Hydraulic Mining Excavators

CAMP/ SIL – Electric System CAT-6060FS AC RH340 E-Drive

Electrical Drawings

Sebastian Fillinger - 2013

Locations of main electric cabinets Service Training

There are four main electrical cabinet on our electric driven machines:

-X3 Electric Cabinet

-X4 Electric Cabinet

-X1 Electrical Cabinet

-High Voltage Cabinet

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X1 Electric cabinet Service Training

-X1 Electrical cabinet

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X3 Electric cabinet Service Training

-X3 Electrical cabinet

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X4 Electric cabinet Service Training

-X4 Electrical cabinet

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High voltage cabinet Service Training

High Voltage cabinet

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Names and descriptions of components – group numbers Service Training

To simplify troubleshooting and orientation of all electric components on the excavator we divided the electric
system in 5 groups. This are group 1, 2, 3, 5 and 6.

On the basis of the group number you can recognize where the electric part belongs to.

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Components group number 1 Service Training

All components not connected to any controller or the high voltage parts belong to group number 1

These are parts like batteries, safety relay or preheating system.

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Components group number 2 Service Training

All components connected to the servo controller belong to group number 2.

This can be components like proportional valves, switches etc…

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Components group number 3 Service Training

All components connected to the drive controller belong to group number 3.

This can be components like vacuum contactors, switches etc…

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Components group number 5 Service Training

All components connected to the auxiliary controller belong to group number 5.

This can be components like fuses, switching valves etc…..

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Components group number 7 Service Training

All high voltage components or parts connected to a high voltage component belong to group number 7.

This can be components like the main motor, motor protection relay etc…..

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Names and descriptions of components Service Training

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Names and descriptions of components Service Training

Identifying number:
Sensors are also divided in 5 different groups.
Group 100:
Pressure sensors and switches for example -3B101 (main pump pressure 1); -2B161 (swing pressure)

Group 200:
Temperature sensors and switches for example -3B241 (gearbox temperature); -5B291 (ambient temperature)

Group 300:
Level sensors and switches for example -3B331 (hydraulic oil level); -5B311 (oil level swing drive 1)

Group 400:
Contamination sensors and switches for example -3B401 (contamination main pump 1)

Group 500:
Proximity switches for example -3B531 (shut off valve hydraulic tank) -2B504 (proximity switch ladder up)

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Names and descriptions of components Service Training

Names and description for electric components:

E.g.: -7M701

Group number: Identifying number:

Letter from DIN

7 M 701

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Electrical Drawings Service Training

The circuit diagram (current flow diagram) is a representation of the electrical circuits of the machine in all their
details.
The diagram shows the way in which the electrical supplies and components are connected, as well as showing
their functions.

The circuit diagram comprises several DIN A 4 sheets arranged in function groups.

All components are shown in the de-energized state (i.e. no current flowing) and without any actuating elements
acting.

Symbols used are according to the DIN standards 40 700, 40 703, 40 708 and 40 711 to 40 716.

Each page is divided into columns 0-9 or current paths with a description below each current path.

Each page has a page number or “Blatt Sheet” located in the bottom right corner. On the bottom left corner is the
machine model that the electrical drawing is applicable to.

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Electrical Drawings Service Training

0 1 2 3 4 5 6 7 8 9

Current Path

6060 Blatt Sheet

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Electrical Symbols Service Training

All symbols can be found in the technical handbook Vol.2

A Assembly or group of parts PLC, combinations of devices

B Transformation from non electrical Sensors

into electrical magnitudes and vice
versa.

E Miscellaneous Lights, heaters

F Safety devices Fuses, interlocks, circuit breakers

G Generators, power supplies Alternators, batteries.

H Monitors Warning lights, alarms.

K Relays Relay contacts and coils.

M Motors Starter motors, fan motors.

P Meters Hour meters, clocks

R Resistance's Variable resistors

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Electrical Symbols Service Training

All symbols can be found in the technical handbook Vol.2

S Switches, Button Switches, Control switches

V Diodes Diodes

X Terminates, plugs, sockets Terminal stripes, isolating plugs/sockets, test sockets.

Y Electrically actuated mechanical

devices. Solenoid valves, proportional valves.

B Sensors Pressure sensors, temperature sensors, contamination sensors

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Main Rule 1: References Service Training

If electric connections are separated on two different pages references will be used.
A reference can be identified by the arrow symbol:

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Main Rule 1: References Service Training

If electric connections are separated on two different pages references will be used.
IMPORTANT: The arrow indicates a reference only and NO point of connection (Terminal).
Physically on the machine the shown connection of the reference might be a cable of 5cm length.

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Main Rule 1: References Service Training

If electric connections are separated on two different pages references will be used.

Reference information:

30/ 16.0

Page number and current path where the

reference continues

Reference name

Arrow indicates a reference

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Main Rule 2: Relays – Different Contact Names Service Training

„Bosch“ type relay „Industrial“ type relay

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Main Rule 2: Relays Service Training

Relays are most of the time separated on two pages: Coil and contacts

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Main Rule 2: Relays Service Training

Relays are most of the time separated on two pages: Coil and contacts

Below the relay coil you can find the information

about the location of the contact.

11 14
72.6
Information about the relay contact. NO
contact. Contact names are 11 and 14

Page number and current path where the

contact is located
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Main Rule 2: Relays Service Training

Relays are most of the time separated on two pages: Coil and contacts

Directly below the relay contact you can find the

information about the location of the coil.

-5K121
70.1

Page number and current path where the coil is located

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Understanding the Electric Symbols Service Training

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Understanding the Electric Symbols Service Training

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Understanding the Electric Symbols Service Training

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Electrical Drawings Service Training

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Electrical Drawings Service Training

Initiator for shut Power supply for Power supply for

Stand by power
down function controller outputs expansion board

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Electrical Drawings – Key to Components Service Training

The key to electrical components in the circuit diagram is a systematically arranged list which supplements the circuit
diagram. Its purpose is to locate components both in the circuit diagrams and on the machine itself. It also contains
the components’ Part No’s.

The key is divided into the following columns:

Dev.desig
Amount
Function/ Description
Schematics
Location
Group
Part No.
Dev.desig: This column lists all electrical components alphabetically. The coding letters used designate the type of
component as specified in DIN 40 719.

Amount: States the number of particular component parts on the machine.

Function/ Description: This column states the type of component (e.g.. warning light) and its function (e.g.. hydraulic oil
level “min”).

Schematics: The current path numbers appear at the top edge of the circuit diagram sheets. They are provided to
help in the location of electrical components in the circuit diagrams.

Location: The location is the approximate position on the machine in which the electrical component is installed.

Group: States the Group where you can find this part in the Machine Parts List (e.g. Component 34.502 for the seat)

Part No: This is the Part No. for ordering spare parts. If no Part No. is given, then the part concerned is associated
with the electrical system but is contained in another assembly group. The Part No. must then be determined using
the relevant spare parts sheet.
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Electrical Drawings – Key to Components Service Training

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X1 Terminal Strip Service Training

X1.31

X1 X1.2

X1.2 X1.5

X1.5

X1.8 X1.9 X1.15

X1.30 X1.6

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Connection Table Service Training

Connection Table – terminal strip X1

The “Connection tables – terminal strips” show the connections between electrical components. They are exact
illustrations of the terminal strips as fitted in the machine. The key to the circuit diagram gives the exact location of the
various terminal strips.The connection tables make it possible to locate the cable connections of a particular component
without having to “ring through” the cables.

Arrangement of the table:

End points (targets) Type of terminal Jumpers Cable Cross Section Terminal No.

End Point: The end point numbers serve in the location of the contact point of a terminal number. They state the
receiver and its connection point. End point numbers 1 and 2 are at the bottom, 3 and 4 at the top. The cables have
tagged sleeves with the appropriate end point number. This makes re-connection easy (and accurate) after several
cables have been disconnected at the same time (e.g.. during trouble-shooting).

Jumpers: If terminal points need to be extended, the relevant terminals are inter-connected with bridges (jumpers). The
terminal No. is then the same for all bridges terminals. Bridges are indicated by a vertical bar Terminal No: All terminals
on a particular strip are listed here. The numbers are also to be found on the strip (in switch box).

Type of terminal: This column contains the terminal coding used by the manufacturer.

Cable cross section: The cross section of the incoming/outgoing cable.

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Connection Table X1.8 Service Training

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Connection Table Service Training

Connection Table – plug connections X105 & X501

The “Connection table – plug connections” gives the pin and sleeve connections of multi-pole plug connections

End Point – sleeve connections

Ø mm2
No.
End point – pin connections

End Point: This is the number of the end point of the sockets (sleeve connections).

Ø mm2 : The cross section of the incoming/outgoing cable

No: This number is that of the relevant pin or sleeve connection. The numbers are stamped into the plug housing.

End Point: End point no. of the plug (pin connections).

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Connection Table Service Training

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Connection Table Service Training

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Questions? Service Training

Questions are free of charge!!!

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