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05
SERVICE
MANUAL
PC4000
MACHINE MODEL SERIAL NUMBER
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.
CONTENTS
TABLE OF CONTENTS
00 Safety - Foreword
01 Technical DATA (Leaflet)
02 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. Cable drum
12. Hints for the hydraulic circuit diagram
13. Hints for the electric circuit diagram
14. Electronic Control System - ECS
15. Lubrication System
APPENDIX
SAFETY
SAFETY NOTICE
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.
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.
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
ENVIRONMENT PROTECTION Environment NOTICE
OPERATION
• Avoid engine idling over long periods. Long periods of idling, more than 10 minutes,
will not only waste fuel, but is also harmful to the engine.
• Avoid operation against the main relief valves of the hydraulic system. Move control
lever to neutral position before the loader attachment stalls due to overload.
• Position trucks in such a way, that loading operation can be carried out in a safe and
economic manner. Avoid swing angles over 90°.
MAINTENANCE
FOREWORD
GENERAL
We describe for you all functions and how to carry out the inspections and
adjustments.
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.
00-4
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
• Heavy parts (25 kg or more) must be lifted with a hoist etc.
WIRE ROPES
Wire ropes
(Standard "Z" or "S" twist ropes without galvanizing)
Rope diameter 10,0 11,2 12,5 14,0 16,0 18,0 20,0 22,4 30,0 40,0 50,0 60,0
[mm]
Allowable 1,0 1,4 1,6 2,2 2,8 3,6 4,4 5,6 10,0 18,0 28,0 40,0
load [tons]
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
00-7
FOREWORD CONVERSION TABLE
CONVERSION TABLE
EXAMPLE
00-8
FOREWORD CONVERSION TABLE
00-9
FOREWORD CONVERSION TABLE
00-10
FOREWORD CONVERSION TABLE
00-11
FOREWORD CONVERSION TABLE
00-12
FOREWORD CONVERSION TABLE
°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
0 100,00 99,61 99,22 98,83 98,44 98,04 97,65 97,26 96,87 96,48
°C 0 1 2 3 4 5 6 7 8 9
0 100,00 100,39 100,78 101,17 101,56 101,95 102,34 102,73 103,12 103,51
10 103,90 104,29 104,68 105,07 105,46 105,85 106,24 106,63 107,02 107,40
20 107,79 108,18 108,57 108,96 109,35 109,73 110,12 110,51 110,90 111,28
30 111,67 112,06 112,45 112,83 113,22 113,61 113,99 114,38 114,77 115,15
40 115,54 115,93 116,31 116,70 117,08 117,47 117,85 118,24 118,62 119,01
50 119,40 119,78 120,16 120,55 120,93 121,32 121,70 122,09 122,47 122,86
60 123,24 123,62 124,01, 124,39 124,77 125,16 125,54 125,92 126,31 126,69
70 127,07 127,45 127,84 128,22 128,60 128,98 129,37 129,75 130,13 130,51
80 130,89 131,27 131,66 132,04 132,42 132,80 133,18 133,56 133,94 134,32
90 134,70 135,08 135,46 135,84 136,22 136,60 136,98 137,36 137,47 138,12
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
Section Page
1.0 Main assembly groups
General lay out 2
1.1 Superstructure 3
1.1.1 Machine house 4
1.1.2 Hydraulic Oil Reservoir 5
1.1.3 Hydraulic Oil Cooler 6
1.1.4 Fuel Tank 7
1.1.5 Counter weight 8
1.1.6 Cab support 9
1.1.7 Operators cab 10
1.1.8 Control Blocks 11
1.1.9 Swing gears 12
1.3 Attachment
1.3.1. Backhoe Attachment (BHA) 14
1.3.2. Front Shovel Attachment (FSA) 15
1.1 Superstructure
1.1 Superstructure
1.1 Superstructure
1.1 Superstructure
1.1 Superstructure
1.1 Superstructure
37000 kg
1.1 Superstructure
(4) Door
(5) Gasket
(6) Door handle (adjustable)
1.1 Superstructure
– KMG Control
– KMG Control
1.1 Superstructure
1.1 Superstructure
1.3 Attachment
1.3 Attachment
Section Page
2.0 Prime drive assembly
General 2
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General
The two electric motors are solid bolted to the motor frame (7).
The thickness of alignment shims (5) has to be selected according to the
results of the alignment procedure, refer to Parts & Service News AH01523,
last edition for more information.
) • The alignment procedure must also be carried out when replacing the
electric motor and/or the PTO.
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(10) Bolt
Quantity Bolt size (mm) Grade SW* (mm) Tightening torque (Nm)
22 M 16 x 310 10.9 24 250.0 +30.0
(11) Washer
(12) Nut
(13) Bolt
Quantity Bolt size (mm) Grade SW* (mm) Tightening torque (Nm)
1 M 36 x 60 8.8 55 2170.0
(14) Bolt
Quantity Bolt size (mm) Grade SW* (mm) Tightening torque (Nm)
10 M 18 x 40 10.9 27 360.0
Design:
VULASTIC-L – coupling type are provided with two flexible rubber
elements (5 + 8). The flexible ring connect the input drive hub (2) via input
drive flange (4) with the output drive hub (3) of the coupling.
Function:
The high flexible LULASTIC–L coupling transfers the torque without any
rotational gap. They are wear-resisting and maintenance free. Because of
symmetrical arrangement of the flexible rings, there are no returning forces
either by the torque transfer or the centrifugal forces.
VULASTIC-L couplings dampen rotating vibrations, reducing same by
partial storing of the shock energy and damp noises.
The coupling allows in an acceptable range axial, radial and angular
misalignment of the shafts.
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Description
The pump distribution gear (PTO gear) is of a spur gear design and driven by
an diesel engine.
The PTO gear runs in antifriction 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 of 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.
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All drive shaft housings are filled with the same gear oil as the pump
distributor gear.
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.
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Function:
Pump (8.2) forces the gear oil from the gear oil pan through filter (20) to
pressure relief valve (21). This pressure relief valve acts as a back pressure
valve causing that most of the oil passes through the gear oil coolers
(17.1+17.2).
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). At too high oil
temperature a fault message will be displayed on the monitor at the dash board.
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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
) • If the pressure of 10,0 bar cannot be adj. 100 %, adj. to the lowest
visible pressure.
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Hydraulic Oil Reservoir Section 3.0
Page 1
Section Page
3.0 Hydraulic oil reservoir
General lay out 2
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Hydraulic Oil Reservoir Section 3.0
Page 4
(6) Nut
(7) Gaskets
(8) Main suction oil strainer
(9) Intermediate pipe
(10) Gaskets
(11) Suction strainer – one for each main pump
(12) Suction hose connection pipe
(13) Bolt
Quantity Bolt size Grade SW* Tightening
(mm) (mm) torque (Nm)
16 M 16 x 40 8.8 24 179
* SW = Wrench size
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(6) Bolt
Quantity Bolt size Grade SW* Tightening
(mm) (mm) torque (Nm)
8 M 20 x 70 10.9 30 510
Task:
The strainer is installed to prevent the hydraulic oil coolers from getting
clogged up in case of contamination in the main return circuit oil.
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.
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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
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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).
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Hydraulic Oil Cooling Section 4.0
Page 1
Section Page
4.0 Hydraulic oil cooling
4.1 General 2
4.2 Function of the hydraulic oil cooling circuit 3
4.3 Adjustment of the Back Pressure Valve 4
4.4 Fan drive (Two stage cooler fan RPM control) 5
4.5 Pressure relief valves and solenoid valve 6+7
4.6 Fixed Displacement Pump, with variable setting 8
4.7 Adjustment of the cooler fan drive speed 9 + 10 + 11
4.8 Function check of fan speed control 11
4.9 Switch points cooler fan speed (PLC controlled) 12
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4.1 General
The hydraulic oil cooling system maintains the hydraulic oil at a normal
operating temperature.
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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Function:
The returning oil from the system flows via the lines (L6 - L7) into the
collector tube (54). On the top of it is the Back Pressure Valve (55) installed.
The back pressure valve (55) causes a back pressure which forces most of the
relative hot oil through the lines (H) to the cooler (39.1 + 39.2).
On its flow through the cooler the hydraulic oil gets cooled and flows than
through the restrictors (32.1 - 32.4) 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 (55) is wide
open, because solenoid valve Y101 is energized, which results in less oil flow
through the cooler which causes that the oil gets its optimum operating
temperature quicker.
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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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 S155 in position “1”)!
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Function:
From pump (5.1) flows the oil through the filter (34.1) to the fan motors (37.1 + 37.2)
and then back to the tank.
The check valve (38) 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
inerrupted by solenoid valve (Y6a/b), or if the motor has been switched off.
The hydraulic circuit "Fan drive" is secured by the pilot controlled pressure relief
valves (31.1) and (124).
These valves are working together with the solenoid valve (Y6a/b), controlled by the
ECS system, depending on the hydraulic oil temperature:
• With de-energized solenoids Y6a and Y6b the relief valve (31.1) is
functioning and the fans are running with max. adjusted speed (1250 RPM)
• With solenoid Y6a energized the relief valve (31.1) 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 (124) is controlling the relief
valve (31.1) and the fans are running with 1000 RPM only.
(See also description on next page)
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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 unloaded (Remote controlled) by means of the
port "X" and the function of the solenoid valve (126).( Function see next page)
continued
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Page 7
Cont’d.
Function:
With de-energized solenoids (Y6a and Y6b), the spool (3) keeps the "X"
connection of valve (31.1) and port “B“ to port “P“ closed. The pressure relief
valve (31.1) operates normal.
The energized solenoid Y6b, operate the spool (3) and a connection is made
between port “P“ and port “B“ and port "X" of valve (31.1)
The system pressure now opens the main piston (7) of valve (31.1), because via
solenoid Y6b (P to B) the oil from the rear side of piston (7) flows from the
"X"-port to the “P“ connection of valve (124). The normal valve function is
now remote controlled by the pressure adjusted at valve (124).
The energized solenoid Y6a, operate the spool (3) and a connection is made
between port “P“ and port “A” and port "X" of relief valve (31.1).
The system pressure now opens the main piston (7) of valve (31.1) because via
the "X"-port the oil from the rear side of piston (7) flows to tank. The normal
relief valve function is eliminated.
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Page 8
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.
ã
• When increasing to maximum swivel angle, there is a danger of
cavitation and over-speeding the hydraulic motor!
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Continued
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Page 10
Cont'd
Basic Adjustment – Maximum Speed, illustration (Z 21932b)
6. Check the fan speed with a non-contact rev counter
Required fan speed: 1250 min-1
7. Increase the output flow of pump (5.1), 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).
8. Loosen lock nut (b) of the relief valve (31.1), and decrease the pressure
with set screw (c) until the correct fan speed is obtained.
9. Tighten lock nut (b) and fix protection cap (a).
)
• Both fans have to be checked. A difference of approx. 50 rpm is
normal due to the higher resistance for the air stream for the lower
fan. If the speed difference between both fans is higher than 50 rpm, a
possible cause could be a worn hydraulic motor or defective bearings.
continued
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Cont'd
Basic Adjustment – Medium Speed, illustration (Z 21932c)
10. Activate the function of pressure relief valve (124), by connecting the plug
connector of solenoid valve Y6b.
11. In order to ensure a proper function of solenoid valve Y6b during the
adjustment, energize the valve by using the manual control “Digital Outputs”
of the ECS-System ( refer to section 3.4 of the operation manual), or
activate Y6b, by connecting the solenoid plug to permanent 24 V. Use the
24V socket at the PTO *)
12. Loosen lock nut (e) of the relief valve (124), and turn set screw (f) fully
counter clockwise and then clockwise until the correct fan speed is obtained.
Required fan speed: 1000 min-1
13. Tighten lock nut (e) and fix protection cap (d).
14. Note down the pressure as reference value (expected ~ 150 bar)
15. Disconnect the pressure gauge from check point (M6).
16. Connect the plug connector of solenoid valve Y6a.
*) 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 (-).
Switch manually the output signals to Y6a/b and check the fan speed:
Y6a
Y6b
0
0} nmaximum ≈ 1250 min-1
Y6a
Y6b
0
1} nmedium ≈ 1000 min-1
Y6a
Y6b
1
0} nminimum ≈ 0 - 50 min-1
) • For operating instructions of the ECS system refer to section 3.4 of the
operation manual
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Page 12
Fan speed
Maximum
Medium
Minimum
Temperature
67°C VG100: 75°C
58°C VG68: 75°C
Switch point: Speed increase 50°C VG46: 69°C
41°C VG32: 59°C
32°C VG22: 48°C
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Controlling Section 5.0
Page 1
Section Page
5.0 Controlling
General lay out 2
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General
The controlling includes the pilot pressure system and the pump regulation
system.
The pump (8.1) forces the oil through the filter (33) 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 motor was shut down or to
pressure relieve 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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Filter:
(33) Pilot pressure and pump regulation
(34.1) Hydraulic oil cooler fan drive
(36) PTO gear lubrication
Miscellaneous:
(29) Pressure relief valve – PTO gear lubrication
(31.1) Pressure relief valve - Hydraulic oil cooler fan drive, with solenoid valve Y6a /
Y6b for fan RPM control
(47) Pressure reducing valve – Track tensioning system (35 bar)
(124) Pressure relief valve Medium speed cooler fan
(252.1) Pressure reducing valve for pilot pressure X2 (45bar)
(252.2) Pressure relief valve for pump support pressure X4 (60 bar)
(253.1) Change over valve – Electronic pump regulation or hydraulic constant regulation
(253.2) Pressure reducing valve – hydraulic constant regulation
(255.4) Pressure reducing valve – ½ Qmax
(257.1) Pressure relief valve – Safety valve for Travel brake / Track tensioning system
(55 bar)
(258.3) Pressure relief valve – Hydraulic access ladder (70 bar)
continued
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Cont'd:
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continued
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Controlling Section 5.0
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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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) • Since the “X2” and the “X4” pressure are influencing each other it is
always necessary to adjust both valves 252.1 + 252.2 alternately.
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Controlling Section 5.0
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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 main drive motor 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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(Exemplary illustration of the function of two axis with one Amplifier only)
Legend for illustration (Z 21638c)
(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 with 24 VDC capacitor supported 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 „X-
axis“ (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 45 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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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 motor start. The
inductive system is designed as a redundant system with two separate coils.
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Application for:
(A) Swing foot brake
(B) Clam Opening/closing
(C) Travelling
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.
In order to be able to monitor the direction of the pedal movement and the neutral
position of travel unit (C), two switches (5 and 6) are fitted; which are actuated by
the actuator (4) as soon as the lever gets moved out of its neutral position.
For the Output Signal generation are used two coils (3.1), in series connected. The
push pin motion causes a variation of the induction and this in turn causes a signal
variation at the AC voltage bridge. The AC voltage gets rectified and becomes the
DC-Signal Voltage for the amplifiers.
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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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The amplifier module contains the necessary electronics for the control of
two proportional solenoids and two directional solenoids. The amplifier
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 80ms 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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Page 16
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,- Bucket (BHA),- Travel,- and Swing Function.
B. Without ramp time module,
i.e. Bucket (FSA),- Clam,- and Swing Brake 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 solenoid valve
• When replacing a module • 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.
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Procedure applicable for all amplifiers except the one for the swing
brake:
(Do not start the motor, 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.
continued
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Controlling Section 5.0
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Cont'd:
11. 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.
12. Repeat the setting as described under item 7 to 10.
13. Remove multimeter, test wire, close* the terminals and reconnect the wire
to terminal 5 of the amplifier module.
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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)
continued
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Controlling Section 5.0
Page 20
Cont'd:
) • It is important that the pilot pressure for the pressure increasing valve
is 24+/- 1 bar.
For more information refer to section 8.2 „Swing Circuit“
10. Repeat settings of item 8 and 9 until both mA values are stabilized, because
R1 and R2 influence each other.
11. Remove multimeter, test wire, close* the terminals and reconnect the wire
to terminal 5 of the amplifier module.
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Basic Adjustment:
1. Connect 0VDC 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 +10VDC 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 Section 5.0
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Cont'd:
5. 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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Cont'd:
E48 Stick
24 Volt at Joy stick Signal Pot Value to be measured at socket "t"
Terminal 9 Neutral ⇒ Stick out 0V to +10V t1 0,10 Volt = 1000 ms
Terminal 10 Stick out ⇒ Neutral +10V to 0V t2 0,10 Volt = 1000 ms
Terminal 11 Neutral ⇒ Stick in 0V to -10V t3 0,10 Volt = 1000 ms
Terminal 12 Stick in ⇒ Neutral -10V to 0V t4 0,10 Volt = 1000 ms
E49 Boom
24 Volt at Joy stick Signal Pot Value to be measured at socket "t"
Terminal 9 Neutral ⇒ Lower 0V to +10V t1 0,2 Volt = 500 ms
Terminal 10 Lower ⇒ Neutral +10V to 0V t2 0,05 Volt = 2000 ms
Terminal 11 Neutral ⇒ Lift 0V to -10V t3 0,10 Volt = 1000 ms
Terminal 12 Lift ⇒ Neutral -10V to 0V t4 0,10 Volt = 1000 ms
E49a Boom
24 Volt at Joy stick Signal Pot Value to be measured at socket "t"
Terminal 9 Neutral ⇒ Lower 0V to +10V t1 0,067 Volt = 1493 ms
Terminal 10 Lower ⇒ Neutral +10V to 0V t2 0,10 Volt = 1000 ms
Terminal 11 Neutral ⇒ Lift 0V to -10V t3 0,10 Volt = 1000 ms
Terminal 12 Lift ⇒ Neutral -10V to 0V t4 0,10 Volt = 1000 ms
E49b Boom
24 Volt at Joy stick Signal Pot Value to be measured at socket "t"
Terminal 9 Neutral ⇒ Lower 0V to +10V t1 0,05 Volt = 2000 ms
Terminal 10 Lower ⇒ Neutral +10V to 0V t2 0,2 Volt = 500 ms
Terminal 11 Neutral ⇒ Lift 0V to -10V t3 0,10 Volt = 1000 ms
Terminal 12 Lift ⇒ Neutral -10V to 0V t4 0,10 Volt = 1000 ms
E49c Boom
24 Volt at Joy stick Signal Pot Value to be measured at socket "t"
Terminal 9 Neutral ⇒ Lower 0V to +10V t1 0,10 Volt = 1000 ms
Terminal 10 Lower ⇒ Neutral +10V to 0V t2 0,067 Volt = 1493 ms
Terminal 11 Neutral ⇒ Lift 0V to -10V t3 0,10 Volt = 1000 ms
Terminal 12 Lift ⇒ Neutral -10V to 0V t4 0,10 Volt = 1000 ms
continued
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5.0
24
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Controlling Section 5.0
Page 24
Cont'd:
E50 Swing
24 Volt at Joy stick Signal Pot Value to be measured at socket "t"
Terminal 9 Neutral ⇒ Swing R 0V to +10V t1 0,067 Volt = 1493 ms
Terminal 10 Swing R ⇒ Neutral +10V to 0V t2 0,05 Volt = 2000 ms
Terminal 11 Neutral ⇒ Swing L 0V to -10V t3 0,067 Volt = 1493 ms
Terminal 12 Swing L ⇒ Neutral -10V to 0V t4 0,05 Volt = 2000 ms
E50a Swing
24 Volt at Joy stick Signal Pot Value to be measured at socket "t"
Terminal 9 Neutral ⇒ Swing R 0V to +10V t1 0,20 Volt = 500 ms
Terminal 10 Swing R ⇒ Neutral +10V to 0V t2 0,10 Volt = 1000 ms
Terminal 11 Neutral ⇒ Swing L 0V to -10V t3 0,20 Volt = 500 ms
Terminal 12 Swing L ⇒ Neutral -10V to 0V t4 0,10 Volt = 1000 ms
E59 Bucket
24 Volt at Joy stick Signal Pot Value to be measured at socket "t"
Terminal 9 Neutral ⇒ Dump 0V to +10V t1 0,05 Volt = 2000 ms
Terminal 10 Dump ⇒ Neutral +10V to 0V t2 0,10 Volt = 1000 ms
Terminal 11 Neutral ⇒ Fill 0V to -10V t3 0,10 Volt = 1000 ms
Terminal 12 Fill ⇒ Neutral -10V to 0V t4 0,10 Volt = 1000 ms
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Components Section 6.0
Page 1
Section Page
6.0 Components
6.1 Hydraulic
6.1.1 Main Control Blocks and High Pressure Filter FSA 2
6.1.2 Main Control Blocks and High Pressure Filter BHA 3
6.1.3 Distributor Manifold – Restrictor blocks FSA 4
6.1.4 Distributor Manifold – Restrictor blocks BHA 5
6.1.5 Single Control Blocks (Floating) for Stick and Boom 6
6.1.6 Restrictor Block with Pressure Relief Valve 7
6.1.7 Anti Cavitation Valve Block 8
6.1.8 Remote Control Valves 9
6.1.9 Directional Solenoid Valves (Three positions / 4-ways) 10
6.1.10 Proportional Solenoid Valves 11
6.1.11 High Pressure Filter 12
6.1.12 Control Blocks and Valves 13 - 18
6.1.13 Travel Brake Valve 19
6.1.14 Pressure Reducing Valve 20
6.1.15 Directional Solenoid Valves (Two positions / 4-ways) 21
6.1.16 Pressure Increasing Valve 22
6.1.17 Hydraulic Cylinder 23
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3
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4
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Page 4
6.1.3 Distributor Manifold - Location of restrictor blocks and anti cavitation valves
Front Shovel Attachment
Legend for illustration (Z 21831):
(SB) Synchronization (Equalization) block
(SL) Synchronization (Equalization) lines
(SRV) Service-line Relief Valve
Pressure check point
(42) Distributor manifold
(64.1) ACV Block Section A, Boom cylinder rod side
(70.1+.2) Restrictor blocks Section B, Boom cylinder piston side
with SRVs and pressure check points M16.1 + M16.2
(65.1) SRV Section C, Bucket cylinder piston side
with SRV and pressure check point M17.1
(70.4) Restrictor block Section C, Bucket cylinder piston side
with pressure check point M17.2
(64.2) ACV Block Section C, Bucket cylinder piston side
(64.3) ACV Block Section D, Bucket cylinder rod side
(70.6) Restrictor block Section E, Clam cylinder rod side
with SRV and pressure check point M19
(64.4) ACV Block Section F, Stick cylinder rod side
(65.2) SRV Section G, Stick cylinder piston side
with pressure check point M20
(64.5) ACV Block Section H, Stick cylinder rod side
(70.8+.9) Restrictor blocks Section J, Stick cylinder piston side
with SRVs and pressure check points M21.1 + M21.2
(18) SRV Section K, Clam cylinder piston side
with pressure check points M22
(64.6) ACV Block Section K, Clam cylinder piston side
(64.7) ACV Block Section L, Bucket cylinder rod side
(64.8) ACV Block Section M, Bucket cylinder piston side
(70.12) Restrictor block Section M, Bucket cylinder piston side
with SRV and pressure check point M24
(65.3) SRV Section N, Bucket cylinder piston side
with pressure check point M25
(65.4) SRV Section O, Boom cylinder piston side
with pressure check point M26.2
(70.13) Restrictor blocks Section O, Boom cylinder piston side
with SRV and pressure check point M26.1
(64.9) ACV Block Section P, Boom cylinder rod side
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Page 5
6.1.4 Distributor Manifold - Location of restrictor blocks and anti cavitation valves
Backhoe Attachment
Legend for illustration (Z 21832):
(SL) Synchronization (Equalization) lines
(SRV) Service-line Relief Valve
Pressure check point
(42) Distributor manifold
(64.1) ACV Block Section A, Boom cylinder rod side
(70.1+.2) Restrictor blocks Section B, Boom cylinder piston side
with SRVs and pressure check points M16.1 + M16.2
(70.3) Restrictor block Section C, Bucket cylinder piston side
with SRV and pressure check point M17.1
(70.4) Restrictor block Section C, Bucket cylinder piston side
with SRV and pressure check point M17.2
(64.2) ACV Block Section C, Bucket cylinder piston side
(64.3) ACV Block Section D, Bucket cylinder rod side
(70.5) Restrictor block Section D, Bucket cylinder rod side
with SRV and pressure check point M18
(64.4) ACV Block Section F, Stick cylinder piston side
(70.7) Restrictor block Section G, Bucket cylinder rod side
with SRV and pressure check point M20
(64.5) ACV Block Section H, Stick cylinder piston side
(70.8+.9) Restrictor blocks Section J, Stick cylinder rod side
with SRVs and pressure check points M21.1 + M21.2
(70.10) Restrictor block Section K, Stick cylinder rod side
with SRV and pressure check point M22
(64.6) ACV Block Section K, Stick cylinder rod side
(70.11) Restrictor block Section L, Bucket cylinder rod side
with SRV and pressure check point M23
(64.7) ACV Block Section L, Bucket cylinder rod side
(70.12) Restrictor block Section M, Bucket cylinder piston side
with SRV and pressure check point M24
(64.8) ACV Block Section M, Bucket cylinder piston side
(70.13) Restrictor blocks Section O, Boom cylinder piston side
with SRV and pressure check point M26.1
(70.14) Restrictor blocks Section O, Boom cylinder piston side
with SRV and pressure check point M26.2
(64.9) ACV Block Section P, Boom cylinder rod side
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Page 6
Function:
Only Front Shovel Attachment
The additionally installed single control blocks (Y132, Y133,Y134 and Y135)
connect the piston side of the cylinders with the rod side and also with the tank:
Y132, Y133 and Y134 for the Stick cylinders
Y135 for the Boom cylinders
In normal operation mode (i.e. float position) the pilot pressure oil is directed via
de-energized solenoid valves to the single control blocks when lowering the
boom or stick.
If a pressurized lowering of the cylinders is required the pilot pressure oil is
directed via energized solenoid valves to the main control blocks.
The solenoid valves (4/2-directional control valves) are controlled by push
buttons located in the control levers (joysticks).
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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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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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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 (11) and
one of the directional solenoid valves (10 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 Section 6.0
Page 10
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 Section 6.0
Page 11
Function:
In unoperated 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 re-established 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.
W
• In order to achieve optimum functioning of the valve, it must be bleed
when commissioning:
- Supply pressure to the valve
- Remove plug 8
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Page 12
Function:
High-pressure in-line filters prevent contamination from entering the
hydraulic circuits. The spin-on filters are installed between the main
hydraulic pumps and multi-valve 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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14
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Components Section 6.0
Page 14
(A) E.g. the spools moves down when pilot pressure is build up in the
control pipe line a1. (Imagine the upper symbol box moves to the
center position.)
Now pump oil flows through check 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.
(B) E.g. the spool #3 moves up when pilot pressure is build up in the
control pipe b3. Now the user port B3 is supplied with pump
pressure. Via port A3 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 check valve (2) which
secures the hydraulic pump from extreme pressure peaks.
The check 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.
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15
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Components Section 6.0
Page 15
Function:
Reset springs (1) moves the spool (3) in neutral position.
Fine control grooves (2) 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 (3) is inter connecting the entire groove to the
user channel.
In neutral position of spool (3) the pump oil is flowing back via port PU to the
tank.
Lower picture:
Example. The spool is moved to left position: Port PU is closed and the
connection through the check valve RP1 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).
Return line of the pressure relief valve MRV is also connected to the port T.
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Components Section 6.0
Page 16
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 Section 6.0
Page 17
Function:
The system pressure forces onto the front area of the valve cone (1). This force
moves the valve cone against the spring (2) and allows the oil to flow from the
pump to the spool.
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 Section 6.0
Page 18
Function:
In neutral position (upper picture) of the spool (1) both valve cones (2) are
closed by the springs (3).
In a switched position (lower picture) forces the circuit pressure onto the
front area of the valve piston (2).
This force moves the piston against spring (3) and allows the oil to flow from
the pump supply (4) to the user port (A) and from port B via boring (5) to the
return oil passage.
If due to an external force the pressure directed to the pump overcomes the
pressure in the pump line; this pressure (force) closes the valve
(direction P to A).
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Components Section 6.0
Page 19
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
overspeeding.
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).
Check 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.
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Components Section 6.0
Page 20
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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21
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Components Section 6.0
Page 21
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 or 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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Page 22
Function:
The valve poppet (2) is connected via the jet bores (11) and (12) with the P
port.
If static pressure increase 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 = 45 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 possible pressure increase p is 440 bar max. or 440 bar minus the basic
setting.
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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Components Section 6.0
Page 23
General A
(1) Piston rod Flange bushing: Boom-, Stick-, Bucket-Cylinder
(2) Rod eye bushing A1 Scraper ring
(3) Piston A2 Support bushing
(4) Cylinder tube A3 Hard-plastic back-up ring
(5) Piston fitting key A4 Back-up ring
(6) Piston nut A5 Chevrons
(7) Piston nut lock (threaded pin) A6 Header ring
(8) Foot end eye bushing A7 Scraper retainer ring
A8 Cover
A9 Steel shims (splitted)
B
Flange bushing: Clam cylinder C = Piston rings
B1 Scraper ring C1 Piston seal ring
B2 „BD“ seal (Dynamic Seal) C2 Piston guide rings, hard
C3 Piston guide, soft
C4 O-ring with back-up rings
Explanation of the cylinder
markings
430/290X3150 Piston diameter / Rod diameter X Stroke
430630 40 Cylinder drawing number (identical with part
No.).
11 / 97 Assembling Month and year (final figure).
261 Internal counting number.
DB 55. Assembling crew personal code
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Main Hydraulic Pumps Section 7.0
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Pump Regulation System
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Main Hydraulic Pumps Section 7.0
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Pump Regulation System
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3
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Main Hydraulic Pumps Section 7.0
and Page 3
Pump Regulation System
General
Controlled output flow of the main pumps is necessary:
• To utilize the available motor power most efficiently in every operating
mode.
• To limit the power consumption of the hydraulic pumps depending on the
load of the motor. (Electronic pump regulation with micro-controller MC7)
• For additional functions, such as rotating dependent or temperature-
dependent flow reduction.
Function:
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Pump Regulation System
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and Page 5
Pump Regulation System
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Main Hydraulic Pumps Section 7.0
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Pump Regulation System
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and Page 7
Pump Regulation System
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Pump Regulation System
continued
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and Page 9
Pump Regulation System
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and Page 10
Pump Regulation System
continued
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Main Assembly Groups Section 7.0
Page 11
Pump support pressure X4 passes valve #7 position "b" and flows via power
control valve #9 position "a" to the large area side of positioning piston #13
Because the large area side of positioning piston #13 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.
continued
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and Page 12
Pump Regulation System
The large area side of positioning piston #13 is connected, via power control
valve (9) position "a" and pressure balance valve (7) 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 #13.
continued
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and Page 13
Pump Regulation System
The large area side of positioning piston #13 is connected, via power control
valve (9) position "a" and pressure balance valve (7), to the return oil line.
The pump moves into ½ Q-max position, because the return oil flow through
pressure balance valve (7) is restricted (due to its intermediate position),
resulting in a pressure at the large area side of the positioning piston (13).
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Main Hydraulic Pumps Section 7.0
and Page 13
Pump Regulation System
continued
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Main Hydraulic Pumps Section 7.0
and Page 14
Pump Regulation System
The operating pressure (with the value for start of de-stroking) at the slipper
pad of piston #14 moves the power control valve (9) 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 #13.
Because the large area side of positioning piston #13 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 #13 are
balanced
continued
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and Page 15
Pump Regulation System
Pressure cut-off valve: (DR control valve, Pump moves into Q-min. position)
The operating pressure moves the pressure cut-off valve #11 (at set pressure)
into position "b" and flows to the large area side of positioning piston #13.
Because the large area side of positioning piston #13 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 position.
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and Page 16
Pump Regulation System
Location of Adjustments
Legend for , illustration (Z21557)
(1) Remote control valve
(2) Q-min. stop bolt
(3) Pressure balance valve
(4) Start of destroking
(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 )
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and Page 17
Pump Regulation System
continued
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and Page 18
Pump Regulation System
The reason of this check is to make sure, the pump starts destroking at an
operating pressure of 180 bar with a pump regulation pressure X1 of 13 bar.
1. Connect a 400 bar pressure gauge to the pressure check point at the
respective high pressure filter for the pumps being checked.
2. Connect a 60 bar pressure gauge to pressure check point M5-1 at
the control and filter panel (X1-pressure).
3. Move the change over valve into position “Hydraulic” (constant
regulation mode).
4. Insert an Allen key into the angle indicator bolt (see illustration)
for better visibility of the start of destroking.
5. Start the motor and adjust at pressure reducing valve (253.2) the
X1-pressure to 13 bar.
6. Stall the hydraulic for the pump to be checked and alter the
operating pressure with the MRV up and down between 160 and
200 bar.
Start of destroking should be at an operating pressure of 180 bar,
shown at the gauge connected to the high pressure filter.
7. Re-adjust the operating pressure at the MRV to 310+10 bar and the X1-
pressure at the pressure reducing valve (253.2) to approx. 12bar.
(For exact values refer to the final test report.)
8. Remove Allen key and gauges.
continued
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and Page 19
Pump Regulation System
The reason 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. Connect a 400 bar pressure gauge to the pressure check point at the
respective high pressure filter for the pumps being checked.
2. Insert an Allen key into the angle indicator bolt (see illustration) for
better visibility of the start of destroking.
3. Start the motor, stall the hydraulic for the pump to be checked and
alter the operating pressure with the MRV up and down between 280
and 310 bar.
4. The angle indicator must indicate Q-min. position at a pressure of
300 bar shown at the gauge connected to the high pressure filter.
continued
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and Page 20
Pump Regulation System
ã
• 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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and Page 21
Pump Regulation System
The drive train of the excavator consists of an electric motor, 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 motors.
Illustration Z22407b shows the principle of the electronic load limiting control.
The MC7 (E32) processes the following input signals:
• Voltage (Pin 47) from electronic signal rectifier (A32)
• Current motor 1 (Pin 45) from electronic signal rectifier (A33)
The electric motor drives four 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 destroking).
The command value (X1-pressure) is present via proportional solenoid valves Y61-1 at
the hydraulic power controllers of each pump.
Function:
The ESR-Module (A32) transforms an AC Voltage, which is proportional to the net
voltage, into a proportional DC Voltage and transfers it into the MC7 (E32).
The ESR-Module (A33) transforms an AC Voltage, which is proportional to the motor
current, into a proportional DC Voltage and transfers it also into the MC7 (E32).
These input signals are the information about the actual load to the motor and serves the
MC7 (E32)
The control algorithm of the load limiting control (MC7) always compares the actual
required power with the rated power.
With increasing load the motor torque will rise and in turn the required power.
For this reason the electronic load limiting control will be initiated when the required
power is higher than the rated power, i.e. the torque of the main pumps will be lowered
(by reducing the X1-pressure) until the rated power is attained again.
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and Page 22
Pump Regulation System
Function check:
Measure the supply voltage. (24 VDC; GND = 0 V).
If the supply voltage is not there, check the supply cable and the circuit
breaker. If the circuit breaker always trips there may be a short within the
cables to the EPM Module or a short in the unit itself.
If the supply voltage is ok. the Output Voltages have to be checked. Check
pos. 15 VDC, neg. 15 VDC, 5 VDC to GND.
If the supply voltages are not ok. the short circuit monitoring system of the
EPM might be activated, therefore disconnect the cables at the terminals (+15
VDC, -15 VDC and +5 VDC) and repeat the voltage check.
If now (with disconnected cables) the voltages are as they should be there
is either a short within the cables or in the other modules itself. To determine
the fault connect the entire modules in sequence.
If the voltage is not ok., even when the cables are disconnected from the
EPM, the EPM-Module is defect.
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and Page 23
Pump Regulation System
W
• The potentiometer settings are under no circumstances
allowed to be altered, because the setting is possible only with a HF-
Generator and an Oscilloscope.
• If the potentiometer set-positions have been altered, a new Module,
with sealed potentiometers, must be ordered.
2. Start the motor and let it run without an extra load on it.
3. Measure the AC-Voltage between the terminals 21 and 41 and record it.
4. Measure the DC-Voltage between the terminals 23 and 11 and record it.
continued
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and Page 24
Pump Regulation System
) • The picture shows a schematic design only and not the actual circuit
diagram, the voltage- and current values may vary, therefore they are
exemplary used.
With the below shown formulas the exact Output Voltages UaDC of an ESR
can be calculated.
Small variations are caused by the transformers.
Variations greater than 20% denotes a faulty transformer.
I 100 A
ESR2 ----------------- ----------------- = 1,202 VDC Current (Condition
2)
T1 x T2 x T3 41,6 x 0.5 x 4
The AC Input Voltage for an ESR-Module can be calculated with the same
formula but without the value for T3.
I 150
ESR2 ----------- ----------- = 7,212 VAC
T1 x T2 41,6 x 0.5
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Main Hydraulic Pumps Section 7.0
and Page 24
Pump Regulation System
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and Page 25
Pump Regulation System
The MC7 microcontroller 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 overvoltage 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
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and Page 26
Pump Regulation System
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 (located in the operators cab)
or
C. With a laptop, running the BODEM software, connected to the serial
interface X13 (located in the operators cab)
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and Page 27
Pump Regulation System
1. Make sure the change over valve (253.1) is in position “Electronic Pump
Regulation”
2. Connect a pressure gauge to check point (M5.1), using a long pressure gauge
hose to be able reading the pressure in front of the X2-panel.
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 54 and 55 for 10 seconds, using two
test leads and disconnect the voltage thereafter.
4. Selection of the motor and in turn the required
proportional solenoid valve :
With the main key switch still in on position, select the output terminal of
proportional solenoid valve Y61-1 is directly selected.
Since there is only one motor with one proportional solenoid valve installed,
a 24V connection is not required.
5. Adjusting the X1-pressure:
Start the motor.
Read the pressure, required = 34± 0,5 bar
If necessary increase the X1-pressure as follows:
Connect 24V to terminal 54.
)
• 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 1bar.
• The adjusted value will be saved immediately and will be available
after power off.
6. To decrease the X1-pressure connect 24V to terminal 55 and proceed as
described under item 5, keeping voltage supply for two seconds , will
decrease the X1-pressure of approximately 1bar.
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.
continued
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Pump Regulation System
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and Page 29
Pump Regulation System
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and Page 30
Pump Regulation System
2. No Jerky movements:
a) Activate the adjusting mode:
Connect 24V, simultaneously to terminal 54 and 55 for 10 seconds, using two
test leads and disconnect the voltage thereafter.
b) Select the PID-factor adjusting mode:
Connect 24V, to terminal 50 permanent, using a test lead.
c) Connect a multi-meter to terminal 60 (reading DC-voltage) and note down the
value (represents the actual adjusted value)
e) Increase the voltage in steps of 250 mV until the system jerks, by connecting
24V to terminal 54. (As close as possible to the boarder line)
f) Now reduce the voltage in steps of 250mV until the system works smoothly
again, as described under item 1d.
3. After the adjustments are finished, remove the test leads and multi-meter, stop the
motors and turn the main key switch in OFF position to deactivate the adjusting
mode.
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and Page 31
Pump Regulation System
Method B - With the electronic service tool (EST) BB-3 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 respective change over valve is in position “Electronic Pump
Regulation”
2. Connect a pressure gauge to check point M5.1, using long pressure gauge
hoses 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 (1S1) in OFF position.
4. Turn key switch (1S1) 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.
F1 Config/Cal.
F2 Diagnostic
PROC Status
TE ACH Storage
Language selection
To change the language press simultaneously The language selection menu appears
the buttons ALT + Clear
F1 Config/Cal.
ALT + CLEAR F2 Diagnostic
PROC Status
TE ACH Storage
continued
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and Page 32
Pump Regulation System
Cont'd:
Language selection
1. Deutsch
2 2. English
3. - - -
4. - - -
One of the four main menu items can be selected using the given keys.
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and Page 33
Pump Regulation System
There are two adjustment modes (SET 1 and SET 2) integrated. SET 1 is for the main settings
and SET 2 is only for the basic adjustments. SET 2 can only activated with a password.
After start up of the MC7 with connected BB3 the adjustment modes SET 1 is active.
SET 1 F1 Config/Cal.
Press F1 Config/Cal F2 Diagnostic
PROC Status
TE ACH Storage
1 Demand Power
Press ALT + in the same time 2 Max current
3 PID - Factor
4 Error Lamp
A password will be requested
Enter password (number: 570875)
?: _
1 ... 9
SET 2 1 Configuration
Press MENU to go back to the main menue 2 PID Control
3 Low Voltage
4 –––
F1’ Config/Cal.
F2 Diagnostic
PROC Status
TE ACH Storage
To switch back to SET 1 repeat this procedure
or switch off and on the MC7.
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and Page 34
Pump Regulation System
1 Configuration
Press
1 Configuration 2
3
PID Control
Low Voltage
4 –––
1 No of valves
Press 2 No of motors 2
3
No of motors
––
4 ––
use or 1 motor
2 No of motors
Press ENTER Acceptation
2 motors
1 No valves
Press. 2 x MENU Return to sub menu. 2 No motors
3 ––
4 ––
F1’ Config/Cal.
F2 Diagnostic
PROC Status
TE ACH Storage
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and Page 35
Pump Regulation System
Press F1 Config/Cal F1
F2
Config/Cal.
Diagnostic
PROC Status
If sub menu SET 2 is displayed change to
TE ACH Storage
sub menu SET 2 as described on page 33.
1 Demand Power
Press
2 Max current 2
3
Max current
PID - Factor
4 Error Lamp
Select desired valve
1 Valve 1 Mot. 1
Press ENTER Acceptation 2 Valve 2 Mot. 1
3 Valve 1 Mot. 2
4 Valve 2 Mot. 2
F1 Config/Cal.
Press. 2 x MENU Return to main menu F2 Diagnostic
PROC Status
TE ACH Storage
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Pump Regulation System
Press F1 Config/Cal
1 Demand Power
Press 1 Configuration 2
3
Max current
PID-Factor
4 Error Lamp
Select desired demand power adjustment
SET 1 1 Set demand m. 1
Press 1 demand power Motor1 2 Set demand m. 2
or 3 Demand power 1
Press
2 demand power Motor2 4 Demand power 2
1 Set demand m. 1
Example Motor 1
0–0±1
0
and
Load respective Motor with max power
Start?
––> <ENTER>
Press ENTER Selection
Cancel?
––> <ENTER>
Press <ENTER>
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Pump Regulation System
PID-Factor adjustment:
Jerky movements while lifting with full bucket and swinging at the same time:
Reduce jerking ⇒ Reduce the PID-Factor in short steps.
To obtain the most efficient pump regulation characteristic adjust to the PID-Factor until
the system jerks as close as possible to the boarder line.
F1 Config/Cal.
Press F1 Config/Cal
F2 Diagnostic
PROC Status
If sub menu SET 2 is displayed change to TE ACH Storage
sub menu SET 1 as described on page 33.
1 PID-Factor
Press
1 PID-Factor. 2
3
–––
–––
4 –––
1 PID-Factor
2 –––
Press ENTER Acceptation 3 –––
4 –––
and check the machine movement again
if necessary repeat PID-Factor adjustment
F1 Config/Cal.
Press. 2 x MENU Return to main menu. F2 Diagnostic
PROC Status
TEACH Storage
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Pump Regulation System
F1 Config/Cal.
F2 Diagnostic
Press TEACH Activate storage menu PROC Status
TE ACH Storage
1 Save Params
Press 1 Save Params 2
3
Default Rarams
Get EEPROM
4 Send EEPROM
Teach?
Press ENTER Store parameters ––> <ENTER>
Cancel?
––> <ENTER>
1 Save Params
Press. MENU Return to main menu. 2 Default Rarams
3 Get EEPROM
4 Send EEPROM
If all adjustments are correct and stored in the MC7, proceed as follow:
• Stop the motors and turn key switch (S1) in OFF position
• Disconnect the electronic service tool (BB-3) and the pressure gauges.
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Pump Regulation System
continued
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and Page 40
Pump Regulation System
Cont'd:
Starting the program
6. The program starts (only) the first time with the Demo Version.
8. Start the program again. Now the computer is connected to the Microcontroller.
During uploading of the MC7 data to the PC a window opened and shows some
hardware and software information.
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Pump Regulation System
Language selection
Open menu FILE → Language , select the required language and confirm with OK .
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and Page 42
Pump Regulation System
Open menu Parameters and select Enter password. Write the correct password (570875)
and confirm with OK.
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Pump Regulation System
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Pump Regulation System
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Main Hydraulic Pumps Section 7.0
and Page 45
Pump Regulation System
Pre-conditions: Normal operating temperature, correct pilot pressure setting and the
system must be free of air.
Open menu Parameters and in the pull down window the menu point Display / Edit
Parameters. Now the window with the demand power adjustment will be on screen.
continued
PC4000-6-E_#08165_Sec_7-0_rev0.doc 02.03.05
7.0
46
PC4000-6-E_#08165_Sec_7-0_rev0.doc 02.03.05
Main Hydraulic Pumps Section 7.0
and Page 46
Pump Regulation System
Cont'd:
Pre-conditions: Normal operating temperature, correct pilot pressure setting and the system
must be free of air.
1. Connect pressure gauges to check points M11, M12, M13 and M14 at the
high pressure filters.
2. Connect a pressure gauge to the X1 pressure check point M5.1.
3. Unplug solenoid valves Y6a and Y6b to ensure that the hydraulic oil cooler
fans are running with maximum speed.
4. Shift the three way cock valve (253.1) to position “Hydraulic (constant)
Regulation Mode”.
5. Start the motor.
6. Set the MRV’s of main valve block I, II, III and IV individually to approx. 120
bar *, to prevent the motor from overloading during the test.
7. Set the X1-pressure at pressure reducing valve (253.2) > 34 bar **, to ensure
that the pumps remain in Q-max. flow position during the adjustment.
8. Apply max. load to all pumps (e.g. extend the bucket cylinders to the stop
position until the hydraulic system stalls), and increase the pressure at all 4
MRV’s * equally to the demand power pressure written in the final test report
e.g. PC4000, S/N 08165 = 172 bar. Check the current drawn of the respective
motor at this stage (reading of text display)
Expected: approx. ~ 128 Ampere. Record this values for other tests.
continued
*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.
PC4000-6-E_#08165_Sec_7-0_rev0.doc 02.03.05
7.0
47
PC4000-6-E_#08165_Sec_7-0_rev0.doc 02.03.05
Main Hydraulic Pumps Section 7.0
and Page 47
Pump Regulation System
Cont'd:
PC4000-6-E_#08165_Sec_7-0_rev0.doc 02.03.05
7.0
48
PC4000-6-E_#08165_Sec_7-0_rev0.doc 02.03.05
Main Hydraulic Pumps Section 7.0
and Page 48
Pump Regulation System
Open Parameters and select Display / Edit Parameters. Select in the left window PID
control. Adjust now the PID-Factor with the slide bar or write direct the requested
value to the window with the % value. Write new adjustment permanent to the MC7
EEPROM with Apply and confirm with OK.
• Jerky movements while lifting and swinging at the same time: Reduce the PID-Factor in
short steps until the system works smoothly. (As close as possible to the boarder line)
• No Jerky movements:
1. Increase the PID-Factor in short steps until the system jerks. (As close as possible to the
boarder line)
2. Now reduce the PID-Factor in short steps until the system works smoothly again.
PC4000-6-E_#08165_Sec_7-0_rev0.doc 02.03.05
7.0
49
PC4000-6-E_#08165_Sec_7-0_rev0.doc 02.03.05
Main Hydraulic Pumps Section 7.0
and Page 49
Pump Regulation System
7.3.1. General
The pilot pressure pump (8.1) delivers the oil through the pressure filter (33)
to port A of the pressure relief valve (252.2) for limiting the pump support
pressure X4 to 60 bar. By the function of pressure reducing valve (252.1), the
X4 pressure of 60 bar is reduced to the pilot pressure X2 of 45 bar. The
common X2 pressure will be reduced by the function of pressure reducing
valves (253.2) to the necessary constant X1 pressure, to prevent the motor from
overloading.
PC4000-6-E_#08165_Sec_7-0_rev0.doc 02.03.05
7.0
50
PC4000-6-E_#08165_Sec_7-0_rev0.doc 02.03.05
Main Hydraulic Pumps Section 7.0
and Page 50
Pump Regulation System
PC4000-6-E_#08165_Sec_7-0_rev0.doc 02.03.05
Operating Hydraulic Section 8.0
Page 1
PC4000-6-E_#08165_Sec_8-0_rev0.doc 02.03.05
8.0
2
PC4000-6-E_#08165_Sec_8-0_rev0.doc 02.03.05
Operating Hydraulic Section 8.0
Page 2
8.0 General
General information
The control blocks, the piping to the distributor manifold and the connecting
hoses to the attachment are 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 4) delivers oil trough the high pressure filter (13.1 to
13.4) to port P of the main control blocks (I to IV).
This results in four main circuits.
If all spools of the control blocks (I to IV) are in neutral position, the oil
leaves the block at port T and returns via return oil pipes, return oil collector
manifold (107), return oil pipes (L6 and L7), return oil collector tube (54),
back pressure valve (55) and the return oil filters (49.1 - 49.4) into the tank.
The function of back pressure valve (55) ensures:
- sufficient oil supply for all anticavitation 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
PC4000-6-E_#08165_Sec_8-0_rev0.doc 02.03.05
8.0
3
PC4000-6-E_#08165_Sec_8-0_rev0.doc 02.03.05
Operating Hydraulic Section 8.0
Page 3
8.0 General
Cont'd:
Function:
The additionally installed single control blocks (Y132, Y133,Y134 and Y135)
connect the piston side of the cylinders with the rod side and also with the tank:
Y132, Y133 and Y134 for the Stick cylinders
Y135 for the Boom cylinders
In normal operation mode (i.e. float position) the pilot pressure oil is directed via
Y132a, Y133a and Y135a to the single control blocks when lowering the boom
or stick.
If a pressurised lowering of the cylinders is required the pilot pressure oil is
directed via Y132a, Y133a and Y135a to the main control blocks.
The solenoid valves Y132a, Y133a and Y135a (4/2-directional control valves) are
controlled by push button S95 and S95a.
Boom: S95 ON ⇒ Y135a ON ⇒ Float position deactivated
S95 OFF ⇒ Y135a OFF ⇒ Float position activated
)
• 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
PC4000-6-E_#08165_Sec_8-0_rev0.doc 02.03.05
Hydraulic for the Section 8.1
Page 1
Attachment Cylinders
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
2
E19
D32
gn
YD -10V
X2 482
X2 481
E49 5
7
Bucket
2 6
K58 4 8 2 6
(boom up) 10 K76 K78
(left crawler) 12 (right crawler) 10
5 5 5 5
A10b A10 A10a A10c
7-8 3 7-8 3 7-8 3 7-8 3
15
14.2 14.1 14.3
1 2
Y73 Y40
Y69 1 2 Y33 3 4 1 2 Y76 1 2 Y46
3 4
95
5 6 3 4 3 4
5 6 1 7 8 5 6 5 6
2 Y63 Y20
b1 b2 b3 b1 b2 b3 b4 b1 b2 b3 b1 b2 b3 b4
I B1 B2 B3 II B1 B2 B3 B4 III B1 B2 B3 IVB1 B2 B3 B4
A1 A2 A3 A1 A2 A3 A4 A1 A2 A3 A1 A2 A3 A4
a1 a2 a3 a1 a2 a3 a4 a1 a2 a3 a1 a2 a3 a4
A B C D E F G H J K L M N O P
42
Z 21956
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
Hydraulic for the Section 8.1
Page 2
Attachment Cylinders
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
3
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
Hydraulic for the Section 8.1
Page 3
Attachment Cylinders
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
4
YC +10V
E19
D32
gn
X2 482
X2 481
E49 5
7
Bucket
2 6
K58 4 8 2 6
(boom up)
10 K76 K78
(left crawler) 12 (right crawler) 10
5 5 5 5
A10b A10 A10a A10c
7-8 9 7-8 9 7-8 9 7-8 9
15
14.2 14.1 14.3
1 2
Y73 Y41
1 2 3 4 1 2 Y76 1 2 Y47
3 4
95
5 6 3 4 3 4
5 6 1 7 8 5 6 5 6
2 Y63 Y21
Y135a
b1 b2 b3 b1 b2 b3 b4 b1 b2 b3 b1 b2 b3 b4
I B1 B2 B3 II B1 B2 B3 B4 III B1 B2 B3 IVB1 B2 B3 B4
A1 A2 A3 A1 A2 A3 A4 A1 A2 A3 A1 A2 A3 A4
a1 a2 a3 a1 a2 a3 a4 a1 a2 a3 a1 a2 a3 a4
A B C D E F G H J K L M N O P
42
Y135
P A
T B
PC4000-6-E_#08165_Sec_8-1_rev0.doc
Z 21958
02.03.05
Hydraulic for the Section 8.1
Page 4
Attachment Cylinders
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
5
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
Hydraulic for the Section 8.1
Page 5
Attachment Cylinders
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
6
YC +10V
E20
gn D32
X2 480
X2 479
E48 5
Bucket fill
1 5 4 8
K74 K78
(Stick out) 9 (right crawler) 12
2 6
5 K76 5
A8 (left crawler) 10 A8a
7-8 9 7-8 9
5
A9
X2 237 236 7-8 9 X2 254 253
X2 210 203
14.2 14.3
1 2
15 1 2
Y68 3 4 Y30 3 4
1 2
5 6 3 4 5 6
Y74 Y42
Y71 5 6 Y37
7 8
b1 b2 b3 b1 b2 b3 b4 b1 b2 b3 b4
I B1 B2 B3 II B1 B2 B3 B4 IVB1 B2 B3 B4
A1 A2 A3 A1 A2 A3 A4 A1 A2 A3 A4
a1 a2 a3 a1 a2 a3 a4 a1 a2 a3 a4
A B C D E F G H J K L M N O P
42
T B T B T B
Z 21960
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
Hydraulic for the Section 8.1
Page 6
Attachment Cylinders
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
7
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
Hydraulic for the Section 8.1
Page 7
Attachment Cylinders
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
8
E20
gn D32
YD -10V
X2 480
X2 479
E48 5
Bucket fill
1 5 4 8
K74 K78
(Stick out) 9 (right crawler) 12
2 6
5 K76 5
A8 (left crawler) 10 A8a
7-8 3 7-8 3
5
A9
X2F 10 14 7-8 9 X2F 51 52
14.2 14.3
1 2 1 2
Y68 3 4 Y31 3 4
5 6 5 6
Y74 Y43
Y132a Y133a
b1 b2 b3 99.5
b1 b2 b3 b4
I B1 B2 B3 IVB1 B2 B3 B4
A1 A2 A3 A1 A2 A3 A4
a1 a2 a3 a1 a2 a3 a4
A B C D E F G H J K L M N O P
42
T B T B T B
PC4000-6-E_#08165_Sec_8-1_rev0.doc
Z 21962
02.03.05
Hydraulic for the Section 8.1
Page 8
Attachment Cylinders
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
9
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
Hydraulic for the Section 8.1
Page 9
Attachment Cylinders
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
10
XB -10V E19
ws/gn D32
X2 477
X2 476
10
K50
6 (Hydr. oil 9
2 not overheat )
5 1
K58
(Boom up )
10 9
K71 K71
6 (Bucket fill ) 1 5 5 (Bucket fill )
2 K74 1
9 (Stick out )
6 2 2 6 3 7
K58
(Boom up ) K76 K78
10 (left crawler) 10 (right crawler) 11
5 5 5 5
A10b A9 A9a A9b
7-8 3 7-8 3 7-8 3 7-8 3
15
14.2 14.1 14.3
1 2
Y69 1 2 Y32 3 4 1 2 1 2
3 4
Y71 5 6 Y36 Y64 3 4 Y22 Y75 3 4 Y44
5 6 7 8 5 6 5 6
b1 b2 b3 b1 b2 b3 b4 b1 b2 b3 b1 b2 b3 b4
I B1 B2 B3 II B1 B2 B3 B4 III B1 B2 B3 IVB1 B2 B3 B4
A1 A2 A3 A1 A2 A3 A4 A1 A2 A3 A1 A2 A3 A4
a1 a2 a3 a1 a2 a3 a4 a1 a2 a3 a1 a2 a3 a4
A B C D E F G H J K L M N O P
42
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
Z 21965
Hydraulic for the Section 8.1
Page 10
Attachment Cylinders
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
11
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
Hydraulic for the Section 8.1
Page 11
Attachment Cylinders
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
12
E19
ws/gn XA +10V D32
X2 477
X2 476
10
K50
6 (Hydr. oil 9
2 not overheat )
5 1
K58
(Boom up )
9
K71
5 (Bucket fill )
1
3 7
K78
(right crawler) 11
5 5
A9a A9b
7-8 9 7-8 9
14.1 14.3
1 2 1 2
b1 b2 b3 b1 b2 b3 b4
III B1 B2 B3 IVB1 B2 B3 B4
A1 A2 A3 A1 A2 A3 A4
a1 a2 a3 a1 a2 a3 a4
A B C D E F G H J K L M N O P
42
PC4000-6-E_#08165_Sec_8-1_rev0.doc Z 21967
02.03.05
Hydraulic for the Section 8.1
Page 12
Attachment Cylinders
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
13
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
Hydraulic for the Section 8.1
Page 13
Attachment Cylinders
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
14
E24
-10V D32
rs
X2 484
3 7
K76
(left crawler) 11
5
A11
7-8 3
X2 209 214
15
1 2
Y72 3 4 Y39
5 6
7 8
b1 b2 b3 b4
II B1 B2 B3 B4
A1 A2 A3 A4
a1 a2 a3 a4
A B C D E F G H J K L M N O P
42
Z 21970
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
Hydraulic for the Section 8.1
Page 14
Attachment Cylinders
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
15
E23
D32
+ 10V
rs
X2 484
3 7
K76
(left crawler) 11
5
A11
7-8 9
X2 209 208
15
1 2
Y72 3 4 Y38
5 6
7 8
b1 b2 b3 b4
II B1 B2 B3 B4
A1 A2 A3 A4
a1 a2 a3 a4
A B C D E F G H J K L M N O P
42
Z 21971
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
Hydraulic for the Section 8.1
Page 15
Attachment Cylinders
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
16
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
Hydraulic for the Section 8.1
Page 16
Attachment Cylinders
8.1.9 Checks and adjustments of the Main Relief Valves (MRV), illustration (Z 21972):
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).
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).
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
17
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
Hydraulic for the Section 8.1
Page 17
Attachment Cylinders
8.1.9 Checks and adjustments of the Main Relief Valves (MRV), illustration (Z 21972):
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).
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.
5. Tighten lock nut (b) and install cap (a).
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
18
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
Hydraulic for the Section 8.1
Page 18
Attachment Cylinders
8.1.10 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 21973):
Boom cylinder “Piston side” FSA + BHA
There are six service line relief valves (secondary valves) installed, four at
the distributor manifold (42), one in main control block II and one in block
IV, 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.
)
• 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.
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
19
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
Hydraulic for the Section 8.1
Page 19
Attachment Cylinders
8.1.10 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 21973):
Cont'd:
Boom cylinder “Piston side” FSA +BHA
9. Adjust all six 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:
70.1 Ì 70.2 Ì 70.13 Ì 65.4 Ì 66.5 Ì 66.7
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- 70.1 to a value below the required value,
and then increase up to the required pressure (350 bar), while
observing all gauges.
) • Now all gauges will show the same value of 350 bar,
but only SRV-70.1 has the correct setting.
11. Proceed with the other valves in the same manner in the following
sequence:
70.2 Ì 70.13 Ì 65.4 Ì 66.5 Ì 66.7
ã
• 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. 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).
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
20
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
Hydraulic for the Section 8.1
Page 20
Attachment Cylinders
8.1.10 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 21974):
)
• If the piston rod 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.
continued
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
21
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
Hydraulic for the Section 8.1
Page 21
Attachment Cylinders
8.1.10 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 21974):
Cont'd:
Boom cylinder “Piston rod side” FSA +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).
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- 68.8 to a value below the required value,
and then increase up to the required pressure (350 bar), while
observing all gauges.
) • Now all gauges will show the same value of 350 bar,
but only SRV-68.8 has the correct setting.
ã
• 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.
12. 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).
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
22
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
Hydraulic for the Section 8.1
Page 22
Attachment Cylinders
8.1.10 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 21977):
Stick cylinder “Piston side” FSA
There are four service line relief valves (secondary valves) installed, three at
the distributor manifold (42) and one in main control block IV, 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.
)
• 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.
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
23
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
Hydraulic for the Section 8.1
Page 23
Attachment Cylinders
8.1.10 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 21977):
Cont'd:
Stick cylinder “Piston side” FSA
9. Adjust all four 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:
65,2 Ì 70.8 Ì 70.9 Ì 66.11
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- 65.2 to a value below the required value,
and then increase up to the required pressure (350 bar), while
observing all gauges.
) • Now all gauges will show the same value of 350 bar,
but only SRV-65.2 has the correct setting.
11. Proceed with the other valves in the same manner in the following
sequence:
70.8 Ì 70.9 Ì 66.11
ã
• 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 four service line relief valves.
12. 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).
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
24
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Page 24
Attachment Cylinders
8.1.10 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 21978):
Stick cylinder “Piston side” BHA
There are three service line relief valves (secondary valves) installed, in main
control blocks I, II and IV, 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.
)
• 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.
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
25
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Page 25
Attachment Cylinders
8.1.10 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 21978):
Cont'd:
Stick 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:
66,4 Ì 66.6 Ì 66.12
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- 66.4 to a value below the required value,
and then increase up to the required pressure (350 bar), while
observing all gauges.
) • Now all gauges will show the same value of 350 bar,
but only SRV-66.4 has the correct setting.
11. Proceed with the other valves in the same manner in the following
sequence:
66.6 Ì 66.12
ã
• 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 three service line relief valves.
12. 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).
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26
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Attachment Cylinders
8.1.10 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 21979):
)
• 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.
continued
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
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27
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Page 27
Attachment Cylinders
8.1.10 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 21979):
Cont'd:
Stick cylinder “Piston 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:
66,4 Ì 66.12
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- 66.4 to a value below the required value,
and then increase up to the required pressure (350 bar), while observing
all gauges.
) • Now all gauges will show the same value of 350 bar,
but only SRV-66.4 has the correct setting.
ã
• 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.
12. 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).
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Attachment Cylinders
8.1.10 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 21980a):
)
• 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.
continued
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
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29
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Attachment Cylinders
8.1.10 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 21980a):
Cont'd:
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:
70.8 Ì 70.9Ì 70.10
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- 70.8 to a value below the required value,
and then increase up to the required pressure (350 bar), while observing
all gauges.
) • Now all gauges will show the same value of 350 bar,
but only SRV-70.8 has the correct setting.
11. Proceed with the other valves in the same manner in the following
sequence:
70.9 Ì 70.10
ã
• 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.
12. 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).
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
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Attachment Cylinders
8.1.10 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 21997):
Bucket cylinder “Piston side” FSA
There are six service line relief valves (secondary valves) installed, four at
the distributor manifold (42), one in main control block III and one in block
IV, 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.
)
• 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.
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
Hydraulic for the Section 8.1
Page 31
Attachment Cylinders
8.1.10 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 21997):
Cont'd:
Bucket cylinder “Piston side” FSA
9. Adjust all six 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:
65.1 Ì 70.4 Ì 70.12 Ì 65.3 Ì 66.1 Ì 66.9
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- 65.1 to a value below the required value,
and then increase up to the required pressure (350 bar), while
observing all gauges.
) • Now all gauges will show the same value of 350 bar,
but only SRV-65.1 has the correct setting.
11. Proceed with the other valves in the same manner in the following
sequence:
70.4 Ì 70.12 Ì 65.3 Ì 66.1 Ì 66.9
ã
• 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. 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).
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Attachment Cylinders
8.1.10 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 21998):
Bucket cylinder “Piston side” BHA
There are three service line relief valves (secondary valves) installed at the
distributor manifold (42), 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.
)
• 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.
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
33
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Page 33
Attachment Cylinders
8.1.10 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 21998):
Cont'd:
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:
70.3 Ì 70.4 Ì 70.12
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- 70.3 to a value below the required value,
and then increase up to the required pressure (350 bar), while
observing all gauges.
) • Now all gauges will show the same value of 350 bar,
but only SRV-70.3 has the correct setting.
11. Proceed with the other valves in the same manner in the following
sequence:
70.4 Ì 70.12
ã
• 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 three service line relief valves.
12. 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).
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
34
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Page 34
Attachment Cylinders
8.1.10 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 21999):
)
• 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.
continued
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
35
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Page 35
Attachment Cylinders
8.1.10 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 21999):
Cont'd:
Bucket cylinder “Piston 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:
66,2 Ì 66.10
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- 66.2 to a value below the required value,
and then increase up to the required pressure (350 bar), while observing
all gauges.
) • Now all gauges will show the same value of 350 bar,
but only SRV-66.2 has the correct setting.
ã
• 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.
12. 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).
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
36
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Page 36
Attachment Cylinders
8.1.10 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 22000):
Bucket cylinder “Piston rod side” BHA
There are three service line relief valves (secondary valves) installed at the
distributor manifold (42), 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.
)
• 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.
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
37
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
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Page 37
Attachment Cylinders
8.1.10 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 22000):
Cont'd:
Bucket cylinder “Piston rod 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:
70.5 Ì 70.7 Ì 70.11
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- 70.5 to a value below the required value,
and then increase up to the required pressure (350 bar), while
observing all gauges.
) • Now all gauges will show the same value of 350 bar,
but only SRV-70.5 has the correct setting.
11. Proceed with the other valves in the same manner in the following
sequence:
70.7 Ì 70.11
ã
• 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 three service line relief valves.
12. 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).
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
38
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Page 38
Attachment Cylinders
8.1.10 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 22001):
Clam cylinder “Piston rod side” FSA
There is one service line relief valve (secondary valve) installed at the
distributor manifold (42), 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.
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
39
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Page 39
Attachment Cylinders
8.1.10 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 22002):
Clam cylinder “Piston side” FSA
There are two service line relief valves (secondary valves) installed, one at
distributor manifold (42) and one in main control block II, to limit the
maximum possible pressure in the service line when closing the bucket.
To avoid damages at the clam shell, due to improper operation, the SRV’s
should be adjusted in a way that the pressure is just sufficient to keep the
bucket closed.
)
• 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.
• For standard buckets the pressure is 150 bar, reinforced or with heavy
wear package attached, the pressure maybe raised up to 200 bar.
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
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40
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Hydraulic for the Section 8.1
Page 40
Attachment Cylinders
and allow pressure equalising by moving the joy sticks several times.
- Loosen the lock nut (1) and turn the bolt (2) cw for more restriction and ccw
for less restricton. If more than one restrictor is used for one movement
make sure all set screws are equally adjusted.
For more information refer to the respective Parts & Service News
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
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41
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Page 41
Attachment Cylinders
Adjustments / Checks:
ã • 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 stroke limiter of
the single control block (Y135).
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.
6. Check lowering speed again and repeat the adjustment if necessary.
7. If the adjustment is finished tighten lock nut (1).
continued
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
42
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
Hydraulic for the Section 8.1
Page 42
Attachment Cylinders
Cont'd:
Boom cylinder FSA
Maximum permissible lowering speed:
Adjustments / Checks:
II. Float position deactivated (with push button S95):
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 engine to high idle speed.
4. 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).
ã • 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 70.1
70.2 and 70.13 at the distributor manifold (42).
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.
O.K.
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
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43
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Page 43
Attachment Cylinders
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 engine 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).
ã • 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
70.1, 70.2 , 70.13 and 70.14 at the distributor manifold (42).
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.
O.K.
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
44
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Page 44
Attachment Cylinders
Adjustments / Checks:
O.K.
Continued
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
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45
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Page 45
Attachment Cylinders
Cont'd:
Stick cylinder FSA
Maximum permissible lowering speed:
Adjustments / Checks:
II. Float position deactivated (with push button S95a):
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 engine to high idle speed.
4. 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).
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 70.8
and 70.9 at the distributor manifold (42).
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.
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
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46
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Page 46
Attachment Cylinders
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 engine to high idle speed.
4. 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).
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
70.8, 70.9 and 70.10 at the distributor manifold (42).
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.
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
47
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
Hydraulic for the Section 8.1
Page 47
Attachment Cylinders
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 engine to high idle speed.
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 70.4
and 70.12 at the distributor manifold (42).
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.
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
48
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
Hydraulic for the Section 8.1
Page 48
Attachment Cylinders
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 engine to high idle speed.
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
70.3, 70.4 and 70.12 at the distributor manifold (42).
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.
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
8.1
49
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
Hydraulic for the Section 8.1
Page 49
Attachment Cylinders
Adjustments / Checks:
1. Use a stop watch to measure the cylinder running time.
2. Open the clam of the empty bucket to the maximum height position (A).
3. Shift the engine to high idle speed.
4. Rapidly push the control pedal (E23) to the 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 valve 70.6
at the distributor manifold (42).
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.
6. Check lowering speed again and repeat the adjustment if necessary.
7. If the adjustment is finished tighten lock nut (1).
PC4000-6-E_#08165_Sec_8-1_rev0.doc 02.03.05
Hydraulic for the Swing Circuit Section 8.2
Page 1
Section Page
8.2 Hydraulic for the swing circuit
8.2.1 Swing Circuit (Brief description) 2+3
8.2.2 Swing Motor 4+5
8.2.3 Swing Gear Box 6
8.2.4 Swing Parking Brake (Gear house Brake) 7
8.2.5 Swing Brake Valve 8+9
8.2.6 Electric / Hydraulic flowchart “Swing Left” 10
8.2.7 Electric / Hydraulic flowchart “Swing Right” 11
8.2.8 Checks and adjustments for the swing circuit 12 + 13 +14
8.2.9 Function check for the hydraulic swing brake 15
8.2.10 Function check for the swing parking brake 16
PC4000-6-E_#08165_Sec_8-2_rev0.doc 02.03.05
8.2
2
PC4000-6-E_#08165_Sec_8-2_rev0.doc 02.03.05
Hydraulic for the Swing Circuit Section 8.2
Page 2
continued
PC4000-6-E_#08165_Sec_8-2_rev0.doc 02.03.05
8.2
3
PC4000-6-E_#08165_Sec_8-2_rev0.doc 02.03.05
Hydraulic for the Swing Circuit Section 8.2
Page 3
Cont'd.:
PC4000-6-E_#08165_Sec_8-2_rev0.doc 02.03.05
8.2
4
PC4000-6-E_#08165_Sec_8-2_rev0.doc 02.03.05
Hydraulic for the Swing Circuit Section 8.2
Page 4
continued
PC4000-6-E_#08165_Sec_8-2_rev0.doc 02.03.05
8.2
5
PC4000-6-E_#08165_Sec_8-2_rev0.doc 02.03.05
Hydraulic for the Swing Circuit Section 8.2
Page 5
Cont'd.:
Function:
The pressure oil inlet (A or B) and consequent oil outlet (B or A) determine
the output drive direction of the drive shaft (1).
Direction of rotation:
"Clockwise" = Direction of flow A to B
"Counter-Clockwise" = Direction of flow B to A
with view onto drive shaft!
Via the control lens (8) the oil is directed to the cylinder bores.
The piston (5) is moved from the lower (6b) to the up- per dead point (6a) by
means of the force acting on it and causes the drive shaft to rotate. On further
rotation of the drive shaft (additional pistons are pressurized) this piston is
moved towards the lower dead point again and oil of the cylinder chamber is
forced out through the kidney formed openings of the control lens. This oil is
fed back to the tank via the return line.
If the supply and return line is changed it changes the output drive direction
of the drive shaft.
By means of the angled arrangement of the cylinder (7) (bent axis design), a
certain piston stroke is produced which results in a fixed displacement per
revolution of the drive shaft. According to the size of the applied flow this
produces a specific output speed.
The output torque at the drive shaft is dependent on the size of the motor and
the required operating pressure.
PC4000-6-E_#08165_Sec_8-2_rev0.doc 02.03.05
8.2
6
PC4000-6-E_#08165_Sec_8-2_rev0.doc 02.03.05
Hydraulic for the Swing Circuit Section 8.2
Page 6
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.
To lubricate the pinion bearing port (22) is connected to the central
lubrication system.
PC4000-6-E_#08165_Sec_8-2_rev0.doc 02.03.05
8.2
7
PC4000-6-E_#08165_Sec_8-2_rev0.doc 02.03.05
Hydraulic for the Swing Circuit Section 8.2
Page 7
Function:
Brake applied:
The outer disks (4) engaged to the housing by serration and the inner disks (3) in
serrated connection with drive shaft (12) are pressed together by the springs (9).
This results in a fixed connection between housing and drive shaft.
Brake released:
Oil pressure via port (13) reaches the bottom of the piston (6) and forces the
piston upwards against the thrust washer (10).
This function eliminates the spring force onto the disks so that the sinus
(spacing) rings can keep the outer disks (4) apart, thus the brake is released.
The releasing pressure is 19 - 20 bar, the maximum permissible pressure
60 bar.
This is a so named "Wet Brake" because the brake housing is splash lubricated
by gear oil.
PC4000-6-E_#08165_Sec_8-2_rev0.doc 02.03.05
8.2
8
PC4000-6-E_#08165_Sec_8-2_rev0.doc 02.03.05
Hydraulic for the Swing Circuit Section 8.2
Page 8
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
continued
PC4000-6-E_#08165_Sec_8-2_rev0.doc 02.03.05
8.2
9
PC4000-6-E_#08165_Sec_8-2_rev0.doc 02.03.05
Hydraulic for the Swing Circuit Section 8.2
Page 9
Cont'd.:
If after a swing motion the joy stick is put 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.
In this period the pressure in the service line is lower than the pressure in
the return line, because there is a back pressure valve at the tank, and oil is
forced through the anti-cavitation valves into the service line.
PC4000-6-E_#08165_Sec_8-2_rev0.doc 02.03.05
8.2
10
PC4000-6-E_#08165_Sec_8-2_rev0.doc 02.03.05
Hydraulic for the Swing Circuit Section 8.2
Page 10
PC4000-6-E_#08165_Sec_8-2_rev0.doc 02.03.05
8.2
11
PC4000-6-E_#08165_Sec_8-2_rev0.doc 02.03.05
Hydraulic for the Swing Circuit Section 8.2
Page 11
PC4000-6-E_#08165_Sec_8-2_rev0.doc 02.03.05
8.2
12
PC4000-6-E_#08165_Sec_8-2_rev0.doc 02.03.05
Hydraulic for the Swing Circuit Section 8.2
Page 12
If adjustment is necessary:
5. Loosen lock nut (e)
6. Adjust the pressure with set screw (f)
7. Tighten lock nut and remove the gauges.
PC4000-6-E_#08165_Sec_8-2_rev0.doc 02.03.05
8.2
13
PC4000-6-E_#08165_Sec_8-2_rev0.doc 02.03.05
Hydraulic for the Swing Circuit Section 8.2
Page 13
8.2.8 Checks and adjustments for the swing circuit, illu. (Z 21948b)
)
• It is important that the complete MRV-valve and the Pressure
Increasing Valve is firmly (with 300 Nm) tightened.
Otherwise, internal leaks could occur which result in:
problems of correct adjustment, loud flow noises and high
temperatures.
• Whenever pressure checks are carried out, they must be carried out
for both, R.H. and L.H. Swing, to make sure the double check valves in
the control lines and the check valves in the brake valve blocks are in
good condition.
• 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.
PC4000-6-E_#08165_Sec_8-2_rev0.doc 02.03.05
8.2
14
PC4000-6-E_#08165_Sec_8-2_rev0.doc 02.03.05
Hydraulic for the Swing Circuit Section 8.2
Page 14
8.2.8 Checks and adjustments for the swing circuit, illu. (Z 21948b)
ã
• Strong pulsation of the return line hoses, indicates deviation in
opening pressure of PIV’s and must be avoided.
Repeat the adjusting procedure until the oil returns well-balanced
via all three pressure increasing valves.
PC4000-6-E_#08165_Sec_8-2_rev0.doc 02.03.05
8.2
15
PC4000-6-E_#08165_Sec_8-2_rev0.doc 02.03.05
Hydraulic for the Swing Circuit Section 8.2
Page 15
PC4000-6-E_#08165_Sec_8-2_rev0.doc 02.03.05
8.2
16
PC4000-6-E_#08165_Sec_8-2_rev0.doc 02.03.05
Hydraulic for the Swing Circuit Section 8.2
Page 16
4. Actuate either L.H. or R.H. rotation, the machine should not turn.
PC4000-6-E_#08165_Sec_8-2_rev0.doc 02.03.05
Hydraulic for the Travel Circuit Section 8.3
Page 1
Section Page
8.3 Hydraulic for the swing circuit
8.3.1 Travel Circuit (Brief description) 2+3
8.3.2 Travel Motor 4
8.3.3 Rotary distributor 5
8.3.4 Travel Gear Box 6
8.3.5 Travel Parking Brake (Gear house Brake) 7
8.3.6 Travel Brake Valve 8
8.3.7 Electric / Hydraulic flowchart “Travel forward” 9
8.3.8 Electric / Hydraulic flowchart “Travel backward” 10
8.3.9 Checks and adjustments for the travel circuit 11
8.3.10 Function check for the travel parking brake 12
PC4000-6-E_#08165_Sec_8-3_rev0.doc 02.03.05
8.3
2
PC4000-6-E_#08165_Sec_8-3_rev0.doc 02.03.05
Hydraulic for the Travel Circuit Section 8.3
Page 2
continued
PC4000-6-E_#08165_Sec_8-3_rev0.doc 02.03.05
8.3
3
PC4000-6-E_#08165_Sec_8-3_rev0.doc 02.03.05
Hydraulic for the Travel Circuit Section 8.3
Page 3
Cont'd.:
Illustration (Z 22506a):
Brief description (Service circuits)
(Study together with the hydraulic and electric circuit diagram).
The travel motors (21.1 + 21.2) are driven by the pumps (2 + 4).
The oil flows from the pumps through the high pressure filters to the control
blocks (II + IV).
In neutral position of the spools the oil flows via the return oil lines into the
collector tube (107) and further via the return oil lines (L6 + L7) into the tank
collector tube (54) and further to the tank.
On its way to tank the oil must flow through the back pressure valve (55) and
the return oil filter (59.1 - 59.4). (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 (19) and travel brake valves (56.1 + 56.2) to the travel
motors (21.1 + 21.2).
The travel brake valve acts as a flow control valve in order to avoid the travel
motors picking up speed when travelling downhill.
Each travel gear includes a spring loaded multi disk brakes (House brakes 57.1 -
57.2). They are used as parking brakes, automatically applied by the function of
Y16 whenever the engine is switched OFF.
The brake release pressure is monitored by the pressure switch (B48).
The leak oil (case drain) flows through the line (L9) and the leak oil filter (53)
back to tank.
PC4000-6-E_#08165_Sec_8-3_rev0.doc 02.03.05
8.3
4
PC4000-6-E_#08165_Sec_8-3_rev0.doc 02.03.05
Hydraulic for the Travel Circuit Section 8.3
Page 4
Function:
The pressure oil inlet (A or B) and consequent oil outlet (B or A) determine
the output drive direction of the drive shaft (1).
Direction of rotation:
"Clockwise" = Direction of flow A to B
"Counter-Clockwise" = Direction of flow B to A
with view onto drive shaft!
Via the control lens (8) the oil is directed to the cylinder bores.
The piston (5) is moved from the lower (6b) to the upper dead point (6a) by
means of the force acting on it and causes the drive shaft to rotate. On further
rotation of the drive shaft (additional pistons are pressurized) this piston is
moved towards the lower dead point again and oil of the cylinder chamber is
forced out through the kidney formed openings of the control lens. This oil is
fed back to the tank via the return line.
If the supply and return line is changed it changes the output drive direction
of the drive shaft.
By means of the angled arrangement of the cylinder (7) (bent axis design), a
certain piston stroke is produced which results in a fixed displacement per
revolution of the drive shaft. According to the size of the applied flow this
produces a specific output speed.
The output torque at the drive shaft is dependent on the size of the motor and
the required operating pressure.
PC4000-6-E_#08165_Sec_8-3_rev0.doc 02.03.05
8.3
5
PC4000-6-E_#08165_Sec_8-3_rev0.doc 02.03.05
Hydraulic for the Travel Circuit Section 8.3
Page 5
Task:
The rotary distributor (joint) permits a hydraulic connection between the
superstructure and the under- carriage, that means between the rotating and the
stationary part.
Ports:
A-D Service lines
K1 / K2 Control oil track tensioning
L Leak oil
ST Control oil
T Return oil to tank
The letters punch marked, beside the ports are marked as they are used in the
hydraulic diagram.
Function:
During operation superstructure and under carriage constantly rotate towards
each other. Nevertheless, the travel oil motors must be supplied with
hydraulic oil in every position in which the superstructure is moved 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.
The sealing of the ring grooves among one another is done by sealing
elements (5).
The hydraulic connection for case drain, house brake and the track tensioning
cylinders is done via the ports (L), (St), (K1) and (K2).
The entering of dirt gets blocked by the seal ring (6) and the collar of the
cover (3). The rotor (1) is at the top and bottom section guided in the housing
by the guide rings (7).
PC4000-6-E_#08165_Sec_8-3_rev0.doc 02.03.05
8.3
6
PC4000-6-E_#08165_Sec_8-3_rev0.doc 02.03.05
Operating Hydraulic Section 8.3
Page 6
The travel gear consists of one spur gear set and two planetary stages.
The travel gearbox is fitted to the side frame with bolts.
Function:
Spur gear (2) is driven by a hydraulic motor and input drive shaft (1).
The planetary carrier first stage (5) is driven by sun gear (3) which is connected
to spur gear (2).
The planetary gears are revolving in the planetary ring gear of the housing. As a
result of the fixed housing the planetary carrier will be turned.
The planetary carrier second stage (8) is turned by sun gear (7) which is
connected to the sprocket drive shaft.
PC4000-6-E_#08165_Sec_8-3_rev0.doc 02.03.05
8.3
7
PC4000-6-E_#08165_Sec_8-3_rev0.doc 02.03.05
Hydraulic for the Travel Circuit Section 8.3
Page 7
Function:
Brake applied:
The outer disks (14) engaged to the housing by serration and the
inner disks (15) in serration connection with the disk carrier, are pressed
together by the springs (3). This results in a fixed connection between
housing and inner disk carrier (23).
Brake released:
Oil pressure via port (9) forces the piston (5) against the springs (3) towards
the retainer (2).
This function eliminates the spring force onto the disks thus the brake is
released.
The minimum releasing pressure is 21 - 23 bar, the maximum permissible
pressure 100 bar.
This is a so named "Wet Brake" because the brake housing is filled with oil.
PC4000-6-E_#08165_Sec_8-3_rev0.doc 02.03.05
8.3
8
PC4000-6-E_#08165_Sec_8-3_rev0.doc 02.03.05
Hydraulic for the Travel Circuit Section 8.3
Page 8
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).
Check 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.
PC4000-6-E_#08165_Sec_8-3_rev0.doc 02.03.05
8.3
9
PC4000-6-E_#08165_Sec_8-3_rev0.doc 02.03.05
Hydraulic for the Travel Circuit Section 8.3
Page 9
PC4000-6-E_#08165_Sec_8-3_rev0.doc 02.03.05
8.3
10
PC4000-6-E_#08165_Sec_8-3_rev0.doc 02.03.05
Hydraulic for the Travel Circuit Section 8.3
Page 10
PC4000-6-E_#08165_Sec_8-3_rev0.doc 02.03.05
8.3
11
PC4000-6-E_#08165_Sec_8-3_rev0.doc 02.03.05
Hydraulic for the Travel Circuit Section 8.3
Page 11
2. Unplug solenoid valve Y16 (located at the control and filter panel) to keep
the parking brake applied.
3. Start engine and let it run with max. speed
4. Engage carefully the desired travel motion and keep the pedal in final
position to built up max. pressure.
5. Increase slowly the MRV-pressure while observing the pressure gauge.
Gauge value must remain at 310bar + 5bar.
If the gauge shows a smaller or greater value the SRV must be adjusted
PC4000-6-E_#08165_Sec_8-3_rev0.doc 02.03.05
8.3
12
PC4000-6-E_#08165_Sec_8-3_rev0.doc 02.03.05
Hydraulic for the Travel Circuit Section 8.3
Page 12
5. Reconnect plug connection to solenoid valve Y16, now the travel function must
be possible again and the monitor returns to standard display.
) • Pressure at B48 <24 bar => real time monitor 0 => Brake applied (ON)
• Pressure at B48 >24 bar => real time monitor 1 => Brake released (OFF)
PC4000-6-E_#08165_Sec_8-3_rev0.doc 02.03.05
Hydraulic Track Tensioning System Section 9.0
Page 1
Section Page
9.0 Hydraulic Track Tensioning System
General 2
Vorlaeufig_#08165_PC8000-6-E_Sec_9-0_#12044_rev1.doc 02.03.05
9.0
2
Vorlaeufig_#08165_PC8000-6-E_Sec_9-0_#12044_rev1.doc 02.03.05
Hydraulic Track Tensioning System Section 9.0
Page 2
9.0 General:
The hydraulic track tensioning system ensures automatically the correct track
tension.
The pilot pressure pumps (9.1 and 9.3) will supply oil to all four tensioning
cylinders (124.1 – 124.4).
The maximum pressure is limited by pressure increasing valves (141).
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 (119.1 + 119.2, first stage) and (120.1 – 120.4, second
stage).
Vorlaeufig_#08165_PC8000-6-E_Sec_9-0_#12044_rev1.doc 02.03.05
9.0
3
Vorlaeufig_#08165_PC8000-6-E_Sec_9-0_#12044_rev1.doc 02.03.05
Hydraulic Track Tensioning System Section 9.0
Page 3
The oil flow of the pilot pressure pumps (9.1 + 9.3), filtered by pressure filters
(68.1 + 68.7) enters port "P" of solenoid valve Y16, via the common pilot
pressure supply line (45 bar) of the central control and filter panel (36).
If solenoid valve Y16 is actuated (i.e. pressure at sensor B48), the oil for the
travel parking brake (reduced to 35 bar by the function of valve 147), flows via
rotary joint (59), shut-off cock (118.1), the orifice, the two check valves (121.1 +
121.2) and the shut-off cocks (118.2 + 118.3) the into the tensioning cylinders
(124.1 – 124.4).
The resulting force moves the guide wheels toward the front, until the correct
track tension is obtained.
Simultaneously the system is via check valves (125.1 + 125.2) connected to the
pressure increasing valve (141).
External forces acting at the guide wheels will be absorbed through the pressure
accumulators (119.1 + 119.2, first stage) and (120.1 – 120.4, second stage).
continued
Vorlaeufig_#08165_PC8000-6-E_Sec_9-0_#12044_rev1.doc 02.03.05
9.0
4
Vorlaeufig_#08165_PC8000-6-E_Sec_9-0_#12044_rev1.doc 02.03.05
Hydraulic Track Tensioning System Section 9.0
Page 4
Illustration (Z 22757):
Cushioning Function
When the tensioning cylinders (124.1 – 124.4) are moved in by external
forces, the none return valves (121.1 + 121.2) 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, oil is taken up by the side frame
accumulators (119.1 + 119.2).
Second stage: at a pressure higher than 150 bar, oil is taken up by the center
section accumulators (120.1 – 120.4).
The system pressure can rise up to 310 bar pressure increasing valve (141)
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, as soon as the pressure in the lines
to the tensioning cylinder is lower than 35 bar.
To avoid serious damages to the pilot pressure system in case of a faulty
check valve, pressure relief valve (257.1) with a 55 bar setting is installed.
Vorlaeufig_#08165_PC8000-6-E_Sec_9-0_#12044_rev1.doc 02.03.05
9.0
5
Vorlaeufig_#08165_PC8000-6-E_Sec_9-0_#12044_rev1.doc 02.03.05
Hydraulic Track Tensioning System Section 9.0
Page 5
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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6
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Hydraulic Track Tensioning System Section 9.0
Page 6
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7
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Hydraulic Track Tensioning System Section 9.0
Page 7
Checking / Setting the 55 bar pressure relief valve (257.1) – safety valve
1. Connect pressure gauges to check point M1.1 + M1.2 + M9.1
2. Start the both motors.
3. Check the X4-pressure at M1.1, required 60 bar.
If necessary correct the setting by the function of valve 252.1 as follow:
a) Loosen lock nut (1).
b) Set pressure with set screw (2).
c) Tighten lock nut (1).
4. Unplug solenoid valve Y16.
5. Increase the pilot pressure X2 by the function of valve 252.2 to ~ 60 bar.
a) Loosen lock nut (3).
b) Set pressure with set screw (4).
c) Tighten lock nut (3).
6. Check the Safety-pressure at M9.1, required 55bar.
If necessary correct the setting by the function of valve 257.1 as follow:
a) Loosen lock nut (5).
b) Set pressure with set screw (6).
c) Tighten lock nut (5).
7. Re-connect solenoid valve Y16.
8. Re-set the X2-pressure to 45 bar by the function of valve 252.2
Checking / Setting the 35 bar pressure reducing valve (147) – supply pressure
1. Connect a pressure gauge to check point M9.2.
2. Start the both motors.
3. Read pressure, required = 35+2 bar
If readjustment is required proceed as follow
a) remove dust cap (a) and loosen lock nut (b).
b) Set pressure with set screw (c).
c) Tighten lock nut (b) and re-install cap (a).
continued
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9.0
8
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Hydraulic Track Tensioning System Section 9.0
Page 8
continued
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9
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Hydraulic Track Tensioning System Section 9.0
Page 9
W
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 141)
a) Loosen lock nut (2).
b) Adjust pressure with set screw (3).
c) Secure adjustment by tightening lock nut (2).
d) 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 141)
a) Stall the hydraulic with the clam opening function (clam cylinders
completely retracted) and observe pressure at check point M29.4.
b) loosen lock nut (4) and turn set screw (5) ccw until gauge at
check-point M29.8 shows 35 bar.
c) Tighten lock nut (4).
d) Re-check pressure setting.
continued
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10
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Hydraulic Track Tensioning System Section 9.0
Page 10
If the pressure remains the at a higher or lower pressure*, re-adjust the low
pressure setting at the pressure increasing valve (141).
) * The pressure may drop below 35 bar after a longer time, this is o.k.
because of internal leakage.
Vorlaeufig_#08165_PC8000-6-E_Sec_9-0_#12044_rev1.doc 02.03.05
Access ladder Section 10.0
Page 1
hydraulically operated
Section Page
10.0 Access ladder hydraulically operated
10.0 General 2
10.1 Function of hydraulically operated access ladder 3+4
10.2 Adjustments / Checks 5
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2
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Access ladder Section 10.0
Page 2
hydraulically operated
General
The access ladder is hydraulically operated by the hydraulic cylinder (Z) with
the pilot pressure X2 of 45 bar. The movement of the ladder is controlled by
the function of switch:
S84: => Lowering the ladder
S84B => Lifting the ladder
Lifting the ladder is only possible with the motor running. The lowering
movement is possible by hydraulic force with the motor running or by the
force of gravity with the motor at stand sill.
) If the ladder is not in the final upper position the pilot control is
switched off and solenoid valve Y120 activates the hydraulic swing
brake. The display in the operators cab shows a message.
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3
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Page 3
hydraulically operated
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4
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Access ladder Section 10.0
Page 4
hydraulically operated
Cont'd:
Prime drive is not running and the ladder is in the “final upper position”
With switch S84 activated in position 2 (ladder down) solenoid valve Y123B
and relay K132 are active. Y123B connects the piston side of the cylinder to
the return line and K132 activates Y125, so that the oil can return without
resistance to the tank. Now the ladder can move down only by its own mass
(due to the force of gravity). The operator has to push the ladder slightly until
it starts moving down by its own weight.
The rod site of the cylinder receives oil via anti-cavitation valve (258.5).
It is not necessary to activate the key switch, because the involved
components are directly battery supplied via fuse F17.
There is an additional pull switch S84A below the ladder support. With this
switch activated the ladder can moved down from the ground.
• 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 could occur.
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5
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Access ladder Section 10.0
9 Page 5
hydraulically operated
Checking / Setting the 70 bar pressure relief valve (258.3) – safety valve
1. Connect pressure gauges to check point M1.1; M1.2 and M37.1.
2. Start the motor.
3. Lift the ladder to the final upper (working) position, using switch (S84B)
4. Increase the X4-pressure to 80 bar, by turning in set screws (2) of
pressure relieve valve (252.2).
5. Increase the X2-pressure to 75 bar, by turning in set screws (4) of
pressure deducing valve (252.1).
6. Check the setting of pressure relieve valve (258.3) at check point M37.1.
Required 70 bar. If necessary correct the setting as follow:
a) Reduce the pressure with set screw (6) at valve (258.3) to 60 bar
b) Set the pressure to 70 bar ± 2 bar.
c) Tighten lock nut (5).
7. Reset valve (252.2) to 60 bar, valve (252.1) to 45 bar and tighten lock nuts
(1 + 3), adjustment is finished.
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Section 11.0
Cable drum Page 1
Section Page
11.0 Cable drum
11.0 General 2
11.1 Components 3
11.2 Function
11.2.1 Controlling of the drive motor 4
11.2.2 Travel motion control 5
11.3 Checks and Adjustments 6
11.4 Description and operating instruction for cam switch 5S4 and 5S6 7
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2
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Section 11.0
Cable drum Page 2
General
Task:
The cable drum, driven by a brake motor with slip ring rotor, is installed to
wind up or unwind the power supply cable automatically.
1. To considerably improve the mobility of the excavator.
2. To make the operation safer (Material and personnel) i.e. less risk to
damage the cable when travelling backwards and less danger of injury
because the cable must not manual moved.
3. To increase the lifetime of the cable, because the cable is not dragging on
the ground.
) For the optimal use of the cable drum it is necessary that the operator
understands the system very well.
Regular maintenance is essential
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Section 11.0
Cable drum Page 3
11.1 Components
Legend for Illustration Z 22832a
(5M6) Brake motor
(5S1) Service switch for manual actuation of cable drum.
(5S3) Rotation direction indicator (switch)
(5R1) Resistor for brake motor torque adjustment
(5S4) Gear type cam switch for resistor controlling and for
monitoring of the two last cable.
(5S6) Pendulum control cam switch, to detect slack or tight cable.
(5S8, 5S9) Proximity switch to detect cable deflection to right or left
(5S10, 5S11) Proximity switch to detect ground contact
(5K7, 5K8, 5K12, 5K13) Relay for brake motor direction controlling
(5K10, 5K11) Relay for brake motor torque controlling
(5F13) Circuit breakers
(5B79) Brake motor temperature probe
(F79) Motor temperature control unit
(X8) Terminal box
The resistor 5R1 serves as a series resistor for a three- phase motor with a slip ring
rotor (stand still, sliding rotor-brake motor)
It is a resistor with one or more taps (as a function of drum design), to make a selection
of different star bridges possible. The taps serve to regulate the motor and brake torque
during winding up and unwinding.
With service switch 5S1 is it possible to control the cable drum manually in both
directions (windup, unwind, stop and automatic)
The terminal box X8 contains the terminal rails , the relays 5K7, 5K8, 5K10, 5K11,
circuit breakers 5F13 + 5F14 and motor temperature control unit F79.
Direction of rotation monitoring switch 5S3 opens its contact and de-energizes 5K10
and 5K11 while unwinding (traveling forward) and eliminates the resistor which
controls the star bridge. (Lowest tensioning force)
Gear type cam switch 5S4* reduces the tensioning as soon as half of the cable is
unwinded (contact 21/22 opens and de-energizes 5K11) or stops reverse travelling as
soon as the max. length of the cable is winded up (contact 31/32 opens and de-
energizes K178) or stops forward travelling as soon as the safety cable length on the
drum gets unwinded (contact 11/12 opens and de-energizes relay K177).
The proximity switch 5S8 stops L.H. crawler reverse travelling at too much deflection
of the power supply cable to the left (contact br/sw opens and de-energizes K179).
The proximity switch 5S9 stops R.H. crawler reverse travelling at too much deflection
of the power supply cable to the right (contact br/sw opens and de-energizes K180).
The proximity switch 5S10 and 5S11 stops reverse travelling with ground contact.
Pendulum control cam switch 5S6* stops forward travelling at too tight power supply
cable (contact 11/12 opens and de-energizes K177) or reverse travelling at too much
slack of power supply cable (contact 21/22 opens and de-energizes K178).
The motor temperature control unit F79 interrupts all travel motions as soon as drive
motor 5M6 reaches a critical temperature (monitored by sensor 5B79).
*Refer to page 7 for adjustment procedure
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11.0
4
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Section 11.0
Cable drum Page 4
11.2 Function
Legend for Illustration Z 22834a
(5M6) Brake motor
(5S3) Rotation direction indicator (switch)
(5R1) Resistor for brake motor torque adjustment
(5S4) Gear type cam switch for resistor controlling
(5K7, 5K8) Relay for brake motor direction controlling
(5K10, 5K11) Relay for brake motor torque controlling
(5F13) Circuit breakers
(F79) Motor temperature control unit
(X2 + X8) Terminal board
D53 Time relay at the X2 board
General:
In the automatic mode of control switch 5S1, the power supply to drive motor
5M6 is controlled by the function of the travel control system, which controls
relay 5K7, i.e. while traveling the contacts of 5K7 are closed and kept closed for
further 10 seconds after stopping the travelling motion (controlled by time relay
D53), before the power supply will be interrupted and the motor brake is active.
The torque of drive motor 5M6 is controlled by the function of the relay 5K10 and
5K11; which changes the resistance at the star bridge (5R1). Both relay are
simultaneously controlled by switch 5S3 (Direction of rotation monitoring
switch), to ensure the lowest tensioning force while unwinding (i.e. traveling
forward)
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5
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Section 11.0
Cable drum Page 5
11.2 Function
General:
The cable drum is equipped with safety switches for the protection of the power
supply cable during travelling and turning operations. Movements which could
damage the power cable are automatically switched off.
Cable condition Monitored by Travel shut off relay Directional Travel response
Solenoid valves
Switch / contacts
1. Too tight 5S6 / 11–12 K177 Y20b + Y28b crawler left + crawler right
forward motion stopped
2. Too slack 5S6 / 21–22 K178 Y20a + Y28a crawler left + crawler right
reverse motion stopped
3. Too strong deflection to the left 5S8 / br–sw K179 Y20a crawler left
reverse motion stopped
4. Too strong deflection to the right 5S9 / br–sw K180 Y28a crawler right
reverse motion stopped
5. Maximum permissible cable 5S4 / 31–32 K178 Y20a + Y28a crawler left + crawler right
length on the drum
reverse motion stopped
6. Safety cable winding unwinded 5S4 / 11–12 K177 Y20b + Y28b crawler left + crawler right
forward motion stopped
7. Ground contact 5S10 and/or 5S11 K178 Y20a + Y28a crawler left + crawler right
reverse motion stopped
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6
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Section 11.0
Cable drum Page 6
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11.0
7
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Section 11.0
Cable drum Page 7
11.4 Description and operating instruction for cam switch 5S4 and 5S6
The cam discs (3), arranged in pairs on the centering discs, can be adjusted
individually and continuously by means of a adjusting spanner (4) The centering
discs can be reversed and are fixed to the square shaft without clearance.
Adjustment can be performed in any position without having to turn the control
shaft. The cam discs, separated from each other by the guard plate, slide past each
other without touching during adjustment. The cam ring next to the cam ring to be
adjusted will not shift and remains in the set position.
Hollow-type rivets prevent accidental shifting of the cam discs.
By selecting the appropriate contact - either make or brake - any angle between 0°
and 350° can be set without changing the cam rings.
When the cam hits the actuator (2), the latter will operate the micro switch (1).
PC4000-6-E_#08165_Sec_11-0_rev0.doc 02.03.05
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Hints for reading the Section 12.0
Page 1
Hydraulic Circuit Diagram
Section Page
12.0 Hints for reading the hydraulic circuit diagram
General 3
12.1 Symbols 5
12.1.1 Lines, unions 5-6
12.1.2 Components, valves 7
12.1.3 Sensors 8
12.1.4 Valves, valve components 9-12
12.1.5 Pumps, motors, cylinders 13-14
12.1.6 Assemblies and main components 15-16
12.2 Legend for the circuit diagram (929 663 40) 17-24
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2
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Hints for reading the Section 12.0
Page 3
Hydraulic Circuit Diagram
12.0 General:
) •
•
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.
A Diagram No. and Type of the 897 895 40 a Diagram No. only for the
respective machine PC8000-E respective machine
B Respective Serial No. 12041
C Sheet-No. / Quantity of sheets 01 / 04 1st of four sheets
D Co-ordinates to describe the 1 C 10 Page 1 on co-ordinate C vertical
location of a component and 10 horizontal Remote control
valve 102.1
E Component-No. 127 127 Main control block I
F Line-No. with cross hint, L37/3B9 Case drain line (Line No.37)
comes from / goes to sheet 2
coordinate E7
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4
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Page 5
Hydraulic Circuit Diagram
12.1 Symbols
Illustration Z 22988
12.1.1 Lines, unions
Symbol Description Used as / at / on
1 Oil supply line, can be a Suction line or pressurized
hose or a pipe. line of main hydraulic circuit
or pilot pressure circuit or
auxiliary circuits (e.g. fan
drive).
2 Return oil line, can be a Return lines, connected to
hose or a pipe. the return oil filter chamber
of the main oil reservoir.
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6
12.1 Symbols
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Page 7
Hydraulic Circuit Diagram
12.1 Symbols
continued
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12.0
8
12.1 Symbols
12.1.3 Sensors
Symbol Description Used as / at / on
20 Pressure switch / sensor e.g. return / leak oil
Input = pressure chamber (digital), high
Output = electrical signal pressure filter (analogue)
analogue or digital
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Page 9
Hydraulic Circuit Diagram
12.1 Symbols
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12.0
10
12.1 Symbols
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Page 11
Hydraulic Circuit Diagram
12.1 Symbols
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12.0
12
12.1 Symbols
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Page 13
Hydraulic Circuit Diagram
12.1 Symbols
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12.0
14
12.1 Symbols
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Page 15
Hydraulic Circuit Diagram
12.1 Symbols
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12.0
16
12.1 Symbols
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Page 17
Hydraulic Circuit Diagram
(1) - (4) Main hydraulic pumps A4VSLO 750 LR3DN / 30L Axial
piston pump (swash plate type)
(5.1) Fan drive pump Hydraulic oil cooler A7FO 63RNZB01
Axial piston pump (fixed displacement with, variable setting)
(5.2) Not used
(6) Not used
(7) Oil intake pipe with bleeder screw (Gear pump 8.2)
(8.1) Gear pump R1A5100C3A1A Pilot pressure - Pump
regulation - Pump bearing lubrication
(8.2) Gear pump R1A5100C3A1A PTO-gearbox lubrication
(9) Control block III MO-3469-00 / 3MO-40
Special spool for lowering the boom (without pump pressure)
(10) Control block I MO-3468-00 / 3MO-40
(11) Control block II MO-3455-00 / 4MO-40
Special spool for lowering the boom (without pump pressure)
(12) Control block IV MO-3454-00 / 4MO-40
(13.1) High pressure filter at Control block III
(13.2) High pressure filter at Control block I
(13.3) High pressure filter at Control block II
(13.4) High pressure filter at Control block IV
(14.1) Remote control valve block
(14.2) Remote control valve block
(14.3) Remote control valve block
(15) Remote control valve block
(16.1 + 16.2) Manifold
(17.1) Grease pump (Hydraulic Cylinder)Lincoln Power Master
Central Lubrication System
(17.2) Grease pump (Hydraulic Cylinder)Lincoln Power Master
Slew ring Lubrication System
(18) Service line relief valve (SRV) Clam closing 150 bar
(19) Rotary distributor
(20.1) Orifice - bearing lubrication Main pump I
(20.2) Orifice - bearing lubrication Main pump II
(20.3) Orifice - bearing lubrication Main pump III
(20.4) Orifice - bearing lubrication Main pump IV
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Hydraulic Circuit Diagram
(45) Service line relief valve (SRV) Clam closing 150 bar the
main control block II
(46.1 + 46.2) Block
(47) Pressure reducing valve – Track tensioning system
(48.1 + 48.2) Swing parking brakes – Spring loaded multi disk brake
(49) Not used
(50) Not used
(51.1 + 51.2) PTO gear oil cooler
(52) Not used
(53) Case drain filter
(54) Return oil collector tube
(55) Back pressure valve
(56.1 + 56.2) Travel brake valve block
(57.1 + 57.2) Travel parking brakes – Spring loaded multi disk brake
(58) Not used
(59.1 – 59.4) Return oil filter
(60.1) Slew gear drive L.H.
Axial piston motor A2FLM 355 /60W-VZH-01
(60.2) Slew gear drive R.H.
Axial piston motor A2FLM 355 /60W-VZH-01
(61.1 + 61.2) Swing brake valve block
(62.1 – 62.3) Shut-off valve – Truck tensioning system
2/2-directional control valve (manual operated)
(63) Pressure switch B17 – Min. PTO gear lubrication pressure
(64.1 – 64.9) Anti cavitation valves (ACV) at the distributor manifold (42)
(65.1 – 65.4) Restrictor block with service line relief valve (SRV) at the
distributor manifold (42)
(66.1 – 66.12) Service line relief valve (SRV) at the main control blocks
(67.1 – 67.4) Dust cap for item (77.1 – 77.4)
(68.1 – 68.7) Check valve – Anti cavitation valve at the main control blocks
(69.1 – 69.23) Cover plate at the main control blocks
(70.1 – 70.13) Restrictor block with service line relief valve (SRV) at the
distributor manifold (42)
(71) Not used
(72) Not used
(73) Not used
(74) Not used
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20
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Hydraulic Circuit Diagram
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22
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Hydraulic Circuit Diagram
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24
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Page 1
Electric Circuit Diagram
Section Page
13.0 Hints for reading the electric circuit diagram
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Electric Circuit Diagram
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3
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Page 3
Electric Circuit Diagram
13.2 Symbols
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Electric Circuit Diagram
13.2 Symbols
31) Rectifier bridge 32) Thermal over load limit 33) Phase, 4-wire system
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Electric Circuit Diagram
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.
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
All circuits are shown currentless and all relays and switches are in neutral position.
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Electric Circuit Diagram
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Electric Circuit Diagram
)
• Examples are shown by sectional drawings out of the electric circuit
diagram 897 844 40 page 08.
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.
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Electric Circuit Diagram
Cont.:
13.4 Reading a Circuit Diagram.
b. F11 / 10.5 = Power line F11, comes from circuit breaker F11, sheet
08 section 8 and continues on sheet 10 section 5.
c. S27 / 20.7 = Line S27, comes from switch S27, sheet 08 section 1
and continues on sheet 20 section 7.
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.
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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 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).
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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.
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.
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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.
Cycle Time Time required for the application program to run through once.
continued
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Cont'd:
Numeral A value expressed in one digit: from 0 to 9 in the decimal system and 0-F
in the hexadecimal system.
Baud Unit used in serial transmission of data: bits per second (bit/s).
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).
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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.
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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• Replace the fuses only by fuses which matches the values given in the
technical dates
ã • 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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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.
LED defect *)
(if DIAG
LED is ON)
others *)
5 V-LED
flashing
continued
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EEPROM- or Initialize
RAM- fault EEPROM *1)
if the fault is
still present *2)
DIAG-LED Program Program Start program *1)
OFF not running stopped
(except LED
defect)No Program Load program *1)
otherwise LED
defect *2)
DIAG Program- Communication via
flashing state Interface COM-SP
unchanged or COM-SK active
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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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.
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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.
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) • .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.
continued
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Cont’d.:
Pin Symbol Operand Definition
22 Output 1.1 A 1.1 Output 1 of the output group 1
23 Output 1.2 A 1.2 Output 2 of the output group 1
24 Output 1.3 A 1.3 Output 3 of the output group 1
25 Output 1.4 A 1.4 Output 4 of the output group 1
26 Output 1.5 A 1.5 Output 5 of the output group 1
27 Output 1.6 A 1.6 Output 6 of the output group 1
28 Output 1.7 A 1.7 Output 7 of the output group 1
29 Output 1.8 A1.8 Output 8 of the output group 1
30 UE/A Under Load Voltage UE/A =
31 UE/A Under Load Voltage Voltage.
32 UE/A Under Load Voltage Input / Output
33 UCPU DIGSY (plus)- Operation Voltage
34 Input 2.1 E 2.1 Input 1 of the input group 2
35 Input 2.3 E 2.3 Input 3 of the input group 2
36 Input 2.5 E 2.5 Input 5 of the input group 2
37 Input 2.7 E 2.7 Input 7 of the input group 2
38 Output 1.1 A 1.1 Output 1 of the output group 1
39 Output 1.2 A 1.2 Output 2 of the output group 1
40 Output 1.3 A 1.3 Output 3 of the output group 1
41 Output1.4 A 1.4 Output 4 of the output group 1
42 Output1.5 A 1.5 Output 5 of the output group 1
43 Output 1.6 A 1.6 Output 6 of the output group 1
44 Output 1.7 A 1.7 Output 7 of the output group 1
45 Output 1.8 A1.8 Output 8 of the output group 1
46 UE/A Under Load Voltage
47 UE/A Under Load Voltage
48 UE/A Under Load Voltage
49 UCPU DIGSY (plus)- Operation Voltage.
50 0 V (GND) Ground / GND
There are two pins (two channels) parallel connected only for output A1.1 –
A1.8 (the same for additional boards A3, A5, A7, A13).
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) • .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 EA-
Configuration chart (EA-Belegungsliste) see Appendix and the
respective electric diagram.
continued
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Cont’d.:
PIN PIN-NAME OPERAND COMMENTARY
26 A1G GND - Output 1
27 4U+E4G GND - Input 4
28 A2G GND - Output 2
29 E3G GND - Input 3
30 A3G GND - Output 3
31 E2G GND - Input 2
32 A4G GND - Output 4
33 E1G GND - Input 1
34 GND/ANA Analogues – GND
35 E8 EW Z+1.4 Input (U/I) 8
36 GND/ANA Analogues – GND
37 E7 EW Z +1.3 Input (U/I) 7
38 GND/ANA Analogues – GND
39 E6 EW Z +1.3 Input (U/I) 6
40 GND/ANA Analogues – GND
41 E5 EW Z +1.3 Input (U/I) 5
42 A1G GND – Output 1
43 E4 EW Z.4 Input (U/I) 4
44 E4 EW Z.4 Input (U/I) 4
45 E3 EW Z.3 Input (U/I) 3
46 E3 EW Z.3 Input (U/I) 3
47 E2 EW Z.2 Input (U/I) 2
48 E2 EW Z.2 Input (U/I) 2
49 E1 EW Z.1 Input (U/I) 1
50 E1 EW Z.1 Input (U/I) 1
• All pins are internal connected
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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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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)
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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.
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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.
(A1¿ MK1, A3¿ MK3, A5¿ MK5)
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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.
14.4.5 Fuse
TR5 / 2.5AT IEC 127-3 Manufacturer Wickmann,
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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 de-
energized relay or normal open switch contact) thus the ECS recognize a fault
after switching ON the system.
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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 ¿ K= 25 V / bar
Sensor 0 – 60 bar ¿ K= 0,1667 V / bar
Sensor 0 – 500 bar ¿ K= 0,02 V / bar
(Pressure sensors with +1 V Offset)
Ua = (P x K) + 1 V
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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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Cont’d.:
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°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
0 100,00 99,61 99,22 98,83 98,44 98,04 97,65 97,26 96,87 96,48
°C 0 1 2 3 4 5 6 7 8 9
0 100,00 100,39 100,78 101,17 101,56 101,95 102,34 102,73 103,12 103,51
10 103,90 104,29 104,68 105,07 105,46 105,85 106,24 106,63 107,02 107,40
20 107,79 108,18 108,57 108,96 109,35 109,73 110,12 110,51 110,90 111,28
30 111,67 112,06 112,45 112,83 113,22 113,61 113,99 114,38 114,77 115,15
40 115,54 115,93 116,31 116,70 117,08 117,47 117,85 118,24 118,62 119,01
50 119,40 119,78 120,16 120,55 120,93 121,32 121,70 122,09 122,47 122,86
60 123,24 123,62 124,01, 124,39 124,77 125,16 125,54 125,92 126,31 126,69
70 127,07 127,45 127,84 128,22 128,60 128,98 129,37 129,75 130,13 130,51
80 130,89 131,27 131,66 132,04 132,42 132,80 133,18 133,56 133,94 134,32
90 134,70 135,08 135,46 135,84 136,22 136,60 136,98 137,36 137,47 138,12
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
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) • 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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Section 15.0
Lubrication System
Page 1
Table of contents
Page
General Function 3
Oscillation Cylinder and Control Block 9
Adjustments 11
One line system 13
Electrical function 17
Capacitive analog sensor for lubricant level monitoring 21
Adjustments
End Line pressure switch 23
Injectors 25
Function Pinion type (dummy wheel) system 27
Electrical Function (dummy wheel) system 31
Capacitive analog sensor for lubricant level monitoring 35
Adjustments
End-Of-Line Switch setting 37
Injectors 39
Components
Hydraulically driven lube pump 41
Injectors 45
End-Line Switch 51
In line Filter 53
Vent valve (Solenoid valve) 55
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2 Lubrication System
Section 15.0
Lubrication System
Page 3
General Function
continued
PC4000-6-E_#08165_Sec_15-0_rev0.doc 02.03.05
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4 Lubrication System
Cont'd.
X-axis Time
Y-axis Lubricant supply line pressure
PI Pressure Increasing
S+ Switch point ON of the end of line pressure switch
PH Pressure Holding
S- Switch point OFF of the end of line pressure switch
PR Pressure Relieve
PT Pause Time
Section 15.0
Lubrication System
Page 5
PT-phase
With the pump and controller system in a rest state a pre-set pause time interval
occurs as determined by the PLC.
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.
continued
PC4000-6-E_#08165_Sec_15-0_rev0.doc 02.03.05
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6 Lubrication System
Cont'd.
X-axis Time
Y-axis Lubricant supply line pressure
PI Pressure Increasing
S+ Switch point ON of the end of line pressure switch
PH Pressure Holding
S- Switch point OFF of the end of line pressure switch
PR Pressure Relieve
PT Pause Time
Section 15.0
Lubrication System
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).
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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8 Lubrication System
Section 15.0
Lubrication System
Page 9
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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10 Lubrication System
Section 15.0
Lubrication System
Page 11
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 motor.
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 motor.
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).
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12 Lubrication System
Section 15.0
Lubrication System
Page 13
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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14 Lubrication System
Section 15.0
Lubrication System
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 re-
initiated 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
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16 Lubrication System
Section 15.0
Lubrication System
Page 17
continued
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18 Lubrication System
Section 15.0
Lubrication System
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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20 Lubrication System
Section 15.0
Lubrication System
Page 21
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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22 Lubrication System
Section 15.0
Lubrication System
Page 23
Adjustments
2. Start motor.
3. Start a lube cycle with the dashboard switch S24.
+
4. 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.
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
PC4000-6-E_#08165_Sec_15-0_rev0.doc 02.03.05
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24 Lubrication System
Section 15.0
Lubrication System
Page 25
Cont'd:
Injectors, illustr. 21181:
) • The max. lubricant output is adjusted if the indicator stem (B) moves
not more further outwards
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26 Lubrication System
Section 15.0
Lubrication System
Page 27
Legend: Z 21183a
(1) Lubricant pump drive (Hydraulic cylinder)
(2) Solenoid valve Y9 (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 Y9A (Solenoid valve, de-energized open)
(8) Grease supply line to injectors
(9) Lubricant level indication
(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) Breather
(17) 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
PC4000-6-E_#08165_Sec_15-0_rev0.doc 02.03.05
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28 Lubrication System
Section 15.0
Lubrication System
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.
PC4000-6-E_#08165_Sec_15-0_rev0.doc 02.03.05
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30 Lubrication System
Section 15.0
Lubrication System
Page 31
continued
PC4000-6-E_#08165_Sec_15-0_rev0.doc 02.03.05
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32 Lubrication System
Section 15.0
Lubrication System
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
PC4000-6-E_#08165_Sec_15-0_rev0.doc 02.03.05
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34 Lubrication System
Section 15.0
Lubrication System
Page 35
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.
PC4000-6-E_#08165_Sec_15-0_rev0.doc 02.03.05
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36 Lubrication System
Section 15.0
Lubrication System
Page 37
Adjustments
1. Connect pressure gauge to check point close to the end of line pressure
switch.
2. Block the swing function with the swing ring parking, use the switch at
the dash board.
3. Start motor.
4. Start a lube cycle with the dashboard switch S26 and activate for a short
time the swing function to the left or right.
+
5. Watch pressure gauge. At a pressure of 180 10 bar the end of line
switch must react and the lubricants pump must be stopped.*
* 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.
If re-setting is required:
continued
PC4000-6-E_#08165_Sec_15-0_rev0.doc 02.03.05
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38 Lubrication System
Section 15.0
Lubrication System
Page 39
Cont'd:
Injectors, illustr. 21181:
) • The max. lubricant output is adjusted if the indicator stem (B) moves
not more further outwards
PC4000-6-E_#08165_Sec_15-0_rev0.doc 02.03.05
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40 Lubrication System
Section 15.0
Lubrication System
Page 41
HINT:
Loss of pressure or to short pump strokes indicates:
continued
PC4000-6-E_#08165_Sec_15-0_rev0.doc 02.03.05
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42 Lubrication System
Section 15.0
Lubrication System
Page 43
PROBLEMS:
PC4000-6-E_#08165_Sec_15-0_rev0.doc 02.03.05
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44 Lubrication System
Section 15.0
Lubrication System
Page 45
TASK:
A readjusted (at the injector) volume of grease is pushed with the injectors to
the bearings or to the progressive distributors.
continued
PC4000-6-E_#08165_Sec_15-0_rev0.doc 02.03.05
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46 Lubrication System
Section 15.0
Lubrication System
Page 47
Cont'd:
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
PC4000-6-E_#08165_Sec_15-0_rev0.doc 02.03.05
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48 Lubrication System
Section 15.0
Lubrication System
Page 49
Cont'd:
The injectors are designed so that the lubricant out- put 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 out- let of injector
No. 2.
This does not interfere with the operation of injector No. 2.
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50 Lubrication System
Section 15.0
Lubrication System
Page 51
End-line switch
TASK:
The pressure control unit is monitoring and controlling the centralized lube
system.
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.
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52 Lubrication System
Section 15.0
Lubrication System
Page 53
In-line filter
• 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!
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54 Lubrication System
Section 15.0
Lubrication System
Page 55
TASK:
By the function of the vent valve the lubricant supply line gets pressure-
relieved, after the lubrication cycle is finished. The injector pistons can move
into their initial position.
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).
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56 Lubrication System