “Pump support pressure and pump bearing flushing”, engine 1 (Y102-2) Solenoid valve “Pump support pressure and pump bearing flushing”, engine 2

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Main Hydraulic Pumps and Pump Regulation System 7.3

Section 7.0 Page 37

Hydraulic Constant Regulation System 7.3.2.

X1-pressure adjustment (constant-pressure) , illustration (Z 22360a)

Connect gauges (min. 400 bar) to check points (M12.1, M12.2, M12.3 and M12.4). Start only one engines and let it run with max. speed. Check High Idle speed = 1900+35 min-1. Shift the respective three way cock valves (79.1 and 79.2) to position “Hydraulic regulation“ Set the X1-pressure at pressure reducing valve (81.2) to approx. 4 bar **. Apply max. load to all pumps (e.g. extend the bucket cylinder to the stop position until the hydraulic system stalls), and increase the pressure at the 3 MRV’s (Block I, II, and III) equally to 260 bar*. Check the engine speed. Required = 1850+10 min-1. If necessary correct the X1-pressure at pressure reducing valve (81.2) until the required engine speed is obtained. Record this pressure for other tests. Stop engine and start the other engine and repeat from position 3. Shift the three way cock valves (79.1 and 79.2) to position “Electronic regulation“ Reset the MRV’s to 310 bar+5bar , and remove the gauges.

)

• A slightly deviation between the two X -1 pressures is normal, caused by tolerances of the pumps and engines.

2. 3. 4. 5. 6.

7. 8.

*Altering the MRV-Setting: − Remove dust cap (a). − Loosen lock nut (b). − Turning the set screw (c) cw the pressure will increase. − Turning the set screw ccw the pressure will decrease. **Altering the X1-Setting: − Remove dust cap (d). − Loosen the lock nut (e). − Turning the set screw (f) cw the pressure will increase. − Turning the set screw ccw the pressure will decrease.

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Main Hydraulic Pumps and Pump Regulation System 7.4

Section 7.0 Page 38

Determination of the Peak point (Engine performance) , illustration (Z 22360a)

1. 2. 3.

5. 6. 7. 8. 9. 11.

12.

)

Connect pressure gauges to check points (M12.1, M12.2, M12.3 and M12.4) at the high pressure filter. Connect a pressure gauge to the X1.1 and X1.2 pressure check point M201 and M20-2. Unplug solenoid valves Y6A-1, Y6B-1, and Y6A-2, Y6B-2, for engine 2, to ensure that the hydraulic oil cooler fans are running with maximum speed. Unplug the solenoid valve Y14A-1, Y14B-1 for engine 1 and Y14A-2, Y14B-2 for engine 2 to ensure that the engine radiator fan is running with maximum speed. Start one engine and let it run with max. speed. Check High Idle speed = 1900+35 min-1. Set the MRV of main valve block I, II and III individually to approx. 120 bar *, to prevent the engine from overloading during the test. Shift the three way cock valves (79.1, 79.2) to position “Hydraulic regulation“. Set the X1-pressure at pressure reducing valve (81.2) > 24 bar **, to ensure that the pumps remaining in Q-max. flow position during the test. Apply max. load to all pumps (e.g. extend the bucket cylinder to the final stop position keep the ), and increase the pressure at the 3 MRV’s * (block I, II, III) equally until the engine speed is 1800±10 min-1. Record this pressure for other tests. Required: 3 times 220±5 bar. Stop engine and start the other one. Repeat from step 6. • If the operating pressure respectively the engine speed is higher than required there is probably not the full volume available. • If the operating pressure respectively the engine speed is lower than required there is probably not the full engine power available.

continued

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Main Hydraulic Pumps and Pump Regulation System 7.4

Section 7.0 Page 39

Determination of the Peak point (Engine performance) , illustration (Z 22360a)

13. 14. 15. 16.

Re-set the X1-pressure at pressure reducing valve (81.2) as recorded **. Shift the three way cock valve (22) to position “Electronic regulation“ Reset the MRV’s to 310 bar+5bar , and remove the gauges. Check MRV on single valve block IV *Altering the MRV-Setting: − Remove dust cap (a). − Loosen lock nut (b). − Turning the set screw (c) cw the pressure will increase. − Turning the set screw ccw the pressure will decrease. **Altering the X1-Setting: − Remove dust cap (d). − Loosen the lock nut (e). − Turning the set screw (f) cw the pressure will increase. − Turning the set screw ccw the pressure will decrease

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Main Hydraulic Pumps and Pump Regulation System 7.5

Section 7.0 Page 40

Engine speed sensor (pick up) Legend for illustration (Z 22360a) 1. Speed sensor (pick up) 2. Fly wheel housing 3. Fly wheel 4. Look nut 5. RPM-module (RPM-relay) General: The engine speed sensor (pick up) together with the RPM-Module use the fly wheel teeth to count the engine RPM. With engine running create each tooth a inductive tension in the pick up coil. That cause a alternative tension at the pick up coil wire. With engine stand still there is no tension at the pick up wire. The frequency of this alternative tension increase or decrease proportional to the engine RPM. The RPM-module convert the frequency in to a proportional voltage signal. This signal is used for different components e.g. pump regulation, display, ECS. 7.5.1.

Engine speed sensor (pick up) adjustment 1. Stop engine. 2. Disconnect plug at the pick-up wire. 3. Loosen look nut 4. Turn out the pick-up completely ccw. 5. Check front end of the pick up and clean it from magnetic chips and dirt. 6. Turn the pick-up completely in ( cw ) until it touch the fly wheel Fig. A. 7. Turn the pick-up ¾ turn out ( ccw ) Fig. B. 8. Secure the pick up with look nut Fig. C. 9. Connect the plug. Final Check 10. Start engine and let them run in high idle 11. Check the tension (AC Voltage) of the pick-up. Use the terminals 1 and 2 of the RPM-module (RPM-relay) or respective terminals at the X2 panel. E.g.: Pick up B64-1 is connected to terminal X2M 7 and X2M 8 and further to RPM-module (RPM-relay) K55-1 terminal 1 and 2. (excavator S/N 15017). 12. The tension should be ≈ 1+ 0,5 Volt AC

• Avoid pick-up contact with the fly wheel while engine running.. • The inductive AC voltage must be measured with connected pick up to the RPM-module (RPM-relay).

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Section 8.0 Page 1

Operating Hydraulic

Table of contents section 8.0 Section 8.0

01.04.03

Page Operating Hydraulic General 8.0.1 Floating function of boom and stick cylinders

2 3+4

8.1

Hydraulic for the attachment cylinder FSA and BHA

8.2

Hydraulic for the swing circuit

8.3

Hydraulic for the travel circuit

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8.0 &2

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Operating Hydraulic

8.0

Section 8.0 Page 2

General Overall view of the Hydraulic system, illustration (Z 21955): (1 – 6) (7) (8) (9) (10) (11) (12) (13)

Main pumps High pressure filters Main control blocks Distributor manifold Attachment cylinders Swing motors Rotary joint Travel motors

General information The control blocks, the piping to the distributor manifold and the connecting hoses to the attachment are in some points different between the Backhoe Attachment (BHA) and the Front Shovel Attachment (FSA). If a conversion is required, contact the service department for further information. Function:

• •

Study together with the circuit diagram. The following numbering refers to the hydraulic circuit diagram.

Each main pump (1 to 6) delivers oil trough the high pressure filter (44.1, 44.2, 46.1 and 46.2) to port P of the main control blocks (FSA – 14, 15, 16 and 13) (BHA - 175, 15,176 and 13). The single valve block IV (13) is in line to valve block II (15) connected. This results in three main circuits. If all spools of the control blocks (1 to 6) are in neutral position, the oil leaves the block at port T and returns via return oil pipes, return oil collector manifold (35), return oil pipes (L6 and L7), return oil collector tube (114), back pressure valve (115) and the return oil filters (117.1-117.4) into the tank (41). The function of back pressure valve (115) ensures: - sufficient oil supply for all anti-cavitation valves - and that sufficient oil is forced through the oil coolers. If a control lever or pedal is actuated, pilot pressure oil moves the spools of the control blocks, directing the oil flow from the main pumps to one side of the user (either cylinders or motors). From the opposite side of the user the oil returns to the control block and from there via the return oil circuit back into the tank. Each circuit is provided with one MRV (also called primary valve, at least one SRV (also called secondary valve) and at least one flow restrictor. continued 01.04.03

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8.0 &3

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8.0 &4 8.0

General Cont'd: 8.0.1

Floating function of boom and stick cylinders FSA: illustration (Z 22568): The Excavator (only front shovel attachment) operates automatically with the float position for boom and stick activated. That means the lowering movement of boom and stick is always done in the float position. For deactivation of the float position, two push buttons are installed: a) S95 in the right joy stick (E19) for the Boom function b) S95a in the left joy stick (E20) for the Stick function Press the respective button and keep it depressed as long as the float position shall be deactivated. When releasing the button the float position is activated again. Function: There are different main valve spools in the three main valve blocks (14, 15 and 16) for boom and stick installed. Only by lowering of the boom or retracting of the stick is the floating function active if the button on the lever is not pushed. The piston and rod side of the respective cylinders are in floating position direct connect to the return line (tank). The pressure free pump circulation is still active there is no pump pressure to the respective cylinders. By external force the cylinder can move up or down with negligible hydraulically resistance. In floating position of the boom only valve spool 4 of main valve block I and 2 of block III active. In floating position of the stick only valve spool 2 of Main valve block I and 4 of block III active. To push down the boom or retract the stick by hydraulically force the respective button on the lever must by activated. S98 for the Stick cylinders S95 for the Boom cylinders In normal operation mode (i.e. float position) the piston side, the rod side and the tank are connected together when lowering the boom or retracting the stick. If a pressurised lowering of the boom or retracting of the stick cylinders is required the connection of piston side, rod side and tank must be disconnected and the rod side must be connected to the pump pressure. This is done by disconnecting the respective special floating valve spool and activating the respective standard valve spool. Now pressurised pump oil can flow to the cylinder rod side.

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8.0 &4

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Operating Hydraulic

Boom: S95 ON

K160 ON

A10 deactivated A10A activated S95 OFF

K160 OFF

A10 activated A10A deactivated Stick: S98 ON

K170 ON

A8B deactivated A8A activated S98 OFF

K170 OFF

A8B activated A8A deactivated

01.04.03

•

Section 8.0 Page 4

Float position deactivated Floating spool block I section 4 off Standard spool block II section 3 ON Float position activated Floating spool block I section 4 ON Standard spool block II section can be on or off

Float position deactivated Floating spool block III section 4 off Standard spool block II section 4 ON Float position activated Floating spool block III section 4 ON Standard spool block II section can be on or off

Due to the two different operation modes for lowering, the lowering speed of boom and stick cylinder must be adjusted twice: A. Float position deactivated B. Float position activated

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Section 8.1 Page 1

Hydraulic for the Attachment Cylinders Table of contents section 8.1 Section 8.1

Page Hydraulic for the attachment cylinder FSA and BHA 8.1.1 Electric / Hydraulic Flowchart Boom raising 8.1.2 Electric / Hydraulic Flowchart Boom lowering 8.1.3 Electric / Hydraulic Flowchart Stick extending 8.1.4 Electric / Hydraulic Flowchart Stick retracting 8.1.5 Electric / Hydraulic Flowchart Bucket filling (curl) 8.1.6 Electric / Hydraulic Flowchart Bucket emptying 8.1.8 Electric / Hydraulic Flowchart Clam opening 8.1.9 Electric / Hydraulic Flowchart Clam closing 8.1.10 Checks and adjustments of the Main Relief Valves (Primary valves) 8.1.11 Checks and adjustments of the Service Line Relief Valves (Secondary valves) Boom cylinder piston side FSA + BHA Boom cylinder piston rod side FSA + BHA Stick cylinder piston side FSA Stick cylinder piston side BHA Stick cylinder piston rod side FSA Stick cylinder piston rod side BHA Bucket cylinder piston side FSA Bucket cylinder piston side BHA Bucket cylinder piston rod side FSA Bucket cylinder piston rod side BHA Clam cylinder piston rod side FSA Clam cylinder piston side FSA 8.1.12 Checks and adjustments for the lowering speed. General: Flow Restrictors Boom cylinder FSA (Float position activated / deactivated) Boom cylinder BHA Stick cylinder FSA (Float position activated / deactivated) Stick cylinder BHA Bucket cylinder FSA Bucket cylinder BHA Clam cylinder 8.1.13 Checks for the valve control logic.

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2+3 4+6 7+8 9 + 11 12 + 13 14 + 15 17 18 19 + 20

21 + 22 23 + 24 25 + 26 27 + 28 29 + 31 32 + 33 34 + 35 36 + 37 38 + 39 40 + 41 42 43 44 44 + 46 47 48 + 49 50 51 52 53 54

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Hydraulic for the Attachment Cylinders

Section 8.1 Page 2

8.1.1 Electric / Hydraulic flowchart “ Boom raising ” FSA Legend for illustration (Z 22493): (E19) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (Y-) Direction (axis) of joy stick (-10V) Signal voltage (Maximum) (gn) Color code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E49) Ramp time module (A10) Amplifier module – Boom (A10A) Amplifier module – Boom (A10B) Amplifier module – Boom (K79) Relay – pilot control: Contacts 8 / 12 only closed while lifting the boom. (K160) Relay – Floating control: Contacts 2 / 10 closed auto floating active . (K80) Relay – pilot control: Contacts 2 / 10 open while bucket filling (priority function). (K76A) Relay – pilot control: Contacts 2 / 10 open while stick extending (priority function). (45.1 – 45.3) Remote control valves (Y23, Y26, Y29) Proportional solenoid valve (Y23a, Y26a, Y29a) Directional solenoid valve (I – III) Main control blocks I – III Electrical signal flow (EURO control). Signal voltage of joy stick (E19) arrives via ramp time module (E49) and the relay contacts (K79, K160) at terminal 5 of the three amplifier modules (A10, A10a and A10b) and further to the proportional and directional solenoid valves of the remote control blocks (45.1, 45.2, and 45.3). Hydraulic signal flow. (pilot pressure) When the respective proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks. Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I to IV) and arrives via the distributor manifold at the hydraulic cylinders.

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8.1 3

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Hydraulic for the Attachment Cylinders

Section 8.1 Page 3

8.1.1 Electric / Hydraulic flowchart “ Boom raising ” BHA Legend for illustration (Z 22471): (E19) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (YD) Direction (axis) of joy stick (-10V) Signal voltage (Maximum) (gn) Color code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E49) Ramp time module (A10) Amplifier module – Boom (A10a) Amplifier module – Boom (A10b) Amplifier module – Boom (45.1 – 45.3) Remote control valves (Y23, 25 + Y29) Proportional solenoid valve (Y23a, Y25a, Y29a) Directional solenoid valve (175, 15, 176) Main control blocks I – IV Electrical signal flow (EURO control). Signal voltage of joy stick (E19) arrives via ramp time module (E49) at terminal 5 of the amplifier modules (A10 to A10b) and further to the proportional and directional solenoid valves of the remote control blocks (45.1, 45.2, 45.3). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks. Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I to III) and arrives via distributor manifold at the hydraulic cylinders piston side. The piston extend and the boom move up.

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8.1 4

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Hydraulic for the Attachment Cylinders

Section 8.1 Page 4

8.1.2 Electric / Hydraulic flowchart “ Boom lowering ” FSA, Auto Float off

Legend for illustration (Z 22530): (E19) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (+Y) Direction (axis) of joy stick (+10V) Signal voltage (Maximum) (gn) Color code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E49) Ramp time module (A10) Amplifier module – Boom (A10A) Amplifier module – Boom (A10B) Amplifier module – Boom (K76A) Relay – pilot control: Contacts 6 / 10 open while extending the stick. (K79) Relay – pilot control: Contacts 6 / 10 open while filling the bucket. (K80) Relay – pilot control: Contacts 8 / 12 closed while moving the boom up. (K160) Relay – pilot control: Contacts 2 / 10 closed and 5 / 9 open while auto floating on. (K207C) Relay – pilot control: Contacts 5 / 9 closed while warming up hydraulic oil (S205). (45.1 – 45.3) Remote control valves (Y23, Y26, Y29) Proportional solenoid valve (Y23b, Y26b, Y29b) Directional solenoid valve (I – III) Main control blocks I – IV Electrical signal flow (EURO control). The auto float button in the right lever E19 is still engaged this will energize relay K160. Signal voltage of joy stick (E19) arrives via ramp time module (E49) only at terminal 5 of the amplifier modules (A10a and A10b) and further to the proportional and directional solenoid valve of the remote control blocks (45.2 and 45.3). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the respective main control blocks. Hydraulic oil flow Only the oil of main pump 3 and 4 flows through the main control blocks (II) and arrives via the distributor manifold at the boom hydraulic cylinders piston rod side. Through main valve block III for boom lowering is no pressure oil flow depend on a different valve spool with closed pressure port.

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Section 8.1 Page 5

8.1.2 Electric / Hydraulic flowchart “ Boom lowering ” FSA, Auto Float on

Legend for illustration (Z 22531): (E19) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (+Y) Direction (axis) of joy stick (+10V) Signal voltage (Maximum) (gn) Color code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E49) Ramp time module (A10) Amplifier module – Boom (A10A) Amplifier module – Boom (A10B) Amplifier module – Boom (K76A) Relay – pilot control: Contacts 6 / 10 open while extending the stick. (K79) Relay – pilot control: Contacts 6 / 10 open while filling the bucket. (K80) Relay – pilot control: Contacts 8 / 12 closed while moving the boom up. (K160) Relay – pilot control: Contacts 2 / 10 closed and 5 / 9 open while auto floating on. (K207C) Relay – pilot control: Contacts 5 / 9 closed while warming up hydraulic oil (S205). (45.1 – 45.3) Remote control valves (Y23, Y26, Y29) Proportional solenoid valve (Y23b, Y26b, Y29b) Directional solenoid valve (I – III) Main control blocks I – III Electrical signal flow (EURO control). The auto float button in the right lever E19 is disengaged and relay K160 is deenergized. Signal voltage of joy stick (E19) arrives via ramp time module (E49) only at terminal 5 of the amplifier modules (A10 and A10b) and further to the proportional and directional solenoid valve of the remote control blocks (45.1 and 45.3). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the respective main control blocks. Hydraulic oil flow Now the pump oil flow still back to the return line. Both pressure lines at valve block I section 3 (A3 and B3) are connected to the same back pressure charged return line. Valve spool 2 of main valve block III connect only port B2 to the return line. The return line, the piston side and the piston rod side of the boom cylinders now connected together. The boom can moved up and down by external force.

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Section 8.1 Page 6

8.1.2 Electric / Hydraulic flowchart “ Boom lowering ” BHA Legend for illustration (Z 22473): (E19) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (+Y) Direction (axis) of joy stick (+10V) Signal voltage (Maximum) (gn) Color code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E49) Ramp time module (A10) Amplifier module – Boom (A10a) Amplifier module – Boom (A10b) Amplifier module – Boom (45.1 – 45.3) Remote control valves (Y23, 25 + Y29) Proportional solenoid valve (Y23a, Y25a, Y29a) Directional solenoid valve (175, 15, 176) Main control blocks I – IV

Electrical signal flow (EURO control). Signal voltage of joy stick (E19) arrives via ramp time module (E49) at terminal 5 of the amplifier modules (A10, A10a and A10b) and further to the proportional and directional solenoid valves of the remote control blocks (45.1 – 45.3). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks. Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I to III) and arrives via distributor manifold at the hydraulic cylinders piston rod side. The piston retract extend and the boom move down..

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Section 8.1 Page 7

8.1.3 Electric / Hydraulic flowchart “ Stick extending ” FSA Legend for illustration (Z 22532): (E20) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (YC) Direction (axis) of joy stick (+10V) Signal voltage (Maximum) (gn) Color code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E48) Ramp time module (A8) Amplifier module – Stick (A8a) Amplifier module – Stick (A8b) Amplifier module – Stick (K76A) Relay – pilot control: Contacts 7 / 11 and 8 / 12 closed while extending the stick. (K80) Relay – pilot control: Contacts 1 / 9 open while bucket filling. (K170) Relay – pilot control: Contacts 5 / 9 closed and 7 / 11 opened while floating system active. (45.1, 45.2, 45.3) Remote control valves (Y21, Y27, Y31) Proportional solenoid valve (Y21a, Y27a, Y31a) Directional solenoid valve (I, II + III) Main control blocks I – III Electrical signal flow (EURO control). Signal voltage of joy stick (E20) arrives via ramp time module (E48) at terminal 5 of the amplifier modules (A8, A8a and A8b) and further to the proportional and directional solenoid valves of the remote control blocks (45.1, 45.2 and 45.3). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks . Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I, II, III) and arrives via the distributor manifold at the hydraulic cylinders.

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Section 8.1 Page 8

8.1.3 Electric / Hydraulic flowchart “ Stick extending ” BHA Legend for illustration (Z 22474): (E20) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (Y+) Direction (axis) of joy stick (+10V) Signal voltage (Maximum) (gn) Color code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E48) Ramp time module (A8) Amplifier module – Stick (A8a) Amplifier module – Stick (A8b) Amplifier module – Stick (45.1-45.3) Remote control valves (Y21, Y27, Y31) Proportional solenoid valve (Y21a, Y27a, Y27b) Directional solenoid valve (I, II, III) Main control blocks I, II III Electrical signal flow (EURO control). Signal voltage of joy stick (E20) arrives via ramp time module (E48) at terminal 5 of the amplifier modules (A8, A8a and A8b) and further to the proportional and directional solenoid valves of the remote control blocks (45.1, 45.2, and 45.3). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks . Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I, II, III) and arrives via distributor manifold at the hydraulic cylinders.

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Section 8.1 Page 9

8.1.4 Electric / Hydraulic flowchart “ Stick retracting ” FSA Auto Float off Legend for illustration (Z 22534): (E20) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (YD) Direction (axis) of joy stick (-10V) Signal voltage (Maximum) (gn) Color code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E48) Ramp time module (A8) Amplifier module – Stick (A8a) Amplifier module – Stick (A8b) Amplifier module – Stick (K76A) Relay – pilot control: Contacts 7 /11 and 8 / 12 open while retracting the stick. (K80) Relay – pilot control: Contacts 1 / 9 only open while bucket moving. (K170) Relay – pilot control: Contacts 1 / 9 closed and 3 / 11 open while auto floating off. (K207C) Relay – pilot control: Contacts 5 / 9 closed while warming up hydraulic oil (S205). (45.1, 45.2, 45.3) Remote control valves (Y23, Y26, Y29) Proportional solenoid valve (Y23b, Y26b, Y29b) Directional solenoid valve (I + III) Main control blocks I + III Electrical signal flow (EURO control). Signal voltage of joy stick (E20) arrives via ramp time module (E48) at terminal 5 of the amplifier modules (A8, A8a) and further to the proportional and directional solenoid valves of the remote control blocks (45.1 and 45.2). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the control blocks ( I and II ). Hydraulic oil flow Only the oil of main pump 3 and 4 flows through the main control block (II) and arrives via the distributor manifold at the stick hydraulic cylinders piston side. Through main valve block I for stick retracting is no pressure oil flow depend on a different valve spool with closed pressure port.

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Section 8.1 Page 10

8.1.3 Electric / Hydraulic flowchart “ Stick retracting ” FSA, Auto Float active

Legend for illustration (Z 22535a): (E20) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (-Y) Direction (axis) of joy stick (-10V) Signal voltage (Maximum) (gn) Color code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E48) Ramp time module (A8) Amplifier module – Stick (A8a) Amplifier module – Stick (A8b) Amplifier module – Stick (45.1-45.3) Remote control valves (Y21, Y27, Y31) Proportional solenoid valve (Y21a, Y27a, Y27b) Directional solenoid valve (I, II, III) Main control blocks I, II III Electrical signal flow (EURO control). The auto float button in the left lever E20 is disengaged relay K170 is deenergized. Signal voltage of joy stick (E20) arrives via ramp time module (E48) at terminal 5 of the amplifier modules (A8, A8a and A8b) and further to the proportional and directional solenoid valve of the remote control blocks (45.1 and 45.3). Amplifier module A8a disengaged with open K80 if bucket filling is actuated.. Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the respective main control blocks. Hydraulic oil flow Both pressure lines at valve block III section 4 (A4 and B4) are connected to the same back pressure charged return line. Valve spool 4 of main valve block I connect only port B2 to the return line. The return line, the piston side and the piston rod side of the stick cylinders now connected together. The stick can move forward and backward by external force. If only the stick retracting function is active section 4 of main valve block II opened additional port A4 and B4 to extend the max. oil flow for max. stick speed.

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Section 8.1 Page 11

8.1.4 Electric / Hydraulic flowchart “ Stick retracting ” BHA Legend for illustration (Z 22475): (E20) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (Y-) Direction (axis) of joy stick (-10V) Signal voltage (Maximum) (gn) Color code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E48) Ramp time module (A8) Amplifier module – Stick (A8a) Amplifier module – Stick (A8b) Amplifier module – Stick (45.1-45.3) Remote control valves (Y21, Y27, Y31) Proportional solenoid valve (Y21b, Y27b, Y31a) Directional solenoid valve (I, II, III) Main control blocks I, II, III

Electrical signal flow (EURO control). Signal voltage of joy stick (E20) arrives via ramp time module (E48) at terminal 5 of the amplifier modules (A8, A8a and A8b) and further to the proportional and directional solenoid valves of the remote control blocks (45.1, 45.2 and 45.3). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks . Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I, II, III) and arrives via distributor manifold at the hydraulic cylinders.

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Section 8.1 Page 12

8.1.5 Electric / Hydraulic flowchart “ Bucket filling ” FSA Legend for illustration (Z 22536): (E19) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (-X) Direction (axis) of joy stick (-10V) Signal voltage (Maximum) (ws / gn) Color code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (A9) Amplifier module – Bucket (A9a) Amplifier module – Bucket (A9b) Amplifier module – Bucket (K50) Relay – pilot control: Bucket cut-off Contacts 6 / 10 only closed if the hydraulic oil is in normal operating temperature. (K78) Relay – pilot control: Contacts 1 / 9 only open while bucket dump. (K79) Relay – pilot control: Contacts 1 / 9 only open while lifting the boom. (45., 45.2, 45.3) Remote control valves (Y22, Y24, Y30) Proportional solenoid valve (Y22A, Y24A, Y30A) Directional solenoid valve (I – III) Main control blocks I – III Electrical signal flow (EURO control). Signal voltage of joy stick (E19) arrives via relay contacts K50 at terminal 5 of the amplifier modules (A9, A9a, A9b) and further to the proportional and directional solenoid valves of the remote control blocks (45.1, 45.2, 45.3). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks. Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I to III) and arrives via the distributor manifold at the hydraulic cylinders.

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Section 8.1 Page 13

8.1.5 Electric / Hydraulic flowchart “ Bucket filling ” BHA Legend for illustration (Z 22476): (E19) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (XB) Direction (axis) of joy stick (-10V) Signal voltage (Maximum) (ws / gn) Color code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (K50) Relay – pilot control: Bucket cut-off Contacts 6 / 10 only closed if the hydraulic oil is overheated. (A9) Amplifier module – Bucket (A9a) Amplifier module – Bucket (A9b) Amplifier module – Bucket (45.1-45.3) Remote control valves (Y22, Y24, Y30) Proportional solenoid valve (Y22a, Y24a, Y30a) Directional solenoid valve (I, II, III) Main control blocks I, II, III Electrical signal flow (EURO control). Signal voltage of joy stick (E19) arrives terminal 5 of the amplifier modules (A9, A9a, A9b) and further to the proportional and directional solenoid valves of the remote control blocks (45.,45.2 and 45.3). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks . Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I, II, III) and arrives via distributor the manifold at the hydraulic cylinders.

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Section 8.1 Page 14

8.1.6 Electric / Hydraulic flowchart “ Bucket dump ” FSA Legend for illustration (Z 22537): (E19) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (+X) Direction (axis) of joy stick (+10V) Signal voltage (Maximum) (ws / gn) Color code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (A9) Amplifier module – Bucket (A9a) Amplifier module – Bucket (A9b) Amplifier module – Bucket (K50) Relay – pilot control: Bucket cut-off Contacts 6 / 10 only closed if the hydraulic oil is in normal operating temperature. (K78) Relay – pilot control: Contacts 1 / 9 only open while bucket dump. (K79) Relay – pilot control: Contacts 1 / 9 only open while lifting the boom. (K205) Relay – pilot control: Contacts 1 / 3 only open while S205 activated (hydraulic oil warming up) (45., 45.2, 45.3) Remote control valves (Y22, Y24, Y30) Proportional solenoid valve (Y22A, Y24A, Y30A) Directional solenoid valve (I – III) Main control blocks I – III Electrical signal flow (EURO control). Signal voltage of joy stick (E19) arrives via relay contacts K50 at terminal 19 of the ELB modules. From ELB modules the signal voltage arrives at terminal 5 of the amplifier modules (A9, A9a, A9b) and further to the proportional and directional solenoid valves of the remote control blocks (45.1, 45.2, 45.3). Only while bucket dump together with boom up K78 and K79 opened the contacts 1 / 9 and deactivate amplifier module A9 (priority to the boom). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks. Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I to III) and arrives via the distributor manifold at the hydraulic cylinders. There is no oil flow through main control block I to the bucket cylinder if bucket dump and boom up is activated.

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Section 8.1 Page 15

8.1.6 Electric / Hydraulic flowchart “ Bucket dump ” BHA Legend for illustration (Z 22477): (E19) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (+X) Direction (axis) of joy stick (+10V) Signal voltage (Maximum) (ws / gn) Color code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (A9) Amplifier module – Bucket (A9a) Amplifier module – Bucket (A9b) Amplifier module – Bucket (K50) Relay – pilot control: Bucket cut-off Contacts 6 / 10 only closed if the hydraulic oil is overheated. (14.1 + 14.3) Remote control valves (15) Remote control valves (Y64) Proportional solenoid valve (Y71 + Y75) Proportional solenoid valve (Y23 + Y45) Directional solenoid valve (Y37) Directional solenoid valve (II, III + IV) Main control blocks II, III + IV (42) Distributor manifold Electrical signal flow (EURO control) Signal voltage of joy stick (E19) arrives via relay contacts K50 at terminal 5 of the amplifier modules (A9, A9a, A9b) and further to the proportional and directional solenoid valves of the remote control blocks (45.1, 45,2 and 45.3). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks . Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (II, III, IV) and arrives via distributor manifold (42) at the hydraulic cylinders.

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Section 8.1 Page 17

8.1.8 Electric / Hydraulic flowchart “ Clam opening ” FSA Legend for illustration (Z 21970): (E24) Control pedal (D32) Time relay – Pilot control: Neutral position monitoring (-10V) Signal voltage (Maximum) (rs) Color code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (A11) Amplifier module – Clam (K76) Relay – pilot control: Contacts 7 / 11 only closed while traveling the left crawler. (15) Remote control valves (Y72) Proportional solenoid valve (Y39) Directional solenoid valve (II) Main control block II (42) Distributor manifold Electrical signal flow (EURO control). Signal voltage of control pedal (E24) arrives via relay contact at terminal 5 of the amplifier module (A11) and further to the proportional and directional solenoid valves of the remote control block (15). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure port of the main control block . Hydraulic oil flow Now the oil of the main pump flows through the main control block (II) and arrives via distributor manifold (42) at the hydraulic cylinders.

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Section 8.1 Page 18

8.1.9 Electric / Hydraulic flowchart “ Clam closing ” FSA Legend for illustration (Z 21971): (E23) Control pedal (D32) Time relay – Pilot control: Neutral position monitoring (+10V) Signal voltage (Maximum) (rs) Color code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (A11) Amplifier module – Clam (K76) Relay – pilot control: Contacts 7 / 11 only closed while traveling the left crawler. (15) Remote control valves (Y72) Proportional solenoid valve (Y38) Directional solenoid valve (II) Main control block II (42) Distributor manifold Electrical signal flow (EURO control). Signal voltage of control pedal (E23) arrives via relay contact at terminal 5 of the amplifier module (A11) and further to the proportional and directional solenoid valves of the remote control block (15). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure port of the main control block . Hydraulic oil flow Now the oil of the main pump flows through the main control block (II) and arrives via distributor manifold (42) at the hydraulic cylinders.

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Hydraulic for the Attachment Cylinders 8.1.10

Checks and adjustments of the Main Relief Valves (MRV), illustration (Z 22481): There are four main relief valves (primary valves) installed, one in each main control block, to limit the maximum pump supply line pressure (operating pressure).

Pump circuit I Pump circuit II Pump circuit III Pump circuit IV

MRV block

Check point

M12.1

travel

stick

bucket

boom

M12.3

clam

bucket

Boom

stick

III

M12.4

travel

boom

bucket

stick

M12.2

Swing, (if no swing active circuit II)

Functions FSA

Extend or retract the cylinder to the stop position for the valve being tested until the hydraulic system stalls. 4. Read the pressure. Required: 310 + 5 bar If the pressure is not correct, carry out a comparative measurement with an other function, in order to avoid wrong measuring results caused by wrongly adjusted SRV or other defects in the system.

)

•

When using the single function “bucket fill”, (gray shadow), all MRV can be adjusted, because all four pump circuits are engaged.

Adjusting: 1. Remove protective cap (a). 2. Loosen lock nut (b). 3. Turn set screw (c) -clockwise to increase pressure, Counter-clock wise to decrease pressure. 4. Tighten lock nut (b) and install cap (a).

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• It is important that the valve body of MRV-valve and the SRV-valve are firmly tightened with 300 Nm. Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.

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Hydraulic for the Attachment Cylinders 8.1.10

Pump circuit I Pump circuit II Pump circuit III Pump circuit IV

MRV in control block I II III IV

Check point M12.1 M12.3 M12.4 M12.2

Functions BHA Travel Stick Bucket Boom Bucket Boom Stick Travel Boom Bucket Stick Swing, (if no swing active circuit II)

Each Pump circuit can be checked or adjusted individually by selecting one function of the required pump circuit. Checking: 1. Connect the gauge to the required check point M12.1 – M12.4. 2. Start both motors.. 3. Extend or retract the cylinder to the stop position for the valve being tested until the hydraulic system stalls. 4. Read the pressure. Required: 310 + 5 bar If the pressure is not correct, carry out a comparative measurement with an other function, in order to avoid wrong measuring results caused by wrongly adjusted SRV or other defects in the system.

)

•

When using the single function “bucket fill”, (gray shadow), all MRV can be adjusted, because all four pump circuits are engaged.

Adjusting: 1. Remove protective cap (a). 2. Loosen lock nut (b). 3. Turn set screw (c) -clockwise to increase pressure, Counterclock wise to decrease pressure. 5. Tighten lock nut (b) and install cap (a).

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• It is important that the valve body of MRV-valve and the SRV-valve are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.

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Section 8.1 Page 21

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22482): Boom cylinder “piston side” FSA + BHA There are three service line relief valves (secondary valves) installed, all three at the distributor manifold, to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV’s is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. SRV FSA SRV BHA 141.1 138.1 141.2 138.2. 141.3 138.3 MRV I MRV II MRV III MRV IV 1. 2. 3. 4.

) 5. 6. 7. 8.

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Press. check point Location M23 Manifold section B M29.1 Manifold section N M29.2 Manifold section N M12.1 (at HP filter) Double HP filter R.H. M12.3 (at HP filter) Single HP filter, block II M12.4 (at HP filter) Double HP L.H.. M12.2 (at HP filter) Single HP filter, block IV

Connect gauges to all above listed check points (min. 400 bar). Start both motors.. Extend the boom cylinder to the stop position until the hydraulic system stalls. Increase slowly the pump supply line pressure, by turning in set screws (3) of the MRV’s in control block I, II, III and IV, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar. • Since the piston side of the boom cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Even when the gauges show the required pressure it is possible that one or more valves have a higher setting. • To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of both MRV’s. Remove protective cap (1) of MRV. Loosen lock nut (2). Turn set screw (3) of the MRV’s ½ turn further in, the gauge pointers will remain at the value shown at item #4 (350 bar + 5 bar). Tighten lock nut (2). continued

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Hydraulic for the Attachment Cylinders

Cont'd: 8.1.10 Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22482a): Boom cylinder “piston side” FSA +BHA 9. Adjust all three SRV’s equally, until all gauges show a pressure of 360 bar. Adjust in steps of ¼ turn of set screw (3) in the following sequence: 141.1 þ 141.2 þ 141.3 Remove protective cap (1) of SRV’s. Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). 10. Reduce the pressure, at SRV- 141.1 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges.

) 11.

•

Now all gauges will show the same value of 350 bar, but only SRV-143.1 has the correct setting. Proceed with the other valves in the same manner in the following sequence: 141.2 þ 141.3

• Strong pulsation of the return line hoses, indicates deviation in opening pressure of SRV’s and must be avoided. Repeat the adjusting procedure until the oil returns well-balanced via all six service line relief valves. 12.

) 06.10.05

Reset the MRV’s to 310 bar + 5 bar after the check / adjustment is finished, as follows: Remove protective cap (1). Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). • It is important that the valve body of MRV-valve and the SRV-valve are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments. PC5500-6-D_Sec_8-1_rev3.doc

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Section 8.1 Page 23

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22483b): Boom cylinder “piston rod side” FSA +BHA There is one service line relief valve (secondary valve) installed in the main control block II, to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve Press. check point SRV 33.4 FSA M12.3 (High pressure filter) SRV 33.6 BHA MRV circuit II M12.3 (High pressure filter) MRV circuit IV M12.2 (High pressure filter)

1. 2. 3.

5. 6.

)

Location Control block II, section A3 FSA section A2 BHA Single high pressure filter, control block II Single high pressure filter, control block IV

Connect gauges to all above listed check points. Start both motors.. Press floating system button S95 at the lever with the boom function and retract the boom cylinder to the stop position until the hydraulic system stalls. Increase slowly the pump supply line pressure, by turning in set screws (3) of the MRV in control blocks II, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar. If there is a setting required follow Turn set screw (3) of the MRV ¼ turn further in, the gauge pointers will remain at the value shown at item #4 . Tighten lock nut (2).

• To ensure that only the SRV open during checks and adjustments it is necessary to further increase the setting of MRV control block II..

continued

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Section 8.1 Page 24

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22483b): Cont'd: 7. Adjust the SRV until the gauges show a pressure of 350 bar. 8. Tighten lock nut (2). 9. Reset the MRV to 310 bar + 5 bar after the check / adjustment is finished 10. Tighten lock nut (2). 11. Stop engine. 12. Install all protective cups (1).

)

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Section 8.1 Page 25

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22542): Stick cylinder “piston side” FSA There are three service line relief valves (secondary valves) installed, all three at the distributor manifold, to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV’s is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve Press. check point SRV 142.5 M27.1 SRV 142.6 SRV 142.7 MRV circuit I M12.1 (High pressure filter) MRV circuit II M12.3 (High pressure filter) MRV circuit III M12.4 (High pressure filter) MRV circuit IV M12.2 (High pressure filter) 1. 2. 3. 4.

)

5. 6. 7. 8.

Location Manifold section F Manifold section F Manifold section J Double high pressure filter R.H. Single HP filter, control block II Double high pressure filter L.H.. Single HP filter, control block IV

Connect gauges to all above listed check points. Start both motors.. Extend the stick cylinder to the stop position until the hydraulic system stalls. Increase slowly the pump supply line pressure, by turning in set screws (3) of the MRV in control block IV, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar. • Since the piston side of the stick cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Even when the gauges show the required pressure it is possible that one or more valves have a higher setting. • To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of the MRV’s. Remove protective cap (1) of MRV. Loosen lock nut (2). Turn set screw (3) of the MRV ½ turn further in, the gauge pointers will remain at the value shown at item #4 (350 bar + 5 bar). Tighten lock nut (2) and install cap (1). continued

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Hydraulic for the Attachment Cylinders

Cont'd: 8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22542): Stick cylinder “piston side” FSA 9. Adjust all three SRV’s equally, until all gauges show a pressure of 360 bar. Adjust in steps of ¼ turn of set screw (3) in the following sequence: 142.5 þ 142.6 þ 142.7 Remove protective cap (1) of SRV’s. Loosen lock nut (2). Turn set screw (3) -clockwise to increase, Counter-clock wise to decrease the setting. Tighten lock nut (2) and install cap (1). 10. Reduce the pressure at SRV 142.5 to a value below the required value, and increase up to the required pressure (350 bar), while observing all gauges.

) 11.

•

Now all gauges will show the same value of 350 bar, but only SRV-65.2 has the correct setting. Proceed with the other valves in the same manner in the following sequence: 142.6 þ 142.7

) 06.10.05

Reset the MRV to 310 bar + 5 bar (320 bar block IV) after the check / adjustment is finished, as follows: Remove protective cap (1). Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). • It is important that the valve body of MRV-valve and the SRV-valve are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.

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Section 8.1 Page 27

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22484): Stick cylinder “piston side” BHA There are two service line relief valves (secondary valves) installed, in main control blocks I and II, to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV’s is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve Press. check point SRV 33.1 M12.1 (High pressure filter) SRV 33.5 M12.3 (High pressure filter) MRV circuit I M12.1 (High pressure filter) MRV circuit II M12.3 (High pressure filter) MRV circuit IV M12.2 (High pressure filter) 1. 2. 3. 4.

) 5. 6. 7. 8.

06.10.05

Location Control block I, section A2 Control block II, section A42 Control block I Control block II Control block IV

Connect gauges to all above listed check points. Start both motors.. Extend the stick cylinder (stick retracting) to the stop position until the hydraulic system stalls. Increase slowly the pump supply line pressure, by turning in set screws (3) of the MRV’s in the control blocks, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar. • Since the piston side of the stick cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Even when the gauges show the required pressure it is possible that one or more valves have a higher setting. • To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of the MRV’s. Remove protective cap (1) of MRV. Loosen lock nut (2). Turn set screw (3) of the MRV’s ½ turn further in, the gauge pointers will remain at the value shown at item #4 (350 bar + 5 bar). Tighten lock nut (2) and install cap (1). continued

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Hydraulic for the Attachment Cylinders

Cont'd: 8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22484): Stick cylinder “piston side” BHA 9. Adjust all two SRV’s equally, until all gauges show a pressure of 360 bar. Adjust in steps of ¼ turn of set screw (3) in the following sequence: 33.1 þ 33.5 Remove protective cap (1) of SRV’s. Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). 10. Reduce the pressure, at SRV- 33.1 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges.

) 11.

•

Now all gauges will show the same value of 350 bar, but only SRV-33.1 has the correct setting. Proceed with the other valves in the same manner in the following sequence: 33.1 þ 33.5

) 06.10.05

Reset the MRV to 310 bar + 5 bar after the check / adjustment is finished, as follows: Remove protective cap (1). Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). • It is important that the valve body of MRV-valve and the SRV-valve are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.

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Section 8.1 Page 29

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22543a): Stick cylinder “piston rod side” FSA There are two service line relief valves (secondary valves) installed, in main control blocks I and II, to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV’s is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve Press. check point Location SRV 33.1 M12.1 (High pressure filter) Double high pressure filter R.H. SRV 33.5 M12.3 (High pressure filter) Single HP filter, control block II MRV circuit I M12.1 (High pressure filter) Double high pressure filter R.H. MRV circuit II M12.3 (High pressure filter) Single HP filter, control block II MRV circuit IV M12.2 (High pressure filter) Single HP filter, control block IV 1. 4. 5. 6.

Connect gauges to all above listed check points. Start both motors.. Retract the stick cylinder to the stop position until the hydraulic system stalls. Increase slowly the pump supply line pressure, by turning in set screws (3) of MRV’s in all above listed control blocks I, II, IV, while observing the respective pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar. a) b) c) d)

06.10.05

Remove protective cap (1). Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counterclock wise to decrease pressure. Tighten lock nut (2). continued

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Hydraulic for the Attachment Cylinders

Cont'd: 8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22543a): Stick cylinder “piston rod side” FSA

)

• Since the piston rod side of the stick cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Even when the gauges show the required pressure it is possible that one valves have a higher setting • To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of the MRV’s.

Turn set screw (3) of both MRV’s ½ turn further in, the gauge pointers will remain at the value shown at item #6 (350 bar + 5 bar). Adjust the SRV’s equally, until all gauges show a pressure of 360 bar. Adjust in steps of ¼ turn of set screw (1) (SRV’s) in the following sequence : 33.1 þ 33.5 Turn set screw (3)-clockwise to increase pressure, Counter-clockwise to decrease pressure. Adjust pressure at SRV 33.1 to ~360 bar if the pressure don’t increase turn set screw from the last setting max. ¼ turn in (c.w.). Adjust pressure at the SRV 33.5 to ~350 bar.

10.

) 11.

06.10.05

•

Now all gauges will show the same value of 350 bar, but only SRV-33.1 has the correct setting. Reduce the pressure, at SRV 33.1 to a value below the required value and then increase up to the required pressure (350 bar), while observing all gauges.

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Section 8.1 Page 31

Cont'd: 8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22543a): Stick cylinder “piston rod side” FSA • Strong pulsation of the return line hoses, indicates deviation in opening pressure of SRV’s and must be avoided. Repeat the adjusting procedure until the oil returns well-balanced via all service line relief valves. 14. 15. 16.

)

06.10.05

Reset the MRV’s to 310 bar + 5 bar after the check / adjustment is finished Stop engine. Install all protective cups (1). • It is important that the valve body of MRV-valve and the SRV-valve are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.

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Hydraulic for the Attachment Cylinders 8.1.11

Section 8.1 Page 32

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22485): Stick cylinder “Piston rod side” BHA There are three service line relief valves (secondary valves) installed at the distributor manifold, to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV’s is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve SRV 142.5 SRV 142.6 SRV 142.7 MRV circuit I MRV circuit II

Press. check point M27.1 M27.2 M28 M12.1 (High pressure filter) M12.3 (High pressure filter)

MRV circuit III M12.4 (High pressure filter) MRV circuit IV M12.2 (High pressure filter) 1. 2. 3. 4.

) 5. 6. 7. 8.

Location Manifold (42) section G Manifold (42) section J Manifold (42) section J Double high pressure filter R.H. Single high pressure filter, control block II Double high pressure filter L.H.. Single high pressure filter, control block IV

Connect gauges to all above listed check points. Start both motors.. Retract the stick cylinder (extend the stick) to the stop position until the hydraulic system stalls. Increase slowly the pump supply line pressure, by turning in set screws (3) of MRV’s in the control blocks, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar. • Since the piston rod side of the stick cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Even when the gauges show the required pressure it is possible that one or more valves have a higher setting. • To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of both MRV’s. Remove protective cap (1) of MRV. Loosen lock nut (2). Turn set screw (3) of both MRV’s ½ turn further in, the gauge Tighten lock nut (2) and install cap (1). continued

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Section 8.1 Page 33

Hydraulic for the Attachment Cylinders

Cont'd: 8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22485): Stick cylinder “Piston rod side” BHA 9. Adjust all SRV’s equally, until all gauges show a pressure of 360 bar. Adjust in steps of ¼ turn of set screw (3) in the following sequence: 142.5 þ 142.6þ 142.7 Remove protective cap (1) of SRV’s. Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). 10. Reduce the pressure, at SRV- 142.5 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges.

) 11.

•

Now all gauges will show the same value of 350 bar, but only SRV-142.5 has the correct setting. Proceed with the other valves in the same manner in the following sequence: 142.6þ 142.7

) 06.10.05

Reset the MRV’s to 310 bar + 5 bar after the check / adjustment is finished, as follows: Remove protective cap (1). Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). • It is important that the valve body of MRV and the SRV are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.

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Section 8.1 Page 34

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22544): Bucket cylinder “Piston side” FSA There are three service line relief valves (secondary valves) installed, all three at the distributor manifold, to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV’s is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve Press. check point Location SRV 142.1 M24.1 Manifold (42) section C SRV 142.2 M24.2 Manifold (42) section C SRV 142.3 M25 Manifold (42) section D MRV circuit I M12.1 (High pressure filter) Double high pressure (HP) filter R.H. MRV circuit II M12.3 (High pressure filter) Single HP filter, control block II MRV circuit III M12.4 (High pressure filter) Double HP filter L.H.. MRV circuit IV M12.2 (High pressure filter) Single HP filter, control block IV 1. 2. 3. 4.

)

5. 6. 7. 8.

06.10.05

Connect gauges to check points M12.1.to M12.4 and M24.1. Start both motors.. Extend the Bucket cylinder to the stop position until the hydraulic system stalls. Increase slowly the pump supply line pressure, by turning in set screws (3) of all four MRV’s in control block I to IV, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar. • Since the piston side of the bucket cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Even when the gauges show the required pressure it is possible that one or more valves have a higher setting. • To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of both MRV’s. Remove protective cap (1) of MRV. Loosen lock nut (2). Turn set screw (3) of both MRV’s ½ turn further in, the gauge pointers will remain at the value shown at item #4 (350 bar + 5 bar). Tighten lock nut (2) and install cap (1). continued

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Section 8.1 Page 35

Hydraulic for the Attachment Cylinders

Cont'd: 8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22544): Bucket cylinder “Piston rod side” FSA 9. Adjust all three SRV’s equally, until all gauges show a pressure of 360 bar. Adjust in steps of ¼ turn of set screw (3) in the following sequence: 142.1 þ 142.2 þ 142.3 Remove protective cap (1) of SRV’s. Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). 10. Reduce the pressure, at SRV- 142.1 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges.

) 11.

•

Now all gauges will show the same value of 350 bar, but only SRV-142.1 has the correct setting. Proceed with the other valves in the same manner in the following sequence: 142.2 þ 142.3

) 06.10.05

Reset the MRV’s to 310 bar + 5 bar after the check / adjustment is finished, as follows: Remove protective cap (1). Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). • It is important that the valve body of MRV and the SRV are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.

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Section 8.1 Page 36

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22486): Bucket cylinder “Piston side” BHA There are three service line relief valves (secondary valves) installed at the distributor manifold, to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV’s is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve Press. check point Location SRV 142.1 M24.1 Manifold section C SRV 142.2 M24.2 Manifold section C SRV 142.3 M25 Manifold section D MRV circuit I M12.1 (High pressure filter) Double high pressure filter R.H. MRV circuit II M12.3 (High pressure filter) Single high pressure filter, block II MRV circuit III M12.4 (High pressure filter) Double high pressure filter L.H.. MRV circuit IV M12.2 (High pressure filter) Singe high pressure filter, block IV 1. 2. 3. 4.

) 5. 6. 7. 8.

06.10.05

Connect gauges to all above listed check points. Start both engines and let them run with max. speed. Extend the bucket cylinder (Bucket filling) to the stop position until the hydraulic system stalls. Increase slowly the pump supply line pressure, by turning in set screws (3) of MRV in control block I, II, III and IV, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar. • Since the piston side of the bucket cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Even when the gauges show the required pressure it is possible that one or more valves have a higher setting. • To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of both MRV’s. Remove protective cap (1) of MRV. Loosen lock nut (2). Turn set screw (3) of both MRV’s ½ turn further in, the gauge pointers will remain at the value shown at item #4 (350 bar + 5 bar). Tighten lock nut (2) and install cap (1). continued

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Section 8.1 Page 37

Hydraulic for the Attachment Cylinders

Cont'd: 8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22486): Bucket cylinder “Piston side” BHA 9. Adjust all three SRV’s equally, until all gauges show a pressure of 360 bar. Adjust in steps of ¼ turn of set screw (3) in the following sequence: 142.1 þ 142.2 þ 142.3 Remove protective cap (1) of SRV’s. Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). 10. Reduce the pressure, at SRV- 142.1 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges.

) 11.

•

Now all gauges will show the same value of 350 bar, but only SRV-142.1 has the correct setting. Proceed with the other valves in the same manner in the following sequence: 142.2 þ 142.3 þ 142.

) 06.10.05

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Hydraulic for the Attachment Cylinders 8.1.11

Section 8.1 Page 38

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22545): Bucket cylinder “Rod side” FSA There are two service line relief valves (secondary valves) installed, one in main control block I section 3 and one in block II section 2, to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV’s is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve Press. check point Location SRV 33.2 M12.1 (High pressure filter) Control block I, section A3 SRV 33.6 M12.3 (High pressure filter) Control block I, section A2 MRV circuit I M12.1 (High pressure filter) Double high pressure filter R.H. MRV circuit II M12.3 (High pressure filter) Single high pressure filter, block II MRV circuit III M12.4 (High pressure filter) Double high pressure filter L.H.. MRV circuit IV M12.2 (High pressure filter) Single high pressure filter, block IV 1. 2. 3. 4.

) 5. 6. 7. 8.

Connect gauges to all above listed check points. Start both motors.. Stall the system with full retracted bucket cylinder in final stop position. Increase slowly the pump supply line pressure, by turning in set screws (3) of MRV’s in the control blocks, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar. • Since the piston rod side of the bucket cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Even when the gauges show the required pressure it is possible that one or more valves have a higher setting. • To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of the MRV’s. Remove protective cap (1) of MRV. Loosen lock nut (2). Turn set screw (3) of both MRV’s ½ turn further in, the gauge Tighten lock nut (2) and install cap (1). continued

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Hydraulic for the Attachment Cylinders

Cont'd: 8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 21999): Bucket cylinder “Rod side” FSA 9. Adjust both SRV’s equally, until all gauges show a pressure of 360 bar. Adjust in steps of ¼ turn of set screw (3) in the following sequence: 33,2 þ 33.6 Remove protective cap (1) of SRV’s. Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). 10. Reduce the pressure, at SRV- 33.2 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges.

) 11.

•

Now all gauges will show the same value of 350 bar, but only SRV-33.2 has the correct setting. Proceed with the other valve in the same manner.

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Reset the MRV’s to 310 bar + 5 bar after the check / adjustment is finished, as follows: Remove protective cap (1). Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). • It is important that the valve body of MRV and the SRV are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.

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Section 8.1 Page 40

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22487): Bucket cylinder “Piston rod side” BHA There are three service line relief valves (secondary valves) installed at the distributor manifold, to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV’s is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve Press. check point Location SRV 142.8 M34.1 Manifold section L SRV 142.9 M34.2 Manifold section L SRV 142.10 M34.3 Manifold section M MRV circuit I M12.1 (High pressure filter) Double high pressure filter R.H. MRV circuit II M12.3 (High pressure filter) Single high pressure filter, block II MRV circuit III M12.4 (High pressure filter) Double high pressure filter L.H.. MRV circuit IV M12.2 (High pressure filter) Single high pressure filter, block IV 1. Connect gauges to all above listed check points. 2. Start both engines and let it run with max. speed. 3. Retract the Bucket cylinder (Bucket dump) to the stop position until the hydraulic system stalls. 4. Increase slowly the pump supply line pressure, by turning in set screws (3) of MRV’s in control block I, I, III and IV, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar.

) 5. 6. 7. 8.

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• Since the piston rod side of the bucket cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Even when the gauges show the required pressure it is possible that one or more valves have a higher setting. • To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of the MRV. Remove protective cap (1) of MRV. Loosen lock nut (2). Turn set screw (3) of both MRV’s ½ turn further in, the gauge pointers will remain at the value shown at item #4 (350 bar + 5 bar). Tighten lock nut (2) and install cap (1). continued

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Hydraulic for the Attachment Cylinders

Cont'd: 8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22487): Bucket cylinder “Piston rod side” BHA 9. Adjust all SRV’s equally, until all gauges show a pressure of 360 bar. Adjust in steps of ¼ turn of set screw (3) in the following sequence: 142.8 þ 142.9 þ 142.10 Remove protective cap (1) of SRV’s. Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). 10. Reduce the pressure, at SRV- 142.8 to a value below the required value and then increase up to the required pressure (350 bar), while observing all gauges.

) 11.

•

Now all gauges will show the same value of 350 bar, but only SRV-142.8 has the correct setting. Proceed with the other valves in the same manner in the following sequence: 142.9 þ 142.10

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Section 8.1 Page 42

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22546): Clam cylinder “Rod side” (clam opening) FSA There is one service line relief valve (secondary valve) installed at the distributor manifold section E, to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve Press. check point Location SRV 142.4 M26 Manifold (42) section E MRV circuit II M12.3 (High pressure filter) Control block II MRV circuit IV M12.2 (High pressure filter) Control block IV 1. 2. 3. 4.

5. 6. 7. 8. 9. 10.

) 06.10.05

Connect gauges to the above listed check points. Start engine 2 and let it run in high idle. Retract the clam cylinder (open the bucket) to the stop position until the hydraulic system stalls. Increase slowly the pump supply line pressure, by turning in set screws (3) of MRV in control block II and IV, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar. If necessary correct the adjustment as follows: Remove protective cap (1) of MRV. Loosen lock nut (2). Turn set screw (3) of the MRV ½ turn further in, the gauge pointers will remain at the value shown at item #4 (350 bar + 5 bar). Tighten lock nut (2) and install cap (1). Reduce the pressure, at SRV 142.4 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all auges. Reset the MRV to 310 bar + 5 bar after adjustment is finished, as follows: Remove protective cap (1). Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). • It is important that the valve body of MRV and the SRV are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.

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Section 8.1 Page 43

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22561): Clam cylinder “Piston side” (clam closing) FSA There are three service line relief valves (secondary valves) installed, two at distributor manifold section K and one at main control block II section 1, to limit the maximum possible pressure in the service line when closing the bucket. To avoid damages at the clam shell, due to wrong operation, the SRV’s should be adjusted in a way that the pressure is just sufficient to close the clam with horizontal back wall. Valve SRV 144 (1) SRV 144 (2) SRV 32.10 1. 2. 3.

•

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Location Manifold section K Manifold section K Control block II

Connect gauges to all above listed check points. Start engine 2 and let them run in high idle. Raise the attachment and bring the back wall of the bucket in a horizontal position (bucket dump). Press carefully pedal “bucket closing”. The clam should close complete and must stay closed after pedal in neutral position. Adjust the SRV’s as follows: Remove protective cap (1) of SRV’s. Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure while depressed pedal “clam closing”. Tighten lock nut (2) and install cap (1). Adjust all three SRV’s equally, until the gauges show a pressure of 220 bar. Now reduce the pressure at one SRV in steps of 5 bar until the bucket opens by gravity (check with released pedal). Now read the pressure and adjust 10% plus the reading to compensate the weight of material stuck at the clam shell.

)

Press. check point M22 M22 MM12.3 (High pressure filter)

Since the piston side of the clam cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Because of different wear packages the pressure can be between 150 bar and more as 200 bar.

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Section 8.1 Page 44

8.1.12 Checks and adjustments of the lowering speed, illustration (Z 22489): General On excavators equipped with Face Shovel Attachment (FSA) there are two different operation modes for lowering the boom and stick: I.

Float position activated the lowering speed has to be adjusted by altering the flow restrictors (throttle valves) at the distributor manifold section B, throttle valve 141.1 and section N, throttle valve 141.3.

II.

Float position deactivated the lowering speed has to be adjusted by altering the flow restrictor (throttle valve) at the distributor manifold section N, throttle valve 141.2.

On excavators equipped with Backhoe Attachment (BHA) the lowering speed has to be adjusted at all flow restrictors on distributor manifold section B and N, throttle valves 141.1, 141.2 and 141.3. Purpose of the Flow Restrictors: • To avoid an interruption of the pump delivery. • To provide an uniform and smooth cylinder travel. • To limit the return oil flow through the control block to the maximum permissible volume.

)

Checks and Adjustments: • Activate service switch S151 (located in the cab base) during the checks and adjustments, to ensure that the main pumps are in Qmax position. • Standard test method is measuring the total cylinder running time by using a stop watch. If it is impossible to move the cylinder over the whole way, mark a distance of one meter with permanent pen P/N 621 566 40 on the piston rod and measure the time for only one meter movement. • Adjust the restrictor as follows: • For easy turning of set screw (2) lower the attachment to ground, stop engines and allow pressure equalizing by moving the lever several times. • Loosen the lock nut (1) and turn the bolt (2) cw for more restriction and ccw for less restriction. If more than one restrictor is used for one movement make sure all set screws are equally adjusted. During commissioning, a throttle adjustment has to be carried out on all machines. For safety reasons, the throttle valves are completely screwed in before each machine is leaving the factory. For more information refer to the respective newest Service Bulletin

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Hydraulic for the Attachment Cylinders 8.1.12

Checks and adjustments of the lowering speed, illustration (Z 22489): Boom cylinder FSA Due to the two different operation modes for lowering the boom, the lowering speed must be adjusted twice: I. Float position activated II. Float position deactivated Maximum permissible lowering speed for both operation modes: Boom FSA

Cylinder retracting time/meter (s /m) 1,4

Total time(s) 4,3

Adjustments / Checks: I.

Float position activated: 1. Use a stop watch to measure the cylinder running time. 2. Raise the fully extended attachment with empty bucket to the maximum height position (A). 3. Shift both engines to high idle speed. 4. Rapidly move the control lever (E19) to the front end position (start the stop watch) and hold it until the final position (B) is reached.(stop the stop watch). • Lower the boom so, that the bucket stops just above the ground. 5.

If the lowering speed is too high, i.e. the measured time is less than the permissible time, the speed must be reduced by altering the throttle valves 141.1 (section B) and 141.3 (section N, pointing to the attachment). Adjust as follows: To decrease the lowering speed loosen lock nut (1) and turn the bolt (2) cw. To increase the lowering speed loosen lock nut (1) and turn the bolt (2) ccw. Since there are several valves throttling the return oil flow the valves must be set synchronously. The adjusting screws have to be turned in by the same amount of revolutions.

O.K.

6. 7.

06.10.05

Check lowering speed again and repeat the adjustment if necessary. If the adjustment is finished tighten lock nut (1). continued

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Section 8.1 Page 46

Cont'd: 8.1.12 Checks and adjustments of the lowering speed, illustration (Z 22489): Boom cylinder FSA Adjustments / Checks: II.

Float position deactivated (with push button S95): 1. Adjust the throttle adjustment bold of throttle valve 141.2 to the same amount of revolutions as the valve 141.1 and 141.3. 2. Use a stop watch to measure the cylinder running time. 3. Raise the fully extended attachment with empty bucket to the maximum height position (A). 4. Shift the engines to high idle speed. 5. Press push button S95 and keep it depressed while lowering the attachment. Rapidly move the control lever (E19) to the front end position (start the stop watch) and hold it until the final position (B) is reached.(stop the stop watch). • Lower the boom so, that the bucket stops just above the ground.

The lowering speed will be the same as with floating position. If the lowering speed is too high, i.e. the measured time is less than the permissible time, the speed must be reduced by altering the throttle valve 141.1, 141.2 and synchronous 141.3 at the distributor manifold section B and N. Adjust as follows: To decrease the lowering speed loosen lock nut (1) and turn the bolt (2) cw. To increase the lowering speed loosen lock nut (1) and turn the bolt (2) ccw. The adjusting screws have to be turned in by the same amount of revolutions.

O.K.

7. 8.

06.10.05

Check lowering speed again and repeat the adjustment if necessary. If the adjustment is finished tighten lock nut (1).

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Hydraulic for the Attachment Cylinders 8.1.12

Checks and adjustments of the lowering speed, illustration (Z 22488): Boom cylinder BHA Maximum permissible lowering speed:

Boom BHA

Cylinder retracting time/meter (s /m) 1,4

Total time (s) 5,0

Adjustments / Checks: 1. Use a stop watch to measure the cylinder running time. 2. Raise the fully extended attachment with empty bucket to the maximum height position (A). 3. Shift the engines to high idle speed. 4. Rapidly move the control lever (E19) to the front end position (start the stop watch) and hold it until the final position (B) is reached.(stop the stop watch). • Lower the boom so, that the bucket stops just above the ground. If the lowering speed is too high, i.e. the measured time is less than the permissible time, the speed must be reduced by altering the throttle valves 141.1, 141.2 and 141.3 at the distributor manifold. Adjust as follows: To decrease the lowering speed loosen the lock nut (1) and turn the bolt (2) cw. To increase the lowering speed loosen the lock nut (1) and turn the bolt (2) ccw. Since there are several valves throttling the return oil flow of the boom cylinder the valves must be set synchronously. The adjusting screws have to be turned in by the same amount of revolutions. 5.

O.K.

06.10.05

Check lowering speed again and repeat the adjustment if necessary. If the adjustment is finished tighten lock nut (1).

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Hydraulic for the Attachment Cylinders 8.1.12

Checks and adjustments of the lowering speed,

illustration (Z 22490):

Stick cylinder FSA Due to the two different operation modes for lowering the stick, the lowering speed must be adjusted twice: I. Float position activated II. Float position deactivated Maximum permissible lowering speed for both operation modes:

Stick FSA

Cylinder retracting time/meter (s /m) 0,9

Total time (s) 2,4

Adjustments / Checks: I.

Float position activated: 1. 2. 3.

Use a stop watch to measure the cylinder running time. Raise the fully extended attachment with empty bucket to the maximum height position (A). Rapidly move the control lever (E20) to the rear end position (start the stop watch until the stick start moving) and hold it until close to the final position (B) is reached.(stop the stop watch). If the lowering speed is too high, i.e. the measured time is less than the permissible time, the speed must be reduced by altering the throttle valves 142.5 and 142.7 at the distributor manifold. Adjust as follows: To decrease the lowering speed loosen lock nut (1) and turn the bolt (2) cw. To increase the lowering speed loosen lock nut (1) and turn the bolt (2) ccw.

Since there are several valves throttling the return oil flow of the stick cylinder the valves must be set synchronously. The adjusting screws have to be turned in by the same amount of revolutions.

O.K.

Check lowering speed again and repeat the adjustment if necessary. If the adjustment is finished tighten lock nut (1). continued

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Section 8.1 Page 49

Cont'd: 8.1.12 Checks and adjustments of the lowering speed, illustration (Z 22490): Stick cylinder FSA Adjustments / Checks: II.

Float position deactivated (with push button S95a): 1. Adjust the throttle adjustment bold of throttle valve 142.6 to the same amount of revolutions as the valve 142.5 and 142.7. 2. Use a stop watch to measure the cylinder running time. 3. Start both engines and let it run in high idle. 4. Raise the fully extended attachment with empty bucket to the maximum height position (A). 5. Press push button S95a and keep it depressed while lowering the stick. Rapidly move the control lever (E20) to the rear end position (start the stop watch) and hold it until the final position (B) is reached.(stop the stop watch). 6. The lowering speed will be the same as with floating position. If the lowering speed is too high, i.e. the measured time is less than the permissible time, the speed must be reduced by altering the throttle valve 142.5, 142.6 and synchronous 142.7 at the distributor manifold section F and J. Adjust as follows: To decrease the lowering speed loosen lock nut (1) and turn the bolt (2) cw. To increase the lowering speed loosen lock nut (1) and turn the bolt (2) ccw. Since there are several valves throttling the return oil flow of the stick cylinder the valves must be set synchronously. The adjusting screws have to be turned in by the same amount of revolutions.

O.K.

7. 8.

06.10.05

Check lowering speed again and repeat the adjustment if necessary. If the adjustment is finished tighten lock nut (1).

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Hydraulic for the Attachment Cylinders 8.1.12

Checks and adjustments of the lowering speed, illustration (Z 22491): Stick cylinder BHA Maximum permissible lowering speed:

Stick BHA

Cylinder extending time/meter (s /m) 0,6

Total time (s) 1,5

Adjustments / Checks: 1. Use a stop watch to measure the cylinder running time. 2. Start both engines and let it run in high idle. 3. Raise the fully extended attachment with empty bucket to the maximum height position (A). 4. Rapidly move the control lever (E20) to the rear end position (start the stop watch) and hold it until close to the final position (B) is reached.(stop the stop watch). 5. If the lowering speed is too high, i.e. the measured time is less than the permissible time, the speed must be reduced by altering the throttle valves 142.5, 142.6 and 142.7 at the distributor manifold. Adjust as follows: To decrease the lowering speed loosen the lock nut (1) and turn the bolt (2) cw. To increase the lowering speed loosen the lock nut (1) and turn the bolt (2) ccw. Since there are several valves throttling the return oil flow of the stick cylinder the valves must be set synchronously. The adjusting screws have to be turned in by the same amount of revolutions.

O.K.

6. 7.

06.10.05

Check lowering speed again and repeat the adjustment if necessary. If the adjustment is finished tighten lock nut (1).

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Hydraulic for the Attachment Cylinders 8.1.12

Checks and adjustments of the lowering speed, illustration (Z 22562): Bucket cylinder FSA Maximum permissible lowering speed:

Bucket FSA

Cylinder retracting time/meter (s /m) 1,1

Total time (s) 3,0

Adjustments / Checks: 1. Use a stop watch to measure the cylinder running time. 2. Raise the fully extended attachment with empty bucket to the maximum height position (A). 3. Start both engines and let it run in high idle. 4. Rapidly move the control lever (E19) to the r.h. end position (start the stop watch) and hold it until the final position (B) is reached.(stop the stop watch). 5. If the lowering speed is too high, i.e. the measured time is less than the permissible time, the speed must be reduced by altering the throttle valves 142.1, 142.2 and 142,3 at the distributor manifold section C and D. Adjust as follows: To decrease the lowering speed loosen lock nut (1) and turn the bolt (2) cw. To increase the lowering speed loosen lock nut (1) and turn the bolt (2) ccw. Since there are several valves throttling the return oil flow of the bucket cylinder the valves must be set synchronously. The adjusting screws have to be turned in by the same amount of revolutions.

O.K.

6. 7.

06.10.05

Check lowering speed again and repeat the adjustment if necessary. If the adjustment is finished tighten lock nut (1).

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Hydraulic for the Attachment Cylinders 8.1.12

Checks and adjustments of the lowering speed, illustration (Z 22492): Bucket cylinder BHA Maximum permissible lowering speed:

Bucket BHA

Cylinder retracting time/meter (s /m) 0,5

Total time (s) 1,1

Adjustments / Checks: 1. Use a stop watch to measure the cylinder running time. 2. Raise the fully extended attachment with empty bucket to the maximum height position (A). 3. Start both engines and let it run in high idle. 4. Rapidly move the control lever (E19) to the r.h. end position (start the stop watch) and hold it until the final position (B) is reached.(stop the stop watch). 5. If the lowering speed is too high, i.e. the measured time is less than the permissible time, the speed must be reduced by altering the throttle valves 142.1, 142.2, 142.3, 142.8, 142.9 and 142.10 at the distributor manifold. Adjust as follows: To decrease the lowering speed loosen the lock nut (1) and turn the bolt (2) cw. To increase the lowering speed loosen the lock nut (1) and turn the bolt (2) ccw. Since there are several valves throttling the return oil flow of the bucket cylinder the valves must be set synchronously. The adjusting screws have to be turned in by the same amount of revolutions.

O.K.

6. 7.

06.10.05

Check lowering speed again and repeat the adjustment if necessary. If the adjustment is finished tighten lock nut (1).

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Section 8.1 Page 53

Checks and adjustments of the lowering speed, illustration (Z 22563): Clam cylinder FSA Maximum permissible lowering speed: Adjustments / Checks: 1. 2. 3. 4.

6. 7.

06.10.05

Use a stop watch to measure the cylinder running time. Start both engines and let it run in high idle. Open the clam of the empty bucket to the maximum position (A). Rapidly push the control pedal (E23) to the end position (start the stop watch) and hold it until the final position (B) is nearly reached.(stop the stop watch). If the lowering speed is too high, i.e. the speed is uncomfortable, the speed must be reduced by altering the throttle valve 142.4 at the distributor manifold section E. Adjust as follows: To decrease the lowering speed loosen lock nut (1) and turn the bolt (2) cw. To increase the lowering speed loosen lock nut (1) and turn the bolt (2) ccw. Check lowering speed again and repeat the adjustment if necessary. If the adjustment is finished tighten lock nut (1) and write down the adjusted running time for later checks.

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Hydraulic for the Attachment Cylinders 8.1.13

Section 8.1 Page 54

Checks for the valve control logic Legend for illustration (Z 22582a): (1) Main pump condition Ö P = pressurized outlet (2) Main pump condition Ö (-) = free flow to reservoir (3) Pilot ports a = outlet ports a (4) Pilot ports b = outlet ports b (5) Port condition Ö (-) = closed port (6) Port condition Ö O = open port (7) Respective function (8) Single control valve block for swing (9) control valve block number (10) Swing parking brake switch S29 General: For harmonic attachment motion and well working floating function the valve spools must be activated with different priorities. The whole valve control logic is a arrangement of electric relay controlling and the main hydraulic control valve sequence. The correct function of the valve control logic can be checked by pressure gauges (0 -50bar) connected to the pressure test ports at the control valve cabs. Checks: a) Connect the pressure gauges (0-50 bar) to all test ports at the pilot control cabs (26 gauges necessary *) and (0-400 bar) to the high pressure filter test ports M44.1, 44.2, 46.1, 46.2 b) Mark the control cab with the respective function and port designation. c) Use the Check list for the Valve Logic in the appendix in this binder. d) Unplug solenoid valve Y16 (travel parking brake closed) and activate the swing brake with the switch at the dash board. The ladder and the refilling arm are in high position (working position) the operator sits on the operators seat. Make sure that the machine can move hazardless all functions e) Start one motor. f) The operator activate carefully step for step the respective lever or pedal as shown in the check list. Compare each step with the pressure condition of the control cabs and main pressure to the check list. If there is a wrong result, check the respective electric circuit and hydraulic pilot circuit.

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Section 8.1 Page 54

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Hydraulic for the Swing Circuit

Section 8.2 Page 1

Table of contents section 8.2 Section 8.2

Page Hydraulic for the swing circuit 8.2.1 Swing Circuit (Brief description)

2+3

8.2.2 Swing Motor

4-7

8.2.3 Swing Gear Box

8.2.4 Swing Parking Brake (Gear house Brake)

8.2.5 Swing Brake Valve

10+12

8.2.6 Electric / Hydraulic flowchart “Swing Left”

8.2.7 Electric / Hydraulic flowchart “Swing Right”

8.2.8 Swing Monitoring System

15 + 16

8.2.9 Adjustments for the swing circuit

17 - 19

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8.2 2

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Hydraulic for the Swing Circuit

Section 8.2 Page 2

8.2.1 Swing Circuit (Brief description) Legend for illustration (Z 22501b): (I - VI) (13) (48) (20.1+ 20.2) (71.1+ 71.2) (25.2) (49.1 + 49.2) (Y48) (Y120) (43) (Y32) (Y32a/b) (20) (50) (A7)

Main pumps Single control block IV Manifold Swing motors Manifold at the control and filter panel Double check valve Pressure increasing valve (swing brake valve) Swing motors power control valve Solenoid valve Remote control valve block Proportional valve of the remote control block Directional solenoid valve of the remote control block Control lever left hand Ramp module Amplifier module

Brief description (Control circuits) (Study together with the for the machine valid hydraulic and electric circuit diagram). When the lever (E20) is moved out of its neutral position, proportional solenoid valves Y32 are energized. Simultaneously the directional solenoid valves Y32a (R.H.-swing) or Y32b (L.H.-swing) are energized. By the function of the remote control valve (43) pilot pressure oil is sent to one side of the control block (13/IV) when operating the control lever for "Swinging". At the same time by the function of the proportional valve (Y127) pilot pressure (proportional to the lever deflection) is present at port „X“ pressure increasing valve (PIV)of each brake valve block (49.1+ 49.2) thus a internal pressure built up (higher as 150 bar) in the service lines is possible. continued

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Section 8.2 Page 3

Cont'd.: 8.2.1 Functional description: Illustration (Z 22501b): Brief description (Service circuits) (Study together with the for the machine valid hydraulic and electric circuit diagram). The swing motors (20.1 + 20.2) are feed by the main pump (III). This pump is at port XLR permanent with 35 bar X2- pressure fix adjusted to Qmax. The oil flows from the pumps through check valve (47.3) and filter (153.3) to the single control block (13 / IV). In neutral position of the spool oil flows via port C into control block II for additional oil volume from pump 3 to valve circuit II. If no function of control block II is activated the oil flow via port T in to the collector tube (35) and further via the return oil lines (L6 + L7) into the tank. On its way to tank the oil must flow through the back pressure valve (115) and the return oil filter (117.2 - 117.5). (Back pressure valve function see chapt. 4.) When operating the control lever for "Swinging" the pump line is connected in the control block (33/IV) with the corresponding service line (A1 or B1) to the swing motors (20.1 + 20.2). The oil flows from the control block through each one of the swing brake valves (49.1 + 49.2; description see page 6 and 7) and the swing motors (20.1 + 20.2). Each swing gear includes one spring loaded multi disk brake (House brake) for locking the superstructure. The leak oil (case drain) flows through the line (L11 + L12) and the leak oil filter (108) back to tank.

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Swing motor A6VM

8.2.2 Swing Motor

Section 8.2 Page 4

Axial Piston Motor A6VM355 HD1D

Legend for illustration (Z 22430): (1) Check valve (2) Check valve (3) Governor valve (4) Positioning piston (5) Boost pressure valve (6) Flushing valve (16l/min) (7) Flow control valve (8) Constant pressure control valve (adjusted: 280 bar) General: A6VM355 HD1D is a variable displacement motor with an axial piston rotary group of bent axis design for hydrostatic drives. Its control range allows the variable displacement motor to meet both, high speed and torque requirements. The output speed is proportional to its displacement. The output speed increases with decreased displacement trough lower operating pressure. The output torque increases with increased displacement trough higher operating pressure.

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Section 8.2 Page 5

Swing motor A6VM

8.2.1 Swing Motor

Axial Piston Motor A6VM355 HD1D

Hydraulic control, illustration Z22430 By switching pilot pressure to port X at the motor (0 bar or 35 bar) the displacement is fixed in Vg max or variable. Without pilot pressure at port X (0 bar) the displacement is fixed to Vg max . With pilot pressure at port X (35 bar) the displacement is variable from Vg min (175 cm3/rpm) to Vg max (355 cm3/rpm). With a swing speed of 0 up to 120 impulses per minute (measured by a proximity switch located at the swing gear) the motors are in maximum displacement position, i.e. min. speed and max. torque available. With a swing speed of more as 120 imp./min. pilot pressure is directed via a solenoid valve to port X at the motors, to actuate governor valve (3). Now the output speed is variable depending on the operating pressure, controlled by the function of control valve (8). As a result of decreasing operating pressure the motors are reducing their displacement so that the swing speed will increase. If the operating pressure rises as a result of load torque, to the setting of the constant pressure control valve (280 bar), the motors are swiveled out to a greater angel (higher displacement) and the swing speed will decrease. Function

Speed Xindicator pressure imp/min bar

Operating pressure bar

Torque

Motor displacement

Start swing Standstill to low speed

0-120

310 à ~280

Max.

Vg max

Swing movement 120-max. Low speed to Max. speed

280 à ~75

Swing movement Max. speed

Max.

~75

Reduced

Vg min

Swing down path

120-0

~170 à 0

Max.

Vg max

120-0

330 à 0

Max.

Vg max

Reduced Vg max à Vg min variable

Control lever in neutral

Counter Swing (braking) Control lever moved to the opposite side of swing direction

Continued

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Swing motor A6VM

8.2.2 Hydraulic Motor

Section 8.2 Page 6

Axial Piston Motor A6VM355 HD1D

Hydraulic control, illustration Z22431b Cont'd:

A Flow from A to B without „X-pressure“ (slow swing speed) : The operating pressure opens check valve (1) and closes the opposite valve (2). The same pressure is present at the control port of pressure control valve (8) and inside the small area side of the positioning piston (4). The large area side is connected via the governor valve (3) to tank (port T2). The motor remains in Vgmax position. = max. torque by low speed.

B Flow from A to B, with „X-pressure“ (higher swing speed), operating pressure 0 –280 bar: Operating pressure opens check valve (1) and closes the opposite valve (2). The same pressure is present at the control port of pressure control valve (8) and inside the small area side of the positioning piston (4). Because of the „X“ pressure at the control port of governor valve (3) a connection is made from the operating pressure to the large area side of positioning piston (4). Same pressure on both sides but different areas causes a greater force at the piston side moving the motor into the Vgmin position. The motor is in regulation mode due to 35 bar “X-pressure” Motor displacement to Vgmin position (<280bar).

C Flow from A to B, with „X-pressure“ (higher swing speed), operating pressure 280-310 bar: Depending on the system pressure (more as 280 bar), valve (8) connect the large area side of the positioning piston (4) with the pressure less return line (T2). Low pressure at the large side cause a greater force at the pressurized small area side of the positioning piston (4) moving the motor into the Vgmax position. The motor is in regulation mode due to high operating pressure (>280bar) : Motor displacement to Vgmax position (>280bar). As a result of decreasing operating pressure the motors are reducing their displacement so that the swing speed will increase. If the operating pressure rises as a result of load torque, to the setting of the constant pressure control valve (280 bar), the motors are swiveled out to a greater angel (higher displacement) and the swing speed will decrease.

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Swing motor A6VM

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Swing motor A6VM

8.2.2

Section 8.2 Page 7

Checks and Adjustments, illustration Z22432 Preconditions before starting checks and adjustments: 1. Main pump 3 must be in full flow position (X1-pressure = 35 bar), no action required because stabilized X1 pressure is automatic activated during swinging 2. MRV’s and SRV’s (pressure increasing valves) correctly adjusted.

Checking the Q-max. and Q-min. stop bolt setting. Q-max : The average outer length of 25.1 mm must not be altered because the max. possible swivel angle is used. Q-min : The Qmin. adjustment depends on the max. permissible swing speed (with reduced swivel angle). The average outer length is 36.1 mm

)

• It is important that the adjustment is equal on both motors!

How to check the Q-min. adjustment. 1. Lift the extended attachment to horizontal position. 2. Measure the time for 5 revolutions after swinging one turn as an approach swing. The time should be t5rev = 90+5 sec . 3. If a adjustment is required: Turn off box nut (1) and loosen lock nut (3) Turn bolt (2) further in for less speed or further out for higher speed. One turn of the Qmin bolt (2) cause a change of approx. ∆t5rev = 4.6 sec. 4. Re-check speed and tighten lock nut and re-fit box nut (1) after setting is finished. How to check / adjust the start of regulation. 1. Activate manually relay K153 to energize Y48 to pressurized swing motor port X with X2-pressur. 2. Connect a pressure gauge (0-400 bar) to check point M12.2 at high pressure filter of single control block IV. 3. Measure and note outer length (L) of Qmax stop bolt (2) (for resetting later on) Loosen lock nut (3) approx. ½ turn without turning the stop bolt.. 4. Start engine 1 and let it run in high idle. 5. Apply the swing parking brake. 6. Operate carefully the control lever for swing in one direction and keep it in end position. The resulting operating pressure should be 320 bar. 7. Loosen look nut of MRV at single control block IV. 8. Decrease / increase alternately the operating pressure between 300 bar and 260 bar at MRV set screw. Check by turning the Qmax stop bolt (2) by hand, if the motor control lens touches the Qmax stop bolt: The lens must touch the stop bolt with a pressure higher than 280 bar. The lens must not touch the stop bolt with a pressure lower than 280 bar 9. Correct the start of regulation with valve (8) if necessary. 10. Reset MRV. Stop engine and deactivate K153

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Section 8.2 Page 8

8.2.3 Swing Gear Box Legend for illustration (Z 25305), manufacturer: Siebenhaar (1) Drive housing (11) Bearing ring (2) Drive shaft (12) Cartridge (3) Sun gear shaft (13) Spherical roller bearing (4) Multi disc brake, spring (14) Oil drain plug, gear box loaded pilot pressure released (15) Cylindrical roller bearing (5) Breather filter motor adapter (16) Oil level gauge (dipstick) housing for gear box (6) Oil level gauge (dipstick) (17) First planetary stage for drive shaft housing (18) Drive shaft to second stage (7) Disk brake housing (19) Second planetary stage (8) Cylindrical roller bearing (20) Radial seal ring (9) Internal ring gear (21) Drive pinion (10) Cylindrical roller bearing (22) Grease line port (23) Centering circle

The swing gear is of compact design with a two stage planetary gear including a multi disk house brake. The gear is bolted to the superstructure and fits firmly due to the machined diameter (A) and the bolt torque. The torque loaded on the hydraulic motor is transmitted by drive shafts (2) and sun gear shaft (3) to the first planetary stage (17). The sun shaft (17) of the first planetary stage transmits the torque into the second planetary stage (19). By the planetary gears the output drive shaft is rotated and transmits the torque to the pinion (21). The drive housing, and the gearbox are filled with gear oil. Aeration is done by breather filters. A grease nipple is via a hose connected to the bearing lubrication port (22).

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Section 8.2 Page 9

8.2.4 Swing Parking Brake (Gear house Brake) The Spring Loaded Multi-disk Brake is a safety brake; applied by spring force and released by oil pressure. Legend for illustration (Z 22439): (1) Clip ring (circlip) (2) Thrust washer (3) Outer discs (4) Inner discs (5) Piston (6) Quad ring with back up ring (7) Quad ring with back up ring (8) Springs (9) Piston back up ring and seal retainer (10) O ring (11) Clip ring (circlip) (12) Oil pressure port Function: Brake applied: The outer disks (3) engaged to the housing by serration and the inner disks (4) in serrated connection with drive shaft are pressed together by the springs (8). This results in a fixed connection between housing and drive shaft. Brake released: Oil pressure via port (12) reaches the bottom of the piston (5) and forces the piston upwards against the thrust washer (2). This function eliminates the spring force to the disc (3) and (4) thus the brake is released. The releasing pressure is 12 - 20 bar, the maximum permissible pressure 60 bar. This is a so named "Wet Brake" because the brake housing is filled with oil.

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Hydraulic for the Swing Circuit

Section 8.2 Page 10

8.2.5 Swing Brake Valve Legend for illustration (Z 21934): (1) Pressure increasing valve (items 6 - 13) (2) Check valve circuit A (3) Check valve circuit B (4) Anti-cavitation valve circuit B (5) Anti-cavitation valve circuit A (6) Jet bore, of main piston plug

(7) Spring of main piston (8) Jet bore (9) Valve poppet (10) Spring (11) Intermediate piston (12) Pilot pressure piston (13) Main piston

Ports: (Y) Leak oil (T) Return oil (A) Service line from control block (A1) Service line to the motor (B) Service line from control block (B1) Service line to the motor Pressure check points: (MA) Circuit A (MB) Circuit B Explanation of the function by the symbol: When ever a swing motion is carried out or the foot brake is used, pilot pressure arrives the pressure increasing valve (1) at port "X". The pilot pressure pre-loads these valves. The oil for the hydraulic motor from the control block arrives the service line port A or B, depending if a R.H. or a L.H. swing motion is carried out. The ports A and B are internally connected to the ports A1 and B1 and these ports in turn with the hydraulic motor. The operating pressure, at either port A or B closes the anti-cavitation valves (4 or 5) and opens the check valves (2 or 3). That means by the check valves (2 or 3) the service lines are connected to the pressure increasing valve. When ever the pressure is higher than the setting of the pressure increasing valve, this valves opens and dumps the oil into the return line (T) to tank. The pressure can be checked at the check points MA or MB. continued

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Section 8.2 Page 11

Cont'd.: 8.2.5 Swing Brake Valve If after a swing motion the joy stick is released into neutral position without using the foot brake, the superstructure is turned by inertial force and the hydraulic motor acts as a pump because it is driven by the swing gear. Both service line’s (pump line and tank line) are blocked at the control valve block. In this period the service line (previously pump line) acts now as suction line and the return line (previously return line) acts now as output line. Because of the closed service ports at the control block all oil from the swing motor must pass the brake valve block. The pressure increasing valve in the brake valve block acts now as a back pressure valve. This variable back pressure is the brake force. Function of the pressure increasing valve. When ever a swing motion is carried out or the foot brake is used, pilot pressure arrives the pressure increasing valve (1) at port "X". The pilot pressure pre-loads these valves. By applying pilot pressure via the external port X to piston (12), the pretensioning of the pressure spring (10) is increased by the amount of the piston stroke "S", which results in the actual valve setting. The system pressure is in front of the main piston (13) and via the jet bore (6) also in the chamber of the spring (7) and via the jet bore (8) at the pressure relief valve poppet (9). Due to the force balance the piston (13) is kept in its position supported by the spring (7). Overcomes the system pressure the setting of the valve (9), this valve opens a channel to the dump line port (Y). Due to the drop of force the piston (13) is moved to the right. The pressure line gets connected with the return line (T). Damped opening and closing are obtained by the throttled volumetric change that is caused by the jet bores.

continued

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Section 8.2 Page 12

Cont'd.: 8.2.5

Swing Brake Valves Anti cavitation prevention. Illustration Z 22672a (1) Return oil collector tube (2) Main back pressure valve (3) Gear pump (8.2 + 8.5).. (4) Swing motor back pressure valve blocks (195.1 + 195.2) (5) Swing brake valve blocks (49.1 + 49.2). (6) Swing motor (20.1 + 20.2) (7) Pressure relieve valve (swing motor back pressure) (8) Check valve (9) Pressure check point M35.1 and M35.2 (10) Valve drain connection A Input from gear pump B Output to swing brake block T Tank connection to return oil collector tube During the swing down phases the swing motors (6) are working as “pumps”. It means that the pressure side change to a suction side and the suction side change to a pressure side. To prevent cavitation in the swing motors during this change there are two back pressure valves (4) fitted. The valves (4) together with the gear pumps (3) increase the main back pressure up to 15 bar. Port B is direct connected to the tank port (return line) of the swing brake valve block (5). Adjustments - Measurements -Settings Setting of the swing circuit back pressure valves (3) 1. Connect pressure gauge (0 – 25 bar) to check points M35.1 and M35.2 at the valve blocks (195.1 +195.2). The valve blocks fitted at the return oil collector tube in front of the hydraulic tank. 2. Start both engines and let them run in high idle. 3. The pressure at the gauges should be 15 bar if the gauges shows a different value the pressure relieve valves in the back pressure valve must be adjusted. a) b) c)

Loosen look nut Turn in or out set screw to increase or decrease the pressure. Tighten look nut

4. Stop engines 5. Disconnect the gauges.

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Hydraulic for the Swing Circuit

Section 8.2 Page 13

8.2.6 Electric / Hydraulic flowchart “Swing Left” Legend for illustration (Z 22503a): (-10V) Signal voltage (Maximum) (13) Main control block IV (20.1 + 20.2) Swing motors (43) Remote control valve block (48) Distribution block (49.1 + 49.2) Swing brake valve blocks (A7) Amplifier module – Swing (Y32 + Y32a/b – Block IV) (A16) Amplifier module – Swing brake (D32) Time relay – Pilot control: Neutral position monitoring (E20) Control lever (Joy stick) (E50) Ramp time module (E50B) Ramp time module – Swing brake (K165) Relay counter lock (option) (K253) Relay controlled by swing brake (foot brake) (ws/gn) Colour code of signal voltage cable ( Joy stick) (-X) Direction (axis) of joy stick (minus x = left) (X2F...) Terminal rail with number (Y32) Proportional solenoid valve (Y32a + Y32b) Directional solenoid valve (Y127) Proportional valve, controlling pressure increasing valve The electrical signal. Signal voltage of joy stick (E20) arrives via ramp time module (E50) at terminal 5 of the amplifier module (A7) and further via relay K165 (if equipped) to the proportional and directional solenoid valves of the remote control blocks (43). In the same time signal voltage of joy stick arrives via K253 and ramp time module E50B to terminal 5 of the amplifier module A16. Relay contact 2 / 10 of relay K165 (if equipped) opened if the excavator superstructure swing in a different direction as the lever direction (counter look). Relay K253 energized if the swing brake pedal is activated this eliminate the ramp time function of E50B. The hydraulic signal. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pressure ports of the main control blocks. Proportional valve Y127 increase proportional to the lever deflection the pilot pressure to the pressure increasing valves. The hydraulic oil flow Now the oil of the main pump 3 flows through the main control block (IV) and arrives via swing brake valves (49.1 + 49.2) at the swing motors (20.1 + 20.2).

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Hydraulic for the Swing Circuit

Section 8.2 Page 14

8.2.7 Electric / Hydraulic flowchart “Swing Right” Legend for illustration (Z 22504a): (+10V) Signal voltage (Maximum) (13) Main control block IV (20.1 + 20.2) Swing motors (43) Remote control valve block (48) Distribution block (49.1 + 49.2) Swing brake valve blocks (A7) Amplifier module – Swing (Y32 + Y32a/b – Block IV) (A16) Amplifier module – Swing brake (D32) Time relay – Pilot control: Neutral position monitoring (E20) Control lever (Joy stick) (E50) Ramp time module (E50B) Ramp time module – Swing brake (K165) Relay counter lock (option) (K253) Relay controlled by swing brake (foot brake) (ws/gn) Colour code of signal voltage cable ( Joy stick) (+X) Direction (axis) of joy stick (plus x = right) (X2F...) Terminal rail with number (Y32) Proportional solenoid valve (Y32a + Y32b) Directional solenoid valve (Y127) Proportional valve, controlling pressure increasing valve The electrical signal. Signal voltage of joy stick (E20) arrives via ramp time module (E50) at terminal 5 of the amplifier module (A7) and further via relay K165 K165 (if equipped) to the proportional and directional solenoid valves of the remote control blocks (43). In the same time signal voltage of joy stick arrives via K253 and ramp time module E50B to terminal 5 of the amplifier module A16. Relay contact 2 / 10 of relay K165 (option) opened if the excavator superstructure swing in a different direction as the lever direction (counter look). Relay K253 energized if the swing brake pedal is activated this eliminate the ramp time function of E50B. The hydraulic signal. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pressure ports of the main control blocks. Proportional valve Y127 increase proportional to the lever deflection the pilot pressure to the pressure increasing valves. The hydraulic oil flow Now the oil of the main pump 3 flows through the main control block (IV) and arrives via swing brake valves (49.1 + 49.2) at the swing motors (20.1 + 20.2).

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Hydraulic for the Swing Circuit

Section 8.2 Page 15

8.2.8 Swing Monitoring System, illustration (Z 21947a) There are two reasons why the swing monitoring system is installed: a) ⇒ To prevent adverse effects of a counter action. b) ⇒ To increase the swing speed, by reducing the swivel angel of the swing motor (lowering the required oil volume per motor rotation) Function of the swing monitoring system: The two sensors B98 and B99, (Proximity switches mounted into a housing near the ring-gear) sensing the direction of rotation. How? Because the distance from sensor to sensor (B) is less than the distance of two teeth (A), one of the sensors recognizes first a swing action. The signals of both sensors are used as input signals for the module (E42) which monitors the swing direction. The same signals from sensor B99 are send to the module E43 for sensing the swing speed. Proximity switch B99 together with module E43 monitors the swing speed to control via relay K154 and K153 solenoid valve (Y48). • Activated solenoid valve Y48 allows full X2 pressure to swing motors (20.1 + 20.2) port X = if the working pressure is less then 280 bar increasing of swing speed is possible. • De activated solenoid valve Y48 causes no X2 pressure to swing motor (20.1 + 20.2) port X = the motors are fixed in maximum swivel angel (max. volume = max. torque and min. speed) ⇒ Acceleration During the first acceleration phase the maximum torque by minimum speed is required, the motors must be in maximum swivel angel (x-port 0 bar). E43 detect the swing speed, if the speed is below 120 Imp./min. relays K154 and K153 are still de energized and further solenoid valve Y48 de-energized (xport = 0 bar = max. motor swivel angel = max torque). After this first acceleration the required torque and hydraulic pressure droops and the swing speed increase. E43 detect more as 120 Imp./min and energize relay K154. If the lever direction and the swing direction is the same K153 energized and further D153 energized solenoid valve Y48 (x-port = 35 bar = variable motor swivel angel is possible). ⇒ “ Braking ” with counter position of the lever If the operator release the lever or move the lever to counter position relay K153 opened contact 5 / 9 it de energize time relay D153. After the time is elapsed (one second) solenoid valve Y48 de energize and change over in neutral position so that pilot line L18 release the pressure to the tank (port X = 0 bar). The swing motors move to maximum swivel angel. Now a maximum breaking torque is available.

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Hydraulic for the Swing Circuit

Section 8.2 Page 16

8.2.8 Swing Monitoring System, illustration (Z 21947a) (Study together with the valid hydraulic and electric circuit diagram for the machine) Adjustments - Measurements -Settings a) Distance between Swing ring teeth and the switches B98 and B99 The sensors B98 and B99 are inductive switches with own electronic. Sensor B98 switches 24V via cable “Sig” to terminal 4 of E42 and Sensor B99 switches 24V via cable “Sig” to terminal 11 of E42 if a tooth comes close to the sensor head. Simultaneously these signal arrives at E43 terminal 4. Adjust the distance “C” of the sensors B98 and B99 to 5±1 mm. b)

E42 for monitoring the slew direction E42 is an programmable module which is factory programmed with the parameters are shown in the electric diagram. Therefore no adjustments or settings are required. The indication light (In1 from B98 / In2 from B99) lights/pulses if a input signal comes up. The indication light (Out1 for swing left / Out2 for swing right) lights if the module indicates a swing direction.

E43 for monitoring the slew direction E43 is an programmable module which is factory programmed with the parameters are shown in the electric diagram below. Settings: E43 (speed monitor) “counter prevention” No

Function

nominal setting

Setting the start up delay

Not used set to “0”

Fine setting of the preset value (pulses / min.)

12 imp/min (i.e.120)

Setting the hysteresis

Not used set to “0”

LED: lights when the output relay is energised

---

Setting the switching function

Set to “III”

Coarse setting of the preset value (pulses / min)

X x 10 imp/min

If necessary increase or decrease the imp/min with set screw no. 2 until a smooth slew operation is possible.

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Section 8.2 Page 17

8.2.9 Checks and adjustments for the swing circuit

)

• It is important that the complete MRV-valve and the Pressure Increasing Valve is firmly (with 300 Nm) tightened. Otherwise, the internal sealing sealed not properly which results in: difficulty setting, loud flow noises and abnormal temperatures. • Whenever pressure checks are carried out, they must be carried out for both, r.h. and l.h. swing, to make sure the check valves in the brake valve are in good shape. • Because the Swing motors are working hydraulically in combined operation, the pressure gauge shows the pressure of the pressure increasing valve with the lowest setting. Even when the gauge shows the required pressure it is possible that one valve has a higher setting. Therefore lower the pressure on one valve below the required pressure and then increase up to required pressure. Proceed with next valve in the same manner.

High pressure check / adjustment 1. Connect the gauge (0-400 bar) to check point M12.2 at the high pressure filter units (153.3) of single control block IV. 2. Release the pilot pressure by several movements of the lever with motor / engine stand still. The key switch S1 must be on the ladder and service arm must be in up position. Disconnect carefully the pilot pressure lines from the pressure increasing valves and close the lines with a suitable plug. 3. Loosen lock nut (3) of both pressure increasing valves (PIV) and screw in set screw (4) until piston (5) comes to stop. 4. Start engine and let it run with max. speed. 5. Lower attachment to ground and apply house brake (swing parking brake). 6. Actuate either l.h. or r.h. rotation until the hydraulic system stalls and increase slowly the MRV-pressure while observing the pressure gauge. Gauge value must remain at 330 -5 bar. Increase MRV setting additional 1/8 turn cw.. 7. If the gauge shows a lower or higher value the pressure increasing valves must be adjusted.

continue

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8.2.9

Section 8.2 Page 18

Checks and adjustments for the swing circuit Cont'd: High pressure check / adjustment Pressure Increasing Valve (PIV) high pressure adjustment Procedure: a) Loosen lock nut (1) of the first pressure increasing valve PIV. b) Adjust pressure with set screw (2) to ~340 bar if the pressure don’t increase turn set crew from the last setting max. ¼ turn in (c.w.). c) Secure by tightening lock nut (1). d) Loosen lock nut (1) of the second PIV. e) Adjust pressure with set screw (2) to 330 –5 bar. f) Secure adjusted set screw (2) by tightening lock nut (1) g) Loosen lock nut (1) of the first PIV. h) Adjust pressure with set screw (2) of the first PIV to 330 –5 bar (lower pressure c.c.w. just as the pressure gauge show a reaction) i) Secure adjusted set screw (2) by tightening lock nut (1) j) Re-check pressure setting. k) Re-set MRV to 310 + 5 bar after the check / adjustment is finished.

Low pressure check / adjustment (Swinging down path (drifting) (with still disconnected pilot pressure line ) 8.

Actuate either l.h. or r.h. rotation until the hydraulic system stalls. a) loosen lock nut (3) at the first PIV and turn out set screw (4) until 150 +5 bar is reached. b) Tighten lock nut (3). c) Loosen lock nut (3) at the second PIV and turn out set screw (4) until the gauge start lowering the pressure. d) Re-check pressure setting. Re-connect the pilot pressure line. Proceed like item 2.

)

• For later one pressure checks the steps 2 + 3 must not be done. • The Swinging down path may be extended, means the low pressure may be decreased a little; e.g. for greater operating radius such as at strip Mining. But a little only otherwise disturbance due Swinging will occur. • The Swinging down path may be shortened, means the low pressure may be increased approx. 20 bar; but not more because that means greater shocks in the systems which will shorten the life time of the components.

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Hydraulic for the Swing Circuit

8.2.10

Section 8.2 Page 19

Checks and adjustments for the swing circuit Cont'd:

Brake pilot pressure - check / adjustment 1. Connect the gauge to the check point M4. 2. Start engine and let it run with max. speed. 3. Depress fully the foot brake pedal and read the pressure. The pressure must be 19 +3 bar. If adjustment is required: Alter the position of the potentiometer R2 of the amplifier A16 as long as the pressure is 19 +3 bar. Basic adjustment for A16 see section 5

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Hydraulic for the travel circuit

Section 8.3 Page 1

Table of contents section 8.3 Section 8.3

Page Travel System 8.3.1 Travel Circuit (Brief description)

2+3

8.3.2 Rotary Distributor

4+5

8.3.3 Side Frame Components

8.3.4 Travel Gear and Parking Brake

8.3.5 Parking Brake

8.3.6 Electric / Hydraulic Flow Chart

8.3.7 Adjustment / Checks

10 + 12

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Travel System

Section 8.3 Page 2

Travel Circuit

Legend for illustration (Z 22521): (1; 2; 5; 6) (14 / I) (16 / III) (21.1- 21.4) (28.1+28.2) (34) (40) (46.1+46.2) (52.1 + 52.4)

Main pumps L.H. Control block R.H. Control block Travel motors (A2FM 355) Travel motors valve blocks Rotary distributor Suction tank Double filter Travel gear house brakes

(M12.1 + M12.4) (M33.1, M33.2) (M33.3, M33.4)

High pressure check points High pressure check points left travel motors High pressure check points right travel motors

Brief description (Study together with the machine valid hydraulic and electric circuit diagram). Control circuits, not shown By the function of the remote control valve (45.1 + 45.3) pilot pressure oil is sent to one side of each control block (14/I + 16/III) when operating the foot pedal for travelling "Forward or Reverse“.

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Travel System

Section 8.3 Page 3

8.3.1 Service circuits ( Z22521) (Study together with the valid hydraulic and electric circuit diagram for the machine). The travel motors (21.1 - 21.4) are driven by the pumps (1; 2; 5; 6). The oil flows from the pumps through check valves and the filters (46.1 + 46.2) to the control blocks (14 / I + 16 / III). In neutral position of the spools the oil flows via the return oil lines into the collector tube (35, not shown). From the collector tube (35) flows the oil via the return oil lines (L6 + L7, not shown) into the collector tube (114) and further to the tank. On its way to tank the oil must flow through the back pressure valve (115) or the oil coolers (106.1 – 106.4) and the return oil filter (117.1 - 117.4). (Back pressure valve function see section 4.) When operating the foot pedal for "Travelling" the pump line of each control block is connected with the corresponding service line (A1 or B1) via the rotary distributor (34) and the valve blocks (175 + 176) to the travel motors (21.1 21.4). The oil flows from the travel motors via the rotary distributor back to the control blocks and further to tank. Each travel gear includes two spring loaded multi disk brakes (House brakes) (52.1 - 52.4). They are used as parking brakes, automatically applied (by the function of Y16) whenever both motors stoped. The brake release pressure is monitored by the pressure switch (B48). The leak oil (case drain) flows through the line (L) and the leak oil filter (108) back to tank.

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Travel System

Section 8.3 Page 4

8.3.2 Rotary Distributor Task: The rotary distributor (joint) permits a hydraulic connection between the superstructure and the undercarriage, that means between the rotating and the stationary part. Legend for illustration (Z 22522): (1) (2) (3) (4) (6) (8+9) (10) (11) (12) (13)

Rotor Rotary distributor housing Cover Thrust washer Sealing plunger Seal ring and O-ring PTFE Sealing V – Sealing Rotor guide rings O-ring

Translations: Schnitt = Cross section Versetzt gezeichnet = Offset drawn Verschlußschraube mit Loctite gesichert = Plug screw sealed with Loctite mit Körnerschlag gesichert = sealed with punch mark Kammer mit Fett gefüllt = Chamber grease filled Ports: A-D L ST X K1 K2

Service lines Leak oil Control oil „Travel break“ Control oil (travel motor flushing) Track tensioning Track tensioning continued

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Travel System

Section 8.3 Page 5

Cont’d.

Function (Z 22522): During operation superstructure and under carriage rotate towards each other. The travel oil motors must be supplied with hydraulic oil in every position in which the superstructure is turned in regard to the undercarriage. Oil is directed by the control blocks to the ports (A-D) of the housing (2). The oil flows to the outlet ports (A-D), of the rotor (1), via ring grooves as well as longitudinal and cross holes. The rotor is bolted to the under carriage and the housing (stator) is fixed by the upper structure. The sealing of the ring grooves among one another is done by seal rings (8) and o-rings (9). The hydraulic connection for the travel motor case drain and the travel motor house brake is done via the ports (L) and (St). The rotor (1) is at the top and bottom section guided in the housing by the guide rings (12).

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Section 8.3 Page 6

8.3.3 Side Frame Components, Cross Sections Illustration Z 22523

A B C D

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Under carriage view from the back side Final drive with Side frame with top and bottom roller Track tensioning cylinder

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Travel System

Section 8.3 Page 7

8.3.4 Travel Gear and Parking Brake Function principle ( illustration Z22524a): The spur gear stage (B) is driven by two hydraulic motors via two drive shafts (A). This in turn causes that by the shaft (C) the first planetary stage (D) is driven; opposite the input drive direction. The planetary gears of the second planetary stage are connected to the hollow shaft (G). The drive sprocket is mounted to the hollow shaft (G).

For maintenance see MAINTENANCE MANUAL For more details see PARTS BOOK.

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Travel System

Section 8.3 Page 8

8.3.5 Parking Brake Illustration Z 22525 The Spring Loaded Multi-disk Brake is used as a safety brake (parking brake); applied by spring force and released by oil pressure. Legend: (1) (2) (3) (4) (5) (6)

Disk housing Piston Back-up ring with radial seal rings (15) Bach-up ring Coupler Inner disks (lamellas)

(7) (8 + 9) (10 - 12) (13) (14) (16) (17) (19) (21 + 22)

Outer disks Springs O-ring Clip ring Clip ring Release pressure port Quad-Ring with back-up rings (18) Quad-Ring with back-up rings (20) Plug screw with seal ring

Function: Brake applied: The outer disks (7) engaged to the housing by serration and the inner disks (6) in serration connection with the coupler, are pressed together by the springs (8 + 9). This results in a fixed connection between housing and coupler. Brake released: Oil pressure via port (16) reaches the left side of the piston (2) and forces the piston towards the back-up ring (4), as shown. This function eliminates the spring force onto the disks thus the brake is released. The releasing pressure is 18 bar, the maximum permissible pressure 60 bar. This brake named "Wet Brake" because the brake housing is filled with gear oil. For maintenance see MAINTENANCE MANUAL For more details see PARTS BOOK

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Section 8.3 Page 9

Electric / Hydraulic Flow Charts Illustration Z 22526 On the following pages are shown the electric / hydraulic flow charts for the travel circuit. The electrical signal created by the foot pedals (E21a and E21b) reach first of all the ramp modules (E51 and E52) and further the amplifier modules (A12 and A13). It is a voltage signal from –10 up to +10 Volt dependent to the pedal deflection and direction. The amplifier modules changes this signal in a current signal from 0 to 1000 mA and a directional signal (0 or 24 V). The current signal activate the proportional valve and the directional signal the directional solenoid valve of the remote control block (45.1 and 45.3). The valves in case activate the pilot pressure to the main control valve blocks. This hydraulic signal (pilot pressure) from the remote control valves flow to the main control blocks (175 and 176) to the pilot pressure ports a1 or b1 which in case push the main control valve spool to control the main hydraulic oil flow from the main pump. The main hydraulic oil flows now from the main control blocks via the rotary distributor (34) to the hydraulic motors (21.1 - 21.4).

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Travel System

Section 8.3 Page 10

Adjustments / Checks

)

• It is important that the complete MRV-valve is firmly (with 300 Nm) tightened. Otherwise, the internal sealing sealed not properly which results in: difficulty setting, loud flow noises and abnormal temperatures.

High pressure check / adjustment (illustration Z 22528) 1. Connect the gauge (0-400 bar) to the check points M12.1. and M12.4 at the double high pressure filters. 2. Unplug solenoid valve Y16 (Z 22529, filter and valve panel motor 2) to 3. 4. 5.

keep the parking brake applied. Start both engines and let it run in high idle. Engage carefully desired travel motion and hold foot pedal in final position to built up max. pressure. Increase * slowly the MRV-pressure while observing the pressure gauge. Gauge value must remain at 310 +5 bar.

Motor 2

continued

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Section 8.3 Page 11

Cont’d. If the gauge shows a lower or higher value and to be sure both SRVs are correct adjusted the SRVs (main valve block and brake valve block) must be adjusted.

)

• A faulty anti cavitation valve (32.1; 32.2; 32.13; 32.14) can influence the SRV pressure reading / setting. In a doubt inspect the valve. Repair or replace faulty valve if necessary. • A faulty rotary distributor or motor gives the same problems. Repair or replace faulty part.

Procedure: 6. 7. 8. 9.

10. 11.

12.

13.

Set MRV of main valve block I and III to a higher setting (~ 340 bar, for adjustment use the function “stick extending” Engage carefully desired travel motion and hold foot pedal in final position to built up max. pressure Adjust* the respective SRV to a higher setting (~330 bar) Connect pressure gauge to check points M33.1, M33.2, M33.3 and M33.4 at the travel valve block in the car body. The respective high pressure check point is on the other side diagonal to the SRV. Adjust* the SRV at the desired travel function to 310 bar. Reset the respective SRV at the main valve block to 310 bar, increase the setting from a lower pressure just to the point when the gauge stop increasing it should be 310 bar (provided setting from the SRV at the brake valve is correct). Create max. pump pressure with “stick extending” to the max. position and re-set MRV to 310 + 5 bar after the check / adjustment is finished and re-plug solenoid valve Y16 Stop enignes.

* a) b) c) d) e)

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Remove dust cap of the SRV (1) Loosen lock nut (2). Adjust pressure with set screw (3). Secure adjustment by tightening lock nut (2). Re-fit dust cap (1).

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Section 8.3 Page 13

Function Check of the Travel Gear House Brake Illustration Z 22529 Connect pressure gauge to check point (M6) at the filter and valve panel motor 2. Start both engines and let it run in high idle. Read the pressure. Gauge must show common pilot pressure (norm. 35 + 1 bar). If not check the pilot pressure. If the pressure is below 24 bar, the text display must show „Travel gear house brake ON“. Operate the travel foot pedals, the machine must travel. In case the machine doesn’t travel the text display must show „Travel gear house brake ON“ Unplug solenoid (Y16) and operate the travel foot pedals, the machine must not travel. The text display must show „Travel gear house brake ON“

1. 2. 3.

)

• In a case of malfunctioning check the electrical controlling and the solenoid valve Y16.

Function check of the pressure switch (B48) 1. Connect pressure gauge to check point (M6). 2. Start one motor. The gauge must show common pilot pressure (norm. 35 + 1 bar). 3. Set pilot pressure relief valve (70.2) to 22 bar X2 pressure. 4. Unplug solenoid valve Y16 to allow pressure release from the pressure line of the house brake. 5. Reconnect solenoid valve Y16. The text display must show „Travel gear house brake ON“ 6. Increase the pilot pressure up to 26 bar „Travel gear house brake ON“ must disappear If not check the pressure switch B48 and exchange it if it is out of the range. 7. Reset pilot pressure to 35 bar

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Hydraulic Track Tensioning System Section 9.0 Page 1

Table of contents section 9.0 Section 9.0

26.03.03

Page Hydraulic Track Tensioning System General

9.1

Functional description

3+4

9.2

Pressure Increasing Valve

9.3

Tensioning Cylinder

9.4

Adjustments / Checks

7–9

9.5

Functional test

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Hydraulic Track Tensioning System Section 9.0 Page 2

9.0

General: Legend for illustration (Z 22453): (62.1 – 62.4) Track tensioning cylinders (M15.3 + M15.4) Bleeder and hydraulic pressure check points at the R.H.- tensioning cylinders. (M15.1 + M15.2) Bleeder and hydraulic pressure check points at the L.H.- tensioning cylinders. (M15.5) Bleeder and hydraulic pressure check point at the bladder accumulator (59.1) for the L.H.-side. (M15.6) Bleeder and hydraulic pressure check point at the bladder accumulator (59.2) for the R.H.-side. (60.1 + 60.2) Membrane accumulator, 1,3 liter (pre-charge pressure 31bar) (54.2) Service shut-off cock for the L.H.-side (54.3) Service shut-off cock for the R.H.-side * "O" = open - "C" = closed (59.1 + 59.2) Bladder accumulator, 5 liter (pre-charge pressure 150bar) (34) Rotary joint L3 (St) Supply line from solenoid valve Y16 over rotary joint port St

The hydraulic track tensioning system ensures automatically the correct track tension. The pilot pressure pumps (7.1+7.2, see hydraulic diagram page 02) will supply oil to all four tensioning cylinders (62.1-62.4). The maximum pressure is limited by the pressure increasing valve (182), one for both sides. The pressure in the tensioning cylinders transmits the required force to move the guide wheels to the front, until the correct track tension is obtained. External forces acting at the guide wheels will be absorbed through the pressure accumulators (60.1 + 60.2, first stage) and (59.1 + 59.2, second stage).

)

• For information about the preventative track inspection, refer to the Operation and Maintenance Manual.

Functional description on next page

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Hydraulic Track Tensioning System Section 9.0 Page 3

9.1

Functional description: Illustration Z 22454:

)

• Under normal operating condition the shut-off cock (54.1) located on the valve block (181) in the car body are closed. The shut-off cock (184) located on the valve block (181) in the car body and (54.2 and 54.3) located inside the side frames are open.

The oil flow of the pilot pressure pumps (7.1 + 7.2), filtered by pressure filter (68.1) enters port "P" of the solenoid valves Y16 via hydraulic line L3 and the rotary joint to the track tensioning valve block (181) in the car body. If solenoid valves Y16 is actuated (i.e. pressure at sensor B48), the oil flows (X2-pressure with 35 bar) via the pressure relive valve (83), rotary joint (34), the shut-off cock (184) and check valves (180.1+180.2) into the tensioning cylinders (62.1 - 62.4). The resulting force moves the guide wheels toward the front, until the correct track tension is obtained. Simultaneously the system is connected to the pressure increasing valve (182). External forces acting at the guide wheels will be absorbed through the pressure accumulators (60.1 + 60.2, first stage) and (59.1 + 59.2, second stage). Purpose of the pressure increasing valve The two system pressures • 35 bar with engine stopped • 315 bar with engine running are controlled by the pressure increasing valve as follows. With stopped engine and switched off ignition there is no pilot pressure (X2) at the pressure increasing valve (182) and only the lowest adjusted pressure of 35 bar remains in the system. As soon as the engine has been started, the pilot pressure (X2) of 35 bar act on the pressure increasing valve. As a result the system pressure can rise to the adjusted pressure of 315 bar.

continued

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Hydraulic Track Tensioning System Section 9.0 Page 4

Cont'd.: 9.1

Functional description: Illustration (Z 22454): Cushioning Function When the tensioning cylinders (62.1 - 62.4) are moved in by external forces, the none return valves (179.1 + 179.2) will be closed. A certain amount from the displaced oil of the tensioning cylinders is taken up by the pressure accumulators. First stage:

at a pressure higher than 31 bar, is taken up by the side frame accumulators (60.1.1 + 60.2).

Second stage: at a pressure higher than 150 bar, is taken up by the center section accumulators (59.1 + 59.2). The system pressure can rise up to 315 bar pressure increasing valve (182) setting. With reduction of external forces, the oil is pushed back by the accumulator pressure into the tensioning cylinders. If the displaced oil volume was higher than the accumulators could take up, oil is added from the pilot pressure circuit (X2), as soon as the pressure in the lines to the tensioning cylinder is lower than 35 bar.

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Hydraulic Track Tensioning System Section 9.0 Page 5

9.2

Pressure Increasing Valve

)

• The pressure increasing valve is a remote controlled pressure relief valve.

Legend for illustration (Z 21846): (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11+12) (13+14)

Pilot valve with valve seat Valve poppet Compression spring Main valve with sleeve Main piston Closing spring Set screw - low pressure 35 bar Set screw - high pressure 310bar Piston Pin Jet bore Lock nut

Function: The valve poppet (2) is connected via the jet bores (11) and (12) with the P port. If static pressure increases above the set pressure value, the valve poppet (2) opens and allows oil to flow freely to tank (T1). This oil generates a pressure drop in the spring chamber of the main spool, the closing force of the spring (6) is cancelled, and the main piston (5) opens to allow the pump flow to flow to tank (T2). Damped opening and closing is obtained by the throttled volumetric change. By applying external pressure of Pst max = 60 bar to the main spool (9) via port X, the pre-tensioning of the pressure spring (3) is increased by the amount of the piston stroke "S" and system pressure is increased correspondingly. The setting is fixed by means of the setting screw (7) and lock nut (13); 1 turn of the screw ~ 150 bar.

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Hydraulic Track Tensioning System Section 9.0 Page 6

9.3

Tensioning cylinder: Legend for illustration (Z 21929): (1)

Cylinder tube

(2)

Piston

(3)

Piston guide ring

(4)

Piston guide strap

(5)

Seal ring

(6)

O-ring

(7)

Scraper

(8)

Retracting device

(M) Bleeder port (P)

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Oil supply

• Maximum permissible piston stroke 350mm! During bench test an external stroke limitation must be used!

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Hydraulic Track Tensioning System Section 9.0 Page 7

9.4

Adjustments / Checks Legend for illustration (Z 22455): (182) (54.3) (54.2) (59.2) (60.2) (MRV)

Pressure increasing valve Service shut-off cock for the R.H.-side Service shut-off cock for the L.H.-side (not illustrated) Bladder accumulator 150 bar Accumulator 31 bar Main relief valve – Operating pressure of main control block I

(M12.4)

Pressure check point – Operating pressure of main control block I

(M15.6)

Bleeder and hydraulic pressure check point at the bladder accumulator (59.2) for the R.H.-side.

(M15.5)

Bleeder and hydraulic pressure check point at the bladder accumulator (59.1) for the L.H.-side (not illustrated).

(M15.3)

Pressure check point - track tensioning system operating pressure – R.H.

(62.3+62.4)

Track tensioning cylinder R.H.

Checking / Setting the pressure increasing valve Pre-conditions: Correct MRV, SRV and pilot pressure setting and the system must be free of air. The description is only for the R.H. track. The same procedure applies also for the L.H. side. Basic Adjustment: 1. Connect a pressure gauge (min.400 bar) to check point M12.4. 2. 3. 4.

Start the engine and let it run with max. speed. Increase the MRV-setting (Block I), ~ 330 to 340 bar. Switch OFF the engine, open cock valve (54.1) to allow pressure relieve of the R.H. track, and close it again. continued

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Hydraulic Track Tensioning System Section 9.0 Page 8

Cont'd.: 9.4

Adjustments / Checks 5. 6. 7. 8. 9. 10.

Move the pressure gauge from M12.4 to M15.3 Connect pressure check point M12.4 with pressure check point M16.1, using a long pressure gauge hose. (required for the oil supply) Disconnect the pilot pressure line at port X of the pressure increasing valve (182) and close the hose (P) ith a plug. Loosen lock nut (4) of the pressure increasing valve and screw in set sleeve (5) until piston (1) comes to stop. (substitution of X2 pressure) Start the engine and let it run with max. speed. Stall the hydraulic with the bucket filling function (bucket cylinders completely extended) and observe pressure at check point M15.3. A pressure of 315 + 5 bar must reached within a time period of 10 – 15 minutes and must remain at this value. The maximum pressure will be shown only after the accumulators are completely filled with oil. When the pressure reaches the pre-charge gas pressure ( 31 bar and 150 bar) the gauge pointer moves slower depending on the gas compression.

If the gauge shows a lower or higher value the pressure increasing valve must be adjusted. Setting procedure, high pressure stage (Valve 58.2) a) Loosen lock nut (2). b) Adjust pressure with set screw (3). c) d)

Secure adjustment by tightening lock nut (2). Re-check pressure setting.

11.

The low pressure setting of the pressure increasing valve must now be reset (with the pilot pressure line at port X still disconnected): Setting procedure, low pressure stage (Valve 58.2) a) Stall the hydraulic with the bucket filling function (bucket cylinders completely extended) and observe pressure at check point M15.3. b) c) d)

loosen lock nut (4) and turn set screw (5) ccw until gauge at check-point M15.8 shows 35 bar. Tighten lock nut (4). Re-check pressure setting. continued

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Hydraulic Track Tensioning System Section 9.0 Page 9

Cont'd.: 9.4

Adjustments / Checks 12. 13.

Switch OFF the engine and open cock (54.1) to allow pressure relieve. Re-connect the pilot pressure line to port X of the pressure increasing valve (182). Remove the pressure gauge hose between pressure check point M12.4 and pressure check point M16.1. Close the cock (54.1). Re-set MRV to 310 + 5 bar after the check / adjustment is finished.

13. 15. 16.

9.5

Functional Test After all adjustments are finished, do the following: a) Bleed all air from the system b) Place shutoff and pressure relief cocks into correct operating position. c) Connect pressure gauge to check point (M15.3). d) Start engine and let it run with max. speed. e) Travel approx. 10 m with the shovel. The pressure should be rise to a higher value. f) Stop the engine. g) The pressure must drop to 35 bar. If the pressure remains at a higher or lower pressure*, re-adjust the low pressure setting at the pressure increasing valve (182) is necessary.

)

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The pressure may drop below 35 bar after a longer time, this is o.k. because of internal leakage.

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Access ladder hydraulically operated

Section 10.0 Page 1

Table of contents section 10.0 Section 10.0

05.10.04

Page Access ladder hydraulic operated 10.0 General

10.1

3+4

Function of hydraulic operated access ladder

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Access ladder hydraulically operated 10.

Section 10.0 Page 2

Access ladder hydraulic operated General

Legend for Illustration Z22494a (A) Access ladder in lowered position (B) Access ladder in upper position (C) Stop bar (R1) Slow ladder movement in both directions (R2) Fast ladder movement in both directions (R3) Slow ladder movement only towards final stop (C). (Z) Hydraulic cylinder (S84) Ladder control switch for lowering (S84a) Ladder control switch for raising. (S84A) Pull switch for emergency lowering of the ladder. (S22) Monitor and control sensor : Cut off of the pilot control system and actuation of the slew brake as soon as the ladder leaves the range R3. (S91) Control sensor. This sensor controls the moving speed in range R1. The access ladder is hydraulic driven by the hydraulic cylinder (Z) via the 60 bar X4 pressure. S84 is the control switch to move the ladder up and down. It is possible to lower the ladder without engine running. For lifting the ladder the engine must run.

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If the ladder is out of range R3 the pilot control will cut off to prevent any machine movement . At the same time the hydraulical swing brake will be applied and the text display in the cab will show a message.

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Access ladder hydraulically operated

10.1

Section 10.0 Page 3

Function of hydraulic operated access ladder illustration (Z 22495):

Legend: (7.1+7.2) (84.1+84.2) (68.1) (70.1) (70.2) (162.3 – 5) (171) (174) (172) Y125 Y123A Y123B X4

Pilot pumps Check valves Filter with filter monitoring switch B22 Pressure relieve valve X4 pressure = 60 bar Pressure relieve valve X2 pressure = 35 bar Check valves Pressure relieve valve (70 bar) Ladder cylinder Orifice Solenoid valve: flow reduction (slow speed) Solenoid valve: ladder up Solenoid valve: ladder down 60 bar auxiliary & control oil pressure

Function: The engine is running In addition to the hydraulic diagram Z 22495 also the electric diagram 897 899 40 on next page. The pumps (7.1) and (7.2) are delivering oil through filter (68.1) to port P of the solenoid valve Y123A/B (3 way- 4 port valve), and to the pressure relief valve (70.1) port A. The pressure relief valve (70.1) maintains the adjusted pressure of 60 bar. With solenoid valve Y123A/B in neutral position ports A, B, P and T are blocked. If one of the solenoid’s is energised the valve directs pump oil to the cylinder. Depending on the activated solenoid the cylinder gets pump oil to the piston or rod side and the ladder move up or down. The pressure relief valve (171) limits the pressure of the ladder cylinder to maximal 70 bar. With activated solenoid valve Y123A/B the return oil from the cylinder must pass solenoid valve Y125. With de-energised solenoid valve Y125 the return oil flow is restricted through orifice (172) resulting in a reduced speed of ladder movement. More over, the combined function of sensors S22 / S91 and solenoid valve Y125 provides smooth and cushioned approach of the ladder to the upper and lower final stops. In the main movement range R2 the ladder speed is faster because the energised solenoid valve Y125 allows unrestricted oil flow back to the tank. continued 05.10.04

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Access ladder hydraulically operated

Section 10.0 Page 4

Cont'd: Y125 is energised when both proximity switches S22 and S91 are not activated (ladder in R2.range) If the ladder is in position B the activated sensor S22 de-energised Y125 and energised Y123A, now unrestricted pump pressure is connected to the cylinder piston side to keep the ladder pressurerized in the upper final stop position B. If switch S84 is in neutral position and the ladder moves out of the R3 range all solenoids (Y125; Y123 A+B) are de-energised and the ladder stops. Engine off and the ladder in position C With activated switch S84 in position 2 (ladder down) solenoid valve Y123B and relay K132 are energised. Y123B connects the cylinder piston side via solenoid valve Y125 to the tank. K132 activate Y125 so that the oil can flow without resistance to the tank. Now, the ladder can move down only by its own weight. The operator have to push the ladder slightly until it starts moving. The rod side of the cylinder receives oil via anti-cavitation valve (162.3). The ladder controlling is independent to the main electric key switch S1 and the battery master switch. The ladder circuit is directly supplied by the battery via circuit breaker F17. There is an additional pull switch S84A below the ladder support. • Make sure that there are no obstacles in the moving range of the ladder. Stop raising the ladder by releasing the control switch (S84) if there are any obstacles in the moving range. • Mount the ladder only in completely lowered position. • Do not lift persons or objects (tools) with the hydraulic access ladder. Serious injury or death can be the result.

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Hydraulic operated refilling arm

Section 11.0 Page 1

Table of contents section 11.0 Section 11.0

26.03.03

Page Hydraulic operated refilling arm 11.0 General

11.1

Function

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Hydraulic Oil Reservoir

Section 11.0 Page 2

11.0 Hydraulic operated refilling arm General Legend for Illustration Z22496 (A) Refilling arm (B) Control switch (pull switch) (B) Hydraulic cylinder (D) Limit switch S23 (7.1+7.2) Pilot Pump (68.1) Pilot filter with filter monitoring switch B22 (70.1) Pressure relieve valve (60 bar) (70.2) Pressure relieve valve (35 bar) (162.1+161.22) Check valves Y124A Solenoid valve: refilling arm up Y124B Solenoid valve: refilling arm down Y125C Solenoid valve: security valve “refilling arm locking” (163) Hydraulic cylinder The excavator is equipped with a central refilling system for easy service and maintenance. One part of this system is the movable refilling arm. This arm is hydraulic driven by the hydraulic cylinder (C) and mounted below the power frame. The refilling arm can moved up or down by pull switch S23. For correct operation of the refilling arm see OPERATION MANUAL:

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If the refilling arm swing out of the upper position the pilot control will stop all working functions and activate the swing brake. The text display show a message.

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Hydraulic Oil Reservoir

10.1

Section 11.0 Page 3

Function of hydraulic operated refilling arm illustration (Z 22496): Legend: (A) (B) (C) (D) (7.1+7.2) (68.1) (70.1) (70.2) (162.1+161.22) Y124A Y124B Y125 (163)

Refilling arm Control switch (pull switch) S87 Hydraulic cylinder Limit switch S23 Pilot Pump Pilot filter with filter monitoring switch B22 Pressure relieve valve (60 bar) Pressure relieve valve (35 bar) Check valves Solenoid valve: refilling arm up Solenoid valve: refilling arm down Solenoid valve: security valve “refilling arm locking” Hydraulic cylinder

The engine is running Additional to the hydraulic diagram from illustration Z22496 use the respective electric diagram. The pumps (7.1) and (7.2) are delivering oil through filter (68.1) to port P of the solenoid valve Y124A/B and the pressure relief valve (70.1) port A. The pressure relief valve (70.1) maintains the adjusted pressure of maximum 60 bar. If the solenoid valves Y124A together with solenoid valve Y124C is energised pressurised oil flows to the arm cylinder piston side and the refilling arm will move up. If the solenoid valves Y124B together with solenoid valve Y124C is energised pressurised oil flows to the arm cylinder rod side and the refilling arm will move down. Solenoid valve Y124C act as a security lock to prevent a uncontrolled down moving of the refilling arm. This valve is a special 100% leek oil free valve. All solenoid valves Y124A/B and C are PLC controlled. Control switch B (S87) is connected to the PLC and act as a remote control. The refilling arm can only moved down or up with activated key contact (key switch S1 in the cabin). Only down moving is possible by gravity with engines stand still.

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Hints for reading the Hydraulic Circuit Diagram

Section 12.0 Page 1

Table of contents section 12.0 Section 12.0

Page Hints for reading the hydraulic circuit diagram General 12.1

22.12.04

Symbols 12.1.1 Lines, unions 12.1.2 Components, valves 12.1.3 Sensors 12.1.4 Valves, valve components 12.1.5 Pumps, motors, cylinders 12.1.6 Assemblies and main components

2 5 5-6 7 8 9-12 13-14 15-16

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Hints for reading the Hydraulic Circuit Diagram

Section 12.0 Page 3

12.0 General: Legend for Illustration Z22987

) Item

• • • • • • • •

•

22.12.04

• • •

The illustrations are used for exemplary explanations only. Use original circuit diagram for detailed reading There are more symbols on the following pages shown as in the diagrams drawn. Some symbols of the diagrams not shown in the following pages. Description

Number / Code

Explanation

Diagram No. and Type of the 897 895 40 a respective machine PC8000-E

Diagram No. only for the respective machine

Respective Serial No.

Sheet-No. / Quantity of sheets 01 / 04

1st of four sheets

Co-ordinates to describe the location of a component

Page 1 on co-ordinate C vertical and 10 horizontal Remote control valve 102.1

Component-No. 127

Line-No. with cross hint,

12041 1 C 10

127 L37/3B9

Main control block I Case drain line (Line No.37) comes from / goes to sheet 2 coordinate E7

All the components drawn in neutral and pressure less position. Full wide continues black line shows a main component or assembly. (Ex.: Valve and Filter panel, Main pump, Hydraulic tank, ...) Continues black line shows a main hydraulic line. This lines are temporary or continues load with high or pilot pressure. Broken line shows a return, drain or control oil line. Black dot shows a connection point. The position of this connection is not definitely fixed. White dot shows a connection or port of a component with a fix definitely position or port number. Page 1 shows the high pressure main hydraulic circuits with all pilot control valves, control blocks, distributor manifold and cylinders or motors. Page 2 shows all main pumps and pilot pressure pumps with the main pump control system, all other auxiliary pilot pressure circuits as lubrication system and ladder and the auxiliary circuits with the fan drive and the oil cooling system with the hydraulic tank and aspiration tank. Page 3 shows the car body hydraulic with travel brakes, travel motors and track tensioning system.

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Hints for reading the Hydraulic Circuit Diagram 12.1

Section 12.0 Page 5

Symbols Illustration Z 22988 12.1.1 Lines, unions Symbol

Description

Used as / at / on

Oil supply line, can be a hose or a pipe.

Return oil line, can be a hose or a pipe.

Suction line or pressurized line of main hydraulic circuit or pilot pressure circuit or auxiliary circuits (e.g. fan drive). Return lines, connected to the return oil filter chamber of the main oil reservoir.

Case drain (leak) oil line, can be a hose or a pipe.

Control oil line, can be a hose or a pipe.

Crossed lines

Pipes or hoses not connected

Connection point, is a connection of hydraulic lines without definite position Component connection point, is a connection with a definite position at a component Plugged connection point, can be plugged with any kind of plugs.

Connection between several lines

Plugged line inside of a manifold, can be plugged with different kind of plugs.

Not used connection points.

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Return lines, connected to the case drain (leak) oil filter chamber of the main oil reservoir. Pilot control line, pump regulation line and parking brake control lines.

Connection to components like, valve blocks, tanks, pumps, ... Not used connection points.

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12.0 6 12.1

Symbols 12.1.1 Line, union Symbol

Description

Used as / at / on

Compensator, Compensate line length differences depend on vibration and temperature. Quick coupling, is a special union with integrated check valve

Oil tank outlet to the pumps

Blind, Orifice, not adjustable with orifice diameter in mm

e.g. Oil cooler inlet,

Pressure check point With a special quick coupling.

HP Filter, Fan valve block....at all important circuits

Distributor block

Connection of lines with the same destination e.g. return lines to tank

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Tank drain couplings, often removed lines (e.g. at grease systems with removable barrels).

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Hints for reading the Hydraulic Circuit Diagram 12.1

Section 12.0 Page 7

Symbols 12.1.2 Components, valves Symbol

Description

Used as / at / on

Accumulator, is filled with nitrogen gas with for the respective accumulator specified pressure Screen filter, the screen size is 1.0 mm

Input line to the remote control valves, return oil collecting tube, track tensioning system

Oil cooler,

Hydraulic oil cooler, PTO oil cooler

Breather filter,

On top of PTO or hydraulic tank

Spray nozzles, inside of a case for cooling and lubricating

Gearbox (PTO) cooling and lubricating system

Installed in suction lines to the pumps, oil tank outlet, return oil collecting tube

continued

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12.0 8 12.1

Symbols 12.1.3 Sensors Symbol

Description

Used as / at / on

Pressure switch / sensor Input = pressure Output = electrical signal analogue or digital

e.g. return / leak oil chamber (digital), high pressure filter (analogue)

Pressure switch Input = pressure Output = digital electrical The switch point is 24 bar

e.g. swing or travel detection PC3000,

Temperature sensor, Input = temperature Output = electric signal proportional to the temperature

e.g. hydraulic tank

Level sensor, Input = fluid level Output = electrical signal analogue or digital

Hydraulic tank, fuel tank

Chip sensor, Input = contaminate oil Output = electrical digital signal

Main pumps

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Section 12.0 Page 9

Hints for reading the Hydraulic Circuit Diagram 12.1

Symbols 12.1.4 Valves, valve components Symbol

Description

Used as / at / on

Manuel operated unit Lever

Valve in track tensioning system,

Electric / magnetic operated unit Solenoid

Solenoid valve

Pilot pressure controlled unit

Pressure relief valve, disc brake, ...

Spring, with fixed force

Solenoid valves,

Spring adjustable spring force is adjustable

Pressure relieve valves,....

Check valve In drawn pos.: from right to left free flow, from left to right blocked flow.

Check valve spring loaded Opened in flow direction only against spring force = pressure Double check valve, in drawn pos.: opened only from the left to the bottom or from the right to bottom

e.g. main pump outlet, swing brake valve block, anti cavitation valves at main control blocks or distribution manifold By pass of the return oil filter, by pass of secondary filter

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Swing brake control,

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12.0 10 12.1

Symbols

Symbol

12.1.4 Valves, valve components Description Used as / at / on Shut-off Valve with Gate valve between main oil monitoring switch, reservoir and suction tank the adjustable switch monitors the valve position

2/2 control valve manual operated, 2/2 cock valve

Track tensioning system

3/2 control valve manual operated, 3/2 cock valve

Change over valve from electronically pump regulation to emergency mode (hydraulically pump regulation)

4/2 directional control valve as solenoid valve 4/2 way solenoid valve, electrically controlled. Neutral position: P-A and B-T connected. Variable throttle valve hydraulically controlled pilot control port pressure less = maximum restriction 3/2 directional control solenoid valve, seat design = leak oil free 3/2 way solenoid valve, neutral = port P-A open 4/3 directional control solenoid valve 4/2 way solenoid valve, in neutral all ports closed External pilot controlled proportional floating valve

e.g. swing parking brake, travel parking brake, ladder controlling,,

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Travel brake valve, located in the car body

Service arm controlling

Ladder controlling, service arm controlling

PC 3000 and PC4000 with floating system

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Hints for reading the Hydraulic Circuit Diagram 12.1

Section 12.0 Page 11

Symbols 12.1.4 Valves and valve components Symbol

Description

Used as / at / on

Main control valve Standard control valve for “standard function” two directions of cylinder or In neutral position: motor. open pump flow (P-PU) and control port flushing (T – a, T – b), in position a or b closed circulation port (P- PU)

Main control valve Control valve for pressure “pressure less lowering” less lowering. Used to assist Neutral position: open pump the floating function of boom flow (P-PU), control port and stick, flushing (T– a, T– b) Position b: closed circulation port (P-PU), normal function P – B and B - T, Position a: open circulation port P – PU, only port B – T connected Main control valve “floating Control valve with floating function” function in position a, Neutral position: open pump e.g. floating valve for boom flow (P-PU), control port or stick, . flushing (T– a, T– b), Position b: closed circulation port (P-PU), normal function P – B and B - T, Position a: open circulation port (P – PU) = A, B, T, P connected together via tank Pressure reducing valve, Emergency mode assembly pressure (X3-pressure), Variable inlet pressure at port pilot oil pressure B and constant lower output pressure at port A, output pressure is adjustable.

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12.0 12 12.1

Symbols 12.1.4 Valves and valve components Symbol

Description

Used as / at / on

Pressure relief valve, direct controlled and adjustable

e.g. ladder controlling, service arm controlling ..

Pressure relief valve with anti cavitation valve (check valve) Assembly, external drain at port Y

Secondary relieve valve at main control blocks

Pressure increasing valve pressure relieve valve with variable setting, pilot pressure controlled via port X. Low pilot pressure = low relieve pressure

Swing brake block, track tensioning system.

Proportional pressure valve, reduce the pressure in port A proportional to the solenoid current. 4 port proportional pressure relief valve, direct operated by a proportional solenoids.

Remote control valves to control the main control blocks,

Pressure relief valve, mechanical and hydraulically via pilot port X adjustable, oil drain port Y

Radiator and oil cooler fan drive

Throttle check valve with secondary relieve valve, throttle and secondary valve mechanical adjustable, external drain at port Y.

Distribution manifold normally in the line to the cylinder piston side.

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Pump regulation, only output port A is used for our systems

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Section 12.0 Page 13

Hints for reading the Hydraulic Circuit Diagram 12.1

Symbols 12.1.5 Pump, motor, cylinder Symbol

Description

Used as / at / on

Single acting Cylinder, pressurised moving only in one direction, return by external force

Track tensioning system

Double acting Cylinder, Cylinder in which the fluid pressure operates alternately in both directions (forward and backward strokes) A = Piston side B = Rod side

Attachment i.e. boom, stick, bucket or clam cylinder

Drive shaft of a motor or pump with one direction

Main pumps, swing motor, fan drive, travel drive

Hydraulic pump with fix volume per revolution suction port S and pressure outlet P

Fan pump, circulation pump, pilot pump, PTO lubrication pump

Hydraulic pump with variable output volume per revolution with external case drain

Main pumps

Hydraulic pump assembly with pump bearing lubrication, one direction and external case drain

Main pumps

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12.0 14 12.1

Symbols 12.1.5 Pump, motor, cylinder Symbol

Description

Used as / at / on

Variable hydraulic pump with charge pump and external drive shaft bearing lubrication

Main pump

Hydraulic motor can be used in both direction, with external case drain L

Fan motor

Motor with disc brake disc brake is spring loaded it means: pressure less pilot line = maximal brake torque

Travel motor

Variable swing motor with integrated control valves and flushing valves

Swing motor PC5500

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Section 12.0 Page 15

Symbols 12.1.6 Assembly and main components Symbol

Description

Used as / at / on

Lubricant pump drive differential cylinder with integrated control valves to propel the grease pump

Lubricant pump station for central lubrication system and swing ring lubrication system

Swing brake valve assembly, act as a hydraulical back pressure system parallel to a motor with variable pressure setting and independent pressure side. Input port A or B and outlet on the opposite connection to the motor..

Swing brake system.

Rotary joint Upper part with connections drawn to the top, lower part with connections drawn to the bottom

Hydraulical connection between superstructure and car body

Travel brake valve block with secondary pressure relieve valve is connected in the line to the travel motors. The return oil flow is restricted according to the pressure inlet.

mounted in the supply line to the travel motors, is located in the car body

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12.0 16 12.1

Symbols 12.1.6 Assembly and main components Symbol

Description

Used as / at / on

Remote control lever to control the main control blocks

Control lever in the operators cabin

Remote control pedal to control the main control blocks

Control lever in the operators cabin

Hydraulic oil tank with leak and return oil filter, back pressure valve and sensors

Main hydraulic tank

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Section 12.0 Page 17

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Hints for reading the Electric Circuit Diagram

Section 13.0 Page 1

Table of contents section 13.0 Section 13.0

Page Hints for reading the electric circuit diagram 13.1

Designation of electrical devices

13.2

Symbols

3+4

13.3

General information

5+6

13.4

Reading a circuit diagram

7+8

Hints for reading the Electric Circuit Diagram

Section 13.0 Page 2

13.1 Designation of electrical devices

Indicating letter A B

C D E F G H K L M N P Q R S T U V W X Y Z

Kind of component System, subassembly, parts group, trigger boxes, control units Transducer for conversion of non-electrical variables to electrical variables, and vice versa. Speed sensors, pressure sensors, pressure switches, oil-pressure switches, temperature sensors Condenser, capacitor, Condensers and capacitors, general Elements with time lag, memory elements, binary elements Various devices and equipment Protection device Fuses, current protection circuits Power supply, generator Batteries, generators, alternators Monitor, alarm, signaling device Indicator lights, signal lights, headlights, warning buzzers, horn Relay, contactors Inductor Coils, windings Motor Regulators, amplifiers Measuring instrument High voltage switching units Resistors, heating devices Switches, selectors Transformer Modulator, converter from one electrical in an other electrical value Semiconductor, electron tubes, diodes, rectifiers, zener diodes Transmission path, conductor, antenna Terminal, Plug, Plug and socket connection Electrically actuated mechanical device Solenoid-operated valves Compensating units, filters, limiters cable connection

13.0 3

Hints for reading the Electric Circuit Diagram

Section 13.0 Page 3

13.2 Symbols Legend for illustration (Z 21816): Our common used symbols in accordance to VDE/IEC (Association of German Electrical Engineers DIN 40710 - 40716 and the International Electrical Commission) differ for the most part from the symbols in accordance to JIC/ASA (Joint Industrial Concil and American Standard Association) USA and Canada JIC EMP-1-1967 and ASA 2 32-3). For this reason the following comparative chart. 1) Normally open contact

2) Maintained contact

4) Normally closed contact

7) Manual operated switch isolator, disconnect switch 10) NO contact with time lag

8) Foot-operated push-button switch 11) Multi-position switch selector

13) Contacts with time lag

14) Resistor general

16) Battery

17) Tapped resistor

18) Voltmeter

19) Inductive resistance

20) Continuously adjustable, general

21) Recording instrument

22) With iron core

23) Adjustable in steps

24) Signal lamps pilot lights

25) Continuously adjustable

26) Potentiometer rhesostat

27) Operating coil solenoid

28) Transformer

29) Capacitor general, continuously adjustable

30) Rectifier, semi conductor

Push-button switch

3) Single pole two way contact break before make 6) Limit switch NO contact NC contact 9) Pressure operated switch 12) Indicating instrument (general) symbol 15) Ammeter

13.0 4

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Section 13.0 Page 4

13.2 Symbols Legend for illustration (Z 21817): 31) Rectifier bridge

32) Thermal over load limit

33) Phase, 4-wire system

34) Current transformer

35) Undervoltage relay

36) Junction of conductors

37) Voltage transformer

38) Temperature relay

39) Junction

40) Circuit interrupter

41) Contactor

42) Terminal

43) Circuit breaker, three phase

44) Generator (G)Motor (M)

45) Terminal

46) Thermal over- ground, load protection

47) 3-phase-motor

48) Earthing, general

49) Magnetic over- socket current protection

50) 3-phase squirrel cage

51) Plug and

52) Slipring motor

53) Fuse with bolted contacts 54) 3-phase squirrel cage induction motor in Star-delta starting 55) Thermal overload relay 55) Two speed motor (tapped windings) (for ex. 8 to 4 poles)

13.0 5

Hints for reading the Electric Circuit Diagram

Section 13.0 Page 5

13.3 General information Legend for illustration (Z 21823): Komatsu circuit diagrams Each sheet has the following information in the bottom right hand corner: Diagram Number example: 897 844 40 Machine Type example: PC4000-6 Sheet Number and Total Number of sheets 01/63 - 02/ . etc. Each sheet is numbered from 8 (at the left corner) to 1 (at the right corner) along the top and bottom lines, and lettered down from F (at the top) to A (at the bottom) along the left and right side lines. This coordinate system enables you to find components easily. On the table of contents, page one, the individual circuits are listed up with the respective page number. Example: The circuit for the superstructure lighting is shown on page 39. Pages number two, three and four are cross reference lists of component codes related to page numbers. Example: The relay with the component code “K1-1” is shown on page 8. On page five is a list of answers to frequently asked questions (FAQ) concerning abbreviations, function of components (e.g. time relays) mathematical symbols etc. used in the diagram. All electrical components are connected via cable harnesses to the main switch board “X2”. There is only one Plug connector in between, which is always located close to the respective component like sensors, solenoids etc. All 24 volt wires are blue and have a printed code (every 10 cm) at each end of the wire. (see illustration) The first part of the code shows the required connection and the second part gives the information what is connected at the other side of the wire. Example: going to coming from coming from going to

X2S 45

= X2-Board, terminal group “S” = Terminal No 45

Y136 = Plug connector to solenoid .1 = Terminal 1 of connector

All circuits are shown currentless and all relays and switches are in neutral position.

13.0 6

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Section 13.0 Page 6

13.3 General information Legend for illustration (Z 21824): Explanation of the Drawing Concept (1) (2) (3) (4) (5) (6) (7) (8)

Drawing number Sheet number / quantity of sheets Designation of drawing Designation of component or assembly Column (vertical sections) Lines (horizontal sections) Component symbol Neutral wire / machine ground

(9) (10) (11) (12) (13) (14) (15) (16)

Designation of phase Phase strip Terminal strip and terminal Cable plug and pin number Relay coil Relay contacts, partially with detailed information Cross reference for the continuation, Page / Column Indication where the relay contact opens or closes

Location of the Main Terminal Boxes (X1) Dashboard inside the cabin (X2) Main switch board inside the cab base (3E14-1) Electronic control module (ECM- Quantum) left bank of the engine (3E54-1) Electronic control module (ECM- Cense) flywheel end of the engine

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Section 13.0 Page 7

13.4 Reading a Circuit Diagram. Legend for illustration (Z 21825): • Examples are shown by sectional drawings out of the electric circuit diagram 897 844 40 page 08.

) (1)

Section F8 / sheet 08 The hint F11/06.1 indicates that the wire from F11 is continued on sheet 06 column 1.

(2)

Section C4 / sheet 08 Shown is the relay coil K51-1 only and not its contacts. The contacts are shown somewhere else in the diagram. Switching and contact positions are shown below at the foot of that particular circuit in row C-C as shown below.

Example for K51-1: 08.5 : : :

1 5 2 6 3 7 4 8

9 10 11 12

opens on sheet 8 section 5 when relay is energized Not used Not used Not used

When diodes are fitted to a relay, they are fitted to allow a current flow in one direction only. An LED* (Light Emitting Diode) indicates a current flow if it lights up. When diodes ** are fitted anti-parallel to a relay coil, they absorb the high induced voltage caused by making and breaking the current flow through the coil. This occurs each time we operate a switch supplying current to the coil. The diode effect allows the induced current to circulate within the coil windings and decay when the energy to the coil is cut. * **

LED between A1 and coil Diode between A1 and A2.

(3)

Section F7 / sheet 08 Connectors and Terminals are identified by a letter and number code. X2 o 23-28 = Terminal box X2 Terminals 23 to 28 are linked with a metal bridge. continued

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Hints for reading the Electric Circuit Diagram

Section 13.0 Page 8

Cont.: 13.4 Reading a Circuit Diagram. Legend for illustration (Z 21826): (4)

Section E 1 sheet 08 The components have a letter and a number prefix, and these are explained below in rows A and B. Components are depicted in a system unique to VDE/IEC (Association of German Electrical Engineers DIN 40710-40716 and the International Electrical Commission) or to KMG standard. S27 = Toggle switch (with non-automatic return)

F11

F11 / 10.5 =

Power line F11, comes from circuit breaker F11, sheet 08 section 8 and continues on sheet 10 section 5.

S27 / 20.7 =

Line S27, comes from switch S27, sheet 08 section 1 and continues on sheet 20 section 7.

Circuit breaker (24V power supply)

Function: If switch S27 is actuated, terminal A and B are connected and 24VDC will energize the coils of K121 and K121a on page 08 and simultaneously via line S27 a digital input to the PLC on sheet 20 section 7. Now the machine can be operated in emergency mode and a warning text appears on the display.

Electronic Control System ECS

Section 14.0 Page 1

Table of contents section 14.0 Section 14.0

Page Electronic Control System ECS 14.1

14.2

14.3

14.4

14.5

14.6

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General Design of the ECS-T System

14.1.1 14.1.2 14.1.3 14.1.4

3 3 4 5 + 6 +7

Input and outputs of the PLC Task PLC DIGSY plus ® Definitions; Symbols and Abbreviations

How to Proceed due Maintenance and Installation

8+9

14.2.1 14.2.2 14.2.3

10 + 11 12 13

Meaning of the Status LED’s Short Circuit Marker -LED “MK” Diagnostic for Temperature-Module “ANM”

Front Connector Arrangement

14.3.1 14.3.2 14.3.3 14.3.4

14 + 15 16 + 17 18 19

Front Connector Arrangement BIM-Module Front Connector Arrangement, ANM-Module Ground connection of the Control Unit Interface-Connection COM SP /SK

Power supply

14.4.1 14.4.2 14.4.3 14.4.4 14.4.5

20 21 22 22 22

Operation Voltages +24 V Safety Precautions for Faultfinding CPU Voltage Range Electric Classification Fuse

Function explanations with electrical diagram

14.5.1 14.5.2 14.5.3 14.5.4

23 24 25 + 26 27

General Pressure Measuring Temperature Measuring Temperature – Resistance Chart PT100

Hints for reading the functional flow charts

14.6.1 14.6.2

28 29

General Example

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14.1 General Design of the ECS System ECS

Electronic Control System

Legend: (1) (2) (3) (4) (5) (6) (7) (8) I/ O

)

•

Illust. Z 21407a

PLC Programmable Logic Control (DIGSY plus ®) Text display Keys for function control and pre-adjustments Outlet “X27” for data transfer Field computer system (like MODULAR MINING) Printer Memory card unit Laptop Input / Output data transfer Items 5 to 8 are optional equipment

Meaning of the PLC front cover codes • BIM Binary Module • ANM Analogous Module • MK Short Circuit Memory • A Digital Output • E Digital Input • DIAG Diagnostic More in detail see page 4

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Section 14.0 Page 3

Input and Output of the PLC, Illust. Z 21408

PLC = Programmable Logic Control (Programmable Logic Control = Control system with a write-readingmemory, whose content can be altered (via an serial interface) by a PC and the resp. Software. No mechanical action necessary.) 14.1.2

Task The PLC receives from the monitored excavator components the actual values and does an evaluation. The evaluation results in a control and display function. See I / O connection table (chapter 10) and electric circuit diagram for I / O levels and ports.

)

•

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The picture shows as an example the application for a two motor version.

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Section 14.0 Page 4

PLC DIGSY plus ® (circuit diagram code E6) Legend for illustration Z 21409b 1. 2. 3. 4. 5. 6.

Central Processing Unit (CPU) board. Binary Module (BIM) board. Analogues Module (ANM) board. MK Output short circuit marker LED red Input state-LED green, Inputs E1.1 - E1.8 up to E14.1-E14.8 Input or Output State-LED red (A2/ E9, Af/E10, A6/E11, A8/E12, A14/E21) Can be used as Inputs or Outputs 7. Output state-LED red, Output A1.1 - A1.8 up to A13.1-E13.8 8. Diagnostic-LED (DIAG), (green flashing = OK.) 5Volt Voltage-LED (+5V), (green = OK.) 9. Diagnostic LED for ANM 10. COM SP Interface (COM SP) (Text display connection) 11. COM SK Interface (COM SK) (PC-Connection) 12. Binary Module BIM-plug-in location (slots) (X1-X5) 13. Analogous Module ANM-plug-in location (slots) (X6-X8) 14. Ground Connection (GND)

)

• The quantity and configuration of the BIM and ANM Module can be vary, depend on the excavator typ and additional options.

MK-LED, The short circuit marker are used to indicate an external short to GND • MK1, MK3, MK5, MK7 & MK9- LED for outputs A1.1 - A1.8 A3.1 - A3.8, A5.1 - A5.8, A7.1 - A7.8 & A13.1 – A13.8 • MK2, MK4 , MK6, MK8 and MK10 if there groups as outputs used • A MK-marker is placed, if an output (e.g. A1.1) gets from the program an output signal and at the same output happens an external short. The red MK 1-LED lights ON

)

• If there is a short all outputs of the resp. Output group i.e.. A1.1 - A1.8) are switched Off • The short circuit marker remains until the control system gets switched Off/ON (after eliminating the short).

State-LED Input lights up with a present 24 Volt signal. State-LED Output lights up with a switched On output. 5V-LED, indicate specified operation states by different colors and duration of lightning (Continuos On or flashing). For detail information see Section 4. DIAG-LED, indicate specified operation states by different colors and duration of lightning (Continuos On or flashing). For detail information see Section 4.

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Electronic Control System ECS 14.1.4

Section 14.0 Page 5

Definitions; Symbols and Abbreviations

≡ ≠ Bit

Sign used for “corresponds to” Sign used for “not equal to” A bit is the smallest unit for information. It can assume only two conditions: logical 0 or logical 1 ( also referred to as logical L-Level and logical H-Level).

Boolean algebra Mathematical rules for binary variables and conditions. For Boolean equations the following signs are used: Logical AND operation (AND or &) ∧ Logical OR operation (OR or >=1) ∨ Logical Negation (NOT or 0) ¬ Byte

Unit for Information unit comprised of 8 bits. A byte can assume a value between 0 and 255.

Word

Memory unit comprised of 2 byte or 16 bit. A word covers the numeric range from –32767 to +32767.

Clock

Signal pulse

VWP

VerWaltungProgramm: (management program) A control program created by the user.

AWP

AnWender Program: (Application program, user program) A control program created by the user.

AWL

AnWeisungsListe: (instruction sequence) Representation of a program using alphanumeric signs and symbols as defined in DIN 19239. Programming in AWL (selection logic) is the at present widely applied method of programming.

CMOS

Complementary Metal-Oxide Semiconductor: Complementary metaloxide semiconductor technology with very low-level closed circuit current. These semiconductors are used above all for accumulator and battery buffering.

RAM

Random Access Memory: Read-write memory in which each memory cell can be addressed in order to read, write or delete at any time. RAM losses all of its information when the computer is turned off which is why it is often buffered by accumulators or batteries.

EPROM

Erasable Programmable Read Only Memory: Read-only memory erasable by ultraviolet light and electrically programmable. With this memory type, the contents remain intact in the event of a power failure. In the case of DIGSY plus ® this memory contains the management program (firmware). continued

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Section 14.0 Page 6

Definitions; Symbols and Abbreviations

Cont'd: EEPROM

Electrically Erasable Programmable Read-Only Memory (also called E2PROM):Electrically erasable and programmable memory. In the event of a power failure, the contents of this type of memory remain intact. The DIGSY plus ® application program (AWP) is loaded into this type of memory.

COMPILER A program that translates the instructions of a programming language (e.g. instruction sequence [AWL]) into machine code (processor instructions). EDITOR

Utility program for the creation and changing of programs.

Loop

Program loop.

Off-Line

Operational method of a programming device without attached automation device.

On-Line

Operational method of a programming device (PC) is connected to the automation device thereby enabling data and programs to be read or changed.

Personal Computer: Programmable unit for the DIGSY plus ®.

Watch-Dog: Internal supervisory unit in computers and automation devices used to recognize system and memory errors. CPU

Central Processing Unit: Control and central unit in an automation device usually based on a microprocessor. It can read the application program code and run the instructions contained therein.

Cycle Time

Time required for the application program to run through once. continued

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Section 14.0 Page 7

Definitions; Symbols and Abbreviations

Cont'd:

Coding Types and Number Systems ASCII

American Standard Code for Information Interchange: A standardized information processing code developed in the USA based on 7 bits = 0 – 127 (7-bit code), (extended ASCII-code of 8-bit = 0 - 255)

Digital

(Eng. Digit) is the representation of a continuos value or a physical quantity (e.g. voltage) in several levels as a numeric value. With regard to automation devices one also refers to “word processing” in which case a “word” is a number (e.g. 573).

Analogue

is the representation of a continuos physical quantity (e.g. current or voltage) which corresponds to the value of a proportional condition (e.g. rotational speed, routing, temperature, etc.) For an automation device this physical value converted into 1024 levels, for example (10-bit analogues-digital conversion). The digitalized value thus acts within a defined range (e.g. 0 ≡ 0 volts to 1024 ≡ 10 volts) in proportion to a certain input quantity (e.g. voltage). Conversely, by using a digital-analog conversion, a digitalized value can be converted into a continuous output signal (current, voltage).

Numeral

A value expressed in one digit: from 0 to 9 in the decimal system and 0-F in the hexadecimal system.

Number

Value consisting of one or more numeric characters.

Baud

Unit used in serial transmission of data: bits per second (bit/s).

Baud Rate

Modulation rate or transmission speed of serial transmission of binary numbers. The DIGSY plus uses a baud rate of 2400 baud for communication and down-loading.

Binary

Numbers, data and information which are exclusively expressed using the two values 0 and 1 are bivalent = binary dates and information, exclusive with the use of digits 0 and 1 (e.g. 1 = current 0 = no current).

Dual(Binary) Number (Dual = 2) is the simplest binary numeric expression. Each position is arranged according to increasing powers of 2. Example: 13463dec. = 0011 0100 1001 0111dual

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Electronic Control System ECS 14.2

Section 14.0 Page 8

How to Proceed due Maintenance and Installation

Keep in mind • - BE CAREFUL • - BE ALERT • - THINK ABOUT WHAT YOU ARE DOING Any PERSON doing any work in or around the machine must be familiar with the local SAFETY INSTRUCTIONS and with the specific SAFETY INSTRUCTIONS REGARDING TO HIS OCCUPATION. • Serious damage may happen at unqualified actions at the System or Unit or when not paying attention to the hints given in this manual or on labels at the units Qualified persons in sense of the safety relevant hints in this manual or on the product, are persons which are • either as project engaged person familiar with the safety concept for automatic control systems; • or as operating personal for the use of an automatic control system being instructed; • or having the authorization and occupation to put such systems into operation or doing repair work as well as having the authorization and occupation to put such systems/units into operation regarding the power circuits and there safety standards and, to earth and to mark it. continued

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Section 14.0 Page 9

How to Proceed due Maintenance and Installation

Cont’d.: • Serious damage may happen at irrelevant opening and improper repair. Open always the resp. circuit breaker before opening a unit. I/O – cables may only be connect or disconnect in a powerless state. A BIM module will be damaged while supplying an external power of 24VDC to the inputs and/ or outputs. If it is necessary for faultfinding or external unit checks the connection to the PLC has to be interrupted. • Without power interruption the interface cable are only allowed to be disconnect or connect when following preconditions are given: 1. The cable must be shielded and the shield must be connected to the cover of the plug-in connector. 2. A potential balance must be made by connecting the GND potential parts of the plug connector parts before connecting the cables. • Replace the fuses only by fuses which matches the values given in the technical dates

• Do not through batteries into open flame and do not solder at their cell body, explosion can occur (max. Temperature 100° C). Do not open and do not recharge batteries that contain lithium or mercury. Replace them by same type only! • Dispose batteries and accumulators as special waste.

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Section 14.0 Page 10

Meaning of the Status LED’s, Illust. Z 21431b The DIGSY plus performs by the function of the Status LED’s (5V and DIAG) and the so named Diagnostic Words* (DW1 up to DW256) many data and statuses. With a PC and the Program- and Diagnostic Software the. Diagnostic Words are visible on a monitor. The following sections explain the diagnostic possibilities more in detail. * Can be called-up by PC assistance only. Table: Statuses of the +5 V-LED and their meaning LED Effect Cause 5 V-LED Voltage green o.k. 5 V-LED CPU not working Supply red (RESET) < 4,65V DIAG-LED red 5 V-LED CPU not working Supply OFF (except the is missing LED is defect) Fuse S1 defect

Remedy

Check the +24 V Supply if not o.k. *) Check the +24 Volt Replace the ** Fuse F1

LED defect (if DIAG LED is ON)

others

Watchdog in operation

5 V-LED flashing red/green

cyclically new starts

red/ orange Continuos Reset Component fault *) ** Replacement only after co-ordination with Komatsu Mining Germany, Dept. 8124.1 *) = Return PLC to manufacturer continued

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14.2.1 Meaning of the Status LED’s, Illust. Z 21431b Cont’d.: Table: State of the DIAG-LED and their meaning LED Effect Cause DIAG-LED Program Communication via green in operation Interface COM-SP not active (interrupted) COM-SP<╪> Text display DIAG-LED ProgramTemperature orange state inside housing unchanged too high +24 VCPU < 14 V

Increase the voltage

Accumulator voltage too low

Replace the accumulator module

Fixed operands deleted

Check the accumulator connections

SPS in start loop after voltage ON

wait

programming in operation EEPROM not Initialized

Stop the programming *1) Initialize EEPROM *1)

EEPROM- or RAM- fault

Initialize EEPROM *1) if the fault is still present *2) Start program *1)

DIAG-LED RED

DIAG-LED OFF

Program not running (stopped)

Program not running (except LED defect)

Program stopped

No Program otherwise LED defect DIAG ProgramCommunication via flashing state Interface COM-SP or COM-SK active unchanged Color State COM-SP⇔ Text depending Display COM-SK⇔ (PC) *1) Function of the Programming Software PROSYD *2) = Return PLC to manufacturer

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Remedy Check the cable connection and the Interface port

External cooling

Load program *1) *2)

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Section 14.0 Page 12

Short Circuit Marker -LED “MK” The short circuit markers are used to indicate a short of the outputs at an external short to GND. A “MK” marker will be initialized if by the user-program an output signal is given and at the same output is an external short present. The “MK” marker remains until (after short elimination) the control system is switched OFF and ON. See also Section 14.1.3 page 4

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Section 14.0 Page 13

Diagnostic for Temperature-Module “ANM” For the function control a two-color LED is used, visible at the front cover. The diagnostic - LED indicates following states: - LED red: System in reset mode or range overflow of one or more analogous outputs. - LED green:

Ordinary operation, no range overflow.

- LED red/green flashing (2Hz) Watch-dog timer response or cyclically overflow of one ore more analogous outputs.

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14.3 Front Connector Arrangement 14.3.1

Front Connector Arrangement, BIM Module (Digital Input / Output)

)

• .This is an example for the first Slot. Additional BIM Modules can be vary depend on configuration of the variable input/output port A2/E9/ A4E10, A6/E11, A8/E12 or A14/E21. • The configuration for the respective excavator is written in the EA-Configuration chart (EA-Belegungsliste) see Apendix.

Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Symbol Input 1.1 Input 1.2 Input 1.3 Input 1.4 Input 1.5 Input 1.6 Input 1.7 Input 1.8 Input 9.1 Input 9.2 Input 9.3 Input 9.4 Input 9.5 Input 9.6 Input 9.7 Input 9.8 0 V (GND) Input 2.2 Input 2.4 Input 2.6 Input 2.8

Operand E 1.1 E 1.2 E 1.3 E 1.4 E 1.5 E 1.6 E 1.7 E 1.8 E 9.1 E 9.2 E 9.3 E 9.4 E 9.5 E 9.6 E 9.7 E 9.8 E2.2 E2.4 E2.6 E2.8

Definition Input 1 of the input group. 1 Input 2 of the input group. 1 Input 3 of the input group 1 Input 4 of the input group 1 Input 5 of the input group 1 Input 6 of the input group 1 Input 7 of the input group 1 Input 8 of the input group 1 Input 1 of the output group 2 Input 2 of the output group 2 Input 3 of the output group 2 Input 4 of the output group 2 Input 5 of the output group 2 Input 6 of the output group 2 Input 7 of the output group 2 Input 8 of the output group 2 Ground Input 2 of the input group 2 Input 4 of the input group 2 Input 6 of the input group 2 Input 8 of the input group 2

continued

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14.3 Front Connector Arrangement 14.3.1

Front Connector Arrangement, BIM Module (Digital Input / Output)

Cont’d.: Pin 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

Symbol Output 1.1 Output 1.2 Output 1.3 Output 1.4 Output 1.5 Output 1.6 Output 1.7 Output 1.8 UE/A UE/A UE/A UCPU Input 2.1 Input 2.3 Input 2.5 Input 2.7 Output 1.1 Output 1.2 Output 1.3 Output1.4 Output1.5 Output 1.6 Output 1.7 Output 1.8 UE/A UE/A UE/A UCPU 0 V (GND)

Operand A 1.1 A 1.2 A 1.3 A 1.4 A 1.5 A 1.6 A 1.7 A1.8

E 2.1 E 2.3 E 2.5 E 2.7 A 1.1 A 1.2 A 1.3 A 1.4 A 1.5 A 1.6 A 1.7 A1.8

Definition Output 1 of the output group 1 Output 2 of the output group 1 Output 3 of the output group 1 Output 4 of the output group 1 Output 5 of the output group 1 Output 6 of the output group 1 Output 7 of the output group 1 Output 8 of the output group 1 Under Load Voltage Under Load Voltage Under Load Voltage DIGSY (plus)- Operation Voltage Input 1 of the input group 2 Input 3 of the input group 2 Input 5 of the input group 2 Input 7 of the input group 2 Output 1 of the output group 1 Output 2 of the output group 1 Output 3 of the output group 1 Output 4 of the output group 1 Output 5 of the output group 1 Output 6 of the output group 1 Output 7 of the output group 1 Output 8 of the output group 1 Under Load Voltage Under Load Voltage Under Load Voltage DIGSY (plus)- Operation Voltage. Ground / GND

UE/A = Voltage. Input / Output

There are two pins (two channels) parallel connected only for output A1.1 – A1.8 (the same for additional boards A3, A5, A7, A13). • • •

E1, E2,...E7, E13 and E14 input port fix configured. A2/E9, A4/E10, A6/E11, A8/E12 and A14/E21 variable input or output ports depend on software programming. A1/A9, A3/A10, A5/A11, A7/A12 and A13/A21 output ports fix configured.

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14.3 Front Connector Arrangement 14.3.2

Front Connector Arrangement, ANM-Module (Analogues Input)

)

• .This is an example for the first ANM slot. Additional ANM modules configuration can be vary depend on configuration (temperature or pressure). • The configuration for the respective excavator is written in the EAConfiguration chart (EA-Belegungsliste) see Appendix and the respective electric diagram.

PIN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

PIN-NAME KR KG KA GND/ANA GND/ANA GND/ANA GND/ANA A1I A1U A2I A2U A3I A3U A4I A4U A4G A3G A2G GND/ANA GND/ANA GND/ANA E8G E7G E6G E5G

OPERAND

•

All pins are internal connected

AW Z.1 AW Z.1 AW Z.2 AW Z.2 AW Z.3 AW Z.3 AW Z.4 AW Z.4

COMMENTARY Relay contact Relay contact Relay contact Analogous GND Analogous GND Analogous GND Analogous GND Current output 1 Tension output 1 Current output 2 Tension output 2 Current output 3 Tension output 3 Current output 4 Tension output 4 GND – Output 4 GND – Output 3 GND – Output 2 Analogues - GND Analogues - GND Analogues - GND GND – input 8 GND – input 7 GND – input 6 GND – input 5 continued

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14.3 Front Connector Arrangement 14.3.2

Front Connector Arrangement, ANM-Module (Analogues Input)

Cont’d.: PIN 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

PIN-NAME A1G 4U+E4G A2G E3G A3G E2G A4G E1G GND/ANA E8 GND/ANA E7 GND/ANA E6 GND/ANA E5 A1G E4 E4 E3 E3 E2 E2 E1 E1

OPERAND

EW Z+1.4 EW Z +1.3 EW Z +1.3 EW Z +1.3 EW Z.4 EW Z.4 EW Z.3 EW Z.3 EW Z.2 EW Z.2 EW Z.1 EW Z.1

COMMENTARY GND - Output 1 GND - Input 4 GND - Output 2 GND - Input 3 GND - Output 3 GND - Input 2 GND - Output 4 GND - Input 1 Analogues – GND Input (U/I) 8 Analogues – GND Input (U/I) 7 Analogues – GND Input (U/I) 6 Analogues – GND Input (U/I) 5 GND – Output 1 Input (U/I) 4 Input (U/I) 4 Input (U/I) 3 Input (U/I) 3 Input (U/I) 2 Input (U/I) 2 Input (U/I) 1 Input (U/I) 1

• All pins are internal connected

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14.3 Front Connector Arrangement 14.3.3

Ground connection of the Control Unit Attention: The complete shield of the analogous cable must be connected to the ground (GND) bolt of the PLC housing. This bolt must be connected to the X2 frame / machine ground by a cable (as short as possible) with 2,5 mm2 cross section. When using plug connectors with metal boxes and connected shield the additional complete shielding of the analogous cable with the ground bolt is not necessary. But attention must be played that the metal box is connected by screws with the PLC housing. The twisted signal lines are pair wise shielded and already via the 50-pol female part of the connector connected to ground. The single shielding at the free end of the cable must not be connected with earth.

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14.3 Front Connector Arrangement 14.3.4

Interface-connection COM SK / SP

Legend for illustration Z 21425a (Exemplary picture about what possible) (1) Text display (2) PLC (3) Plug socket “X27” (4) Laptop computer (5) Memory card system (6) Portable printer (7) Field dispatch system Cables: VL3 X27 to Laptop VL4 X27 to Memory Card System VL5 24V Power supply to Memory Card System VL6 X27 to Portable Printer VL7 24V Power supply to Portable Printer VL8 X27 to Field Computer System Communication interface: COM-SK => Programming interface (Baud rate 19200) COM-SP => Communication with text display (Baud rate 9600)

)

• Data cables and/or communication systems are optional equipment. • For more detailed information see OPERATION MANUAL of the shovel and the Software Program for the individual Communication System

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14.4 Power supply 14.4.1 Operation Voltages +24 V, Illust. Z 21426 Study together with the relevant circuit diagram 50-pin SUB Connector: + 24 V CPU-Supply: GND: + 24 V I/O-Supply:

Pin 33 and 49 Pin 17 and 50 Pin 30 - 32, 46 – 48

This supply voltage is the operating voltage for the module outputs. It must be strong enough to carry the load current of all outputs. It is provided with a LOAD-DUMP protection to protect (for short times) wrong polarity and over voltage peaks. • Wrong polarity causes destroying of the module! • External 24 V supply to the outputs causes destroying of the module!

See next page for more information

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14.4 Power supply 14.4.2

Safety Precautions for Faultfinding, Illust. Z21427

• As already mentioned no external 24 V supply is allowed to the outputs of the BIM modules of the PLC. • If it is necessary while tracing faults, the cable to the PLC must be disconnected subsequent to a component check, thus as relays, solenoids or others by the PLC controlled components. Procedure: Study together with the relevant circuit diagram 1. Find the terminal between the component and the PLC. 2. Example terminal 8X2-280 for the solenoid valve 8Y6.1. 3. Disconnect the wire on one side of the terminal. 4. 5.

Now supply 24 V to the solenoid and check function of it. Finally re-connect the wire to the terminal

Binary Outputs A 2A-Short circuit proof Each single Output of the Output group can withstand a load of 2A, but the total load must not exceed 10 A. The Output group will be switched OFF if one of the Output becomes overloaded (> 2 A), the short circuit marker will be set and the “MK”- LED comes ON. (A1ñ MK1, A3ñ MK3, A5ñ MK5)

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Electronic Control System ECS

Section 14.0 Page 22

14.4 Power supply 14.4.3 CPU Voltage Range • Electrical requirements +24 supply volt • 14 V up to 36 V without any restrictions regarding the max. current consumption of 4 amps out of the +5 V logic voltage. • At voltage drops below 18 V the 2amps-outputs switched OFF due to safety reasons. The short circuit markers initiated. • The +24 V CPU is monitored on the CPU plus DB16.1 After the diagnostic bit “Under-voltage UCPU “ DB16.1 has been set, all access to the EEPROM memory of the CPU plus is blocked • A drop below 9V results in a reset. • During and after voltage drops according to DIN 40839 part 2 operates the CPU plus normally.

14.4.4 Electric classification The voltage supply meets the requirements according to: • ISO 7637-2 Automotive Technique 24V • DIN 0871-B • IEC 801-4 step 4, VDE 0843-4. • DIN/VDE 0470 part1 (old DIN 40050)

14.4.5 Fuse TR5 / 2.5AT IEC 127-3 Manufacturer Wickmann,

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Electronic Control System ECS

Section 14.0 Page 23

14.5 Function explanations with electrical diagram 14.5.1

General

Signal Status Voltage level: „1“ = 24 V* between E (Input) and GND „0“ =

0 V** between E (Input) and GND

* 13 V up to actual supply voltage ** 0V up to 5 V

The left half of the picture shows so named PULL-DOWN resistors and the right half PULL-UP resistors. The resistors are installed to get a low ohmical input. A system with contacts only leads to a (high ohmical) input if dust or moisture bridges the contacts. PULL-DOWN resistors are installed with a normal NC contact (means with a de-energized relay or normal closed switch contact) thus the ECS recognize a fault after switching ON the system. PULL-UP resistors are installed with a normal NO contact (means with a deenergized relay or normal open switch contact) thus the ECS recognize a fault after switching ON the system.

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Electronic Control System ECS

Section 14.0 Page 24

14.5 Function explanations with electrical diagram 14.5.2

Pressure Measuring (Hydraulic System), Illustration Z 22805 (study with the respective circuit diagram) (Program run see Flowchart)

Analogous Inputs: „EW 14.1“ for pressure sensor B87A (0 up to 500 bar) Measuring channel: 0......10 V Function: - Voltage supply for the pressure sensor: 24 V - Output voltages Ua (OUT+, pin 2) of the pressure sensors: Sensor 0 – 0,4 bar ñ K= 25 V / bar Sensor 0 – 60 bar ñ K= 0,1667 V / bar Sensor 0 – 500 bar ñ K= 0,02 V / bar (Pressure sensors with +1 V Offset) Possible voltage checks: 24 V Supply between supply line 15 (start at circuit breaker) and GND. Output voltage OUT (pin 2) of the sensor between GND. Use respective circuit diagram for terminal numbers. * How to calculate the Output voltage Ua: Ua = output voltage proportional to the pressure input. P = input pressure K = calculation factor for the respective pressure sensor. Ua = (P x K) + 1 V Example for 200 bar and a 0 – 500 bar sensor: Ua = (200 x 0,02) + 1 V = 5 V

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Electronic Control System ECS

Section 14.0 Page 25

14.5.3 Temperature Measuring and trouble shooting Illustration Z22803a General: (study with the respective circuit diagram) The signal of the PT100 temperature probe can’t connect direct to the ANM – Module (Analog input of the PLC). A temperature transducer module change the PT100 signal (Ohm) into a suitable current (mA) signal for the ANM – Module. The temperature probe is connected with a four wire technique to compensate the line resistance of the long wire between the X2 switch board and the temperature probe. Analogous Inputs (eg.: Hydraulic oil temperature sensor B15) The temperature probe B15 is with 4-wire technology (distorting compensation) connected to the transducer U15 terminal 1, 4, 2, and 3 (measuring range: -50° C......+150° C). The output terminal 5 and 6 of the transducer is connected to the ECS analogues input „EW 2.1“ (input range 4 – 20 mA). The transducer need 24 V power supply via terminal 7 and 8 (+24V, ground). Function: The temperature transducer convert the measured values from the PT100 temperature probe into electrically standardized analog signals. With the four wire technique the length and the cross section of the wires are not important; because the electrical resistance of the two current lines gets compensated. The sensor is supplied with a low electrical current from the temperature transducer (I+ and I-). Additional to the temperature probe (PT100) resistance the line resistance influence the current “flow” what falsified the PT100 measurement. To compensate the line resistance there are two additional lines (U+ and U-) close to the PT100 connected. Via this lines the transducer measure exact a tension drop between in- and output of the PT100 probe witch is only created by the PT100 resistance. Because there is no current “flow” through this lines witch are influenced by the line resistance (compared to hydraulic system- it’s like a test hose with a pressure gauge). The module convert this tension drop into a current signal (4-20mA) which is proportional to the temperature. In the interest of proper function must the line resistance not exceed 50 Ω. Additional the lines must be shielded according to the standards. The picture shows the wiring of a PT100 probe to a temperature transducer in four wire technique. continued

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Electronic Control System ECS 14.5.3

Section 14.0 Page 26

Temperature Measuring and trouble shooting, illustration Z22803a Cont’d.: Possible measurements PT100: Disconnect the wires at the resistor and measure the resistance across the resistor. Compare the measured resistance with the values given in the table on next page. If the value correspond to the temperature measured with an other temperature gauge the PT100 resistor is OK.; otherwise replace resistor. Wiring: Disconnect the wires at the resistor and inside X2-box at the temperature transducer terminal 1, 2, 3, and 4. Measure the line resistance to the ground. All single wire resistance must be the same. Transducer: Connect a Ampere-meter in line between terminal 5 of the transducer and the disconnected wire to the ECS. Select mA range and check the current. The value must compare to the PT100 resistance with the following calculation: I = [( 50 + t ) x 0,08 ] + 4 t = temperature [°C] (Check temperature via PT100 resistance and temperature chart next page) I = current [mA] to the ECS

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Electronic Control System

Section 14.0 Page 27

ECS 14.5 Function explanations with electrical diagram 14.5.4

Temperature – Resistance Chart PT100 Basic Values in Ohm according to DIN 43 76 For Measuring Resistor PT100

°C

-0

-1

-2

-3

-4

-5

-6

-7

-8

-9

-50

80,31

79,91

79,51

79,11

78,72

78,32

77,92

77,52

77,13

76,73

-40

84,27

83,88

83,48

83,08

82,69

82,29

81,89

81,50

81,10

80,70

-30

88,22

87,83

87,43

87,04

86,64

86,25

85,85

85,46

85,06

84,67

-20

92,16

91,77

91,37

90,98

90,59

90,19

89,80

89,40

89,01

88,62

-10

96,09

95,69

95,30

94,91

94,52

94,12

93,73

93,34

92,95

92,55

100,00

99,61

99,22

98,83

98,44

98,04

97,65

97,26

96,87

96,48

°C

100,00

100,39

100,78

101,17

101,56

101,95

102,34

102,73

103,12

103,51

103,90

104,29

104,68

105,07

105,46

105,85

106,24

106,63

107,02

107,40

107,79

108,18

108,57

108,96

109,35

109,73

110,12

110,51

110,90

111,28

111,67

112,06

112,45

112,83

113,22

113,61

113,99

114,38

114,77

115,15

115,54

115,93

116,31

116,70

117,08

117,47

117,85

118,24

118,62

119,01

119,40

119,78

120,16

120,55

120,93

121,32

121,70

122,09

122,47

122,86

123,24

123,62 124,01, 124,39

124,77

125,16

125,54

125,92

126,31

126,69

127,07

127,45

127,84

128,22

128,60

128,98

129,37

129,75

130,13

130,51

130,89

131,27

131,66

132,04

132,42

132,80

133,18

133,56

133,94

134,32

134,70

135,08

135,46

135,84

136,22

136,60

136,98

137,36

137,47

138,12

100

138,50

138,88

139,26

139,64

140,02

140,39

140,77

141,15

141,53

141,91

110

142,29

142,66

143,04

143,42

143,80

144,17

144,55

144,93

145,31

145,68

120

146,06

146,44

146,81

147,19

147,57

147,94

148,32

148,70

149,07

149,45

130

149,82

150,20

150,57

150,95

151,33

151,70

152,08

152,45

152,83

153,20

140

153,58

153,95

154,32

154,70

155,07

155,45

155,82

156,19

156,57

156,94

150

157,31

157,69

158,06

158,43

158,81

159,18

159,55

159,93

160,30

16067

Example:

84 ° C

þ 80° + 4° = 132,42 Ω

124,4 Ω

þ 124,4 ≈ 124,39 = 60° + 3° = 63 °C

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Electronic Control System ECS

Section 14.0 Page 28

14.6 Hints for reading the functional flow charts 14.6.1

)

General

• Probably the best aid for trouble shooting is the confidence of knowing the system and how to use the ECS. Every component has a purpose in the system. The construction and operating characteristics of each one should be understood. • Use always the electric/hydraulic circuit diagram the flowchart and the operation manual for the specific machine.

1. Select on page 1 of the flow chart, (which contains the table of contents and the main program) the respective subprogram, for example the Power-Master lube system. 2. Components in the flow chart, have the same identification code as in the electric/hydraulic circuit diagram, as shown in cross reference list (page 2-4). For example: Relay K50 = ? On page 2 (cross reference list) you find out that relay K50 is shown on page 43 of the flowchart. 3. On each page of the respective subprogram you will find the functional description in plain text. In case of problems concerning reading the program loops, you may find answers in the frequently asked questions list on page 6 and 7 of the flow chart.

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Electronic Control System ECS

Section 14.0 Page 29

14.6 Hints for reading the functional flow charts 14.6.2

Example: Monitoring the X1-pressure for pump control, illustration Z25072 Grey shaded fields in the table below shows the normal way , used from the program, if the excavator is in “standard condition”. Item 1)

query Sensor or cable defect?

Yes No B85-X : 5 sec. < --6bar B85-X : 5 sec. : Voltage i.e. <1V at EW13.3 between 1V and 11V at or EW13.3 B85-X : 5 sec. > +55,3bar i.e. > 11V at EW13.3

⇓

2) 3)

_running_motor-x > 15 sec ? X1-pressure to high?

Fault message No 1190 Motor X is running for more than 15 seconds B85-X : 2 sec. > 40bar i.e. > 6,5V at EW13.3

⇓

Motor X is not running B85-X : 5 sec. : Voltage below 6,5V at EW13.3

Fault message No 962

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Section 15.0 Page 1

Lubrication System

Table of contents Page General Function Oscillation Cylinder and Control Block Adjustments One line system Electrical function Capacitive analog sensor for lubricant level monitoring Adjustments End Line pressure switch Injectors Function Pinion type (dummy wheel) system Electrical Function (dummy wheel) system Capacitive analog sensor for lubricant level monitoring Adjustments End-Of-Line Switch setting Injectors Components Hydraulically driven lube pump Injectors End-Line Switch In line Filter Vent valve (Solenoid valve)

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3 9 11 13 17 21 23 25 27 31 35 37 39 41 45 51 53 55

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Lubrication System

Section 15.0 Page 3

Lubrication System

General Function

Legend: illustration Z 24042a (1) Lubricant pump drive (Hydraulic cylinder) (2) Solenoid valve (Oil pressure supply) (3) Flow control valve (4) Pressure reducing valve (5) Hydraulic oil supply line (Pilot pressure) (6) Hydraulic oil return line (7) Vent valve (Solenoid valve, de-energized open to barrel) (8) (9)

Grease supply line to injectors Lubricant level indication (capacitively analog sensor)

(10) (11) (12) (13) (14) (15) (16) (17)

Lubricant barrel Pump mechanism Lubricant filter Hydraulic pressure test plug (Operating pressure) Lubricant pressure gauge (Operating pressure) Vent line to barrel Breather Electrical terminal box

)

• Cylinder pressure must not exceed 650 psi (45 bar)

continued

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15.0 4

Lubrication System

Cont'd.

X-axis Y-axis

Time Lubricant supply line pressure

PI S+ PH SPR PT

Pressure Increasing Switch point ON of the end of line pressure switch Pressure Holding Switch point OFF of the end of line pressure switch Pressure Relieve Pause Time

Lubrication System

Function of a lubrication cycle

Section 15.0 Page 5

illustration Z24042c and Z22023a

PT-phase With the pump and controller system in a rest state a pre-set pause time interval occurs as determined by the PLC. Diagram position (a): A 24 VDC signal from the PLC activate solenoid valve (2) that opens and activate the lubrication pump. (*). As solenoid valve (2) opens hydraulic oil flows through the pressure reducing valve (4), it lowers the hydraulically pilot oil pressure to the operating range of the hydraulic driven lube pump. The reduced pilot oil pressure operates now the grease pump. The oil cylinder shuttle’s the grease cylinder at 18 – 20 double strokes per minute and delivering 612 – 680 cm³ (37.3 – 41.5 in³) of lubricant per minute (approx. 550 – 612 g / 19.64 – 21.45 oz.) At the same time a 24 V signal energize release valve (7), it close now the release line to the lubrication container. PI-phase With energized release valve (7) (*) and solenoid valve (2) the pump continues to cycle until maximum pressure is achieved and the injectors have metered lubricant to the bearings. S+ point, diagram position (b) When the maximum system pressure is reached the end-of-line switch (*) open its contact. In the normal application is the end-of-line switch adjusted to 185 bar (2630 psi. ).The pressure increasing phase is now finished. The open pressure switch (*) signals the controller to stop the pumping cycle and the controller terminates the signal to the solenoid valves (2) The pilot oil flow to the pump stops.

Solenoid valve 2 Y7, CLS

Vent valve 7 Y7a, CLS (1)

end-of-line switch B43, CLS

Y8a, CLS (2) Y9, SLS

Y9a, SLS

B46, SLS

SLS = Slew Ring Teeth Lubrication System CLS = Central Lubrication System (*) check respective circuit diagram continued 05.10.04 rev.5

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15.0 6

Lubrication System

Cont'd.

X-axis Y-axis

Time Lubricant supply line pressure

PI S+ PH SPR PT

Pressure Increasing Switch point ON of the end of line pressure switch Pressure Holding Switch point OFF of the end of line pressure switch Pressure Relieve Pause Time

Lubrication System

Section 15.0 Page 7

Cont'd.

PH-phase Release valve (7) is still energized to keep the pressure in the lubricant line for a fix adjusted time (pressure holding time normally 5 min). Diagram position (c): With expired pressure holding time vent valve (7) de-energize. It opens the release line to the lubricant container. The lubricant line pressure drop to zero so the injectors can recharge for the next lubricant injection. (PR-phase). PR-phase In the pressure relieve phase the end of line switch (*) move back to neutral contact position it signals the PLC that the lube pressure relieve phase is now active. PT-phase The system is now at rest (pause time), ready for another lube cycle and the sequence repeats itself.

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Lubrication System

Section 15.0 Page 9

Lubrication System

Oscillation Cylinder and Control Block, illustration Z 21174

Description: Oscillation cylinder (6) is auto directional controlled, non pressure related. This differential cylinder is connected to the pilot pressure suppliy line (P) and a tank line (T). The speed is contolled by a flow contol valve (3) and the maximum working pressure is controlled by a pressure reducing valve (2).

Function: The Oscillatin cylinder (6) starts as soon pilot pressure is send via the connection (P) to the control block (1). Design related the cylinder (6) retract always first after start or from any position the piston has stopped before. When the cylinder reaches the fully retracted position the flow will be redirected automatically and the cylinders moves in the extending position. If the cylinder comes to an stop in between the end positions weather the oil supply get stopped or the cylinder is hold back by a higher work resistance than the supply pressure, the cylinder changes direction and retracts.

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Lubrication System

Adjustments

Section 15.0 Page 11

(illustration Z21175b):

Stroke speed For a sufficient lube pump operation 18 – 20 double strokes / min for the pump drive cylinder are required. Therefore the flow reducing valve (3) has to be adjusted accordingly. Procedure: 1. Remove electrical plug connection form the discharge valve (7), so no pressure built up will take place during the following test. 2. Start engine and run at high idle. 3. Switch “ON” the lube system annually and count strokes per minute, visible on the moving up and down of pipe (1). If adjustment is required: a. Loosen lock nut (3.1) b. Turn adjustment (3) until the right number of strokes is achieved. turn set screw ccw for more speed and cw to reduce the speed c. Tighten lock nut (3.1). Working pressure The pressure reducing valve (2) mounted in the oscillation control block reduce the supply pressure internally to maximal allowed 45 bar. The pressure ration is 6,55 to 1, that means 45 bar supply pressure result in 295 bar maximum lubricant pressure. At the end of line pressure switch the pressure should be 180 ±0,5 bar. With the lubricant line resistance and different lubricant viscosity the pressure at the lubricant pump output must be higher as 180 bar. For standard condition adjust the maximum pump pressure to 220 bar –250 bar, depend on lubricant line resistance and different lubricant viscosity. Procedure: 1. Disconnect quick coupling (8), so the pump will be blocked when started. 2. Start engine and run at high idle. 3. Switch “ON” the lube system manually, the gauge should show 220-250 bar. If adjustment is required: a. Loosen lock nut (2.1) d. Turn adjustment (2) until the right pressure is shown at the gauge. turn set screw ccw for lower pressure and cw to increase the pressure b. Tighten lock nut (2.1). c. Reconnect quick coupling (8).

) 05.10.04 rev.5

• If the required pressure can’t be adjusted, check adjustment of the 60 bar pilot pressure valve (X-4 pressure) at the filter and control panel in the machinery house. PC5500-6-D_Sec_15-0_rev1.doc

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Lubrication System

Section 15.0 Page 13

Lubrication System

One line system Legend: illustr. Z 21176 (1) Lubricant pump drive (Hydraulic cylinder) (2) Solenoid valve (Oil pressure supply) (3) Flow control valve (4) Pressure reducing valve (5) Hydraulic oil supply line (Pilot pressure) (6) Hydraulic oil return line (7) Vent valve (Solenoid valve, de-energized open to barrel) (8) Grease supply line to injectors (9) Lubricant level indication (capacitively analog sensor) (10) Lubricant barrel (11) Pump mechanism (12) Lubricant filter (13) Hydraulic pressure test plug (Operating pressure) (14) Lubricant pressure gauge (Operating pressure) (15) Vent line to barrel (16) End-of-line switch (17) (Pressure check point) (18) Injector block (19) Lubricant feed line to bearing

Function: As soon as the adj. "Pause-Time" is finished the solenoid valves (2) and (7) are energized. The lubricant pump (1) start to pump lubricant in the lubricant supply line. By the function of the solenoid valve (7) the port to the vent line (15) (return line to the lubricant container) is closed, thus a pressure built up is possible. The high-pressure barrel pump (1) supplies lubricant into the supply line (8). It continuos through the lubricant filter (12) to the injectors (metering valves) (18).

)

• The picture shows an example only. The hole system includes much more injectors which are connected via pipes or hoses to the supply line (8).

In the Injectors the lubricant forced with full pump pressure via the feed lines (19) to the lube points. The actual operating pressure can be monitored at the pressure gauge (14) and checked at the pressure check point (17). continued

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Lubrication System

Section 15.0 Page 15

Cont'd. Illustr. Z 21176 When all injectors pistons have reached there final position no more lubricant is accepted from the supply line which causes a pressure increase in the supply line (8). As soon as the pressure reaches the adjusted value of the end-of-line switch (16) the solenoid valves (2) de-energized and the lubricant pump switched Off. Depend on different factory settings vent valve (7) de energize together with solenoid valve (2) or after a fix adjusted time of max. 5 minutes. With de-energized solenoid valve (7) the port to vent line (15) ( return line to the lubricant container ) opened and release the lubricant and lubricant pressure in to the container. With the diminishing pressure in the main line the pistons of the injector (18) are forced by spring force in their initial position and the discharge chambers are filled with grease for the following lubrication cycle. The system is now prepared for a new lubrication cycle. The operation is reinitiated after the next "Pause Time" is elapsed. The proper build-up of the pressure in the supply line (8) is monitored by the end-of-line switch (16). If the pressure adjusted at the end-of-line switch will not reached within the adjusted "Monitoring Time" the fault message ”Central lubrication system fault” comes up on the text display and the system switch off

W )

05.10.04 rev.5

• Grease qualities to be used: According to NLGI classes 000, 00, 0 and 1 according to the lowest ambient temperature in the operation area 1. The content of molybdenum must not exceed 5 %. 2. Only synthetic graphite allowed in graphite contained lubricants

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Lubrication System

Section 15.0 Page 17

Electrical function. illustr. Z 21177a

)

• It follows an exemplary explanation for a central lubrication system for machines equipped with PLC System. For details see the circuit diagram of the respective machine. The Lubrication Systems are PLC controlled. No relay adjustment necessary. Central lubrication system controlling : The PLC from the ECS System controls the whole lubrication systems. The solenoid valves (Y7, Y7A or Y9, Y9A) on top of the lubrication stations are direct connected to digital output ports of the PLC. On a few machines there are additional relays between PLC outputs and the solenoid valves. Depend on a PLC input from the end-of-line pressure switch (B43 or B46) and a PLC internal time counter the grease system start a lubrication cycle. The lubrication cycle starts. If the pause time elapsed the PLC energize both solenoid valves (Y7, Y7A or Y9, Y9A) of the respective lubrication system. The engine must run in high idle. The pilot pump pressure activate now the lubrication pump and the lubrication pressure to the injectors increase. If the lubricant pressure reach the adjusted pressure of the end-of-line pressure switch (B43 or B46) its contact change and the PLC input signal change. The PLC de energize the respective lubrication pump supply valve (Y7 or Y9) to stop the pump. For the next 5 min the respective pressure releasing valve (Y7A or Y9A) are continued energized to keep the lubricant pressure still on a high level to be able all injectors inject the hole adjusted amount of lubricant. After the 5 min. pressure holding time the PLC de energize the respective pressure releasing valve (Y7A or5 Y9A) The lubricant pressure drops and the injectors move by spring load back in its initial position. A PLC internal counter is still counting a additional decreasing time to monitor the end-of-line pressure switch (B43 or B46) position. The PLC internal time counter is still counting up to the next lubrication cycle. The lubrication cycle is finished. continued

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Lubrication System

Section 15.0 Page 19

Cont'd: Illustr. Z 21177a The next lubrication cycle starts after the decreasing time and pause time has expired. With the switch S24 an additional lubrication can be carried out any time provided the end of line pressure switch (B43) contact is closed.

Monitoring: The orderly built-up of the pressure in the lubricant supply line is monitored by the end-of-line switch (B43 or B46). If the pressure adjusted at the end-of-line switch is not reached within the adjusted maximal increasing time the PLC switch off both solenoid (Y7 and Y7A or Y9 and Y9A) valves and send the fault message ”Central lubrication system fault” or “Swing ring lubrication system fault” to the text display at the dash board. If the excavator is still working additional four hours with faulty lubrication system the PLC stop the bucket function. This function is to prevent trouble depend on a lack of lubricant.

Continued

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Lubrication System

Section 15.0 Page 21

Lubrication System

Capacitive analog sensor for lubricant level monitoring, Illustration Z 21179f Task: A lubricant (L) maximum filling level monitoring is necessary to prevent an overfilling of the grease barrel (C) via the refilling system (only systems with refilling arm). The PLC use the analog level signal from the sensor to activate a lamp at the refilling arm just in the moment when the lubricant container is full. The sensor (S) is mounted on top of the lubricant container and reaches into the lubricant. The refilling level activate only a message at the text display to inform that the lubricant level must be filled up. The message comes up if the lubricant level reach 5% (910 mm from the cover plate). The minimum level stop the respective lubrication pump and release the lubricant pressure until the lubricant level reach the 0% mark (950 mm from the cover plate). It is necessary to stop the lubrication system with empty lubricant container to prevent the lubrication pump from running dry. With empty lubricant container the bucket motion will be switched off after four hours. Function: The capacitively level sensor (S) check continuous the lubricant level (L) and convert the capacitive signal into a current signal between 4 and 20mA. The current signal increase with increasing lubricant level. Use the specific electric circuit diagram and program flow charts.

)

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• The capacitively proximity switch used in our machines are programmed by the supplier and therefor no adjustment or settings required.

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Lubrication System

Section 15.0 Page 23

Adjustments End line switch setting. Illustration Z 21180 1.

)

Connect pressure gauge to check point.

• Use an other gauge as for checking hydraulic pressures because the gauge remains filled with grease after the test 2. 3. 4.

Start engine. Start a lube cycle with the dashboard switch S24. + Watch pressure gauge. At a pressure of 180 10 bar the end-line switch must react and the lubricants pump must stop.*

)

If at the same time the pressure shown at the built-in gauge is noted down, this pressure can be taken for later on checks as a reference pressure. • 180 bar is the normal setting. Under particular circumstances it may be necessary to increase the pressure slightly If re-setting is required: 5. Screw out screw 1 and take off cover 2. 6. Alter the spring tension with adjustment screw 3 that the switch operates at 180 bar. 7. Install cover 2 and screw 1.

continued

05.10.04 rev.5

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15.0 24

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Section 15.0 Page 25

Lubrication System

Cont'd: Injectors, illustr. 21181: Series SL-1 injector: Lubricant output adjustable from 0.13 up to 1.3 cm³ per cycle. Hydraulic type fitting with screw type cover cap is provided for initial filling of feeder line, and may also be used for visual check of injector operation. Series SL-1 injectors incorporate a stainless steel visual indicator. Series SL-11 injector: Lubricant output adjustable from 0.82 up to 8.2 cm³ per cycle. Designed for systems where a high amount of lubricant is required. Principle of operation similar to series SL-1. Adjusting the lubricant output: 1. Loosen lock nut (C). 2. Turn adjusting screw (A) counterclockwise (OUT) for more lubricant output or clockwise (IN) for less lubricant output. 3. Tighten lock nut (C).

)

05.10.04 rev.5

• The max. lubricant output is adjusted if the indicator stem (B) moves not more further outwards

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15.0 26

Lubrication System

Section 15.0 Page 27

Lubrication System

Function Pinion type (dummy wheel) system. Legend: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17)

Z 21183a Lubricant pump drive (Hydraulic cylinder) Solenoid valve Y9 (Oil pressure supply) Flow control valve Pressure reducing valve Hydraulic oil supply line (Pilot pressure) Hydraulic oil return line Vent valve Y9A (Solenoid valve, de-energized open) Grease supply line to injectors Lubricant level indication Lubricant barrel Pump mechanism Lubricant filter Hydraulic pressure test plug (Operating pressure) Lubricant pressure gauge (Operating pressure) Vent line to barrel Breather Electrical terminal box

Principle of operation: By the lubricant pump, the lubricant is supplied to the centered bore hole (B) of the lubrication type pinion (R). Bore hole (B) must be perfectly aligned to the center of the lubrication type pinion (A) to be greased, so that lubricant leaves the tooth flank always when the gear tooth is in contact. The grease outlet (D) of the lubricating type pinion is arranged at a different angle for each tooth, so that the lubricant is distributed in a uniform and perfect manners on the tooth flank of the drive pinion to be lubricated. Function: As soon as the adjusted "Pause-Time" elapse the solenoid valves (2 + 7). energized and the lubricant pump (1) start to pump lubricant. By the function of the solenoid valve (8) the port to the vent line (15) (return line to the lubricant container) closed, thus a pressure built up is possible. The high-pressure lubricant pump (1) supplies lubricant into the supply line (8). It continuos through the lubricant filter (12) to the injectors (metering valves) (18). •

The picture shows an example with one pinion only. There are also machines which have more lubrication type pinion (dummy wheel). By the injectors the lubricant is forced with full pump pressure via the feed line (19) to the centered bore hole (B) of the lubricating type pinion (R). continued

05.10.04 rev.5

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Lubrication System

Section 15.0 Page 29

Cont'd. Illustr. Z 21183a The actual operating pressure can be monitored at the pressure gauge (14) and checked at the pressure check point (17). When all injector pistons have reached there final position no more lubricant will accepted from the supply line (8) which causes a pressure increase in the supply line. Depend on different factory settings vent valve (7) de energize together with solenoid valve (2) or after a fix adjusted time of max. 5 minutes. With de-energized solenoid valve (7) the port to vent line (15) ( return line to the lubricant container ) opened and release the lubricant and lubricant pressure in to the container. With the diminishing pressure in the main line the pistons of the injector (18) are forced by spring force in their initial position and the discharge chambers fill up with grease for the following lubrication cycle. The system is prepared for the next lubrication cycle. The operation is reinitiated after the next "Pause Time". The proper build-up of the pressure in the supply line (8) is monitored by the end-of-line switch (16). If the pressure adjusted at the end-of-line switch is not reached within the adjusted "Monitoring Time" the fault message ”Slew ring gear lubrication system fault” is shown on the text display and the pump switch off.

• Grease qualities to be used: According to NLGI classes 000, 00, 0 and 1 according to the lowest ambient temperature in the operation area

)

05.10.04 rev.5

1. The content of molybdenum must not exceed 5 %. 2. Only synthetic graphite must be contained in graphic lubricants

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15.0 30

Lubrication System

Electrical function.

)

Section 15.0 Page 31

Illustration Z 21177b

• It follows an exemplary explanation for a Slew Ring Lubrication System for machines equipped with ECS System. For details see the circuit diagram of the respective machine. The Lubrication Systems are controlled through the ECS. No relay adjustment required. Slew Ring Gear Lubrication (Teeth lubrication) controlling : The PLC from the ECS System control the whole lubrication systems. Solenoid valves (Y9, Y9A) on top of the lubrication container are direct connected to digital output ports of the PLC. On few machines there are additional relays between PLC and the solenoid valves. Depend on a PLC input from the end-of-line pressure switch (B43 or B46) and a PLC internal time counter the grease system start a lubrication cycle. The lubrication cycle starts. If the pause time elapsed and the swing function was activated for a short time the PLC energize both solenoid valves ( Y9 , Y9A ). To start one swing ring gear lubrication cycle the swing function must be activated one time. If the lubricant pressure reach the adjusted pressure of the end of line pressure switch its contact change the position now the input port of the PLC change. The PLC de energize the respective lubrication pump supply valve (Y9) to stop the pump. For the next 5 min the respective pressure releasing valve (Y9A) are continued energized to keep the lubricant pressure still on a high level to be able all injectors inject the hole amount of lubricant. After 5 min. pressure holding time the PLC de energize the respective pressure releasing valve (Y9A) The lubricant pressure drops and the injectors move by spring load back in its initial position. A internal counter is still counting a additional decreasing time to prevent a to early new lubrication cycle with the risk of not complete reset injectors. The lubrication cycle is finished. continued

05.10.04 rev.5

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Lubrication System

Section 15.0 Page 33

Cont'd: Illustr. Z 21177b The next lubrication cycle starts after the decreasing time and pause time has expired. With the switch S26 an additional lubrication can be carried out any time provided the end of line pressure switch (B46) contact is closed.

Monitoring: The orderly built-up of the pressure in the lubricant supply line is monitored by the end-of-line switch (B46). If the pressure adjusted at the end-of-line switch is not reached within the adjusted maximal increasing time the PLC switch off both solenoid valves (Y9 and Y9A) and send the fault message ”Central lubrication system fault” to the text display at the dash board. If the excavator was working additional four hours with faulty lubrication system the PLC stop the bucket function. This function is to prevent trouble depend on a lack of lubricant.

Continued

05.10.04 rev.5

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Section 15.0 Page 35

Lubrication System

)

05.10.04 rev.5

• The capacitively proximity switch used in our machines are programmed by the supplier and therefor no adjustment or settings required.

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Section 15.0 Page 37

Adjustments End of line switch setting, illustration Z 21185 1.

)

• Use an other gauge as for checking hydraulic pressures because the gauge remains filled with grease after the test 2.

Block the swing function with the swing ring parking, use the switch at the dash board.

3. 4.

Start engine. Start a lube cycle with the dashboard switch S26 and activate for a short time the swing function to the left or right. + Watch pressure gauge. At a pressure of 180 10 bar the end of line switch must react and the lubricants pump must be stopped.*

)

Connect pressure gauge to check point close to the end of line pressure switch.

If at the same time the pressure shown at the built-in gauge is noted down, this pressure can be taken for later on checks as a reference pressure. But be careful this pressure is higher than the pressure shown at the test gauge because of the long distance between pump and end of the supply line.

• 180 bar is the normal setting. Under particular circumstances it may be necessary to increase the pressure slightly If re-setting is required: 6. 7. 8.

Screw out screw (1) and take off cover (2). Alter the spring tension with adjustment screw (3) that the switch operates at 180 bar. Install cover (2) and screw (1). continued

05.10.04 rev.5

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Section 15.0 Page 39

Lubrication System

)

05.10.04 rev.5

• The max. lubricant output is adjusted if the indicator stem (B) moves not more further outwards

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Lubrication System

Section 15.0 Page 41

Lubrication System

Hydraulically driven “Power Master III” lube pump, illustr. Z 21186 Legend: (more detailed see parts list 90-0781) Fig.: 12 (P) Hydraulic oil supply (T) Hydraulic oil return (Pr) Pressure reducing valve (Q) Flow regulator valve (1) Hydr. actuator piston (2) Oscillator control block (3) Pump tube (4) Breather port (5) Grease outlet port (6) Piston rod (7) (8) (9) (10) (11) (12) (13) (14)

Breather plug Ball, outlet check valve Ball and seat, check valve Main piston and plunger Piston rod set Inlet valve Scoop piston Grease inlet

HINT: Loss of pressure or to short pump strokes indicates: A

Foreign material lodged under Piston Ball Checks or between Upper and Lower Inlet Checks (8 + 9). To correct this problem the upper lower inlet checks (8 + 9) and inlet valve (13) should be removed and cleaned thoroughly. If sealing surfaces between upper and lower inlet checks (8 + 9) are rough or pitted, replace or resurface if damages are slight.

Shovel rod packing worn or damaged. Before installing new packing, inspect surface of shovel rod and replace if rough or pitted. Do not grip shovel rod when disassembling lower pump tube assembly. continued

05.10.04 rev.5

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Section 15.0 Page 43

Trouble shooting, illustr. Z 21186 If the following procedures do not correct the problem, contact a factory authorized service center. PROBLEMS: CYLINDER PRESSURE GAUGE DOES NOT REGISTER PRESSURE. A. Check system pressure to pump. B. Check for 24 VDC signal at solenoids. C. Pressure reducing valve set too low. Check pressure. PUMP PRESSURE BUILT UP VERY SLOWLY OR NOT AT ALL. A. B. C. D. E. F. G. H.

05.10.04 rev.5

No oscillation of pump, check oscillation control block (2). Pressure reducing valve (Pr) may be setting too low. Grease viscosity may be too high for the actual ambient temperature. If pressure is not building up at all, solenoid valve (pilot pressure supply solenoid) may be inoperative. Pump piston (11) and inlet checks may have foreign matter trapped causing leakage. Remove, inspect and clean if necessary. Inspect sealing surface on upper and lower checks (8 + 9). Replace if rough or pitted. Replace scoop piston if rough or pitted. Replace rod packing (15) if it is leaking. Inspect lubricant supply line for leaks or breaks.

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Section 15.0 Page 45

Lubrication System

Lubricant Injector (metering valve), illustr. Z 21187

TASK: A readjusted (at the injector) volume of grease is pushed with the injectors to the bearings or to the progressive distributors. Design: (model SL1) (01+02) Metering valve, assy. (03+04) Injector bar (05) Adjusting screw

Design: (model SL11) (01) Metering valve, assy. (02) Adjusting screw (03) Nut

(06) (07)

Nut Plug screw

(04) (05)

Plug screw O-ring

(08) (09) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21)

Seal ring Disk Seal ring Bolt with nut Disk Seal ring Piston Compression spring Spring retainer Seal ring Disk Seal ring Disk Piston

(06) (07) (08) (09) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19)

Disk Seal ring Disk Guide Indicator pin Seal ring Piston Seal ring Pin Compression spring Spring retainer Bolt with piston Seal ring Valve housing

(22) (23) (24) (25)

Seal Adapter bolt Valve housing Union

(20)

Union

continued

05.10.04 rev.5

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Lubrication System

Section 15.0 Page 47

Cont'd: Function: illustr. Z 21188 Pos. 1

The injector piston (2) is in its normal or rest position. The discharge chamber (9) is filled with lubricant from the previous cycle. Under the pressure of incoming lubricant the slide valve (4) is about to open the passage (5) leading to the piston.

Pos. 2

When the slide valve (4) uncovers the passage lubricant is admitted to the top of piston (2) forcing the piston down. The piston force lubricant from the discharge chamber (9) through the outlet port (10) to the bearing or progressive distributor. The lubricant pressure at the bearing or the progressive distributor is always the same as the pump pressure.

Pos. 3

As the piston completes its stroke, it pushes the slide valve (4) past the passage, cutting off further admission of lubricant to the passage. Piston and slide valve remain in this position until lubricant pressure in the supply line is vented (relieved) at the pump. This is indicated by the injector stem (8). (fully in)

Pos. 4

After pressure is relieved the compressed spring (3) moves the slide valve (4) to closed position. This opens the port from the measuring chamber and permits the lubricant to be transferred from the top of the piston to the discharge chamber. This is also indicated by the injector stem (8) (fully out) continued

05.10.04 rev.5

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Section 15.0 Page 49

Cont'd: Connection of one or more injectors, illustr. Z 21189 The injectors are designed so that the lubricant output of two or more injectors can be combined without the use of tees. The injector body (1) has two outlets ports (a + b), one above the other. The connector tube (2) is used to couple the injectors together. Lubricant from injector No. 1 is directed through the connector tube into the discharge chamber of injector No. 2 but simply combines with the lubricant delivery of injector No. 2 to yield double output from the outlet of injector No. 2. This does not interfere with the operation of injector No. 2.

05.10.04 rev.5

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Lubrication System

Section 15.0 Page 51

End-line switch

TASK: The pressure control unit is monitoring and controlling the centralized lube system.

Design: illustr. Z 21190 (1) Piston (2) Disk (3) Switch contact (4) Spring (5) (6) (7) (8)

Pressure switch Adjustment sleeve Connection to pressure circuit Electrical connection

Function: One pressure control unit is installed in each greasing circuit. The grease pressure, produced by the pneumatic barrel pump, is with his force also at the piston (1) If the grease pressure reaches the tension of the spring (4), the piston (1) is forced against the disk (2), thus that the contacts of the switch (5) are operated and a electric impulse is given to the electronic control unit of the greasing equipment. Adjusting has to be done with the sleeve (6). Clockwise - higher switch point, counterclockwise - lower switch point.

05.10.04 rev.5

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Section 15.0 Page 53

In-line filter

Legend: illustr. Z 21191 (1) Plug screw (2) Plug screw gasket (3) Filter element (4) Filter housing (5) Spring guide (6) Spring • Before servicing stop the motor and remove ignition key in order to prevent operation of the system.

)

• A clogged filter element will be moved against the spring force by the lubricant pressure and unfiltered lubricant reaches the system!

For maintenance proceed as follows: 1. Remove plug screw (1) using 36 mm width wrench. 2. Remove plug screw gasket (2). 3. Take out spring (6), spring guide (5) and filter element (3). 4. Clean all parts and inspect for damage. Replace as necessary. 5. Insert filter element, spring guide (5) and spring. 6. Install plug screw (1) with gasket (2) and tighten with a wrench.

)

05.10.04 rev.5

• For service intervals see SERVICE LITERATURE chapter 6.6

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Lubrication System

Section 15.0 Page 55

Vent valve, illustr. Z 21192 TASK: By the function of the vent valve the lubricant supply line gets pressurerelieved, after the lubrication cycle is finished. The injector pistons can move into their initial position. Legend: (Valve VP1 S-G). Fig. 19 (1) Solenoid (2) Valve assy. (3) Solenoid stem (4) Lever (5) Main valve cone (6) (7)

Auxiliary valve cone Reset spring

Function: The solenoid gets energized. When the lubrication starts. The connection from A to B gets closed, thus a pressure build-up is possible. The solenoid gets de-energized, as soon as the lubrication cycle is finished. This causes opening of the connection A to B, thus the supply line to the lubricant barrel is open. The lubricant flows from A to B or vice versa along the main valve cone (5).

05.10.04 rev.5

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Lubrication System

Appendix Page 0

Appendix

Table of contents Appendix Section Appendix

26.03.03

Page 01

Check list valve logic

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3& B)URQWVKRYHO 6HU 1R 'DWH

01 Check Single Movement (title)

b a - - - - 0 I

b a - - - - 0 II

0 b 0

IV a b a III

02 Right forw

b a - - - - - I

b a - - - - - II

- IV - a - b b a - - - O P III

03 Right back

b a - - - - - I

b a - - - - - II

b P

IV a b a O III

b -

IV a b a III

04 Left forw

b a - - - - O P I

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b a - - - - - II

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05 Left back

b O P

a I

b a - - - - - II

b -

IV a b a III

06 Boom up

b O P

a I

b O P

a II

P IV - a - b b a - - O - P III

07 Boom down

b a - O - - - - I

b a - - O - - - II

b -

IV a b a O III

08 Stick out

b O P

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a I

b O P

a II

P IV - a - b b a O - - - P III

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09 Stick in

b a - - - O - - I

b a - O - - - - II

b -

IV a b a O III

10 Bucket fill

b O P

a I

b O P

a II

P IV - a - b b a - O - - P III

11 Bucket empty

b a - - O - - P I

b a - - - O - - II

b P

IV a b a O III

P b -

IV a b a III

12 Clam open

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b a - - - - O P II

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13 Clam close

b a - - - - - I

b O P

a II

P b -

IV a b a III

14 Swing right

b a - - - - - I

b a - - - - - II

P IV - a O b b a - - - - - III

15 Swing left

b a - - - - - I

b a - - - - - II

P IV O a - b b a - - - - - III

16 Check Automatic Priority (title)

b a - - - - - I

PC5500_6_FS.xls

b a - - - - - II

b -

IV a b a III

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17 Boom up, Bucket empty

b O P

a I

b O P

a O II

P IV - a - b b a - - O O - P III

18 Boom up, Bucket fill

b O O P

a I

b O P

a II

P IV - a - b b a - O O - P III

19 Check Unfloat Switch Function (title)

b a - - - - - I

b a - - - - - II

b -

IV a b a III

20 Boom down, Stick Unfloat switch pressed

b a - O - - - - I

PC5500_6_FS.xls

b a - - O - - - II

b -

IV a b a O III

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21 Boom down, Boom Unfloat switch pressed

b a - - - - - I

b a - - O - - P II

P b -

IV a b a O III

22 Boom down, Boom Unfloat switch pressed, Bucket fill

b O P

a I

b O P

a O II

P IV - a - b b a - O - O - P III

23 Boom down, Boom Unfloat switch pressed, Stick out

b O P

a I

b O P

a O II

P IV - a - b b a O - - O - P III

24 Stick in, Boom Unfloat switch pressed

b a - - - O - - I

PC5500_6_FS.xls

b a - O - - - - II

b -

IV a b a O III

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3& B)URQWVKRYHO 6HU 1R 'DWH

25 Stick in, Stick Unfloat switch pressed

b a - - - O - - I

b a - O - - - P II

P b -

IV a b a III

26 Stick in, Stick Unfloat switch pressed, Bucket fill

b O P

a O I

b O P

a O II

P IV - a - b b a - O - - P III

27 Check Operating Situations (title)

b a - - - - - I

b a - - - - - II

b -

IV a b a III

28 Boom down, Stick in, Bucket empty, Clam close, Swing right

b P

PC5500_6_FS.xls

a O O O I

b O P

a O O O II

P IV - a O b b a - O - O - O - P III

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29 Boom down, Stick out, Bucket fill

b O O P

a O I

b O O P

a II

P IV - a - b b a O O - O - P III

30 Boom down, Stick out, Bucket empty

b O P

a O O I

b O P

a O II

P IV - a - b b a O - O - O - P III

31 Boom down, Stick in, Bucket fill

b O P

a O O I

b O P

a II

P IV - a - b b a - O O - O - P III

32 Boom up, Stick in, Bucket empty, Swing left

b O P

PC5500_6_FS.xls

a O I

b O P

a O O II

P IV O a - b b a - O - O O - P III

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33 Boom up, Stick out, Bucket empty, Swing left

b O O P

a I

b O O P

a O II

P IV O a - b b a O - O O - P III

34 Boom up, Stick in, Bucket fill, Swing left

b O O P

a O I

b O P

a II

P IV O a - b b a - O O O - P III

35 Boom up, Stick out, Bucket fill, Swing left

b O O O P

a I

b O O P

a II

P IV O a - b b a O O O - P III

36 Boom up, Stick out, Bucket empty, Clam open

b O O P

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a I

b O O P

a O O II

P IV - a - b b a O - O O - P III

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37 Boom up, Stick out, Bucket empty, Clam open, Swing right

b O O P

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b O O P

a O O II

P IV - a O b b a O - O O - P III

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3& B%DFNKRH 6HU 1R 'DWH

01 Check Single Movement

02 Right forw b a - - - b a - - - II - - - - I

- IV - a - b b a - - - O P III

03 Right back b a - - - b a - - - II - - - - I

- IV - a - b b a - - - - O P III

04 Left forw b a - - - b a - - - II - - - O P I

b -

IV a b a III

05 Left back b b a - - - O P I

b -

IV a b a III

a II

PC5500_6_BH.xls

Stand_13.10.04

1/7

3& B%DFNKRH 6HU 1R 'DWH

06 Boom up b O b a O P - - - P I

a II

- IV - a - b b a - - O - P III

07 Boom down b a - - - O b a - - O - II - - - - I

- IV - a - b b a - - - O - P III

08 Stick out b O b a - P - O - P I

b -

a II

IV a b a O III

09 Stick in

b P

a O I

b P

a O II

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- IV - a - b b a O - - - P III

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10 Bucket fill b a - - - b a O - P II O - - P I

- IV - a - b b a - O - - P III

11 Bucket empty b a - - - b a - - - II - O - - P I

- IV - a - b b a - - O - - P III

12 Swing right b a - - - b a - - - II - - - - I

P IV - a O b b a - - - - - III

13 Swing left b a - - - b a - - - II - - - - I

P IV O a - b b a - - - - - III

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14 Check Operating Situations

15 Boom down, Stick out, Bucket empty b a O - IV - - a - O - b b a - O b a - O P II - O - O - O O - O - - P I P III

16 Boom down, Stick out, Bucket empty, Swing right b a O P IV - - a - O O b b a - O b a - O P II - O - O - O O - O - - P I P III

17 Boom down, Stick in, Bucket fill b a - O - IV - - a - O - b b a O b a - O P II O O O - O - O - - P I P III

18 Stick in, Bucket fill b a - O - IV - - a - - b b a O b a - P II O O O - O - - - P I P III

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19 Boom up, Bucket fill b a - - IV - - a O - b b a O b a O P II - O O - O - - P I P III

20 Boom up, Stick in b a - O - IV - - a O - b b a - b a O P II O - - - O O - - P I P III

21 Boom up, Stick in, Bucket fill b a - O - IV - - a O - b b a O b a O P II O O O - O O - - P I P III

22 Boom up, Stick in, Bucket empty b a - O - IV - - a O - b b a - O b a O P II O - O - O - O O - - P I P III

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23 Boom up, Stick in, Swing left b a - O P IV - O a O - b b a - b a O P II O - - - O O - - P I P III

24 Boom up, Stick out b a O - IV - - a O - b b a - b a O P II - O - - O O - - P I P III

25 Boom up, Stick out, Swing left b a O P IV - O a O - b b a - b a O P II - O - - O O - - P I P III

26 Boom up, Stick out, Bucket fill b a O - IV - - a O - b b a O b a O P II - O O O O O - - P I P III

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27 Boom up, Stick out, Bucket fill, Swing left b a O P IV - O a O - b b a O b a O P II - O O O O O - - P I P III

28 Boom down, Stick out, Bucket empty b a O - IV - - a - O - b b a - O b a - O P II - O - O - O O - O - - P I P III

29 Stick out, Bucket empty b a O - IV - - a - - b b a - O b a - P II - O - O - O O - - - P I P III

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Appendix Page 1

MC7 Fault Code, Diagnostic

The fault message LED (H138 at the X2 panel) send a flash code (blink code) after a MC7 fault occurs. The “regulation active LED (H63)” light on when the MC7 (electronic pump control) is active (reduced X1-pressure = reduced current signal to Y61 proportional valve).

Blink Code 1

Error Message Working Pump 1

Sav e yes

Low Speed 52

Low Speed 53

High Speed 1

yes

Low Battery

yes

MC7 Calibration

yes

MC7 ADC

yes

Working Pump 2

yes

Low Speed 54

High Speed 2

yes

Possible Cause

Effect

Working pump solenoid circuit open or shorted to ground Diesel engine is not running or engine rpm too low or no signal from motor controller because of short cut or break Diesel engine is not running or engine rpm too low or no signal from motor controller because of short cut or break Diesel engine defect or rpm too high

Pump has maximum Check DRE power valve

Battery voltage is below 17V MC7 was not precalibrated at BRUENINGHAUS HYDROMATIK Internal MC7 fault

Engine lug too large

Fixing

Reduction of hydraulic power

Check connection to motor controller

Reduction of hydraulic power

Check connection to motor controller

Load limiting control malfunction

Check mechanical high idle limitation Check voltage generator Replace MC7

Adjustable current range is different

Analog input signals Replace MC7 can be wrong Pump has maximum Check DRE power valve Reduction of hydraulic power

Check connection to motor controller

Load limiting control malfunction

Check mechanical high idle limitation

- All output ports of the MC7 are protected against short circuit. - It is not allowed to connect 24 Volt to the output terminals.