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SHOP 15016-upE-GB-1

Shop Manual

HYDRAULIC
EXCAVATOR
PC5500E-6

Serial Number 15016 and up


SHOP MANUAL SHOP XS(*%

CONTENTS OF SHOP MANUAL

Binder 1

00 FOREWORD

01 SPECIFICATIONS

10 STRUCTURE, FUNCTION

40 TROUBLESHOOTING (WITHOUT CONTENT)

Binder 2

50 ASSEMBLY AND DISASSEMBLY

Table of contents
SHOP MANUAL SHOP 15016-upE-GB-0

HYDRAULIC EXCAVATOR
PC5500E-6

Machine model Serial number

PC5500E-6 15016 and up

00 Foreword

PC3000-6 1
1.1 CONTENTS OF THE BINDER INTRODUCTION

1.1 CONTENTS OF THE BINDER


Assembled in this file are the Operation- and Maintenance Manu-
als for your KOMATSU Mining Shovel.

4
INTRODUCTION 1.2 DIVISION OF THE BINDER

1.2 DIVISION OF THE BINDER


Part 1:
Operation Manual

Part 2:
Maintenance Manual

Part 3:
Depending on the volume of Part 3 a second Binder "Volume 2" is
being delivered with the Shovel. This Binder contains the General
Assembly Procedure Manual for the Shovel, Specification Book-
let, Service Literature for the Power Unit (Diesel Engine or Elec-
tric Motor) and for Special Equipment. The Electrical- and
Hydraulic Diagrams are attached in the pocket of the front cover.

Refer to the -TABLE OF CONTENTS VOLUME 2 BINDER-


for details.

Read the Manuals before You Start the Engine.

Before operating the machine, familiarize yourself with its instru-


ments and controls.

Observe the instructions in these manuals for:

● your Personal SAFETY

● Operating SAFETY, and

● READY an d E FFICIENT P ERFORMANCE of y our


KOMATSU Shovel.

Periodic preventive inspections and maintenance are the surest


means of keeping the machine in proper working order. Prompt
detection and correction of minor irregularities, and immediate
replacement of worn out or broken parts will prevent failures and
avoid expenses.

Replace damaged graphics and symbols.

Observe safety precautions to prevent injury and damage.

If you have any questions concerning this literature please con-


tact

Komatsu Mining Germany GmbH

Service Information
Department 8151.30
P.O. Box 18 03 61
D - 40570 Düsseldorf
GERMANY

5
1.3 DESIGNATED USE OF THE SHOVEL INTRODUCTION

1.3 DESIGNATED USE OF THE SHOVEL


This machine h as been ma nufactured in accor dance with
advanced and up-to-date technology standards including recog-
nized safety rules. Nevertheless, its use may constitute a risk to
life and limb of the user or of third parties, or cause damage to the
machine and to other material property.

The machine must only be used in technically perfect condition in


accordance with its designated use and the instructions set out in
the operation manual. Only trained safety-conscious operators
who are fully aware of the risks involved should operate the
machine. Any functional disorders, especially those affecting the
safety of the machine, should, therefore, be rectified immediately.

The hydraulic Shovel is designed exclusively for excavating, i.e.


excavation of bulk material and natural soil structure (e.g. earth,
clay, sand and stones ashore and off-shore). Observe local and
national safety regulations. Special conditions at the worksite
require additional safe working precautions, follow your com-
pany's safety instructions. Short traveling distances for changing
the working site are considered as part of the designated use of
the Shovel.
Using the Shovel for purposes other than those mentioned above
(such as object handling and use as a transport vehicle) is consid-
ered contrary to its designated use. The manufacturer/supplier
cannot be held liable for any damage resulting from such use.
The risk of such misuse lies entirely with the user.

WARNING
Special use of the Shovel beyond its designated use, e.g.
object handling operations, require written agreement from
the manufacturer and retrofitment of the Shovel with respec-
tive safety related equipment before such special applica-
tions are permitted.

6
INTRODUCTION 1.4 DELIVERY OF THE SHOVEL

1.4 DELIVERY OF THE SHOVEL


The Shovel is being delivered disassembled into its main compo-
nents.

For assembling the Shovel refer to the


”General Assembly Procedure Manual”
in Volume 2 Service Literature Binder.

WARNING
● Improper a ssembling o f t he S hovel can c ause s erious
accidents with personal injury or death.

● Personnel e ntrusted with wor k on the m achine must


have read the Assembly Manual, the Operation- and
Maintenance Manual and in particular the section on
safety before beginning work. Reading the instructions
after work has begun is too late. If there are any ques-
tions concerning safe assembling procedure, contact
your local Komatsu Service Organization.

Prior to first operation, inspect the Shovel thoroughly with the Ser-
vice Engineer responsible for the erection of the machine. Check
all fluid levels according to the Lubrication and Maintenance
Schedule.

Damages and defects caused by incorrect operation and mainte-


nance are not covered by the manufacturers guarantee.

NOTICE
If the Shovel is equipped with a fire suppression system,
make sure that the system is ready for operation.

SPARE PARTS

For your spare part orders refer to the Parts Catalogue.

In order to keep your Shovel in first-class operating condition use


only genuine spare and wear parts.

The use of any part other than the genuine part releases the

KOMATSU MINING GERMANY GmbH from any guarantee.

SERVICE

For all questions related to your Shovel please contact your local
Service Center.

In all your written or phoned inquiries please indicate the model


and serial number of your Shovel.

7
1.5 EXPLANATION OF ABBREVIATIONS INTRODUCTION

1.5 EXPLANATION OF ABBREVIATIONS

ABB Definition

A Ampere
AC Alternating Current

API American Petroleum Institute

cSt Centistoke
°C Degree Celsius

CENSE Engine Monitoring System

CLS Central Lubrication System


DC Direct Current

DIN German Institute for Standardization

EBL Electronic Bucket Levelling System

ECM Electronic Control Module (Engine)

FGPS Front Guard Protective Structure

FOPS Falling-Object Protective Structure

GL Gear Lubricant

h hours of operation

HPF High Pressure Filter


(Hydraulic Oil)

HT High Tension

LED Light Emitting Diode

LT Low Tension

N Newton

Nm Newton meter

QSK Type of Engine Fuel System


PLC Programmable Logic Controller

PM Planned Maintenance

ppm parts per million

Power Take-Off
PTO
(Pump Distributor Gear)

SLS Swing circle pinion Lubrication System

V Volt
VHMS Vehicle Health Monitoring System

1/min Revolutions Per Minute (RPM)

8
SAFETY

2 SAFETY

IGNORING THE INSTRUCTIONS IN THIS MANUAL COULD LEAD TO SERIOUS


INJURY OR DEATH.
Please read and make sure that you fully understand the precautions described in this section and the
safety labels on the machine. When operating or servicing the machine, always follow these precaution
strictly.

2 -1
SAFETY

CONTENTS

2.1 SAFETY INFORMATION ................................................................................................................... 2-3


2.2 OVERVIEW......................................................................................................................................... 2-4
2.2.1 NORMAL OPERATIONS ....................................................................................................... 2-4
2.2.2 REGULAR MAINTENANCE................................................................................................... 2-4
2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR ....................................................... 2-4
2.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND
TRANSPORTATION OF THE EXCAVATOR......................................................................... 2-4
2.3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB. .............................................................. 2-5
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR........................... 2-6
2.4.1 UNDERSTANDING THE MACHINE ...................................................................................... 2-6
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR ...................... 2-6
2.4.2.1 ENSURING SAFE OPERATION............................................................................ 2-6
2.4.3 PREPARATIONS FOR SAFE OPERATION.......................................................................... 2-6
2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT........................ 2-6
2.4.3.2 INSPECTING THE MACHINE................................................................................ 2-6
2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT.................. 2-7
2.4.3.4 KEEP MACHINE CLEAN ....................................................................................... 2-7
2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT ................................... 2-7
2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT ........................................ 2-8
2.4.3.7 IF A PROBLEM IS FOUND .................................................................................... 2-8
2.4.4 FIRE PREVENTION............................................................................................................... 2-8
2.4.4.1 PRECAUTIONS TO PREVENT FIRE .................................................................... 2-8
2.4.4.2 ACTION IF FIRE OCCURS.................................................................................... 2-9
2.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB................................................. 2-10
2.4.5 PRECAUTIONS WHEN CLEANING CAB GLASS .............................................................. 2-10
2.4.6 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE ....................................... 2-10
2.4.6.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE
MACHINE............................................................................................................. 2-10
2.4.6.2 NO JUMPING ON OR OFF THE MACHINE ........................................................ 2-10
2.4.6.3 NO PEOPLE ON THE ATTACHMENT ................................................................ 2-10
2.4.6.4 WORKING IN HIGH PLACES .............................................................................. 2-10
2.4.6.5 LEAVING OPERATOR’S SEAT WITH LOCK ...................................................... 2-11
2.4.6.6 LEAVING THE MACHINE .................................................................................... 2-11
2.4.7 BURN PREVENTION........................................................................................................... 2-11
2.4.7.1 HOT COOLANT .................................................................................................. 2-11
2.4.7.2 HOT OIL .............................................................................................................. 2-12
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES .......................................... 2-12
2.4.8.1 UNAUTHORIZED MODIFICATION...................................................................... 2-12
2.4.9 PRECAUTIONS AT JOBSITE.............................................................................................. 2-14
2.4.9.1 VISIBILITY FROM OPERATOR’S SEAT ............................................................. 2-15
2.4.9.2 CAMERA SYSTEM WITH MONITORS................................................................ 2-15
2.4.9.3 ENSURE GOOD VISIBILITY................................................................................ 2-15
2.4.9.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS............................................ 2-15
2.4.9.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS.................................... 2-16
2.4.9.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES .......................................... 2-16
2.4.9.7 WORKING ON LOOSE GROUND ....................................................................... 2-17
2.4.9.8 GAS, DUST, STEAM AND SMOKE ..................................................................... 2-17
2.4.9.9 VENTILATION OF ENCLOSED AREAS.............................................................. 2-18

2 -2
SAFETY

2.4.10 STARTING ENGINE ............................................................................................................ 2-19


2.4.10.1 WARNING TAG ................................................................................................... 2-19
2.4.10.2 CHECKS BEFORE STARTING ENGINE ............................................................ 2-19
2.4.10.3 PRECAUTION WHEN STARTING ENGINE........................................................ 2-19
2.4.10.4 PRECAUTION IN COLD AREAS ......................................................................... 2-20
2.4.11 OPERATION........................................................................................................................ 2-20
2.4.11.1 CHECKS BEFORE OPERATION ........................................................................ 2-20
2.4.11.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE ............... 2-21
2.4.11.3 PRECAUTIONS WHEN TRAVELLING ................................................................ 2-22
2.4.11.4 TRAVELLING ON SLOPES ................................................................................. 2-23
2.4.11.5 OPERATIONS ON SLOPES................................................................................ 2-24
2.4.11.6 PROHIBITED OPERATIONS............................................................................... 2-24
2.4.11.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES....................... 2-25
2.4.11.8 PARKING THE MACHINE ................................................................................... 2-25
2.4.11.9 TRANSPORTATION ............................................................................................ 2-25
2.5 PRECAUTION FOR MAINTENANCE.............................................................................................. 2-26
2.5.1 GENERAL PRECAUTIONS ................................................................................................. 2-26
2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC
RESPONSIBILITIES ............................................................................................ 2-27
2.5.1.2 STOP ENGINE FOR MAINTENANCE ................................................................. 2-28
2.5.1.3 WARNING TAG ................................................................................................... 2-28
2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY ............................................................. 2-29
2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS ..................................... 2-30
2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS
RUNNING ............................................................................................................ 2-30
2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS ............................... 2-30
2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR
EQUIPMENT........................................................................................................ 2-31
2.5.1.9 NOISE .................................................................................................................. 2-31
2.5.1.10 WHEN USING A HAMMER ................................................................................. 2-31
2.5.1.11 PROPER TOOLS................................................................................................. 2-32
2.5.1.12 ACCUMULATOR ................................................................................................. 2-32
2.5.1.13 PERSONNEL ....................................................................................................... 2-32
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE................................................ 2-32
2.5.2.1 PRECAUTION WHEN WELDING ........................................................................ 2-32
2.5.2.2 BATTERY HANDLING ......................................................................................... 2-33
2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID............................................................... 2-34
2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE ................................................ 2-34
2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES .......................................... 2-34
2.5.3.3 REPLACEMENT OF HOSE LINES...................................................................... 2-34
2.5.3.4 INSPECTION OF HOSE LINES........................................................................... 2-35
2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ............................ 2-35
2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE............................................................... 2-36
2.5.3.7 AIR CONDITIONING MAINTENANCE ................................................................ 2-36
2.5.3.8 COMPRESSED AIR............................................................................................. 2-36
2.5.3.9 WASTE MATERIALS ........................................................................................... 2-37
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND
ADJUSTMENTS............................................................................................................................... 2-38
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM ................................................................... 2-38
2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING

2 -3
SAFETY

ADJUSTMENTS................................................................................................................... 2-38
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR...................................... 2-38
2.7 SPECIAL SAFETY EQUIPMENT..................................................................................................... 2-40
2.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB ................ 2-41
2.7.2 OBJECT HANDLING ........................................................................................................... 2-41
2.7.3 LIGHTING ............................................................................................................................ 2-41
2.7.4 WARNING BEACON............................................................................................................ 2-41
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) ........... 2-41
2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361
(EUROPEAN STANDARD) .................................................................................. 2-41
2.7.5.2 INSTRUCTIONS FOR USE ................................................................................. 2-43
2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL ......................... 2-45
2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND
HOLD-BACK HOOKS OF THE SAFETY HARNESS (1), .................................... 2-45
2.7.5.5 INSTRUCTIONS FOR USE ................................................................................. 2-47

2 -4
SAFETY SAFETY INFORMATION

2.1 SAFETY INFORMATION


To enable you to use this machine safely, and to prevent injury to operators, service personnel or bystanders, the
precautions and warnings included in this manual and the safety signs attached to the machine must always be
followed.

To identify important safety messages in the manual and on the machine labels, the following signal
words are used.

The "Safety Alert Symbol" identifies important safety messages on machines, in manuals, and elsewhere. When
you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety message.

DANGER
This signal word indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.

WARNING
This signal word indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.

CAUTION
This signal word indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.

NOTICE
This signal word is used to alert you to information that must be followed to avoid damage to the machine.
This precaution is given where the machine may be damaged or the service life reduced if the precaution
is not followed.

2 -5
OVERVIEW SAFETY

2.2 OVERVIEW
The appropriate safety information for specific working modes on the excavator can be found in the following:-

2.2.1 NORMAL OPERATIONS


– For normal operating procedures, refer to the OPERATION section of the Operation and Maintenance Manual.
– For operational safety information, refer to section 2.4 on page 3-8.
– For on site safety information, refer to section 2.4.9 on page 3-16.

2.2.2 REGULAR MAINTENANCE


– For information on regular maintenance, including maintenance intervals, refer to the MAINTENANCE section
of the Operation and Maintenance Manual.
– For maintenance safety information, refer to section 2.5 on page 3-28.

2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR


– For additional safety information for troubleshooting and adjustments refer to section 2.6 on page 3-40.
– For maintenance solutions, refer to the separate manuals TROUBLESHOOTING manual. Available through
Komatsu Mining Germany.
– For servicing information and adjustments, refer to the separate SERVICE MANUAL. Available through
Komatsu Mining Germany.

2.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING,


DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR
– Prior to starting assembling, disassembling and transportation of the excavator read and follow the additional
safety precautions given in the ASSEMBLY PROCEDURE MANUAL.

2 -6
SAFETY SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB.

2.3 SOUND PRESSURE LEVEL IN THE OPERATOR’S


CAB.

Fig. 3-1

The sound pressure level in the operator’s cab is measured according to ISO 6396 (Dynamic test method).

The sound pressure value is also shown on the decal attached to the wall inside the operator’s cab, see Fig. 3-1.

2 -7
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR SAFETY

2.4 GENERAL PRECAUTIONS COMMON TO OPERATION


ON THE EXCAVATOR

WARNING
WHEN MISUSED, THESE MACHINES ARE DANGEROUS.
Mistakes in operation, inspection, or maintenance may result in personal injury or death.
Before carrying out operation, inspection, or maintenance, always read this manual and the safety labels
on the machine carefully and obey the warnings.

2.4.1 UNDERSTANDING THE MACHINE


Before operating the machine, read this manual thoroughly. If there are any places in this manual that you do not
understand, ask the person in charge of safety to give an explanation.

2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE


EXCAVATOR

2.4.2.1 ENSURING SAFE OPERATION


– Only trained and authorized personnel can operate and maintain the machine.
– During operations, personnel are not allowed outside of the operator’s cabin.
– Follow all safety rules, precautions and instructions when operating or performing inspection or maintenance
on the machine.
– If you are not feeling well, or are under the influence of alcohol or medication, your ability to safely operate or
repair your machine may be severly impaired putting yourself and everyone else on your jobsite in danger.
– When working with another operator or with a person on worksite traffic duty, discuss the content of the opera-
tion beforehand and use pre-determined signals when carrying out these operations.

2.4.3 PREPARATIONS FOR SAFE OPERATION

2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT


– Be sure that all guards, covers and mirrors are in their proper positions. Have guards and covers repaired
immediately if they are damaged.
– Understand the method of use of safety features and use them properly.
– Never remove any safety features. Always keep them in good operating condition.

2.4.3.2 INSPECTING THE MACHINE


Check the machine before starting operations. If any abnormality is found, do not operate the machine until repairs
of the problem location have been completed.

2 -8
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT


– Do not wear loose clothing and accessories. If these catch on
the control levers or moving parts, there is a danger that it
may cause the machine to move unexpectedly.
– Always wear a hard hat and safety shoes when working on
the machine outside of the cabin. If the nature of the work
requires it, wear safety glasses, mask, gloves, ear plugs and
a safety belt when operating or maintaining the machine (Fig.
3-2).
– If you have long hair and it hangs out from your hard hat,
there is a hazard that it may get caught up in the machine, so
tie your hair up and be careful not to let it get caught.
– Check that all protective equipment functions properly before
using it. Fig. 3-2

2.4.3.4 KEEP MACHINE CLEAN


– If you get on or off the machine or carry out inspection or
maintenance when the machine is dirty with mud or oil, there
is a hazard that you will slip and fall. Wipe off any mud or oil
from the machine. Always keep the machines clean.
– If water gets into the electrical system (Fig. 3-3), there is a
hazard that it will cause malfunctions or a misoperation. If
there is any misoperation, there is a danger that the machine
may move unexpectedly and cause serious personal injury or
death. When washing the machine with water or steam, do
not allow the water or steam to come into direct contact with
electrical components.

Fig. 3-3

2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT


– When entering the operator’s compartment, always remove all mud and oil from your shoes. If you operate the
pedal with mud or oil affixed to your shoes, you may slip and this may cause a serious accident.
– Do not leave tools or machine parts lying around inside the operator’s compartment. If tools or parts get into
the control devices, they may obstruct operation and cause the machine to move unexpectedly, resulting in
serious personal injury or death.
– Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.
– Do not use a cell phone when driving or operating the machine. This may lead to mistakes in operation, which
could cause serious personal injury or death.
– Never bring any dangerous objects such as flammable or explosive items into the operator’s compartment.

2 -9
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR SAFETY

2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT


Always follow the precautions below to prepare for action if any
injury or fire should occur.

– Be sure that fire extinguishers have been provided and read


the labels to ensure that you know how to use them in emer-
gencies.
– Carry out periodic inspection and maintenance to ensure that
the fire extinguisher can always be used.
– Provide a first aid kit. Carry out periodic checks and add to
the contents if necessary (Fig. 3-4).

Fig. 3-4

2.4.3.7 IF A PROBLEM IS FOUND


If you find any problems in the machine during operation and maintenance (noise, vibration, smell, incorrect
gauges, smoke, oil, leakage, etc., or any abnormal display on the warning devices or monitor), report to the person
in charge and have the necessary action taken. Do not operate the machine until the problem has been corrected.

2.4.4 FIRE PREVENTION

2.4.4.1 PRECAUTIONS TO PREVENT FIRE

Fire caused by fuel, oil, antifreeze, or window washer fluid.

Do not bring any flame or fire close to flammable substances such as fuel, oil, antifreeze, or window washer fluid.
There is a danger they may catch fire. To prevent fire, always observe the following:

– Do not smoke or use any flame near fuel or other flamma-


ble substances. (Fig. 3-5)
– Stop the engines before adding fuel.
– Do not leave the machine while adding fuel or oil.
– Tighten all fuel and oil caps securely.
– Be careful not to spill fuel on overheated surfaces or on
parts of the electrical system.
– After adding fuel or oil, wipe up any spillage.
– Put greasy rags and other flammable materials into a safe
container to maintain safety in the workplace.
– When washing parts with oil, use a non-flammable oil. Do Fig. 3-5
not use diesel oil or gasoline. There is a danger that they
may catch fire.
– Do not weld or use a cutting torch to cut any pipe or tubes
that contain flammable liquids.
– Determine well ventilated areas for storing oil and fuel.
Keep the oil and fuel in the determined place and do not
allow unauthorised persons to enter.

REMARKS: Before carrying out grinding or welding work on the machine, remove any flammable materials.

2 - 10
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

– Fire caused by accumulation of flammable material.


Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or
affixed around the engines, exhaust manifold, muffler or battery, or inside the undercovers.
– Fire coming from electrical wiring
Short circuits in the electrical system can cause fire. To prevent fire, always observe the following:
– Keep all electrical connections clean and securely tightened.
– Check the wiring every day for looseness or damage. Tighten any loose connectors or wiring clamps.
Repair or replace any damaged wiring.
– Fire coming from piping
Check that all hose and tube clamps, guards, and cushions are securely fixed in position.
If they are loose, they may vibrate during operation and rub against other parts. There is a danger that this
may lead to damage to the hoses and cause high pressure oil to spurt out, leading to fire, personal injury, or
death.
– Explosion caused by lighting equipment
– When checking fuel, oil, battery electrolyte, or coolant, always use lighting with anti-explosion specifica-
tions.
– When taking the electrical power for the lighting from the machine itself, follow the instructions of this man-
ual.

2.4.4.2 ACTION IF FIRE OCCURS


– Activate the STOP switch to stop the engine.
– Use the access ladders and steps to get off the machine.
– If it is impossible to escape from the rear of the cab, use the
rope ladder provided for emergency escape to escape from
the side of the cab. (Fig. 3-6.)

Fig. 3-6

– After escaping with the emergency escape ladder, activate


the engine stop chains (1 on Fig. 3-7) to shut down the engine
if they are equipped on your shovel.

Fig. 3-7

2 - 11
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR SAFETY

2.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB


If the cab door does not open, use the sliding window for an emergency escape. On machines without a sliding
window, use the emergency escape hammer to break the window glass and use the window as an emergency
escape.

2.4.5 PRECAUTIONS WHEN CLEANING CAB GLASS


Always keep the cab glass clean to ensure good visibility when operating.
Use an ethyl alcohol based washer liquid. Methyl alcohol based liquid may irritate your eyes, so do not use it.
If the cab glass on the work equipment side is broken, there is a hazard that the intruding objects may contact the
operator's body directly. Stop operation immediately and replace the glass.

2.4.6 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE

2.4.6.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE
To prevent personal injury caused by slipping or falling off the machine, always do as follows.

– Always use the handrails and steps when getting on or off the
machine.
– To ensure safety, always face the machine and maintain
three-point contact (both feet and one hand, or both hands
and one foot - see Fig. 3-8). with the handrails and steps to
ensure that you support yourself.
– When walking around the machine, where possible, move
only in areas that have non-slip padded walkways and non-
slip gratings. Extra care is to be taken when moving around
outside of these areas.
– Before getting on or off the machine, check the handrails and
steps. If there is any oil, grease, or mud on the handrails or
steps, wipe it off immediately. Always keep these parts clean. Fig. 3-8
Repair any damage and tighten any loose bolts.

2.4.6.2 NO JUMPING ON OR OFF THE MACHINE


– Never jump on or off the machine. Never get on or off a moving machine.
– If the machine starts to move when there is no operator on the machine, do not jump onto the machine and try
to stop it.

2.4.6.3 NO PEOPLE ON THE ATTACHMENT


Never let any person mount the boom, arm, bucket, or other attachment without appropriate safety equipment.
There is danger of falling and suffering serious personal injury. For further information refer to section 2.7 on page
3-42.

2.4.6.4 WORKING IN HIGH PLACES


When working in high places, use safety harness and fall absorber to ensure that the work can be carried out
safely. For further information refer to section 2.7 on page 3-42.

2 - 12
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

2.4.6.5 LEAVING OPERATOR’S SEAT WITH LOCK


– Before standing up from the operator's seat in order to adjust
the seat, always lower the work equipment to the ground, turn
off the engine, relieve the pressure in the hydraulic system
and set lock lever to LOCK position (L, Fig. 3-9.). If the lock is
not applied, there is danger of serious personal injury if the
work equipment control levers are touched by mistake and
the machine moves suddenly. For information on relieving the
pressure in the hydraulic system, refer to chapter ’RELIEV-
ING THE PRESSURE IN THE HYDRAULIC SYSTEM’ in the
’OPERATION’ part of this manual.

Fig. 3-9

2.4.6.6 LEAVING THE MACHINE


– When leaving the machine, always lower the work equipment
completely to the ground, turn off the engine, relieve the pres-
sure in the hydraulic system and set lock lever (1) securely to
the LOCK position (L), then stop the engine. Use the key to
lock all the equipment. Always remove the key, take it with
you, and keep it in the specified place (Fig. 3-10). For infor-
mation on relieving the pressure in the hydraulic system, refer
to chapter ’RELIEVING THE PRESSURE IN THE HYDRAU-
LIC SYSTEM’ in the ’OPERATION’ part of this manual.

Fig. 3-10

2.4.7 BURN PREVENTION

2.4.7.1 HOT COOLANT


– To prevent burns from hot water or steam spurting out when
checking or draining the coolant, wait for the water to cool to a
temperature where it is possible to touch the radiator cap
(Fig. 3-11 and Fig. 3-12) by hand before starting the opera-
tion. Even when the coolant has cooled down, loosen the cap
slowly to relieve the pressure inside the radiator before
removing the cap.

Fig. 3-11

2 - 13
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR SAFETY

2.4.7.2 HOT OIL


– To prevent burns from hot oil spurting out when checking or
draining the oil, wait for the oil to cool to a temperature where
it is possible to touch the cap or plug by hand before starting
the operation (Fig. 3-12). Even when the oil has cooled down,
loosen the cap or plug slowly to relieve the internal pressure
before removing the cap or plug.

Fig. 3-12

2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES


On jobsites where there is a hazard that falling objects (Fig. 3-13),
flying objects (Fig. 3-14), or intruding objects may hit or enter the
operator's cab, consider the operating conditions and install the
necessary guards to protect the operator.

– When carrying out operations in mines or quarries where


there is danger of falling or flying rocks, order/use the option-
ally available front guard.
– When carrying out the above operations, always ensure that
bystanders are a safe distance away and are not in hazard
from falling or flying objects.
– The above recommendations assume that the conditions are Fig. 3-13
for standard operations, but it may be necessary to add addi-
tional guards according to the operating conditions on the job-
site. Always contact your Komatsu distributor for advice.

Fig. 3-14

2.4.8.1 UNAUTHORIZED MODIFICATION


– Komatsu will not be responsible for any injuries, accidents, product failures or other property damage resulting
in modifications made without authorisation from Komatsu.
– Any modifications made without authorisation from Komatsu can create hazards. Before making a modifica-
tion, consult your komatsu distributor.
– Any injuries, accidents, or product failures resulting from the use of unauthorized attachments or parts will not
be the responsibility of Komatsu.

2 - 14
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

Please continue reading on the next page.

2 - 15
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR SAFETY

2.4.9 PRECAUTIONS AT JOBSITE

Fig. 3-15

2 - 16
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

2.4.9.1 VISIBILITY FROM OPERATOR’S SEAT

WARNING
THE AREA AROUND THE EXCAVATOR DURING OPERATION IS EXTREMELY DANGER-
OUS!
Death and serious injury can occur. Make sure the job site is organized in such a way, that the safety of
man and equipment is always ensured.

Fig. 3-15 shows an example of general blind areas of large Komatsu hydraulic mining shovels.

The grey shaded areas (A) show the areas where the view is blocked when the operator is sitting in the operator’s
seat, and the shovel is equipped with standard mirrors. The boundary line (B) shows the distance of 1 meter from
outside surface of the shovel. Please be fully aware that there are places that can not seen when operating the
machine.

REMARKS: The blind areas (A) differ depending on the machine type, attachment and position of attachment.

The International Standard ISO 5006 defines criteria for Operator’s visibility. This standard is not met
and does not apply to large hydraulic mining shovels.

2.4.9.2 CAMERA SYSTEM WITH MONITORS


Komatsu Mining Germany offers optionally camera systems and monitors to improve the overall visibility. See lat-
est version of the OMM for typical arrangement of cameras and monitors.

The camera system can be installed ex works and can also be retrofitted in the field. If you need more information,
please contact your local Komatsu distributor.

2.4.9.3 ENSURE GOOD VISIBILITY


When operating or travelling in places with poor visibility, if it is impossible to confirm the condition of the job side
or obstacle is in the area around the machine, there is danger that the machine may suffer damage or the operator
may suffer serious personal injury. When operating or travelling in places with poor visibility, always observe the
following items strictly.

– If the visibility cannot be sufficiently assured, position a flagman if necessary. The operator should pay careful
attention to the signs and follow the instructions of the flagman.
– The signals should be given only by one flagman.
– When working in dark places, turn on the working lamps and front lamps of the machine, and if necessary, set
up additional lighting in the area.
– Stop operations if there is poor visibility, such as in fog, snow, rain, or sand storms.
– Check the mirrors on the machine before starting operations every day. Clean off any dirt and adjust the view
to ensure good visibility.
– In areas where it is impossible to confirm the area around the machine and observation cameras have been
set up, clean off any dirt from the lens and make sure that the cameras give a clear view of the working area of
the machine.

2.4.9.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS


– Set up signs to inform of road shoulders or soft ground. If the visibility is not good, position a signalman if nec-
essary. Operators should pay careful attention to the signs and follow the instructions from the signalman.
– Only one signalman should give signals.
Make sure that all workers understand the meaning of all signals and signs before starting work.

2 - 17
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR SAFETY

2.4.9.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS


On the jobsite, there are various hidden dangers that may lead to personal injury or death. Before starting opera-
tions, always check the following to confirm there are no dangers on the jobsite.

– When carrying out operations near combustible materials,


there is a hazard of fire, so be careful when operating.
– Check the terrain and condition of the ground at the worksite,
and determine the safest method of operation. Do not operate
where there is a hazard of landslides or falling rocks.
– If water lines, gas lines, or high-voltage electrical lines may be
buried under the worksite, contact each utility and identify
their locations. Be careful not to sever or damage any of
these lines (Fig. 3-16).
– Take necessary measures to prevent any unauthorized per-
son from entering the operating area.
– If there is a fire near the machine, there is danger of sparks
being sucked in and causing a fire on the machine. Fig. 3-16

– When travelling or operating in shallow water or on soft


ground, check the shape and condition of the bedrock, and
the depth and speed of flow of the water before starting oper-
ations.
– Maintain the travel path on the jobsite so that there is no
obstruction to travel operations.

2.4.9.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES

DANGER
HIGH VOLTAGE!
Do not travel or operate the machine near electric cables
(Fig. 3-17). There is a hazard of electric shock, which may
cause serious injury or property damage. Even going close
to high-voltage cables can cause an electric shock, which
may cause serious burns or even death.

Fig. 3-17

2 - 18
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

On jobsites where the machine may go close to electric cables,


always do as follows.
Voltage of Cables Safety Distance
– Before starting work near electric cables, inform the local 100 V - 200 V Over 2 m (7 ft)
power company of the work to be performed, and ask them to 6,600 V Over 2 m (7 ft)
take the necessary action. 22,000 V Over 3 m (10 ft)
– Always maintain a safe distance (see the table on the right) 66,000 V Over 4 m (14 ft)
between the machine and the electric cable. Check with the 154,000 V Over 5 m (17 ft)
local power company about safe operating procedure before 187,000 V Over 6 m (20 ft)
starting operations. 275,000 V Over 7 m (23 ft)
– To prepare for any possible emergencies, wear rubber shoes 500,000 V Over 11 m (36 ft)
and gloves. Lay a rubber sheet on top of the seat, and be
careful not to touch the chassis with any exposed part of your
body.
– Use a signalman to give warning if the machine approaches
too close to the electric cables.
– When carrying out operations near high voltage cables, do
not let anyone near the machine.
– If the machine should come too close or touch the electric
cable, to prevent electric shock, the operator should not leave
the operator's compartment until it has been confirmed that
the electricity has been shut off. Also, do not let anyone near
the machine.

2.4.9.7 WORKING ON LOOSE GROUND


– Avoid travelling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The
ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine,
there is a hazard that the machine may fall or tip over. Remember that the soil after heavy rain or blasting or
after earthquakes is weak in these areas.
– When working on embankments or near excavated ditches, there is a hazard that the weight and vibration of
the machine will cause the soil to collapse. Before starting operations, take steps to ensure that the ground is
safe and to prevent the machine from rolling over or falling.

2.4.9.8 GAS, DUST, STEAM AND SMOKE

WARNING
RISK OF EXPOLSION AND FIRE!
Welding, flame-cutting and grinding work on the machine increases the risk of explosion and fire which
may result in serious injury or death.
All relevent safety measures must be followed and only under expressly obtained authorization.

Special care must be taken before welding, flame-cutting and grinding operations are carried out on the
counterweight. The filling of the counterweight chambers can create explosive gases which will accumu-
late in the chambers of the counterweight.

These gases must be expelled before welding, flame-cutting and grinding operations are carried out on
the counterweight.
Follow the instructions given in PARTS & SERVICE NEWS No. AH04518 for expelling the gases from the
counterweight chambers. (See Volume 2 binder)

2 - 19
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR SAFETY

WARNING
RISK OF EXPLOSION!
Substances and objects igniting can lead to fire or explosion resulting in serious injury or death.
Before carrying out welding, flame-cutting and grinding operations, clean the machine and its surround-
ings from dust and other inflammable substances and make sure that the premises are adequately venti-
lated as there is a risk of explosion.

2.4.9.9 VENTILATION OF ENCLOSED AREAS

WARNING
POISONOUS FUMES!
Unventilated areas where poisonous fumes can accumulate can kill.
Always ensure adequate ventilation.

– Operate internal combustion engines and fuel operated heat-


ing systems only on adequately ventilated premises. Before
starting the machine on enclosed premises, make sure that
there is sufficient ventilation (Fig. 3-18).
Observe the regulations in force at the respective site.
– If it is necessary to start the engine within an enclosed area,
or when handling fuel, flushing oil, or paint, open the doors
and windows to ensure that adequate ventilation is provided
to prevent gas poisoning.

Fig. 3-18

2 - 20
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

2.4.10 STARTING ENGINE

2.4.10.1 WARNING TAG


– If there is a "DANGER DO NOT OPERATE!" warning tag dis-
played, it means that someone is carrying out inspection and
maintenance on the machine (Fig. 3-19). If the warning sign is
ignored and the machine is operated, there is a danger that
the person carrying out the inspection or maintenance may
be caught in the rotating parts or moving parts and suffer per-
sonal injury or death. Do not start the engine or touch the
levers.

Fig. 3-19

2.4.10.2 CHECKS BEFORE STARTING ENGINE


Carry out the following checks before starting the engine at the beginning of the day's work to ensure that there is
no problem with the operation of the machine. If this inspection is not carried out properly, problems may occur
with the operation of the machine, and there is the danger that this could lead to serious personal injury or death.

– Remove all dirt from the surface of the window glass to


ensure a good view.
– Completely remove all flammable materials accumulated
around the engine and battery, and remove any dirt from the
windows, mirrors, handrails, access ladder and steps.
– Check the coolant levels, fuel levels, and oil levels, and check
for damage to the electric wiring.
– Adjust the operator's seat to a position where it is easy to
carry out operations, check the camera system functions and
check that there is no damage or wear to the seat belt or
mounting clamps.
– Check the operation of the instruments and gauges, check
the angle of the mirror, and check that the control levers are Fig. 3-20
all at the Neutral position.
– Before starting the engine, check that lock lever (Fig. 3-20) is
in LOCK position (L).
– Adjust the mirrors so that the rear of the machine can be seen
clearly from the operator's seat.
– Check that there are no persons or obstacles above, below,
or in the area around the machine.

2.4.10.3 PRECAUTION WHEN STARTING ENGINE


– Start and operate the machine only while seated.
– Do not short circuit the starting motor circuit to start the engine. Short circuiting can cause fire.
– When starting the engine, sound the horn as a warning.

2 - 21
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR SAFETY

– Do not let any person on the machine other than the operator and the operator's assistant (1 person). For
demonstration purposes or during training, more than two people can be present in the operator’s cabin at the
same time. All personnel within the cabin at such times must secure good hand-holds and be aware of sudden
movements. All appropriate relevant safety measures are to be observed.

2.4.10.4 PRECAUTION IN COLD AREAS


– Carry out the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the control
levers or control pedals are operated, the reaction of the machine will be slow or the machine may move in a
way not expected by the operator. Particularly in cold weather, be sure to carry out the warming-up operation
thoroughly.
– If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.
There is a hazard that this will ignite the battery and cause the battery to explode.
– Before charging or starting the engine with a different power source, melt the battery electrolyte and check that
there is no leakage of electrolyte before starting.

2.4.11 OPERATION

2.4.11.1 CHECKS BEFORE OPERATION


If the checks before starting are not carried out properly, the machine will be unable to display its full performance,
and there is also danger that it may lead to serious personal injury or death.

When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate
slowly. Do not allow anyone near the machine.

– Always fasten your seat belt.


– Check that the movement of the machine matches the display on the control pattern label in the cabin. If it
does not match, replace it immediately with the correct control pattern label.
– Check the operation of the gauges and equipment, and check the operation of the bucket, arm, boom, travel
system and swing system.
– Check for any problem in the sound of the machine, vibration, heat, smell, or gauges; check also that there is
no leakage of oil or fuel.
– If any problem is found, carry out repairs immediately.

2 - 22
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

2.4.11.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE


– Before travelling, set the machine so that sprocket (1) is
behind the operator's seat (Fig. 3-21).
– If sprocket (1) is in front of the operator's cab, the machine
moves in the opposite direction from the operation of the ped-
als (front and rear travel is reversed, left and right steering is
reversed). Be extremely careful when operating the machine
in this situation.

Fig. 3-21

– Before travelling, check again that there is no one in the sur-


rounding area, and that there are no obstacles (Fig. 3-22).
– Before travelling, sound the horn to warn people in the area.
– Always operate the machine only when seated.
– Do not allow anyone apart from the operator to ride on the
machine.
– Check that the travel alarm works properly.
– Secure the cab door when it is both open and closed.
– Always keep the cab door closed when operating the
machine.

Fig. 3-22

– If there is an area to the rear of the machine which cannot be


seen, position a signal person. Take special care not to hit
other machines, objects or people when turning or swinging
the machine (Fig. 3-23)

Fig. 3-23

NOTE! Always be sure to carry out the above precautions even when the machine is equipped with mirrors
or camera systems.

2 - 23
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR SAFETY

2.4.11.3 PRECAUTIONS WHEN TRAVELLING


– When travelling on flat ground, keep the work equipment 100
to 150 cm (39 to 59 in) high above the ground (Fig. 3-24).
– If the view to the right side is poor, raise the boom to ensure
better visibility.
– When travelling on rough ground, travel at low speed and do
not operate the steering suddenly. There is danger that the
machine may turn over. The work equipment may hit the
ground surface and cause the machine to lose its balance, or
may damage the machine or structures in the area.

Fig. 3-24

– Avoid travelling over obstacles when possible. If the machine


has to travel over an obstacle, keep the work equipment close
to the ground and travel at low speed. Never travel over
obstacles which make the machine tilt strongly to one side
(Fig. 3-25).
– When travelling or carrying out operations, always keep a
safe distance from people, structures or other machines to
avoid coming into contact with them.

Fig. 3-25

2 - 24
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

2.4.11.4 TRAVELLING ON SLOPES


To prevent the machine from tipping over or slipping to the side,
always do as follows.

– Keep the work equipment 100 - 150 cm (39 - 59 in) above the
ground surface so that the work equipment can be lowered to
the ground immediately to stop the machine in emergencies
(Fig. 3-26).
– When travel up slopes, set the operator's cab facing uphill,
when travel down slopes, set the operator's cab facing down-
hill. Always be aware and informed about the firmness and
bearing capacity of the ground under the machine when trav-
elling. Cavaties and underground mines may cause the
ground beneath the excavator to collapse.
Fig. 3-26

– When travelling up a steep slope, extend the work equipment


to the front to improve the balance, keep the work equipment
approximately 100 to 150 cm (39 to 59 in) above the ground,
and travel at low speed (Fig. 3-27).

Fig. 3-27

– When travelling downhill, keep the travel pedals close to the


neutral position, and travel at low speed.
– Always travel straight up or down a slope. travelling at an
angle or across the slope is extremely dangerous.
– Do not turn on slopes or travel across slopes. Always go
down to a flat place to change the position of the machine,
then travel on to the slope again (Fig. 3-28).
– Travel on slippery ground with low speed. Even with slight
slopes there is a hazard that the machine may slip

Fig. 3-28

2 - 25
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR SAFETY

2.4.11.5 OPERATIONS ON SLOPES


– When working on slopes, there is a hazard that the machine
may lose its balance and turn over when the swing or work
equipment are operated. This may lead to serious injury or
property damage, so always provide a stable place when car-
rying out these operations, and operate carefully.
– Do not swing the work equipment from the uphill side to the
downhill side when the bucket is loaded. This operation is
dangerous, and may cause the machine to tip over.
– If the machine has to be used on a slope, pile the soil to make
a platform (A on Fig. 3-29) that will keep the machine as hori-
zontal as possible.

Fig. 3-29

2.4.11.6 PROHIBITED OPERATIONS


– Never dig the work face under an overhang. There is a haz-
ard that rocks may fall or that the overhang may collapse and
fall on top of the machine (Fig. 3-30).

Fig. 3-30

– Do not excavate too deeply under the front of the machine.


The ground under the machine may collapse and cause the
machine to fall (Fig. 3-31).

Fig. 3-31

2 - 26
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

– To make it easier to escape if there is any problem, set the


tracks at right angles to the road shoulder or cliff with the
sprocket at the rear when carrying out operations (Fig. 3-32).
– Generally speaking, the machine is more liable to overturn
when the work equipment is at the side than when it is at the
front or rear.
– Do not suddenly lower, swing, or stop the work equipment.
– Do not suddenly extend or retract the boom cylinder.
There is a hazard that impact will cause the machine to tip
over.
– Do not pass the bucket over the head of other workers or over
the operator's seat of dump trucks or other hauling equip-
ment. The load may spill or the bucket may hit the dump truck Fig. 3-32
and cause serious injury or property damage.

2.4.11.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES


– Snow-covered or frozen surfaces are slippery, so be extremely careful when travelling or operating the
machine, and do not operate the pedals suddenly. Even a slight slope may cause the machine to slip, so be
particularly careful when working on slopes.
– With frozen ground surfaces, the ground becomes soft when the temperature rises, and this may cause the
machine to tip over.
– If the machine enters deep snow, there is a hazard that it may tip over or become buried in the snow. Be care-
ful not to leave the road shoulder or to get trapped in a snow drift.
– When clearing snow, the road shoulder and objects placed beside the road are buried in the snow and cannot
be seen. There is a hazard of the machine tipping over or hitting covered objects, so always carry out opera-
tions carefully.

2.4.11.8 PARKING THE MACHINE


– Park the machine on firm, level ground. Select a place where
there is no hazard of falling rocks or landslides, or of flooding
if the land is low.
– Lower the work equipment completely to the ground.
– When leaving the machine, set lock lever (1) to the LOCK
position (L), then stop the engine (Fig. 3-33).
– Always close the operator's cab door, and use the key to lock
all the equipment in order to prevent any unauthorized person
from moving the machine. Always remove the key, take it with
you, and leave it in the specified place.
– If it is necessary to park the machine on a slope, always set
the bucket on the downhill side, then dig it into the ground.
Fig. 3-33

2.4.11.9 TRANSPORTATION
This machine must be disassembled for transportation. When transporting the machine, please consult your
Komatsu distributor.
Use only appropriate means of transport and lifting gear of adequate capacity.
The recommissioning procedure must be strictly in accordance with the General Assembly Procedure Manual.

2 - 27
PRECAUTION FOR MAINTENANCE SAFETY

2.5 PRECAUTION FOR MAINTENANCE

2.5.1 GENERAL PRECAUTIONS


– Observe the adjusting, maintenance and inspection activities and intervals set out in the Operation,- Lubrica-
tion and Maintenance Manual, including information on the replacement of parts and equipment. These activi-
ties may be executed by skilled personnel only.
– Brief operating personnel before beginning special operations and maintenance work, and appoint a person to
supervise the activities.
– In any work concerning the operation, conversion or adjustment of the machine and its safety-oriented devices
or any work related to maintenance, inspection and repair, always observe the start-up and shut-down proce-
dures set out in the Operation,- Lubrication and Maintenance Manual and the information on maintenance
work.
– Ensure that the maintenance area is adequately secured.
– If the machine is completely shut down for maintenance and repair work, it must be secured against inadver-
tent starting by:
– locking the principal control elements and removing the ignition key and/or
– attaching a warning tag to the main switch or control levers.
– setting the maintenance safety switch to the 0 position and securing it with a padlock
– Carry out maintenance and repair work only if the machine is positioned on stable and level ground and has
been secured against inadvertent movement and buckling.
– To avoid the risk of accidents, individual parts and large assemblies being moved for replacement purposes
should be carefully attached to lifting tackle and secured. Use only suitable and technically perfect lifting gear
and suspension systems with adequate lifting capacity. Never work or stand under suspended loads.
– The fastening of loads and the instructing of crane operators should be entrusted to experienced persons only.
The marshaller giving the instructions must be within sight or sound of the operator.
– For carrying out overhead assembly work always use specially designed or otherwise safety-oriented ladders
and working platforms. Never use machine parts as a climbing aid. Wear a safety harness when carrying out
maintenance work at greater heights.
Keep all handles, steps, handrails, platforms, landings and ladders free from dirt, snow and ice.
– Always tighten any screwed connections that have been loosened during maintenance and repair.
– Any safety devices removed for set-up, maintenance or repair purposes must be refitted and checked immedi-
ately upon completion of the maintenance and repair work.
– Ensure that all consumables and replaced parts are disposed of safely and with minimum environmental
impact.
– Before starting any lubrication or maintenance work read the Fundamental Safety Instructions on page 3-1.
– Park the Excavator at a safe place on level ground. Proceed according to the instructions ”Parking the
Shovel”. Lower the attachment flat onto the ground. Move all control levers to neutral position.
– Stop the engines and move all control levers through their shift positions to relieve the pressure in the hydrau-
lic system. Refer to ”Stopping the Engines” for detailed description of the stopping procedure.
– Before any maintenance work is started, set the maintenance safety switch to 0 position.
Find to the location of the maintenance safety switch refer to section 2.5.1.3 on page 3-30. In the 0 position the
engines can not be started. Secure this position by inserting a padlock into the holes of the switch. Up to ten
padlocks can be attached to the holes provided.
– A warning plate ”Caution Machine Maintenance” must be fixed in the Operator’s cab before any lubrication or
maintenance work is started.
– Block the machine to prevent machine movement

2 - 28
SAFETY PRECAUTION FOR MAINTENANCE

– Always use safety devices to block hydraulic cylinders. Never rely on the machine hydraulic system to hold
when working on the loader attachment. A hydraulic line or cylinder could fail or someone could accidently
strike the control levers causing the loader to fall.
– Relieve all pressure in the hydraulic system before servicing the hydraulic system.For information on relieving
the pressure in the hydraulic system, refer to chapter ’Relieving The Pressure In The Hydraulic System’ in the
’Operation’ part of this manual.
– Oily cloth and inflammable material must be removed from the machine. Clean the excavator before starting
maintenance work.
– Switch-off battery main switch and remove key, before working on the electrical system.
– Wear safety clothing, goggles, respirator and other safety devices, whenever working conditions make this
necessary. Observe the local safety rules.
– Never allow unauthorized persons access to the machine during lubrication and maintenance work.
– After servicing, remove oily cloth, inflammable material and all tools from the machine.
– Clean the Excavator with a steam jet, especially after servicing the hydraulic system and fuel system.

WARNING
BEWARE OF STEAM!
Hot steam can cause serious personal injury. When using a steam cleaner, wear safety glasses and pro-
tective clothing.

– For cleaning the Excavator and its components use only fresh water with a salt content of less than 0.05%.
– DO NOT use steam jet, high pressure cleaning device or strong water jet for cleaning headlights, solenoid
valves, sensors, cable connections and bearings.
– Be sure to reinstall safety devices, guards or shields after adjusting and/or servicing the machine.

2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES


– Any work on and with the machine must be executed by reliable personnel only. Statutory minimum age limits
must be observed.
– Employ only trained or instructed staff and set out clearly the individual responsibilities of the personnel for
operation, set-up, maintenance and repair.
– All personnel must be aware of the appropriate safety measures when working on or around the machine.
– Make sure that only authorized personnel works on or with the machine.
– Define the machine operator’s responsibilities - also with regard to observing traffic regulations - giving the
operator the authority to refuse instruction by third parties that are contrary to safety.
– Do not allow persons to be trained or instructed or persons taking part in a general training course on or with
the machine without being permanently supervised by an experienced person.
– Work on the electrical system and equipment of the machine must be carried out only by skilled electricians or
by persons instructed under the supervision and guidance of a skilled electrician and in accordance with elec-
trical engineering rules and regulations.
– Work on the chassis, brake and steering systems must be performed only by skilled personnel who have been
specifically trained for such work.
Work on the hydraulic system must be carried out only by personnel with special knowledge and experience of
hydraulic equipment.

2 - 29
PRECAUTION FOR MAINTENANCE SAFETY

2.5.1.2 STOP ENGINE FOR MAINTENANCE


– Stop the machine (Fig. 3-34) on firm, level ground.
– Select a place where there is no hazard of falling rocks or
landslides, or of flooding if the land is low.
– Lower the work equipment completely to the ground and stop
the engine.

Fig. 3-34

– Turn the main key switch to the ON position. Operate the


work equipment control lever back and forth, left and right at
the full stroke 2 to 3 times to eliminate the remaining internal
pressure in the hydraulic circuit, and then push up lock lever
(1) to the LOCK position (Fig. 3-35).
– Check that the battery main switch is off and main power is
not conducted. (Wait for approx. one minute after activating
the engine STOP switch and press the horn switch. If the
horn does not sound, it is not activated.)

Fig. 3-35

2.5.1.3 WARNING TAG


– Always attach the “DO NOT OPERATE“ warning tag (Fig. 3-
36) to the work equipment control lever in the operator's cab
to alert others that you are performing service or maintenance
on the machine. Attach additional warning tags around the
machine if necessary.
– Keep this warning tag in the tool box while it is not used. If
there is not the tool box, keep the tag in the operation manual
pocket.
– If any other person starts the engine, or touches or operates
the control levers or control pedals while you are performing
service or maintenance, you may suffer serious injury.

Fig. 3-36

2 - 30
SAFETY PRECAUTION FOR MAINTENANCE

– Before entering the machinery house, switch off maintenance


safety switch (Fig. 3-37)
– The maintenance safety switch is located in the machinery
house, next to the entrance door (Pos. 1 on Fig. 3-38).
– Before beginning maintenance operations, set the safety
switch to "0" to prevent a starting of the engines. Secure this
position by inserting a padlock into the holes of the safety
switch. Up to ten padlocks can be attached.

Fig. 3-37

Fig. 3-38

2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY

CAUTION
HAZARD OF ACCIDENTS!
If the work place is not kept clean and tidy, there is the danger that you will trip, slip, or fall over and injure
yourself.
Observe the following points.

– Do not leave hammers or other tools lying around in the work place. Wipe up all grease, oil, or other sub-
stances that will cause you to slip. Always keep the work place clean and tidy to enable you to carry out oper-
ations safely.
– Never drop or insert tools or other objects into the fan or fan belt. Parts may break or be sent flying

2 - 31
PRECAUTION FOR MAINTENANCE SAFETY

2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS


When repairing the machine or when removing and installing the work equipment, appoint a leader and follow his
instructions during the operation.

2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING


– To prevent injury, do not perform maintenance or adjustments
while the engine runs. If work must be carried out with the
engine running, carry out the operation with at least two work-
ers and do as follows:
– One worker must always sit in the operator's seat and be
ready to stop the engine at any time. All workers must
maintain contact with each other and be fully aware of all
relevant safety measures.
– For safety information when working with high pressure oil in
the hydraulic system, refer to section 2.6 on page 3-40.
– When carrying out operations near rotating parts, there is a
hazard of being caught in the parts, so be careful not to come
close (Fig. 3-39). Fig. 3-39
– Do not touch any control levers or pedals. If they must be
operated, always give a signal to other workers to warn them
to move to a safe place.

2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS


– Appoint a leader before starting removal or installation opera-
tions for attachments.
– Place attachments that have been removed from the machine
in a stable condition so that they do not fall (Fig. 3-40). And
take steps to prevent unauthorized persons from entering the
storage area.

Fig. 3-40

2 - 32
SAFETY PRECAUTION FOR MAINTENANCE

2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT


– If it is necessary to go under the work equipment or the
machine to carry out service and maintenance (Fig. 3-41),
support the work equipment and machine securely with
blocks and stands strong enough to support the weight of the
work equipment and machine.
– It is extremely dangerous to work under the machine if the
track shoes are lifted off the ground and the machine is sup-
ported only with the work equipment. If any of the control
levers are touched by accident, or there is damage to the
hydraulic piping, the work equipment or the machine will sud-
denly drop. This is extremely dangerous. Never work under
the work equipment or the machine.

Fig. 3-41

2.5.1.9 NOISE
When carrying out maintenance of the engine and you are exposed to noise for long periods of time, wear ear cov-
ers or ear plugs while working. If the noise from the machine is too loud, it may cause temporary or permanent
hearing problems.

2.5.1.10 WHEN USING A HAMMER


When using a hammer, pins may fly out or metal particles may be scattered. This may lead to serious injury.
Always do as follows.

– If hard metal parts such as pins, bucket teeth, cutting edges,


or bearings are hit with a hammer, there is a hazard that
pieces might be scattered and cause injury. Always wear
safety glasses and gloves (Fig. 3-42).
– When hitting pins or bucket teeth, there is a hazard that bro-
ken pieces might be sent flying and injure people in the sur-
rounding area. Always check that there is no one in the
surrounding area.
– There is a hazard that the pin hit with strong force may fly out
and injure people in the surrounding area.

Fig. 3-42

2 - 33
PRECAUTION FOR MAINTENANCE SAFETY

2.5.1.11 PROPER TOOLS


– Use only tools suited to the task and be sure to use the tools
correctly. Using damaged, low quality, faulty, makeshift tools
or improper use of the tools could cause serious personal
injury (Fig. 3-43).

Fig. 3-43

2.5.1.12 ACCUMULATOR
The accumulator is charged with high-pressure nitrogen gas.
When handling the accumulator, careless procedure may cause
an explosion which could lead to serious injury or property dam-
age (Fig. 3-44). For this reason, always observe the following
precautions.

– Do not disassemble the accumulator.


– Do not bring it near flame or dispose of it in fire.
– Do not make holes in it, weld it, or use a cutting torch.
– Do not hit or roll the accumulator, or subject it to any impact.
– When disposing of the accumulator, the gas must be
released. Please contact your Komatsu distributor to have
this work performed. Fig. 3-44

2.5.1.13 PERSONNEL
Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the area.
If necessary, employ an observer.

2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE

2.5.2.1 PRECAUTION WHEN WELDING

WARNING
RISK OF EXPOLSION AND FIRE!
Welding, flame-cutting and grinding work on the machine increases the risk of explosion and fire which
may result in serious injury or death.
All relevent safety measures must be followed and only under expressly obtained authorization.

Welding operations must always be carried out by a qualified welder and in a place equipped with proper equip-
ment. There is a hazard of gas, fire, or electrocution when carrying out welding, so never allow any unqualified
personnel to carry out welding.

2 - 34
SAFETY PRECAUTION FOR MAINTENANCE

2.5.2.2 BATTERY HANDLING

WARNING
RISK OF EXPLOSION AND FIRE!
Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may
explode. Wrong handling can lead to serious injury or fire. For this reason, always observe the following
precautions.

– Do not use or charge the battery if the battery electrolyte level


is below the LOWER LEVEL line. This may cause an explo-
sion. Check the battery electrolyte level periodically and add
distilled water to bring the electrolyte level to the UPPER
LEVEL line.
– When working with batteries, always wear safety glasses and
rubber gloves.
– Never smoke or use any flame near the battery (Fig. 3-45).

Fig. 3-45

– If you spill acid on your clothes or skin, immediately flush the


area with large amount of water.
– If acid gets into your eyes (Fig. 3-46), flush them immediately
with large amount of water and seek medical attention.
– Before working with batteries, activate the STOP switch and
remove battery main switch key.

Fig. 3-46

As there is a hazard that sparks will be generated, always do as follows.

– Do not let tools or other metal objects make any contact between the battery terminals. Do not leave tools or
other metal objects lying around near the battery.
– When disconnecting the battery terminals, wait for approx. one minute after activating the engine STOP switch
and be sure to disconnect the grounding terminal
(negative (-) terminal) first. Conversely, when connecting them, begin with the positive (+) terminal and then
the grounding (-) terminal. Make sure that all the terminals are connected securely.
– Attach the battery terminal securely.
– Flammable hydrogen gas is generated when the battery is charged, so remove the battery from the chassis,
take it to a well-ventilated place, and remove the battery caps before charging it.
– Tighten the battery caps securely.
– Install the battery securely to the determined place.

2 - 35
PRECAUTION FOR MAINTENANCE SAFETY

2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID

WARNING
FLUID UNDER HIGH PRESSURE!
The hydraulic system is always under internal pressure and can lead to serious injury when leaking.
When inspecting or replacing piping or hoses, always check that the pressure in the hydraulic circuit has
been released.

2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE


– For details of the method of releasing the pressure, see the
latest version of the Operation and Maintenance Manual. If
the circuit is still under pressure, do not carry out any inspec-
tion or replacement operation.
– If there is any leakage from the piping or hoses, the surround-
ing area will be wet, so check for cracks in the piping and
hoses and for swelling in the hoses.
– When carrying out inspections, wear full-face protection and
penetration resistant clothing and gloves (leather).
– There is a hazard that high-pressure oil leaking from small
holes may penetrate your skin or cause blindness if it con-
tacts your eyes directly (Fig. 3-47). If you are hit by a jet of
high-pressure oil and suffer injury to your skin or eyes, wash Fig. 3-47
the place with clean water, and consult a doctor immediately
for medical attention.

High pressure is generated inside the engine fuel piping when the engine is running. When carrying out inspection
or maintenance of the fuel piping system, wait for at least 30 seconds after stopping the engine to let the internal
pressure go down before starting inspection or maintenance.

2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES


– If oil or fuel leaks from high-pressure hoses, it may cause fire or defective operation, which may lead to serious
injury. If any loose bolts are found, stop work and tighten to the specified torque. If any damaged hoses are
found, stop operations immediately and contact your Komatsu distributor.
Replace the hose if any of the following problems are found.

– Damaged or leaking hydraulic fitting.


– Frayed or cut covering or exposed reinforcement wire layer.
– Covering swollen in places.
– Twisted or crushed movable portion.
– Foreign material embedded in covering.

2.5.3.3 REPLACEMENT OF HOSE LINES


Hydraulic hoses are subjected to natural aging. Hence, their usable lifetime is limited to maximum 6 years.

NOTICE
The maximum permissible storage time of hydraulic hoses must be observed.

2 - 36
SAFETY PRECAUTION FOR MAINTENANCE

– This storage period is part of the usable lifetime and must be considered when installing a new hose line. If, for
example, a hose line with a one year storage time is to be installed, the remaining service life of the hose line
must be considered. All hose lines are marked with the date of production.
– Hose lines considered as Safety Critical Parts have to be replaced earlier. Refer to the chapter "Lubrication
and Maintenance Schedule" in the MAINTENANCE section of the Operation and Maintenance Manual for fur-
ther information.

All hydraulic hoses of the Shovel have to be replaced when their service life has expired, even if there is no visible
damage. Refer to the chapter "Lubrication and Maintenance Schedule" in the MAINTENANCE section of the
Operation and Maintenance Manual for further information.

NOTICE
Repairs on hydraulic hoses are not allowed. Use ONLY GENUINE Komatsu Mining Germany replacement
hose lines.

2.5.3.4 INSPECTION OF HOSE LINES

WARNING
FLUID UNDER HIGH PRESSURE!
The hydraulic system is always under internal pressure and can lead to serious injury when leaking.
When inspecting or replacing piping or hoses, always check that the pressure in the hydraulic circuit has
been released.

Inspect all hoses, hose lines and fittings carefully during the course of the daily walk-around inspection. Check for
leaks and damages. Beware of pinhole leakages. Replace damaged parts without delay.

Some examples of faults on hydraulic hoses requiring replacement of the concerned part:

– Damage to the outer layer (e.g. chafed spots, cuts or scratches).


– Brittle top layers. Flaws on the hose material
– Distortion of the hose line (strong deviation from the original shape) under pressurized and pressureless con-
ditions or when kinked or crushed, e.g. disintegration of hose layers or blistering.
– Leaks.
– Detachment of hose and fitting. Damaged hose fitting.

2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS


To ensure safety at all times when operating the machine, the user of the machine must always carry out periodic
maintenance. In addition, to further improve safety, the user should also carry out periodic replacement of the parts
given in the table. These parts are particularly closely connected to safety and fire prevention.

With these parts, the material changes as time passes, or they easily wear or deteriorate. However, it is difficult to
judge the condition of the parts simply by periodic maintenance, so they should always be replaced after a fixed
time has passed, regardless of their condition. This is necessary to ensure that they always maintain their function
completely. However, if these parts show any abnormality before the replacement interval has passed, they should
be repaired or replaced immediately.

If the hose clamps show any deterioration, such as deformation or cracking, replace the clamps at the same time
as the hoses.

When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time.

2 - 37
PRECAUTION FOR MAINTENANCE SAFETY

– Ask your Komatsu distributor to replace safety critical parts.

2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE

DANGER
HIGH VOLTAGE!
High voltage appliances cause serious injury or death.
Authorized staff only.

– When the engine is running and immediately after it is stopped, high voltage is generated inside the engine
controller and the engine injector.
– The headlights also operates using high voltage. Never perform maintenance on the headlights.
– If it is necessary to touch the inside of the controller or the engine injector portion, or the headlight electrics
please contact your Komatsu distributor.
– The cab base contains high voltage electrical appliances. Access to the cab base for authorized service staff
only.

2.5.3.7 AIR CONDITIONING MAINTENANCE

WARNING
AIR CONDITIONING REFRIGERANT IS HARMFUL!
If air conditioner refrigerant gets into your eyes, it may cause blindness; if it touches your skin, it may
cause frostbite.
Never touch refrigerant.

2.5.3.8 COMPRESSED AIR

WARNING
COMPRESSED AIR IS HAZARDOUS!
When carrying out cleaning with compressed air, there is a hazard of serious injury caused by flying parti-
cles.
Wear protective clothing.

– When using compressed air to clean elements or the radiator, always wear safety glasses, dust mask, gloves,
and other protective equipment.
– Never drop or insert tools or other objects into the fan or fan belt. Parts may break or be sent flying.

2 - 38
SAFETY PRECAUTION FOR MAINTENANCE

2.5.3.9 WASTE MATERIALS


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 Fig. 3-48


– Preserve our environment. To prevent environmental pollu-
tion, pay careful attention to the method of disposing waste
materials.
– Always drain fluids from your machine into containers. Never
drain fluids onto the ground or dump it into the sewage sys-
tem, rivers, the sea or lakes. (Fig. 3-48).
– Dispose of harmful material, such as oil, fuel, coolant, sol-
vent, filters and batteries in accordance with local environ-
mental regulations and laws.

2 - 39
ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS SAFETY

2.6 ADDITIONAL SAFETY INFORMATION


FOR TROUBLESHOOTING AND ADJUSTMENTS

2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM


A hands-on approach to inspecting the hoses and pipes of the hydraulic system can only be made when the exca-
vator is shut down and there is no oil pressure in the hydraulic system.

– Do not use your hands during inspection or move in the vicinity of the hydraulic system’s piping or tubing when
the engine is running before checking for leaks, as hydraulic fluid escaping under pressure can cause serious
injuries.
– Additional to the general personal protective clothing as described on page 3-9, full face protection and pene-
tration resistant clothing and gloves must be worn.
– Troubleshooting and adjustments may only be performed by personnel trained by Komatsu Mining Germany in
safe and correct hydraulic handling procedures.
– Before troubleshooting or adjustments, the inspection of areas of potential dangers for damages, leaks or
loose connections on the pressure lines and hydraulic components must be carried out visually only when the
engine is shutdown and when there is no hydraulic pressure in the system.
– When the machine is running, the areas of potential danger can only be entered when no leakages or other
irregularities have been noticed when the high pressure oil circulation has been brought up to maximum pres-
sure from a safe distance (operator’s cab, machinery house roof, ladder platform).

2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING


ADJUSTMENTS
To prevent injury, do not carry out adjustments with the engine running. If work must be carried out with the engine
running, perform the task with, at maximum, two maintenance workers and an operator and do as follows.

– An operator that has been trained on the machine he is oper-


ating, must always sit in the operator's seat and be ready to
stop the engine at any time. All workers must maintain con-
tact with the other workers and be fully aware of all relevant
safety measures.
– When carrying out operations near the fan, fan belt, or other
rotating parts, there is a hazard of being caught in the parts,
so be careful not to come close (Fig. 3-49).
– Do not touch any control levers or control pedals. If any con-
trol levers or control pedals must be operated, always give a
signal to the other workers to warn them to move to a safe
place.
Fig. 3-49

2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR

General safety rules for working on the excavator

– Only trained personnel who are aware of all dangers are allowed to work on the hydraulic system
– Visually inspect all potential danger areas for leakages before pressure build up.
– Do not remain on or around the excavator for longer than is absolutely necessary in order to perform your
tasks.

2 - 40
SAFETY ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS

Please continue reading on the next page.

2 - 41
SPECIAL SAFETY EQUIPMENT SAFETY

2.7 SPECIAL SAFETY EQUIPMENT

Fig. 3-50

2 - 42
SAFETY SPECIAL SAFETY EQUIPMENT

2.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S


CAB
The Shovel must be equipped with a front guard protective structure ”OPG Front Guard” if it is used for applica-
tions where there is a risk of hitting objects from the front.

2.7.2 OBJECT HANDLING


Object handling operations are not allowed.

2.7.3 LIGHTING
The Shovel must only be operated when the operator has sufficient visibility in relation to the work area.
Disturbing shady areas or dazzling effects must be avoided.

If necessary, the Shovel must be retrofitted with additional lighting equipment (working lights) in order to ensure
sufficient visibility conditions.

2.7.4 WARNING BEACON


The Shovel can be retrofitted with a warning beacon which is fitted on the cab roof by means of a magnetic
bracket.

REMARKS: The above-mentioned special safety devices can be ordered as accessories together with the
Shovel.
They are also available as a field package for installation through our service organization.

2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN


STANDARD)
The safety harness should only be used together with connectors according to
EN 354, and fall arrest according to EN 355, or fall protection devices according to EN 360.

See the following pages for further information.

2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)

WARNING
RISK OF FALLING!
Injuries can occur when working in high areas. Always use a Safety Harness (1) in conjunction with a
strap type Fall Absorber (2), illust. (Fig. 3-50) before boarding the loader attachment or other unsecured
areas on the Shovel.

– The Safety Harness is located in the Cabinet in the Operator’s Cab.


– The illustration (Fig. 3-50) shows the standard use of the safety harness with a strap type fall absorber.

2 - 43
SPECIAL SAFETY EQUIPMENT SAFETY

2 - 44
SAFETY SPECIAL SAFETY EQUIPMENT

Legend for Fig. 3-50

(1) Safety Harness according to EN 361

(2) Strap-Type Fall Absorber according to DIN EN 355

(3) Railings (attachment points)

(4) Walkway on the boom

(A) Shoulder Strap

(B) Back Plate

(C) Catching Hook

(D) Shoulder-Strap Fixing

(E) Belly Strap

(F) Holding Hook

(G) Hold-Back Hook

(H) Pelvis Strap

(J) Leg Strap

2.7.5.2 INSTRUCTIONS FOR USE


Open the lock, lift the harness by the catch hook (C), ensuring the leg straps hang below (J). Pull the harness over
the shoulders as you would a jacket. Insert the end of the belly strap (E) through the buckle and tighten securely,
as shown in the illustration (Fig. 3-50).

Prevent the shoulder straps from slipping by fastening the breast strap. Pull the leg straps (J) between the legs
and securely buckle them at the front as illustrated. Adjust the harness so that it snugly fits the body ensuring that
the catching hook (C) is in the center of the back.

The safety harness is a personal accessory and should only belong to its owner.

The safety harness should only be used together with connectors acc. to EN 354, and fall arrest acc. to EN 355, or
fall protection devices acc. to EN 360.

The attachment point for the safety harness should be above the wearer, and the carrying capacity of the attach-
ment point should be sufficient to correspond with the minimum carrying capacity acc. to EN 795.

2 - 45
SPECIAL SAFETY EQUIPMENT SAFETY

2 - 46
SAFETY SPECIAL SAFETY EQUIPMENT

2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL


– Carry out a visual check of the system or component; correct functioning and perfect working order have to be
assured.
– Make sure that the recommendations for use with other components of the system be observed in conformity
with the instructions for use.
The system or component must no longer be used, if there are any doubts in respect of its safe condition. The
equipment has to be inspected by the manufacturer or by a qualified person.

It is essential for safety reasons that a fall protection system or system component which has already been sub-
jected to fall be removed from service and sent back to the manufacturer or an authorized qualified repair shop for
maintenance and renewed testing.

Fall protection systems have to be treated with care and to be kept clean and ready for use. It has to be warned
against bringing the systems into contact with acids or other caustic liquids and gases, oils, detergents, or sharp-
edged objects.

Should the harness have become wet during use or cleaning, do not dry near a fire or other sources of heat, but
rather in a natural way in not too warm rooms. Keep the harness freely suspended or loosely rolled up.

When using the fall protection systems, the pertaining safety regulations in force and the "Rules for Use of Per-
sonal Fall Arrest Systems" have to be observed for protection against danger.

At least every 12 months, the safety harness and its components have to be inspected by a competent person
authorized by the manufacturer and maintained, if the manufacturer considers it necessary.

2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK


HOOKS OF THE SAFETY HARNESS (1),
During the holding function, the connectors may only be placed around a mast or other construction between the
two holding hooks, so that free fall is limited to max. 0.5 m.

It should be strictly seen to it that the connector be not slung around constructions with too small diameter or sharp
edges.

With the lateral holding hooks, work may only be carried out on horizontal or almost horizontal surfaces (roofs).
The connectors have to be adjusted in such a way that the area, where danger of falling down prevails, cannot be
reached.

2 - 47
SPECIAL SAFETY EQUIPMENT SAFETY

2 - 48
SAFETY SPECIAL SAFETY EQUIPMENT

2.7.5.5 INSTRUCTIONS FOR USE


Strap-Type Fall Absorber acc. to DIN EN 355 (Type E.K.N.-BFD)

Use

Within a fall-arrest system, the strap-type fall absorber (2) has to be used in conjunction with a safety harness (1)
acc. to DIN EN 361. The maximum length including the safety rope must not exceed 2.0 m. For longer ropes, a
rope-shortening device has to be applied in addition.

Fix the rope to the attachment point and attach the strap-type fall absorber to the catching hook in the back of the
safety harness. The attachment point should be above the wearer and its minimum carrying capacity should be 10
KN, acc. to DIN EN 795.

The strap-type fall absorber and the safety rope must not be damaged, e.g. never pull

them over sharp edges nor get them burnt by welding sparks.

Storing and maintenance

The strap-type fall absorber has to be kept dry in an airy and shady room. It must not be ex-posed to acids, caustic
chemicals, nor to an aggressive atmosphere, and contact with oils has to be avoided. If the strap-type fall absorber
is dirty, it may be cleaned with a little water and a light-duty detergent. Dry it in a shady place (nowhere near fire or
other sources of heat). Protect it from sharp-edged objects.

Inspection

Prior to use, all parts have to be inspected for safe condition and damages. At least once a year, the strap-type fall
absorber has to be tested by a competent person. A damaged or used strap-type fall absorber has to be removed
from service immediately. The strap-type fall absorber must not be changed in any way.

2 - 49
SPECIAL SAFETY EQUIPMENT SAFETY

2 - 50
HYDRAULIC MINING EXCAVATOR

PC5500E-6

Machine model Serial numbers


PC5500E-6 15016 and up

01 Specification

® Copyright 2010 KOMATSU MINING GERMANY GmbH

PC5500-6E 1
OPERATING WEIGHT
531-549 ton 1,170,000-1,200,000 lb
SHOVEL CAPACITY
29 m3 38 yd3 SAE 2:1 heaped
BACKHOE CAPACITY
29 m3 38 yd3 SAE 1:1 heaped

PC5500
PC
5500

SUPER SHOVEL
PC 5500 S UPER S HOVEL

WALK-AROUND

Quality
● Quality management ISO 9001 certified.
● Environmental Management
ISO 14001 certified.
● Consistent high quality
through continuous investment
in personnel, design and manufacturing
systems and processes.

Reliability and Durability


Designed for lower operating costs
● Robust structural design developed
from field experience and finite
element analaysis.
● Extended life undercarriage wear parts;
Big diameter rollers, idlers and sprockets.
Large surface area and extensive
precision hardening.
Hardened track link pin bores.

Productivity
Designed for more tons per hour
● Powerful digging forces.
● Ease of bucket filling.
● Proven attachment design.
● All cylinders mounted under the shovel attachment for additional protection.
● Buckets and Wear Packages to suit all material densities and ground conditions.

2
SUPER SHOVEL
PC 5500
MATCHED FOR
Large Comfortable Cab 150 to 320 U.S. ton
Full shift comfort TRUCKS
● Komatsu low noise cab on multiple viscous mounts for
reduced noise and vibration. SHOVEL AND BACKHOE
● Large volume cab with deep wide front window. BUCKET CAPACITY
● Comprehensive climate control with pressurised filtered air 29 m3 38 yd3
ventilation and air conditioning.
● High specification multi-adjustable air suspension seat.
● Well elevated operator position giving good all round view.

Advanced Hydraulics
Extended reliability and precise control
● Comprehensive monitored filtration.
● Simple open circuit hydraulic system with
high efficency swing out oil coolers.

Powerful Diesel Engine


Two Komatsu SSA12V159 engines
● Rated (each) 940 kW 1260 HP, at 1800 rpm.
● Electronic engine management.
● Low engine emission levels meet EPA regulations.
● Time saving oil management system
fitted as standard; Centinel Engine Oil Management,
Reserve Engine Oil Supply and Eliminator
Oil Filter systems.
Option:
● Two Komatsu SDA12V159E-2 engines
Tier 2 certificated
Rated (each) 940 kW 1260 HP at 1800 rpm.

Easy Maintenance
Simple, common-sense design gives quick safe access to all major components
● Generous access to all major service points from machinery house floor level.
● Enclosed, internally lit machinery house with firewall separating engine from pump area.
● Automatic central lubrication.
● ECS electronic monitoring system providing real time information about the operating status of the machine.
● Ground-level access to hydraulically powered swing down service arm with Wiggins connections.

3
PC 5500 S UPER S HOVEL

SPECIFICATIONS

DIESEL DRIVE SWING SYSTEM


Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2x Komatsu SSA12V159 Hydraulic motors and drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Type . . . . . . . . . . . . . . . . . . . 4-cycle, water-cooled, direct injection Swing brake, service . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic brake
Aspiration . . . . . . . . . . . . . . . . . . . . . Turbocharged and aftercooled Swing brake, parking. . . . . . . . . . . . . . . . . . . . . . Wet, multiple-disc
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Swing ring teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External
Rated power. . . . . . . . . . . . . . . . . 2x 940 kW 1260 HP @ 1800 rpm Swing speed (maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 rpm
(SAE 1995/J1349)
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . All-speed, electronic
Optional US Tier 2 Version: ELECTRIC DRIVE
Model . . . . . . . . . . . 2x Komatsu SDA12V159E-2 Tier 2 certificated
Type . . . . . . . . . . . . . . . . . . . . . . . 2x Squirrel-cage induction motor
Type . . . . . . . . . . . . . . . . . . . 4-cycle, water-cooled, direct injection
Power output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2x 900 kW
Aspiration . . . . . . . . . . . . . . . . . . . . . Turbocharged and aftercooled
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6600 V*
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Amperage (approximate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 A
Rated power. . . . . . . . . . . . . . . . . 2x 940 kW 1260 HP @ 1800 rpm
(SAE 1995/J1349) Start-up . . . . . . . . . . . . . . . . . . Soft start each motor in succession
Controller/Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quantum Frequency (standard) . . . . . . . . . . . . . . . . . . . . . 50 Hz @ 1500 rpm
Optional frequency . . . . . . . . . . . . . . . . . . . . . . . 60 Hz @ 1800 rpm
The integrated engine oil and filter system combining the oil stabilising
systems, Reserve and Centinel, with the Eliminator self cleaning oil filter *Other voltages available on request
extends, with oil analysis, the oil change interval to 4000 hours.
(not available in Australia)

UNDERCARRIAGE
ELECTRICS Undercarriage consists of one center carbody and two track frames,
each side attached by 80 high torque bolts.
System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 V
Center frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-type
Batteries (series/parallel) (diesel version). . . . . . . . . . . . 2 + 6 x 12 V
Track frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steel box-section
Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2x 100 A
Standard working lights. . . . . . . . . . . . . . . . . . . . . . . 8 Xenon lights
Standard service lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 lights
CRAWLER ASSEMBLY
Track adjustment . . . . . . . . . . . . . . . . . . . Automatic hydraulic type
HYDRAULICS Number of shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 each side
Number of top rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . 3 each side
The power train consists of two main drives. Diesel engines or electric
Number of bottom rollers. . . . . . . . . . . . . . . . . . . . . . . . 7 each side
motors can be supplied. Each connected to a gearbox and 3 identical
main pumps which draw hydraulic oil from an unpressurized hydraulic
tank. Open circuit hydraulics provide maximum cooling and filtering
efficiency. COOLING SYSTEM
Rated flow (total output) . . . . . . . . . . . . 4200 ltr/min 1110 U.S. gal The high capacity engine radiators are cooled by hydraulically driven
Relief valve setting . . . . . . . . . . . . . . . . . . . . . . . . 310 bar 4,495 psi fans for superior cooling efficiency and require little maintenance.
Swing flow rate . . . . . . . . . . . . . . . . . . . . . 700 ltr/min 185 U.S. gal The hydraulic system includes four large swing-out vertical air-to-oil
High pressure in line filters . . . . . . . . . . . . . . . . . . . . . . 200 microns hydraulic coolers with temperature-regulated hydraulically driven fans.
one per pump located at the valve blocks
Full flow return line filters (10 double elements) . . . . . . . 10 microns AUTOMATIC CENTRALISED
at head of hydraulic tank
Case drain/by-pass return line filters . . . . . . . . . . . . . . . . 3 microns LUBRICATION
The four-circuit system features a load-limiting governor with oil Two hydraulically powered Lincoln single line automatic lubrication
delivery summation to the working circuits and incorporates systems are provided as standard, complete with time and volume
pressure cut-off control. Hydropilot prioritizes hydraulic flow giving variable controls. Activity and malfunction events are linked to the
smooth hydraulic response, simple hydraulic system layout, and a ECS. The central lube grease system is supplied from a refillable
reduced number of components. Filtration is at the oil intake to 300 litre 80 gal. container. A second, identical system supplies open
pumps, valve blocks, heat exchangers and the oil tank. gear lubricant to the swing ring teeth through a lube pinion.
Replenishment of the containers is through the service arm.

DRIVES AND BRAKES


SERVICE CAPACITIES
Travel control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 foot pedals
Gradeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Up to 50% Hydraulic oil tank . . . . . . . . . . . . . . . . . . .3800 ltr 1,000 U.S. gal
Travel speed (maximum) . . . . . . . . . . . . . . . . . . . 2.1 km/h 1.4 mph Hydraulic system . . . . . . . . . . . . . . . . . . .6000 ltr 1,585 U.S. gal
Service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic brake Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.800 ltr 2,853 U.S. gal
Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . Wet, multiple-disc Engine coolant . . . . . . . . . . . . . . . . . . . .2x 360 ltr 2x 95 U.S. gal
Engine oil . . . . . . . . . . . . . . . . . . . . . . . .2x 190 ltr 2x 50 U.S. gal
Centinel engine oil make up tank . . . . . .2x 580 ltr 2x 153 U.S. gal

4
SUPER SHOVEL
PC 5500

CAB
The large welded steel safety cab is mounted with 18 viscous Cab engineering standards are;
damping pads and sound insulated. • ISO 3449 Falling Objects Protection Structure
It is equipped with automatic climate control and is pressurised. • ISO 6396 Noise in operator´s cab is 76 dB(A)
The operator’s seat is fully adjustable, air suspended, electrically • ISO 2631-1/ 5349-1 Vibration and Shock
heated and has a lap seat belt. There is a trainer’s seat. • Air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . .10kW 34120 Btu
Low effort joy stick controls are electric over hydraulic and foot • Heater/Demister (Diesel version) . . . . . . . . . . . . .10kW 34120 Btu
controls are for front shovel clam, crawler and swing brake. • Heater/Demister (Electric version) . . . . . . . . . . . .12kW 40940 Btu
Full instrumentation and ECS are provided. Space in the console
is provided for an additional monitor. AM/FM radio is fitted. The
windshield wash wiper has two speed and intermittent operation. CS
(Water reservoir 7 litres 1.8 gal.) Amenities include a wash basin HEALTH MONITORING SYSTEM
with running water, water reservoir, (50 litres 13 gal.), refrigerator
The ECS digital diagnostic system, mounted in the operator‘s
and storage cabinets. Powered mirrors are adjusted from inside
console, provides a text display of real time and stored information
the cab.
about the status of the operating machine. Non serious and critical
There are left and right hand sliding windows. All windows
faults are immediately announced, and for major malfunctions the
are tinted parsol green. External metal louvres are provided on the
engines are also shut down. The integrated digital storage provides
cab side windows.
full event history, which can be down loaded with a laptop computer.
The ability to electronically record service events provides precise
service information to assist in reducing downtime.

OPERATING WEIGHTS (APPROXIMATE)

PC 5500 Backhoe: PC 5500 Front Shovel:


Operating weight including 11.000 mm 36’1’’ boom, 5100 mm 16’9’’ stick, Operating weight including 7600 mm 24’11’’ boom, 5600 mm 18’4’’ stick, 29 m3 38 yd3
29 m3 38 yd3 backhoe bucket, operator, lubricant, coolant, full fuel tank and standard shovel bucket, operator, lubricant, coolant, full fuel tank and standard equipment.
equipment.

Shoe Width Operating Weight Ground Pressure Shoe Width Operating Weight Ground Pressure

1350 mm 535 t 23.9 N/cm2 1350 mm 531 t 23.1 N/cm2


53’’ 1,180,000 lb 33.4 psi 53’’ 1,170,000 lb 33.5 psi

1800 mm 549 t 18.3 N/cm2 1800 mm 545 t 18.2 N/cm2


71’’ 1,210,000 lb 26.5 psi 71’’ 1,200,000 lb 26.4 psi

Diesel SKZ 5506_50A Electric SKZ 5506_51

Explanation Variation for Electric Lower-Level


1 Operator’s Cab 6Swing Motors Drive Version Walkways
2 Power Trains 7Fuel Tank 2 Electric Motor Upper-Level
3 Hydraulic Cooler 8Counterweight 7 High Voltage
4 Hydraulic Reservoir 9Autolube Systems Electric Cabinet
5 Valve Blocks (on upper deck)
10 Secondary Egress

5
PC 5500 S UPER S HOVEL

PRODUCTIVITY-FEATURES
BACKHOE ATTACHMENT

5506074

Boom length 11000 mm 36’ 1” Max. digging height 15500 mm 50’ 10”
Stick length 5100 mm 16’ 9” Max. dumping height 10100 mm 33’ 2”
Break-out force (SAE) 1450 kN 326,250 lb Max. digging depth 8300 mm 27’ 3”
Tear-out force (SAE) 1290 kN 290,250 lb Max. digging reach 19800 mm 64’ 12”
Max. digging reach 18700 mm 61’ 4”
at ground level

Bucket Capacity Width Teeth Wear Weight Max. Material Density Recommended
(Heaped 1 :1) SAE Package (Loose) Mining
cum cuyd mm foot/inch qty *) t lb t/cum lb/cuyd Uses

26.0 34.0 4380 14’4” 5 3 32.2 71,000 2.0 3400 Heavy Duty
29.0 38.0 4380 14’4” 5 2 33.1 73,000 1.8 3000 Standard Mining

*) WP 1 Non abrasive
WP 2 Standard Mining
WP 3 Heavy Duty

Alternative buckets on request

6
SUPER SHOVEL
PC 5500

FRONT SHOVEL ATTACHMENT

5506068

Boom length 7600 mm 24’ 11” Max. cutting height 19500 mm 63’ 12”
Stick length 5600 mm 18’ 4” Max. dumping height 13300 mm 43’ 8”
Break-out force (SAE) 1865 kN 419,200 lb Max. digging depth 2700 mm 8’ 10”
Crowd force (SAE) 1870 kN 420,300 lb Max. digging reach 16500 mm 54’ 2”
Level crowd at ground level 5600 mm 18’ 5”
Bucket opening width 2700 mm 8’ 10”

Bucket Capacity Width Teeth Wear Weight Max. Material Density Recommended
(Heaped 1 : 2) SAE Package (Loose) Mining
cum cuyd mm foot/inch qty *) t lb t/cum lb/cuyd Uses
21.0 27.5 4410 14’6” 5 4 48.6 107,200 2.6 4400 Heavy Duty
26.0 34.0 4570 14’12” 6 3 48.9 107,800 2.2 3700 Standard Mining
29.0 38.0 4570 14’12” 6 3 49.5 109,100 1.9 3200 Standard Mining
*) WP 1 Non abrasive
WP 2 Light abrasive
WP 3 Standard Mining
WP 4 Heavy Duty

Alternative buckets on request

7
STANDARD EQUIPMENT

Hydraulic Mining Shovel with Diesel Drive ● SUPERSTRUCTURE Windshield wash wipers with two speed
will comprise: The main frame mounted over an and intermittent operation. (reservoir 7 ltr
externally toothed swing circle carries 1.8 gal). AM-FM radio. External metal sun
● FRONT SHOVEL ATTACHMENT
the main drive module, including two blinds. Left and right hand sliding windows.
7.6 m 24'11" boom and 5.6 m 18'4"
Komatsu SSA12V159 diesel engines, All windows tinted parsol green.
stick complete with cylinders. 29 m3
oil and fuel reservoirs, counterweight,
38 yd3 (SAE 2:1) shovel bucket with ● LUBRICATION
operator’s cab and base.
mechanical teeth and lip system. LINCOLN central lubrication for basic
● LIGHTING machine, attachment, and bucket.
OR
8 Xenon high performance working lights. 300 ltr 80 gal refillable container.
● BACKHOE ATTACHMENT 14 service lights throughout platform. LINCOLN automatic pinion lubrication
11.0 m 36'1" boom and 5.1 m 16'9" system for swing circle teeth with
● OPERATOR’S CAB
stick with 29 m3 38 yd3 (SAE 1:1) 300 ltr 80 gal refillable container.
Fully enclosed steel cab which
bucket with mechanical teeth and
incorporates the ISO 3449 standard Service point (diesel version only as standard)
lip system.
FOPS structure and CARRIER SÜTRAK on hydraulic arm carrying WIGGINS fluid
● CRAWLER UNDERCARRIAGE air-conditioning unit. Mounted on viscous receiving connectors for filling of fuel,
Heavy-duty shovel type undercarriage pads. GRAMMER full suspension engine oil and coolant, hydraulic oil, grease,
consisting of a center carbody and 2 operator´s seat with lap-belt. An auxiliary cabwater and the evacuation of coolant,
heavy box-type track frames, each seat. Full selection of controls, switches, and hydraulic and engine oils.
having 7 bottom rollers, 3 top rollers, and ECS (Electronic Health Monitor).
and 1350 mm 53" cast steel track shoes. Joy stick and pedal-operated controls ● ACCESSORIES
Hydraulic track adjustment and parking are electric over hydraulic. Acoustic travel alarm
brake provided. Hydraulically actuated ground access
ladder
Electric air horn

OPTIONAL EQUIPMENT

● 1800 mm 71’’ track shoes ● Electric drive ● Low temperature package


● Extra or alternative, lighting ● Cable reel (Electric version) (incl. KIM hot start)
● Fire suppression system ● Independant LINCOLN central lubrication
system for bucket

DIMENSIONS

BASIC MACHINE WITH COUNTERWEIGHT


N OR
M L O
A 1350mm 53" H 3310mm 10'10"
B 1800mm 71" I 3100mm 10'2"
CA 7540mm 24'9" J 7910mm 25'11"
CB 7990mm 26'3" K 8610mm 28'10" K I
J
D 2715mm 8'11" L 3970mm 13'0"
E 3712mm 12'2" M 3300mm 10'10"
D H
F 7424mm 24'4" N 7900mm 25'11"
G 9720mm 31'11" O 7260mm 23'10" A E
OR 7550mm 24'9" B F
CA G
CB
Ground Clearance: 995mm 3'3" SKZ5506_49 SKZ5506_48

QESS0556 04 ©2008 Komatsu Printed in Germany

KOMATSU MINING GERMANY GMBH


BUSCHERHOFSTRASSE 10
D-40599 DÜSSELDORF
PHONE +49 (0) 211/ 71 09-0
FAX +49 (0) 211/ 71 58 22

www.komatsu-mining.de Materials and specifications are subject to change without notice.


is a trademark of Komatsu Ltd. Japan.
SHOP MANUAL

HYDRAULIC EXCAVATOR
PC5500-6 Diesel

Machine model Serial numbers

PC5500E-6 15016 and up

10 Structure, function

PC5500-6 1
Contents and 00_Foreworda15028.doc 04.01.07
Contents and 00_Foreworda15028.doc 04.01.07

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 weel
12. Hints for the hydraulic circuit diagram
13. Hints for the electric circuit diagram
14. ECS-T
15. Lubrication Systems

APPENDIX

) • Each section includes a detailed table of contents.


Contents and 00_Foreworda15028.doc 04.01.07
SAFTEY SAFTEY NOTICE

SAFETY
SAFETY NOTICE

• IMPORTANT SAFETY NOTICE


Proper service and repair is extremely important for safe machine operation. The
service and repair techniques recommended by Komatsu and described in this manual
are both effective and safe. Some of these techniques require the use of tools specially
designed by Komatsu for the specific purpose.

The following Symbols are used in this Manual to designate Instructions of


particular Importance.

WARNING - Serious personal injury or extensive property damage can


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

CAUTION - Minor personal injury can result or a part, an assembly, or


the shovel can be damaged if the caution instructions are not
followed.

) NOTICE - Refers to special information

GENERAL PRECAUTIONS

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

00-1
SAFTEY SAFTEY NOTICE

Cont'd:
GENERAL PRECAUTIONS

3. If welding repairs are needed, always have a trained, experienced welder carry out the
work. When carrying out welding work, always wear welding gloves, apron, glasses, cap
and other clothes suited for welding work.
4. When carrying out any operation with two or more workers, always agree on the
operating procedure before starting. Always inform your fellow workers before starting
any step of the operation. Before starting work, hang UNDER REPAIR signs on the
controls in the operator's compartment.
5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the
tools and parts in their correct places. Always keep the work area clean and make sure
that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking.
Never smoke while working.

PREPARATIONS FOR WORK

7. Before adding oil or making repairs, park the machine on hard, level ground, and block
the wheels or tracks to prevent the machine from moving.
8. Before starting work, lower bucket, hammer or any other work equipment to the ground.
If this is not possible, insert the safety pin or use blocks to prevent the work equipment
from falling. In addition, be sure to lock all the control levers and hang warning signs on
them.
9. When disassembling or assembling, support the machine with blocks, jacks or stands
before starting work.
10. Remove all mud and oil from the steps or other places used to get on and off the machine.
Always use the handrails, ladders or steps when getting on or off the machine. Never
jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a
stand to provide safe footing.

PRECAUTIONS DURING WORK

11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs,
loosen them slowly to prevent the oil from spurting out.
Before disconnecting or removing components of the oil, water or air circuits, first
remove the pressure completely from the circuit.
12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to
get burned.
Wait for the oil and water to cool before carrying out work on the oil or water circuits.

continued

00-2
SAFTEY SAFTEY NOTICE

Cont'd:
PRECAUTIONS DURING WORK

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

00-3
ENVIRONMENT PROTECTION Environment NOTICE

RECOMMENDATIONS FOR ENVIRONMENTALLY FRIENDLY OPERATION


AND MAINTENANCE OF HYDRAULIC MINING SHOVELS

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

• Preserve our environment. To prevent environmental pollution, pay careful attention


to the method of disposing waste materials.
• Always drain fluids from your machine into containers. Never drain fluids onto the
ground or dump it into the sewage system, rivers, the sea or lakes.
• Dispose of harmful material, such as oil, fuel, coolant, solvent, filters and batteries in
accordance with environmental regulations and laws.

00-3
ENVIRONMENT PROTECTION Environment NOTICE

FOREWORD
GENERAL

With this SERVICE MANUAL KOMATSU provides you with the


description of the construction and the function of the major systems of the
Hydraulic Excavator PC5500-E.

We describe for you all functions and how to carry out the inspections and
adjustments.

How do you find "your" desired information?

In the table of CONTENT all the functions and components are shown in
their sequence of the description.

If after reading this SERVICE MANUAL you can give us suggestions and
comments for improvements - please do not hesitate to contact us.

Komatsu Mining Germany GmbH


- Service Training -
Postfach 180361
40570 Düsseldorf

Tel.:0211 / 7109 - 206


Fax.:0211 / 74 33 07

The editorial staff will be pleased about your co-operation.

- FROM THE PRACTICE - FOR THE PRACTICE -

) • This service manual corresponds to the state of development of the


machine at the time the manual was produced.
Variations based on special customers request and special equipment
are not included in this manual

00-4
FOREWORD HOISTING INSTRUCTIONS

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

) • If a part cannot be smoothly removed from the machine by hoisting,


the following checks should be made:
1. Check for removal of all bolts fastening the part to the relative
parts.
2. Check for existence of another part causing interface with the part
to be removed.

WIRE ROPES

1. Use adequate ropes depending on the weight of parts to be hoisted, referring


to the table below:

Wire ropes
(Standard "Z" or "S" twist ropes without galvanizing)
Rope diameter 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]

) • The allowable load value is estimated to be 1/6 or 1/7 of the breaking


strength of the rope used.

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

continued
Cont'd:

00-5
FOREWORD HOISTING INSTRUCTIONS

WIRE ROPES

3. Do not sling a heavy load with one rope alone, but sling with two or more
ropes symmetrically wound on to the load.

• Slinging with one rope may cause turning of the load during hoisting,
untwisting of the rope, or slipping of the rope from its original
winding position on the load, which can result in a dangerous
accident.

4. Do not sling a heavy load with ropes forming a wide hanging angle from the
hook. When hoisting a load with two or more ropes, the force subjected to
each rope will increase with the hanging angles. The table below shows the
variation of allowable load (kg) when hoisting is made with two ropes, each of
which is allowed to sling up to 1000 kg vertically, at various hanging angles.
When two ropes sling a load vertically, up to 2000 kg of total weight can be
suspended. This weight becomes 1000 kg when two ropes make a 120°
hanging angle. On the other hand, two ropes are subject to an excessive force
as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150.

00-6
FOREWORD STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE (1Kgm = 9,806Nm)


STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS

Bolt Wrench Tightening torque


dia. size [mm] [Nm]
Quality grades

8.8 10.9 12.9


M 8 13 6 21 31 36
M 10 17 8 43 63 73
M 12 19 10 74 108 127
M 14 22 12 118 173 202
M 16 24 14 179 265 310
M 18 27 14 255 360 425
M 20 30 17 360 510 600
M 22 32 17 485 690 810
M 24 36 19 620 880 1030
M 27 41 19 920 1310 1530
M 30 46 22 1250 1770 2080
M 33 50 24 1690 2400 2800
M 36 55 27 2170 3100 3600
M 39 60 2800 4000 4700
M 42 65 32 3500 4950 5800
M 45 70 4350 6200 7200
M 48 75 35 5200 7500 8700
M 52 80 6700 9600 11200
M 56 85 41 8400 12000 14000
M 60 90 10400 14800 17400
M 64 95 46 12600 17900 20900
M 68 100 15200 21600 25500
Insert all bolts lubricated with MPG, KP2K

00-7
FOREWORD CONVERSION TABLE

CONVERSION TABLE

METHOD OF USING THE CONVERSION TABLE


The Conversion Table in this section is provided to enable simple conversion of
figures. For details of the method of using the Conversion Table, see the example
given below.

EXAMPLE

Method of using the Conversion Table to convert from millimeters to inches.

1. Convert 55 mm into inches.


(a) Locate the number 5 in the vertical column at the left side, take this as (A),
then draw a horizontal line from (A).
(b) Locate the number 5 in the row across the top, take this as (B), then draw a
perpendicular line down from (B).
(c) Take the point where the two lines cross as (C). This point (C) gives the
value when converting from millimeters to inches.
Therefore, 55 millimeters = 2.165 inches.

2. Convert 550 mm into inches.


(a) The number 550 does not appear in the table, so divide by 10 (move the
decimal one place to the left) to convert it to 55 mm.
(b) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(c) The original value (550 mm) was divided by 10, so multiply 2.165 inches
by 10 (move the decimal one place to the right) to return to the original
value. This gives 550 mm = 21.65 inches.

00-8
FOREWORD CONVERSION TABLE

00-9
FOREWORD CONVERSION TABLE

00-10
FOREWORD CONVERSION TABLE

00-11
FOREWORD CONVERSION TABLE

00-12
FOREWORD CONVERSION TABLE

Basic Values in Ohm according to DIN 43 76


For Measuring Resistor PT100

°C -0 -1 -2 -3 -4 -5 -6 -7 -8 -9

-50 80,31 79,91 79,51 79,11 78,72 78,32 77,92 77,52 77,13 76,73
-40 84,27 83,88 83,48 83,08 82,69 82,29 81,89 81,50 81,10 80,70
-30 88,22 87,83 87,43 87,04 86,64 86,25 85,85 85,46 85,06 84,67
-20 92,16 91,77 91,37 90,98 90,59 90,19 89,80 89,40 89,01 88,62
-10 96,09 95,69 95,30 94,91 94,52 94,12 93,73 93,34 92,95 92,55
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

Table of contents section 1.0

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 High tension switch cabinet 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

1.2 Under carriage 13

1.3 Attachment
1.3.1. Backhoe Attachment (BHA) 14
1.3.2. Front Shovel Attachment (FSA) 15

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Page 2

1. General lay out

Legend for illustration (Z 22387):


(1) Superstructure
(2) Under carriage
(3) Front Shovel Attachment (FSA)
(4) Backhoe Attachment (BHA)

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Page 3

1.1 Superstructure

Legend for illustration (Z 22386):


(1) Operators Cab with integrated FOPS
(2) Cable drum
(3)
(4) Cab support (contains the low tension electric switch board)
(5) Swing ring connection
(6) Switch cabinet, middle tension (main electric supply )
(7) Hydraulic ladder
(8) Counter weight
(9) Hydraulic oil cooler with hydraulic driven fans
(10) Hydraulic oil reservoir
(11) Batteries
(12) Swing Gear
(13) Grease pump of the Central Lubrication System (CLS)
(14) Grease pump of the Swing gear pinion Lubrication System (SLS)
(15) Main Control blocks with high pressure filters

(16) Main electric motor 1


(17) Flexible coupling
(18) PTO gear with hydraulic pumps
(19) Main hydraulic pumps 1, 2 and 3
(20) Capacitor motor 1

(21) Main electric motor 2


(22) Flexible coupling
(23) PTO gear with hydraulic pumps
(24) Main hydraulic pumps 4, 5 and 6
(25) Capacitor motor 2

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Main Assembly Groups Section 1.0
Page 4

1.1 Superstructure

1.1.1 Machine house

Legend for illustration (Z 22390a):

A View from the back of machinery house without counter weight


B View from the right side of machinery house
C Top view

(1) Motor coolant air outlet


(2) Main motor supply cable
(3) Capacitor
(4) Hydraulic control and filter panel
(5) PTO gear box
(6) Main hydraulic pumps
(7) Auxiliary pumps, installed at the drive through shaft of the main
hydraulic pumps (piggyback pumps)
(8) Hydraulic pump for radiator fan drive
(9) Hydraulic pump for the hydraulic oil cooler fan drive
(10) Suction oil reservoir
(11) Flexible coupling, oil filled
(12) Batteries
(13) Engine 1
(14) Engine 2
(15) Hydraulic motor for the radiator fan drive
(16) Radiator for the engine cooling system

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Page 5

1.1 Superstructure

1.1.2 Hydraulic Oil Reservoir

Legend for illustration (Z 22391a):


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

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Page 6

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Main Assembly Groups Section 1.0
Page 6

1.1 Superstructure

1.1.3 Hydraulic Oil Cooler

Legend for illustration (Z 22392):


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

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7

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Main Assembly Groups Section 1.0
Page 7

1.1 Superstructure

1.1.4 High tension switch cabinet

Legend for illustration (Z 22638):

A Left side view


B Front side view
C Top view
X High tension switch cabinet

(1) Main fuses, high tension


(2) Main supply switch, manual controlled
(3) Main motor switches, remote controlled
(4) Current transformer
(5) Main transformer
(6) Air condition for switch cabinet
(7) Access stair

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Page 8

1.1 Superstructure

1.1.5 Counter weight

Legend for illustration (Z 21474):


(1) Counter weight
Total weight

~40000 kg

(2) Mounting bolts


Quantity Bolt size Grade SW* Tightening
(mm) (mm) torque (Nm)
16 M 48 x 380 10.9 75 7500
* SW = Wrench size

(3) Lifting points

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9

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Main Assembly Groups Section 1.0
Page 9

1.1 Superstructure

1.1.6 Cab support

Legend for illustration (Z 21475):


(1) Cab support (Location of electrical switch board “X2”)
(2) Mounting bolts
Quantity Bolt size Grade SW* Tightening
(mm) (mm) torque (Nm)
6 M 36 x 320 10.9 55 3100
* SW = Wrench size

(3) Mounting bolts


Quantity Bolt size Grade SW* Tightening
(mm) (mm) torque (Nm)
6 M 36 x 160 10.9 55 3100
* SW = Wrench size

(4) Door
(5) Gasket
(6) Door handle (adjustable)

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Page 10

1.1 Superstructure

1.1.7 Operators cab

Legend for illustration (Z 21476):

(1) Monitor panel


(2) Switch panel
(3) Operators seat
(E19) Control lever
– EURO Control

– KMG Control

(E20) Control lever


– EURO Control

– KMG Control

(E21a) Control pedal A - forward


Left track
B - reverse

(E21b) Control pedal A - forward


Right track
B - reverse
(E22) Control pedal - Swing brake
(E23) Control pedal (left) Clam closing
(E24) Control pedal (right) Clam opening

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Page 11

1.1 Superstructure

1.1.8 Control blocks

Legend for illustration (Z 21477a):


(1) Control block carrier
(2) Remote control valves
(3) Main control blocks
(4) High pressure filter

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Page 12

1.1 Superstructure

1.1.9 Swing gears

Legend for illustration (Z 22395):


(1) Swing gear box
(2) Swing parking brake – Spring loaded multi disk brake
(Released by oil pressure)
(3) Parking brake Control port (X)
(4) Oil level gauge - gear box
(5) Breather – gear box
(6) Oil filling plug – gear box
(7) Oil level gauge – motor adapter housing
(8) Breather – motor adapter housing
(9) Oil drain plug – motor adapter housing
(10) Oil drain plug - gear box
(20.1 + 20.2) Swing motor
(49.1 + 49.2) Swing brake valve block

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Page 13

1.2 Under carriage

Legend for illustration (Z 21481a):


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

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Page 14

1.3 Attachment

1.3.1 Backhoe attachment (BHA)

Legend for illustration (Z 21482):


(1) Boom
(2) Boom Cylinders
(3) Stick
(4) Stick Cylinders
(5) Bucket
(6) Bucket Cylinders
(7) Control arm
(8) Linkage

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Page 15

1.3 Attachment

1.3.2 Front Shovel Attachment (FSA)

Legend for illustration (Z 21483):


(1) Boom
(2) Boom Cylinders
(3) Stick
(4) Stick Cylinders
(5) Bucket backwall
(6) Bucket Cylinders
(7) Clam
(8) Bucket Clam cylinders

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Drive Section 2.0
Page 1

Table of contents section 2.0

Section Page
2.0 Prime drive assembly
General 2

2.1 Coupling 3
2.2 Pump-spline lubrication 4
2.3 PTO Lubrication and cooling 5-6
2.4 Hydraulic pumps – location, drive speed and flow rates 7
2.0
2
Drive Section 2.0
Page 2

2.0 Prime drive assembly

Legend for illustration (Z 22644):


(1) Cooling air intake
(2) Cooling air exhaust
(3) Electric Motor
(4) Alignment shims
(5) Alignment supports
(6) Motor frame
(7) Coupling
(8) Pump distributor gear (PTO)

General
The two electric motors are solid bolted to the motor frame (6).
The alignment shims (4) thickness must be determined due the alignment
procedure. The alignment must be done in accordance to the Parts & Service
News AH01523, last edition.

) • The alignment shims thickness must be also determined when


replacing the electric motor! Never use the existing shims without
determination.
2.0
3
Drive Section 2.0
Page 3

2.1 Coupling

Legend for illustration (Z 22645):


(1) Input drive hub
(2) Output drive flange
(3) Outside rubber support ring
(4) Rubber element
(5) Motor drive shaft
(6) Gearbox input flange
(7) Hub looking washer
(8) Coupling ring

) • Repair and replacement have to be done accordingly to Parts &


Service News AH01523, last edition.

Design:
VULASTIC-L – coupling type are provided with one flexible rubber element
(4). The flexible ring connect the input drive hub (1) via the coupling ring (8)
with the output drive flange (2) of the coupling.

Function:
The high flexible VLULASTIC–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.
Replacement and alignment refer to Parts & Service News AH01523, last
edition.
2.0
4
Drive Section 2.0
Page 4

2.2 Pump-spline lubrication


Drive shaft housings

Legend for illustration (Z 21608):


(1) Oil filler plug with breather pipe of main pump drive shaft housing
(2) Oil collector reservoir for auxiliary pump drive shaft housing
(M) Configuration, main pump drives
(A) Configuration, auxiliary pump drives

All drive shaft housings are filled with the same gear oil as the pump
distributor gear.

This is done for two reasons:


1. To lubricate the multi-spline connections, to prevent wear and corrosion.
2. It makes it easier to determine a sealring leak at one of the drive shaft
connections.

Function:
M If the oil level increases the oil drops out of the breather pipe (1).
If this oil is gear oil it indicates a possible leak at the gearbox side.
If the oil is a mixture of gear oil and hydraulic oil it shows a possible
leak at the pump side.
If at an oil level check a loss of oil is found it may be due to worn or
defective radial seal rings.

Function:
A The oil is filled in via the oil collector reservoir (2). All auxiliary drive
shaft housings are connected by pipes with the reservoir. The reservoir
is filled approx. one half with oil.
If the oil level in the reservoir increases due to leakage the oil drops out
from the breather filter (with oil level gauge) on top of the reservoir.
Now a check has to be done to find out which one of the drive shafts
seals is damaged.
It can be done by disconnecting temporary the pipe to the reservoir.
Disconnect the pipe at the drive shaft housing, plug the pipe and leave
the union open.
If now at operation the oil still comes out of the union, this drive shaft
seal is gone.
Otherwise check sequential all auxiliary drives.
2.0
5
Drive Section 2.0
Page 5

2.3 PTO Lubrication and cooling


Legend for illustration (Z 22410e):
The machine is equipped with two motors and gearboxes. The motor close to
the counter weight is called motor 1 and the motor to the front is called motor
2. The extension of the component designation shows the mounted position.
Example: Pressure filter (69.1) is the pressure filter for the PTO lubrication of
motor 1 and (69.2) of motor 2.
(1) Line to the cooler (hot oil)
(2) Return line from the cooler (cooled oil)
(3) Return line from valve
(4) Suction line from PTO oil pan to the pump
(P) Pressure port
(8.1)(8.4) Gear pump PTO-gearbox lubrication
(69.1)(69.2) Pressure filter - PTO gear lubrication
(74.1)(74.2) Pressure relief valve, 7,5 bar
(78.14)(78.15) Solenoid valve (Y53-x), (reduction of relief valve pressure)
(105.3+105.4) Oil cooler, part of hydraulic oil cooler motor 1
(105.1+105.2) Oil cooler, part of hydraulic oil cooler motor 2
(M1-1)(M1-2) Pressure check point
(B17-1)(B17-2) Pressure switch, 0,5 bar
(B27-1)(B27-2) Maintenance switch, 5 bar
(B49-1) Temperature sensor

Function:
Pump (8.1)/(8.4) forces the gear oil from the gear oil pan through filter
(69.1)/(69.2)) to pressure relief valve (74.1/74.2). This pressure relief valve
acts as a back pressure valve causing that most of the oil passes through the
gear oil coolers (105.3+105.4)/(105.1+105.2).
The gear oil coolers are a small part of the hydraulic oil coolers, thus the gear
oil gets cooled by the same air stream as the hydraulic oil. From the coolers
the oil flows to the port (P) of the gear and internally via a system of pipes to
the several spray nozzles. The spray nozzles in the gear case ensure proper
and adequate distribution of the lube oil. The circuit is monitored by the
pressure switches (B17-1). At too low lube oil pressure (0.5 bar), a fault
message will be displayed on the monitor at the dash board.
The gear oil temperature is monitored by the sensor unit (B49-1) (B49-2). At too
high oil temperature a fault message will be displayed on the monitor at the dash
board.
If the oil temperature is to low, solenoid valve (Y53-1) (Y53-2) energised and
opened port X of the pressure relive valve (74.1) (74.2). This reduced the relieve
valve pressure setting. The main gear oil flow direct back to the PTO to quick
warm up of the gear oil.
continued
2.0
6
Drive Section 2.0
Page 6

Cont`d.

2.3 PTO Lubrication and cooling


Legend for illustration (Z 22414):
(1) Pilot operated relief valve (8) Valve spring
(2) Plug screw (9) Seal rings
(3) Valve piston (B27-x) Maintenance switch
(4) Port for pressure switch B17-1 (74.x) Pressure relief valve
(6) Port for pressure check stud (A) Pressure port
(7) Jet bore (T) Return from valve

Adjustments:
• The adjustment of the maximum permissible PTO lube pressure, has
to be carried out with cold oil to avoid serious damages to the coolers.

• The check for a sufficient PTO lube pressure has to be carried out
with warm oil to avoid serious damages gearbox.

Setting the pressure relief valve (74.x) at cold oil.


1. Connect a pressure gauge to check point (M1.x).
2. Disconnect plug of solenoid valve Y53-1/ Y53-2
3. Start the respective motor
4. Required pressure: 7,5 bar.
If adjustment is required:
5. Remove protection cap (1a).
6. Loosen lock nut (1b).
7. Set the pressure with set screw (1c).
8. Tighten lock nut (1b) and re-install protection cap (1a)
9. Reconnect plug of Y53-1/ Y53-2

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

Checking the PTO lube pressure at operating temperature (warm oil)


1. Connect a pressure gauge to check point (M1.x).
2. Start the motor and let it run with max. speed.
3. Required pressure: 2-7,5 bar.
2.0
7
Drive Section 2.0
Page 7

2.4 Hydraulic pumps – location, drive speed and flow rates

Legend for illustration (Z 22415b):


(1 - 6) Axial piston pump (swash plate type)
pump volume Vg = 500 cm³/rev
theoretical flow rate, each Qmax = 700 Liter/min
Drive speed* n = 1409 min-1
for all working motions pmax = 310 bar

(10.1), (10.2) Axial piston pump


pump volume Vg = 80 cm³
theoretical flow rate Qmax = 142 Liter/min
Drive speed* n = 1632 min-1
for oil cooler fan drive pmax = 180 bar

(8.1), (8.4) Gear pump


pump volume Vg = 58.7 cm³/rev
theoretical flow rate Qmax = 82,2 Liter/min
Drive speed* n = 1409 min-1
for PTO gear lubrication pmax = 7,5 bar

(8.2), (8.5) Gear pump


pump volume Vg = 58.7 cm³/rev
theoretical flow rate Qmax = 82,2 Liter/min
Drive speed* n = 1409 min-1
for hydraulic oil circulation pmax = 15 bar

(7.1), (7.2) Gear pump


pump volume Vg = 85.7 cm³/rev
theoretical flow rate Qmax = 120 Liter/min
Drive speed* n = 1409 min-1
for pilot pressure supply pmax = 60 bar

) • * at 1500 min-1 (50Hz) or 1800 min-1 (60Hz) input drive speed


Hydraulic Oil Reservoir Section 3.0
Page 1

Table of contents section 3.0

Section Page
3.0 Hydraulic oil reservoir
General lay out 2

3.1 Main oil tank, location of switches, sensors etc. 3


3.2 Suction oil tank with strainers 4
3.3 Return oil collector tube with strainer 5
3.4 Back pressure valve 6
3.5
3.6 Return and Leak Oil Filter 8
3.7 Breather Filter 9

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3. General lay out

Legend for illustration (Z 22416b):


(1) Filter cover retainer
(2) Filter cover
(3) (A) – Return oil filter – 10 µm (4x)
(B) – Case drain filter – 3 µm (1x)
(4) Man hole cover
(5) Hydraulic oil filler plug
(6) Differential pressure switch, screen filter monitoring
(7) Test port, back pressure 8 bar
(8) Test port, back pressure swing motor 15 bar
(24) Pressure switch B24 – monitors item (132.1+132.2)
(39) Hydraulic oil level gauge
(41) Main oil reservoir
(114) Return oil collector tube with pressure check point M10
(115) Back pressure valve
(118) Oil drain, quick release coupling
(128) Shut off valve (Gate valve) with monitoring switch S31
(129) Compensator
(132.1 + 132.2) Breather filter
(178) Oil cooler filter (screen filter)

The hydraulic oil tank is a welded sheet-metal construction.


The filling capacity is about 3800 litres. The tank contains four return oil
filters (3-A) and one case drain filter (3-B).
The breather filter (132.1 + 132.2) cleans the air that streams into the tank.
The back pressure valve (115) and the pressure check point (M10) are located
at the collector tube (114) for return oil.
The connection to the suction tank can be closed with the shut- off valve (118)
to prevent oil flow during repairs on the hydraulic pumps. This unit is
controlled by the switch S31, to prevent a motor start with closed shut-off
valve. Fault message ”Start blocked because of main Shut-Off (gate) valve” is
displayed at the operators dash board.
The screen filter (178) protect the oil cooler for internal contamination, the
filter is monitored by differential pressure switch (178).
The back pressure valves (8) increase the circulation pump pressure to 15 bar
for cavitation protection of the swing motors.

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3.1 Main oil tank, location of switches, sensors etc.

Legend for illustration (Z 21495a):


(B4) Oil level sensor “Hydraulic oil level too low”
(B15) Hydraulic oil temperature probe
“Hydraulic oil temperature below: too hot”
(B24) Breather filter pressure switch
(B25) Pressure switch – Pressure leak oil chamber
(B26) Pressure switch – Pressure return oil chamber
(B32) Hydraulic oil temperature probe “Temp. gauge cabin”
(B42) Oil level sensor “Oil level maximum”
(B50) Oil level sensor “Hydraulic oil refill level”
(Y101) Solenoid valve “Back pressure reduction”

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3.2 Suction oil tank with strainers

Legend for illustration (Z 22418):


(1) Suction oil reservoir
(2) Drain coupling
(3) Bolt
(4) Gaskets
(5) Main suction oil strainer
(6) Gaskets
(7) Intermediate pipe
(8) Nut
(9) Bolt
(10) Compensator
(11) Suction strainer – one for each main pump
(12) Suction hose connection pipe

The suction oil tank (1) is a welded sheet-metal construction.


The capacity is 187 liters.
The suction lines of all hydraulic pumps are connected to the suction tank.

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3.3 Return oil collector tube with strainer

Legend for illustration (Z 21497a):


(1) Return oil collector tube - Part 1 -
(2) Return oil collector tube - Part 2 -
(3) Return oil collector tube - Part 3 -
(4) Strainer
(5) Bolt
(6) Self locking nut
(7) Gasket
(8) Differential pressure switch B165

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

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3.4 Back pressure valve

Legend for illustration (Z 21498):


(1) Back pressure valve assembly
(2) Solenoid valve (Y101)

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

) • Further information about the function principle and adjustments,


refer to Section 4.0 this Manual.

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3.6 Return and Leak Oil Filter

Legend for illustration (Z 21500):


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

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

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3.7 Breather filter

Legend for illustration (Z 21501a):


(1) Nut
(2) Cover
(3) Filter element
(4) Filter pot

A breather filter is installed to clean the air that streams into the tank any time
the oil level decreases while extending attachment cylinders
The filter element condition is monitored by a vacuum type pressure switch
(B24, 80mbar).
Maintenance see MAINTENANCE MANUAL

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Table of contents section 4.0

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+6
4.5 Pressure relief valves and solenoid valve 7+8
4.6 Fixed Displacement Pump, with variable setting 9
4.7 Radiator fan drive speed adjustment 10 –
12

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4.1 General

The hydraulic oil cooling system maintains the hydraulic oil at a normal
operating temperature.

Legend for illustration (Z 21594)


(1) Noise shield
(1) Cooler (Radiator)
(2) Cooler frame
(3) Fan
(4) Fan motor (Axial piston motor)
(5) Bolt
(6) Bolt
(7) Drive shaft
(8) Shaft protecting Sleeve
(9) Drive shaft seal
(10) Ball bearings
(11) Seeger clip ring
(12) Bearing group carrier
(13) Oil level plug
(14) Breather filter

Design:
There are four hydraulic oil coolers in front of the hydraulic tank on the R.H.
side of the platform.
They are in pairs mounted in one frame, one above the other. The air stream
needed for the cooling is produced by hydraulic driven fans. The air flows
from inside to outside through the coolers.
For a better cleaning, the coolers can be moved to the side. (“Swing out
cooler”)
The bearing group carrier is filled with oil to lubricate the bearings.

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4.2 Function of the hydraulic oil cooling circuit

Legend for illustration (Z 22419aa)


(107.1-107.4) Restrictor, shock absorbers for the hydraulic oil cooler
(106.1-106.4) Hydraulic oil cooler
(41) Main oil reservoir
(114) Return oil collector tube
(115) Back pressure valve
(L6 + L7) Return line from control blocks
(C1 + C2) Supply line for the anticavitation circuit of the swing
motors
(M10) Pressure check point
(C1 + C2) Supply line for the anticavitation circuit of the swing
motors
(Y101) Solenoid valve – 4/2-directional control valve
(H) Lines to cooler (hot oil)
(C) Lines to tank (cold oil)

Function:
The returning oil from the system flows via the lines (L6 - L7) into the
collector tube (114). On the top of it is the Back Pressure Valve (115)
installed.
The back pressure valve (115) causes a back pressure which forces most of
the relative hot oil through the lines (H) to the cooler (106.1-106.4).
On its flow through the cooler the hydraulic oil gets cooled and flows than
through the restrictors (107.1-107.4) and the lines (C) into the filter chamber
of the main oil reservoir (41).
The restrictors are acting like shock absorbers to prevent cooler cracking at
pressure peaks.
Besides the back pressure valve acts as an oil flow control valve as far as the
oil temperature has not reached its steady temperature.
During the warm up period (1/2 Qmax) the back pressure valve (115) is wide
open, because solenoid valve Y101 is energized, which results in less oil
flows through the cooler which causes that the oil gets quicker its optimum
operating temperature.
With increasing oil temperature the oil gets thinner, so that the main pumps
can be shifted to Qmax position and simultaneously solenoid valve Y101 will
be de-energized, so that the valve piston will be more closed by the force of
the spring thus that more oil passes the cooler.

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4.3 Adjustment of the Back Pressure Valve

Checks and settings only at normal operating temperature of the hydraulic oil,
main pumps in maximum flow position and "Idle Time" control eliminated
(service switch S151 actuated)!

1. Connect a pressure gauge to check point (M10).


2. Disconnect plug connector (13) of solenoid valve Y101.
3. Actuate service switch S151 ().
4. Start both both the motors..
5. Required pressure: 8 ±0,5 bar
If adjustment is required:
a) Take off protective cap (12).
b) Loosen lock nut (5).
c) Adjust the pressure with the set screw (6).
d) Tighten lock nut (5) and refit protective cap (12).
6. Disconnect the pressure gauge, reconnect solenoid valve Y101 and
switch back service switch S151.

Legend for illustration (Z 21596c):


(1) Control oil port
(2) "Y"- port (external return to tank)
(2a) "X"- port (external return to tank via solenoid valve Y101)
(3) Poppet
(4) Valve spring
(5) Lock nut
(6) Set screw
(7) Jet bore (large)
(8) Valve spring
(9) Valve piston
(10) Jet bore (small)
(11) Plug screw
(12) Protective cap
(13) Plug connector
(A) Return to tank (Filter chamber)
(Z) Pressure oil to valve

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4.4 Fan drive (Two stage cooler fan RPM control)

Legend for illustration (Z 22420aa)


(10.2) Axial piston pump Motor 1 (fixed displacement pump, with
variable setting)
(10.4) Axial piston pump Motor 2 (fixed displacement pump, with
variable setting)
(22.1) Fan motor (Axial piston motor)
(22.2) Fan motor (Axial piston motor)
(41) Main oil reservoir
(168.1) Pressure relief valve – Motor 1 radiator fan drive
(168.2) Pressure relief valve – Motor 2 radiator fan drive
(68.1) Pressure filter with pressure differential switch B28-1 (Motor 1)
(68.2) Pressure filter with pressure differential switch B28-2 (Motor 2)
(103.1) Check valve– (Anti cavitation valve for fan drive motor)
(103.2) Check valve– (Anti cavitation valve for fan drive motor)
(148.11) 4/3 direction flow valve – Motor 1 radiator fan speed (stop, low and
high speed), solenoid Y6A-1 + Y6B-1
(148.12) 4/3 direction flow valve – Motor 2 radiator fan speed (stop, low and
high speed), solenoid Y6A-2 + Y6B-2
(169.1) pressure reduction valve (low fan speed adjusting) motor 1
(169.2) pressure reduction valve (low fan speed adjusting) motor 2
(L) Leak oil (case drain) to tank
(P) Pressure to motor
(R) Return oil to tank
Mot1 Mot1 PVG PVG of Motor 1
Mot2 Mot2 PVG PVG of Motor 2

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

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4.5 Pressure relief valves and solenoid valves


Pressure relief valves (168.x)

Legend for illustration (Z 21598b)


(1) Valve cartridge
(2) Spring
(3) Spring chamber
(4) "X" port
(5) Jet bore, Pilot poppet
(6) Jet bore, Main piston
(7) Main piston
(8) Valve housing
(9) Pilot poppet
(Y) External leak oil port
(A) Pressure port
(B) Return oil port

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

continued

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Cont’d.

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

Function:
With de-energized solenoids (Y6A-x and Y6B-x), the spool (3) of the 4/3
direction flow valve 148.x keeps the "X" connection of valve (168.x) and port
“B“ to port “P“ closed. The pressure relief valve (168.x) operates normal with
the max. adjusted pressure. The fan turn with maximum speed.

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

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4.6 Fixed Displacement Pump, with variable setting

Legend for illustration (Z 21852)


(1) Drive shaft
(2) Bearings
(3) Cylinder with pistons
(4) Center pin
(5) Control lens
(6) Q-min adjustment bolt
(7) Q-max adjustment bolt
(8) Pressure port
(9) Tank port

Description.
Pump type A7F0 is a variable displacement pump, designed to operate in open
circuits. It has an internal case drain return. The rotary group is a robust self
aspirating unit. External forces may be applied to the drive shaft.
Changing the swivel angle of the rotary group is achieved by sliding the
control lens along a cylindrical formed track by means of an adjusting screw.
• With an increase in the swivel angel, the pump output increase together
with necessary drive torque.
• With an decrease in the swivel angel, the pump output decreases together
with the necessary drive torque.

• When increasing to maximum swivel angle, there is a danger of


cavitation and over-speeding the hydraulic motor!

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4.7 Oil cooler Radiator fan drive speed adjustment

Basic Adjustment

Legend for illustration (Z 22400a):


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

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

continued

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Cont'd

4.7 Oil cooler fan drive speed adjustment Radiator fan drive speed
adjustment
Basic Adjustment max fan speed
1. Reduce the output flow of the respective pump (P),by adjusting the
minimum possible swivel angle, to avoid over speeding the fan:
To do this, loosen both lock nuts (6.1 + 7.1) and turn out bolt (6)and
turn in bolt (7) up to final stop.
This is necessary to avoid a loose positioning pin (10), resulting in
oscillating of the cylinder barrel.
Tighten the lock nuts.
2. Remove protection cap (1) from relief valve (168.x), loosen lock nut
(2) and turn set screw (3) fully clockwise and then a half turn
counter clockwise.
3. Disconnect the plug connectors (Y6A-x and Y6B-x) of the 4/3
direction flow valve, to ensure that the full flow of pump P will be
delivered to the fan motor. The valve is in neutral position and all
ports are blocked.
4. Connect a pressure gauge to check point (M5-x).
5. Start the respective motor. and let it run in high idle.
6. Check the fan speed with a non-contact rev counter
Required fan speed: 1300250 RPM

• Be careful not to get caught in the fan or other rotating parts

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

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

continued

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Cont'd

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

Basic Adjustment middle fan speed


10. Activate the 4/3 direction flow valve (Y6B-x), by connecting the
solenoid plug (Y6B-x ) to permanent 24 V. Use a the 24V socket
(close to the motor house light switch or emergency switch.at the
PTO *) or activate the fan via PLC control ( digital output, key
switch required).
11. Check the fan speed with a non-contact rev counter Required fan
speed: 1000 RPM
12. If adjustment is necessary loosen lock nut (5) of the relief valve
(169.x), and decrease the pressure with set screw (4) until the correct
fan speed is obtained.
13. Stop motor and reconnect the plugs to the correct positions.
14. Disconnect the pressure gauge from check point (M5-x).

Fan speed check


If the maximum fan speed is out of adjustment, increase or decrease first the
pressure at relief valve (168.x), to change the speed.

• Do not exceed the maximum permissible operating pressure of 230 bar

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

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

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Table of contents section 5.0

Section Page
5.0 Controlling
General lay out 2

5.1 Control and filter panel location of components 3


(valves, switches, sensors etc.)
5.2 Pilot Pressure Supply and Adjustments 4–7
5.3 Remote control valves arrangement 8
5.4 Function principle of the 9 + 10
Electro-Hydraulic- Proportional Control
5.5 Potentiometer Control (Lever, Joy Stick) 11
5.6 Potentiometer Control (Pedal) 12
5.7 Proportional amplifier module, Type A 13
(for swing brake only)
5.8 Proportional amplifier module, Type B 14
(for Boom, Stick, Bucket, Swing and Travel)
5.9 Ramp Time Module 15
(Analogue command value module for Boom,
Stick, Travel and Swing function)
5.10 Adjustments of Amplifier Modules (General) 16
5.11 Adjusting the Amplifiers Type B 17 + 18
5.12 Adjusting the Amplifiers Type A 19 + 20
5.13 Adjusting the Ramp Time Module 21 + 23

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X4 - pump support
pressure X3 – remote control
pressure (1/2Qmax; Qmin)

X2
pump regulation
pilot pressure

X1 - pump regulation
pressure

to (45.2); (45.3) and (43) Z 22429

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5.0 General lay out


Legend for illustration (Z 21631):
(7.1 / (7.2) Pumps for pilot pressure and pump regulation system
(84.1 / 84.2) Check valve (for combined operation)
(68.1) Filter
(70.1) Pressure relief valve (X4 – pressure)
(70.2) Pressure relief valve (X2 – pressure)
(85) Pressure accumulator (10 Liter, 10 bar pre-charge
pressure)
(91) Check valve
(45.1; 45.2 ;45.3, 43) Remote control valves
(14; 15; 16; 13)) Control blocks

General
The controlling includes the pilot pressure system and the pump regulation
system.
The pumps (7.1 / 7.2) forcing the oil through the filter (68.1) to all involved
valves.
The pressure accumulator ensures that under any circumstances enough pilot
pressure oil is available. The accumulator (85) is also functioning as a
hydraulic battery for a certain time when the motor was shut down or to
pressure relive the system for repair works.
When the operator is using his controls an electrical signal causes energizing
of the selected solenoid valve of the remote control valves(14).
By the function of the remote control valves pilot pressure oil is send to the
relevant control block spools which in turn allows operating hydraulic oil to
the users.

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5.1 Control and filter panel location of components Legend for illustration (Z 22497):
Solenoid valves
Motor 1 Motor 2
(Y5) Swing gear house brake (swing parking brake)
(Y6A-1) (Y6B-1) Oil cooler fan RPM control
(Y6A-2) (Y6B-2) Oil cooler fan RPM control
(Y14A-1) (Y14A-2) Radiator fan RPM control, low speed (only diesel drive)
(Y14B-1) (Y14B-2) Radiator fan RPM control, middle speed (only diesel drive)
(Y16) Travel gear house brake (travel parking brake)
(Y17) Idle time control (Qmin)
(Y17a) ½ Q-max (reduced oil flow at cold oil)
(Y127) Swing service brake control
(Y61.1) (Y61.2) „XLR“ pressure, pumps 1 - 3, „XLR“ pressure, pumps 4 - 6
(Y102.1) (Y102.2) „X4“ pressure, pumps 1 - 3, „X4“ pressure, pumps 4 - 6
(Y124A/B) Refilling arm – up and down (only with diesel engines)
(Y124c) Refilling arm lock (only with diesel engines)
(Y48) Swing motor power/ speed control
(Y120) Emergency swing service brake control
(Y123A/B) ladder up and down
(Y125) ladder speed control
Pressure switches:
(B16) Pilot pressure for Swing gear house brake (24 bar)
(B21.1) (B21.2) Radiator fan drive filter differential switch (filters 68.3+5) (only diesel)
(B22) Differential pressure switch, pilot pressure system filter
(B27.1) (B27.2) Differential pressure switch, PTO gear oil filter
(B28.1) (B28.2) Pressure switch, cooler fan drive filter
(B48) Pilot pressure for travel gear house brake (24 bar)
(B97.1) (B97.2) „X4.1“ pressure, pumps 1 - 3, „X4.2“ pressure, pumps 4 - 6
(B85.1) (B85.2) “X1.1” pressure, pumps 1+2; “X1.2” pressure pumps 4 - 6
(B86) X2 pressure sensor
Pressure check points:
(M1.1) (M1.2) Pressure PTO gear lubrication
(M2) X4 - pressure
(M3) X2 - pressure
(M5.1) (M5.2) Cooler fan drive pressure
(M6) Pressure travel gear house brake
(M7) Pressure Swing gear house brake
(M11) Pressure swing brake (safety circuit )
(M18) Pressure for hydraulic pump regulation (electronic out)
(M19.1) (M19.2) Radiator fan drive pressure (only with diesel engines)
(M20.1) (M20.2) X1 pressure pumps 1, 2, 4, 5, 6
(M30) X3 pressure for pumps at ½ flow position
(M32) X3 pressure for pumps at ½ flow position
(M40) Pilot pressure, X-2
Filter:
(68.1) Pilot pressure and pump regulation
(68.2) (68.4) Oil cooler fan drive
(68.3) (68.5) Engine radiator fan drive (only with diesel engines)
(69.1) (69.2) PTO gear lubrication
continued

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5.2 Pilot Pressure Supply and Adjustments

Pilot Pressure Circuit


The pilot pressure oil is used for the following functions.
To move the control block spools, to supply the main pump regulation
system, to lubricate the main pump bearings, to release the travel- and swing
gear house brakes (spring loaded multi disk brakes), to drive the Lincoln
Lubrication pumps, to move the hydraulic operated ladder, to move the
hydraulic operated refilling arm and to supply the hydraulic track tensioning
system.

Legend for illustration (Z 22498):


(7.1 / 7.2) Pilot pressure pumps
(84.1 / 84.2) Check valve (for combined operation)
(68.1) Filter
(70.1) Pressure relief valve 60 bar
(70.2) Pressure relief valve 35 bar
(85) Pressure accumulator
(43 + 45.x) Remote control valves
(M2) 60 bar pressure check point (X4-Pressure)
(M3) 35 bar pressure check point (X2-Pressure)
(M40) 35 bar pres. check point (X2-Pressure in front of accumulator)

Function:
Study together with the hydraulic circuit diagram
The pumps (7.1 and 7.2) are delivering the oil through the filter (68.1) to port A
of the pressure relief valve (70.1) and the pressure relief valve (70.2) port A.
The pressure relief valve (70.1) maintains the adjusted pressure of 60 bar it is
called X4-pressure.
X4 - pressure: Pump support pressure
Pump bearing lubrication
Actuation of refilling arm and ladder
Lubrication system
Track tensioning system

continued

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Cont’d.:

The pressure relief valve (70.2) maintains the adjusted pressure of 35 bar it is
the X2-pressure.

X2 – pressure: Pilot pressure system


Pump regulation system
Capacity regulation swing motors
Travel- and Swing gear house brakes (spring loaded multi -
disk brakes)
The pressure accumulator (85) holds an amount of oil under pressure to ensure
sufficient pilot pressure during normal operations and a limited number of
operations without motor power.
The check valves (91) prevents return flow of the pilot pressure oil.

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Cont'd:

5.2 Pilot Pressure Supply and Adjustments

Pilot Pressure Circuit

Legend for illustration (Z 22500):


(41) Main oil reservoir
(91) Check valve
(85) Bladder Accumulator – 10 liter, 10 bar (located behind the filter and
valve panel of motor 2 on top of the PTO)
(PX2) Pilot pressure line
(LX2) Leak / return oil line from the remote control blocks

Function:
The pilot pressure oil flows via line (PX2) to port (P) of each remote control
block and is present via a gallery at all proportional and directional solenoid
valves.
These solenoid valves are energized by the function of the Electro
proportional controls (Joy sticks or pedals) and direct the pilot pressure oil to
the respective spools of the main control blocks with a variable pilot pressure
proportional to the deflection of the controls.

) • For the location and designation of the proportional and directional


solenoid valves of the remote control blocks see “5.3 Remote control
valves arrangement” in this section.

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5.2 Pilot Pressure Supply and Adjustments

Checks and Adjustment of Pilot Pressure


Legend for illustration (Z 21635a):
(85) Bladder Accumulator – 10 liter, 10 bar pre-charge pressure
(located underneath the catwalk in front of the PTO)
(70.1) Pressure relief valve for pump support pressure X4 (60 bar)
(70.2) Pressure relief valve for pilot pressure X2 (35 bar)
(M2) Pressure check point X4, pump support pressure (60 bar)
(M3) Pressure check point X2 pressure, pilot pressure (35 bar)
(M40) Pressure check point for accumulator (If not factory installed, fit a
T-union with test connector as shown in illustration Z 21635a)

) • Since the “X2” and the “X4” pressure are influencing each other it is
always necessary to adjust both valves 70.1+70.2 alternately.
60 bar pressure „X4“, valve 70.1:
1. Connect pressure gauge to check point (M2)
2. Start both motors
3. Read pressure, required = 60 -2 bar
If readjustment is required *:
35 bar pressure „X2“, valve 70.2:
1. Connect pressure gauge to check point (M3)
2. Start both motors
3. Read pressure, required = 35+3 bar
If readjustment is required *:
* Valve adjustment:
a Remove dust cap (1).
b. Loosen lock nut (2).
c. Set pressure with set screw (3).
d. Tighten lock nut (2) and re-fit dust cap (1).

Checking of Accumulator Function


1. Connect pressure gauge to check point (M40).
2. Start one motor.
3. After build-up of pressure stop the motor, but do not turn the
key switch to zero position.
4. Watch pressure gauge. Pressure should remain constant for at
least 5 minutes.

) • If the pressure droops the system must be checked for leakage’s.


• To check the accumulator charging pressure refer to SERVICE
BULLETIN AH01531a latest edition.

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5.3 Remote control valves arrangement

Legend for illustration (Z 21636)

No. Solenoid Proportional Function


valve valve FSA BHA

Y20a Y20 L.H. Crawler forward


Y20b L.H. Crawler reverse
Y21a Y21 Stick extending
45.1 Y21b Stick retracting
Y22a Y22 Bucket filling (curl)
Y22b Bucket emptying (dump)
Y23a Y23 Boom raising
Y23b Boom lowering

Y24a Y24 Clam closing Bucket filling (curl)


X24b Clam opening Bucket emptying (dump)
Y25a Y25 Bucket filling (curl) Boom raising
45.2 Y25b Bucket emptying (dump) Boom lowering
Y26a Y26 Boom raising Reserved
Y26b Boom lowering Reserved
Y27a Y27 Stick extending Stick extending
Y27b Stick retracting Stick retracting

Y28a Y28 R.H. Crawler reverse


Y28b R.H. Crawler forward
Y29a Y29 Boom raising
45.3 Y29b Boom lowering
Y30a Y30 Bucket filling (curl)
Y30b Bucket emptying (dump)
Y31a Y31 Stick extending
Y31b Stick retracting

43 Y32a Y32 R.H. Swing


Y32b L.H. Swing

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5.4 Function principle of the Electro-Hydraulic- Proportional Control

Legend for illustration (Z 21637)


(1) Pump
(2) Filter
(3) Pressure relief valve
(4) Check valve
(5) Pressure Accumulator
(6) Directional Solenoid valve, a side
(7) Directional Solenoid valve, b side
(8) Proportional Solenoid valve
(9) Control valve block
(10) Battery
(11) Electronic units with amplifiers etc.
(12) Control lever

Function:
The electric-hydraulic control system is used to control the direction and
volume of oil flow to the operating cylinders and motors via the control valve
blocks.
Hydraulically:
The oil volume of pump (1) flows through filter (2) into the pilot pressure
system. The pressure is limited by the pressure relief valve (3).
With the pressurized oil stored in accumulator (5), a limited number of spool
movements can be carried out with the motors 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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Cont'd:

5.4 Function principle of the Electro-Hydraulic- Proportional Control

(Exemplary illustration of the function of two axis with one Amplifier only)
Legend for illustration (Z 21638a)
(1) Control lever (joystick)
(2) Capacitor-Module
(3) Ramp time module
(4) Proportional-Amplifier-Module
(5) Relay (Supply Voltage)
(6) Proportional solenoid valve-(Pressure-Reducing Valve)
(7) Directional solenoid valve
(8) Control block spool

General Function
Control lever (1) is supplied with 24 VDC battery voltage for the switch contacts
and for the internal electronics to create the signal voltage.
When moving lever (1) out of its neutral position, 24 VDC battery voltage arrives
at relay (5) and energizes the Proportional Amplifier (4) with capacitor
supported 24 VDC via terminal 1.
Depending on the function of the control lever, 1 to 4 Amplifiers can be involved
for the „Y-axis“ (forward/ backwards direction) and 1 to 4 Amplifiers for the „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 35 bar to a
value proportional to the Current Signal.
This pressure controls the movement of the control block spool (8) between
neutral and full stroke position.

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5.5 Potentiometer Control (Lever, Joy Stick)

Legend for illustration (Z 21639b)


(1) Push button *
(2) Toggle switch *
(3) Inductive linear transmitter
(4) Universal joint
(5) Electronics
(6) Push pin
(7) Shaft seal
(8) Reset spring
(9) Coil core
(10) Coil
* Alternative application

The non-contacting lever control (inductive linear transmitter) contains both


the electronic and mechanical components which converts the lever
movement into a proportional electrical voltage. The lever can be operate in
two axes:
Axis "Y", splitted into the half axis Y- and Y + (backward and forward)
Axis "X", splitted into the half axis X- and X + (left and right)
Of course the lever can be moved in any other direction (Joy stick function)

In order to be able to monitor the direction of the lever movement and the
neutral position, the electronics (8) sends a 24V signal as soon as the lever
gets moved out of its neutral position.

For one axis are used two inductive linear transmitter (3). The motion of the
coil core (9) connected to the push pin (6) causes a variation of the induction
in the coils (10). The electronics convert this inductive signal into a
proportional output signal of –10...0...+10 V for the amplifiers.

The electronic part of the lever is equipped with a internal fault detector. In
case of a internal electronic fault the electronic send a 24V signal to the test
output. The test input is used for a lever system check before motor start. The
inductive system is designed as a redundant system with two separate coils.

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5.6 Potentiometer Control (Pedal)

Legend for illustration (Z 21300)


(1) Potentiometer Control Unit
(2) Pedal
(3) Standard cable
(4) Connection cable for combined operation

Application for:
(A) Swing foot brake
(B) Clam Opening/closing, (only face shovel attachment)
(C) Travelling

The Potentiometer Control (inductive linear transmitter) contains both the


electronic and mechanical components which converts the pedal movement
into a proportional electrical voltage.

In order to be able to electrically monitor the pedal (2) action a neutral


position switch is fitted.
This switch closes when the pedal is moved out of the rest position.

When using the double unit (B) (combined operation) only the signal output
from one unit is used for the Clam Operation.
Due to the cross lined connection via the connection cable (4) the signal is
once positive and once negative (inverted), depending on the Pedal used.

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5.7 Proportional Amplifier Module, Type A

Legend for illustration (Z 21516)


Type A (for swing brake only)
(LED) LED for Solenoid A or B
(P) Set Potentiometer
R1 for the lowest current value

R2 for the highest current value

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

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5.8 Proportional Amplifier Module, Type B

Legend for illustration (Z 21640)


Type B (for Boom, Stick, Bucket, Clam, Swing and Travel)

(LED) (P) Set Potentiometer:


AX: Proportional output AX active - 10% for the lowest current value
AS: Switched output AS active - J2 for the highest current value
BX: Proportional output BX active (Pt) Set Potentiometer for the „Ramp
BS: Switched output BS active Time“
Power: Internal supply voltage
Fault: Fault indication

The amplifier module is snapped onto mounting rails inside the X2-box.
The amplifier module contains the necessary electronics for the control of
two proportional solenoids and two directional solenoids. The outputs for
proportional solenoids Ax and Bx and the switched outputs As and Bs are
activated by connecting a minimum of approx. 10 % signal voltage at the
amplifier input.
A positive signal voltage controls outputs A, a negative signal voltage
controls output B.
A signal voltage of approx. 10% with respect to +/- 10 V input voltage at the
amplifier, produces a stepped output voltage. The height of this 10% jump
may be set separately for proportional outputs Ax and Bx via external
potentiometer. As the signal voltage rises the solenoid current for the
proportional outputs increases linearly.
A further step in output current occurs at approx. 90% signal voltage.
The maximum current or the 90% jump may be set separately for outputs Ax
and Bx via external potentiometers and hence the gradient of the output curve
may be influenced.
LED’s indicate the current output to each proportional and switched output,
whereby the brightness is approx. proportional to the solenoid current in Ax
and Bx. This function should not be used for setting.
A Ramp Time function is included in the amplifier which may be externally
changed by a set potentiometer. The setting range for the ramp time is
approx. from 80 ms to 1s. The time setting applies to both up and down
ramps and to both proportional solenoids.
A fault is indicated by the LED „Fault“.

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5.9 Ramp Time Module


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

Legend for illustration (Z 21518)


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

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5.10 Adjustments of Amplifier Modules (General)

Legend for illustration (Z 21641)


(1) Potentiometer control
(2) Terminal with a separating possibility
(3) Ramp time module
(4) Amplifier
(5) Solenoid valve
(6) Service module

Introduction:
The illustration shows simplified the route of the signal voltage from
Potentiometer Control (1) to Solenoid-Valve (5):
A. With ramp time module,
i.e. Boom,- Stick,- Travel,- and Swing Function.
B. Without ramp time module,
i.e. Bucket and Clam Function.

The ramp time modules (3) and the amplifiers (4) are adjustable.
Adjustments are required:
Ramp time modules Amplifiers
• When commissioning the machine • When replacing a 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.

Accessories required for the adjustments: "a" "b" "c" "d"


a) A multimeter, good readable for
mA VDC
values between 0 and 1000 mA.
b) More convenient is a second meter
for reading voltage simultaneously.
c) A simple wire, 1m length, or better
a prepared test lead same length
d) Four test leads, 1m length, with
banana type connectors on each
end.

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5.11 Adjusting the Amplifiers Type B, illustration (Z 21642a)

Procedure applicable for all amplifiers except the one for the swing
brake:
(Do not start the motors leave 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 electric circuit diagram (see page adjustments of amplifier and
time ramp modul) e.g. 330 mA. (The first step (10 %) value)
If necessary correct the value with potentiometer (10%).
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. 570 mA. (The second step (90 %) value).
If necessary correct the value with potentiometer (J2).

* How to open and close the terminal:


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

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Cont'd:

5.11 Adjusting the Amplifiers Type B, illustration (Z 21642)

10. Repeat settings of item 8 and 9 until both mA values are stabilized, because
the 10% and J2 adjustment influence each other.
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 ice
versa.
Attantion! The adjustment values can be different betwin the directions (poitiv A
or negative B) and the single amplifier. Use the respective electric diagram of
your machine (page: adjustments of amplifier and time ramp modul)
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.

Adjusting the Ramp Time


In the amplifier module is a ramp time function integrated which is active
when there is no additional ramp time module in the respective control
circuit.
1. Turn potentiometer (time) 30 revolutions counter clockwise to guarantee the
correct start position at the complete left side.
2. Turn potentiometer (time) so many revolutions clockwise as shown in the
table below (part of the electrical circuit diagram).

* How to open and close the terminal:


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

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5.12 Adjusting the Amplifiers Type B, illustration (Z 21643)

The amplifiers for the crawler foot pedals are adjustable in the same way as
the amplifiers for the joy sticks.(refer to page 17 and 18 in this section)

The amplifier for the swing foot brake is similar.

Procedure for the swing foot brake:


1. Open* the respective separating terminal (T1) between the pedal unit and
the amplifier module to be set.
2. Open* the respective separating terminal (T2) between the amplifier module
to be set and the proportional solenoid valve.
3. Disconnect the wire from terminal five.
4. Connect the positive output of the service module with terminal five of the
amplifier module, using test lead (2).
5. Attach a multimeter for voltage reading to the service module, using test
lead (3).
6. Attach a multimeter (in series) for Amp reading to the terminal between
amplifier module and solenoid valve, using test lead (3).
7. Press the pedal fully down ; or manual override the relay which allows 24 V
operating voltage to the amplifier module; thus the amplifier gets 24 V
operating voltage.
8. Turn the potentiometer (P) of the Service-Module until the multimeter
shows 1 VDC ; the multimeter for the current reading will show a value
which should correspond to the value giving in the circuit diagram e.g. 10
mA. (10 % value)
If necessary correct the value with potentiometer (R1).

* How to open and close the terminal:


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

continued

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Cont'd:

5.12 Adjusting the Amplifiers Type B, illustration (Z 21643)

9. Turn the potentiometer (P) of the Service-Module further until the


multimeter shows 10 VDC; the multimeter for the current reading will show
a value which should correspond to the value giving in the circuit diagram
e.g. 500 mA. (100 % value).
If necessary correct the value with potentiometer (R2).

) • It is important that the pilot pressure for the pressure increasing valve
is 19± 1 bar.
For more information refer to section 8.2 „Swing Circuit“

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.

* How to open and close the terminal:


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

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5.13 Adjusting the Ramp Time Module

Legend for illustration (Z 21644)


(2) Capacitor-Module
(3) Ramp time module
(6) Service module
(P) Potentiometer

) • The following adjustments have to be done when commissioning the


machine and whenever the Ramp Time Module has been replaced.
• Do not start the motors turn only the key switch in ON – position.

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

) • Repeat settings of item 1 and 2 until both values are stabilized,


because "Pot Z" and "Pot G" influence each other.
• The factory setting of potentiometer "w1" to "w4" for the command
value call-ups must not be adjusted.

continued

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Cont'd:

5.13 Adjusting the Ramp Time Module

Legend for illustration (Z 21645)


(1) Control lever (joystick)
(2) Capacitor-Module
(3) Ramp time module
(4) Proportional-Amplifier-Module
(5) Relay (Supply Voltage)

Ramp time adjustment in relation to the operating movements:

3. Disconnect the cables at terminal 3 and terminal 5 of the respective


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

4. To check the adjustments under operating conditions reconnect terminal


3 and terminal 5 and measure the ramp time with a stopwatch.

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:

5.13 Adjusting the Ramp Time Module (values as a example only)

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 0,10 Volt = 1000 ms
Terminal 10 Lower ⇒ Neutral +10V to 0V t2 5,00 Volt = 20 ms
Terminal 11 Neutral ⇒ Lift 0V to -10V t3 0,10 Volt = 1000 ms
Terminal 12 Lift ⇒ Neutral -10V to 0V t4 5,00 Volt = 20 ms

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 0,20 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

E50B Swing brake


24 Volt at Joy stick Signal Pot Value to be measured at socket "t"
Terminal 9 Neutral ⇒ counter 0V to +10V t1 0,10 Volt = 1000 ms
swing right
Terminal 10 Counter swing right +10V to 0V t2 0,500 Volt = 20 ms
⇒ Neutral
Terminal 11 Neutral ⇒ counter 0V to -10V t3 0,10 Volt = 1000 ms
swing left
Terminal 12 Counter swing left -10V to 0V t4 0,500 Volt = 20 ms
⇒ Neutral

continued

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E51 Left crawler


24 Volt at Joy stick Signal Pot Value to be measured at socket "t"
Terminal 9 Neutral ⇒ Forward 0V to +10V t1 0,500 Volt = 20 ms
Terminal 10 Forward ⇒ Neutral +10V to 0V t2 0,500 Volt = 20 ms
Terminal 11 Neutral ⇒ 0V to -10V t3 0,500 Volt = 20 ms
Backward
Terminal 12 Backward ⇒ -10V to 0V t4 0,500 Volt = 20 ms
Neutral

E52 Right crawler


24 Volt at Joy stick Signal Pot Value to be measured at socket "t"
Terminal 9 Neutral ⇒ 0V to +10V t1 0,500 Volt = 20 ms
Backward
Terminal 10 Backward ⇒ +10V to 0V t2 0,500 Volt = 20 ms
Neutral
Terminal 11 Neutral ⇒ Forward 0V to -10V t3 0,500 Volt = 20 ms
Terminal 12 Forward ⇒ Neutral -10V to 0V t4 0,500 Volt = 20 ms

E59 Bucket (only BHA)


24 Volt at Joy stick Signal Pot Value to be measured at socket "t"
Terminal 9 Neutral ⇒ Fill 0V to +10V t1 0,05 Volt = 2000 ms
Terminal 10 Fill ⇒ Neutral +10V to 0V t2 0,10 Volt = 1000 ms
Terminal 11 Neutral ⇒ Dump 0V to -10V t3 0,10 Volt = 1000 ms
Terminal 12 Dump ⇒ Neutral -10V to 0V t4 0,10 Volt = 1000 ms

04.01.07 PC5500-6-E_Sec_5-0_rev3.doc
Components Section 6.0
Page 1

Table of contents section 6.0

Section Page
6.0 Components

6.1 Hydraulic
6.1.1 Main Control Blocks and High Pressure Filter FSA 2-3
6.1.2 Main Control Blocks and High Pressure Filter BHA 4-5
6.1.3 Distributor Manifold – Restrictor blocks FSA 6
6.1.4 Distributor Manifold – Restrictor blocks BHA 7
6.1.5 Restrictor Block with Pressure Relief Valve 8
6.1.6 Anti Cavitation Valve Block 9
6.1.7 Remote Control Valves 10
6.1.8 Directional Solenoid Valves (4 way / 3 positions) 11
6.1.9 Proportional Solenoid Valves 12
6.1.10 High Pressure Filter 13
6.1.11 Control Blocks and Valves 14-17
6.1.12 Load Holding Valve 18
6.1.13 Travel Brake Valve 19
6.1.14 Pressure Reducing Valve 20
6.1.15 Directional Solenoid Valves (2 positions / 4-ways) 21
6.1.16 Pressure Increasing Valve 22

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6.1.1 Main Control Blocks and High Pressure Filter


Front Shovel Attachment FSA

Legend for illustration (Z 22566):


Pump circuit No. I
(14 / I ) Control block I (L.H. Travel, Stick, Bucket, Boom,)
(46.1) High pressure filter, Pump 2 and 5
(31.01) SRV Travel motors left backward
(32.01) ACV Travel motors left backward
(31.02) SRV Travel motors left forward
(32.02) ACV Travel motors left forward
(33.1) SRV Stick cylinder piston side
(32.3) ACV Stick cylinder piston side
(32.4) ACV Stick cylinder rod side
(32.5) ACV Bucket cylinder rod side
(33.2) SRV Bucket cylinder rod side
(32.6) ACV Bucket cylinder piston side
(32.7) ACV Boom cylinder rod side
(32.8) ACV Boom cylinder piston side

Pump circuit No. II


(15 / II) Control block II (Bucket, Boom, Reserved, Stick)
(44.2) High pressure filter, Pump4
(32.9) ACV Bucket cylinder rod side
(32.10) ACV Bucket piston side
(30) SRV Clam cylinder piston side
(33.06) SRV Bucket cylinder rod side
(32.11) ACV Bucket cylinder rod side
(32.12) ACV Bucket cylinder piston side
(32.13) ACV Boom cylinder rod side
(33.4) SRV Bucket cylinder rod side
(32.14) ACV Boom cylinder piston side
(32.15) ACV Stick cylinder piston side
(191) SRV (pressure increasing valve) Stick cylinder rod side
(32.16) ACV Stick cylinder piston side

continue

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Pump circuit No. III


(176 / III) Control block (R. H. Travel, Boom, Bucket, Stick)
(46.2) High pressure filter, Pump 1 and 6
(31.03) SRV Travel motors right forward
(32.17) ACV Travel motors right forward
(31.04) SRV Travel motors right backward
(32.18) ACV Travel motors right backward
(32.19) ACV Boom cylinder rod side
(32.20) ACV Boom cylinder piston side
(32.21) ACV Bucket cylinder rod side
(32.22) ACV Bucket cylinder piston side
(32.23) ACV Stick cylinder rod side
(32.24) ACV Stick cylinder piston side

Pump circuit No. IV


(13 / IV) Control block IV (Single spool for swing)
(44.1) High pressure filter, Pump 3

) • There is one MRV in each control block.

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Page 4

6.1.2 Main Control Blocks and High Pressure Filter


Backhoe Attachment

Legend for illustration (Z 22433):


Pump circuit No. I
(175 / I ) Control block I (L.H. Travel, Stick, Bucket, Boom,)
(46.1) High pressure filter, Pump 2 and 5
(31.01) SRV Travel motors left backward
(32.01) ACV Travel motors left backward
(31.02) SRV Travel motors left forward
(32.02) ACV Travel motors left forward
(33.1) SRV Stick cylinder piston side
(32.3) ACV Stick cylinder piston side
(32.4) ACV Stick cylinder rod side
(32.5) ACV Bucket cylinder rod side
(32.11) ACV Bucket cylinder piston side
(32.12) ACV Boom cylinder rod side
(32.13) ACV Boom cylinder piston side

Pump circuit No. II


(15 / II) Control block II (Bucket, Boom, Reserved, Stick)
(44.2) High pressure filter, Pump4
(32.14) ACV Bucket cylinder rod side
(32.15) ACV Bucket piston side
(33.06) SRV Boom cylinder rod side
(32.11) ACV Boom cylinder rod side
(33.05) SRV Stick cylinder piston side
(32.15) ACV Stick cylinder piston side
(32.16) ACV Stick cylinder rod side

continue

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Cont’d
Main Control Blocks and High Pressure Filter BHA

Pump circuit No. III


(176 / III) Control block (R. H. Travel, Boom, Bucket, Stick)
(46.2) High pressure filter, Pump 1 and 6
(31.03) SRV Travel motors right backward
(32.17) ACV Travel motors right backward
(31.04) SRV Travel motors right forward
(32.18) ACV Travel motors right forward
(32.19) ACV Boom cylinder rod side
(32.20) ACV Boom cylinder piston side
(32.21) ACV Bucket cylinder rod side
(32.22) ACV Bucket cylinder piston side
(32.23) ACV Stick cylinder rod side
(32.25) ACV Stick cylinder piston side

Pump circuit No. IV


(13 / IV) Control block IV (Single spool for swing)
(44.1) High pressure filter, Pump 3

) • There is one MRV in each control block.

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6.1.3 Distributor Manifold - Location of restrictor blocks and anti cavitation


valves

Front Shovel Attachment (FSA)

Legend for illustration (Z 22434):


(1) Distributor manifold
(2) Synchronization (Equalization) lines
(3) Synchronization (Equalization) lines
(4) Anti Cavitation Valve Block (ACV)
(5) Restrictor Block (Throttle valve)
(6) Restrictor Block (Throttle valve)
(7) Service-line Relief Valve

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6.1.4 Distributor Manifold - Location of restrictor blocks and anti cavitation


valves

Backhoe Attachment

Legend for illustration (Z 22434):


(1) Distributor manifold
(2) Synchronization (Equalization) lines
(3) Synchronization (Equalization) lines
(5) Service-line Relief Valve
(4) ACV Block Section A ,Boom cylinder rod side
(6) Service-line Relief Valve
Pressure check point
(7) Restrictor blocks

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6.1.5 Restrictor Block with Pressure Relief Valve

) • A restrictor block is used for limiting cylinder lowering speeds.


• A Service Line Relief Valve is installed to limit the maximum system
pressure due to external forces.

Legend for illustration (Z 21834):

(1) Adjustment spindle


(2 + 3) O-ring with back-up ring
(4) Retainer
(5 + 6) O-ring with back-up ring
(7) Spring
(8) Spring cup
(9) Throttle sleeve
(10) O-ring
(11 Housing
(12) Return line port, T
(13) Pressure relief valve
(14) Allen bolt
(15) Clip ring
(16) Lock nut
A+B Line ports
M Pressure check point
Y Control oil drain port

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

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6.1.6 Anti Cavitation Valve Block

) • ACVs are installed to avoid cavitation damages on users (hydraulic


cylinders), by compensating a possible lack of oil, when the SRV at the
opposite side of the cylinder opens (see circuit diagram).

Legend for illustration (Z 21835):


(Type 64.1 to 64.9 of the hydraulic circuit diagram)
(1) Housing
(2) Valve cone
(3) Spring
(4) O-ring
(5) Control and leak oil bore
(6) Cap screw (torque 900 Nm)
S Supply line (Return oil pressurized to approximately 10 bar by
back pressure valve)
A and B Line connections

Function:
The circuit pressure in the line A and B hold the valve cone (2) closed. The
pressure of the supply line S forces onto the valve cone.
The valve cone opens, whenever the pressure at the A and B side is lower
than the back pressure at return oil port S, to allow necessary oil supply into
the circuit.

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6.1.7 Remote control valves

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

Legend for illustration (Z 21838a):


(1) Pilot pressure supply port (marked with P)
(2) Pilot pressure return port to tank (marked with L)
(3) Pilot pressure output lines to the control block
(marked with A1/B1, A2/B2, . . . . )
(4) Directional solenoid valve, 3 position / 4 ports
(5) Proportional solenoid valve, (0 – 700 mA, 0 – 35 bar).

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 (5) and one
of the directional solenoid valves (3 either Ax or Bx) 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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6.1.8 Directional Solenoid Valves


(4/3 direction flow valve = 4 way / 3 positions)

) • This solenoid operated directional spool valves are installed to control


the start, stop and direction of an oil flow.

Legend for illustration (Z 21839):


(1) Housing
(2) Solenoids
(3) Control spool
(4) Reset springs
(5) Plunger
(6) End cover

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

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6.1.9 Proportional Solenoid Valve

) • This valves are responsible for the creation of a variable control


pressure proportional to the electrical signal output of an amplifier.

Legend for illustration (Z 21697):


(1) Proportional solenoid (5) Pressure measuring spool
(2) Control piston (6) Connection plug
(3) Valve housing (7) Return spring
(4) Pressure measuring spool (8) Bleed screw

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

- When no more air bubbles appear screw in plug 8.

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6.1.10 High Pressure Filter

) • There is one filter in each pump line installed.

Legend for illustration (Z 21696):


(1) Filter head
(2) Drain plug
(3) Filter case
(4) Hexagon
(5) Filter element
(6) Seal
(7) O-ring
(8) Back-up ring
(9) O-ring
(10) Spring
(11) Differential pressure switch
P1 Input pressure
P2 Output pressure
a Electrical connection
b REED contact
c Permanent magnet piston
d Spring
e Plug screw

Function:
High-pressure in-line filters prevent contamination from entering the
hydraulic circuits. The high pressure filters are installed between the main
hydraulic pumps and main control blocks. All hydraulic components, behind
the pumps, are effectively protected from damage and undue wear. Each filter
is equipped with a differential pressure switch to monitor the filter flow
restriction. If the pressure reaches an unsafe difference of 8.5 bar, a
visual/acoustic warning appears on the display in the cab and the engines will
be shifted automatically to low idle.

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Page 14

6.1.12 Control Blocks and Valves

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

Legend for illustration (Z 22436):


(1) Control block housing
(2) Cab ("A side)
(3) Cap ("B" side)
(4) Solid spool
(5) "B" side service line ports
(6) Centering springs
(7) MRV, main relief valve
(8) Port A, to cylinder/motor
(9) Port B, to cylinder / motor
(10) Fine controlling grooves
(11) Port P, from pumps
(12) Port T, to tank
(13) Load holding valves
(14) Spin look spool extension (only block I and II)
(15) Spin look balls (only block I and II)
(16) Spin look cab extension

Control blocks with "Open Center and Closed Ports".


Control blocks I, II and III are 4 spool blocks and IV is a 1 spool block.
See hydraulic circuit diagram for spool details.
Each spool is provided with "Fine Controlling Grooves" and ring grooves for
hydraulically centering of the spool.
Between 8 and 19 bar pilot pressure the spools are moved in their fine control
range.
Spool number 4 of block I, 2 of block II and 4 of block III are special designed,
to keep the pressure channel connected to the center channel during the floating
function is activated, so that pump flow is available for other functions. This
spools are marked in the hydraulic diagram with (#) symbol.
The Load Holding Valves are installed inside of the spool, for each port to the
cylinder or motor one valve. The hydraulic diagram shows only one.
The MRV is a pilot operated pressure relief valve.
Control block I, II and III are equipped with a spool spin look system (item 14,
15, 16) to prevent spool spinning because of high oil flow during lowering
function.

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Page 15

6.1.11 Control Blocks and Valves

Legend for illustration (Z 22440):


(1) Main relief valve (MRV)Control block housing
(2) Load holding valve
(3) Anti cavitation valve (ACV)
(4) Service line relief valve (SRV)

Explanation of the schematic drawing of the control block:


The hydraulic oil flows through the control block from port P to T, if all
spools are in neutral position ("pressure-less circuit" or “Free circulation“).

(A) 4 valve block


E.g. the spools moves up when pilot pressure is build up in the control pipe
line a1. (Imagine the lower symbol box moves to the center position.)
Now pump oil flows through holding valve (2) to the user port A1 because
the free flow circulation to the hydraulic reservoir is closed. The main relief
valve (1) limits the maximum operation pressure in this circuit. Via port B1
the return oil from the user is flowing back to the hydraulic reservoir.
During down hill travelling motion and stopping procedure (e.g. travel
motors) the anti cavitation valves (3) prevents cavitation on the hydraulic
motors. Because during these short periods of time the hydraulic motor needs
a higher oil supply than the pump can deliver.

E.g. the spool (4) moves up when pilot pressure is build up in the control pipe
A4. Now the user port A4 is connected to the pump pressure line and the free
circulation to the tank. There is no high pressure build up only 8 bar from the
back pressure valve and line resistance. Via port B4 the return oil from the
user is flowing back to the hydraulic reservoir. Service line relief valve (4) is
additional installed in this circuit to protect the circuit for extreme pressure.
The shortly extreme pressure closes also the holding valve (2) which secures
the hydraulic pump from extreme pressure peaks.

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

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6.1.11 Control Blocks and Valves

Legend for illustration (Z 22441):


(1) Spool
(2) Reset springs
(3) Load holding valve

Function:
Reset springs (2) moves the spool (1) in neutral position.

Fine control grooves provide for sensitive controlling, because a motion is


started always while the pressure oil and the return oil first passes this fine
control grooves before spool (1) is inter connecting the entire groove to the
user channel.

In neutral position of spool (1) the pump oil is flowing back via port PU to the
tank.

Lower picture:
Example. The spool is moved by pilot pressure on the left spool side to right
position: Port PU is closed and the connection through the holding valve (3)
to the user (port A) is open. Also the connection from the other user side (port
B return)is connected to the port T (return line to tank).

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Page 17

6.1.11 Control Blocks and Valves

Legend for illustration (Z 21705):


(01) Service -Line Relief Valve (9) Set screw
(02) Anti Cavitation Valve (10 Lock nut
(03) Main Relief Valve (11) Spring, pilot part
(04) Closing plate (12) Poppet
(5) Plug screw (13) + 16) Jet bore
(6) Spring (14) Spring, main cone
(7) Valve cone (15) Main valve cone
(8) Dust cap (17) Pilot oil dump line to tank

MRVs and SRVs are pilot operated relief valves. The MRV limits the max.
Pump supply line pressure. The SRV limits the max. possible pressure peak in
the service-line.
The valves have an „opening characteristic“. That means, that in case of
contamination after the response procedure no further pressure increasing is
possible and damages are avoided.

Function:
The circuit pressure P forces with the force F1 on the piston surface A of the
main valve cone (15). Because there is via the jet bore (16) the same pressure on
the back side of the main cone, this results together with the spring (14) force in
a force F2 that keeps the main cone closed. Via the jet bore (13) the circuit
pressure is in front of the poppet (12). Exceeds the circuit pressure the setting
value of the spring (11), the poppet opens against the force of the spring (11).
This causes that the force F2 decreases and there is no more balance condition
between F1 and F2. Valve cone (15) is moved upwards by the greater force F1.
That means there is now a direct connection from port P to T (tank).

ACVs serve for compensation possible lack of feed when the SRV at the
opposite port is actuated (see circuit diagram) and for avoiding cavitation
damages. In addition, to supply a user in case it is continuously moved by
acceleration forces at zero position of the control spool.

Function:
The circuit pressure inside the spring chamber closes the valve cone (7).
The back pressure of the return line acts on the surface of the valve cone (7).
Whenever the pressure in the service-line is lower than the springs force the
valve cone opens by the force of the back pressure and hydraulic oil is additional
supplied.

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Page 18

6.1.12 Load Holding Valve

Legend for illustration (Z 22441):


(1) Spool
(2) Reset springs
(3) Load holding valve

Control Blocks I to IV (4 spool blocks and single spool block)


Two load holding valves are fitted into each spool of the control blocks, one
valve for each port (A and B).

They have three tasks:


1. When circuit pressure due to attachment weight is higher than pump
pressure these valves prevent dropping of the attachment, within their
sensitive (fine controlling) range.
2. Due suddenly pressure peaks in the service lines the valves also protect
the pump.
3. When two pumps flows are used for one user they ensure that at least
the flow of one pump reaches the user in case one MRV is defect or not
more correct adjusted.
That means: Up to the max. Pressure of the defective valve both load holding
valves are open allowing the flow of both pumps to the user, then one valve will
be closed by the higher pressure and the flow of one pump only flows to the
user.

Function:
The system pressure forces onto the front area of the valve cone (1). This force
moves the valve cone against the spring and allows the oil to flow from the
pump through the spool centre to the port.
In neutral position of the spool no further flow is possible. (see circuit diagram)
If the spool is not more in neutral the flow continues to the user.
If due to an external force the pressure directed to the pump overcomes the
pump line pressure, this pressure forces the valve onto its seat (closed position)

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6.1.13 Travel Brake Valve

Illustration Z 21695

Task:
Travel brake valves control the oil flow from the hydraulic motor to the tank
depending on operating pressure. This braking action prevents the motors from
over speeding.

Function:
Spring force keeps the spool in the lowest flow position. with increasing
operating pressure the opening for the return oil flow becomes larger.
On its way to the hydraulic motor the oil flows from A to A1 respectively from
B to B1 depending on the selected travel motion.

Example:
Operating pressure at port A moves spool (1) against the force of the spring (2)
and opens the way for the return oil (B1 to B).
Holding valve (3) prevents a direct oil flow from B1 to B.
If the operating pressure decreases to such an extend that the spring force
overcomes the pressure, the flow to the tank becomes restricted, resulting in
braking of the machine.
For more information and adjustment see section 8.3.

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6.1.14 Pressure Reducing Valve

) • Pressure reducing valves are installed to reduce the common 35 bar


pilot pressure to a lower pressure for other systems, e.g. the pump
regulation system.

Legend for illustration (Z 21844):


(1) Set screw
(2) Spool
(3) Compression spring
(4) Threaded sleeve
(5) Non return valve
(6) Boring
(7) Spring chamber
(8) Control land

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

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6.1.15 Directional Solenoid Valves (2 positions / 4-ways)

) • This solenoid operated directional spool valves are installed to control


the start, stop or direction of an oil flow.

Legend for illustration (Z 21845):


(1) Housing
(2) Solenoid
(3) Control spool
(4) Return spring
(5) Plunger
(6) Dust cap with stem for manual operation

Function:
When there is no flow through the valve, control spool (3) is held in neutral
or output position by means of the return springs (4). The control spool (3) is
operated by means of oil immersed solenoid (2).
The force of the solenoid (2) effects control spool (3) by means of the plunger
(5) and pushes it from its resting position to the required end position.
This results in free flow from P to B and A to T.
When solenoid (2) is de-energized, control spool (3) is moved back to its
resting position by means of return springs (4).
An optional hand emergency (6) allows movement of the control spool (3)
without energizing the solenoid.

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6.1.16 Pressure Increasing Valve

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


valve, actuated by hydraulic pressure. The individual pressure is in
such a way determined by the pilot pressure.

Legend for illustration (Z 21846):


(1) Pilot valve with valve seat
(2) Valve poppet
(3) Compression spring
(4) Main valve with sleeve
(5) Main piston
(6) Closing spring
(7+8) Set screws
(9) Piston
(10) Pin
(11+12) Jet bore
(13+14) Lock nut

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

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Main Hydraulic Pumps Section 7.0
and Page 1
Pump Regulation System

Table of contents section 7.0

Section Page
7.0 Main hydraulic pumps and pump regulation system
General 2–5
7.1 Main Pumps
7.1.1 Location of Pumps 6
7.1.2 Pump bearing flushing / lubrication 7
7.1.3 Operating Principles 8 - 15
7.1.4 Checks and Adjustments 16 - 20
7.2 Electronic Pump Regulation System
7.2.1 Electronic load limiting control - General 21
7.2.2 Electronic Power Module EPM 22
7.2.3 Electronic Signal Rectifier ESR 23 - 24
7.2.4 Microcontroller MC7 25
7.2.5 Checks and adjustments - General 26
Method A - With 24V supply to terminals
- X1- pressure adjustment 27
- Demanded power adjustment 28 - 29
- PID – Factor adjustment 30
Method B - With the electronic service tool BB-3
- Language selection 31 - 32
- Adjustment mode SET1 and SET2 33
- Number of motor selection 34
- X1-pressure (max. current) adjust. 35
- Demanded power adjustment 36
- PID – Factor adjustment 37
- Storage new settings 38
Method C - With a laptop and BODEM software
- Starting the program 39 - 40
- Language selection 41
- Entering of the password 42
- Number of Motor selection 43
- X1-pressure (max. current) adjust. 44
- Demanded power adjustment 45 - 47
- PID – Factor adjustment 48
7.3 Hydraulic Constant Regulation System
7.3.1 General 49
7.3.2 X1-pressure adjustment (constant-pressure) 50
7.0
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Main Hydraulic Pumps Section 7.0
and Page 2
Pump Regulation System

7.0 Main hydraulic pumps and pump regulation system

Pump regulation system general

Legend for illustration (Z 22442):


(1 - 6) Main hydraulic pumps
(7.1) Pilot pressure pumps, motor 1
(7.2) Pilot pressure pumps, motor 2
(68.1) Pilot pressure filter unit
(70.1) 60 bar pressure relief valve
(70.2) 35 bar pressure relief valve
(Y17) Solenoid valve: "Idle time control and low hydraulic oil temperature"
Q-min flow for all main pumps
(Y17a) Solenoid valve: "Remote control pressure" ½ Q-max flow reduction
for all main pumps (low hydraulic oil temperature)
(Y102-1) Solenoid valve: "Pump regulation support pressure and pump bearing
lubrication"
(Y102-2) Solenoid valve:
"Pump regulation support pressure and pump bearing lubrication"
(81.1) Pressure reducing valve: "Remote control pressure" ½ Q-max flow re-
duction for the warming-up period
(81.2) Pressure reducing valve: "Pump regulation pressure X1 at hydraulic
pump regulation" (Hydraulic constant regulation mode)
(Y61-1) Proportional solenoid valve: "Pump regulation pressure X1 at electronic
pump regulation, motor 1" (Standard operation mode)
(Y61-2) Proportional solenoid valve: "Pump regulation pressure X1 at electronic
pump regulation, motor 1" (Standard operation mode)
(79.1) Change over valve: "Electronic or Hydraulic pump regulation", motor 1
(79.2) Change over valve: "Electronic or Hydraulic pump regulation", motor 2
7.0
3
Main Hydraulic Pumps Section 7.0
and Page 3
Pump Regulation System

7.0 Main hydraulic pumps and pump regulation system

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 of 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:

X1 – pump regulation pressure (0 – 24 bar):


The power controller of the main pumps can be remotely controlled by applying an ex-
ternal pilot pressure (X1 ) at port X LR to the spring chamber of the power control valve.
The start of destroking can be varied in proportion to the applied X1 - pressure.

X2 – pilot pressure (35 bar):


Constant pilot pressure to regulate the main pumps at special circumstances, e.g. to fix
pump # 3 in Q-max position (pump for swinging.)

X3 – remote control pressure (0 / 16 / 35bar):


Basic setting Q-min (0 bar), the flow rate increases with the
pilot pressure X3 at port Pst, up to Q-max (35 bar).
The hyperbolic power control is superimposed on the pilot pressure
signal and keeps the specified drive power constant. (p x Vg = constant).
The flow rates are:
Q-min.: X3 = 0 bar
½ Q-max.: X3 = 16 bar
Q-max.: X3 = 35 bar

X4 – pump support pressure (60 bar):


Constant pilot pressure to support the regulation function at low operating pressure and to
lubricate the main pump bearings.
7.0
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Main Hydraulic Pumps Section 7.0
and Page 4
Pump Regulation System

7.0 Main hydraulic pumps and pump regulation system

Pump regulation system general

Function:

Solenoid valve Y17: (33/7)*


If de-energized pumps #1-6 are in Q-min position. It gets energized as soon as one of
the control levers/pedals has been operated and de-energized when ever all controls
are in neutral position for more than 20 seconds.

Solenoid valve Y17a: (33/5)*


The solenoid is de-energized as long the hydraulic oil temperature is below the val-
ues of temperature range „T2“ (depending on the filled in hydraulic oil) shown in the
table. ( pumps #1-6 are in ½ Q-max. position)

Note: * Electric circuit diagram page / column (based on Id # 897 899 40)
7.0
5
Main Hydraulic Pumps Section 7.0
and Page 5
Pump Regulation System

7.0 Main hydraulic pumps and pump regulation system

Pump regulation system general

Function:

Proportional Solenoid valve Y61-1 and Y61-2: (40/2)*


This valves, connected to the MC7 micro-controller E32 (electronic pump regula-
tion), creates a X1-pressure depending on the load of the motor.
This X1-pressure is the information to reduce pump delivery, in order to keep the
motor at rated power.

Pressure reducing valve 81.1:


"Remote control pressure" (X3)
- ½ Q-max flow reduction during the warming-up period for all pumps by the
function of solenoid valve Y17a.
- ½ Q-max flow reduction only for pump #1 while swinging with max. speed by
the function of solenoid valve Y126.

Pressure reducing valve 81.2:


Pump regulation pressure X1 at "hydraulic pump regulation" (Hydraulic constant
regulation mode) by the function of change over valve (79.1 / 79.2). One valve for
both motors. This valve create a constant X1 pressure, the pressure can be change for
different pump regulation checks and adjustments.

Change over valve 79.1 and 79.2:


Change over three way cock valve to select "Electronic or constant regulation
mode", one for each motor.

Note: * Electric circuit diagram page / column (based on Id # 897 878 40)
7.0
6
Main Hydraulic Pumps Section 7.0
and Page 6
Pump Regulation System

7.1 Main Pumps

7.1.1. Location of Pumps


Legend for illustration (Z 22415b):
(1 - 6) Axial piston pump (swash plate type)
theoretical flow rate, each Qmax = 700 Liter/min
Drive speed* n = 1400 min-1
for all working motions pmax = 310 bar

(10.2), (10.4) Axial piston pump


theoretical flow rate Qmax = 142 Liter/min
Drive speed* n = 1770 min-1
for oil cooler fan drive pmax = 180 bar

(8.1), (8.4) Gear pump


theoretical flow rate Qmax = 82,2 Liter/min
Drive speed* n = 1400 min-1
for PTO gear lubrication pmax = 7,5 bar

(8.2), (8.5) Gear pump


theoretical flow rate Qmax = 82,2 Liter/min
Drive speed* n = 1400 min-1
for hydraulic oil circulation pmax = 15 bar

(7.1), (7.2) Gear pump


theoretical flow rate Qmax = 120 Liter/min
Drive speed* n = 1409 min-1
for pilot pressure supply pmax = 60 bar

) • * at 1500 min-1 input drive with electric motor speed


7.0
7
Main Hydraulic Pumps Section 7.0
and Page 7
Pump Regulation System

7.1 Main Pumps

7.1.2. Pump bearing flushing / lubrication


The installed main pumps are provided with an external cooling and lubrication system
for flushing of drive shaft bearing and shaft seal.
Oil supply is provided from the X4-pressure circuit.
To reach the restricted guidance of the coolant for external bearing flushing, the throt-
tle screw (located behind the union at port U) must screwed in all the way.
An information sign is fixed at the pump.

Legend for illustration (Z 22443):


(1 – 4) Main pumps
(147.1-147.6) Orifice (one for each main pump)
(33) Filter for pilot pressure
(P) Ports for X4-pressure (pump support pressure)
(U) Port for the pump bearing flushing / lubrication
7.0
8
Main Hydraulic Pumps Section 7.0
and Page 8
Pump Regulation System

7.1 Main Pumps

7.1.3 Operating Principles


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

Function and characteristics:


• The A4VSO variable displacement axial piston pump in swash plate design is
intended for drives in open circuit operation.
• The flow volume is proportional to the drive speed and the displacement. By
adjusting the swash plate a infinitely variable flow adjustment is possible.
• Pumps of the same nominal size can be built onto the trough drive. Combina-
tions with gear pumps are also possible.

Legend for illustration (Z 22446):


The lower illustration shows only a principle pump construction
(1) Drive shaft
(2) Cylindrical roller bearing
(3) Slipper pad
(4) Swivel angle indicator
(5) Positioning piston
(6) Swivel pin
(7) Cylinder with pistons
(8) Final connecting plate
(9) Cylindrical roller bearing
(10) Splints for the through drive coupling (Aux. pump drive)
(11) Swivel cradle
(12) Q-min stop bolt
(13) Power control valve
(14) Pressure balance valve
(15) Power curve correction
(16) Pressure cut off valve
(17) Q-max. stop bolt
(18) Remote control valve
continued
7.0
9
Main Hydraulic Pumps Section 7.0
and Page 9
Pump Regulation System

7.1 Main Pumps


7.1.3 Operating Principles
Cont'd:
Symbol of main hydraulic pump A4VSO 500 LR3DN / 30L
Legend for illustration (Z 22447):
(1) Main pump (swash plate pump, variable displacement)
(2) Pump bearing group
(3) Drive shaft
(4) Non return valves
(5) Remote control valve
(5.1) Mechanical stroke limitation*
(5.2) Remote pressure (PST) operated piston for item 6
(5.3) Mechanical stroke limitation*
(6) Spool valve (pressure balance valve)
(7) Nozzle
(8) Power control valve
(9) Nozzle
(10) Pressure cut-off valve
(11) Auxiliary pump (Gear pump, fixed displacement
(12) Positioning piston
(13) Slipper pad piston
(14) Lever
(15) Cam
(16) Through drive shaft

)
• * Factory side adjusted, no field adjustment required

B/B1 Pressure port


S Oil intake (suction port)
MB Operating pressure check point
Mst Control pressure check point
R(L) Filler and bleeder port
T, K1, K2 Connection port for chip indicator
P Pump support pressure (”X4”-pressure)
Pst Remote control pressure port (”X3”-pressure)
U Bearing flushing port
XLR Regulating pressure port (”X1”-pressure)
continued
7.0
10
Main Hydraulic Pumps Section 7.0
and Page 10
Pump Regulation System

7.1 Main Pumps


7.1.3 Operating Principles
Cont'd:

Sectional drawing of Power Controller LR3DN / 30L


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

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


7.0
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Main Hydraulic Pumps Section 7.0
and Page 11
Pump Regulation System

7.1 Main Pumps

7.1.3 Operating Principles, illustration (Z 21552a)


Cont'd:

Q-min position: (remember Q means volume)

When are the pumps in Q-min position?


A: Motor at standstill
B: Motor running and the controls are not used for 20 sec. or longer
at low operating temperature
C: Motor running and service switch S150 activated

Example C with the following conditions:


• Motor running
• Pump pressure lower as X4 = 60 bar (pump support pressure)
• X1 = 24 bar (pump regulation pressure), this pressure will not influence
the Q-min position under these conditions.
• X3 = 0 bar (remote control pressure); Y17 de-energized (S150 activated)
for pumps #1, #2 #4, #5, #6 and #3 except during swinging than the pump
is out of regulation and keeps in Qmax.
• X4 = 60 bar (pump support pressure)
Pump support pressure is present at valve #6, the slipper pad of
piston #13 and the small area side of the positioning piston #12

Response of pump control mechanism:


Valve #6 moves to position "b" because the X4-pressure will overcome the spring
force, since the oil behind nozzle (7) flows through valve #5 (which is in position
"a", due to the missing remote control pressure X3) back to tank.

Pump support pressure X4 passes valve #6 position "b" and flows via power control
valve #8 position "a" to the large area side of positioning piston #12.
Because the large area side of positioning piston #12 is approximately three times larger
as the small area side, the pump support pressure X4 of 60 bar present on both sides, re-
sulting in stronger force at the large area side, keeps the pump in Q-min position.

The pump remains in Q-min position


continued
7.0
12
Main Hydraulic Pumps Section 7.0
and Page 12
Pump Regulation System

7.1 Main Pumps


7.1.3 Operating Principles, illustration (Z 21553a)
Cont'd:

Q-max position: (remember Q means volume)


When does the pumps move into Q-max position?
Motor running
and hydraulic oil at normal operating temperature (> T2)
and the controls frequently used within 20 sec.
(or Service switch S151 activated)
and a pump pressure below start of de-stroking.

Example with the following conditions:


• Motor running
• Pump pressure between 60 bar and 300 bar, present at the slipper pad
of piston #13 and the small area side of the positioning piston #12
• X1 = 24 bar (pump regulation pressure)
• X3 = 35 bar (remote control pressure); Y17 and Y17a energized
for all six pumps.
• X4 = 60 bar (pump support pressure), present at valve #6.

Response of pump control mechanism:


Valve #6 moves to position "a" because the spring force is supported by the X4-
pressure, since the oil flow back to tank is blocked at valve #5 (which is in position
"b", due to the 35 bar remote control pressure X3).

The large area side of positioning piston #12 is connected, via power control valve
(8) position "a" and pressure balance valve (6) position "a", to the return oil line.

The pump moves into Q-max position, because the pump pressure acts only at the
small area side of positioning piston #12.

The pump moves into Q-max position

continued
7.0
13
Main Hydraulic Pumps Section 7.0
and Page 13
Pump Regulation System

7.1 Main Pumps

7.1.3 Operating Principles, illustration (Z 21554a)


Cont'd:

½ Q-max position: (remember Q means volume)


When does the pumps move into half Q-max position?
Motor running
and hydraulic oil below normal operating temperature (< T2)
and the controls frequently used within 20 sec.
(or Service switch S151 activated)
and a pump pressure below start of de-stroking.

Example with the following conditions:


• Motor running
• Pump pressure between 60 bar and 300 bar, present at the slipper pad
of piston #14 and the small area side of the positioning piston #13
• X1 = 24 bar (pump regulation pressure)
• X3 = 16 bar (remote control pressure); Y17 energized and Y17a de-
energized
for all six pumps.
• X4 = 60 bar (pump support pressure), present at valve #6.

Response of pump control mechanism:


Valve #6 moves to an intermediate position (in-between "a" and "b"), since a certain
amount of oil behind nozzle (7) flows through valve #5 (which is also in an interme-
diate position, due to the 16 bar remote control pressure X3) back to tank.

The large area side of positioning piston #12 is connected, via power control valve
(8) position "a" and pressure balance valve (6), to the return oil line.

The pump moves into ½ Q-max position, because the return oil flow through pres-
sure balance valve (6) is restricted (due to its intermediate position), resulting in a
pressure at the large area side of the positioning piston (12).

The pump moves into ½ Q-max position

continued
7.0
14
Main Hydraulic Pumps Section 7.0
and Page 14
Pump Regulation System

7.1 Main Pumps


7.1.3 Operating Principles, illustration (Z 21555a)
Cont'd:

Destroking: (Pump moves from Q-max. into of Q-min. direction)

When does the pumps start to destroke


Motor running
and hydraulic at normal operating temperature (> T2)
and Service switch S150 deactivated
and The hydraulic load is higher than the rated power of the motor.
⇒ (The electronic pump regulation system will reduce the X1-pressure)
or With pump pressure above ≈ 150 bar (Hydraulic constant regulation)
(Constant X1-pressure of approximately 8 bar)

Example with the following conditions:


• Motor running
• Pump pressure 260 bar adjustable at main relief valve, present at the slipper
pad of piston #13 and the small area side of the positioning piston #12
• X1 = 12 bar (constant regulation pressure adjustable at pressure reducing
valve 81.2) Change over valve (79.1 / 73.2) switched to hydraulic mode
• X3 = 35 bar (remote control pressure); Y17 energized and Y17a energized
• X4 = 60 bar (pump support pressure), present at valve #7.

Response of pump control mechanism:


Valve #6 moves to position "a" because the spring force is supported by the X4-
pressure, since the oil flow back to tank is blocked at valve #5 (which is in position
"b", due to the 35 bar remote control pressure X3).

The operating pressure (with the value for start of de-stroking) at the slipper pad of
piston #13 moves the power control valve (8) into position "b" (against the spring
force supported by the X1-pressure).
This in turn connects the operating pressure to the large area side of positioning pis-
ton #12.

Because the large area side of positioning piston #12 is approximately three times
larger as the small area side, the operating pressure present on both sides, resulting in
stronger force at the large area side, moving the pump in Q-min direction.

The pump de-strokes until the forces at positioning piston #12 are balanced

continued
7.0
15
Main Hydraulic Pumps Section 7.0
and Page 15
Pump Regulation System

7.1 Main Pumps


7.1.3 Operating Principles, illustration (Z 21556a)
Cont'd:

Pressure cut-off valve: (DR control valve, Pump moves into Q-min. position)

When is the pressure cut-off valve active?


Motor running
and With pump pressure above ≈ 300 bar

Example with the following conditions:


Motor running
Pump pressure 300 bar
X1 = 24 bar (pump regulation pressure)
X3 = 35 bar (remote control pressure)
X4 = 60 bar (pump support pressure)

Response of pump control mechanism:


Independent of the position of power control valve #8 the pressure cut-off valve #10
causes the pump to de-stroke to the pre-adjusted Q-min position.

The operating pressure moves the pressure cut-off valve #10 (at set pressure) into
position "b" and flows to the large area side of positioning piston #12.

Because the large area side of positioning piston #12 is approximately three times
larger as the small area side, the operating pressure present on both sides, resulting in
stronger force at the large area side, moving the pump in Q-min position.

The pump moves into Q-min position


7.0
16
Main Hydraulic Pumps Section 7.0
and Page 16
Pump Regulation System

7.1 Main Pumps

7.1.4 Checks / Adjustments

Location of Adjustments
Legend for , illustration (Z21557)
(1) Remote control valve
(2) Q-min. stop bolt
(3) Pressure balance valve
(4) Start of 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 screws (bolts)

location Length “L” (mm)


1 13.4
2 21.9
3 7,6
4 8.1
5 ----
6 6.0
7 27.6

) • The measurement "L" is an orientation only if the adjustment is to-


tally out of requirements.
They must not be used for final adjustments.
The detail for (5) shows the position of the housing edge and the edge
of the eccentric set bolt. The example shows them in parallel position
which is mostly not the case. The adjustment should never be altered.

Further information see next pages


7.0
17
Main Hydraulic Pumps Section 7.0
and Page 17
Pump Regulation System

7.1 Main Pumps

7.1.4 Checks / Adjustments

Pressure balance valve (Δ P 20bar), illustration (Z21558)

Pressure balance valve, illustration (Z 21558b)

• The pressure balance valve is bench adjusted. There is no field set-


ting with a sufficient result possible.

continued
7.0
18
Main Hydraulic Pumps Section 7.0
and Page 18
Pump Regulation System

7.1 Main Pumps

7.1.4 Checks / Adjustments


Cont'd:

Start of destroking(LR valve), illustration (Z21559)

The reason of this check is to make sure, the pump starts destroking at an operating
pressure of 150 bar with a pump regulation pressure X1 of 0 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 25 bar pressure gauge to respective pressure check point M20-1 or
M20-2 at the control and filter panel (X1-pressure).
3. Change over the respective three way cock to electronic regulation.
4. Unplug the respective proportional valve Y61.1 / Y61.2.
5. Insert an Allen key into the angle indicator bolt (see illustration) for better visi-
bility of the start of.
6. Start the respective motor. The X1-pressure should be 0 bar.
7. Stall the hydraulic for the pump to be checked and alter the operating pressure
with the MRV between 140 and 160 bar.
Start of de-stroking should be at an operating pressure of 150 bar, shown at the
gauge connected to the high pressure filter.

If readjustment is required proceed as follow:


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

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

continued
7.0
19
Main Hydraulic Pumps Section 7.0
and Page 19
Pump Regulation System

7.1 Main Pumps

7.1.4 Checks and Adjustments


Cont'd:

Pressure cut-off valve (DR control valve), illustration (Z21560)

The sense of this check is to make sure that the pump is in Q-min. position at an op-
erating pressure between 300 bar and 310 bar.

1. Connect a 400 bar pressure gauge to the pressure check point at the respec-
tive 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 de-stroking.
3. Start the respective motor, stall the hydraulic only for the pump to be
checked and alter the operating pressure with the respective MRV between
280 and 310 bar.
• Stall only one pump per motor to prevent an influence of the regula-
tion system..

Recommendation to stall the respective pump with FSA:


Pump 1 and 6: a) Unplug solenoid valve Y16 (park brake travel motor active)
b) Activate carefully the left travel motor with full pressed
pedal in one direction
Pump 3 and 4: a) Activate carefully the clam open function and keep it in final
position
Pump 2 and 5 a) Unplug solenoid valve Y16 (park brake travel motor active)
b) Activate carefully the right travel motor with fully pressed
pedal in one direction and keep it in this position.
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.
If readjustment is required proceed as follow:
a) Loosen lock nut #8.
b) Turn set bolt #9, so that the pump is in Q-min. at the required value.
c) Tighten lock nut #8.
5. Re-adjust the operating pressure at the MRV to 310+10 bar
6. Remove Allen key, gauges and plug in the unplugged plugs.
continued
7.0
20
Main Hydraulic Pumps Section 7.0
and Page 20
Pump Regulation System

7.1 Main Pumps


7.1.4 Checks and Adjustments
Cont'd:

Q-max. and Q-min. stop bolt, illustration (Z21561)

1. Unscrew box nut (10 or 14).


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

• Turning the Q-min. stop bolt too much out can cause serious damage
to the pump.
The pump moves over 0 (zero) position into the opposite drive direc-
tion: (suction line becomes pressure line and pressure line becomes
suction line)
7.0
21
Main Hydraulic Pumps Section 7.0
and Page 21
Pump Regulation System

7.2 Electronic Pump Regulation System

7.2.1 Electronic load limiting control - General, illustration (Z 22448)

The drive train of the excavator consists of two electric motors, 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 Z22407a shows the principle of the electronic load limiting control.
The MC7 (E32-1) processes the following input signals:
• Voltage (Pin 47) from electronic signal rectifier (A32)
• Current motor 1 (Pin 45) from electronic signal rectifier (A33-1)
• Current motor 2 (Pin 46) from electronic signal rectifier (A33-2)

The MC7 (E32-1) processes the following output signals:


• Signal value to control the proportional solenoid valve Y61-1 (Pin 28) Motor 1
• Signal value to control the proportional solenoid valve Y61-2 (Pin 30) Motor 2
• Switch signals (Pin 32 and 33), diagnostic of the MC7 (E32-1)

Each electric motor drives three variable displacement pumps by means of a PTO-
gearbox. Each pump is equipped with a hydraulic power controller (HPC).
This controller limits the input torque of the pump to an adjusted command value (X1-
pressure, for start of destroking).
The command value (X1-pressure) is present via proportional solenoid valves Y61-1 re-
spectively Y61-2 at the hydraulic power controllers of each pump.

) • The auxiliary hydraulic pumps and other consumers can be operated


without being directly affected by the load limiting control.

Function:
The ESR-Module (A32) transforms an AC Voltage, which is proportional to the net volt-
age, into a proportional DC Voltage and transfers it into the MC7 (E32-1).
The ESR-Module (A33-1 + A33-2) transforms an AC Voltage, which is proportional to the
respective motor current, into a proportional DC Voltage and transfers it also into the MC7
(E32-1).
These input signals are the information about the actual load to the motors and serves the
MC7 (E32-1)
The control algorithm of the load limiting control (MC7) always compares the actual re-
quired 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.
7.0
22
Main Hydraulic Pumps Section 7.0
and Page 22
Pump Regulation System

7.2 Electronic Pump Regulation System

7.2.2 Electronic Power Module EPM, illustration (Z 22624b)

The power – Module A31a transforms the 24 VDC battery voltage into posi-
tive/negative 15 VDC and the power Module A31b into positive 5 VDC which is the
supply voltage for the ESR Modules.

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 Power
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 Power
Modules 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 ei-
ther 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 Power
Module, the Module is defect.
7.0
23
Main Hydraulic Pumps Section 7.0
and Page 23
Pump Regulation System

7.2 Electronic Pump Regulation System

7.2.3 Electronic Signal Rectifier ESR – Modules, illustration (Z 22625a)


Function:
The ESR-Module transforms an AC signal-voltage, which is proportional to the net-
work voltage respectively the motor current, into a proportional DC Voltage and trans-
fers it into the MC7.

Testing the ESR-Module, A32 + A33.1 + A33.2

Testing the ESR input/output voltage


For a transformer function test the AC-Input Voltage and the
DC-Output Voltage must be measured and compared.

• 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.

Procedure: Same procedure for all three Modules

1. Disconnect the wire from terminal 23 of the ESR Module.

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.

5. The measured DC-Voltage must be 1/4 of the AC-Voltage.

Example: 2.5 VDC


________ = 1/4 = 0,25 (1 % plus/minus is ok)
10 VAC

Small variations are based on amplitude variations of the AC-Input voltage while
measuring the DC-Output voltage.
Greater variations denotes a faulty ESR Module.

continued
7.0
24
Main Hydraulic Pumps Section 7.0
and Page 24
Pump Regulation System

7.2 Electronic Pump Regulation System

7.2.3 Electronic Signal Rectifier ESR – Modules, illustration (Z 22626a)


Cont'd:

The DC-Output Voltage (UaDC ) can be compared with a calculated Voltage Value.
The calculation can be done with the ratios of the intermediate transformers given in
the circuit diagram, and by the Voltmeter and Ammeter readings of the cab gauges.

) • 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.

EXAMPLE FOR ESR 1:


U 6570 V
ESR1 ----------------- --------------- = 2,488 VDC Voltage
T1 x T2 x T3 66 x 10 x 4

EXAMPLE FOR ESR 2:


I 80 A
ESR2 ----------------- ----------------- = 1,333 VDC Current Motor 1
T1 x T2 x T3 30 x 0.5 x 4

EXAMPLE FOR ESR 3:


I 75 A
ESR3 ----------------- ----------------- = 1,25 VDC Current Motor 2
T1 x T2 x T3 30 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.

EXAMPLE FOR ESR 2:


I 80
ESR2 ----------- ----------- = 5,333 VDC
T1 x T2 30 x 0.5
7.0
25
Main Hydraulic Pumps Section 7.0
and Page 25
Pump Regulation System

7.2 Electronic Pump Regulation System

7.2.4 Microcontroller MC7, illustration (Z 21716)


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 over-voltage and electrical
interference.
As output signals, the output stages of the MC7 deliver closed loop controlled currents
for the connection of proportional solenoids.
The analog voltage output is suitable for the simple forwarding of analog information to
other electronic circuits.
Characteristics
• Closed loop control of solenoid currents, i.e. independent of voltage and temperature.
• Pulse width modulated (PWM) solenoid currents for minimal hysteresis.
• Internal buzzer for programmable monitoring of functions or errors.
Setting and Display Facilities
All calibration operations and the display of functions, faults and system variables are con-
nected via the serial interface to the BB-3 control panel or to a PC running the BODEM
software.
MC7 - Unit Dimensions

Plug Contacts

8 junior power timer contacts


47 micro timer I contacts
MC7 - Block Circuit Diagram
7.0
26
Main Hydraulic Pumps Section 7.0
and Page 26
Pump Regulation System

7.2 Electronic Pump Regulation System

7.2.5 Checks and adjustments General


Microcontroller MC7, illustration (Z 21714c)

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 inter-
face X13-1 (located in the operators cab)
or
C. With a laptop, running the BODEM software, connected to the serial inter-
face X13-1 (located in the operators cab)

) • Procedure B and C should only be carried out by authorized person-


nel. [ Dealer or KMG-factory staff ]
Because it is possible to influence the behavior of the pump regulation
system.
On the following pages are only the necessary setups described.
If additional information is required, please contact KMG-Service de-
partment.
7.0
27
Main Hydraulic Pumps Section 7.0
and Page 27
Pump Regulation System

7.2 Electronic Pump Regulation System

7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22628)


Method A - X1-pressure adjustment
with 24V supply to separating terminals at the X2-panel.
Pre-conditions: Normal operating temperature, correct pilot pressure setting and the
system must be free of air.

1. Make sure the change over valves (79.1 – motor 1 respectively 79.2– motor 2) are in
position “Electronic Pump Regulation”
2. Connect a pressure gauge to the respective check points (M20.1 or M20.2), 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 applying terminal for propor-
tional solenoid valve Y61-1 or Y61-2 as follows:
Motor1 →Y 61-1 → No connection to 24V required.
Motor2 →Y 61-2 → Connect permanent 24V to terminal 53, using a test lead.
5. Adjusting the X1-pressure:
Start the respective motor.
Read the pressure, required = 24± 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
7.0
28
Main Hydraulic Pumps Section 7.0
and Page 28
Pump Regulation System

7.2 Electronic Pump Regulation System

7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22629a)


Cont'd:
Method A - Demanded power adjustment
Pre-conditions: Normal operating temperature, correct pilot pressure setting and the
system must be free of air.

) • The adjustment has to be carried out separately for each motor

1. Connect pressure gauges to check points M12.1, M12.2, M12.3 and M12.4 at the
high pressure filters.
2. Connect pressure gauges to the X1 pressure check points M20.1 and M20.2.
3. Unplug solenoid valves Y6a-1, Y6b-1 and Y6a-2, Y6b-2 to ensure that the hy-
draulic oil cooler fans are running with maximum speed.
4. Start main motor of the circuit to be adjusted.
5. Set the MRV individually to approx. 120 bar *, to prevent the motors from over-
loading during the adjustment.
6. Shift the three way cock valves (79.1 and 79.2) to position “Hydraulic (con-
stant) Regulation Mode”.
7. Set the X1-pressure at pressure reducing valve (81.2) > 25 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 final stop
position and keep it fully under load), and increase the pressure at all 4 MRV’s *
equally to 212 bar.
Expected motor current at 3 times 212 bar ≅ 88 Ampere (reading of text display)
(peak point).
Record this current for other tests.

)
• If the motor current is lower respectively the operating pressure is
higher than required there is probably not the full volume available.

*Altering the MRV-Setting:


− Remove dust cap (a).
− Loosen lock nut (b).
− Turning the set screw (c) cw the pressure will increase.
− Turning the set screw ccw the pressure will decrease.

**Altering the X1-Setting:


− Loosen the lock nut (e).
− Turning the set screw (f) cw the pressure will increase.
− Turning the set screw ccw the pressure will decrease.
continued
7.0
29
Main Hydraulic Pumps Section 7.0
and Page 29
Pump Regulation System

7.2 Electronic Pump Regulation System

7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22629a)


Cont'd:

Method A - Demanded power adjustment


1. Store the demanded power (peak point) into the MC7 as follows:
a) Activate the adjusting mode:
Connect 24V, simultaneously to terminal 54 and 55 for 10 seconds, using test
leads and disconnect the voltage thereafter.
b) Select the demanded power adjusting mode of Motor 1:
Connect 24V, simultaneously to terminal 50 and 52 permanent.
c) Select the demanded power adjusting mode of Motor 2:
Connect 24V, simultaneously to terminal 50, 52 and 53 permanent.
d) Stall the hydraulic with the values of item 8 (Peak point)
3 times ≅ 212 bar => ≅ 88 Ampere (each motor) (all pumps Q-max position
and cooler fans with max. speed).
e) Save the actual measured power:
Connect 24V to terminal 55 for 1 second and disconnect the voltage thereafter.

) • The actual measured power will be saved immediately as the de-


manded power
2. Re-set the X1-pressure at pressure reducing valves (81.2) as recorded**.
3. Shift the three way cock valves (79.1 and 79.2) to position “Electronic Regulation
Mode”
4. Reset the MRV’s to 310 bar+5bar , and remove the gauges.
5. After the adjustments are finished, remove the test leads and pressure gauges, stop
the motors and turn the main key switch in OFF position to deactivate the adjusting
mode.

*Altering the MRV-Setting:


− Remove dust cap (a).
− Loosen lock nut (b).
− Turning the set screw (c) cw the pressure will increase.
− Turning the set screw ccw the pressure will decrease.

**Altering the X1-Setting:


− Loosen the lock nut (e).
− Turning the set screw (f) cw the pressure will increase.
− Turning the set screw ccw the pressure will decrease.
continued
7.0
30
Main Hydraulic Pumps Section 7.0
and Page 30
Pump Regulation System

7.2 Electronic Pump Regulation System


7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22636)
Cont'd:
Method A - PID - Factor adjustment to obtain the most efficient pump
regulation characteristic.
Pre-conditions: Normal operating temperature, correct pilot pressure setting and the
system must be free of air.
• With the PID-Factor adjustment (proportional, integral and differen-
) tial factors) it is possible to influence the regulation dynamics.
• The PID-Factor adjustment range is between 80 % and 120 %
• The voltage at the analogue output (terminal 60) represents the actual
adjusted value. (80 % = 0VDC / 100 % = 2,5VDC / 120 %= 5VDC)
• This factor is multiplied with all PID parameters.

1. Jerky movements while lifting and swinging at the same time:


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)
d) Reduce the voltage in steps of 250mV until the system works smoothly, by
connecting 24V to terminal 55. (As close as possible to the boarder line)

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 connect-
ing 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 ad-
justing mode.
7.0
31
Main Hydraulic Pumps Section 7.0
and Page 31
Pump Regulation System

7.2 Electronic Pump Regulation System


7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22357a)

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 Regu-
lation”
2. Connect a pressure gauge to check point (respective M20-1, M20-2 ), using a
long pressure gauge hose to be able reading the pressure inside the operators
cab.
3. Connect the electronic service tool (BB-3) to the data link adapter X13,
with key switch (S1) in OFF position.
4. Turn key switch (S1) in ON position:
After switching on the power for the Control panel BB-3 the following functions
are carried out and shown on the display:
4.1 Self-test and baud rate recognition:
The BB-3 automatically recognizes the rate
of data transmission from the MC electronics.
4.2 Identification:
On recognition of the MC electronics the
relevant software in the BB-3 will be started up.
4.3 Main menu:
Initialization of remote control unit BB-3 is complete.
One of the four main menu items can be selected using the given keys.
First screen (main menu) after connection and Key switch turned ON in German.

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
7.0
32
Main Hydraulic Pumps Section 7.0
and Page 32
Pump Regulation System

7.2 Electronic Pump Regulation System

7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22357a)

Cont'd:
Method B Language selection

Press button 2 The language will change to English


and the display show the main menu

1. Deutsch
2 2. English
3. - - -
4. - - -

One of the four main menu items can be selected using the given keys.
7.0
33
Main Hydraulic Pumps Section 7.0
and Page 33
Pump Regulation System

7.2 Electronic Pump Regulation System

7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22357a)

Method B - A: Adjustment mode SET 1 and SET 2

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.

Main display SET 1 Main display SET 2


Standard after start up Only with password

F1 Config/Cal. F1’ Config/Cal.


F2 Diagnostic F2 Diagnostic
PROC Status PROC Status
TE ACH Storage TE ACH Storage

Change from SET 1 to SET 2:

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 (5 7 0 8 7 5)
?: _
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.
continued
7.0
34
Main Hydraulic Pumps Section 7.0
and Page 34
Pump Regulation System

7.2 Electronic Pump Regulation System

7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22357a)

Method B - Number of motor selection:

Activate adjustment mode SET 2 as


described on page 65
F1’ Config/Cal.
F2 Diagnostic
Press F1 Config/Cal
PROC Status
TE ACH Storage

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 ––

Select desired number of motors 2 No of motors

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

Save setting to the EEPROM of the MC7 as described at page 75.

continued
7.0
35
Main Hydraulic Pumps Section 7.0
and Page 35
Pump Regulation System

7.2 Electronic Pump Regulation System

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

Method B

X1-Pressure (maximum current) Adjustment:

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 65.

1 Demand Power
Press
2 Max current 2
3
Max current
PID - Factor
4 Error Lamp
Select desired valve

Press 1 Valve 1, Motor1


1
2
Valve
Valve
1
2
Mot.
Mot.
1
1
or 3 Valve 1 Mot. 2
Press
3 Valve 1, Motor2 4 Valve 2 Mot. 2

Example Motor 1, Valve1 1 Valve 1 Mot. 1


0 – 100±1
71
Start the respective motor. Do not load the motor.
Check the X1-pressure with a pressure gauge and set
it to the desired value by:
1 Valve 1 E1
0 – 100±1
pressing or 78

1 Valve 1 Mot. 1
Press ENTER Accept tion 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

Save setting to the EEPROM of the MC7 as described at page 75.


continued
7.0
36
Main Hydraulic Pumps Section 7.0
and Page 36
Pump Regulation System

7.2 Electronic Pump Regulation System

7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22357)a

Method B -
Demanded power adjustment:

Cont'd:
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 2 as described on page 65.
1 Demand Power
2 Max current
Press 1 Configuration
3 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
4 Demand power 2
Press
2 demand power Motor2

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 Starting Function ended


Saved

Press <ENTER>

Press ENTER Confirm


F1 Config/Cal.
F2 Diagnostic
Press. 2 x MENU Return to main menu PROC Status
TE ACH Storage

Save setting to the EEPROM of the MC7 as described at page 75.


continued
7.0
37
Main Hydraulic Pumps Section 7.0
and Page 37
Pump Regulation System

7.2 Electronic Pump Regulation System

7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22357a)

Method B
Cont'd:
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 2 as described on page 65.

SET 1 1 Demand Power


Press 3 PID-Factor. 2
3
Max current
PID-Factor
4 Error Lamp

1 PID-Factor
Press
1 PID-Factor. 2
3
–––
–––
4 –––

Adjust the PID-Factor


1 PID-Factor
by pressing . 80–120±1%
or 100

1 PID-Factor
2 –––
Press ENTER Acception 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

Save setting to the EEPROM of the MC7 as described at page 75.


continued
7.0
38
Main Hydraulic Pumps Section 7.0
and Page 38
Pump Regulation System

7.2 Electronic Pump Regulation System

7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22357a)

Method B

Cont'd:
Storage all new settings to the MC7:
This menu item permits storage of all edited parameters to the EEPROM
of the MC electronics
.
F1 Config/Cal.
Press TEACH Activate storage menu F2 Diagnostic
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 gauge.
7.0
39
Main Hydraulic Pumps Section 7.0
and Page 39
Pump Regulation System

7.2 Electronic Pump Regulation System

7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22358a)

Method C - With a laptop computer and BODEM software connected to the


serial interface X13 (located in the operators cab)
Starting the program
Pre-conditions: Normal operating temperature, correct pilot pressure set-
ting and the system must be free of air.
1. Connect the laptop computer to the data link adapter X13,
with key switch (S1) in OFF position.
2. Make sure that the dongle is connected to the laptop computer. If not

3. Turn key switch (S1) in ON position.


4. Start the computer.
5. Click on the Bottom - icon to start the program.

continued
7.0
40
Main Hydraulic Pumps Section 7.0
and Page 40
Pump Regulation System

7.2 Electronic Pump Regulation System

7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22358a)

Method C, Starting the program


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

7. Open menu FILE → INTERFACE , select the required interface connection


(Standard COM1), confirm with OK and leave the program.

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 hard-
ware and software information.
7.0
41
Main Hydraulic Pumps Section 7.0
and Page 41
Pump Regulation System

7.2 Electronic Pump Regulation System

7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22358a)

Method C

Language selection

Open menu FILE → Language , select the required language and confirm with OK .
7.0
42
Main Hydraulic Pumps Section 7.0
and Page 42
Pump Regulation System

7.2 Electronic Pump Regulation System

7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22358a)

Method C

Entering of the password:

) • The password is only required to adjust the number of valves or en-


gines and for fine tuning of special regulation parameters. All other
adjustments are possible without the password.

Open menu Parameters and select Enter password.... Write the correct password and con-
firm with OK. (Password 570875)

) • After entering a correct password and confirming with OK the BODEM


software start a new upload from the MC7 memory to the PC.
7.0
43
Main Hydraulic Pumps Section 7.0
and Page 43
Pump Regulation System

7.2 Electronic Pump Regulation System

7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22358a)

Method C
Cont'd:
Number of Motor selection:
Pre condition: The correct password was entered as described on page 83.
Open Parameters and select Display / Edit Parameters. Then select in the left window
Configuration. Now on the right side there two pull down menus.
Example: select for PC 5500 1 valve per motor and 2 Motors.
Write new setting permanent to the MC7 EEPROM with Apply and confirm with OK.
7.0
44
Main Hydraulic Pumps Section 7.0
and Page 44
Pump Regulation System

7.2 Electronic Pump Regulation System

7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22358a)

Method C

X1-Pressure (maximum current) Adjustment:


Make sure the change over valve is in position “Electronic Pump Regulation”
Connect a pressure gauge to the respective check point (M20-x), using a long pressure gauge
hose to be able reading the pressure inside the operators cab.
Open menu Parameters select Display/Edit parameters and Max current,
start respective motor without load and wait 30 sec.. The X1-pressure will raise to the max.
adjusted value. If necessary adjust the required pressure (according to the final test report or
hydraulic diagram) with the respective slide bar. (Valve 1 Mot. 1 is the X1-1 pressure and
Valve 1 Mot. 2 the X1-2 pressure).
Write new setting permanent to the MC7 EEPROM with Apply and confirm with OK.
7.0
45
Main Hydraulic Pumps Section 7.0
and Page 45
Pump Regulation System

7.2 Electronic Pump Regulation System

7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22360a)

Method C

Demand power adjustment:

) • The adjustment has to be carried out separately for each motor

Pre-conditions: Normal operating temperature, correct pilot pressure setting and the sys-
tem must be free of air.

Open menu Parameters and in the pull down window the menu point Display / Edit Pa-
rameters.... Now the window with the demand power adjustment will be on screen.

Screen with password Screen without password.


The demand power adjustment is possible both modes.

continued
7.0
46
Main Hydraulic Pumps Section 7.0
and Page 46
Pump Regulation System

7.2 Electronic Pump Regulation System

7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22360a)


Cont'd:

Method C

Demand power adjustment:

) • The adjustment has to be carried out separately for each motor

Pre-conditions: Normal operating temperature, correct pilot pressure setting and the
system must be free of air.

1. Connect pressure gauges to the high pressure check points at the high pres-
sure filters. (M12.1, M12.2, M12.3 and M12.4)
2. Connect pressure gauges to the X1 pressure check points (M20.1 and M20.2).
3. Unplug fan control solenoid valves (Y6a-1, Y6b-1 and Y6a-2, Y6b-2) to ensure
that the hydraulic oil cooler fans are running with maximum speed.
4. Shift the three way cock valves (79.1 and 79.2) to position “Hydraulic (constant)
Regulation Mode”.
5. Start one motor.
6. Set the X1-pressure at pressure reducing valve (81.2) > 25 bar **, to ensure that
the pumps remain in Q-max. flow position during the adjustment.
7. Apply max. load to all pumps (e.g. extend the bucket cylinders to the stop posi-
tion 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 (PC5500,
S/N 15016 = 212 bar). Check the current drawn of the respective motor at this
stage (reading of text display)
Expected approx. ~ 88 Ampere. Record this values for other tests.

*Altering the MRV-Setting:


− Remove dust cap (a).
− Loosen lock nut (b).
− Turning the set screw (c) cw the pressure will increase.
− Turning the set screw ccw the pressure will decrease.

**Altering the X1-Setting:


− Loosen the lock nut (e).
− Turning the set screw (f) cw the pressure will increase.
− Turning the set screw ccw the pressure will decrease.
continued
7.0
47
Main Hydraulic Pumps Section 7.0
and Page 47
Pump Regulation System

7.2 Electronic Pump Regulation System


7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22360a)

Cont'd:
Method C Demand power adjustment:

8. Select Execute... of menu point Set demand m. 1 for motor 1 or


Set demand m. 2 for motor 2.
Select Start to set the actual power as demand power. Confirm with OK. The
new actual demand power will be only shown after a new upload of the MC7
settings. Exit the BODEM software and start again.
9. Stop motor and repeat from item 5 for the second motor.
7.0
48
Main Hydraulic Pumps Section 7.0
and Page 48
Pump Regulation System

7.2 Electronic Pump Regulation System

7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22358a)


Cont'd:

PID Factor adjustment: Method C


to obtain the most efficient pump regulation characteristic.
Pre-conditions: Normal operating temperature, correct pilot pressure setting and the
system must be free of air.
• With the PID-Factor adjustment (proportional, integral and differen-
) tial factors) it is possible to influence the regulation dynamics.
• This factor is multiplied with all PID parameters.
• Only one factor / adjustment for both motors

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 possi-
ble to the boarder line)
2. Now reduce the PID-Factor in short steps until the system works smoothly
again.
7.0
49
Main Hydraulic Pumps Section 7.0
and Page 49
Pump Regulation System

7.3 Hydraulic Constant Regulation System

7.3.1 General
The pilot pressure pumps ( 7.1 and 7.2) deliver the oil through the pressure filter
(68.1) to port A of the pressure relief valve (70.1) for limiting the pump support
pressure X4 to 60 bar. By the function of pressure reducing valve (70.2), the X4
pressure of 60 bar is reduced to the pilot pressure X2 of 35 bar. The common X2
pressure will be reduced by the function of pressure reducing valves ( 81.2 ) to the
necessary constant X1 pressure, to prevent the motors from overloading.

) • For testing purposes the pump regulation system can be changed to


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

Legend for illustration (Z 22442a):


(1 - 3) Main hydraulic pumps (driven by Motor 1)
(4 - 6) Main hydraulic pumps (driven by Motor 2)
(7.1) Pilot pressure pump (driven by Motor 1)
(7.2) Pilot pressure pump (driven by Motor 2)
(68.1) Pilot pressure filter unit
(70.1) Pressure relief valve 60 bar (X4)
(70.2) Pressure reducing valve 35 bar (X2)
(81.1) Pressure reducing valve: "½ Qmax , remote control X3 pressure”
(81.2) Pressure reducing valve: "Pump regulation pressure X1 at hydraulic
constant regulation mode "
(Y61-1) Proportional solenoid valve: "Pump regulation pressure X1 at electronic
operation mode" (Standard mode Motor 1)
(Y61-2) Proportional solenoid valve: "Pump regulation pressure X1 at electronic
operation mode" (Standard mode Motor 2)
(79.1) Change over valve: "Electr. or Hydr. pump regulation" Motor 1
(79.1) Change over valve: "Electr. or Hydr. pump regulation" Motor 2
7.0
50
Main Hydraulic Pumps Section 7.0
and Page 50
Pump Regulation System

7.3 Hydraulic Constant Regulation System

7.3.2 X1-pressure adjustment (constant-pressure), illustration (Z 22639a)


1. Connect pressure gauges to check points M12.1, M12.2, M12.3 and M12.4 at
the high pressure filters.
2. Connect pressure gauges to the X1 pressure check points M20.1 and M20.2.
3. Unplug solenoid valves Y6a-1, Y6b-1 and Y6a-2, Y6b-2 to ensure that the hy-
draulic oil cooler fans are running with maximum speed.
4. Shift the three way cock valves (79.1 and 79.2) to position “Hydraulic (constant)
Regulation Mode”.
5. Start motor 1.
6. Set the X1-pressure at pressure reducing valve (81.2) to approx. 3 bar **
7. 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 260bar.
8. Check the current drawn of motor 1 at this stage (reading of text display)
Expected approx. .. ≅ 70±5 Ampere. If necessary adjust the X1-pressure at pres-
sure reducing valve (81.2) . Record this values for other tests.
9. Stop motor 1 and start motor 2 .
10. Apply max. load to all pumps (e.g. extend the bucket cylinders to the stop position
until the hydraulic system stalls), and set the pressure at all 4 MRV’s * equally to
260 bar.
11. Check the current drawn of motor 2 at this stage (reading of text display)
The current of motor 1 should be approx. ≅ 70±5 Ampere depend on the setting
of motor 1. There is only one valve (81.2) for both motors.
12. Shift the three way cock valves (253.1 and 254.1) to position “Electronic regulation“.
13. Plug on the unplugged solenoid valve.
14. Reset the MRV’s * to 310 bar+5bar , and remove the gauges.

) • The adjustment has to be carried out separately for each motor

*Altering the MRV-Setting:


− Remove dust cap (a).
− Loosen lock nut (b).
− Turning the set screw (c) cw the pressure will increase.
− Turning the set screw ccw the pressure will decrease.

**Altering the X1-Setting:


− Remove dust cap (d).
− Loosen the lock nut (e).
− Turning the set screw (f) cw the pressure will increase.
− Turning the set screw ccw the pressure will decrease.

04.01.07 rev.2 PC5500-6-E_Sec_7-0_15016E_rev2.doc


04.01.07 rev.2 PC5500-6-E_Sec_7-0_15016E_rev2.doc
Operating Hydraulic Section 8.0
Page 1

Table of contents section 8.0


Section Page
8.0 Operating Hydraulic
General 2
8.0.1 Floating function of boom and stick cylinders 3+4

8.1 Hydraulic for the attachment cylinder FSA and BHA

8.2 Hydraulic for the swing circuit

8.3 Hydraulic for the travel circuit

01.04.03 PC5500-6_Sec_8-0_rev1.doc
8.0
&2

01.04.03 PC5500-6_Sec_8-0_rev1.doc
Operating Hydraulic Section 8.0
Page 2

8.0 General
Overall view of the Hydraulic system, illustration (Z 21955):
(1 – 6) Main pumps
(7) High pressure filters
(8) Main control blocks
(9) Distributor manifold
(10) Attachment cylinders
(11) Swing motors
(12) Rotary joint
(13) Travel motors

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

Function:

F •

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

01.04.03 PC5500-6_Sec_8-0_rev1.doc
8.0
&3

01.04.03 PC5500-6_Sec_8-0_rev1.doc
8.0
&4

8.0 General
Cont'd:

8.0.1 Floating function of boom and stick cylinders FSA:


illustration (Z 22568):
The Excavator (only front shovel attachment) operates automatically with the float
position for boom and stick activated.
That means the lowering movement of boom and stick is always done in the float
position.
For deactivation of the float position, two push buttons are installed:
a) S95 in the right joy stick (E19) for the Boom function
b) S95a in the left joy stick (E20) for the Stick function
Press the respective button and keep it depressed as long as the float position shall
be deactivated.
When releasing the button the float position is activated again.

Function:
There are different main valve spools in the three main valve blocks (14, 15 and
16) for boom and stick installed. Only by lowering of the boom or retracting of the
stick is the floating function active if the button on the lever is not pushed. The
piston and rod side of the respective cylinders are in floating position direct
connect to the return line (tank). The pressure free pump circulation is still active
there is no pump pressure to the respective cylinders. By external force the
cylinder can move up or down with negligible hydraulically resistance.

In floating position of the boom only valve spool 4 of main valve block I and 2 of
block III active.
In floating position of the stick only valve spool 2 of Main valve block I and 4 of
block III active.
To push down the boom or retract the stick by hydraulically force the respective
button on the lever must by activated.
S98 for the Stick cylinders
S95 for the Boom cylinders
In normal operation mode (i.e. float position) the piston side, the rod side and the
tank are connected together when lowering the boom or retracting the stick.
If a pressurised lowering of the boom or retracting of the stick cylinders is
required the connection of piston side, rod side and tank must be disconnected and
the rod side must be connected to the pump pressure. This is done by
disconnecting the respective special floating valve spool and activating the
respective standard valve spool. Now pressurised pump oil can flow to the
cylinder rod side.

01.04.03 PC5500-6_Sec_8-0_rev1.doc
8.0
&4

01.04.03 PC5500-6_Sec_8-0_rev1.doc
Operating Hydraulic Section 8.0
Page 4

Boom:
S95 ON K160 ON Float position deactivated

A10 deactivated Floating spool block I section 4 off


A10A activated Standard spool block II section 3 ON

S95 OFF K160 OFF Float position activated

A10 activated Floating spool block I section 4 ON


A10A deactivated Standard spool block II section can be on or off

Stick:
S98 ON K170 ON Float position deactivated

A8B deactivated Floating spool block III section 4 off


A8A activated Standard spool block II section 4 ON

S98 OFF K170 OFF Float position activated

A8B activated Floating spool block III section 4 ON


A8A deactivated Standard spool block II section can be on or off

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

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Attachment Cylinders Page 1

Table of contents section 8.1


Section Page
8.1 Hydraulic for the attachment cylinder FSA and BHA
8.1.1 Electric / Hydraulic Flowchart Boom raising 2+3
8.1.2 Electric / Hydraulic Flowchart Boom lowering 4+6
8.1.3 Electric / Hydraulic Flowchart Stick extending 7+8
8.1.4 Electric / Hydraulic Flowchart Stick retracting 9 + 11
8.1.5 Electric / Hydraulic Flowchart Bucket filling (curl) 12 + 13
8.1.6 Electric / Hydraulic Flowchart Bucket emptying 14 + 15
8.1.8 Electric / Hydraulic Flowchart Clam opening 17
8.1.9 Electric / Hydraulic Flowchart Clam closing 18
8.1.10 Checks and adjustments of the 19 + 20
Main Relief Valves (Primary valves)
8.1.11 Checks and adjustments of the
Service Line Relief Valves (Secondary valves)
Boom cylinder piston side FSA + BHA 21 + 22
Boom cylinder piston rod side FSA + BHA 23 + 24
Stick cylinder piston side FSA 25 + 26
Stick cylinder piston side BHA 27 + 28
Stick cylinder piston rod side FSA 29 + 31
Stick cylinder piston rod side BHA 32 + 33
Bucket cylinder piston side FSA 34 + 35
Bucket cylinder piston side BHA 36 + 37
Bucket cylinder piston rod side FSA 38 + 39
Bucket cylinder piston rod side BHA 40 + 41
Clam cylinder piston rod side FSA 42
Clam cylinder piston side FSA 43

8.1.12 Checks and adjustments for the lowering speed. 44


General: Flow Restrictors
Boom cylinder FSA (Float position activated / deactivated) 44 + 46
Boom cylinder BHA 47
Stick cylinder FSA (Float position activated / deactivated) 48 + 49
Stick cylinder BHA 50
Bucket cylinder FSA 51
Bucket cylinder BHA 52
Clam cylinder 53
8.1.13 Checks for the valve control logic. 54

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8.1.1 Electric / Hydraulic flowchart “ Boom raising ” FSA

Legend for illustration (Z 22493):


(E19) Control lever (Joy stick)
(D32) Time relay – Pilot control: Neutral position monitoring
(Y-) Direction (axis) of joy stick
(-10V) Signal voltage (Maximum)
(gn) Color code of signal voltage cable ( Joy stick)
(X2...) Terminal rail with number
(E49) Ramp time module
(A10) Amplifier module – Boom
(A10A) Amplifier module – Boom
(A10B) Amplifier module – Boom
(K79) Relay – pilot control:
Contacts 8 / 12 only closed while lifting the boom.
(K160) Relay – Floating control:
Contacts 2 / 10 closed auto floating active .
(K80) Relay – pilot control:
Contacts 2 / 10 open while bucket filling (priority function).
(K76A) Relay – pilot control:
Contacts 2 / 10 open while stick extending (priority
function).
(45.1 – 45.3) Remote control valves
(Y23, Y26, Y29) Proportional solenoid valve
(Y23a, Y26a, Y29a) Directional solenoid valve
(I – III) Main control blocks I – III

Electrical signal flow (EURO control).


Signal voltage of joy stick (E19) arrives via ramp time module (E49) and the
relay contacts (K79, K160) at terminal 5 of the three amplifier modules (A10,
A10a and A10b) and further to the proportional and directional solenoid valves
of the remote control blocks (45.1, 45.2, and 45.3).
Hydraulic signal flow. (pilot pressure)
When the respective proportional and directional solenoid valves are energized
pilot pressure oil flows to the pilot pressure ports of the main control blocks.
Hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (I to IV)
and arrives via the distributor manifold at the hydraulic cylinders.

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8.1.1 Electric / Hydraulic flowchart “ Boom raising ” BHA

Legend for illustration (Z 22471):


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

Electrical signal flow (EURO control).


Signal voltage of joy stick (E19) arrives via ramp time module (E49) at
terminal 5 of the amplifier modules (A10 to A10b) and further to the
proportional and directional solenoid valves of the remote control blocks (45.1,
45.2, 45.3).
Hydraulic signal flow. (pilot pressure)
When the proportional and directional solenoid valves are energized pilot
pressure oil flows to the pilot pressure ports of the main control blocks.
Hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (I to III)
and arrives via distributor manifold at the hydraulic cylinders piston side.
The piston extend and the boom move up.

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

Legend for illustration (Z 22530):


(E19) Control lever (Joy stick)
(D32) Time relay – Pilot control: Neutral position monitoring
(+Y) Direction (axis) of joy stick
(+10V) Signal voltage (Maximum)
(gn) Color code of signal voltage cable ( Joy stick)
(X2...) Terminal rail with number
(E49) Ramp time module
(A10) Amplifier module – Boom
(A10A) Amplifier module – Boom
(A10B) Amplifier module – Boom
(K76A) Relay – pilot control:
Contacts 6 / 10 open while extending the stick.
(K79) Relay – pilot control:
Contacts 6 / 10 open while filling the bucket.
(K80) Relay – pilot control:
Contacts 8 / 12 closed while moving the boom up.
(K160) Relay – pilot control:
Contacts 2 / 10 closed and 5 / 9 open while auto floating on.
(K207C) Relay – pilot control:
Contacts 5 / 9 closed while warming up hydraulic oil (S205).
(45.1 – 45.3) Remote control valves
(Y23, Y26, Y29) Proportional solenoid valve
(Y23b, Y26b, Y29b) Directional solenoid valve
(I – III) Main control blocks I – IV

Electrical signal flow (EURO control).


The auto float button in the right lever E19 is still engaged this will energize
relay K160. Signal voltage of joy stick (E19) arrives via ramp time module
(E49) only at terminal 5 of the amplifier modules (A10a and A10b) and further
to the proportional and directional solenoid valve of the remote control blocks
(45.2 and 45.3).
Hydraulic signal flow. (pilot pressure)
When the proportional and directional solenoid valves are energized pilot pressure
oil flows to the pilot pressure ports of the respective main control blocks.
Hydraulic oil flow
Only the oil of main pump 3 and 4 flows through the main control blocks (II)
and arrives via the distributor manifold at the boom hydraulic cylinders piston
rod side. Through main valve block III for boom lowering is no pressure oil
flow depend on a different valve spool with closed pressure port.

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

Legend for illustration (Z 22531):


(E19) Control lever (Joy stick)
(D32) Time relay – Pilot control: Neutral position monitoring
(+Y) Direction (axis) of joy stick
(+10V) Signal voltage (Maximum)
(gn) Color code of signal voltage cable ( Joy stick)
(X2...) Terminal rail with number
(E49) Ramp time module
(A10) Amplifier module – Boom
(A10A) Amplifier module – Boom
(A10B) Amplifier module – Boom
(K76A) Relay – pilot control:
Contacts 6 / 10 open while extending the stick.
(K79) Relay – pilot control:
Contacts 6 / 10 open while filling the bucket.
(K80) Relay – pilot control:
Contacts 8 / 12 closed while moving the boom up.
(K160) Relay – pilot control:
Contacts 2 / 10 closed and 5 / 9 open while auto floating on.
(K207C) Relay – pilot control:
Contacts 5 / 9 closed while warming up hydraulic oil (S205).
(45.1 – 45.3) Remote control valves
(Y23, Y26, Y29) Proportional solenoid valve
(Y23b, Y26b, Y29b) Directional solenoid valve
(I – III) Main control blocks I – III

Electrical signal flow (EURO control).


The auto float button in the right lever E19 is disengaged and relay K160 is de-
energized. Signal voltage of joy stick (E19) arrives via ramp time module
(E49) only at terminal 5 of the amplifier modules (A10 and A10b) and further
to the proportional and directional solenoid valve of the remote control blocks
(45.1 and 45.3).
Hydraulic signal flow. (pilot pressure)
When the proportional and directional solenoid valves are energized pilot pressure
oil flows to the pilot pressure ports of the respective main control blocks.
Hydraulic oil flow
Now the pump oil flow still back to the return line. Both pressure lines at valve
block I section 3 (A3 and B3) are connected to the same back pressure charged
return line. Valve spool 2 of main valve block III connect only port B2 to the
return line. The return line, the piston side and the piston rod side of the boom
cylinders now connected together. The boom can moved up and down by external
force.

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8.1.2 Electric / Hydraulic flowchart “ Boom lowering ” BHA

Legend for illustration (Z 22473):


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

Electrical signal flow (EURO control).


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

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8.1.3 Electric / Hydraulic flowchart “ Stick extending ” FSA

Legend for illustration (Z 22532):


(E20) Control lever (Joy stick)
(D32) Time relay – Pilot control: Neutral position
monitoring
(YC) Direction (axis) of joy stick
(+10V) Signal voltage (Maximum)
(gn) Color code of signal voltage cable ( Joy stick)
(X2...) Terminal rail with number
(E48) Ramp time module
(A8) Amplifier module – Stick
(A8a) Amplifier module – Stick
(A8b) Amplifier module – Stick
(K76A) Relay – pilot control:
Contacts 7 / 11 and 8 / 12 closed while extending the stick.
(K80) Relay – pilot control:
Contacts 1 / 9 open while bucket filling.
(K170) Relay – pilot control:
Contacts 5 / 9 closed and 7 / 11 opened while floating
system active.
(45.1, 45.2, 45.3) Remote control valves
(Y21, Y27, Y31) Proportional solenoid valve
(Y21a, Y27a, Y31a) Directional solenoid valve
(I, II + III) Main control blocks I – III

Electrical signal flow (EURO control).


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

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8.1.3 Electric / Hydraulic flowchart “ Stick extending ” BHA

Legend for illustration (Z 22474):


(E20) Control lever (Joy stick)
(D32) Time relay – Pilot control: Neutral position monitoring
(Y+) Direction (axis) of joy stick
(+10V) Signal voltage (Maximum)
(gn) Color code of signal voltage cable ( Joy stick)
(X2...) Terminal rail with number
(E48) Ramp time module
(A8) Amplifier module – Stick
(A8a) Amplifier module – Stick
(A8b) Amplifier module – Stick
(45.1-45.3) Remote control valves
(Y21, Y27, Y31) Proportional solenoid valve
(Y21a, Y27a, Y27b) Directional solenoid valve
(I, II, III) Main control blocks I, II III

Electrical signal flow (EURO control).


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

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8.1.4 Electric / Hydraulic flowchart “ Stick retracting ” FSA Auto Float off

Legend for illustration (Z 22534):


(E20) Control lever (Joy stick)
(D32) Time relay – Pilot control: Neutral position
monitoring
(YD) Direction (axis) of joy stick
(-10V) Signal voltage (Maximum)
(gn) Color code of signal voltage cable ( Joy stick)
(X2...) Terminal rail with number
(E48) Ramp time module
(A8) Amplifier module – Stick
(A8a) Amplifier module – Stick
(A8b) Amplifier module – Stick
(K76A) Relay – pilot control:
Contacts 7 /11 and 8 / 12 open while retracting the stick.
(K80) Relay – pilot control:
Contacts 1 / 9 only open while bucket moving.
(K170) Relay – pilot control:
Contacts 1 / 9 closed and 3 / 11 open while auto floating
off.
(K207C) Relay – pilot control:
Contacts 5 / 9 closed while warming up hydraulic oil
(S205).
(45.1, 45.2, 45.3) Remote control valves
(Y23, Y26, Y29) Proportional solenoid valve
(Y23b, Y26b, Y29b) Directional solenoid valve
(I + III) Main control blocks I + III

Electrical signal flow (EURO control).


Signal voltage of joy stick (E20) arrives via ramp time module (E48) at terminal 5
of the amplifier modules (A8, A8a) and further to the proportional and directional
solenoid valves of the remote control blocks (45.1 and 45.2).
Hydraulic signal flow. (pilot pressure)
When the proportional and directional solenoid valves are energized pilot pressure
oil flows to the pilot pressure ports of the control blocks ( I and II ).
Hydraulic oil flow
Only the oil of main pump 3 and 4 flows through the main control block (II)
and arrives via the distributor manifold at the stick hydraulic cylinders piston
side. Through main valve block I for stick retracting is no pressure oil flow
depend on a different valve spool with closed pressure port.

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

Legend for illustration (Z 22535a):


(E20) Control lever (Joy stick)
(D32) Time relay – Pilot control: Neutral position monitoring
(-Y) Direction (axis) of joy stick
(-10V) Signal voltage (Maximum)
(gn) Color code of signal voltage cable ( Joy stick)
(X2...) Terminal rail with number
(E48) Ramp time module
(A8) Amplifier module – Stick
(A8a) Amplifier module – Stick
(A8b) Amplifier module – Stick
(45.1-45.3) Remote control valves
(Y21, Y27, Y31) Proportional solenoid valve
(Y21a, Y27a, Y27b) Directional solenoid valve
(I, II, III) Main control blocks I, II III

Electrical signal flow (EURO control).


The auto float button in the left lever E20 is disengaged relay K170 is de-
energized. Signal voltage of joy stick (E20) arrives via ramp time module
(E48) at terminal 5 of the amplifier modules (A8, A8a and A8b) and further to
the proportional and directional solenoid valve of the remote control blocks
(45.1 and 45.3). Amplifier module A8a disengaged with open K80 if bucket
filling is actuated..
Hydraulic signal flow. (pilot pressure)
When the proportional and directional solenoid valves are energized pilot pressure
oil flows to the pilot pressure ports of the respective main control blocks.
Hydraulic oil flow
Both pressure lines at valve block III section 4 (A4 and B4) are connected to the
same back pressure charged return line. Valve spool 4 of main valve block I
connect only port B2 to the return line. The return line, the piston side and the
piston rod side of the stick cylinders now connected together. The stick can move
forward and backward by external force.
If only the stick retracting function is active section 4 of main valve block II
opened additional port A4 and B4 to extend the max. oil flow for max. stick
speed.

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8.1.4 Electric / Hydraulic flowchart “ Stick retracting ” BHA

Legend for illustration (Z 22475):


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

Electrical signal flow (EURO control).


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

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8.1.5 Electric / Hydraulic flowchart “ Bucket filling ” FSA

Legend for illustration (Z 22536):


(E19) Control lever (Joy stick)
(D32) Time relay – Pilot control: Neutral position
monitoring
(-X) Direction (axis) of joy stick
(-10V) Signal voltage (Maximum)
(ws / gn) Color code of signal voltage cable ( Joy stick)
(X2...) Terminal rail with number
(A9) Amplifier module – Bucket
(A9a) Amplifier module – Bucket
(A9b) Amplifier module – Bucket
(K50) Relay – pilot control: Bucket cut-off
Contacts 6 / 10 only closed if the hydraulic oil is in normal
operating temperature.
(K78) Relay – pilot control:
Contacts 1 / 9 only open while bucket dump.
(K79) Relay – pilot control:
Contacts 1 / 9 only open while lifting the boom.
(45., 45.2, 45.3) Remote control valves
(Y22, Y24, Y30) Proportional solenoid valve
(Y22A, Y24A, Y30A) Directional solenoid valve
(I – III) Main control blocks I – III

Electrical signal flow (EURO control).


Signal voltage of joy stick (E19) arrives via relay contacts K50 at terminal 5 of
the amplifier modules (A9, A9a, A9b) and further to the proportional and
directional solenoid valves of the remote control blocks (45.1, 45.2, 45.3).
Hydraulic signal flow. (pilot pressure)
When the proportional and directional solenoid valves are energized pilot
pressure oil flows to the pilot pressure ports of the main control blocks.
Hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (I to III)
and arrives via the distributor manifold at the hydraulic cylinders.

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8.1.5 Electric / Hydraulic flowchart “ Bucket filling ” BHA

Legend for illustration (Z 22476):


(E19) Control lever (Joy stick)
(D32) Time relay – Pilot control: Neutral position
monitoring
(XB) Direction (axis) of joy stick
(-10V) Signal voltage (Maximum)
(ws / gn) Color code of signal voltage cable ( Joy stick)
(X2...) Terminal rail with number
(K50) Relay – pilot control: Bucket cut-off
Contacts 6 / 10 only closed if the hydraulic oil is
overheated.
(A9) Amplifier module – Bucket
(A9a) Amplifier module – Bucket
(A9b) Amplifier module – Bucket
(45.1-45.3) Remote control valves
(Y22, Y24, Y30) Proportional solenoid valve
(Y22a, Y24a, Y30a) Directional solenoid valve
(I, II, III) Main control blocks I, II, III

Electrical signal flow (EURO control).


Signal voltage of joy stick (E19) arrives terminal 5 of the amplifier modules (A9,
A9a, A9b) and further to the proportional and directional solenoid valves of the
remote control blocks (45.,45.2 and 45.3).
Hydraulic signal flow. (pilot pressure)
When the proportional and directional solenoid valves are energized pilot pressure
oil flows to the pilot pressure ports of the main control blocks .
Hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (I, II, III)
and arrives via distributor the manifold at the hydraulic cylinders.

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8.1.6 Electric / Hydraulic flowchart “ Bucket dump ” FSA

Legend for illustration (Z 22537):


(E19) Control lever (Joy stick)
(D32) Time relay – Pilot control: Neutral position
monitoring
(+X) Direction (axis) of joy stick
(+10V) Signal voltage (Maximum)
(ws / gn) Color code of signal voltage cable ( Joy stick)
(X2...) Terminal rail with number
(A9) Amplifier module – Bucket
(A9a) Amplifier module – Bucket
(A9b) Amplifier module – Bucket
(K50) Relay – pilot control: Bucket cut-off
Contacts 6 / 10 only closed if the hydraulic oil is in normal
operating temperature.
(K78) Relay – pilot control:
Contacts 1 / 9 only open while bucket dump.
(K79) Relay – pilot control:
Contacts 1 / 9 only open while lifting the boom.
(K205) Relay – pilot control:
Contacts 1 / 3 only open while S205 activated (hydraulic
oil warming up)
(45., 45.2, 45.3) Remote control valves
(Y22, Y24, Y30) Proportional solenoid valve
(Y22A, Y24A, Y30A) Directional solenoid valve
(I – III) Main control blocks I – III

Electrical signal flow (EURO control).


Signal voltage of joy stick (E19) arrives via relay contacts K50 at terminal 19 of
the ELB modules. From ELB modules the signal voltage arrives at terminal 5 of
the amplifier modules (A9, A9a, A9b) and further to the proportional and
directional solenoid valves of the remote control blocks (45.1, 45.2, 45.3). Only
while bucket dump together with boom up K78 and K79 opened the contacts 1 / 9
and deactivate amplifier module A9 (priority to the boom).
Hydraulic signal flow. (pilot pressure)
When the proportional and directional solenoid valves are energized pilot
pressure oil flows to the pilot pressure ports of the main control blocks.
Hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (I to III)
and arrives via the distributor manifold at the hydraulic cylinders. There is no oil
flow through main control block I to the bucket cylinder if bucket dump and boom
up is activated.

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8.1.6 Electric / Hydraulic flowchart “ Bucket dump ” BHA

Legend for illustration (Z 22477):


(E19) Control lever (Joy stick)
(D32) Time relay – Pilot control: Neutral position monitoring
(+X) Direction (axis) of joy stick
(+10V) Signal voltage (Maximum)
(ws / gn) Color code of signal voltage cable ( Joy stick)
(X2...) Terminal rail with number
(A9) Amplifier module – Bucket
(A9a) Amplifier module – Bucket
(A9b) Amplifier module – Bucket
(K50) Relay – pilot control: Bucket cut-off
Contacts 6 / 10 only closed if the hydraulic oil is overheated.
(14.1 + 14.3) Remote control valves
(15) Remote control valves
(Y64) Proportional solenoid valve
(Y71 + Y75) Proportional solenoid valve
(Y23 + Y45) Directional solenoid valve
(Y37) Directional solenoid valve
(II, III + IV) Main control blocks II, III + IV
(42) Distributor manifold

Electrical signal flow (EURO control)


Signal voltage of joy stick (E19) arrives via relay contacts K50 at terminal 5 of
the amplifier modules (A9, A9a, A9b) and further to the proportional and
directional solenoid valves of the remote control blocks (45.1, 45,2 and 45.3).
Hydraulic signal flow. (pilot pressure)
When the proportional and directional solenoid valves are energized pilot pressure
oil flows to the pilot pressure ports of the main control blocks .
Hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (II, III, IV)
and arrives via distributor manifold (42) at the hydraulic cylinders.

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8.1.8 Electric / Hydraulic flowchart “ Clam opening ” FSA

Legend for illustration (Z 21970):


(E24) Control pedal
(D32) Time relay – Pilot control: Neutral position monitoring
(-10V) Signal voltage (Maximum)
(rs) Color code of signal voltage cable ( Joy stick)
(X2...) Terminal rail with number
(A11) Amplifier module – Clam
(K76) Relay – pilot control:
Contacts 7 / 11 only closed while traveling the left crawler.
(15) Remote control valves
(Y72) Proportional solenoid valve
(Y39) Directional solenoid valve
(II) Main control block II
(42) Distributor manifold

Electrical signal flow (EURO control).


Signal voltage of control pedal (E24) arrives via relay contact at terminal 5 of the
amplifier module (A11) and further to the proportional and directional solenoid
valves of the remote control block (15).
Hydraulic signal flow. (pilot pressure)
When the proportional and directional solenoid valves are energized pilot pressure
oil flows to the pilot pressure port of the main control block .
Hydraulic oil flow
Now the oil of the main pump flows through the main control block (II) and
arrives via distributor manifold (42) at the hydraulic cylinders.

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8.1.9 Electric / Hydraulic flowchart “ Clam closing ” FSA

Legend for illustration (Z 21971):


(E23) Control pedal
(D32) Time relay – Pilot control: Neutral position monitoring
(+10V) Signal voltage (Maximum)
(rs) Color code of signal voltage cable ( Joy stick)
(X2...) Terminal rail with number
(A11) Amplifier module – Clam
(K76) Relay – pilot control:
Contacts 7 / 11 only closed while traveling the left crawler.
(15) Remote control valves
(Y72) Proportional solenoid valve
(Y38) Directional solenoid valve
(II) Main control block II
(42) Distributor manifold

Electrical signal flow (EURO control).


Signal voltage of control pedal (E23) arrives via relay contact at terminal 5 of the
amplifier module (A11) and further to the proportional and directional solenoid
valves of the remote control block (15).
Hydraulic signal flow. (pilot pressure)
When the proportional and directional solenoid valves are energized pilot pressure
oil flows to the pilot pressure port of the main control block .
Hydraulic oil flow
Now the oil of the main pump flows through the main control block (II) and
arrives via distributor manifold (42) at the hydraulic cylinders.

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8.1.10 Checks and adjustments of the Main Relief Valves (MRV),


illustration (Z 22481):

There are four main relief valves (primary valves) installed, one in each main
control block, to limit the maximum pump supply line pressure (operating
pressure).
MRV Check
Functions FSA
block point
Pump circuit
I M12.1 travel stick bucket boom
I
Pump circuit
II M12.3 clam bucket Boom stick
II
Pump circuit
III M12.4 travel boom bucket stick
III
Pump circuit
IV M12.2 Swing, (if no swing active circuit II)
IV

Each Pump circuit can be checked or adjusted individually by selecting one


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

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

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

• It is important that the valve body of MRV-valve and the SRV-valve


) are firmly tightened with 300 Nm.
Otherwise, the internal sealing is not properly which results in loud
flow noises and wrong adjustments.

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8.1.10 Checks and adjustments of the Main Relief Valves (MRV),


illustration (Z 22481):

There are four main relief valves (primary valves) installed, one in each main
control block, to limit the maximum pump supply line pressure (operating
pressure).

MRV in Check Functions BHA


control block point
Pump circuit I I M12.1 Travel Stick Bucket Boom
Pump circuit II II M12.3 Bucket Boom - Stick
Pump circuit III III M12.4 Travel Boom Bucket Stick
Pump circuit IV IV M12.2 Swing, (if no swing active circuit II)

Each Pump circuit can be checked or adjusted individually by selecting one


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

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

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

• It is important that the valve body of MRV-valve and the SRV-valve


) are firmly tightened (with 300 Nm).
Otherwise, the internal sealing is not properly which results in loud
flow noises and wrong adjustments.

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

SRV FSA SRV BHA Press. check point Location


141.1 138.1 M23 Manifold section B
141.2 138.2. M29.1 Manifold section N
141.3 138.3 M29.2 Manifold section N
MRV I M12.1 (at HP filter) Double HP filter R.H.
MRV II M12.3 (at HP filter) Single HP filter, block II
MRV III M12.4 (at HP filter) Double HP L.H..
MRV IV M12.2 (at HP filter) Single HP filter, block IV

1. Connect gauges to all above listed check points (min. 400 bar).
2. Start both motors..
3. Extend the boom cylinder to the stop position until the hydraulic
system stalls.
4. Increase slowly the pump supply line pressure, by turning in set screws (3)
of the MRV’s in control block I, II, III and IV, while observing the
pressure gauges. Stop as soon the pressure does not raise any further.
The gauge pointers should remain at 350 bar + 5 bar.

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

5. Remove protective cap (1) of MRV.


6. Loosen lock nut (2).
7. Turn set screw (3) of the MRV’s ½ turn further in, the gauge
pointers will remain at the value shown at item #4 (350 bar + 5 bar).
8. Tighten lock nut (2).
continued

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Cont'd:
8.1.10 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 22482a):

Boom cylinder “piston side” FSA +BHA


9. Adjust all three SRV’s equally, until all gauges show a pressure of
360 bar.
Adjust in steps of ¼ turn of set screw (3) in the following sequence:
141.1 þ 141.2 þ 141.3
Remove protective cap (1) of SRV’s.
Loosen lock nut (2).
Turn set screw (3) -clockwise to increase pressure, Counter-clock
wise to decrease pressure.
Tighten lock nut (2) and install cap (1).
10. Reduce the pressure, at SRV- 141.1 to a value below the required value,
and then increase up to the required pressure (350 bar), while
observing all gauges.

) • Now all gauges will show the same value of 350 bar,
but only SRV-143.1 has the correct setting.

11. Proceed with the other valves in the same manner in the following
sequence:
141.2 þ 141.3

• Strong pulsation of the return line hoses, indicates deviation in


opening pressure of SRV’s and must be avoided.
Repeat the adjusting procedure until the oil returns well-balanced
via all six service line relief valves.

12. Reset the MRV’s to 310 bar + 5 bar after the check / adjustment is finished,
as follows:
Remove protective cap (1).
Loosen lock nut (2).
Turn set screw (3) -clockwise to increase pressure, Counter-clock
wise to decrease pressure.
Tighten lock nut (2) and install cap (1).

• It is important that the valve body of MRV-valve and the SRV-valve


) are firmly tightened (with 300 Nm).
Otherwise, the internal sealing is not properly which results in loud
flow noises and wrong adjustments.

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

Valve Press. check point Location


SRV 33.4 FSA M12.3 (High pressure filter) Control block II, section A3 FSA
SRV 33.6 BHA section A2 BHA
MRV circuit II M12.3 (High pressure filter) Single high pressure filter,
control block II
MRV circuit IV M12.2 (High pressure filter) Single high pressure filter,
control block IV

1. Connect gauges to all above listed check points.


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

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

continued

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8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 22483b):

Cont'd:
7. Adjust the SRV until the gauges show a pressure of 350 bar.
8. Tighten lock nut (2).
9. Reset the MRV to 310 bar + 5 bar after the check / adjustment is finished
10. Tighten lock nut (2).
11. Stop engine.
12. Install all protective cups (1).

• It is important that the valve body of MRV-valve and the SRV-valve


) are firmly tightened (with 300 Nm).
Otherwise, the internal sealing is not properly which results in loud
flow noises and wrong adjustments.

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8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 22542):
Stick cylinder “piston side” FSA
There are three service line relief valves (secondary valves) installed, all three
at the distributor manifold, to limit the maximum possible pressure peaks in
the service line.
Since the opening pressure of the SRV’s is higher than the setting of the Main
Relief Valves (MRV’s) it is necessary to increase the main relief pressure for
testing and adjusting purposes.

Valve Press. check point Location


SRV 142.5 Manifold section F
SRV 142.6 M27.1 Manifold section F
SRV 142.7 Manifold section J
MRV circuit I M12.1 (High pressure filter) Double high pressure filter R.H.
MRV circuit II M12.3 (High pressure filter) Single HP filter, control block II
MRV circuit III M12.4 (High pressure filter) Double high pressure filter L.H..
MRV circuit IV M12.2 (High pressure filter) Single HP filter, control block IV

1. Connect gauges to all above listed check points.


2. Start both motors..
3. Extend the stick cylinder to the stop position until the hydraulic
system stalls.
4. Increase slowly the pump supply line pressure, by turning in set screws (3)
of the MRV in control block IV, while observing the pressure gauges.
Stop as soon the pressure does not raise any further.
The gauge pointers should remain at 350 bar + 5 bar.

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

5. Remove protective cap (1) of MRV.


6. Loosen lock nut (2).
7. Turn set screw (3) of the MRV ½ turn further in, the gauge
pointers will remain at the value shown at item #4 (350 bar + 5 bar).
8. Tighten lock nut (2) and install cap (1).

continued

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Cont'd:
8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 22542):

Stick cylinder “piston side” FSA


9. Adjust all three SRV’s equally, until all gauges show a pressure of 360
bar.
Adjust in steps of ¼ turn of set screw (3) in the following sequence:
142.5 þ 142.6 þ 142.7
Remove protective cap (1) of SRV’s.
Loosen lock nut (2).
Turn set screw (3) -clockwise to increase, Counter-clock wise to
decrease the setting.
Tighten lock nut (2) and install cap (1).
10. Reduce the pressure at SRV 142.5 to a value below the required value,
and increase up to the required pressure (350 bar), while observing all
gauges.

) • 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: 142.6 þ 142.7

• 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 (320 bar block IV) after the check /
adjustment is finished, as follows:
Remove protective cap (1).
Loosen lock nut (2).
Turn set screw (3) -clockwise to increase pressure, Counter-clock
wise to decrease pressure.
Tighten lock nut (2) and install cap (1).

• It is important that the valve body of MRV-valve and the SRV-valve


) are firmly tightened (with 300 Nm).
Otherwise, the internal sealing is not properly which results in loud
flow noises and wrong adjustments.

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8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 22484):
Stick cylinder “piston side” BHA
There are two service line relief valves (secondary valves) installed, in main
control blocks I and II, to limit the maximum possible pressure peaks in the
service line.
Since the opening pressure of the SRV’s is higher than the setting of the Main
Relief Valves (MRV’s) it is necessary to increase the main relief pressure for
testing and adjusting purposes.

Valve Press. check point Location


SRV 33.1 M12.1 (High pressure filter) Control block I, section A2
SRV 33.5 M12.3 (High pressure filter) Control block II, section A42
MRV circuit I M12.1 (High pressure filter) Control block I
MRV circuit II M12.3 (High pressure filter) Control block II
MRV circuit IV M12.2 (High pressure filter) Control block IV

1. Connect gauges to all above listed check points.


2. Start both motors..
3. Extend the stick cylinder (stick retracting) to the stop position until
the hydraulic system stalls.
4. Increase slowly the pump supply line pressure, by turning in set screws (3)
of the MRV’s in the control blocks, while observing the pressure gauges.
Stop as soon the pressure does not raise any further.
The gauge pointers should remain at 350 bar + 5 bar.

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

5. Remove protective cap (1) of MRV.


6. Loosen lock nut (2).
7. Turn set screw (3) of the MRV’s ½ turn further in, the gauge
pointers will remain at the value shown at item #4 (350 bar + 5 bar).
8. Tighten lock nut (2) and install cap (1).
continued

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Cont'd:
8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 22484):

Stick cylinder “piston side” BHA


9. Adjust all two SRV’s equally, until all gauges show a pressure of
360 bar.
Adjust in steps of ¼ turn of set screw (3) in the following sequence:
33.1 þ 33.5
Remove protective cap (1) of SRV’s.
Loosen lock nut (2).
Turn set screw (3) -clockwise to increase pressure, Counter-clock
wise to decrease pressure.
Tighten lock nut (2) and install cap (1).
10. Reduce the pressure, at SRV- 33.1 to a value below the required value,
and then increase up to the required pressure (350 bar), while
observing all gauges.

) • Now all gauges will show the same value of 350 bar,
but only SRV-33.1 has the correct setting.

11. Proceed with the other valves in the same manner in the following
sequence: 33.1 þ 33.5

• 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).

• It is important that the valve body of MRV-valve and the SRV-valve


) are firmly tightened (with 300 Nm).
Otherwise, the internal sealing is not properly which results in loud
flow noises and wrong adjustments.

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

There are two service line relief valves (secondary valves) installed, in main
control blocks I and II, to limit the maximum possible pressure peaks in the
service line.
Since the opening pressure of the SRV’s is higher than the setting of the Main
Relief Valves (MRV’s) it is necessary to increase the main relief pressure for
testing and adjusting purposes.

Valve Press. check point Location


SRV 33.1 M12.1 (High pressure filter) Double high pressure filter R.H.
SRV 33.5 M12.3 (High pressure filter) Single HP filter, control block II
MRV circuit I M12.1 (High pressure filter) Double high pressure filter R.H.
MRV circuit II M12.3 (High pressure filter) Single HP filter, control block II
MRV circuit IV M12.2 (High pressure filter) Single HP filter, control block IV

1. Connect gauges to all above listed check points.


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

a) Remove protective cap (1).


b) Loosen lock nut (2).
c) Turn set screw (3) -clockwise to increase pressure, Counter-
clock wise to decrease pressure.
d) Tighten lock nut (2).
continued

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Cont'd:
8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 22543a):

Stick cylinder “piston rod side” FSA

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

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

) • Now all gauges will show the same value of 350 bar,
but only SRV-33.1 has the correct setting.

11. Reduce the pressure, at SRV 33.1 to a value below the required value and
then increase up to the required pressure (350 bar), while observing all
gauges.

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Cont'd:
8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 22543a):

Stick cylinder “piston rod side” FSA


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

14. Reset the MRV’s to 310 bar + 5 bar after the check / adjustment is finished
15. Stop engine.
16. Install all protective cups (1).

• It is important that the valve body of MRV-valve and the SRV-valve


) are firmly tightened (with 300 Nm).
Otherwise, the internal sealing is not properly which results in loud
flow noises and wrong adjustments.

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8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 22485):

Stick cylinder “Piston rod side” BHA


There are three service line relief valves (secondary valves) installed at the
distributor manifold, to limit the maximum possible pressure peaks in the
service line.
Since the opening pressure of the SRV’s is higher than the setting of the Main
Relief Valves (MRV’s) it is necessary to increase the main relief pressure for
testing and adjusting purposes.

Valve Press. check point Location


SRV 142.5 M27.1 Manifold (42) section G
SRV 142.6 M27.2 Manifold (42) section J
SRV 142.7 M28 Manifold (42) section J
MRV circuit I M12.1 (High pressure filter) Double high pressure filter R.H.
MRV circuit II M12.3 (High pressure filter) Single high pressure filter,
control block II
MRV circuit III M12.4 (High pressure filter) Double high pressure filter L.H..
MRV circuit IV M12.2 (High pressure filter) Single high pressure filter,
control block IV

1. Connect gauges to all above listed check points.


2. Start both motors..
3. Retract the stick cylinder (extend the stick) to the stop position until
the hydraulic system stalls.
4. Increase slowly the pump supply line pressure, by turning in set screws (3)
of MRV’s in the control blocks, while observing the pressure gauges. Stop
as soon the pressure does not raise any further. The gauge pointers should
remain at 350 bar + 5 bar.

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

5. Remove protective cap (1) of MRV.


6. Loosen lock nut (2).
7. Turn set screw (3) of both MRV’s ½ turn further in, the gauge
8. Tighten lock nut (2) and install cap (1).
continued

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Cont'd:
8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 22485):

Stick cylinder “Piston rod side” BHA


9. Adjust all SRV’s equally, until all gauges show a pressure of
360 bar.
Adjust in steps of ¼ turn of set screw (3) in the following sequence:
142.5 þ 142.6þ 142.7
Remove protective cap (1) of SRV’s.
Loosen lock nut (2).
Turn set screw (3) -clockwise to increase pressure, Counter-clock
wise to decrease pressure.
Tighten lock nut (2) and install cap (1).
10. Reduce the pressure, at SRV- 142.5 to a value below the required value,
and then increase up to the required pressure (350 bar), while observing
all gauges.

) • Now all gauges will show the same value of 350 bar,
but only SRV-142.5 has the correct setting.

11. Proceed with the other valves in the same manner in the following
sequence: 142.6þ 142.7

• 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).

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

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8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 22544):
Bucket cylinder “Piston side” FSA
There are three service line relief valves (secondary valves) installed, all three
at the distributor manifold, to limit the maximum possible pressure peaks in
the service line.
Since the opening pressure of the SRV’s is higher than the setting of the Main
Relief Valves (MRV’s) it is necessary to increase the main relief pressure for
testing and adjusting purposes.

Valve Press. check point Location


SRV 142.1 M24.1 Manifold (42) section C
SRV 142.2 M24.2 Manifold (42) section C
SRV 142.3 M25 Manifold (42) section D
MRV circuit I M12.1 (High pressure filter) Double high pressure (HP) filter R.H.
MRV circuit II M12.3 (High pressure filter) Single HP filter, control block II
MRV circuit III M12.4 (High pressure filter) Double HP filter L.H..
MRV circuit IV M12.2 (High pressure filter) Single HP filter, control block IV

1. Connect gauges to check points M12.1.to M12.4 and M24.1.


2. Start both motors..
3. Extend the Bucket cylinder to the stop position until the hydraulic
system stalls.
4. Increase slowly the pump supply line pressure, by turning in set screws (3)
of all four MRV’s in control block I to IV, while observing the
pressure gauges. Stop as soon the pressure does not raise any further.
The gauge pointers should remain at 350 bar + 5 bar.

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

5. Remove protective cap (1) of MRV.


6. Loosen lock nut (2).
7. Turn set screw (3) of both MRV’s ½ turn further in, the gauge
pointers will remain at the value shown at item #4 (350 bar + 5 bar).
8. Tighten lock nut (2) and install cap (1).
continued

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Cont'd:
8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 22544):

Bucket cylinder “Piston rod side” FSA


9. Adjust all three SRV’s equally, until all gauges show a pressure of
360 bar.
Adjust in steps of ¼ turn of set screw (3) in the following sequence:
142.1 þ 142.2 þ 142.3
Remove protective cap (1) of SRV’s.
Loosen lock nut (2).
Turn set screw (3) -clockwise to increase pressure, Counter-clock
wise to decrease pressure.
Tighten lock nut (2) and install cap (1).
10. Reduce the pressure, at SRV- 142.1 to a value below the required value,
and then increase up to the required pressure (350 bar), while
observing all gauges.

) • Now all gauges will show the same value of 350 bar,
but only SRV-142.1 has the correct setting.

11. Proceed with the other valves in the same manner in the following
sequence:
142.2 þ 142.3

• Strong pulsation of the return line hoses, indicates deviation in


opening pressure of SRV’s and must be avoided.
Repeat the adjusting procedure until the oil returns well-balanced
via all six service line relief valves.

12. Reset the MRV’s to 310 bar + 5 bar after the check / adjustment is finished,
as follows:
Remove protective cap (1).
Loosen lock nut (2).
Turn set screw (3) -clockwise to increase pressure, Counter-clock
wise to decrease pressure.
Tighten lock nut (2) and install cap (1).

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

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8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 22486):
Bucket cylinder “Piston side” BHA
There are three service line relief valves (secondary valves) installed at the
distributor manifold, to limit the maximum possible pressure peaks in the service
line.
Since the opening pressure of the SRV’s is higher than the setting of the Main Relief
Valves (MRV’s) it is necessary to increase the main relief pressure for testing and
adjusting purposes.

Valve Press. check point Location


SRV 142.1 M24.1 Manifold section C
SRV 142.2 M24.2 Manifold section C
SRV 142.3 M25 Manifold section D
MRV circuit I M12.1 (High pressure filter) Double high pressure filter R.H.
MRV circuit II M12.3 (High pressure filter) Single high pressure filter, block II
MRV circuit III M12.4 (High pressure filter) Double high pressure filter L.H..
MRV circuit IV M12.2 (High pressure filter) Singe high pressure filter, block IV

1. Connect gauges to all above listed check points.


2. Start both engines and let them run with max. speed.
3. Extend the bucket cylinder (Bucket filling) to the stop position until
the hydraulic system stalls.
4. Increase slowly the pump supply line pressure, by turning in set screws (3)
of MRV in control block I, II, III and IV, while observing the pressure
gauges. Stop as soon the pressure does not raise any further. The gauge
pointers should remain at 350 bar + 5 bar.

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

5. Remove protective cap (1) of MRV.


6. Loosen lock nut (2).
7. Turn set screw (3) of both MRV’s ½ turn further in, the gauge
pointers will remain at the value shown at item #4 (350 bar + 5 bar).
8. Tighten lock nut (2) and install cap (1).
continued

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Cont'd:
8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 22486):

Bucket cylinder “Piston side” BHA


9. Adjust all three SRV’s equally, until all gauges show a pressure of
360 bar.
Adjust in steps of ¼ turn of set screw (3) in the following sequence:
142.1 þ 142.2 þ 142.3
Remove protective cap (1) of SRV’s.
Loosen lock nut (2).
Turn set screw (3) -clockwise to increase pressure, Counter-clock
wise to decrease pressure.
Tighten lock nut (2) and install cap (1).
10. Reduce the pressure, at SRV- 142.1 to a value below the required value,
and then increase up to the required pressure (350 bar), while
observing all gauges.

) • Now all gauges will show the same value of 350 bar,
but only SRV-142.1 has the correct setting.

11. Proceed with the other valves in the same manner in the following
sequence: 142.2 þ 142.3 þ 142.

• 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).

• It is important that the valve body of MRV-valve and the SRV-valve


) are firmly tightened (with 300 Nm).
Otherwise, the internal sealing is not properly which results in loud
flow noises and wrong adjustments.

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8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 22545):

Bucket cylinder “Rod side” FSA


There are two service line relief valves (secondary valves) installed, one in
main control block I section 3 and one in block II section 2, to limit the
maximum possible pressure peaks in the service line.
Since the opening pressure of the SRV’s is higher than the setting of the Main
Relief Valves (MRV’s) it is necessary to increase the main relief pressure for
testing and adjusting purposes.

Valve Press. check point Location


SRV 33.2 M12.1 (High pressure filter) Control block I, section A3
SRV 33.6 M12.3 (High pressure filter) Control block I, section A2
MRV circuit I M12.1 (High pressure filter) Double high pressure filter R.H.
MRV circuit II M12.3 (High pressure filter) Single high pressure filter, block II
MRV circuit III M12.4 (High pressure filter) Double high pressure filter L.H..
MRV circuit IV M12.2 (High pressure filter) Single high pressure filter, block IV

1. Connect gauges to all above listed check points.


2. Start both motors..
3. Stall the system with full retracted bucket cylinder in final stop position.
4. Increase slowly the pump supply line pressure, by turning in set screws (3)
of MRV’s in the control blocks, while observing the pressure gauges.
Stop as soon the pressure does not raise any further.
The gauge pointers should remain at 350 bar + 5 bar.

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

5. Remove protective cap (1) of MRV.


6. Loosen lock nut (2).
7. Turn set screw (3) of both MRV’s ½ turn further in, the gauge
8. Tighten lock nut (2) and install cap (1).

continued

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Cont'd:
8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 21999):

Bucket cylinder “Rod side” FSA


9. Adjust both SRV’s equally, until all gauges show a pressure of
360 bar.
Adjust in steps of ¼ turn of set screw (3) in the following sequence:
33,2 þ 33.6
Remove protective cap (1) of SRV’s.
Loosen lock nut (2).
Turn set screw (3) -clockwise to increase pressure, Counter-clock
wise to decrease pressure.
Tighten lock nut (2) and install cap (1).
10. Reduce the pressure, at SRV- 33.2 to a value below the required value,
and then increase up to the required pressure (350 bar), while observing
all gauges.

) • Now all gauges will show the same value of 350 bar,
but only SRV-33.2 has the correct setting.

11. Proceed with the other valve in the same manner.

• 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).

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

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8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 22487):
Bucket cylinder “Piston rod side” BHA
There are three service line relief valves (secondary valves) installed at the
distributor manifold, to limit the maximum possible pressure peaks in the
service line.
Since the opening pressure of the SRV’s is higher than the setting of the Main
Relief Valves (MRV’s) it is necessary to increase the main relief pressure for
testing and adjusting purposes.

Valve Press. check point Location


SRV 142.8 M34.1 Manifold section L
SRV 142.9 M34.2 Manifold section L
SRV 142.10 M34.3 Manifold section M
MRV circuit I M12.1 (High pressure filter) Double high pressure filter R.H.
MRV circuit II M12.3 (High pressure filter) Single high pressure filter, block II
MRV circuit III M12.4 (High pressure filter) Double high pressure filter L.H..
MRV circuit IV M12.2 (High pressure filter) Single high pressure filter, block IV
1. Connect gauges to all above listed check points.
2. Start both engines and let it run with max. speed.
3. Retract the Bucket cylinder (Bucket dump) to the stop position until
the hydraulic system stalls.
4. Increase slowly the pump supply line pressure, by turning in set screws (3)
of MRV’s in control block I, I, III and IV, while observing the pressure
gauges. Stop as soon the pressure does not raise any further.
The gauge pointers should remain at 350 bar + 5 bar.

)
• 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.

5. Remove protective cap (1) of MRV.


6. Loosen lock nut (2).
7. Turn set screw (3) of both MRV’s ½ turn further in, the gauge
pointers will remain at the value shown at item #4 (350 bar + 5 bar).
8. Tighten lock nut (2) and install cap (1).
continued

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Cont'd:
8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 22487):

Bucket cylinder “Piston rod side” BHA


9. Adjust all SRV’s equally, until all gauges show a pressure of 360 bar.
Adjust in steps of ¼ turn of set screw (3) in the following sequence:
142.8 þ 142.9 þ 142.10
Remove protective cap (1) of SRV’s.
Loosen lock nut (2).
Turn set screw (3) -clockwise to increase pressure, Counter-clock wise
to decrease pressure.
Tighten lock nut (2) and install cap (1).
10. Reduce the pressure, at SRV- 142.8 to a value below the required value
and then increase up to the required pressure (350 bar), while observing
all gauges.

) • Now all gauges will show the same value of 350 bar,
but only SRV-142.8 has the correct setting.

11. Proceed with the other valves in the same manner in the following
sequence: 142.9 þ 142.10

• 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).

• It is important that the valve body of MRV-valve and the SRV-valve


) are firmly tightened (with 300 Nm).
Otherwise, the internal sealing is not properly which results in loud
flow noises and wrong adjustments.

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Attachment Cylinders

8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 22546):
Clam cylinder “Rod side” (clam opening) FSA
There is one service line relief valve (secondary valve) installed at the distributor
manifold section E, to limit the maximum possible pressure peaks in the service line.
Since the opening pressure of the SRV is higher than the setting of the Main Relief
Valves (MRV’s) it is necessary to increase the main relief pressure for testing and
adjusting purposes.

Valve Press. check point Location


SRV 142.4 M26 Manifold (42) section E
MRV circuit II M12.3 (High pressure filter) Control block II
MRV circuit IV M12.2 (High pressure filter) Control block IV

1. Connect gauges to the above listed check points.


2. Start engine 2 and let it run in high idle.
3. Retract the clam cylinder (open the bucket) to the stop position until the
hydraulic system stalls.
4. Increase slowly the pump supply line pressure, by turning in set screws (3) of
MRV in control block II and IV, while observing the pressure gauges.
Stop as soon the pressure does not raise any further.
The gauge pointers should remain at 350 bar + 5 bar.
If necessary correct the adjustment as follows:
5. Remove protective cap (1) of MRV.
6. Loosen lock nut (2).
7. Turn set screw (3) of the MRV ½ turn further in, the gauge pointers will
remain at the value shown at item #4 (350 bar + 5 bar).
8. Tighten lock nut (2) and install cap (1).
9. Reduce the pressure, at SRV 142.4 to a value below the required value, and
then increase up to the required pressure (350 bar), while observing all auges.
10. Reset the MRV to 310 bar + 5 bar after adjustment is finished, as follows:
Remove protective cap (1).
Loosen lock nut (2).
Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to
decrease pressure.
Tighten lock nut (2) and install cap (1).

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

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

Valve Press. check point Location


SRV 144 (1) M22 Manifold section K
SRV 144 (2) M22 Manifold section K
SRV 32.10 MM12.3 (High pressure filter) Control block II

1. Connect gauges to all above listed check points.


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

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

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8.1.12 Checks and adjustments of the lowering speed,


illustration (Z 22489):
General
On excavators equipped with Face Shovel Attachment (FSA) there are two
different operation modes for lowering the boom and stick:
I. Float position activated the lowering speed has to be adjusted by altering
the flow restrictors (throttle valves) at the distributor manifold section B,
throttle valve 141.1 and section N, throttle valve 141.3.
II. Float position deactivated the lowering speed has to be adjusted by
altering the flow restrictor (throttle valve) at the distributor manifold
section N, throttle valve 141.2.

On excavators equipped with Backhoe Attachment (BHA) the lowering speed has
to be adjusted at all flow restrictors on distributor manifold section B and N,
throttle valves 141.1, 141.2 and 141.3.

Purpose of the Flow Restrictors:


• To avoid an interruption of the pump delivery.
• To provide an uniform and smooth cylinder travel.
• To limit the return oil flow through the control block to the maximum
permissible volume.

Checks and Adjustments:


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

) During commissioning, a throttle adjustment has to be carried out on


all machines. For safety reasons, the throttle valves are completely
screwed in before each machine is leaving the factory.

For more information refer to the respective newest Service Bulletin

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8.1.12 Checks and adjustments of the lowering speed,


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

Cylinder retracting time/meter (s /m) Total time(s)


Boom FSA 1,4 4,3

Adjustments / Checks:

I. Float position activated:


1. Use a stop watch to measure the cylinder running time.
2. Raise the fully extended attachment with empty bucket to the maximum
height position (A).
3. Shift both engines to high idle speed.
4. Rapidly move the control lever (E19) to the front end position (start the stop
watch) and hold it until the final position (B) is reached.(stop the stop
watch).

• Lower the boom so, that the bucket stops just above the ground.

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

O.K.

6. Check lowering speed again and repeat the adjustment if necessary.


7. If the adjustment is finished tighten lock nut (1).
continued

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Cont'd:
8.1.12 Checks and adjustments of the lowering speed,
illustration (Z 22489):

Boom cylinder FSA


Adjustments / Checks:

II. Float position deactivated (with push button S95):


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

• Lower the boom so, that the bucket stops just above the ground.

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

O.K.

7. Check lowering speed again and repeat the adjustment if necessary.


8. If the adjustment is finished tighten lock nut (1).

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8.1.12 Checks and adjustments of the lowering speed,


illustration (Z 22488):
Boom cylinder BHA

Maximum permissible lowering speed:

Cylinder retracting time/meter Total time


(s /m) (s)
Boom BHA 1,4 5,0

Adjustments / Checks:
1. Use a stop watch to measure the cylinder running time.
2. Raise the fully extended attachment with empty bucket to the maximum
height position (A).
3. Shift the engines to high idle speed.
4. Rapidly move the control lever (E19) to the front end position (start the stop
watch) and hold it until the final position (B) is reached.(stop the stop
watch).

• Lower the boom so, that the bucket stops just above the ground.

5. If the lowering speed is too high, i.e. the measured time is less than the
permissible time, the speed must be reduced by altering the throttle valves
141.1, 141.2 and 141.3 at the distributor manifold.
Adjust as follows:
To decrease the lowering speed loosen the lock nut (1) and turn the bolt (2)
cw. To increase the lowering speed loosen the lock nut (1) and turn the bolt
(2) ccw.
Since there are several valves throttling the return oil flow of the boom
cylinder the valves must be set synchronously. The adjusting screws have
to be turned in by the same amount of revolutions.

O.K.

6. Check lowering speed again and repeat the adjustment if necessary.


If the adjustment is finished tighten lock nut (1).

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8.1.12 Checks and adjustments of the lowering speed, illustration (Z 22490):


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

Cylinder retracting time/meter Total time


(s /m) (s)
Stick FSA 0,9 2,4

Adjustments / Checks:

I. Float position activated:

1. Use a stop watch to measure the cylinder running time.


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

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

O.K.

5. Check lowering speed again and repeat the adjustment if necessary.


If the adjustment is finished tighten lock nut (1).
continued

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Attachment Cylinders Page 49

Cont'd:
8.1.12 Checks and adjustments of the lowering speed, illustration (Z 22490):

Stick cylinder FSA


Adjustments / Checks:

II. Float position deactivated (with push button S95a):


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

O.K.

7. Check lowering speed again and repeat the adjustment if necessary.


8. If the adjustment is finished tighten lock nut (1).

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8.1.12 Checks and adjustments of the lowering speed,


illustration (Z 22491):
Stick cylinder BHA

Maximum permissible lowering speed:

Cylinder extending time/meter Total time


(s /m) (s)
Stick BHA 0,6 1,5

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

O.K.

6. Check lowering speed again and repeat the adjustment if necessary.


7. If the adjustment is finished tighten lock nut (1).

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8.1.12 Checks and adjustments of the lowering speed,


illustration (Z 22562):
Bucket cylinder FSA

Maximum permissible lowering speed:

Cylinder retracting time/meter Total time


(s /m) (s)
Bucket FSA 1,1 3,0

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

O.K.

6. Check lowering speed again and repeat the adjustment if necessary.


7. If the adjustment is finished tighten lock nut (1).

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8.1.12 Checks and adjustments of the lowering speed,


illustration (Z 22492):
Bucket cylinder BHA

Maximum permissible lowering speed:

Cylinder retracting time/meter Total time


(s /m) (s)
Bucket BHA 0,5 1,1

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

O.K.

6. Check lowering speed again and repeat the adjustment if necessary.


7. If the adjustment is finished tighten lock nut (1).

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8.1.12 Checks and adjustments of the lowering speed,


illustration (Z 22563):
Clam cylinder FSA

Maximum permissible lowering speed:


Adjustments / Checks:

1. Use a stop watch to measure the cylinder running time.


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

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8.1.13 Checks for the valve control logic

Legend for illustration (Z 22582a):


(1) Main pump condition Ö P = pressurized outlet
(2) Main pump condition Ö (-) = free flow to reservoir
(3) Pilot ports a = outlet ports a
(4) Pilot ports b = outlet ports b
(5) Port condition Ö (-) = closed port
(6) Port condition Ö O = open port
(7) Respective function
(8) Single control valve block for swing
(9) control valve block number
(10) Swing parking brake switch S29
General:
For harmonic attachment motion and well working floating function the valve
spools must be activated with different priorities. The whole valve control logic is
a arrangement of electric relay controlling and the main hydraulic control valve
sequence.
The correct function of the valve control logic can be checked by pressure gauges
(0 -50bar) connected to the pressure test ports at the control valve cabs.

Checks:
a) Connect the pressure gauges (0-50 bar) to all test ports at the pilot control
cabs (26 gauges necessary *) and (0-400 bar) to the high pressure filter
test ports M44.1, 44.2, 46.1, 46.2
b) Mark the control cab with the respective function and port designation.
c) Use the Check list for the Valve Logic in the appendix in this binder.
d) Unplug solenoid valve Y16 (travel parking brake closed) and activate the
swing brake with the switch at the dash board. The ladder and the
refilling arm are in high position (working position) the operator sits on
the operators seat. Make sure that the machine can move hazardless all
functions
e) Start one motor.
f) The operator activate carefully step for step the respective lever or pedal
as shown in the check list. Compare each step with the pressure condition
of the control cabs and main pressure to the check list.
If there is a wrong result, check the respective electric circuit and hydraulic
pilot circuit.

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06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Hydraulic for the Swing Circuit Section 8.2
Page 1

Table of contents section 8.2

Section Page
8.2 Hydraulic for the swing circuit
8.2.1 Swing Circuit (Brief description) 2+3
8.2.2 Swing Motor 4-7
8.2.3 Swing Gear Box 8
8.2.4 Swing Parking Brake (Gear house Brake) 9
8.2.5 Swing Brake Valve 10+12
8.2.6 Electric / Hydraulic flowchart “Swing Left” 13
8.2.7 Electric / Hydraulic flowchart “Swing Right” 14
8.2.8 Swing Monitoring System 15 + 16
8.2.9 Adjustments for the swing circuit 17 - 19

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Page 2

8.2.1 Swing Circuit (Brief description)

Legend for illustration (Z 22501b):

(I - VI) Main pumps


(13) Single control block IV
(48) Manifold
(20.1+ 20.2) Swing motors
(71.1+ 71.2) Manifold at the control and filter panel
(25.2) Double check valve
(49.1 + 49.2) Pressure increasing valve (swing brake valve)
(Y48) Swing motors power control valve
(Y120) Solenoid valve
(43) Remote control valve block
(Y32) Proportional valve of the remote control block
(Y32a/b) Directional solenoid valve of the remote control block
(20) Control lever left hand
(50) Ramp module
(A7) Amplifier module

Brief description (Control circuits)


(Study together with the for the machine valid hydraulic and electric circuit
diagram).
When the lever (E20) is moved out of its neutral position, proportional
solenoid valves Y32 are energized. Simultaneously the directional solenoid
valves Y32a (R.H.-swing) or Y32b (L.H.-swing) are energized.

By the function of the remote control valve (43) pilot pressure oil is sent to
one side of the control block (13/IV) when operating the control lever for
"Swinging". At the same time by the function of the proportional valve
(Y127) pilot pressure (proportional to the lever deflection) is present at port
„X“ pressure increasing valve (PIV)of each brake valve block (49.1+ 49.2)
thus a internal pressure built up (higher as 150 bar) in the service lines is
possible.

continued

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Hydraulic for the Swing Circuit Section 8.2
Page 3

Cont'd.:

8.2.1 Functional description:

Illustration (Z 22501b):
Brief description (Service circuits)
(Study together with the for the machine valid hydraulic and electric circuit
diagram).
The swing motors (20.1 + 20.2) are feed by the main pump (III). This pump is
at port XLR permanent with 35 bar X2- pressure fix adjusted to Qmax.
The oil flows from the pumps through check valve (47.3) and filter (153.3) to
the single control block (13 / IV).
In neutral position of the spool oil flows via port C into control block II for
additional oil volume from pump 3 to valve circuit II. If no function of
control block II is activated the oil flow via port T in to the collector tube (35)
and further via the return oil lines (L6 + L7) into the tank.

On its way to tank the oil must flow through the back pressure valve (115)
and the return oil filter (117.2 - 117.5). (Back pressure valve function see
chapt. 4.)
When operating the control lever for "Swinging" the pump line is connected
in the control block (33/IV) with the corresponding service line (A1 or B1) to
the swing motors (20.1 + 20.2).
The oil flows from the control block through each one of the swing brake
valves (49.1 + 49.2; description see page 6 and 7) and the swing motors (20.1
+ 20.2).
Each swing gear includes one spring loaded multi disk brake (House brake)
for locking the superstructure.
The leak oil (case drain) flows through the line (L11 + L12) and the leak oil
filter (108) back to tank.

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4

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Swing motor A6VM Section 8.2
Page 4

8.2.2 Swing Motor Axial Piston Motor A6VM355 HD1D

Legend for illustration (Z 22430):


(1) Check valve
(2) Check valve
(3) Governor valve
(4) Positioning piston
(5) Boost pressure valve
(6) Flushing valve (16l/min)
(7) Flow control valve
(8) Constant pressure control valve (adjusted: 280 bar)

General:
A6VM355 HD1D is a variable displacement motor with an axial piston rotary
group of bent axis design for hydrostatic drives.
Its control range allows the variable displacement motor to meet both, high speed
and torque requirements. The output speed is proportional to its displacement.
The output speed increases with decreased displacement trough lower
operating pressure.
The output torque increases with increased displacement trough higher
operating pressure.

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Page 5

8.2.1 Swing Motor Axial Piston Motor A6VM355 HD1D

Hydraulic control, illustration Z22430


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

Function Speed X- Operating Torque Motor


indicator pressure pressure displacement
imp/min bar bar
Start swing 0-120 0 310 à ~280 Max. Vg max
Standstill to low speed
Swing movement 120-max. 35 280 à ~75 Reduced Vg max à Vg min
Low speed to Max. speed variable
Swing movement Max. 35 ~75 Reduced Vg min
Max. speed
Swing down path 120-0 0 ~170 à 0 Max. Vg max
Control lever in neutral
Counter Swing (braking) 120-0 0 330 à 0 Max. Vg max
Control lever moved to the
opposite side of swing direction

Continued

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Swing motor A6VM Section 8.2
Page 6

8.2.2 Hydraulic Motor Axial Piston Motor A6VM355 HD1D

Hydraulic control, illustration Z22431b


Cont'd:

A Flow from A to B without „X-pressure“ (slow swing speed) :


The operating pressure opens check valve (1) and closes the opposite valve (2). The
same pressure is present at the control port of pressure control valve (8) and inside
the small area side of the positioning piston (4). The large area side is connected via
the governor valve (3) to tank (port T2).
The motor remains in Vgmax position. = max. torque by low speed.

B Flow from A to B, with „X-pressure“ (higher swing speed),


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

C Flow from A to B, with „X-pressure“ (higher swing speed),


operating pressure 280-310 bar:
Depending on the system pressure (more as 280 bar), valve (8) connect the large
area side of the positioning piston (4) with the pressure less return line (T2). Low
pressure at the large side cause a greater force at the pressurized small area side of
the positioning piston (4) moving the motor into the Vgmax position.
The motor is in regulation mode due to high operating pressure (>280bar) :
Motor displacement to Vgmax position (>280bar).

As a result of decreasing operating pressure the motors are reducing their


displacement so that the swing speed will increase.
If the operating pressure rises as a result of load torque, to the setting of the constant
pressure control valve (280 bar), the motors are swiveled out to a greater angel (higher
displacement) and the swing speed will decrease.

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Page 6

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Swing motor A6VM Section 8.2
Page 7

8.2.2 Checks and Adjustments, illustration Z22432


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

Checking the Q-max. and Q-min. stop bolt setting.


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

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

How to check the Q-min. adjustment.


1. Lift the extended attachment to horizontal position.
2. Measure the time for 5 revolutions after swinging one turn as an approach swing.
The time should be t5rev = 90+5 sec .
3. If a adjustment is required:
Turn off box nut (1) and loosen lock nut (3)
Turn bolt (2) further in for less speed or further out for higher speed.
One turn of the Qmin bolt (2) cause a change of approx. ∆t5rev = 4.6 sec.
4. Re-check speed and tighten lock nut and re-fit box nut (1) after setting is finished.

How to check / adjust the start of regulation.


1. Activate manually relay K153 to energize Y48 to pressurized swing motor port
X with X2-pressur.
2. Connect a pressure gauge (0-400 bar) to check point M12.2 at high pressure
filter of single control block IV.
3. Measure and note outer length (L) of Qmax stop bolt (2) (for resetting later on)
Loosen lock nut (3) approx. ½ turn without turning the stop bolt..
4. Start engine 1 and let it run in high idle.
5. Apply the swing parking brake.
6. Operate carefully the control lever for swing in one direction and keep it in end
position. The resulting operating pressure should be 320 bar.
7. Loosen look nut of MRV at single control block IV.
8. Decrease / increase alternately the operating pressure between 300 bar and 260 bar
at MRV set screw. Check by turning the Qmax stop bolt (2) by hand, if the motor
control lens touches the Qmax stop bolt:
The lens must touch the stop bolt with a pressure higher than 280 bar.
The lens must not touch the stop bolt with a pressure lower than 280 bar
9. Correct the start of regulation with valve (8) if necessary.
10. Reset MRV. Stop engine and deactivate K153

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Page 8

8.2.3 Swing Gear Box

Legend for illustration (Z 25305), manufacturer: Siebenhaar


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

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

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8.2.4 Swing Parking Brake (Gear house Brake)

The Spring Loaded Multi-disk Brake is a safety brake; applied by


spring force and released by oil pressure.

Legend for illustration (Z 22439):


(1) Clip ring (circlip)
(2) Thrust washer
(3) Outer discs
(4) Inner discs
(5) Piston
(6) Quad ring with back up ring
(7) Quad ring with back up ring
(8) Springs
(9) Piston back up ring and seal retainer
(10) O ring
(11) Clip ring (circlip)
(12) Oil pressure port

Function:
Brake applied:
The outer disks (3) engaged to the housing by serration and the inner disks (4) in
serrated connection with drive shaft are pressed together by the springs (8). This
results in a fixed connection between housing and drive shaft.

Brake released:
Oil pressure via port (12) reaches the bottom of the piston (5) and forces the
piston upwards against the thrust washer (2).
This function eliminates the spring force to the disc (3) and (4) thus the brake is
released.
The releasing pressure is 12 - 20 bar, the maximum permissible pressure
60 bar.

This is a so named "Wet Brake" because the brake housing is filled with oil.

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Page 10

8.2.5 Swing Brake Valve

Legend for illustration (Z 21934):


(1) Pressure increasing valve (7) Spring of main piston
(items 6 - 13) (8) Jet bore
(2) Check valve circuit A (9) Valve poppet
(3) Check valve circuit B (10) Spring
(4) Anti-cavitation valve circuit B (11) Intermediate piston
(5) Anti-cavitation valve circuit A (12) Pilot pressure piston
(6) Jet bore, of main piston plug (13) Main piston

Ports:
(Y) Leak oil
(T) Return oil
(A) Service line from control block
(A1) Service line to the motor
(B) Service line from control block
(B1) Service line to the motor

Pressure check points:


(MA) Circuit A
(MB) Circuit B

Explanation of the function by the symbol:


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

continued

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Cont'd.:

8.2.5 Swing Brake Valve

If after a swing motion the joy stick is released into neutral position
without using the foot brake, the superstructure is turned by inertial force
and the hydraulic motor acts as a pump because it is driven by the swing
gear.
Both service line’s (pump line and tank line) are blocked at the control
valve block. In this period the service line (previously pump line) acts now
as suction line and the return line (previously return line) acts now as
output line. Because of the closed service ports at the control block all oil
from the swing motor must pass the brake valve block. The pressure
increasing valve in the brake valve block acts now as a back pressure
valve. This variable back pressure is the brake force.

Function of the pressure increasing valve.


When ever a swing motion is carried out or the foot brake is used, pilot
pressure arrives the pressure increasing valve (1) at port "X". The pilot
pressure pre-loads these valves.
By applying pilot pressure via the external port X to piston (12), the pre-
tensioning of the pressure spring (10) is increased by the amount of the piston
stroke "S", which results in the actual valve setting.
The system pressure is in front of the main piston (13) and via the jet bore (6)
also in the chamber of the spring (7) and via the jet bore (8) at the pressure
relief valve poppet (9).
Due to the force balance the piston (13) is kept in its position supported by
the spring (7).
Overcomes the system pressure the setting of the valve (9), this valve opens a
channel to the dump line port (Y). Due to the drop of force the piston (13) is
moved to the right.
The pressure line gets connected with the return line (T).
Damped opening and closing are obtained by the throttled volumetric change
that is caused by the jet bores.

continued

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Page 12

Cont'd.:

8.2.5 Swing Brake Valves


Anti cavitation prevention. Illustration Z 22672a
(1) Return oil collector tube
(2) Main back pressure valve
(3) Gear pump (8.2 + 8.5)..
(4) Swing motor back pressure valve blocks (195.1 + 195.2)
(5) Swing brake valve blocks (49.1 + 49.2).
(6) Swing motor (20.1 + 20.2)
(7) Pressure relieve valve (swing motor back pressure)
(8) Check valve
(9) Pressure check point M35.1 and M35.2
(10) Valve drain connection
A Input from gear pump
B Output to swing brake block
T Tank connection to return oil collector tube

During the swing down phases the swing motors (6) are working as “pumps”.
It means that the pressure side change to a suction side and the suction side
change to a pressure side. To prevent cavitation in the swing motors during
this change there are two back pressure valves (4) fitted. The valves (4)
together with the gear pumps (3) increase the main back pressure up to 15
bar. Port B is direct connected to the tank port (return line) of the swing brake
valve block (5).

Adjustments - Measurements -Settings


Setting of the swing circuit back pressure valves (3)

1. Connect pressure gauge (0 – 25 bar) to check points M35.1 and M35.2


at the valve blocks (195.1 +195.2). The valve blocks fitted at the return
oil collector tube in front of the hydraulic tank.
2. Start both engines and let them run in high idle.
3. The pressure at the gauges should be 15 bar if the gauges shows a
different value the pressure relieve valves in the back pressure valve
must be adjusted.

a) Loosen look nut


b) Turn in or out set screw to increase or decrease the pressure.
c) Tighten look nut

4. Stop engines
5. Disconnect the gauges.

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8.2.6 Electric / Hydraulic flowchart “Swing Left”


Legend for illustration (Z 22503a):
(-10V) Signal voltage (Maximum)
(13) Main control block IV
(20.1 + 20.2) Swing motors
(43) Remote control valve block
(48) Distribution block
(49.1 + 49.2) Swing brake valve blocks
(A7) Amplifier module – Swing (Y32 + Y32a/b – Block IV)
(A16) Amplifier module – Swing brake
(D32) Time relay – Pilot control: Neutral position monitoring
(E20) Control lever (Joy stick)
(E50) Ramp time module
(E50B) Ramp time module – Swing brake
(K165) Relay counter lock (option)
(K253) Relay controlled by swing brake (foot brake)
(ws/gn) Colour code of signal voltage cable ( Joy stick)
(-X) Direction (axis) of joy stick (minus x = left)
(X2F...) Terminal rail with number
(Y32) Proportional solenoid valve
(Y32a + Y32b) Directional solenoid valve
(Y127) Proportional valve, controlling pressure increasing valve

The electrical signal.


Signal voltage of joy stick (E20) arrives via ramp time module (E50) at
terminal 5 of the amplifier module (A7) and further via relay K165 (if
equipped) to the proportional and directional solenoid valves of the remote
control blocks (43). In the same time signal voltage of joy stick arrives via
K253 and ramp time module E50B to terminal 5 of the amplifier module A16.
Relay contact 2 / 10 of relay K165 (if equipped) opened if the excavator
superstructure swing in a different direction as the lever direction (counter
look). Relay K253 energized if the swing brake pedal is activated this
eliminate the ramp time function of E50B.
The hydraulic signal. (pilot pressure)
When the proportional and directional solenoid valves are energized pilot
pressure oil flows to the pressure ports of the main control blocks.
Proportional valve Y127 increase proportional to the lever deflection the pilot
pressure to the pressure increasing valves.
The hydraulic oil flow
Now the oil of the main pump 3 flows through the main control block (IV) and
arrives via swing brake valves (49.1 + 49.2) at the swing motors (20.1 + 20.2).

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8.2.7 Electric / Hydraulic flowchart “Swing Right”

Legend for illustration (Z 22504a):


(+10V) Signal voltage (Maximum)
(13) Main control block IV
(20.1 + 20.2) Swing motors
(43) Remote control valve block
(48) Distribution block
(49.1 + 49.2) Swing brake valve blocks
(A7) Amplifier module – Swing (Y32 + Y32a/b – Block IV)
(A16) Amplifier module – Swing brake
(D32) Time relay – Pilot control: Neutral position monitoring
(E20) Control lever (Joy stick)
(E50) Ramp time module
(E50B) Ramp time module – Swing brake
(K165) Relay counter lock (option)
(K253) Relay controlled by swing brake (foot brake)
(ws/gn) Colour code of signal voltage cable ( Joy stick)
(+X) Direction (axis) of joy stick (plus x = right)
(X2F...) Terminal rail with number
(Y32) Proportional solenoid valve
(Y32a + Y32b) Directional solenoid valve
(Y127) Proportional valve, controlling pressure increasing valve

The electrical signal.


Signal voltage of joy stick (E20) arrives via ramp time module (E50) at
terminal 5 of the amplifier module (A7) and further via relay K165 K165 (if
equipped) to the proportional and directional solenoid valves of the remote
control blocks (43). In the same time signal voltage of joy stick arrives via
K253 and ramp time module E50B to terminal 5 of the amplifier module A16.
Relay contact 2 / 10 of relay K165 (option) opened if the excavator
superstructure swing in a different direction as the lever direction (counter
look). Relay K253 energized if the swing brake pedal is activated this
eliminate the ramp time function of E50B.
The hydraulic signal. (pilot pressure)
When the proportional and directional solenoid valves are energized pilot
pressure oil flows to the pressure ports of the main control blocks.
Proportional valve Y127 increase proportional to the lever deflection the pilot
pressure to the pressure increasing valves.

The hydraulic oil flow


Now the oil of the main pump 3 flows through the main control block (IV) and
arrives via swing brake valves (49.1 + 49.2) at the swing motors (20.1 + 20.2).

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Page 15

8.2.8 Swing Monitoring System, illustration (Z 21947a)


There are two reasons why the swing monitoring system is installed:
a) ⇒ To prevent adverse effects of a counter action.
b) ⇒ To increase the swing speed, by reducing the swivel angel of the
swing motor (lowering the required oil volume per motor rotation)

Function of the swing monitoring system:


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

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Page 16

8.2.8 Swing Monitoring System, illustration (Z 21947a)

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

b) E42 for monitoring the slew direction


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

c) E43 for monitoring the slew direction


E43 is an programmable module which is factory programmed with the
parameters are shown in the electric diagram below.

Settings:
E43 (speed monitor) “counter prevention”
No Function nominal setting
1 Setting the start up delay Not used set to “0”
2 Fine setting of the preset value (pulses / min.) 12 imp/min (i.e.120)
3 Setting the hysteresis Not used set to “0”
4 LED: lights when the output relay is energised ---
5 Setting the switching function Set to “III”
6 Coarse setting of the preset value (pulses / min) X x 10 imp/min

If necessary increase or decrease the imp/min with set screw no. 2


until a smooth slew operation is possible.

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Page 17

8.2.9 Checks and adjustments for the swing circuit

) • It is important that the complete MRV-valve and the Pressure


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

High pressure check / adjustment


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

continue

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Page 18

8.2.9 Checks and adjustments for the swing circuit

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

Low pressure check / adjustment (Swinging down path (drifting)


(with still disconnected pilot pressure line )

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

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

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Page 19

8.2.10 Checks and adjustments for the swing circuit

Cont'd:

Brake pilot pressure - check / adjustment


1. Connect the gauge to the check point M4.
2. Start engine and let it run with max. speed.
3. Depress fully the foot brake pedal and read the pressure.

The pressure must be 19 +3 bar.


If adjustment is required:
Alter the position of the potentiometer R2 of the amplifier A16 as long as the
pressure is 19 +3 bar.

Basic adjustment for A16 see section 5

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Hydraulic for the travel circuit Section 8.3
Page 1

Table of contents section 8.3

Section Page
8.3 Travel System
8.3.1 Travel Circuit (Brief description) 2+3
8.3.2 Rotary Distributor 4+5
8.3.3 Side Frame Components 6
8.3.4 Travel Gear and Parking Brake 7
8.3.5 Parking Brake 8
8.3.6 Electric / Hydraulic Flow Chart 9
8.3.7 Adjustment / Checks 10 + 12

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Travel System Section 8.3
Page 2

Travel Circuit

Legend for illustration (Z 22521):

(1; 2; 5; 6) Main pumps


(14 / I) L.H. Control block
(16 / III) R.H. Control block
(21.1- 21.4) Travel motors (A2FM 355)
(28.1+28.2) Travel motors valve blocks
(34) Rotary distributor
(40) Suction tank
(46.1+46.2) Double filter
(52.1 + 52.4) Travel gear house brakes
(M12.1 + M12.4) High pressure check points
(M33.1, M33.2) High pressure check points left travel motors
(M33.3, M33.4) High pressure check points right travel motors

Brief description
(Study together with the machine valid hydraulic and electric circuit dia-
gram).

Control circuits, not shown


By the function of the remote control valve (45.1 + 45.3) pilot pressure oil is
sent to one side of each control block (14/I + 16/III) when operating the foot
pedal for travelling "Forward or Reverse“.

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Travel System Section 8.3
Page 3

8.3.1 Service circuits ( Z22521)

(Study together with the valid hydraulic and electric circuit diagram for the
machine).

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

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Travel System Section 8.3
Page 4

8.3.2 Rotary Distributor

Task:
The rotary distributor (joint) permits a hydraulic connection between the su-
perstructure and the under- carriage, that means between the rotating and the
stationary part.

Legend for illustration (Z 22522):

(1) Rotor
(2) Rotary distributor housing
(3) Cover
(4) Thrust washer
(6) Sealing plunger
(8+9) Seal ring and O-ring
(10) PTFE Sealing
(11) V – Sealing
(12) Rotor guide rings
(13) O-ring

Translations:
Schnitt = Cross section
Versetzt gezeichnet = Offset drawn
Verschlußschraube mit Loctite gesichert = Plug screw sealed with Loctite
mit Körnerschlag gesichert = sealed with punch mark
Kammer mit Fett gefüllt = Chamber grease filled

Ports:
A-D Service lines
L Leak oil
ST Control oil „Travel break“
X Control oil (travel motor flushing)
K1 Track tensioning
K2 Track tensioning

continued

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Travel System Section 8.3
Page 5

Cont’d.

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

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Page 6

8.3.3 Side Frame Components, Cross Sections


Illustration Z 22523

A Under carriage view from the back side


B Final drive with
C Side frame with top and bottom roller
D Track tensioning cylinder

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Page 7

8.3.4 Travel Gear and Parking Brake

Function principle ( illustration Z22524a):


The spur gear stage (B) is driven by two hydraulic motors via two drive
shafts (A). This in turn causes that by the shaft (C) the first planetary stage
(D) is driven; opposite the input drive direction.
The planetary gears of the second planetary stage are connected to the hollow
shaft (G).
The drive sprocket is mounted to the hollow shaft (G).

For maintenance see MAINTENANCE MANUAL


For more details see PARTS BOOK.

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Travel System Section 8.3
Page 8

8.3.5 Parking Brake


Illustration Z 22525
The Spring Loaded Multi-disk Brake is used as a safety brake (parking
brake); applied by spring force and released by oil pressure.

Legend:
(1) Disk housing
(2) Piston
(3) Back-up ring with radial seal rings (15)
(4) Bach-up ring
(5) Coupler
(6) Inner disks (lamellas)
(7) Outer disks
(8 + 9) Springs
(10 - 12) O-ring
(13) Clip ring
(14) Clip ring
(16) Release pressure port
(17) Quad-Ring with back-up rings (18)
(19) Quad-Ring with back-up rings (20)
(21 + 22) Plug screw with seal ring

Function:
Brake applied:
The outer disks (7) engaged to the housing by serration and the inner disks (6) in
serration connection with the coupler, are pressed together by the springs (8 +
9). This results in a fixed connection between housing and coupler.

Brake released:
Oil pressure via port (16) reaches the left side of the piston (2) and forces the
piston towards the back-up ring (4), as shown.
This function eliminates the spring force onto the disks thus the brake is re-
leased.
The releasing pressure is 18 bar, the maximum permissible pressure 60 bar.
This brake named "Wet Brake" because the brake housing is filled with gear oil.
For maintenance see MAINTENANCE MANUAL
For more details see PARTS BOOK

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Travel System Section 8.3
Page 9

Electric / Hydraulic Flow Charts

Illustration Z 22526

On the following pages are shown the electric / hydraulic flow charts for the
travel circuit.

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

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Travel System Section 8.3
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Adjustments / Checks

) • It is important that the complete MRV-valve is firmly (with 300 Nm)


tightened.
Otherwise, the internal sealing sealed not properly which results in:
difficulty setting, loud flow noises and abnormal temperatures.

High pressure check / adjustment (illustration Z 22528)


1. Connect the gauge (0-400 bar) to the check points M12.1. and M12.4
at the double high pressure filters.
2. Unplug solenoid valve Y16 (Z 22529, filter and valve panel motor 2) to
keep the parking brake applied.
3. Start both engines and let it run in high idle.
4. Engage carefully desired travel motion and hold foot pedal in final po-
sition to built up max. pressure.
5. Increase * slowly the MRV-pressure while observing the pressure
gauge. Gauge value must remain at 310 +5 bar.

Motor 2

continued

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Page 11

Cont’d.

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

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

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

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

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Page 13

Function Check of the Travel Gear House Brake

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

) • In a case of malfunctioning check the electrical controlling and the


solenoid valve Y16.

Function check of the pressure switch (B48)


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

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Hydraulic Track Tensioning System Section 9.0
Page 1

Table of contents section 9.0

Section Page
9.0 Hydraulic Track Tensioning System
General 2

9.1 Functional description 3+4


9.2 Pressure Increasing Valve 5
9.3 Tensioning Cylinder 6
9.4 Adjustments / Checks 7–9
9.5 Functional test 9

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9.0 General:

Legend for illustration (Z 22453):


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

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

) For information about the preventative track inspection, refer to the


Operation and Maintenance Manual.

Functional description on next page

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Page 3

9.1 Functional description:

Illustration Z 22454:

) Under normal operating condition the shut-off cock (54.1) located on


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

The oil flow of the pilot pressure pumps (7.1 + 7.2), filtered by pressure filter
(68.1) enters port "P" of the solenoid valves Y16 via hydraulic line L3 and
the rotary joint to the track tensioning valve block (181) in the car body.
If solenoid valves Y16 is actuated (i.e. pressure at sensor B48), the oil flows
(X2-pressure with 35 bar) via the pressure relive valve (83), rotary joint (34), the
shut-off cock (184) and check valves (180.1+180.2) into the tensioning cylinders
(62.1 - 62.4).
The resulting force moves the guide wheels toward the front, until the correct
track tension is obtained.
Simultaneously the system is connected to the pressure increasing valve (182).
External forces acting at the guide wheels will be absorbed through the pressure
accumulators (60.1 + 60.2, first stage) and (59.1 + 59.2, second stage).

Purpose of the pressure increasing valve


The two system pressures
• 35 bar with motors stopped
• 315 bar with motors running
are controlled by the pressure increasing valve as follows.
With stopped motors and switched off ignition there is no pilot pressure (X2) at
the pressure increasing valve (182) and only the lowest adjusted pressure of 35
bar remains in the system.
As soon as one motor has been started, the pilot pressure (X2) of 35 bar act
on the pressure increasing valve. As a result the system pressure can rise to
the adjusted pressure of 315 bar.

continued

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Hydraulic Track Tensioning System Section 9.0
Page 4

Cont'd.:

9.1 Functional description:

Illustration (Z 22454):

Cushioning Function
When the tensioning cylinders (62.1 - 62.4) are moved in by external forces,
the none return valves (179.1 + 179.2) will be closed.
A certain amount from the displaced oil of the tensioning cylinders is taken
up by the pressure accumulators.
First stage: at a pressure higher than 31 bar, is taken up by the side frame
accumulators (60.1.1 + 60.2).
Second stage: at a pressure higher than 150 bar, is taken up by the center section
accumulators (59.1 + 59.2).
The system pressure can rise up to 315 bar pressure increasing valve (182)
setting.
With reduction of external forces, the oil is pushed back by the accumulator
pressure into the tensioning cylinders.
If the displaced oil volume was higher than the accumulators could take up,
oil is added from the pilot pressure circuit (X2), as soon as the pressure in the
lines to the tensioning cylinder is lower than 35 bar.

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Page 5

9.2 Pressure Increasing Valve

) The pressure increasing valve is a remote controlled pressure relief


valve.

Legend for illustration (Z 21846):


(1) Pilot valve with valve seat
(2) Valve poppet
(3) Compression spring
(4) Main valve with sleeve
(5) Main piston
(6) Closing spring
(7) Set screw - low pressure 35 bar
(8) Set screw - high pressure 310bar
(9) Piston
(10) Pin
(11+12) Jet bore
(13+14) Lock nut

Function:
The valve poppet (2) is connected via the jet bores (11) and (12) with the 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); one
turn of the screw ~ 150 bar. The possible max. pressure setting with the set
screw (8) on block is about 440 bar.

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9.3 Tensioning cylinder:

Legend for illustration (Z 21929):

(1) Cylinder tube


(2) Piston
(3) Piston guide ring
(4) Piston guide strap
(5) Seal ring
(6) O-ring
(7) Scraper
(8) Retracting device
(M) Bleeder port
(P) Oil supply

• Maximum permissible piston stroke 350mm!


During bench test an external stroke limitation must be used!

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Hydraulic Track Tensioning System Section 9.0
Page 7

9.4 Adjustments / Checks

Legend for illustration (Z 22455):


(182) Pressure increasing valve
(54.3) Service shut-off cock for the R.H.-side
(54.2) Service shut-off cock for the L.H.-side (not illustrated)
(59.2) Bladder accumulator 150 bar
(60.2) Accumulator 31 bar
(MRV) Main relief valve – Operating pressure of main control
block I
(M12.4) Pressure check point – Operating pressure of main control
block I
(M15.6) Bleeder and hydraulic pressure check point at the bladder
accumulator (59.2) for the R.H.-side.
(M15.5) Bleeder and hydraulic pressure check point at the bladder
accumulator (59.1) for the L.H.-side (not illustrated).
(M15.3) Pressure check point - track tensioning system
operating pressure – R.H.
(62.3+62.4) Track tensioning cylinder R.H.

Checking / Setting the pressure increasing valve


Pre-conditions: Correct MRV, SRV and pilot pressure setting and the system
must be free of air.
The description is only for the R.H. track. The same procedure applies also
for the L.H. side.
Basic Adjustment:
1. Connect a pressure gauge (min.400 bar) to check point M12.4.
2. Start one motor.
3. Increase the MRV-setting (Block I), ~ 330 to 340 bar.
4. Switch OFF the motor, open cock valve (54.1) to allow pressure
relieve of the R.H. track, and close it again.

continued

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Hydraulic Track Tensioning System Section 9.0
Page 8

Cont'd.:

9.4 Adjustments / Checks

5. Move the pressure gauge from M12.4 to M15.3


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

If the gauge shows a lower or higher value the pressure increasing valve
must be adjusted.
Setting procedure, high pressure stage (Valve 58.2)
a) Loosen lock nut (2).
b) Adjust pressure with set screw (3).
c) 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 58.2)
a) Stall the hydraulic with the bucket filling function (bucket
cylinders completely extended) and observe pressure at check
point M15.3.
b) loosen lock nut (4) and turn set screw (5) ccw until gauge at
check-point M15.8 shows 35 bar.
c) Tighten lock nut (4).
d) Re-check pressure setting.
continued
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Hydraulic Track Tensioning System Section 9.0
Page 9

Cont'd.:

9.4 Adjustments / Checks

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

9.5 Functional Test

After all adjustments are finished, do the following:


a) Bleed all air from the system
b) Place shutoff and pressure relief cocks into correct operating position.
c) Connect pressure gauge to check point (M15.3).
d) Start both motors.
e) Travel approx. 10 m with the shovel. The pressure should be rise to a
higher value.
f) Stop the motors.
g) The pressure must drop to 35 bar.

If the pressure remains at a higher or lower pressure*, re-adjust the low


pressure setting at the pressure increasing valve (182) is necessary.

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

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Access ladder Section 10.0
Page 1
hydraulically operated

Table of contents section 10.0

Section Page
10.0 Access ladder hydraulic operated
10.0 General 2
10.1 Function of hydraulic operated access ladder 3+4

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Access ladder Section 10.0
Page 2
hydraulically operated

10. Access ladder hydraulic operated


General

legend for Illustration Z22494


(A) Access ladder in lowered position
(B) Access ladder way to upper position
(C) Stop bar
(Z) Hydraulic cylinder
(S84) Ladder control switch “up”
(S84B) Ladder control switch “down”
(S84A) safety switch operated from ground level for lowering (pull switch)
(S22) Control sensor : Cut off the pilot control system and actuation of the
slew brake with ladder in lowered position.
(S91) Monitor and control sensor: It monitors the ladder position and
controls the moving speed of the ladder. In case the sensor (S22)
fails, the sensor (S91) prevents unintended movement of the ladder .

The access ladder is hydraulic driven by the hydraulic cylinder (Z) via the 60
bar X4 pressure. S84 is the control switch to move the ladder up and down.
The additional pull switch S84A move the ladder only down from the ground.
To lower the ladder the motor can run or stand still. Only to move the ladder
up the motor must running.

) If the ladder is out of the upper position the pilot control system
switches off (all machine movements stoped) and the solenoid valve
Y120 activates the service swing brake. The text display in the cab
shows a message.

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hydraulically operated

10.1 Function of hydraulic operated access ladder


illustration (Z 22495):

Legend:
(7.1+7.2) Pumps
(84.1+84.2) Check valves
(68.1) Filter with filter monitoring switch B22
(70.1) Pressure relieve valve (60 bar)
(70.2) Pressure relieve valve (35 bar)
(162.3 – 5) Check valves
(171) Pressure relieve valve (70 bar)
(174) Ladder cylinder
(172) Orifice
Y125 Solenoid valve: lower speed limit
Y123A Solenoid valve: ladder up
Y123B Solenoid valve: ladder down

The motor is running


Additional to the hydraulic diagram Z22495 use the electric diagram on next
page

The pumps (7.1) and (7.2) are delivering oil through filter (68.1) to port P of the
solenoid valve Y123A/B and the pressure relief valve (70.1) port A. The pressure
relief valve (70.1) maintains the adjusted pressure of maximum 60 bar.
Solenoid valve Y123A/B lead pump oil to the cylinder if one of the solenoids is
energised. Depend on the activated solenoid valve the ladder move up or down.
The pressure relief valve (171) limits the pressure of the ladder cylinder to max.
70 bar.
Return oil from the cylinder flows back via solenoid valve Y123A/B to the
solenoid valve Y125. With energised solenoid this valve lead back oil unhindered
to the oil tank It is energised when both approximately switch S22 and S91 are not
activated (ladder between upper and lower end position). A short way before the
ladder reached one of the end positions one sensor (S 22 – in up position; S 91 –
in down position) switch on and de energise Y125. Now back oil must pass the
orifice (172). By the flow resistance of the orifice the ladder motion will be
slowed down.
If the ladder is in the “Up – position” the activated sensor S22 de-energised Y125
and energised Y123A, now the still connected pump pressure to the cylinder
piston side keep the ladder in the final up position.
If switch S84 is in neutral position and the ladder in “down – position” sensor S91
de-energise all solenoids (Y125; Y123 A+B) and the ladder is “blocked”.

continued

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Access ladder Section 10.0
9 Page 4
hydraulically operated

Cont'd:

The motor is out and the ladder is in the “Up – position”

With activated switch S84 to position 2 (ladder down) solenoid valve Y123B
and relay K132 are active. Y123B opened the piston side of the cylinder to
the tank and K132 activate Y125 that the oil can flow without resistance to
the tank. Now the ladder can move down only by its own mass (gravity). The
operator have 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 (162.3).
It is no key contact necessary this function is direct supplied to the battery via
fuse F17.
There is an additional pull switch S84A below the ladder support. With this
switch 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 can be the result.

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Section 11.0
Cable drum
Page 1

Table of contents section 11.0

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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Section 11.0
Cable drum
Page 2

11.0 Cable drum

General

Legend for Illustration Z 22831a


(5M6) Brake motor
(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 windings.
(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 for ground contact protection.

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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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).
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).
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 limit switch 5S7* stops forward travelling by de-energizing K177 as soon as the safety
cable length on the drum gets unwinded.
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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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

11.2.1 Controlling of the drive motor

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)

Winding up (automatic mode of control switch 5S1):


While winding up the NC-contact of switch 5S3 remains closed which allows
voltage to the relay 5K10 and (if the contact 21/22 of switch 5S4 is closed) also to
5K11.
Example travelling reverse:
Cable length on drum: ½Max. – Max. => 5K10 ON + 5K11 ON => max. torque
Cable length on drum: Min. – ½Max. => 5K10 ON + 5K11 OFF => reduced torque

Unwinding (automatic mode of control switch 5S1):


The NC-contact of switch 5S3 opens while traveling forward and de-energizes
simultaneously 5K10 and 5K11, with the result that there is just enough torque to
hold the cable tight.

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11.2 Function

11.2.2 Travel motion control, illustration Z 22835

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

) If the reverse motion stopped because of a activated ground contact


switch 5S10 or 5S11 it is possible to activate the reverse motion manually
via activation of horn switch at the left control lever in the cab.

) Refer to section 8.3 in this Manual for further information.

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Page 6

11.3 Checks and Adjustments


Legend for Illustration Z 22836a
(5S3) Rotation direction indicator (switch)
No adjustment required. Check the function of contact 2/P.
The built-in switch must open while unwinding.
(5S4) Gear type cam switch for resistor controlling and safety switch
to detect full cable drum and the last two safety cable windings.
The contact 31/32 must open as soon as the maximum
permissible cable length is on the drum, travel reverse will stop
by deactivated relay K178.
As soon as the last second winding comes up contact 11/12
opens and travel forward will stop by deactivated relay K177.
Adjusting procedure see section 11.4 on next page and check the
function under operating conditions.
(5S6) Pendulum control cam switch, to detect slack or tight cable.
Adjust the switch in such a way that contact 11/12 opens at
too tight cable and contact 21/22 opens at too slack cable.
Check the function under operating conditions. Make sure
that the shock absorber at the pendulum will work in its
permissible range.
Adjusting procedure see section 11.4 on next page.
(5S7)
(5S8, 5S9) Proximity switch to detect cable deflection to right or left.
Adjust the distance between switch and metal bar to 7mm.
Check the function under operating conditions.
(F79) Motor temperature control unit with monitoring LED’s.
(R) – red LED on => motor temperature to high.
(G) – green LED on => permissible temperature range.
Hysteresis:
Rcold ≤ 1kΩ, Rswitch point ≥ 3kΩ (Sensor between P1 and P2)
Check the function with potentiometer.
(D53) Time relay for power cut off after 10 seconds without travelling.
Check adjustment, refer to service Bulletin 21-584 for more
information.
(X2 + X8) Terminal board

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11.4 Description and operating instruction for cam switch 5S4

Legend for Illustration Z 22837


(1) Micro switch housing
(2) Actuator (Roller lever)
(3) Cam disc
(4) Adjusting spanner
(5) Cup spring
(6) Tension nut

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).

Adjustment of the switch mechanism.


1. Loosen the tensioning nut (6) with the handle of the adjusting spanner (4).
2. Bring the adjusting spanner (4) in the position shown on illustration Z22837.
3. Set the cam discs (3) to the required position.
4. Adjust all other cam discs, following this procedure.
5. When all cam discs have been adjusted, tighten the tensioning nut.

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Hints for reading the Section 12.0
Page 1
Hydraulic Circuit Diagram

Table of contents section 12.0

Section Page
12.0 Hints for reading the hydraulic circuit diagram
General 2

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

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12.0
2

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Page 3
Hydraulic Circuit Diagram

12.0 General:

Legend for Illustration Z22987

) •

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.

Item Description Number / Code Explanation

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

• All the components drawn in neutral and pressure less position.


• Full wide continues black line shows a main component or assembly. (Ex.: Valve
and Filter panel, Main pump, Hydraulic tank, ...)
• Continues black line shows a main hydraulic line. This lines are temporary or
continues load with high or pilot pressure.
• Broken line shows a return, drain or control oil line.
• Black dot shows a connection point. The position of this connection is not definitely
fixed.
• White dot shows a connection or port of a component with a fix definitely position
or port number.
• Page 1 shows the high pressure main hydraulic circuits with all pilot control valves,
control blocks, distributor manifold and cylinders or motors.
• Page 2 shows all main pumps and pilot pressure pumps with the main pump control
system and the other auxiliary pilot pressure circuits as lubrication system and
ladder.
• Page 3 shows the main pump control arrangement, the auxiliary circuits with oil
cooling system and the hydraulic tank.
• Page 4 shows the car body hydraulic with travel brakes, travel motors and track

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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.

3 Case drain (leak) oil line, Return lines, connected to


can be a hose or a pipe. the case drain (leak) oil filter
chamber of the main oil
reservoir.
4 Control oil line, can be a Pilot control line, pump
hose or a pipe. regulation line and parking
brake control lines.

5 Crossed lines Pipes or hoses not


connected

6 Connection point, is a Connection between


connection of hydraulic several lines
lines without definite
position
7 Component connection Connection to components
point, is a connection with like, valve blocks, tanks,
a definite position at a pumps, ...
component
8 Plugged connection point, Not used connection
can be plugged with any points.
kind of plugs.

9 Plugged line inside of a Not used connection


manifold, can be plugged points.
with different kind of plugs.

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12.0
6

12.1 Symbols

12.1.1 Line, union


Symbol Description Used as / at / on
10 Compensator, Oil tank outlet to the
Compensate line length pumps
differences depend on
vibration and temperature.
11 Quick coupling, Tank drain couplings, often
is a special union with removed lines (e.g. at grease
integrated check valve systems with removable
barrels).
12 Blind, Orifice, e.g. Oil cooler inlet,
not adjustable with
orifice diameter in mm

13 Pressure check point HP Filter, Fan valve


With a special quick block....at all important
coupling. circuits

14 Distributor block Connection of lines with


the same destination e.g.
return lines to tank

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Hints for reading the Section 12.0
Page 7
Hydraulic Circuit Diagram

12.1 Symbols

12.1.2 Components, valves


Symbol Description Used as / at / on
15 Accumulator, Input line to the remote
is filled with nitrogen gas control valves, return oil
with for the respective collecting tube, track
accumulator specified tensioning system
pressure
16 Screen filter, Installed in suction lines to
the screen size is 1.0 mm the pumps, oil tank outlet,
return oil collecting tube

17 Oil cooler, Hydraulic oil cooler,


PTO oil cooler

18 Breather filter, On top of PTO or


hydraulic tank

19 Spray nozzles, Gearbox (PTO) cooling


inside of a case for and lubricating system
cooling and lubricating

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

21 Pressure switch e.g. swing or travel


Input = pressure detection PC3000,
Output = digital electrical
The switch point is 24 bar

22 Temperature sensor, e.g. hydraulic tank


Input = temperature
Output = electric signal
proportional to the
temperature

23 Level sensor, Hydraulic tank, fuel tank


Input = fluid level
Output = electrical signal
analogue or digital

24 Chip sensor, Main pumps


Input = contaminate oil
Output = electrical digital
signal

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Page 9
Hydraulic Circuit Diagram

12.1 Symbols

12.1.4 Valves, valve components


Symbol Description Used as / at / on
25 Manuel operated unit Valve in track tensioning
Lever system,

26 Electric / magnetic Solenoid valve


operated unit
Solenoid

27 Pilot pressure Pressure relief valve, disc


controlled unit brake, ...

28 Spring, Solenoid valves,


with fixed force

29 Spring adjustable Pressure relieve valves,....


spring force is adjustable

30 Check valve e.g. main pump outlet,


In drawn pos.: from right swing brake valve block,
to left free flow, from left anti cavitation valves at
to right blocked flow. main control blocks or
distribution manifold
31 Check valve spring By pass of the return oil
loaded filter, by pass of
Opened in flow direction secondary filter
only against spring force
= pressure
32 Double check valve, Swing brake control,
in drawn pos.: opened
only from the left to the
bottom or from the right
to bottom

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10

12.1 Symbols

12.1.4 Valves, valve components


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

34 2/2 control valve Track tensioning system


manual operated,
2/2 cock valve

35 3/2 control valve Change over valve from


manual operated, electronically pump
3/2 cock valve regulation to emergency
mode (hydraulically
pump regulation)
36 4/2 directional control valve e.g. swing parking brake,
as solenoid valve travel parking brake,
4/2 way solenoid valve, ladder controlling,,
electrically controlled.
Neutral position:
P-A and B-T connected.
37 Variable throttle valve Travel brake valve,
hydraulically controlled located in the car body
pilot control port pressure
less = maximum restriction
38 3/2 directional control Service arm controlling
solenoid valve, seat
design = leak oil free
3/2 way solenoid valve,
neutral = port P-A open
39 4/3 directional control Ladder controlling,
solenoid valve service arm controlling
4/2 way solenoid valve,
in neutral all ports closed
40 External pilot PC 3000 and PC4000
controlled proportional with floating system
floating valve

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Hints for reading the Section 12.0
Page 11
Hydraulic Circuit Diagram

12.1 Symbols

12.1.4 Valves and valve components


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

42 Main control valve Control valve for pressure


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

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12.0
12

12.1 Symbols

12.1.4 Valves and valve components


Symbol Description Used as / at / on
45 Pressure relief valve, e.g. ladder controlling,
direct controlled and service arm controlling ..
adjustable

46 Pressure relief valve Secondary relieve valve


with anti cavitation at main control blocks
valve (check valve)
Assembly, external drain
at port Y

47 Pressure increasing valve Swing brake block, track


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

48 Proportional pressure Remote control valves to


valve, reduce the control the main control
pressure in port A blocks,
proportional to the
solenoid current.
49 4 port proportional Pump regulation, only
pressure relief valve, output port A is used for
direct operated by a our systems
proportional solenoids.

50 Pressure relief valve, Radiator and oil cooler


mechanical and fan drive
hydraulically via pilot
port X adjustable, oil
drain port Y
51 Throttle check valve Distribution manifold
with secondary relieve normally in the line to the
valve, throttle and cylinder piston side.
secondary valve
mechanical adjustable,
external drain at port Y.

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Page 13
Hydraulic Circuit Diagram

12.1 Symbols

12.1.5 Pump, motor, cylinder


Symbol Description Used as / at / on
52 Single acting Cylinder, Track tensioning system
pressurised moving only
in one direction, return by
external force

53 Double acting Cylinder, Attachment i.e. boom,


Cylinder in which the fluid stick, bucket or clam
pressure operates alternately cylinder
in both directions (forward
A B and backward strokes)
A = Piston side
B = Rod side
54 Drive shaft of a motor Main pumps, swing
or pump with one motor, fan drive, travel
direction drive

55 Hydraulic pump with fix Fan pump, circulation


volume per revolution pump, pilot pump, PTO
suction port S and pressure lubrication pump
outlet P

56 Hydraulic pump with Main pumps


variable output volume
per revolution
with external case drain

57 Hydraulic pump Main pumps


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

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12.0
14

12.1 Symbols

12.1.5 Pump, motor, cylinder


Symbol Description Used as / at / on
58 Variable hydraulic Main pump
pump with charge
pump
and external drive shaft
bearing lubrication

59 Hydraulic motor Fan motor


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

60 Motor with disc brake Travel motor


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

61 Variable swing motor Swing motor PC5500


with integrated control
valves and flushing
valves

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Page 15
Hydraulic Circuit Diagram

12.1 Symbols

12.1.6 Assembly and main components


Symbol Description Used as / at / on
62 Lubricant pump drive Lubricant pump station
differential cylinder with for central lubrication
integrated control valves system and swing ring
to propel the grease pump lubrication system

63 Swing brake valve Swing brake system.


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

64 Rotary joint Hydraulical connection


Upper part with between superstructure
connections drawn to and car body
the top, lower part with
connections drawn to
the bottom

65 Travel brake valve block mounted in the supply


with secondary pressure line to the travel motors,
relieve valve is located in the car body
is connected in the line to
the travel motors. The
return oil flow is restricted
according to the pressure
inlet.

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12.0
16

12.1 Symbols

12.1.6 Assembly and main components


Symbol Description Used as / at / on
66 Remote control lever to Control lever in the
control the main control operators cabin
blocks

67 Remote control pedal to Control lever in the


control the main control operators cabin
blocks

68 Hydraulic oil tank with Main hydraulic tank


leak and return oil filter,
back pressure valve and
sensors

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Page 17
Hydraulic Circuit Diagram

04.01.07 PC5500-6_Sec_12-0_rev3.doc
Hints for reading the Section 13.0
Page 1
Electric Circuit Diagram

Table of contents section 13.0

Section Page
13.0 Hints for reading the electric circuit diagram

13.1 Designation of electrical devices 2


13.2 Symbols 3+4
13.3 General information 5+6
13.4 Reading a circuit diagram 7+8
13.0
2
Hints for reading the Section 13.0
Page 2
Electric Circuit Diagram

13.1 Designation of electrical devices

Indicating letter Kind of component


A System, subassembly, parts group, trigger boxes, control units
B Transducer for conversion of non-electrical variables to electrical
variables, and vice versa.
Speed sensors, pressure sensors, pressure switches, oil-pressure
switches, temperature sensors
C Condenser, capacitor, Condensers and capacitors, general
D Elements with time lag, memory elements, binary elements
E Various devices and equipment
F Protection device
Fuses, current protection circuits
G Power supply, generator
Batteries, generators, alternators
H Monitor, alarm, signaling device
Indicator lights, signal lights, headlights, warning buzzers, horn
K Relay, contactors
L Inductor
Coils, windings
M Motor
N Regulators, amplifiers
P Measuring instrument
Q High voltage switching units
R Resistors, heating devices
S Switches, selectors
T Transformer
U Modulator, converter from one electrical in an other electrical value
V Semiconductor, electron tubes, diodes, rectifiers, zener diodes
W Transmission path, conductor, antenna
X Terminal, Plug, Plug and socket connection
Y Electrically actuated mechanical device
Solenoid-operated valves
Z Compensating units, filters, limiters cable connection
13.0
3
Hints for reading the Section 13.0
Page 3
Electric Circuit Diagram

13.2 Symbols

Legend for illustration (Z 21816):

Our common used symbols in accordance to VDE/IEC (Association of


German Electrical Engineers DIN 40710 - 40716 and the International
Electrical Commission) differ for the most part from the symbols in
accordance to JIC/ASA (Joint Industrial Concil and American Standard
Association) USA and Canada JIC EMP-1-1967 and ASA 2 32-3).
For this reason the following comparative chart.

1) Normally open 2) Maintained 3) Single pole


contact contact two way contact
break before make
4) Normally 5) Push-button 6) Limit switch
closed contact switch NO contact
NC contact
7) Manual operated 8) Foot-operated 9) Pressure
switch isolator, push-button operated switch
disconnect switch switch
10) NO contact with 11) Multi-position 12) Indicating
time lag switch selector instrument
(general) symbol
13) Contacts with 14) Resistor 15) Ammeter
time lag general

16) Battery 17) Tapped 18) Voltmeter


resistor

19) Inductive 20) Continuously 21) Recording


resistance adjustable, instrument
general

22) With iron core 23) Adjustable in 24) Signal lamps


steps pilot lights

25) Continuously 26) Potentiometer 27) Operating coil


adjustable rhesostat solenoid

28) Transformer 29) Capacitor 30) Rectifier, semi


general, conductor
continuously
adjustable
13.0
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Hints for reading the Section 13.0
Page 4
Electric Circuit Diagram

13.2 Symbols

Legend for illustration (Z 21817):

31) Rectifier bridge 32) Thermal over load limit 33) Phase, 4-wire system

34) Current transformer 35) Undervoltage relay 36) Junction of conductors

37) Voltage transformer 38) Temperature relay 39) Junction

40) Circuit interrupter 41) Contactor 42) Terminal

43) Circuit breaker, three 44) Generator (G)- 45) Terminal


phase Motor (M)

46) Thermal over- ground, 47) 3-phase-motor 48) Earthing, general


load protection

49) Magnetic over- socket 50) 3-phase squirrel cage


current protection

51) Plug and 52) Slipring motor

53) Fuse with bolted contacts 54) 3-phase squirrel cage


induction motor in
Star-delta starting
55) Thermal over- load relay 55) Two speed motor
(tapped windings)
(for ex. 8 to 4 poles)
13.0
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Hints for reading the Section 13.0
Page 5
Electric Circuit Diagram

13.3 General information

Legend for illustration (Z 21823):

Komatsu circuit diagrams


Each sheet has the following information in the bottom right hand corner:
Diagram Number example: 897 844 40
Machine Type example: PC4000-6
Sheet Number and Total Number of sheets 01/63 - 02/ . etc.

Each sheet is numbered from 8 (at the left corner) to 1 (at the right corner) along the
top and bottom lines, and lettered down from F (at the top) to A (at the bottom)
along the left and right side lines.
This coordinate system enables you to find components easily.

On the table of contents, page one, the individual circuits are listed up with the
respective page number.
Example: The circuit for the superstructure lighting is shown on page 39.

Pages number two, three and four are cross reference lists of component codes
related to page numbers.
Example: The relay with the component code “K1-1” is shown on page 8.

On page five is a list of answers to frequently asked questions (FAQ) concerning


abbreviations, function of components (e.g. time relays) mathematical symbols etc.
used in the diagram.

All electrical components are connected via cable harnesses to the main switch
board “X2”. There is only one Plug connector in between, which is always located
close to the respective component like sensors, solenoids etc.
All 24 volt wires are blue and have a printed code (every 10 cm) at each end of the
wire. (see illustration)
The first part of the code shows the required connection and the second part gives
the information what is connected at the other side of the wire.
Example:
going to coming from coming from going to

X2S = X2-Board, terminal group “S” Y136 = Plug connector to solenoid


45 = Terminal No 45 .1 = Terminal 1 of connector

All circuits are shown currentless and all relays and switches are in neutral position.
13.0
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Hints for reading the Section 13.0
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Electric Circuit Diagram

13.3 General information

Legend for illustration (Z 21824):

Explanation of the Drawing Concept

(1) Drawing number


(2) Sheet number / quantity of sheets
(3) Designation of drawing
(4) Designation of component or assembly
(5) Column (vertical sections)
(6) Lines (horizontal sections)
(7) Component symbol
(8) Neutral wire / machine ground
(9) Designation of phase
(10) Phase strip
(11) Terminal strip and terminal
(12) Cable plug and pin number
(13) Relay coil
(14) Relay contacts, partially with detailed information
(15) Cross reference for the continuation, Page / Column
(16) Indication where the relay contact opens or closes

Location of the Main Terminal Boxes

(X1) Dashboard inside the cabin


(X2) Main switch board inside the cab base
(3E14-1) Electronic control module (ECM- Quantum) left bank of the engine
(3E54-1) Electronic control module (ECM- Cense) flywheel end of the engine
13.0
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Hints for reading the Section 13.0
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Electric Circuit Diagram

13.4 Reading a Circuit Diagram.

Legend for illustration (Z 21825):

• Examples are shown by sectional drawings out of the electric circuit


) diagram 897 844 40 page 08.

(1) Section F8 / sheet 08


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

(2) Section C4 / sheet 08


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

Example for K51-1:


1 9
08.5 5 opens on sheet 8 section 5 when relay is energized
2 10
: 6 Not used
3 11
: 7 Not used
4 12
: 8 Not used

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

* LED between A1 and coil


** Diode between A1 and A2.

(3) Section F7 / sheet 08


Connectors and Terminals are identified by a letter and number
code. X2 o 23-28 = Terminal box X2 Terminals 23 to 28 are linked
with a metal bridge.
continued
13.0
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Hints for reading the Section 13.0
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Electric Circuit Diagram

Cont.:
13.4 Reading a Circuit Diagram.

Legend for illustration (Z 21826):

(4) Section E 1 sheet 08


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

a. F11 = Circuit breaker (24V power supply)

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.
Electronic Control System Section 14.0
ECS Page 1

Table of contents section 14.0


Section Page
14.0 Electronic Control System ECS

14.1 General Design of the ECS-T System 2


14.1.1 Input and outputs of the PLC 3
14.1.2 Task 3
14.1.3 PLC DIGSY plus ® 4
14.1.4 Definitions; Symbols and Abbreviations 5 + 6 +7

14.2 How to Proceed due Maintenance and Installation 8+9


14.2.1 Meaning of the Status LED’s 10 + 11
14.2.2 Short Circuit Marker -LED “MK” 12
14.2.3 Diagnostic for Temperature-Module “ANM” 13

14.3 Front Connector Arrangement 14


14.3.1 Front Connector Arrangement BIM-Module 14 + 15
14.3.2 Front Connector Arrangement, ANM-Module 16 + 17
14.3.3 Ground connection of the Control Unit 18
14.3.4 Interface-Connection COM SP /SK 19

14.4 Power supply 20


14.4.1 Operation Voltages +24 V 20
14.4.2 Safety Precautions for Faultfinding 21
14.4.3 CPU Voltage Range 22
14.4.4 Electric Classification 22
14.4.5 Fuse 22

14.5 Function explanations with electrical diagram 23


14.5.1 General 23
14.5.2 Pressure Measuring 24
14.5.3 Temperature Measuring 25 + 26
14.5.4 Temperature – Resistance Chart PT100 27

14.6 Hints for reading the functional flow charts 28


14.6.1 General 28
14.6.2 Example 29

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14.1 General Design of the ECS System

ECS Electronic Control System

Legend: Illust. Z 21407a

(1) PLC Programmable Logic Control (DIGSY plus ®)


(2) Text display
(3) Keys for function control and pre-adjustments
(4) Outlet “X27” for data transfer
(5) Field computer system (like MODULAR MINING)
(6) Printer
(7) Memory card unit
(8) Laptop
I/ O Input / Output data transfer

) • Items 5 to 8 are optional equipment

Meaning of the PLC front cover codes


• BIM Binary Module
• ANM Analogous Module
• MK Short Circuit Memory
• A Digital Output
• E Digital Input
• DIAG Diagnostic
More in detail see page 4

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14.1.1 Input and Output of the PLC, Illust. Z 21408

PLC = Programmable Logic Control


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

14.1.2 Task

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

) • The picture shows as an example the application for a two motor


version.

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ECS Page 4

14.1.3 PLC DIGSY plus ® (circuit diagram code E6)

Legend for illustration Z 21409b


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

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

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

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

State-LED Input lights up with a present 24 Volt signal.


State-LED Output lights up with a switched On output.

5V-LED, indicate specified operation states by different colors and duration of


lightning (Continuos On or flashing). For detail information see Section 4.

DIAG-LED, indicate specified operation states by different colors and duration of


lightning (Continuos On or flashing). For detail information see Section 4.

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ECS Page 5

14.1.4 Definitions; Symbols and Abbreviations


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

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

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

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

Clock Signal pulse

VWP VerWaltungProgramm: (management program) A control program


created by the user.

AWP AnWender Program: (Application program, user program) A control


program created by the user.

AWL AnWeisungsListe: (instruction sequence) Representation of a program


using alphanumeric signs and symbols as defined in DIN 19239.
Programming in AWL (selection logic) is the at present widely applied
method of programming.

CMOS Complementary Metal-Oxide Semiconductor: Complementary metal-


oxide semiconductor technology with very low-level closed circuit
current. These semiconductors are used above all for accumulator and
battery buffering.

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

EPROM Erasable Programmable Read Only Memory: Read-only memory erasable


by ultraviolet light and electrically programmable. With this memory type,
the contents remain intact in the event of a power failure. In the case of
DIGSY plus ® this memory contains the management program (firmware).
continued

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14.1.4 Definitions; Symbols and Abbreviations

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

COMPILER A program that translates the instructions of a programming language


(e.g. instruction sequence [AWL]) into machine code (processor
instructions).

EDITOR Utility program for the creation and changing of programs.

Loop Program loop.

Off-Line Operational method of a programming device without attached


automation device.

On-Line Operational method of a programming device (PC) is connected to the


automation device thereby enabling data and programs to be read or
changed.

PC Personal Computer: Programmable unit for the DIGSY plus ®.

Watch-Dog: Internal supervisory unit in computers and automation devices used to


recognize system and memory errors.

CPU Central Processing Unit: Control and central unit in an automation


device usually based on a microprocessor. It can read the application
program code and run the instructions contained therein.

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

continued

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ECS Page 7

14.1.4 Definitions; Symbols and Abbreviations

Cont'd:

Coding Types and Number Systems


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

Digital (Eng. Digit) is the representation of a continuos value or a physical


quantity (e.g. voltage) in several levels as a numeric value.
With regard to automation devices one also refers to “word processing”
in which case a “word” is a number (e.g. 573).

Analogue is the representation of a continuos physical quantity (e.g. current or


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

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

Number Value consisting of one or more numeric characters.

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

Baud Rate Modulation rate or transmission speed of serial transmission of binary


numbers. The DIGSY plus uses a baud rate of 2400 baud for
communication and down-loading.

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

Dual(Binary) Number (Dual = 2) is the simplest binary numeric expression. Each


position is arranged according to increasing powers of 2.
Example: 13463dec. = 0011 0100 1001 0111dual

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14.2 How to Proceed due Maintenance and Installation

Keep in mind
• - BE CAREFUL
• - BE ALERT
• - THINK ABOUT WHAT YOU ARE DOING

Any PERSON doing any work in or around the machine must be familiar
with the local SAFETY INSTRUCTIONS and with the specific SAFETY
INSTRUCTIONS REGARDING TO HIS OCCUPATION.

• Serious damage may happen at unqualified actions at the System or


Unit or when not paying attention to the hints given in this manual or
on labels at the units

Qualified persons in sense of the safety relevant hints in this manual or on the
product, are persons which are
• either as project engaged person familiar with the safety concept for
automatic control systems;
• or as operating personal for the use of an automatic control system being
instructed;
• or having the authorization and occupation to put such systems into operation
or doing repair work as well as having the authorization and occupation to put
such systems/units into operation regarding the power
circuits and there safety standards and, to earth and to mark it.

continued

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ECS Page 9

14.2 How to Proceed due Maintenance and Installation


Cont’d.:

• Serious damage may happen at irrelevant opening and improper repair.


Open always the resp. circuit breaker before opening a unit.
I/O – cables may only be connect or disconnect in a powerless state.

A BIM module will be damaged while supplying an external power


of 24VDC to the inputs and/ or outputs. If it is necessary for
faultfinding or external unit checks the connection to the PLC has to be
interrupted.

• Without power interruption the interface cable are only allowed to be


disconnect or connect when following preconditions are given:
1. The cable must be shielded and the shield must be connected to the
cover of the plug-in connector.
2. A potential balance must be made by connecting the GND
potential parts of the plug connector parts before connecting
the cables.

• Replace the fuses only by fuses which matches the values given in the
technical dates

m • 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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14.2.1 Meaning of the Status LED’s, Illust. Z 21431b

The DIGSY plus performs by the function of the Status LED’s (5V and DIAG) and
the so named Diagnostic Words* (DW1 up to DW256) many data and statuses.
With a PC and the Program- and Diagnostic Software the. Diagnostic Words are
visible on a monitor.
The following sections explain the diagnostic possibilities more in detail.
* Can be called-up by PC assistance only.

Table: Statuses of the +5 V-LED and their meaning


LED Effect Cause Remedy
5 V-LED Voltage
green o.k.
5 V-LED CPU not working Supply Check the
red (RESET) < 4,65V +24 V Supply
DIAG-LED red if not o.k. *)
5 V-LED CPU not working Supply Check the
OFF (except the is missing +24 Volt
LED is defect)
Fuse S1 Replace the **
defect Fuse F1

LED defect *)
(if DIAG
LED is ON)

others *)
5 V-LED
flashing

red/green cyclically Watchdog *)


new starts in operation
red/
orange Continuos Reset Component fault *)
** Replacement only after co-ordination with Komatsu Mining Germany, Dept. 8124.1

*) = Return PLC to manufacturer

continued

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14.2.1 Meaning of the Status LED’s, Illust. Z 21431b


Cont’d.:
Table: State of the DIAG-LED and their meaning
LED Effect Cause Remedy
DIAG-LED Program Communication via Check the cable
green in operation Interface COM-SP connection and the
not active Interface port
(interrupted)
COM-SP<╪> Text
display
DIAG-LED Program- Temperature External cooling
orange state inside housing
unchanged too high
+24 VCPU < 14 V Increase the voltage
Accumulator voltage Replace the
too low accumulator module
Fixed operands Check the
deleted accumulator
connections
SPS in start loop wait
after voltage ON
programming in Stop the
operation programming *1)
DIAG-LED Program EEPROM not Initialize
RED not running (stopped) Initialized EEPROM *1)

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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14.2.2 Short Circuit Marker -LED “MK”

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

See also Section 14.1.3 page 4

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14.2.3 Diagnostic for Temperature-Module “ANM”

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

- LED green: Ordinary operation, no range overflow.

- LED red/green flashing (2Hz) Watch-dog timer response or cyclically


overflow of one ore more analogous outputs.

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14.3 Front Connector Arrangement


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

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

Pin Symbol Operand Definition


1 Input 1.1 E 1.1 Input 1 of the input group. 1
2 Input 1.2 E 1.2 Input 2 of the input group. 1
3 Input 1.3 E 1.3 Input 3 of the input group 1
4 Input 1.4 E 1.4 Input 4 of the input group 1
5 Input 1.5 E 1.5 Input 5 of the input group 1
6 Input 1.6 E 1.6 Input 6 of the input group 1
7 Input 1.7 E 1.7 Input 7 of the input group 1
8 Input 1.8 E 1.8 Input 8 of the input group 1
9 Input 9.1 E 9.1 Input 1 of the output group 2
10 Input 9.2 E 9.2 Input 2 of the output group 2
11 Input 9.3 E 9.3 Input 3 of the output group 2
12 Input 9.4 E 9.4 Input 4 of the output group 2
13 Input 9.5 E 9.5 Input 5 of the output group 2
14 Input 9.6 E 9.6 Input 6 of the output group 2
15 Input 9.7 E 9.7 Input 7 of the output group 2
16 Input 9.8 E 9.8 Input 8 of the output group 2
17 0 V (GND) Ground
18 Input 2.2 E2.2 Input 2 of the input group 2
19 Input 2.4 E2.4 Input 4 of the input group 2
20 Input 2.6 E2.6 Input 6 of the input group 2
21 Input 2.8 E2.8 Input 8 of the input group 2

continued

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14.3 Front Connector Arrangement


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

Cont’d.:
Pin 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 Ou