KOMATSU MINING GERMANY PC5500 SERVICE REPAIR MANUAL (SN:15016 & UP) KOMATSU MINING GERMANY PC5500

MACHINE MODEL

SERIAL NUMBER

PC5500-6 E

15016 and up

This service manual may contain attachments and optional equipment that are not available in your area.

Please consult your local Komatsu distributor for those items you may require.

Materials and specifications are subject to change without notice.

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CONTENTS TABLE OF CONTENTS

00 01 02

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

Section 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14 15

Main assembly groups Drive.

Hydraulic oil tank.

Hydraulic oil cooling.

Controlling.

Components Main hydraulic pumps and pump regulation.

Operating hydraulic.

Hydraulic track tensioning system.

Hydraulic operated access ladder Cable-drum Hints for the hydraulic circuit diagram Hints for the electric circuit diagram VHMS / ECS-T / ETM Lubrication Systems

APPENDIX

F

25.03.03

• Each section includes a detailed table of contents.

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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.

ã

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.

F

CAUTION -

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

NOTE -

Refers to special information

GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.

2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.

• Always wear safety glasses when hitting parts with a hammer.

• Always wear safety glasses when grinding parts with a grinder, etc. continued 00-1 25.03.03

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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 25.03.03

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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. In particular, use only the minimum of gasoline when washing electrical 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.

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SAFTEY

SAFTEY NOTICE

FOREWORD GENERAL With this SERVICE MANUAL KOMATSU provides you with the description of the construction and the function of the major systems of the Hydraulic Excavator PC5500.

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 -

F

• 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

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FOREWORD

HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS HOISTING

ã F

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

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

2. Check for existence of another part causing interface with the part to be removed.

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

10,0

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

Allowable load [tons]

1,0

1,4

F

1,6

2,2

2,8

3,6

4,4

5,6

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

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

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

continued Cont'd: 00-5 25.03.03

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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.

ĂŁ

• 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 120E hanging angle. On the other hand, two ropes are subject to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150.

00-6

FOREWORD

STANDARD TIGHTENING TORQUE

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

Bolt dia.

Tightening torque [Nm] Quality grades

Wrench size [mm]

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

3500

4950

5800

M 45

70

4350

6200

7200

M 48

75

5200

7500

8700

M 52

80

6700

9600

11200

M 56

85

8400

12000

14000

M 60

90

10400

14800

17400

M 64

95

12600

17900

20900

M 68

100

15200

21600

25500

32 35 41 46

Insert all bolts lubricated with MPG, KP2K

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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.

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FOREWORD

CONVERSION TABLE

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FOREWORD

CONVERSION TABLE

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FOREWORD

CONVERSION TABLE

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FOREWORD

CONVERSION TABLE

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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.

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Main Assembly Groups

Section 1.0 Page 1

Table of contents section 1.0 Section 1.0

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Page 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

1.3

Attachment

13

1.3.1.

Backhoe Attachment (BHA)

14

1.3.2.

Front Shovel Attachment (FSA)

15

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1.0 2

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Main Assembly Groups

1.

Section 1.0 Page 2

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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1.0 3

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Main Assembly Groups

1.1

Section 1.0 Page 3

Superstructure Legend for illustration (Z 22386): (1) Operators Cab with integrated FOP system (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

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

Main electric motor 1 Elastic coupling PTO gear with hydraulic pumps Main hydraulic pumps 1, 2 and 3 Capacitor motor 1

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

Main electric motor 2 Elastic coupling PTO gear with hydraulic pumps Main hydraulic pumps 4, 5 and 6 Capacitor motor 2

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1.0 4

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Main Assembly Groups

1.1

Section 1.0 Page 4

Superstructure 1.1.1

Machine house

Legend for illustration (Z 22390a): A B C

View from the back of machinery house without counter weight View from the right side of machinery house Top view

(1) (2) (3) (4) (5) (6) (7)

Motor coolant air outlet Main motor supply cable Capacitor Hydraulic control and filter panel PTO gear box Main hydraulic pumps Auxiliary pumps, installed at the drive through shaft of the main hydraulic pumps (piggyback pumps) Hydraulic pump for radiator fan drive Hydraulic pump for the hydraulic oil cooler fan drive Suction oil reservoir Flexible coupling, oil filled Batteries Engine 1 Engine 2 Hydraulic motor for the radiator fan drive Radiator for the engine cooling system

(8) (9) (10) (11) (12) (13) (14) (15) (16)

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1.0 5

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Main Assembly Groups

1.1

Section 1.0 Page 5

Superstructure 1.1.2

Hydraulic Oil Reservoir

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

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Main Assembly Groups

05.04.03

Section 1.0 Page 6

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Main Assembly Groups

1.1

Section 1.0 Page 6

Superstructure 1.1.3

Hydraulic Oil Cooler

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

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1.0 7

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Main Assembly Groups

1.1

Section 1.0 Page 7

Superstructure 1.1.4

High tension switch cabinet

Legend for illustration (Z 22638):

05.04.03

A B C X

Left side view Front side view Top view High tension switch cabinet

(1) (2) (3) (4) (5) (6) (7)

Main fuses, high tension Main supply switch, manual controlled Main motor switches, remote controlled Current transformer Main transformer Air condition for switch cabinet Access stair

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1.0 8

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Section 1.0 Page 8

Main Assembly Groups

1.1

Superstructure 1.1.5

Counter weight

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

Mounting bolts Quantity 16

05.04.03

Bolt size (mm) M 48 x 380

*

SW = Wrench size

(3)

Lifting points

Grade

SW* (mm)

10.9

75

Tightening torque (Nm) 7500

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1.0 9

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Section 1.0 Page 9

Main Assembly Groups

1.1

Superstructure 1.1.6

Cab support

Legend for illustration (Z 21475): (1) Cab support (Location of electrical switch board “X2�)

(2) Mounting bolts Quantity Bolt size Grade SW* Tightening (mm) (mm) torque (Nm) 6

M 36 x 320

10.9

55

Grade

SW* (mm)

10.9

55

3100

*SW = Wrench size (3)

Mounting bolts Quantity Bolt size (mm) 6

M 36 x 160

Tightening torque (Nm) 3100

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

05.04.03

Door Gasket Door handle (adjustable)

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1.0 10

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Section 1.0 Page 10

Main Assembly Groups

1.1

Superstructure 1.1.7

Operators cab

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

Monitor panel Switch panel Operators seat Control lever – EURO Control

– KMG Control

(E20)

Control lever – EURO Control

– KMG Control

(E21a)

Control pedal

A - forward Left track B - reverse

(E21b)

Control pedal

A - forward Right track B - reverse

(E22) (E23) (E24)

05.04.03

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

Clam closing Clam opening

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1.0 11

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Main Assembly Groups

1.1

Section 1.0 Page 11

Superstructure 1.1.8

Control blocks

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

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1.0 12

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Main Assembly Groups

1.1

Section 1.0 Page 12

Superstructure 1.1.9

Swing gears

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

05.04.03

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

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1.0 13

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Main Assembly Groups

1.2

Section 1.0 Page 13

Under carriage Legend for illustration (Z 21481): (1) Undercarriage center body (2) Crawler carrier R.H.-side (3) Crawler carrier L.H.-side (4) Connecting 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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1.0 14

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Main Assembly Groups

1.3

Section 1.0 Page 14

Attachment 1.3.1

Backhoe attachment (BHA)

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

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1.0 15

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Main Assembly Groups

1.3

Section 1.0 Page 15

Attachment 1.3.2

Front Shovel Attachment (FSA)

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

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Drive

Section 2.0 Page 1

Table of contents section 2.0 Section 2.0

Page Prime drive assembly General

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

(7)

Section 2.0 Page 2

Prime drive assembly

Legend for illustration (Z 22644): (8) Cooling air intake (9) Cooling air exhaust (10) Electric Motor (11) Alignment shims (12) Alignment supports (13) Motor frame (14) Coupling (15) 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.

F

• The alignment shims thickness must be also determined when replacing the electric motor! Never use the existing shims without determination.

2.0 &3

Drive

(16)

Section 2.0 Page 3

Coupling

Legend for illustration (Z 22645): (17) Input drive hub (18) Output drive flange (19) Outside rubber support ring (20) Rubber element (21) Motor drive shaft (22) Gearbox input flange (23) Hub looking washer (24) Coupling ring

F

• 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 LULASTIC–L coupling transfers the torque without any rotational gap. They are wear-resisting and maintenance free. Because of symmetrical arrangement of the flexible rings, there are no returning forces either by the torque transfer or the centrifugal forces.

VULASTIC-L couplings dampen rotating vibrations, reducing same by partial storing of the shock energy and damp noises.

The coupling allows in an acceptable range axial, radial and angular misalignment of the shafts.

Replacement and alignment refer to Parts & Service News AH01523, last edition.

2.0 &4

Drive

2.2

Section 2.0 Page 4

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

2.3

Section 2.0 Page 5

PTO Lubrication and cooling Legend for illustration (Z 22410): 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) for 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

Section 2.0 Page 6

Drive

Cont`d.

2.3

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

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

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

Adjustments:

W

• 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

F

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

Section 2.0 Page 7

Drive

2.4

Hydraulic pumps – location, drive speed and flow rates Legend for illustration (Z 22415a): (1 - 6) Axial piston pump (swash plate type) pump volume theoretical flow rate, each Drive speed* for all working motions

Vg Qmax n pmax

= 500 cm³/rev = 700 Liter/min = 1400 min-1 = 310 bar

(10.2), (10.4) Axial piston pump pump volume theoretical flow rate Drive speed*

Vg Qmax n

= 80 cm³ = 142 Liter/min = 1770 min-1

for oil cooler fan drive

pmax

= 180 bar

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

Vg Qmax n pmax

= 58.7 cm³/rev = 82,2 Liter/min = 1400 min-1 = 7,5 bar

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

Vg Qmax n pmax

= 58.7 cm³/rev = 82,2 Liter/min = 1400 min-1 = 10 bar

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

Vg Qmax n pmax

= 85.7 cm³/rev = 120 Liter/min = 1400 min-1 = 60 bar

(8.1), (8.4)

(8.2), (8.5)

(7.1), (7.2)

F

• * at 1400 min-1 input drive speed

Hydraulic Oil Reservoir

Section 3.0 Page 1

Table of contents section 3.0 Section 3.0

Page Hydraulic oil reservoir General lay out

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

3.6

Return and Leak Oil Filter

8

3.7

Breather Filter

9

3.5

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Hydraulic Oil Reservoir

3.

Section 3.0 Page 2

General lay out Legend for illustration (Z 22416a): (1) Filter cover retainer (2) Filter cover (3) Filter location (A) – Return oil filter – 10 µm (4x) (B) – Case drain filter – 3 µm (1x) (4) Man hole cover (5) Hydraulic oil filler plug (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) Return pipe filter (screen filter) The hydraulic oil tank is a welded sheet-metal construction.

The capacity is about 3800 litres. The tank contains four return oil filters (3A) 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

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Hydraulic Oil Reservoir

3.1

Section 3.0 Page 3

Main oil tank, location of switches, sensors etc.

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

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Hydraulic Oil Reservoir

3.2

Section 3.0 Page 4

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

The capacity is 187 liters.

The suction lines of all hydraulic pumps are connected to the suction tank.

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Hydraulic Oil Reservoir

Section 3.0 Page 5

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

Task: The strainer is installed to prevent the hydraulic oil coolers from getting clogged up in case of contamination in the main return circuit oil.

Excessive increase of the hydraulic oil temperature can be an indication for a restricted strainer, i.e. bad cooling performance due to insufficient oil flow through the coolers.

In case that main components such as cylinders or motors are internal fragmentary damaged, the strainer should be inspected for metal chips.

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Hydraulic Oil Reservoir

3.4

Section 3.0 Page 6

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

Task: The back pressure valve has to fulfill two functions in the hydraulic system: 1. To ensure a sufficient pressure within the return oil circuit, i.e. to supply oil via the anticavitaton valves to the low pressure side of cylinders, respectively motors.

2. To force the return oil through the coolers depending on the present hydraulic oil temperature, controlled by solenoid valve Y101.

- Low temperature ⇒ low volume through the coolers - High temperature ⇒ high volume through the coolers

)

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

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Hydraulic Oil Reservoir

3.6

Section 3.0 Page 7

Return and Leak Oil Filter Legend for illustration (Z 21500): (1) Filter cover retainer (2) Filter cover with o-ring (3) Pre-tensioning spring (4) Retainer (5) Filter assembly (6) Filter pot with machined cover (7) Main filter element, 10 micron absolute (8) Safety filter element (200 micron strainer) (9) By pass-valve, 2.3bar (9.1) Valve cone (9.2) Valve spring (9.3) O-ring (10) Profile gasket (11) Seal ring (12) Self locking nut (13) Self locking nut Function: The returning oil flows into the filter chamber (A) of the hydraulic tank. (The sketch shows one section only).

The chamber is split into two sections; one sections with 4 filters for the return oil and one for the leak oil. But the five filters are all the same. The hydraulic oil enters the filter at the top and passes then on its way to the entire tank the filterelement (7). "Inside to outside filtration."

The filter element condition is monitored by a pressure switch (B25, 0.5 bar for the leak oil filter) and (B26, 2 bar for the return oil filter).

As soon as the pressure inside the filter chamber reaches the set pressure of those switches due to the restriction of the filter-element which is caused by foreign matters, the fault message ”Return oil filter restricted" or ”Leak oil filter restricted” is displayed at the operator's dash board The filter elements must be replaced. For safety pre-cautions the filter is equipped with a by-pass valve. As the filter chamber pressure increases the by-pass valve opens at 2.3 bar and protects the element from bursting.

But the oil flows not totally unfiltered into the tank because it must flow through the strainer (8).

)

•

•

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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 chapter. 6.5 of MAINTENANCE MANUAL

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3.7

Section 3.0 Page 8

Breather filter Legend for illustration (Z 21501): (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 chapter 6.5 of MAINTENANCE MANUAL

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Hydraulic Oil Cooling

Section 4.0 Page 1

Table of contents section 4.0 Section 4.0

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Page 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

4.7

Radiator fan drive speed adjustment

9 10 -12

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(1)

Section 4.0 Page 2

General

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

Legend for illustration (Z 21594) (1) Noise shield (2) Cooler (Radiator) (3) Cooler frame (4) Fan (5) Fan motor (Axial piston motor) (6) Bolt (7) Bolt (8) Drive shaft (9) Shaft protecting Sleeve (10) Drive shaft seal (11) Ball bearings (12) Seeger clip ring (13) Bearing group carrier (14) Oil level plug (15) Breather filter Design: There are four* hydraulic oil coolers in front of the hydraulic tank on the R.H. side of the platform.

They are in pairs mounted in one frame, one above the other. The air stream needed for the cooling is produced by hydraulic driven fans. The air flows from inside to outside through the coolers.

For a better cleaning, the coolers can be moved to the side. (“Swing out cooler�)

The bearing group carrier is filled with oil to lubricate the bearings.

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Hydraulic Oil Cooling

4.2

Section 4.0 Page 3

Function of the hydraulic oil cooling circuit Legend for illustration (Z 22419) (107.1-107.4) Restrictor, shock absorbers for the hydraulic oil cooler (106.1-106.4) Hydraulic oil cooler (41) Main oil reservoir (114) Return oil collector tube (115) Back pressure valve (L6 + L7) Return line from control blocks (L8 + L9) Supply line for the anticavitation circuit of the swing motors (M10) Pressure check point (Y101) Solenoid valve – 4/2-directional control valve (H) Lines to cooler (hot oil) (C) Lines to tank (cold oil)

Function: The returning oil from the system flows via the lines (L6 - L7) into the collector tube (114). On the top of it is the Back Pressure Valve (115) installed.

The back pressure valve (115) causes a back pressure which forces most of the relative hot oil through the lines (H) to the cooler (106.1-106.4).

On its flow through the cooler the hydraulic oil gets cooled and flows than through the restrictors (107.1-107.4) and the lines (C) into the filter chamber of the main oil reservoir (41).

The restrictors are acting like shock absorbers to prevent cooler cracking at pressure peaks.

Besides the back pressure valve acts as an oil flow control valve as far as the oil temperature has not reached its steady temperature.

During the warm up period (1/2 Qmax) the back pressure valve (115) is wide open, because solenoid valve Y101 is energized, which results in less oil flows through the cooler which causes that the oil gets quicker its optimum operating temperature.

With increasing oil temperature the oil gets thinner, so that the main pumps can be shifted to Qmax position and simultaneously solenoid valve Y101 will be de-energized, so that the valve piston will be more closed by the force of the spring thus that more oil passes the cooler.

(See sectional drawing on next page.)

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Section 4.0 Page 4

Hydraulic Oil Cooling

4.3

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

1.

Connect a pressure (e.g. 0-25 bar) gauge to check point (M10).

2.

Disconnect plug connector (13) of solenoid valve Y101.

3.

Actuate service switch S151 ().

4.

Start both motors.

5.

Required pressure: 8 Âą0,5 bar without any excavator motion.

If adjustment is required: a) Take off protective cap (12). b) Loosen lock nut (5). c) Adjust the pressure with the set screw (6). d) Tighten lock nut (5) and refit protective cap (12).

6.

Disconnect the pressure gauge, reconnect solenoid valve Y101 and switch back service switch S151.

Legend for illustration (Z 21596): (1) Control oil port (2) "Y"- port (external return to tank) (2a) "X"- port (external return to tank via solenoid valve Y101) (3) Poppet (4) Valve spring (5) Lock nut (6) Set screw (7) Jet bore (large) (8) Valve spring (9) Valve piston (10) Jet bore (small) (11) Plug screw (12) Protective cap (13) Plug connector (A) Return to tank (Filter chamber) (Z) Pressure oil to valve

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4.4

Section 4.0 Page 5

Fan drive (Two stage cooler fan RPM control) Legend for illustration (Z 22420) (10.2) (10.4) (22.1) (22.2) (41) (168.1) (168.2) (68.1) (68.2) (103.1) (103.2) (148.11) (148.12) (169.1) (169.2) (L) (P) (R) 1 2

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Axial piston pump Motor 1 (fixed displacement pump, with variable setting) Axial piston pump Motor 2 (fixed displacement pump, with variable setting) Fan motor (Axial piston motor) Fan motor (Axial piston motor) Main oil reservoir Pressure relief valve – Motor 1, lower oil cooler fan drive Pressure relief valve – Motor 2, upper oil cooler fan drive Pressure filter with pressure differential switch B28-1 (Motor 1) Pressure filter with pressure differential switch B28-2 (Motor 2) Check valve motor 1– (Anti cavitation valve for fan drive motor) Check valve motor 2– (Anti cavitation valve for fan drive motor) 4/3 direction flow valve – Motor 1 oil cooler fan speed (stop, low and high speed), solenoid Y6A-1 + Y6B-1 4/3 direction flow valve – Motor 2 oil cooler fan speed (stop, low and high speed), solenoid Y6A-2 + Y6B-2 pressure reduction valve (low fan speed adjusting) motor 1 pressure reduction valve (low fan speed adjusting) motor 2 Leak oil (case drain) to tank Pressure to motor Return oil to tank Motor 1 Motor 2

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Section 4.0 Page 6

Function: From pump (10.x) flows the oil through the filter (68.x) to the fan motor (22.x) and then back to the tank.

The check valve (103.x) act as an anti cavitation valve and is installed, because the fan motor -driven by inertial force- is running for a short period after the oil flow is interrupted by solenoid valve (Y6A-x/Y6B-x) or if the motor has been switched off.

The hydraulic circuit "Fan drive" is secured by the pilot controlled pressure relief valves (168.x).

These valves are working together with the solenoid valve (Y6A-x/Y6B-x), controlled by the PLC, depending on the hydraulic oil temperature: • With de-energized solenoids Y6A-x and Y6B-x the relief valve (168.x) is functioning and the fans are running with max. adjusted speed (1300 RPM) • With solenoid Y6A-x energized the relief valve (168.x) is not functioning and the fans are running with a very low speed caused by the flow resistance only. • With solenoid Y6b energized the relief valve (169.x) is controlling the relief valve (168.x) and the fans are running with 1000 RPM only.

(See also description on next page)

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4.5

Section 4.0 Page 7

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

Section 4.0 Page 8

Cont’d.

4.5

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

Section 4.0 Page 9

Fixed Displacement Pump, with variable setting Legend for illustration (Z 21852) (1) Drive shaft (2) Bearings (3) Cylinder with pistons (4) Center pin (5) Control lens (6) Q-min adjustment bolt (7) Q-max adjustment bolt (8) Pressure port (9) Tank port Description.

Pump type A7F0 is a variable displacement pump, designed to operate in open circuits. It has an internal case drain return. The rotary group is a robust self aspirating unit. External forces may be applied to the drive shaft.

Changing the swivel angle of the rotary group is achieved by sliding the control lens along a cylindrical formed track by means of an adjusting screw.

• With an increase in the swivel angel, the pump output increase together with necessary drive torque.

• With an decrease in the swivel angel, the pump output decreases together with the necessary drive torque.

• When increasing to maximum swivel angle, there is a danger of cavitation and over-speeding the hydraulic motor!

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2.7

Section 4.0 Page 10

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

)

• A blocked cooler, restricted air flow, defect cooler seal or bend fan influence the fan RPM and air volum.

• 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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2.7

Section 4.0 Page 11

Radiator fan drive speed adjustment

Cont'd 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.

6. Check the fan speed with a non-contact rev counter. The speed should be lower as the required fan speed of 1300 min-1 • Be careful not to get caught in the fan or other rotating parts 7. Increase the output flow of pump P , by adjusting the swivel angle, until the fan speed will be 20 min-1 higher than required (1320 min-1 ) : 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.

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Hydraulic Oil Cooling

Section 4.0 Page 11

) Continued

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Hydraulic Oil Cooling

Section 4.0 Page 12

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 the 24V socket at the PTO *).

11. Check the fan speed with a non-contact rev counter. Required fan speed: 1000 min-1 12. If adjustment is necessary loosen lock nut (5) of the relief valve (169.x), and decrease the pressure with set screw (4) until the correct fan speed is obtained.

13. Stop 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 230bar.

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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Controlling

Section 5.0 Page 1

Table of contents section 5.0 Section 5.0

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Page Controlling General lay out

2

5.1

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

3

5.2

Pilot Pressure Supply and Adjustments

4–7

5.3

Remote control valves arrangement

8

5.4

Function principle of the Electro-Hydraulic- Proportional Control

9 + 10

5.5

Potentiometer Control (Lever, Joy Stick)

11

5.6

Potentiometer Control (Pedal)

12

5.7

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

13

5.8

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

14

5.9

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

15

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

X2 pilot pressure

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

X1 - pump regulation pressure

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

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Controlling

5.0

Section 5.0 Page 2

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

The pumps (7.1 / 7.2) forcing the oil through the filter (68.1) to all involved valves.

The pressure accumulator ensures that under any circumstances enough pilot pressure oil is available. The accumulator (85) is also functioning as a hydraulic battery for a certain time when the engine was shut down or to pressure relive the system for repair works.

When the operator is using his controls an electrical signal causes energising 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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Controlling

5.1

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

Engine 1

Engine 2 (Y5)

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

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

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

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

Pressure switches: (B16) (B21.1)

(B21.2) (B22)

(B27.1) (B28.1)

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

(B97.1) (B85.1)

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

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

Pressure check points: (M1.1)

(M1.2) (M2) (M3)

(M5.1)

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

(M19.1) (M20.1)

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

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

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

(68.4) (68.5) (69.2)

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

continued

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5.2

Section 5.0 Page 4

Pilot Pressure Supply and Adjustments Pilot Pressure Circuit The pilot pressure oil is used for the following functions.

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

Legend for illustration (Z 22498): (7.1 / 7.2) Pilot pressure pumps (84.1 / 84.2) Check valve (for combined operation) (68.1) (70.1) (70.2) (85) (43 + 45.x) (M2) (M3) (M40)

Filter Pressure relief valve 60 bar Pressure relief valve 35 bar Pressure accumulator Remote control valves 60 bar pressure check point (X4-Pressure) 35 bar pressure check point (X2-Pressure) 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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5.0 5 con’t The pressure relief valve (70.2) maintains the adjusted pressure of 35 bar it is the X2-pressure.

X2 – pressure: Pilot pressure system Pump regulation system Capacity regulation swing motors Travel- and Swing gear house brakes (spring loaded multi disk brakes) The pressure accumulator (85) holds an amount of oil under pressure to ensure sufficient pilot pressure during normal operations and a limited number of operations without engine power.

The check valves (91) prevents return flow of the pilot pressure oil.

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Controlling

5.2

Section 5.0 Page 6

Pilot Pressure Supply and Adjustments

Cont'd: Pilot Pressure Circuit Legend for illustration (Z 22500): (41) Main oil reservoir (91) Check valve (85) Bladder Accumulator – 10 liter, 10bar (located behind the filter and valve panel of engine 2 on top of the PTO) (PX2) Pilot pressure line (LX2) Leak / return oil line from the remote control blocks Function: The pilot pressure oil flows via line (PX2) to port (P) of each remote control block and is present via a gallery at all proportional and directional solenoid valves.

These solenoid valves are energized by the function of the Electro proportional controls (Joy sticks or pedals) and direct the pilot pressure oil to the respective spools of the main control blocks with a variable pilot pressure proportional to the deflection of the controls.

)

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• For the location and designation of the proportional and directional solenoid valves of the remote control blocks refer to page 8 in this section.

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5.2

Section 5.0 Page 7

Pilot Pressure Supply and Adjustments

)

Checks and Adjustment of Pilot Pressure Legend for illustration (Z 21635a): (85) Bladder Accumulator – 10 liter, 10bar pre-charge pressure (located underneath the catwalk in front of the PTO) (70.1) Pressure relief valve for pump support pressure X4 (60bar) (70.2) Pressure relief valve for pilot pressure X2 (35bar) (M2) Pressure check point X4, pump support pressure (60bar) (M3) Pressure check point X2 pressure, pilot pressure (35bar) (M40) Pressure check point for accumulator (If not factory installed, fit a T-union with test connector as shown in illustration Z 21635a) • Since the “X2” and the “X4” pressure are influencing each other it is always necessary to adjust both valves 70.1+70.2 alternately.

60 bar pressure „X4“, valve 70.1: 1.

Connect pressure gauge to check point (M2) 2.

Start engine and let it run with max. speed 3.

Read pressure, required = 60 -2 bar If readjustment is required *: 35 bar pressure „X2“, valve 70.2: 1.

Connect pressure gauge to check point (M3) 2.

Start engine and let it run with max. speed 3.

Read pressure, required = 35+3 bar If readjustment is required *: * Valve adjustment: a Remove dust cap (1). b.

Loosen lock nut (2). c.

Set pressure with set screw (3). d.

Tighten lock nut (2) and re-fit dust cap (1).

Checking of Accumulator Function 1.

Connect pressure gauge to check point (M40).

2.

Start the engine and let it run with maximum speed.

3.

After build-up of pressure stop the drive motor, but do not turn the key switch to zero position.

4.

Watch pressure gauge. Pressure should remain constant for at least 5 minutes.

)

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• If the pressure droops the system must be checked for leakages.

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

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Section 5.0 Page 8

Controlling

5.3

Remote control valves arrangement Legend for illustration (Z 21636) No.

45.1

45.2

45.3

43

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Solenoid Proportional valve valve

Function FSA

BHA

Y20a Y20b

Y20

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

Y21a Y21b

Y21

Stick extending Stick retracting

Y22a Y22b

Y22

Bucket filling (curl) Bucket emptying (dump)

Y23a Y23b

Y23

Boom raising Boom lowering

Y24a X24b

Y24

Clam closing Clam opening

Bucket filling (curl) Bucket emptying (dump)

Y25a Y25b

Y25

Bucket filling (curl) Bucket emptying (dump)

Boom raising Boom lowering

Y26a Y26b

Y26

Boom raising Boom lowering

Reserved Reserved

Y27a Y27b

Y27

Stick extending Stick retracting

Stick extending Stick retracting

Y28a Y28b

Y28

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

Y29a Y29b

Y29

Boom raising Boom lowering

Y30a Y30b

Y30

Bucket filling (curl) Bucket emptying (dump)

Y31a Y31b

Y31

Stick extending Stick retracting

Y32a Y32b

Y32

R.H. Swing L.H. Swing

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Section 5.0 Page 9

Controlling

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 (Potentiometer control) Function: The electric-hydraulic control system is used to control the direction and volume of oil flow to the operating cylinders and motors via the control valve blocks.

Hydraulically: The oil volume of pump (1) flows through filter (2) into the pilot pressure system. The pressure is limited by the pressure relief valve (3).

With the pressurized oil stored in accumulator (5), a limited number of spool movements can be carried out with the main drive motor at standstill.

When a lever (or pedal) is actuated, proportional solenoid valve (8) and one of the directional solenoid valves (either 6 or 7) are energized, and allows the pilot pressure oil to flow to the spools of the control blocks.

Electrical Whenever a lever or a pedal is moved out of its neutral position, an amplifier will created a current between 0 and 1000 mA. (For detailed information refer to page 10 in this section) Depending on the lever direction, simultaneously one of the directional solenoid valves (either 6 or 7) is energized.

The proportional solenoid valve alters the pilot pressure, proportional to the lever deflection, this results a spool movement between neutral and full stroke position. continued

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Section 5.0 Page 10

Controlling

5.4

Function principle of the Electro-Hydraulic- Proportional Control

Cont'd: (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 with 24 VDC capacitor supported to create the signal voltage.

When moving lever (1) out of its neutral position, 24 VDC battery voltage arrives at relay (5) and energizes the Proportional Amplifier (4) with capacitor supported 24 VDC via terminal 1.

Depending on the function of the control lever, 1 to 4 Amplifiers can be involved for the „Y-axis“ (forward/ backwards direction) and 1 to 4 Amplifiers for the „Xaxis“ (left/right direction.)

The polarity of the Output Signal from joystick (1), either positive or negative, between 0 and 10 VDC indicates the direction of the lever movement and is proportional to the lever deflection. This is the Input Signal to the ramp time module (3) at terminal 5 which will arrive after the adjusted ramp time delay via terminal 7 to the proportional amplifier (4) at terminal 5.

This Input Signal (between 0 and 10 VDC) is amplified to an Output Signal between 0 to 1000 mA and is simultaneously send via terminal 7 (negative) or terminal 8 (positive) to the Proportional Solenoid valve (6) and to the Directional solenoid valve (7) via terminal 3 (negative) or terminal 9 (positive) to the “a” or “b”-side.

The proportional Solenoid valve (6) alters the pilot pressure (“X2”) of 35 bar to a value proportional to the Current Signal.

This pressure controls the movement of the control block spool (8) between neutral and full stroke position.

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Controlling

5.5

Section 5.0 Page 11

Potentiometer Control (Lever, Joy Stick) Legend for illustration (Z 21639a) (1) Push button * (2) Toggle switch * (3) Push pin (3.1) Coil (4) Switch actuator Switches for: (5) Direction monitoring (5.1) Directional contacts (6) Neutral position monitoring (6.1) Neutral position contacts (7) Electronic * Alternative application The Potentiometer Control (inductive, linear travel 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 + Axis "X", splitted into the half axis X- and X + 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, two switches (5 and 6) are fitted per half axis; which are actuated by the actuator (4) as soon as the lever gets moved out of its neutral position.

For the Output Signal generation are used two coils (3.1), in series connected, for one axis. The push pin motion causes a variation of the induction and this in turn causes a signal variation at the AC voltage bridge. The AC voltage gets rectified and becomes the DC-Signal Voltage for the amplifiers.

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Section 5.0 Page 12

Controlling

5.6

Potentiometer Control (Pedal) Legend for illustration (Z 21300) (1) Potentiometer Control Unit (2) Pedal (3) Standard cable (4) Connection cable for combined operation Application for: (A) Swing foot brake (B) Clam Opening/closing, (only face shovel attachment) (C) Travelling The Potentiometer Control (inductive, linear travel transmitter) contains both the electronic and mechanical components which converts the pedal movement into a proportional electrical voltage.

In order to be able to electrically monitor the pedal (2) action a neutral position switch is fitted.

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

When using the double unit (B) (combined operation) only the signal output from one unit is used for the Clam Operation.

Due to the cross lined connection via the connection cable (4) the signal is once positive and once negative (inverted), depending on the Pedal used.

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Controlling

5.7

Section 5.0 Page 13

Proportional Amplifier Module, Type A Legend for illustration (Z 21516) Type A (for swing brake only) (LED) LED for Solenoid A or B (P) Set Potentiometer R1 for the lowest current value R2 for the highest current value The amplifier module contains the necessary electronics for the control of two proportional solenoids. Depending on the input polarity, either solenoid A or solenoid B is operated.

The solenoid current (solenoid A - solenoid B) is measured and compared with the external input value. Differences between feed-back and input values, for example caused by changes in solenoid temperature or supply voltage, are compensated.

The module also generates a direction-dependent voltage signal (solenoid A solenoid B) as soon as the solenoid current reaches the lowest set value.

The lowest and highest values are set externally via the potentiometer R1 + R2.

The brightness of the LED's changes with the current.

This function should not be used for setting.

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Controlling

5.8

Section 5.0 Page 14

Proportional Amplifier Module, Type B Legend for illustration (Z 21640) Type B (for Boom, Stick, Bucket, Clam, Swing and Travel) (LED) (P) Set Potentiometer: AX: Proportional output AX active - 10% for the lowest current value AS: Switched output AS active - J2 for the highest current value BX: Proportional output BX active (Pt) Set Potentiometer for the „Ramp BS: Switched output BS active Time“ Power: Internal supply voltage Fault: Fault indication The amplifier module contains the necessary electronics for the control of two proportional solenoids and two directional solenoids. The amplifier outputs for proportional solenoids Ax and Bx and the switched outputs As and Bs are activated by connecting a minimum of approx. 10% signal voltage at the amplifier input.

A positive signal voltage controls outputs A, a negative signal voltage controls output B. A signal voltage of approx. 10% with respect to +/- 10 V input voltage at the amplifier, produces a stepped output voltage. The height of this 10% jump may be set separately for proportional outputs Ax and Bx via external potentiometer. As the signal voltage rises the solenoid current for the proportional outputs increases linearly.

A further step in output current occurs at approx. 90% signal voltage.

The maximum current or the 90% jump may be set separately for outputs Ax and Bx via external potentiometers and hence the gradient of the output curve may be influenced.

LED`s indicate the current output to each proportional and switched output, whereby the brightness is approx. proportional to the solenoid current in Ax and Bx. This function should not be used for setting.

A Ramp Time function is included in the amplifier which may be externally changed by a set potentiometer. The setting range for the ramp time is approx. from 80ms to 1s. The time setting applies to both up and down ramps and to both proportional solenoids.

A fault is indicated by the LED „Fault“.

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5.9

Section 5.0 Page 15

Ramp Time Module (Analogue command value module for Boom, Stick, Travel and Swing function) Legend for illustration (Z 21518) Potentiometer: "t1" to "t5" ⇒ Ramp times "w1" to "w4" ⇒ Command value call-ups "G" ⇒ Zero point matching "Z" ⇒ Amplitude attenuation for the differential input LED displays: (1) green ⇒ Operational power (2) "4-Q" ⇒ Quadrant recognition (3) "INV" ⇒ Inversion active (4) yellow ⇒ display for potentiometer t1 to t4 (5) yellow ⇒ display for potentiometer w1 to w4 (6) Measurement sockets: "t" ⇒ Actual ramp time "w" ⇒ Internal adjustment variable "⊥" ⇒ Reference potential / GND General The Ramp Time Module is snapped onto mounting rails inside the X2-box.

The electrical connection is done via screw terminals.

The module is operated with 24 VDC. A power supply provides the internally required positive and negative supply voltages.

As soon as the power supply is in operation the green LED (power) lights up.

Internal command values The internal command value signal is generated from the external command value signal which is being applied to the differential input, a called-up signal and an offset signal (zero point potentiometer "Z").

The external command value signal can, via potentiometer "G", changed from 0% to approx. 110%.

Command value call-ups The call-up signals w1 to w4 also have an adjustment range of 0% to 110%.

No settings required. (factory set to 100%).

Ramp time call up If the quadrant recognition is not activated, then each command value call-up "w1" to "w4" is allocated its own ramp time "t1" to "t4".

As long as there is a signal change, the LED allocated to the actual ramp time is alight.

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Controlling

5.10 Adjustments of Amplifier Modules (General) Legend for illustration (Z 21641) (1) Potentiometer control (2) Terminal with a separating possibility (3) Ramp time module (4) Amplifier (5) Solenoid valve (6) Service module Introduction: The illustration shows simplified the route of the signal voltage from Potentiometer Control (1) to Solenoid-Valve (5): A. With ramp time module, i.e. Boom,- Stick,- Travel,- and Swing Function.

B. Without ramp time module, i.e. Bucket,- Clam,- and Swing Brake Function.

The ramp time modules (3) and the amplifiers (4) are adjustable.

Adjustments are required: Ramp time modules • When commissioning the machine • When replacing a module

Amplifiers • When replacing a solenoid valve • When replacing an amplifier

For Checking and Setting the Signal Current at the Proportional-Amplifier (4), both separating terminal (2) before and behind the Amplifier (4) must be opened.

For the setting procedure the signal voltage from the potentiometer control (1) can be simulated with the potentiometer of Service-Module (6),which is installed on the X2-panel.

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

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"a"

"b"

mA

VDC

"c" "d"

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Section 5.0 Page 17

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 motor, turn only the key switch in ON – position.)

1.

Open* the respective separating terminal (T1) between the lever unit and the amplifier module to be set.

2.

Open* the respective separating terminal (T2) between the amplifier module to be set and the proportional solenoid valve.

3.

Disconnect the wire from terminal five.

4.

Connect the positive output of the service module with terminal five of the amplifier module, using test lead (2).

5.

Attach a multimeter for voltage reading to the service module, using test lead (3).

6.

Attach a multimeter (in series) for Amp reading to the terminal between amplifier module and solenoid valve, using test leads (3).

7.

Move the lever of the Potentiometer Control into its final position; or override manual the relay which allows 24 V operating voltage to the amplifier module; thus the amplifier gets 24 V operating voltage. The power LED and simultaneously LED A(+) or B(-) lights up, depending on the polarity.

8.

Turn the potentiometer (P) of the Service-Module until the multimeter shows 1 VDC (it may be either positive or negative); the multimeter for the current reading will show a value which should correspond to the value giving in the circuit diagram e.g. 330 mA. (The first step (10 %) value) If necessary correct the value with potentiometer (R1).

9.

Turn the potentiometer (P) of the Service-Module further until the multimeter shows 9 VDC; the multimeter for the current reading will show a value which should correspond to the value giving in the circuit diagram e.g. 660 mA. (The second step (90 %) value).

If necessary correct the value with potentiometer (R2).

10. Repeat settings of item 8 and 9 until both mA values are stabilized, because R1 and R2 influence each other.

* 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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Section 5.0 Page 18

5.11 Adjusting the Amplifiers Type B, illustration (Z 21642) Cont'd: 11.

12.

13.

If the setting with either positive or negative potential was successful, turn the potentiometer (P) of the service module into the opposite direction and check the settings with the other polarity i.e. if the first setting was done with positive potential then turn the pot into negative direction; otherwise vice versa.

Repeat the setting as described under item 7 to 10.

Remove multimeter, test wire, close* the terminals and reconnect the wire to terminal 5 of the amplifier module.

Adjusting the Ramp Time 1.

2.

Turn potentiometer (Rt) 30 revolutions counter clockwise, to guarantee the correct start position at the complete left side.

Turn potentiometer (Rt) so many revolutions clockwise as shown in the table below (part of the electrical circuit diagram).

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

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Controlling

Section 5.0 Page 19

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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Controlling

Section 5.0 Page 20

5.12 Adjusting the Amplifiers Type B, illustration (Z 21643) Cont'd: 9.

) 10.

11.

Turn the potentiometer (P) of the Service-Module further until the multimeter shows 10 VDC; the multimeter for the current reading will show a value which should correspond to the value giving in the circuit diagram e.g. 500 mA. (100 % value).

If necessary correct the value with potentiometer (R2).

• It is important that the pilot pressure for the pressure increasing valve is 19+/- 1 bar.

For more information refer to section 8.2 „Swing Circuit“ Repeat settings of item 8 and 9 until both mA values are stabilized, because R1 and R2 influence each other.

Remove multimeter, test wire, close* the terminals and reconnect the wire to terminal 5 of the amplifier module.

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

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Controlling

Section 5.0 Page 21

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 motor, turn only the key switch in ON – position.

Basic Adjustment: 1.

Connect 0VDC with a test lead from the red positive terminal of the service module (6) to terminal 5 of the Ramp Time Module (3) and adjust with "Pot Z" a value of 0 VDC measured at terminal 7. Disconnect the test lead after the setting is done.

2.

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

)

• Repeat settings of item 1 and 2 until both values are stabilized, because "Pot Z" and "Pot G" influence each other.

• The factory setting of potentiometer "w1" to "w4" for the command value call-ups must not be adjusted.

continued

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Section 5.0 Page 22

5.13 Adjusting the Ramp Time Module Cont'd: 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 24Volt 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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Section 5.0 Page 23

Controlling

5.13 Adjusting the Ramp Time Module Cont'd: E48 Stick 24 Volt at

Joy stick Signal

Pot

Value to be measured at socket "t"

Terminal 9

Neutral ⇒ Stick out

0V to +10V

t1

0,10 Volt = 1000ms

Terminal 10

Stick out ⇒ Neutral +10V to 0V

t2

5,00 Volt = 20ms

Terminal 11

Neutral ⇒ Stick in

0V to -10V

t3

0,10 Volt = 1000ms

Terminal 12

Stick in ⇒ Neutral

-10V to 0V

t4

5,00 Volt = 20ms

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 = 1000ms

Terminal 10

Lower ⇒ Neutral

+10V to 0V

t2

5,00 Volt = 20ms

Terminal 11

Neutral ⇒ Lift

0V to -10V

t3

0,10 Volt = 1000ms

Terminal 12

Lift ⇒ Neutral

-10V to 0V

t4

5,00 Volt = 20ms

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

0,10 Volt = 1000ms

Terminal 10

Swing R ⇒ Neutral

+10V to 0V

t2

0,10 Volt = 1000ms

Terminal 11

Neutral ⇒ Swing L

0V to -10V

t3

0,10 Volt = 1000ms

Terminal 12

Swing L ⇒ Neutral

-10V to 0V

t4

0,10 Volt = 1000ms

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

0,10 Volt = 1000ms

Terminal 10

Fill ⇒ Neutral

+10V to 0V

t2

5,00 Volt = 20ms

Terminal 11

Neutral ⇒ Dump

0V to -10V

t3

0,10 Volt = 1000ms

Terminal 12

Dump ⇒ Neutral

-10V to 0V

t4

5,00 Volt = 20ms

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Controlling

Section 5.0 Page 23

continued

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Section 5.0 Page 24

Controlling

E51 Left crawler 24 Volt at

Joy stick Signal

Pot

Value to be measured at socket "t"

Terminal 9

Neutral ⇒ Forward

0V to +10V

t1

0,10 Volt = 1000ms

Terminal 10

Forward ⇒ Neutral

+10V to 0V

t2

0,10 Volt = 1000ms

Terminal 11

Neutral ⇒ Backward

0V to -10V

t3

0,10 Volt = 1000ms

Terminal 12

Backward ⇒ Neutral

-10V to 0V

t4

0,10 Volt = 1000ms

E52 Right crawler 24 Volt at

Joy stick Signal

Pot

Value to be measured at socket "t"

Terminal 9

Neutral ⇒ Backward

0V to +10V

t1

0,10 Volt = 1000ms

Terminal 10

Backward ⇒ Neutral

+10V to 0V

t2

0,10 Volt = 1000ms

Terminal 11

Neutral ⇒ Forward

0V to -10V

t3

0,10 Volt = 1000ms

Terminal 12

Forward ⇒ Neutral

-10V to 0V

t4

0,10 Volt = 1000ms

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Section 6.0 Page 1

Components

Table of contents section 6.0 Section 6.0

Page Components 6.1

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Hydraulic Main Control Blocks and High Pressure Filter FSA 6.1.1

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

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

14-17

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Section 6.0 Page 2

Components

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

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Section 6.0 Page 3

Components

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

)

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• There is one MRV in each control block.

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Section 6.0 Page 4

Components

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

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Section 6.0 Page 5

Components

Cont’d Main Control Blocks and High Pressure Filter BHA

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

)

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• There is one MRV in each control block.

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Components

Section 6.0 Page 6

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

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(2)

Synchronization (Equalization) lines

(3)

Synchronization (Equalization) lines

(4)

Anti Cavitation Valve Block (ACV)

(5)

Restrictor Block (Throttle valve)

(6)

Restrictor Block (Throttle valve)

(7)

Service-line Relief Valve

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Components

Section 6.0 Page 7

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)

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Restrictor blocks

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Components

Section 6.0 Page 8

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) (2 + 3) (4) (5 + 6) (7) (8) (9) (10) (11 (12) (13) (14) (15) (16) A+B M Y

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

Function: Setting of the maximum permissible cylinder speed (flow B to A) is carried out by spindle (1). Depending on the spindle setting, the radial holes (9.1) in the valve poppet (9) will be partially opened to achieve the required throttling of the oil flow.

The extra holes (fixed throttle 9.2) prevents the valve from becoming completely closed.

For the lifting operation (flow A to B), the valve poppet (9), which is guided by the spindle (1), is pressed against spring (7) so that the valve will be completely open.

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Components

Section 6.0 Page 9

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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Components

Section 6.0 Page 10

6.1.7 Remote control valves

)

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

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

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

Function: The electric-hydraulic control system is used to control the direction and volume of oil flow to the operating cylinders and motors via the main control valve blocks.

When a lever (or pedal) is actuated, a proportional solenoid valve (13) and one of the directional solenoid valves (12 either a or b) are energized, and allows the pilot pressure oil to flow to the spools of the main control blocks.

The proportional solenoid valve alters the pilot pressure, proportional to the lever deflection, this results a spool movement between neutral and full stroke position.

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Components

Section 6.0 Page 11

6.1.8 Directional Solenoid Valves (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) (2) (3) (4) (5) (6)

Housing Solenoids Control spool Reset springs Plunger End cover

Function: In un-operated condition the control spool (3) is held in the neutral or starting position by the reset springs (4). Operation of the control spool is by means of oil immersed solenoids (2).

The force of the solenoid (2) acts via the plunger (5) on the control spool (3) and pushes its from its resting position into the required end position. This results in the required free flow from P to A and B to T or from P to B and A to T. When the solenoid (2) is de-energised, the control spool (3) is returned to its original position by the reset springs (4).

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Components

Section 6.0 Page 12

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) (2) (3) (4)

Proportional solenoid Control piston Valve housing Pressure measuring spool

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

Pressure measuring spool Connection plug Return spring Bleed screw

Function: In un-operated condition the control spool (2) is held in the neutral or starting position by reset springs.

The control spool (2) is directly operated by the proportional solenoid (1).

If the solenoid is energized, it produces a force to operate the control spool (2) via the pressure measuring spool (4) and moves the spool to the left. Oil flows from P to A. As pressure in A increases, it passes via the radial borings in the control spool (2) to the inner end of the pressure measuring spool (2).

The force generated by the pressure now works against the solenoid force and pushes the control spool (2) to the right (closing direction) until a balance is achieved between the two forces. In order to achieve this, the pressure measuring spool (2) moves to the left until it is supported by the pin (5).

When the force balance is achieved, the connection between P and A is interrupted and the pressure in line A is held constant.

Any reduction in the solenoid force leads to the pressure force exceeding the solenoid force on the control spool (2). The control spool is then moved to the right causing a connection from A to T allowing the pressure to fall until a balance is 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.

:

05.04.03

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

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Components

Section 6.0 Page 13

6.1.10 High Pressure Filter

)

• There is one filter in each pump line installed.

Legend for illustration (Z 21696): (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) P1 P2 a b c d e

Filter head Drain plug Filter case Hexagon Filter element Packing ring O-ring Back-up ring O-ring Spring Differential pressure switch Higher static pressure Lower static pressure Electrical connection REED contact Permanent magnet piston Spring Plug screw

Function: High-pressure in-line filters prevent contamination from entering the hydraulic circuits. The spin-on filters are installed between the main hydraulic pumps and multi-valve control blocks. All hydraulic components, behind the pumps, are effectively protected from damage and undue wear.

Each filter is equipped with a differential pressure switch to monitor the filter flow restriction. If the pressure reaches an unsafe difference of 8.5 bar, a visual/acoustic warning appears on the display in the cab and the motors will stoped automaticaly.

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Components

Section 6.0 Page 14

6.1.11 Control Blocks and Valves

)

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

Legend for illustration (Z 22436): (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13)

Control block housing Cab ("A side) Cap ("B" side) Solid spool "B" side service line ports Centering springs MRV, main relief valve Port A, to cylinder/motor Port B, to cylinder / motor Fine controlling grooves Port P, from pumps Port T, to tank Load holding valves

Control blocks with "Open Center and Closed Ports".

Control blocks I, II and III are 4 spool blocks and IV is a 1 spool block.

See hydraulic circuit diagram for spool details.

Each spool is provided with "Fine Controlling Grooves" and ring grooves for hydraulically centering of the spool.

Between 8 and 19 bar pilot pressure the spools are moved in their fine control range.

Spool number 4 of block I, 2 of block II and 4 of block III are special designed, to keep the pressure channel connected to the center channel during the floating function is activated, so that pump flow is available for other functions. This spools are marked in the hydraulic diagram with (#) symbol.

The Load Holding Valves are installed inside of the spool, for each port to the cylinder or motor one valve. The hydraulic diagram shows only one.

The MRV is a pilot operated pressure relief valve.

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6.1.11 Control Blocks and Valves Legend for illustration (Z 22440): (1) (2) (3) (4)

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

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

(A) 4 valve block E.g. the spools moves up when pilot pressure is build up in the control pipe line a1. (Imagine the lower symbol box moves to the center position.)

Now pump oil flows through holding valve (2) to the user port A1 because the free flow circulation to the hydraulic reservoir is closed. The main relief valve (1) limits the maximum operation pressure in this circuit. Via port B1 the return oil from the user is flowing back to the hydraulic reservoir.

During down hill travelling motion and stopping procedure (e.g. travel motors) the anti cavitation valves (3) prevents cavitation on the hydraulic motors. Because during these short periods of time the hydraulic motor needs a higher oil supply than the pump can deliver.

E.g. the spool #4 moves up when pilot pressure is build up in the control pipe a4. Now the user port A4 is connected to the pump pressure line and the free circulation to the tank. There is no high pressure build up only 8 bar from the back pressure valve and line resistance. Via port B4 the return oil from the user is flowing back to the hydraulic reservoir. Service line relief valve (4) is additional installed in this circuit to protect the circuit for extreme pressure.

The shortly extreme pressure closes also the holding valve (2) which secures the hydraulic pump from extreme pressure peaks.

(B)

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

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6.1.11 Control Blocks and Valves Legend for illustration (Z 22441): (1) (2) (3)

Spool Reset springs 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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6.1.11 Legend for illustration (Z 21705): (01) (02) (03) (04) (5) (6) (7) (8)

Service -Line Relief Valve Anti Cavitation Valve Main Relief Valve Closing plate Plug screw Spring Valve cone Dust cap

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

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

MRVs and SRVs are pilot operated relief valves. The MRV limits the max.

Pump supply line pressure. The SRV limits the max. possible pressure peak in the service-line.

The valves have an „opening characteristic“. That means, that in case of contamination after the response procedure no further pressure increasing is possible and damages are avoided.

Function: The circuit pressure P forces with the force F1 on the piston surface A of the main valve cone (15). Because there is via the jet bore (16) the same pressure on the back side of the main cone, this results together with the spring (14) force in a force F2 that keeps the main cone closed. Via the jet bore (13) the circuit pressure is in front of the poppet (12). Exceeds the circuit pressure the setting value of the spring (11), the poppet opens against the force of the spring (11).

This causes that the force F2 decreases and there is no more balance condition between F1 and F2. Valve cone (15) is moved upwards by the greater force F1.

That means there is now a direct connection from port P to T (tank).

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

Function: The circuit pressure inside the spring chamber closes the valve cone (7).

The back pressure of the return line acts on the surface of the valve cone (7).

Whenever the pressure in the service-line is lower than the springs force the valve cone opens by the force of the back pressure and hydraulic oil is additional supplied.

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6.1.12 Load Holding Valve Legend for illustration (Z 21706): Legend for illustration (Z 22441): (1) (2) (3)

Spool Reset springs 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 overspeeding.

Function: Spring force keeps the spool in the lowest flow position. with increasing operating pressure the opening for the return oil flow becomes larger.

On its way to the hydraulic motor the oil flows from A to A1 respectively from B to B1 depending on the selected travel motion.

Example: Operating pressure at port A moves spool (1) against the force of the spring (2) and opens the way for the return oil (B1 to B).

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.

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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) (2) (3) (4) (5) (6) (7) (8)

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

Housing Solenoid Control spool Return spring Plunger 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 or P to B and A to T. When solenoid (2) is de-energized, control spool (3) is moved back to its resting position by means of return springs (4).

An optional hand emergency (6) allows movement of the control spool (3) without energizing the solenoid.

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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) (2) (3) (4) (5) (6) (7+8) (9) (10) (11+12) (13+14)

Pilot valve with valve seat Valve poppet Compression spring Main valve with sleeve Main piston Closing spring Set screws Piston Pin Jet bore Lock nut

Function: The valve poppet (2) is connected via the jet bores (11) and (12) with the pressure port (P).

If static pressure increase above the set pressure value, the valve poppet (2) opens and allows oil to flow freely via port (T1) to tank. This out flowing oil generates a pressure drop in the spring chamber of the main spool (5). The closing force of the spring (6) is now lower as the oil pressure from the pressure port (P) and the main piston (5) opens to release pressurized oil to the tank via port (T2).

Damped opening and closing is obtained by the throttled volumetric change.

By applying external pressure of Pst max = 35 bar to the main spool (9) via port X, the pre-tensioning of the pressure spring (3) is increased by the amount of the piston stroke "S" and system pressure is increased correspondingly.

The maximal possible pressure (P) adjustment is 440 bar with max. control pressure at port X. The lower setting is fixed by means of the setting screw (7) and lock nut (13); 1 turn of setting screw reduce or increase the pressure about ~150 bar.

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Main Hydraulic Pumps and Pump Regulation System

Section 7.0 Page 1

Table of contents section 7.0 Section 7.0

Page Main hydraulic pumps and pump regulation system General 7.1

7.2

7.3

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2–9

Main Pumps 7.1.1 Location of Pumps 7.1.2 Pump bearing flushing / lubrication 7.1.3 Operating Principles 7.1.4 Checks and Adjustments

10 - 11 12 - 13 14 – 29 30 – 39

Electronic Pump Regulation System 7.2.1 Electronic load limiting control - General 7.2.2 Electronic Power Module EPM 7.2.3 Electronic Signal Rectifier ESR 7.2.4 Microcontroller MC7 7.2.5 Checks and adjustments - General Method A - With 24V supply to terminals - X1- pressure adjustment - Demanded power adjustment - PID – Factor adjustment Method B - With the electronic service tool BB-3 - Language selection - Adjustment mode SET1 and SET2 - Number of motor selection - X1-pressure (max. current) adjust.

- Demanded power adjustment - PID – Factor adjustment - Storage new settings Method C - With a laptop and BODEM software - Starting the program - Language selection - Entering of the password - Number of Motor selection - X1-pressure (max. current) adjust.

- Demanded power adjustment - PID – Factor adjustment Hydraulic Constant Regulation System 7.3.1 General 7.3.2 X1-pressure adjustment (constant-pressure)

40 – 41 42 - 43 44 - 47 48 - 49 50 - 51 52 - 53 54 - 57 58 - 59 60 - 63 64 - 65 66 - 67 68 - 69 70 - 71 72 - 73 74 - 75 76 - 79 80 - 81 82 - 83 84 - 85 86 - 87 88 - 93 94 - 95 96 - 97 98 - 99

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Section 7.0 Page 3

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 reduction for the warming-up period (81.2) Pressure reducing valve: "Pump regulation pressure X1 at hydraulic pump regulation" (Hydraulic constant regulation mode) (Y61-1) Proportional solenoid valve: "Pump regulation pressure X1 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

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Section 7.0 Page 5

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 temperaturedependent flow reduction.

Function: X1 – pump regulation pressure (0 – 24 bar): The power controller of the main pumps can be remotely controlled by applying an external pilot pressure (X1 ) at port X LR to the spring chamber of the power control valve. The start of destroking can be varied in proportion to the applied X1 - pressure.

X2 – pilot pressure (35 bar): Constant pilot pressure to regulate the main pumps at special circumstances, e.g. to fix pump # 3 in Q-max position (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.

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Section 7.0 Page 7

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 values of temperature range „T2“ (depending on the filled in hydraulic oil) shown in the table. ( pumps #1-6 are in ½ Q-max. position)

Note:

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* Electric circuit diagram page / column (based on Id # 897 899 40)

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Section 7.0 Page 9

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 regulation), 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:

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Main Hydraulic Pumps and Pump Regulation System

7.1

Section 7.0 Page 11

Main Pumps 7.1.1. Location of Pumps Legend for illustration (Z 22415a): (1 - 6) Axial piston pump (swash plate type) theoretical flow rate, each Qmax Drive speed* n for all working motions pmax

= 700 Liter/min = 1400 min-1 = 310 bar

(10.1), (10.3) Axial piston pump (only with diesel engine) theoretical flow rate Qmax Drive speed* n for radiator fan drive pmax

= 158 Liter/min = 1973 min-1 = 230 bar

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

Qmax n pmax

= 142 Liter/min = 1770 min-1 = 180 bar

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

Qmax n pmax

= 82,2 Liter/min = 1400 min-1 = 7,5 bar

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

Qmax n pmax

= 58,7 Liter/min = 1400 min-1 = 10 bar

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

Qmax n pmax

= 120 Liter/min = 1400 min-1 = 50 bar

(8.1), (8.4)

(8.2), (8.5)

(7.1), (7.2)

F 13.11.02 rev.25

• * at 1800 min-1 input drive with diesel engine speed • * at 1400 min-1 input drive with electric motor speed

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Section 7.0 Page 13

Main Pumps 7.1.2. Pump bearing flushing / lubrication The installed main pumps are provided with an external cooling and lubrication system for flushing of drive shaft bearing and shaft seal.

Oil supply is provided from the X4-pressure circuit.

To reach the restricted guidance of the coolant for external bearing flushing, the throttle screw (located behind the union at port U) must screwed in all the way.

An information sign is fixed at the pump.

Legend for illustration (Z 22443): (1 – 4) Main pumps (147.1-147.6) Orifice (one for each main pump) (33) Filter for pilot pressure (P) Ports for X4-pressure (pump support pressure) (U) Port for the pump bearing flushing / lubrication

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Section 7.0 Page 15

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

Function and characteristics: • The A4VSO variable displacement axial piston pump in swash plate design is intended for drives in open circuit operation.

• The flow volume is proportional to the drive speed and the displacement.

By adjusting the swash plate a infinitely variable flow adjustment is possible.

• Pumps of the same nominal size can be built onto the trough drive.

Combinations with gear pumps are also possible.

Legend for illustration (Z 22446): The lower illustration shows only a principle pump construction (1) Drive shaft (2) Cylindrical roller bearing (3) Slipper pad (4) Swivel angle indicator (5) Positioning piston (6) Swivel pin (7) Cylinder with pistons (8) Final connecting plate (9) Cylindrical roller bearing (10) Splints for the through drive coupling (Aux. pump drive) (11) Swivel cradle (12) Q-min stop bolt (13) Power control valve (14) Pressure balance valve (15) Power curve correction (16) Pressure cut off valve (17) Q-max. stop bolt (18) Remote control valve continued

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Section 7.0 Page 17

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

F

• * Factory side adjusted, no field adjustment required

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

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

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Section 7.0 Page 19

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

F

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

continued

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Main Hydraulic Pumps and Pump Regulation System 7.1

Section 7.0 Page 21

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 normal 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 = 25 bar (pump regulation pressure), this pressure will not influence the Q-min position under these conditions.

• X3 = 0 bar (remote control pressure); Y17 de-energized (S150 activated) for pumps #1, #2 #4, #5 and #6.

Pump #3 is not connected in the regulation circuit its port XLR is permanent charged with X2-pressure • X4 = 60 bar (pump support pressure) Pump support pressure is present at valve #6, the slipper pad of piston #13 and the small area side of the positioning piston #12 Response of pump control mechanism: Valve #6 moves to position "b" because the X4-pressure will overcome the spring force, since the oil behind nozzle (7) flows through valve #5 (which is in position "a", due to the missing remote control pressure X3) back to tank.

Pump support pressure X4 passes valve #6 position "b" and flows via power control valve #8 position "a" to the large area side of positioning piston #12.

Because the large area side of positioning piston #12 is approximately three times larger as the small area side, the pump support pressure X4 of 60 bar present on both sides, resulting in stronger force at the large area side, keeps the pump in Q-min position.

The pump remains in Q-min position continued

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Section 7.0 Page 23

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? and and and

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

Example with the following conditions: • 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 = 25 bar (pump regulation pressure) • X3 = 35 bar (remote control pressure); Y17 and Y17a energized for all six pumps.

• X4 = 60 bar (pump support pressure), present at valve #6.

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

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

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

The pump moves into Q-max position continued

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Main Hydraulic Pumps and Pump Regulation System 7.1

Section 7.0 Page 25

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? and and and

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

Example with the following conditions: • 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 = 25 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 intermediate position, due to the 16 bar remote control pressure X3) back to tank.

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

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

The pump moves into ½ Q-max position continued

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Main Hydraulic Pumps and Pump Regulation System 7.1

Section 7.0 Page 27

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. Þ (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 piston #12.

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

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

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Main Hydraulic Pumps and Pump Regulation System 7.1

Section 7.0 Page 29

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 â&#x2030;&#x2C6; 300 bar Example with the following conditions: Motor running Pump pressure 300 bar X1 = 25 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

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Main Hydraulic Pumps and Pump Regulation System 7.1

Section 7.0 Page 31

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 1 2 3 4 5 6 7

F

Length “L” (mm) 13.4 21.9 8.3 8.1 ---6.3 27.6

• The measurement "L" is an orientation only if the adjustment is totally out of requirements.

They must not be used for final adjustments.

The detail for (5) shows the position of the housing edge and the edge of the eccentric set bolt. The example shows them in parallel position which is mostly not the case. The adjustment should never be altered.

Further information see next pages

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Main Hydraulic Pumps and Pump Regulation System 7.1

Section 7.0 Page 33

Main Pumps 7.1.4 Checks / Adjustments Pressure balance valve (∆ ∆ P 20bar), illustration (Z21558) 1.

Connect a 60 bar pressure gauge to check point MST.

2.

Eliminate "Idle Time Control" by using the switch ”S151” of the X2-panel, if necessary see Operation Manual.

3.

Unplug solenoid valve Y17a (this causes a remote control. pressure (X3) of approx.16 bar).

4.

Start the respective motor.

5.

Gauge reading at MST must be 40 bar (20bar less than the pump support pressure of 60bar) Loosen lock nut #4 and adjust with the set bolt #5

6.

Plug-on Y17a

7

Remove the pressure gauge and set S151 for "Idle Time" elimination into normal position.

continued

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Main Hydraulic Pumps and Pump Regulation System 7.1

Section 7.0 Page 35

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.

2.

3.

4.

5.

6.

7.

Connect a 400 bar pressure gauge to the pressure check point at the respective high pressure filter for the pumps being checked.

Connect a 25 bar pressure gauge to respective pressure check point M20-1 or M20-2 at the control and filter panel (X1-pressure).

Change over the respective three way cock to electronic regulation.

Unplug the respective proportional valve Y61.1 / Y61.2.

Insert an Allen key into the angle indicator bolt (see illustration) for better visibility of the start of.

Start the respective motor. The X1-pressure should be 0 bar.

Stall the hydraulic for the pump to be checked and alter the operating pressure with the MRV between 140 and 160 bar.

Start of de-stroking should be at an operating pressure of 150 bar, shown at the gauge connected to the high pressure filter.

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

8.

Re-adjust the operating pressure at the MRV to 310+10 bar and plug

9.

on the Y61.1 resp. Y61.2 (For exact values refer to the final test report.)

Remove Allen key and gauges. continued

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Main Hydraulic Pumps and Pump Regulation System 7.1

Section 7.0 Page 37

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 operating pressure between 300 bar and 310 bar.

1.

2.

3.

4.

Connect a 400 bar pressure gauge to the pressure check point at the respective high pressure filter for the pumps being checked.

Insert an Allen key into the angle indicator bolt (see illustration) for better visibility of the start of de-stroking.

Start the respective motor, stall the hydraulic for the pump to be checked and alter the operating pressure with the MRV between 280 and 310 bar.

The angle indicator must indicate Q-min. position at a pressure of 300 bar shown at the gauge connected to the high pressure filter.

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

5.

6.

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

continued

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Main Hydraulic Pumps and Pump Regulation System 7.1

Section 7.0 Page 39

Main Pumps 7.1.4 Checks and Adjustments Cont'd: Q-max. and Q-min. stop bolt, illustration (Z21561) 1.

2.

3.

5.

ĂŁ

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Unscrew box nut (10 or 14).

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

â&#x20AC;˘ Turning the Q-min. stop bolt too much out can cause serious damage to the pump.

The pump moves over 0 (zero) position into the opposite drive direction: (suction line becomes pressure line and pressure line becomes suction line)

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Main Hydraulic Pumps and Pump Regulation System 7.2

Section 7.0 Page 41

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 PTOgearbox. Each pump is equipped with a hydraulic power controller (HPC).

This controller limits the input torque of the pump to an adjusted command value (X1pressure, for start of destroking).

The command value (X1-pressure) is present via proportional solenoid valves Y61-1 respectively Y61-2 at the hydraulic power controllers of each pump.

F

• 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 voltage, 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 required power with the rated power.

With increasing load the motor torque will rise and in turn the required power.

For this reason the electronic load limiting control will be initiated when the required power is higher than the rated power, i.e. the torque of the main pumps will be lowered (by reducing the X1-pressure) until the rated power is attained again.

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Main Hydraulic Pumps and Pump Regulation System 7.2

Section 7.0 Page 43

Electronic Pump Regulation System

7.2.2 Electronic Power Module EPM, illustration (Z 22624a) The EPM – Module transforms the 24 VDC battery voltage into positive/negative 15 VDC and positive 5 VDC which is the supply voltage for the ESR Modules. The LED’s besides the terminals are indicating the function.

Testing the EPM-Module, A31 Adjustment: • The fine tuning for the positive 5 VDC can be done with the potentiometer P1. Plus / minus 0.5 VDC are allowed.

• Seal the potentiometer with silicone after the tuning.

F

Function check: Measure the supply voltage. (24 VDC; GND = 0 V).

If the supply voltage is not there, check the supply cable and the circuit breaker. If the circuit breaker always trips there may be a short within the cables to the EPM Module or a short in the unit itself.

If the supply voltage is ok. the Output Voltages have to be checked. Check pos. 15 VDC, neg. 15 VDC, 5 VDC to GND. If the supply voltages are not ok. the short circuit monitoring system of the EPM might be activated, therefore disconnect the cables at the terminals (+15 VDC, -15 VDC and +5 VDC) and repeat the voltage check.

If now (with disconnected cables) the voltages are as they should be there is either a short within the cables or in the other modules itself. To determine the fault connect the entire modules in sequence.

If the voltage is not ok., even when the cables are disconnected from the EPM, the EPM-Module is defect.

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Main Hydraulic Pumps and Pump Regulation System 7.2

Section 7.0 Page 45

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 network voltage respectively the motor current, into a proportional DC Voltage and transfers 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 tested.

W

• The potentiometer settings are under no circumstances allowed to be altered, because the setting is possible only with a HFGenerator 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

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Main Hydraulic Pumps and Pump Regulation System 7.2

Section 7.0 Page 47

Electronic Pump Regulation System

7.2.3 Electronic Signal Rectifier ESR â&#x20AC;&#x201C; 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.

F

â&#x20AC;˘ 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 ESR1 ----------------T1 x T2 x T3

6570 V --------------66 x 10 x 4

= 2,488 VDC

Voltage

Example for ESR 2: I ESR2 ----------------T1 x T2 x T3

80 A ----------------- = 1,333 VDC 30 x 0.5 x 4

Current Motor 1

75 A ----------------- = 1,25 VDC 30 x 0.5 x 4

Current Motor 2

Example for ESR 3: I ESR3 ----------------T1 x T2 x T3

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 ESR2 ----------T1 x T2

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80 ----------- = 5,333 VDC 30 x 0.5

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Main Hydraulic Pumps and Pump Regulation System 7.2

Section 7.0 Page 49

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 overvoltage and electrical interference.

As output signals, the output stages of the MC7 deliver closed loop controlled currents for the connection of proportional solenoids.

The analog voltage output is suitable for the simple forwarding of analog information to other electronic circuits.

Characteristics • Closed loop control of solenoid currents, i.e. independent of voltage and temperature.

• Pulse width modulated (PWM) solenoid currents for minimal hysteresis.

• Internal buzzer for programmable monitoring of functions or errors.

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

MC7 - Unit Dimensions

Plug Contacts

8 junior power timer contacts 47 micro timer I contacts MC7 - Block Circuit Diagram

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Main Hydraulic Pumps and Pump Regulation System 7.2

Section 7.0 Page 51

Electronic Pump Regulation System

7.2.5 Checks and adjustments General Microcontroller MC7, illustration (Z 22623) The adjustment of the X1-pressure can be done with three different methods: A. With 24V supply to separating terminals at the X2-switch board or B. With the electronic service tool (EST) BB-3 connected to the serial interface X13-1 (located in the operators cab) or C. With a laptop, running the BODEM software, connected to the serial interface X13-1 (located in the operators cab)

F

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â&#x20AC;˘ Procedure B and C should only be carried out by authorized personnel. [ Dealer or KMG-factory staff ] Because it is possible to influence the behavior of the pump regulation system.

On the following pages are only the necessary setups described.

If additional information is required, please contact KMG-Service department.

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Main Hydraulic Pumps and Pump Regulation System 7.2

Section 7.0 Page 53

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 proportional 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 motor.

Read the pressure, required = 25± 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

F

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Main Hydraulic Pumps and Pump Regulation System 7.2

Section 7.0 Page 55

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.

F

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

F

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

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 hydraulic oil cooler fans are running with maximum speed.

4. Start one motor.

5. Set the MRV individually to approx. 120 bar *, to prevent the motors from overloading during the adjustment.

6. Shift the three way cock valves (79.1 and 79.2) to position “Hydraulic (constant) 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 stop position until the hydraulic system stalls), 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.

*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

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Main Hydraulic Pumps and Pump Regulation System 7.2

Section 7.0 Page 57

Electronic Pump Regulation System

7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22629) Cont'd: Method A - Demanded power adjustment 1.

F 2.

3.

4.

5.

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 (Motor 1): Connect 24V, simultaneously to terminal 50 and 52 permanent. c) Select the demanded power adjusting mode (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 Qmax 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 demanded power Re-set the X1-pressure at pressure reducing valves (81.2) as recorded**.

Shift the three way cock valves (79.1 and 79.2) to position “Electronic Regulation Mode” Reset the MRV’s to 310 bar+5bar , and remove the gauges.

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 13.11.02 rev.25

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Main Hydraulic Pumps and Pump Regulation System 7.2

Section 7.0 Page 59

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 differential 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.

F 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 connecting 24V to terminal 54. (As close as possible to the boarder line) f) Now reduce the voltage in steps of 250mV until the system works smoothly again, as described under item 1d.

3.

After the adjustments are finished, remove the test leads and multi-meter, stop the motors and turn the main key switch in OFF position to deactivate the adjusting mode.

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Main Hydraulic Pumps and Pump Regulation System

Section 7.0 Page 61

7.2 Electronic Pump Regulation System 7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22357) 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.

2.

3.

4.

Make sure the respective change over valve is in position â&#x20AC;&#x153;Electronic Pump Regulationâ&#x20AC;?

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.

Connect the electronic service tool (BB-3) to the data link adapter X13, with key switch (S1) in OFF position.

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 F2 PROC TE ACH Language selection To change the language press simultaneously the buttons ALT + Clear

ALT

+

CLEAR

Config/Cal. Diagnostic Status Storage

The language selection menu appears

F1 F2 PROC TE ACH

Config/Cal. Diagnostic Status Storage continued

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Section 7.0 Page 63

Electronic Pump Regulation System

7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22357) Cont'd:

Method B Language selection Press button 2

2

The language will change to English and the display show the main menu

1.

2.

3.

4.

Deutsch English - - - - -

One of the four main menu items can be selected using the given keys.

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Main Hydraulic Pumps and Pump Regulation System 7.2

Section 7.0 Page 65

Electronic Pump Regulation System

7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22357) 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 Standard after start up F1 F2 PROC TE ACH

Main display SET 2 Only with password

Config/Cal. Diagnostic Status Storage

F1’ F2 PROC TE ACH

Config/Cal. Diagnostic Status Storage

F1 F2 PROC TEACH

Config/Cal. Diagnostic Status Storage

Change from SET 1 to SET 2:

Press

F1

Press

ALT

SET 1 Config/Cal Config/Cal

+

in the same time

1 2 3 4

Demand Power Max current PID - Factor Error Lamp

A password will be requested Enter password (number)

1 Press

MENU

...

9

SET 2 to go back to the main menue

To switch back to SET 1 repeat this procedure or switch off and on the MC7.

?: _

1 2 3 4

Configuration PID Control Low Voltage –––

F1’ F2 PROC TEACH

Config/Cal. Diagnostic Status Storage

continued

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Main Hydraulic Pumps and Pump Regulation System 7.2

Section 7.0 Page 67

Electronic Pump Regulation System

7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22357) Method B - Number of motor selection: Activate adjustment mode SET 2 as described on page 65 Press

F1

Press

1

Configuration

Press

2

No of motors

Config/Cal Config/Cal

F1’ F2 PROC TEACH

Config/Cal. Diagnostic Status Storage

1 2 3 4

Configuration PID Control Low Voltage –––

1 2 3 4

No of valves No of motors –– ––

Select desired number of motors

2

No of motors

use

1

motor

2

No of motors

2

motors

1 2 3 4

No valves No motors –– ––

Press

or

ENTER Acceptation

Press. 2 x MENU Return to sub menu.

F1’ F2 PROC TE ACH

Config/Cal. Diagnostic Status Storage

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

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Main Hydraulic Pumps and Pump Regulation System 7.2

Section 7.0 Page 69

Electronic Pump Regulation System

7.2.5 Checks and adjustments Micro-controller MC7, illustration (Z 22357) Method B X1-Pressure (maximum current) Adjustment:

F1

Press

Config/Cal Config/Cal

If sub menu SET 2 is displayed change to sub menu SET 2 as described on page 65.

2

Press

Max current

F1 F2 PROC TE ACH

Config/Cal. Diagnostic Status Storage

1 2 3 4

Demand Power Max current PID - Factor Error Lamp

1 2 3 4

Valve Valve Valve Valve

Select desired valve

1

Press or Press

Valve 1, Motor1 Valve 1, Motor2

3

Example Motor 1, Valve1

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: pressing

Press

or

ENTER

Press. 2 x

Accept tion

MENU

Return to main menu

1 2 1 2

Mot. Mot. Mot. Mot.

1 1 2 2

1 Valve 1 Mot. 1 0 – 100±1 71

1 Valve 1 E1 0 – 100±1 78

1 2 3 4

Valve Valve Valve Valve

F1 F2 PROC TE ACH

1 2 1 2

Mot. Mot. Mot. Mot.

1 1 2 2

Config/Cal. Diagnostic Status Storage

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

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Section 7.0 Page 71

Electronic Pump Regulation System

7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22357) Method B Demanded power adjustment: Cont'd: Press

F1

F1 F2 PROC TE ACH

Config/Cal Config/Cal

Config/Cal. Diagnostic Status Storage

If sub menu SET 2 is displayed change to sub menu SET 2 as described on page 65.

Press

1

Configuration

1 2 3 4

Demand Power Max current PID-Factor Error Lamp

1 2 3 4

Set demand m.

Set demand m.

Demand power Demand power

Select desired demand power adjustment Press or Press

SET 1

1

demand power Motor1 demand power Motor2

2

1 2 1 2

1 Set demand m. 1 0–0±1 0

Example Motor 1

and Load respective Motor with max power Press ENTER

Selection

Start?

––> <ENTER> Cancel?

––> <ENTER>

Press ENTER

Starting

Function ended Saved Press <ENTER>

Press ENTER Confirm

Press. 2 x

MENU

Return to main menu

F1 F2 PROC TE ACH

Config/Cal. Diagnostic Status Storage

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

Continued

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Electronic Pump Regulation System

7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22357) Method B Cont'd: PID-Factor adjustment: Jerky movements while lifting with full bucket and swinging at the same time: Reduce jerking Þ 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.

Press

F1

F1 F2 PROC TEACH

Config/Cal Config/Cal

If sub menu SET 2 is displayed change to sub menu SET 2 as described on page 65.

SET 1 Press

3

PID-Factor.

Press

1

PID-Factor.

Adjust the PID-Factor by pressing . or

Press

ENTER

Accepttion

Config/Cal. Diagnostic Status Storage

1 2 3 4

Demand Power Max current PID-Factor Error Lamp

1 2 3 4

PID-Factor ––– ––– –––

1 PID-Factor 80–120±1% 100

1 2 3 4

PID-Factor ––– ––– –––

and check the machine movement again if necessary repeat PID-Factor adjustment

Press. 2 x

MENU

Return to main menu.

F1 F2 PROC TEACH

Config/Cal. Diagnostic Status Storage

Save setting to the EEPROM of the MC7 as described at page 75. continued 13.11.02 rev.25

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7.0 & 74 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 .

Press TEACH

Press

1

Press ENTER

Press. MENU

Activate storage menu

F1 F2 PROC TE ACH

Config/Cal. Diagnostic Status Storage

Save Params

1 2 3 4

Store parameters

Teach?

––> <ENTER> Cancel?

––> <ENTER>

Return to main menu.

1 2 3 4

Save Params Default Rarams Get EEPROM Send EEPROM

Save Params Default Rarams Get EEPROM 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.

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Electronic Pump Regulation System

7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22358) 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 setting 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 Bodem - icon to start the program.

continued

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Electronic Pump Regulation System

7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22358) Method C, Starting the program Cont'd: 6. The program starts (only) the first time with the Demo Version.

7. Open menu FILE â&#x2020;&#x2019; 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 hardware and software infromation.

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Electronic Pump Regulation System

7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22358) Method C Language selection Open menu FILE â&#x2020;&#x2019; Language , select the required language and confirm with OK .

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Electronic Pump Regulation System

7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22358) Method C Entering of the password:

F

â&#x20AC;˘ The password is only required to adjust the number of valves or engines 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 confirm with OK.

F 13.11.02 rev.25

â&#x20AC;˘ After entering a correct password and confirming with OK the BODEM software start a new upload from the MC7 memory to the PC.

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7.0 & 84 7.2

Electronic Pump Regulation System

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

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Electronic Pump Regulation System

7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22358) Method C X1-Pressure (maximum current) Adjustment: Make sure the change over valve is in position â&#x20AC;&#x153;Electronic Pump Regulationâ&#x20AC;?

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.

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7.0 & 88 7.2

Electronic Pump Regulation System

7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22358) Method C Demand power adjustment:

F

â&#x20AC;˘ 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.

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

Screen with password Screen without password.

The demand power adjustment is possible both modes. continued

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7.0 & 90 7.2

Electronic Pump Regulation System 7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22358) Cont'd: Method C Demand power adjustment:

F

• 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.

2.

3.

4.

5.

6.

7.

Connect pressure gauges to the high pressure check points at the high pressure filters. (M12.1, M12.2, M12.3 and M12.4) Connect pressure gauges to the X1 pressure check points (M20.1 and M20.2).

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.

Shift the three way cock valves (79.1 and 79.2) to position “Hydraulic (constant) Regulation Mode”.

Start one motor.

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.

Apply max. load to all pumps (e.g. extend the bucket cylinders to the stop position until the hydraulic system stalls), and increase the pressure at all 4 MRV’s * equally to the demand power pressure written in the final test report (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. continued *Altering the MRV-Setting: − Remove dust cap (a). − Loosen lock nut (b). − Turning the set screw (c) cw the pressure will increase. − Turning the set screw ccw the pressure will decrease. **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.

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7.0 & 92 7.2

Electronic Pump Regulation System 7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22358) Cont'd: Method C Demand power adjustment: 8.

9.

13.11.02 rev.25

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.

Stop motor and repeat from item 5 for the second motor.

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Electronic Pump Regulation System 7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22358) 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 differential factors) it is possible to influence the regulation dynamics.

• This factor is multiplied with all PID parameters.

• Only one factor / adjustment for both motors

F

Open Parameters and select Display / Edit Parameters. Select in the left window PID control. Adjust now the PID-Factor with the slide bar or write direct the requested value to the window with the % value. Write new adjustment permanent to the MC7 EEPROM with Apply and confirm with OK. • Jerky movements while lifting and swinging at the same time: Reduce the PID-Factor in short steps until the system works smoothly. (As close as possible to the boarder line) • No Jerky movements: 1. Increase the PID-Factor in short steps until the system jerks. (As close as possible to the boarder line) 2. Now reduce the PID-Factor in short steps until the system works smoothly again.

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7.0 & 96 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.

F

• 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 22442): (1 - 3) (4 - 6) (7.1) (7.2) (68.1) (70.1) (70.2) (81.1) (81.2) (Y61-1) (Y61-2) (79.1) (79.1)

13.11.02 rev.25

Main hydraulic pumps (driven by Motor 1) Main hydraulic pumps (driven by Motor 2) Pilot pressure pump (driven by Motor 1) Pilot pressure pump (driven by Motor 2) Pilot pressure filter unit Pressure relief valve 60 bar (X4) Pressure reducing valve 35 bar (X2) Pressure reducing valve: "½ Qmax , remote control X3 pressure” Pressure reducing valve: "Pump regulation pressure X1 at hydraulic constant regulation mode " Proportional solenoid valve: "Pump regulation pressure X1 at electronic operation mode" (Standard mode Motor 1) Proportional solenoid valve: "Pump regulation pressure X1 at electronic operation mode" (Standard mode Motor 2) Change over valve: "Electr. or Hydr. pump regulation" Motor 1 Change over valve: "Electr. or Hydr. pump regulation" Motor 2

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7.0 & 98

7.3

Hydraulic Constant Regulation System 7.3.2

X1-pressure adjustment (constant-pressure), 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

F

illustration (Z 22639a)

Connect pressure gauges to check points M12.1, M12.2, M12.3 and M12.4 at the high pressure filters.

Connect pressure gauges to the X1 pressure check points M20.1 and M20.2.

Unplug solenoid valves Y6a-1, Y6b-1 and Y6a-2, Y6b-2 to ensure that the hydraulic oil cooler fans are running with maximum speed.

Shift the three way cock valves (79.1 and 79.2) to position “Hydraulic (constant) Regulation Mode”.

Start motor 1.

Set the X1-pressure at pressure reducing valve (81.2) to approx. 3 bar ** 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.

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 pressure reducing valve (81.2) . Record this values for other tests.

Stop motor 1 and start motor 2 .

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.

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.

Shift the three way cock valves (253.1 and 254.1) to position “Electronic regulation“.

Plug on the unplugged solenoid valve.

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.

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Section 8.0 Page 1

Operating Hydraulic

Table of contents section 8.0 Section 8.0

06.04.03

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

2 3+4

8.1

Hydraulic for the attachment cylinder FSA and BHA

8.2

Hydraulic for the swing circuit

8.3

Hydraulic for the travel circuit

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8.0 2

06.04.03

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Operating Hydraulic

8.0

Section 8.0 Page 2

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

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

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

Function:

)

• •

Study together with the circuit diagram.

The following numbering refers to the hydraulic circuit diagram.

Each main pump (1 to 6) delivers oil trough the high pressure filter (44.1, 44.2, 46.1 and 46.2) to port P of the main control blocks (FSA – 14, 15, 16 and 13) (BHA - 175, 15,176 and 13). The single valve block IV (13) is in line to valve block II (15) connected.

This results in three main circuits.

If all spools of the control blocks (1 to 6) are in neutral position, the oil leaves the block at port T and returns via return oil pipes, return oil collector manifold (35), return oil pipes (L6 and L7), return oil collector tube (114), back pressure valve (115) and the return oil filters (117.1-117.4) into the tank (41).

The function of back pressure valve (115) ensures: - sufficient oil supply for all anti-cavitation valves - and that sufficient oil is forced through the oil coolers.

If a control lever or pedal is actuated, pilot pressure oil moves the spools of the control blocks, directing the oil flow from the main pumps to one side of the user (either cylinders or motors). From the opposite side of the user the oil returns to the control block and from there via the return oil circuit back into the tank.

Each circuit is provided with one MRV (also called primary valve, at least one SRV (also called secondary valve) and at least one flow restrictor. continued 06.04.03

PC5500-6_Sec_8-0_rev1.doc

8.0 3

06.04.03

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8.0 4 8.0

General Cont'd: 8.0.1

Floating function of boom and stick cylinders FSA: illustration (Z 22568): The Excavator (only front shovel attachment) operates automatically with the float position for boom and stick activated.

That means the lowering movement of boom and stick is always done in the float position.

For deactivation of the float position, two push buttons are installed: a) S95 in the right joy stick (E19) for the Boom function b) S95a in the left joy stick (E20) for the Stick function Press the respective button and keep it depressed as long as the float position shall be deactivated.

When releasing the button the float position is activated again.

Function: There are different main valve spools in the three main valve blocks (14, 15 and 16) for boom and stick installed. Only by lowering of the boom or retracting of the stick is the floating function active if the button on the lever is not pushed.

The piston and rod side of the respective cylinders are in floating position direct connect to the return line (tank). The pressure free pump circulation is still active there is no pump pressure to the respective cylinders. By external force the cylinder can move up or down with negligible hydraulically resistance.

In floating position of the boom only valve spool 4 of main valve block I and 2 of block III active.

In floating position of the stick only valve spool 2 of Main valve block I and 4 of block III active.

To push down the boom or retract the stick by hydraulically force the respective button on the lever must by activated.

S98 for the Stick cylinders S95 for the Boom cylinders In normal operation mode (i.e. float position) the piston side, the rod side and the tank are connected together when lowering the boom or retracting the stick.

If a pressurised lowering of the boom or retracting of the stick cylinders is required the connection of piston side, rod side and tank must be disconnected and the rod side must be connected to the pump pressure. This is done by disconnecting the respective special floating valve spool and activating the respective standard valve spool. Now pressurised pump oil can flow to the cylinder rod side.

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Operating Hydraulic

Boom: S95 ON

K160 ON

A10 deactivated A10A activated S95 OFF

K160 OFF

A10 activated A10A deactivated Stick: S98 ON

K170 ON

A8B deactivated A8A activated S98 OFF

K170 OFF

A8B activated A8A deactivated

)

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Section 8.0 Page 4

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

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

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

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Section 8.1 Page 1

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

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

General: Flow Restrictors Boom cylinder FSA (Float position activated / deactivated) Boom cylinder BHA Stick cylinder FSA (Float position activated / deactivated) Stick cylinder BHA Bucket cylinder FSA Bucket cylinder BHA Clam cylinder 8.1.13 Checks for the valve control logic.

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

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

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Section 8.1 Page 2

8.1.1 Electric / Hydraulic flowchart “ Boom raising ” FSA Legend for illustration (Z 22493): (E19) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (Y-) Direction (axis) of joy stick (-10V) Signal voltage (Maximum) (gn) Colour 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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Hydraulic for the Attachment Cylinders

Section 8.1 Page 3

8.1.1 Electric / Hydraulic flowchart “ Boom raising ” BHA Legend for illustration (Z 22471): (E19) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (YD) Direction (axis) of joy stick (-10V) Signal voltage (Maximum) (gn) Colour 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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Section 8.1 Page 4

Hydraulic for the Attachment Cylinders 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) Colour code of signal voltage cable ( Joy stick) (X2...)

Terminal rail with number (E49) Ramp time module (A10) Amplifier module – Boom (A10A) Amplifier module – Boom (A10B) Amplifier module – Boom (K76A) Relay – pilot control: Contacts 6 / 10 open while extending the stick.

(K79) Relay – pilot control: Contacts 6 / 10 open while filling the bucket.

(K80) Relay – pilot control: Contacts 8 / 12 closed while moving the boom up.

(K160) Relay – pilot control: Contacts 2 / 10 closed and 5 / 9 open while auto floating on.

(K207C) Relay – pilot control: Contacts 5 / 9 closed while warming up hydraulic oil (S205).

(45.1 – 45.3) Remote control valves (Y23, Y26, Y29) Proportional solenoid valve (Y23b, Y26b, Y29b) Directional solenoid valve (I – III) Main control blocks I – IV Electrical signal flow (EURO control).

The auto float button in the right lever E19 is still engaged this will energize relay K160. Signal voltage of joy stick (E19) arrives via ramp time module (E49) only at terminal 5 of the amplifier modules (A10a and A10b) and further to the proportional and directional solenoid valve of the remote control blocks (45.2 and 45.3).

Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the respective main control blocks.

Hydraulic oil flow Only the oil of main pump 3 and 4 flows through the main control blocks (II) and arrives via the distributor manifold at the boom hydraulic cylinders piston rod side. Through main valve block III for boom lowering is no pressure oil flow depend on a different valve spool with closed pressure port.

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Section 8.1 Page 5

Hydraulic for the Attachment Cylinders 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) Colour code of signal voltage cable ( Joy stick) (X2...)

Terminal rail with number (E49) Ramp time module (A10) Amplifier module – Boom (A10A) Amplifier module – Boom (A10B) Amplifier module – Boom (K76A) Relay – pilot control: Contacts 6 / 10 open while extending the stick.

(K79) Relay – pilot control: Contacts 6 / 10 open while filling the bucket.

(K80) Relay – pilot control: Contacts 8 / 12 closed while moving the boom up.

(K160) Relay – pilot control: Contacts 2 / 10 closed and 5 / 9 open while auto floating on.

(K207C) Relay – pilot control: Contacts 5 / 9 closed while warming up hydraulic oil (S205).

(45.1 – 45.3) Remote control valves (Y23, Y26, Y29) Proportional solenoid valve (Y23b, Y26b, Y29b) Directional solenoid valve (I – III) Main control blocks I – III Electrical signal flow (EURO control).

The auto float button in the right lever E19 is disengaged and relay K160 is deenergized. Signal voltage of joy stick (E19) arrives via ramp time module (E49) only at terminal 5 of the amplifier modules (A10 and A10b) and further to the proportional and directional solenoid valve of the remote control blocks (45.1 and 45.3).

Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the respective main control blocks.

Hydraulic oil flow Now the pump oil flow still back to the return line. Both pressure lines at valve block I section 3 (A3 and B3) are connected to the same back pressure charged return line. Valve spool 2 of main valve block III connect only port B2 to the return line. The return line, the piston side and the piston rod side of the boom cylinders now connected together. The boom can moved up and down by external force.

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Hydraulic for the Attachment Cylinders

Section 8.1 Page 6

8.1.2 Electric / Hydraulic flowchart “ Boom lowering ” BHA Legend for illustration (Z 22473): (E19) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (+Y) Direction (axis) of joy stick (+10V) Signal voltage (Maximum) (gn) Colour 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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Hydraulic for the Attachment Cylinders

Section 8.1 Page 7

8.1.3 Electric / Hydraulic flowchart “ Stick extending ” FSA Legend for illustration (Z 22532): (E20) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (YC) Direction (axis) of joy stick (+10V) Signal voltage (Maximum) (gn) Colour 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 / 12closed 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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Hydraulic for the Attachment Cylinders

Section 8.1 Page 8

8.1.3 Electric / Hydraulic flowchart “ Stick extending ” BHA Legend for illustration (Z 22474): (E20) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (Y+) Direction (axis) of joy stick (+10V) Signal voltage (Maximum) (gn) Colour 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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Hydraulic for the Attachment Cylinders

Section 8.1 Page 9

8.1.4 Electric / Hydraulic flowchart “ Stick retracting ” FSA Autor 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) Colour 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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Hydraulic for the Attachment Cylinders

Section 8.1 Page 10

8.1.3 Electric / Hydraulic flowchart “ Stick retracting ” FSA, Auto Float active Legend for illustration (Z 22535): (E20) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (-Y) Direction (axis) of joy stick (-10V) Signal voltage (Maximum) (gn) Colour code of signal voltage cable ( Joy stick) (X2...)

Terminal rail with number (E48) Ramp time module (A8) Amplifier module – Stick (A8a) Amplifier module – Stick (A8b) Amplifier module – Stick (45.1-45.3) Remote control valves (Y21, Y27, Y31) Proportional solenoid valve (Y21a, Y27a, Y27b) Directional solenoid valve (I, II, III) Main control blocks I, II III Electrical signal flow (EURO control).

The auto float button in the left lever E20 is disengaged relay K170 is deenergized. Signal voltage of joy stick (E20) arrives via ramp time module (E48) at terminal 5 of the amplifier modules (A8, A8a and A8b) and further to the proportional and directional solenoid valve of the remote control blocks (45.1 and 45.3). Amplifier module A8a disengaged with open K80 if bucket filling is actuated..

Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the respective main control blocks.

Hydraulic oil flow Both pressure lines at valve block III section 4 (A4 and B4) are connected to the same back pressure charged return line. Valve spool 4 of main valve block I connect only port B2 to the return line. The return line, the piston side and the piston rod side of the stick cylinders now connected together. The stick can move forward and backward by external force.

If only the stick retracting function is active section 4 of main valve block II opened additional port A4 and B4 to extend the max. oil flow for max. stick speed.

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Hydraulic for the Attachment Cylinders

Section 8.1 Page 11

8.1.4 Electric / Hydraulic flowchart “ Stick retracting ” BHA Legend for illustration (Z 22475): (E20) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (Y-) Direction (axis) of joy stick (-10V) Signal voltage (Maximum) (gn) Colour 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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Hydraulic for the Attachment Cylinders

Section 8.1 Page 12

8.1.5 Electric / Hydraulic flowchart “ Bucket filling ” FSA Legend for illustration (Z 22536): (E19) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (-X) Direction (axis) of joy stick (-10V) Signal voltage (Maximum) (ws / gn) Colour 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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Hydraulic for the Attachment Cylinders

Section 8.1 Page 13

8.1.5 Electric / Hydraulic flowchart “ Bucket filling ” BHA Legend for illustration (Z 22476): (E19) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (XB) Direction (axis) of joy stick (-10V) Signal voltage (Maximum) (ws / gn) Colour code of signal voltage cable ( Joy stick) (X2...)

Terminal rail with number (K50) Relay – pilot control: Bucket cut-off Contacts 6 / 10 only closed if the hydraulic oil is overheated.

(A9) Amplifier module – Bucket (A9a) Amplifier module – Bucket (A9b) Amplifier module – Bucket (45.1-45.3) Remote control valves (Y22, Y24, Y30) Proportional solenoid valve (Y22a, Y24a, Y30a) Directional solenoid valve (I, II, III) Main control blocks I, II, III Electrical signal flow (EURO control).

Signal voltage of joy stick (E19) arrives terminal 5 of the amplifier modules (A9, A9a, A9b) and further to the proportional and directional solenoid valves of the remote control blocks (45.,45.2 and 45.3).

Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks .

Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I, II, III) and arrives via distributor the manifold at the hydraulic cylinders.

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Section 8.1 Page 14

8.1.6 Electric / Hydraulic flowchart “ Bucket dump ” FSA Legend for illustration (Z 22537): (E19) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (+X) Direction (axis) of joy stick (+10V) Signal voltage (Maximum) (ws / gn) Colour code of signal voltage cable ( Joy stick) (X2...)

Terminal rail with number (A9) Amplifier module – Bucket (A9a) Amplifier module – Bucket (A9b) Amplifier module – Bucket (K50) Relay – pilot control: Bucket cut-off Contacts 6 / 10 only closed if the hydraulic oil is in normal operating temperature.

(K78) Relay – pilot control: Contacts 1 / 9 only open while bucket dump.

(K79) Relay – pilot control: Contacts 1 / 9 only open while lifting the boom.

(K205) Relay – pilot control: Contacts 1 / 3 only open while S205 activated (hydraulic oil warming up) (45., 45.2, 45.3) Remote control valves (Y22, Y24, Y30) Proportional solenoid valve (Y22A, Y24A, Y30A) Directional solenoid valve (I – III) Main control blocks I – III Electrical signal flow (EURO control).

Signal voltage of joy stick (E19) arrives via relay contacts K50 at terminal 19 of the ELB modules. From ELB modules the signal voltage arrives at terminal 5 of the amplifier modules (A9, A9a, A9b) and further to the proportional and directional solenoid valves of the remote control blocks (45.1, 45.2, 45.3). Only while bucket dump together with boom up K78 and K79 opened the contacts 1 / 9 and deactivate amplifier module A9 (priority to the boom).

Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks.

Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I to III) and arrives via the distributor manifold at the hydraulic cylinders. There is no oil flow through main control block I to the bucket cylinder if bucket dump and boom up is activated.

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Section 8.1 Page 15

8.1.6 Electric / Hydraulic flowchart “ Bucket dump ” BHA Legend for illustration (Z 22477): (E19) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (+X) Direction (axis) of joy stick (+10V) Signal voltage (Maximum) (ws / gn) Colour code of signal voltage cable ( Joy stick) (X2...)

Terminal rail with number (A9) Amplifier module – Bucket (A9a) Amplifier module – Bucket (A9b) Amplifier module – Bucket (K50) Relay – pilot control: Bucket cut-off Contacts 6 / 10 only closed if the hydraulic oil is overheated.

(14.1 + 14.3) Remote control valves (15) Remote control valves (Y64) Proportional solenoid valve (Y71 + Y75) Proportional solenoid valve (Y23 + Y45) Directional solenoid valve (Y37) Directional solenoid valve (II, III + IV) Main control blocks II, III + IV (42) Distributor manifold Electrical signal flow (EURO control) Signal voltage of joy stick (E19) arrives via relay contacts K50 at terminal 5 of the amplifier modules (A9, A9a, A9b) and further to the proportional and directional solenoid valves of the remote control blocks (45.1, 45,2 and 45.3).

Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks .

Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (II, III, IV) and arrives via distributor manifold (42) at the hydraulic cylinders.

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Section 8.1 Page 17

8.1.8 Electric / Hydraulic flowchart “ Clam opening ” FSA Legend for illustration (Z 21970): (E24) Control pedal (D32) Time relay – Pilot control: Neutral position monitoring (-10V) Signal voltage (Maximum) (rs) Colour code of signal voltage cable ( Joy stick) (X2...)

Terminal rail with number (A11) Amplifier module – Clam (K76) Relay – pilot control: Contacts 7 / 11 only closed while traveling the left crawler.

(15) Remote control valves (Y72) Proportional solenoid valve (Y39) Directional solenoid valve (II) Main control block II (42) Distributor manifold Electrical signal flow (EURO control).

Signal voltage of control pedal (E24) arrives via relay contact at terminal 5 of the amplifier module (A11) and further to the proportional and directional solenoid valves of the remote control block (15).

Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure port of the main control block .

Hydraulic oil flow Now the oil of the main pump flows through the main control block (II) and arrives via distributor manifold (42) at the hydraulic cylinders.

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Section 8.1 Page 18

8.1.9 Electric / Hydraulic flowchart “ Clam closing ” FSA Legend for illustration (Z 21971): (E23) Control pedal (D32) Time relay – Pilot control: Neutral position monitoring (+10V) Signal voltage (Maximum) (rs) Colour code of signal voltage cable ( Joy stick) (X2...)

Terminal rail with number (A11) Amplifier module – Clam (K76) Relay – pilot control: Contacts 7 / 11 only closed while traveling the left crawler.

(15) Remote control valves (Y72) Proportional solenoid valve (Y38) Directional solenoid valve (II) Main control block II (42) Distributor manifold Electrical signal flow (EURO control).

Signal voltage of control pedal (E23) arrives via relay contact at terminal 5 of the amplifier module (A11) and further to the proportional and directional solenoid valves of the remote control block (15).

Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure port of the main control block .

Hydraulic oil flow Now the oil of the main pump flows through the main control block (II) and arrives via distributor manifold (42) at the hydraulic cylinders.

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Hydraulic for the Attachment Cylinders

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

Pump circuit I

MRV in control block I

Check point M14

Pump circuit II

II

M12

Boom

Pump circuit III Pump circuit IV

III IV

M11 M13

Swing Boom Bucket

Functions FSA Swing Clam

Bucket filling Boom raise Bucket filling Stick extending Bucket Stick

Stick Travel Boom Travel

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 M11 - M14.

2.

Start both motor.

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 “boom up”, as indicated in the table (gray shaded), all MRV can be adjusted, because all four pump circuits are engaged.

Adjusting: 1.

Remove protective cap (a).

2.

Loosen lock nut (b).

3.

Turn set screw (c) -clockwise to increase pressure, Counterclock wise to decrease pressure.

4.

Tighten lock nut (b) and install cap (a).

) 06.04.03

• It is important that the valve body of MRV-valve and the SRV-valve are firmly tightened (with 300 Nm).

Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.

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Hydraulic for the Attachment Cylinders

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

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

MRV in control block I II III IV

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

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

Each Pump circuit can be checked or adjusted individually by selecting one function of the required pump circuit.

Checking: 1.

Connect the gauge to the required check point M12.1 – M12.4.

2.

Start both motors.

3.

Extend or retract the cylinder to the stop position for the valve being tested until the hydraulic system stalls.

4.

Read the pressure. Required: 310 + 5 bar If the pressure is not correct, carry out a comparative measurement with an other function, in order to avoid wrong measuring results caused by wrongly adjusted SRV or other defects in the system.

)

•

When using the single function “stick in or out”, as indicated in the table (gray shaded), all MRV can be adjusted, because all four pump circuits are engaged.

Adjusting: 1.

Remove protective cap (a).

2.

Loosen lock nut (b).

3.

Turn set screw (c) -clockwise to increase pressure, Counterclock wise to decrease pressure.

5.

Tighten lock nut (b) and install cap (a).

) 06.04.03

• It is important that the valve body of MRV-valve and the SRV-valve are firmly tightened (with 300 Nm).

Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.

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Hydraulic for the Attachment Cylinders 8.1.11

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.

Valve SRV 141.1 SRV 141.2 SRV 141.3 MRV circuit I MRV circuit II

Press. check point M23 M29.1 M29.2 M12.1 (High pressure filter) M12.3 (High pressure filter)

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

2.

3.

4.

)

5.

6.

7.

8.

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Location Manifold section B Manifold section N Manifold section N Double high pressure filter R.H. Singl high pressure filter, control block II Double high pressure filter L.H..

Singl high pressure filter, control block IV

Connect gauges to all above listed check points (min. 400 bar).

Start both motors.

Extend the boom cylinder to the stop position until the hydraulic system stalls.

Increase slowly the pump supply line pressure, by turning in set screws (3) of the MRV’s in control block I, II, III and IV, while observing the pressure gauges. Stop as soon the pressure does not raise any further.

The gauge pointers should remain at 350 bar + 5 bar.

• Since the piston side of the boom cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting.

Even when the gauges show the required pressure it is possible that one or more valves have a higher setting.

• To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of both MRV’s.

Remove protective cap (1) of MRV. Loosen lock nut (2).

Turn set screw (3) of the MRV’s ½ turn further in, the gauge pointers will remain at the value shown at item #4 (350 bar + 5 bar).

Tighten lock nut (2). continued PC5500-6-E_Sec_8-1_rev2.doc

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Hydraulic for the Attachment Cylinders 8.1.10

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22482a): Cont'd: 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 Ì 141.2 Ì 141.3 Remove protective cap (1) of SRV’s.

Loosen lock nut (2).

Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure.

Tighten lock nut (2) and install cap (1).

10.

Reduce the pressure, at SRV- 141.1 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges.

) 11.

Now all gauges will show the same value of 350 bar, but only SRV-143.1 has the correct setting.

Proceed with the other valves in the same manner in the following sequence: 141.2 Ì 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.

M 12.

) 06.04.03

•

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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Hydraulic for the Attachment Cylinders 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 SRV 33.4 FSA M12.3 (High pressure filter) SRV 33.6 BHA MRV circuit II M12.3 (High pressure filter) MRV circuit IV M12.2 (High pressure filter)

1.

2.

3.

4.

5.

6.

)

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

Connect gauges to all above listed check points.

Start both motors.

Press floating system button S95 at the lever with the boom function and retract the boom cylinder to the stop position until the hydraulic system stalls.

Increase slowly the pump supply line pressure, by turning in set screws (3) of the MRV in control blocks II, while observing the pressure gauges. Stop as soon the pressure does not raise any further.

The gauge pointers should remain at 350 bar + 5 bar.

If there is a setting required follow Turn set screw (3) of the MRV ¼ turn further in, the gauge pointers will remain at the value shown at item #4 .

Tighten lock nut (2).

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

continued

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Hydraulic for the Attachment Cylinders 8.1.11

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22543b): 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 motors.

12.

Install all protective cups (1).

)

06.04.03

â&#x20AC;˘ It is important that the valve body of MRV-valve and the SRV-valve are firmly tightened (with 300 Nm).

Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.

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Hydraulic for the Attachment Cylinders 8.1.11

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 SRV 142.5 SRV 142.6 SRV 142.7 MRV circuit I MRV circuit II MRV circuit III MRV circuit IV 1.

2.

3.

4.

)

5.

6.

7.

8.

Press. check point M27.1 M12.1 (High pressure filter) M12.3 (High pressure filter) M12.4 (High pressure filter) M12.2 (High pressure filter)

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

Single HP filter, control block IV

Connect gauges to all above listed check points.

Start both motors.

Extend the stick cylinder to the stop position until the hydraulic system stalls.

Increase slowly the pump supply line pressure, by turning in set screws (3) of the MRV in control block IV, while observing the pressure gauges.

Stop as soon the pressure does not raise any further.

The gauge pointers should remain at 350 bar + 5 bar.

• Since the piston side of the stick cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting.

Even when the gauges show the required pressure it is possible that one or more valves have a higher setting.

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

Remove protective cap (1) of MRV. Loosen lock nut (2).

Turn set screw (3) of the MRV ½ turn further in, the gauge pointers will remain at the value shown at item #4 (350 bar + 5 bar).

Tighten lock nut (2) and install cap (1). continued

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Hydraulic for the Attachment Cylinders 8.1.11

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22542): Cont'd: 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 Ì 142.6 Ì 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 SRV142.5 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges.

) 11.

Now all gauges will show the same value of 350 bar, but only SRV-65.2 has the correct setting.

Proceed with the other valves in the same manner in the following sequence: 142.6 Ì 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.

M 12.

) 06.04.03

•

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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Hydraulic for the Attachment Cylinders 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 SRV 33.1 SRV 33.5 MRV circuit I MRV circuit II MRV circuit IV 1.

2.

3.

4.

)

5.

6.

7.

8.

06.04.03

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

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

Connect gauges to all above listed check points.

Start both motors.

Extend the stick cylinder (stick retracting) to the stop position until the hydraulic system stalls.

Increase slowly the pump supply line pressure, by turning in set screws (3) of the MRV’s in the control blocks, while observing the pressure gauges.

Stop as soon the pressure does not raise any further.

The gauge pointers should remain at 350 bar + 5 bar.

• Since the piston side of the stick cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting.

Even when the gauges show the required pressure it is possible that one or more valves have a higher setting.

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

Remove protective cap (1) of MRV. Loosen lock nut (2).

Turn set screw (3) of the MRV’s ½ turn further in, the gauge pointers will remain at the value shown at item #4 (350 bar + 5 bar).

Tighten lock nut (2) and install cap (1). continued

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Section 8.1 Page 28

Hydraulic for the Attachment Cylinders 8.1.11

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22484): Cont'd: 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 Ì 33.5 Remove protective cap (1) of SRV’s.

Loosen lock nut (2).

Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure.

Tighten lock nut (2) and install cap (1).

10.

Reduce the pressure, at SRV- 33.1 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges.

) 11.

Now all gauges will show the same value of 350 bar, but only SRV-33.1 has the correct setting.

Proceed with the other valves in the same manner in the following sequence: 33.1 Ì 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.

M 12.

) 06.04.03

•

Reset the MRV to 310 bar + 5 bar after the check / adjustment is finished, as follows: Remove protective cap (1).

Loosen lock nut (2).

Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure.

Tighten lock nut (2) and install cap (1).

• It is important that the valve body of MRV-valve and the SRV-valve are firmly tightened (with 300 Nm).

Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.

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Section 8.1 Page 29

Hydraulic for the Attachment Cylinders 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 SRV 33.1 SRV 33.5 MRV circuit I MRV circuit II MRV circuit IV 1.

4.

5.

6.

Location Double high pressure filter R.H. Single HP filter, control block II Double high pressure filter R.H. Single HP filter, control block II Single HP filter, control block IV

Connect gauges to all above listed check points.

Start both motors.

Retract the stick cylinder to the stop position until the hydraulic system stalls.

Increase slowly the pump supply line pressure, by turning in set screws (3) of MRV’s in all above listed control blocks I, II, IV, while observing the respective pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar. a) b) c) d)

06.04.03

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

Remove protective cap (1).

Loosen lock nut (2).

Turn set screw (3) -clockwise to increase pressure, Counterclock wise to decrease pressure.

Tighten lock nut (2).

Continued

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Hydraulic for the Attachment Cylinders 8.1.11

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22543a): Cont'd: 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).

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 Ì 33.5 Turn set screw (3)-clockwise to increase pressure, Counter-clockwise to decrease pressure.

Adjust pressure at SRV 33.1 to ~360 bar if the pressure don’t increase turn set screw from the last setting max. ¼ turn in (c.w.).

Adjust pressure at the SRV 33.5 to ~350 bar.

8.

9.

10.

) 11.

06.04.03

•

Now all gauges will show the same value of 350 bar, but only SRV-33.1 has the correct setting.

Reduce the pressure, at SRV 33.1 to a value below the required value and then increase up to the required pressure (350bar), while observing all gauges.

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Hydraulic for the Attachment Cylinders 8.1.11

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22543a):

M

Cont'd: Stick cylinder “piston rod side” FSA • Strong pulsation of the return line hoses, indicates deviation in opening pressure of SRV’s and must be avoided.

Repeat the adjusting procedure until the oil returns well-balanced via all service line relief valves.

14.

15.

16.

)

06.04.03

Reset the MRV’s to 310 bar + 5 bar after the check / adjustment is finished Stop motors.

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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Section 8.1 Page 32

Hydraulic for the Attachment Cylinders 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 SRV 142.5 SRV 142.6 SRV 142.7 MRV circuit I MRV circuit II

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

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

2.

3.

4.

)

5.

6.

7.

8.

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

Singl high pressure filter, control block IV

Connect gauges to all above listed check points.

Start both motors.

Retract the stick cylinder (extend the stick) to the stop position until the hydraulic system stalls.

Increase slowly the pump supply line pressure, by turning in set screws (3) of MRV’s in the control blocks, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar.

• Since the piston rod side of the stick cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting.

Even when the gauges show the required pressure it is possible that one or more valves have a higher setting.

• To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of both MRV’s.

Remove protective cap (1) of MRV. Loosen lock nut (2).

Turn set screw (3) of both MRV’s ½ turn further in, the gauge Tighten lock nut (2) and install cap (1). continued

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Section 8.1 Page 33

Hydraulic for the Attachment Cylinders 8.1.11

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22485): Cont'd: Stick cylinder “Piston rod side” BHA 9.

Adjust all SRV’s equally, until all gauges show a pressure of 360 bar.

Adjust in steps of ¼ turn of set screw (3) in the following sequence: 142.5 Ì 142.6Ì 142.7 Remove protective cap (1) of SRV’s.

Loosen lock nut (2).

Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure.

Tighten lock nut (2) and install cap (1).

10.

Reduce the pressure, at SRV- 142.5 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges.

) 11.

Now all gauges will show the same value of 350 bar, but only SRV-142.5 has the correct setting.

Proceed with the other valves in the same manner in the following sequence: 142.6Ì 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.

M 12.

) 06.04.03

•

Reset the MRV’s to 310 bar + 5 bar after the check / adjustment is finished, as follows: Remove protective cap (1).

Loosen lock nut (2).

Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure.

Tighten lock nut (2) and install cap (1).

• It is important that the valve body of MRV and the SRV are firmly tightened (with 300 Nm).

Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.

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Section 8.1 Page 34

Hydraulic for the Attachment Cylinders 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 SRV 142.1 SRV 142.2 SRV 142.3 MRV circuit I MRV circuit II MRV circuit III MRV circuit IV 1.

2.

3.

4.

)

5.

6.

7.

8.

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Press. check point M24.1 M24.2 M25 M12.1 (High pressure filter) M12.3 (High pressure filter) M12.4 (High pressure filter) M12.2 (High pressure filter)

Location Manifold (42) section C Manifold (42) section C Manifold (42) section D Double high pressure (HP) filter R.H.

Single HP filter, control block II Double HP filter L.H..

Single HP filter, control block IV

Connect gauges to check points M12.1.to M12.4 and M24.1.

Start both motors.

Extend the Bucket cylinder to the stop position until the hydraulic system stalls.

Increase slowly the pump supply line pressure, by turning in set screws (3) of all four MRV’s in control block I to IV, while observing the pressure gauges. Stop as soon the pressure does not raise any further.

The gauge pointers should remain at 350 bar + 5 bar.

• Since the piston side of the bucket cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting.

Even when the gauges show the required pressure it is possible that one or more valves have a higher setting.

• To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of both MRV’s.

Remove protective cap (1) of MRV. Loosen lock nut (2).

Turn set screw (3) of both MRV’s ½ turn further in, the gauge pointers will remain at the value shown at item #4 (350 bar + 5 bar).

Tighten lock nut (2) and install cap (1). continued

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Hydraulic for the Attachment Cylinders 8.1.11

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22544): Cont'd: 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 Ì 142.2 Ì 142.3 Remove protective cap (1) of SRV’s.

Loosen lock nut (2).

Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure.

Tighten lock nut (2) and install cap (1).

10.

Reduce the pressure, at SRV- 142.1 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges.

) 11.

Now all gauges will show the same value of 350 bar, but only SRV-142.1 has the correct setting.

Proceed with the other valves in the same manner in the following sequence: 142.2 Ì 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.

M 12.

) 06.04.03

•

Reset the MRV’s to 310 bar + 5 bar after the check / adjustment is finished, as follows: Remove protective cap (1).

Loosen lock nut (2).

Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure.

Tighten lock nut (2) and install cap (1).

• It is important that the valve body of MRV and the SRV are firmly tightened (with 300 Nm).

Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.

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Section 8.1 Page 36

Hydraulic for the Attachment Cylinders 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 SRV 142.1 SRV 142.2 SRV 142.3 MRV circuit I MRV circuit II MRV circuit III MRV circuit IV 1.

2.

3.

4.

)

5.

6.

7.

8.

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Press. check point M24.1 M24.2 M25 M12.1 (High pressure filter) M12.3 (High pressure filter) M12.4 (High pressure filter) M12.2 (High pressure filter)

Location Manifold section C Manifold section C Manifold section D Double high pressure filter R.H. Singl high pressure filter, block II Double high pressure filter L.H..

Singl high pressure filter, block IV

Connect gauges to all above listed check points.

Start both motors.

Extend the bucket cylinder (Bucket filling) to the stop position until the hydraulic system stalls.

Increase slowly the pump supply line pressure, by turning in set screws (3) of MRV in control block I, II, III and IV, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar.

• Since the piston side of the bucket cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting.

Even when the gauges show the required pressure it is possible that one or more valves have a higher setting.

• To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of both MRV’s.

Remove protective cap (1) of MRV. Loosen lock nut (2).

Turn set screw (3) of both MRV’s ½ turn further in, the gauge pointers will remain at the value shown at item #4 (350 bar + 5 bar).

Tighten lock nut (2) and install cap (1). continued

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Section 8.1 Page 37

Hydraulic for the Attachment Cylinders 8.1.11

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22486): Cont'd: Bucket cylinder “Piston side” BHA 9.

Adjust all three SRV’s equally, until all gauges show a pressure of 360 bar.

Adjust in steps of ¼ turn of set screw (3) in the following sequence: 142.1 Ì 142.2 Ì 142.3 Remove protective cap (1) of SRV’s.

Loosen lock nut (2).

Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure.

Tighten lock nut (2) and install cap (1).

10.

Reduce the pressure, at SRV- 142.1 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges.

) 11.

Now all gauges will show the same value of 350 bar, but only SRV-142.1 has the correct setting.

Proceed with the other valves in the same manner in the following sequence: 142.2 Ì 142.3 Ì 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.

M 12.

) 06.04.03

•

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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Section 8.1 Page 38

Hydraulic for the Attachment Cylinders 8.1.11

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22545): Bucket cylinder “Piston 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 SRV 33.2 SRV 33.6 MRV circuit I MRV circuit II MRV circuit III MRV circuit IV 1.

2.

3.

4.

)

5.

6.

7.

8.

Press. check point M12.1 (High pressure filter) M12.3 (High pressure filter) M12.1 (High pressure filter) M12.3 (High pressure filter) M12.4 (High pressure filter) M12.2 (High pressure filter)

Location Control block I, section A3 Control block I, section A2 Double high pressure filter R.H. Singl high pressure filter, block II Double high pressure filter L.H..

Singl high pressure filter, block IV

Connect gauges to all above listed check points.

Start both motors.

Retract the bucket cylinder to the stop position until the hydraulic system stalls.

Increase slowly the pump supply line pressure, by turning in set screws (3) of MRV’s in the control blocks, while observing the pressure gauges.

Stop as soon the pressure does not raise any further.

The gauge pointers should remain at 350 bar + 5 bar.

• Since the piston rod side of the bucket cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting.

Even when the gauges show the required pressure it is possible that one or more valves have a higher setting.

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

Remove protective cap (1) of MRV. Loosen lock nut (2).

Turn set screw (3) of both MRV’s ½ turn further in, the gauge Tighten lock nut (2) and install cap (1). continued

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Section 8.1 Page 39

Hydraulic for the Attachment Cylinders 8.1.11

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 21999): Cont'd: 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 Ì 33.6 Remove protective cap (1) of SRV’s.

Loosen lock nut (2).

Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure.

Tighten lock nut (2) and install cap (1).

10.

Reduce the pressure, at SRV- 33.2 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges.

) 11.

Now all gauges will show the same value of 350 bar, but only SRV-33.2 has the correct setting.

Proceed with the other valve in the same manner.

• 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.

M 12.

) 06.04.03

•

Reset the MRV’s to 310 bar + 5 bar after the check / adjustment is finished, as follows: Remove protective cap (1).

Loosen lock nut (2).

Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure.

Tighten lock nut (2) and install cap (1).

• It is important that the valve body of MRV and the SRV are firmly tightened (with 300 Nm).

Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.

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Section 8.1 Page 40

Hydraulic for the Attachment Cylinders 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) Singl 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) Singl high pressure filter, block IV 1.

Connect gauges to all above listed check points.

2.

Start both motors.

3.

Retract the Bucket cylinder (Bucket dump) to the stop position until the hydraulic system stalls.

4.

Increase slowly the pump supply line pressure, by turning in set screws (3) of MRV’s in control block I, I, III and IV, while observing the pressure gauges. Stop as soon the pressure does not raise any further.

The gauge pointers should remain at 350 bar + 5 bar.

)

5.

6.

7.

8.

06.04.03

• Since the piston rod side of the bucket cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting.

Even when the gauges show the required pressure it is possible that one or more valves have a higher setting.

• To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of the MRV. Remove protective cap (1) of MRV. Loosen lock nut (2).

Turn set screw (3) of both MRV’s ½ turn further in, the gauge pointers will remain at the value shown at item #4 (350 bar + 5 bar).

Tighten lock nut (2) and install cap (1). continued

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Section 8.1 Page 41

Hydraulic for the Attachment Cylinders 8.1.11

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22487): Cont'd: 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 Ì 142.9 Ì 142.10 Remove protective cap (1) of SRV’s.

Loosen lock nut (2).

Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure.

Tighten lock nut (2) and install cap (1).

10.

Reduce the pressure, at SRV- 142.8 to a value below the required value and then increase up to the required pressure (350 bar), while observing all gauges.

) 11.

•

Now all gauges will show the same value of 350 bar, but only SRV-142.8 has the correct setting.

Proceed with the other valves in the same manner in the following sequence: 142.9 Ì 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.

M 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).

) 06.04.03

• It is important that the valve body of MRV-valve and the SRV-valve are firmly tightened (with 300 Nm).

Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.

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Section 8.1 Page 42

Hydraulic for the Attachment Cylinders 8.1.11

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22546): Clam cylinder “Piston 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 SRV 142.4 MRV circuit II MRV circuit IV 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

) 06.04.03

Press. check point M26 M12.3 (High pressure filter) M12.2 (High pressure filter)

Location Manifold (42) section E Control block II Control block IV

Connect gauges to the above listed check points.

Start motor 2.

Retract the clam cylinder (open the bucket) to the stop position until the hydraulic system stalls.

Increase slowly the pump supply line pressure, by turning in set screws (3) of MRV in control block II and IV, while observing the pressure gauges.

Stop as soon the pressure does not raise any further.

The gauge pointers should remain at 350 bar + 5 bar.

If necessary correct the adjustment as follows: Remove protective cap (1) of MRV. Loosen lock nut (2).

Turn set screw (3) of the MRV ½ turn further in, the gauge pointers will remain at the value shown at item #4 (350 bar + 5 bar).

Tighten lock nut (2) and install cap (1).

Reduce the pressure, at SRV 142.4 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges.

Reset the MRV to 310 bar + 5 bar after adjustment is finished, as follows: Remove protective cap (1).

Loosen lock nut (2).

Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure.

Tighten lock nut (2) and install cap (1).

• It is important that the valve body of MRV and the SRV are firmly tightened (with 300 Nm).

Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.

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Section 8.1 Page 43

Hydraulic for the Attachment Cylinders 8.1.11

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22561): Clam cylinder “Piston side” (clam losingt) 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 improper operation, the SRV’s should be adjusted in a way that the pressure is just sufficient to keep the bucket closed.

Valve SRV 144 (1) SRV 144 (2) SRV 32.10 1.

2.

3.

the

•

•

06.04.03

Location Manifold section K Manifold section K Control block II

Connect gauges to all above listed check points.

Start motor 2.

Raise the attachment and bring the back wall of the bucket in a horizontal position (bucket dump).

Depress pedal “bucket closing” until the hydraulic system stalls.

Release the pedal back to neutral position.

The bucket must stay closed. That means the clam-cylinders must not be retracted by the force (weight) of the clam shell.

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 all three SRV’s equally in steps of 5 bar until bucket opens by gravity (check with released pedal).

Read the pressure and increase the setting with 10%, to compensate the weight of material stuck at the clam shell.

4.

)

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

Since the piston side of the clam cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting.

For standard buckets the pressure is 150 bar, reinforced or with heavy wear package attached, the pressure maybe raised up to 200 bar.

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Hydraulic for the Attachment Cylinders 8.1.12

Section 8.1 Page 44

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 motors and allow pressure equalising 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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Section 8.1 Page 45

Hydraulic for the Attachment Cylinders 8.1.12

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

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

Total time(s) 4,3

Adjustments / Checks: I.

Float position activated: 1.

Use a stop watch to measure the cylinder running time.

2.

Raise the fully extended attachment with empty bucket to the maximum height position (A).

3.

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).

M

â&#x20AC;˘ Lower the boom so, that the bucket stops just above the ground.

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 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.

5.

6.

06.04.03

Check lowering speed again and repeat the adjustment if necessary.

If the adjustment is finished tighten lock nut (1). continued

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Hydraulic for the Attachment Cylinders 8.1.12

Section 8.1 Page 46

Checks and adjustments of the lowering speed, illustration (Z 22489): Cont'd: Boom cylinder FSA Adjustments / Checks: II. 1.

2.

3.

4.

M

Float position deactivated (with push button S95): Adjust the throttle adjustment bold of throttle valve 141.2 to the same amount of revolutions as the valve 141.1 and 141.3.

Use a stop watch to measure the cylinder running time.

Raise the fully extended attachment with empty bucket to the maximum height position (A).

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).

â&#x20AC;˘ Lower the boom so, that the bucket stops just above the ground.

5.

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.

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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Section 8.1 Page 47

Hydraulic for the Attachment Cylinders 8.1.12

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

Boom BHA

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

Total time (s) 5,0

Adjustments / Checks: 1. Use a stop watch to measure the cylinder running time.

2. Raise the fully extended attachment with empty bucket to the maximum height position (A).

3. 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).

M

â&#x20AC;˘ Lower the boom so, that the bucket stops just above the ground.

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 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.

5. Check lowering speed again and repeat the adjustment if necessary.

If the adjustment is finished tighten lock nut (1).

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Section 8.1 Page 48

Hydraulic for the Attachment Cylinders 8.1.12

Checks and adjustments of the lowering speed, illustration (Z 22490): Stick cylinder FSA Due to the two different operation modes for lowering the stick, the lowering speed must be adjusted twice: I. Float position activated II. Float position deactivated Maximum permissible lowering speed for both operation modes:

Stick FSA

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

Total time (s) 2,4

Adjustments / Checks: I.

Float position activated: 1.

2.

3.

4.

Use a stop watch to measure the cylinder running time.

Raise the fully extended attachment with empty bucket to the maximum height position (A).

Rapidly move the control lever (E20) to the rear end position (start the stop watch) and hold it until the final position (B) is reached.(stop the stop watch).

If the lowering speed is too high, i.e. the measured time is less than the permissible time, the speed must be reduced by altering the throttle valves 142.5 and 142.7 at the distributor manifold.

Adjust as follows: To decrease the lowering speed loosen lock nut (1) and turn the bolt (2) cw. To increase the lowering speed loosen lock nut (1) and turn the bolt (2) ccw.

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

O.K.

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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8.1 49

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Hydraulic for the Attachment Cylinders 8.1.12

Section 8.1 Page 49

Checks and adjustments of the lowering speed, illustration (Z 22490): Cont'd: Stick cylinder FSA Adjustments / Checks: II. 1.

2.

3.

4.

5.

Float position deactivated (with push button S95a): Adjust the throttle adjustment bold of throttle valve 142.6 to the same amount of revolutions as the valve 142.5 and 142.7.

Use a stop watch to measure the cylinder running time.

Raise the fully extended attachment with empty bucket to the maximum height position (A).

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).

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.

6.

7.

06.04.03

Check lowering speed again and repeat the adjustment if necessary.

If the adjustment is finished tighten lock nut (1).

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Section 8.1 Page 50

Hydraulic for the Attachment Cylinders 8.1.12

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

Stick BHA

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

Total time (s) 1,5

Adjustments / Checks: 1. Use a stop watch to measure the cylinder running time.

2. 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) and hold it until 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, 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.

5. Check lowering speed again and repeat the adjustment if necessary.

If the adjustment is finished tighten lock nut (1).

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Section 8.1 Page 51

Hydraulic for the Attachment Cylinders 8.1.12

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

Bucket FSA

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

Total time (s) 3,0

Adjustments / Checks: 1.

Use a stop watch to measure the cylinder running time.

2.

Raise the fully extended attachment with empty bucket to the maximum height position (A).

3.

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).

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 142.1, 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.

5.

6.

06.04.03

Check lowering speed again and repeat the adjustment if necessary.

If the adjustment is finished tighten lock nut (1).

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Section 8.1 Page 52

Hydraulic for the Attachment Cylinders 8.1.12

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

Bucket BHA

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

Total time (s) 1,1

Adjustments / Checks: 1. Use a stop watch to measure the cylinder running time.

2. Raise the fully extended attachment with empty bucket to the maximum height position (A).

3. 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).

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 142.1, 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.

5. Check lowering speed again and repeat the adjustment if necessary.

6. If the adjustment is finished tighten lock nut (1).

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Hydraulic for the Attachment Cylinders 8.1.12

Section 8.1 Page 53

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

2.

3.

4.

5.

6.

06.04.03

Use a stop watch to measure the cylinder running time.

Open the clam of the empty bucket to the maximum height position (A).

Rapidly push the control pedal (E23) to the end position (start the stop watch) and hold it until the final position (B) is reached.(stop the stop watch).

If the lowering speed is too high, i.e. the speed is uncomfortable, the speed must be reduced by altering the throttle valve 142.4 at the distributor manifold section E. Adjust as follows: To decrease the lowering speed loosen lock nut (1) and turn the bolt (2) cw.

To increase the lowering speed loosen lock nut (1) and turn the bolt (2) ccw.

Check lowering speed again and repeat the adjustment if necessary.

If the adjustment is finished tighten lock nut (1) and write down the adjusted running time for later checks.

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Section 8.1 Page 54

Hydraulic for the Attachment Cylinders 8.1.13

Checks for the valve control logic illustration (Z 22530): Controlling of the amplifier modules 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 main hydraulic valve connection.

If the hydraulic pilot control hoses to the main valve blocks are correct connected (checked during final test in the factory) the hydraulically part should be working correct. The correct function of the electrically part of the valve control logic can be easy checked by the light (LEDs) of the amplifier modules Checks: Use the Check list for the Valve Logic in the appendix in this binder. a) The ladder and the refilling arm are in high position (working position) the operator sits on the operators seat b) The operator turn the key switch S1 in on position. The motors stand still. c) Now the operator move step for step the respective lever or pedal as shown in the check list. Each lever function causes a amplifier activation as shown in the check list. Compare the amplifier reaction to the check list.

Additional information for trouble shouting: Lever deflection to the right ( + X-Axis) ⇒ 0..- .. + 10V = Ax/As of Amplifier lights Lever deflection to the front (+ Y – Axis) ⇒ 0..- .. + 10V = Ax/As of Amplifier lights Lever deflection to the left ( - X-Axis) ⇒ -10V..- .. 0 = Bx/Bs of Amplifier lights Lever deflection to the front (- Y – Axis) ⇒ -10V..- .. 0 = Bx/Bs of Amplifier lights Travel pedal deflection to the front (+ X) ⇒ 0..- .. + 10V = Ax/As of Amplifier lights Travel pedal deflection to the front (+ X) ⇒ -10V..- .. 0 = Bx/Bs of Amplifier lights left clam pedal activated ⇒ 0..- .. + 10V = Ax/As of Amplifier lights right clam pedal activated ⇒ -10V..- .. 0 = Bx/Bs of Amplifier lights swing brake pedal activated ⇒ 0..- .. + 10V = Ax of Amplifier lights

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Hydraulic for the Swing Circuit

Section 8.2 Page 1

Table of contents section 8.2 Section 8.2

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

2+3

8.2.2 Swing Motor

4-7

8.2.3 Swing Gear Box

8

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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Hydraulic for the Swing Circuit

Section 8.2 Page 2

8.2.1 Swing Circuit (Brief description) Legend for illustration (Z 22501a): (I - VI) (13) (48) (20.1+ 20.2) (71.1+ 71.2) (25.2) (49.1 + 49.2) (Y48) (Y120)

Main pumps Single control block Manifold Swing motors Manifold at the control and filter panel Double check valve Pressure increasing valve (swing brake valve) Power control valve of swing motors Solenoid valve

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“ of each brake valve block (49.1+ 49.2) thus a pressure built up (higher as 150 bar) in the service lines is possible.

“EURO”

2

3

1 0

m iscel lane ous ser vice

adjust m ent

2 1

0

3

0 0

E22

engine

0

0

1

0

1

lig ht in

g

1

1

0

P

0

1

0

2

1

0

0

2

0

0

1

1

0

1

3

2

0

3

0

1

en gin e

S29

E20

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continued

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Hydraulic for the Swing Circuit

Section 8.2 Page 3

Cont'd.: 8.2.1 Functional description: Illustration (Z 22430): 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 pump (III).

The oil flows from the pumps through the check valve (47.3) and the filter (153.3) to the single control block (13 / IV).

In neutral position of the spool the oil flows via port C into control block II for additional oil volume from pump 3 to valve circuit II. If no function of control block II is activated the oil flow via port T in to the collector tube (35) and further via the return oil lines (L6 + L7) into the tank.

On its way to tank the oil must flow through the back pressure valve (115) and the return oil filter (117.2 - 117.5). (Back pressure valve function see chapt. 4.)

When operating the control lever for "Swinging" the pump line is connected in the control block (33/IV) with the corresponding service line (A1 or B1) to the swing motors (20.1 + 20.2).

The oil flows from the control block through each one of the swing brake valves (49.1 + 49.2; description see page 6 and 7) and the swing motors (20.1 + 20.2).

Each swing gear includes one spring loaded multi disk brake (House brake) for locking the superstructure.

The leak oil (case drain) flows through the line (L11 + L12) and the leak oil filter (108) back to tank.

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Swing motor A6VM

8.2.2 Swing Motor

Section 8.2 Page 4

Axial Piston Motor A6VM355 HD1D

Legend for illustration (Z 22430): (1) Check valve (2) Check valve (3) Governor valve (4) Positioning piston (5) Boost pressure valve (6) Flushing valve (16l/min) (7) Flow control valve (8) Constant pressure control valve (adjusted: 280 bar) General: A6VM355 HD1D is a variable displacement motor with an axial piston rotary group of bent axis design for hydrostatic drives.

Its control range allows the variable displacement motor to meet both, high speed and torque requirements. The output speed is proportional to its displacement.

The output speed increases with decreased displacement trough lower operating pressure.

The output torque increases with increased displacement trough higher operating pressure.

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Section 8.2 Page 5

Swing motor A6VM

8.2.1 Swing Motor

Axial Piston Motor A6VM355 HD1D

Hydraulic control, illustration Z22430 By switching pilot pressure to port X at the motor (0 bar or 35 bar) the displacement is fixed in Vg max or variable.

Without pilot pressure at port X (0 bar) the displacement is fixed to Vg max .

With pilot pressure at port X (35 bar) the displacement is variable from Vg min (175 cm3/rpm) to Vg max (355 cm3/rpm).

With a swing speed of 0 up to 120 impulses per minute (measured by a proximity switch located at the swing gear) the motors are in maximum displacement position, i.e. min. speed and max. torque available.

With a swing speed of more than 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

Operating pressure bar

Torque

Motor displacement

0

310 ¯ ~280

Max.

Vg max

Swing movement 120-max.

Low speed to Max. speed

35

280 ¯ ~75

Swing movement Max. speed

Max.

35

~75

Reduced

Vg min

Swing down path

120-0

0

~170 ¯ 0

Max.

Vg max

120-0

0

330 ¯ 0

Max.

Vg max

Start swing Standstill to low speed

Speed Xindicator pressure imp/min bar 0-120

Reduced Vg max ¯ Vg min variable

Control lever in neutral

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

Continued

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Swing motor A6VM

8.2.2 Hydraulic Motor

Section 8.2 Page 6

Axial Piston Motor A6VM355 HD1D

Hydraulic control, illustration Z22431 Cont'd: 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 constant 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.

Flow from A to B with „X-pressure“ (higher swing speed): Operating pressure opens check valve (1) and closes the opposite valve (2). The same pressure is present at constant pressure control valve (8) and inside the small area side of the positioning piston (4).

Because the „X“ pressure shifts governor valve (3) a connection is made to the large area side of positioning piston (4).

Depending on the system pressure (lower than 280 bar), valve (8) starts closing the return line. 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: Displacement between Vgmax position(>280bar) and Vgmin position(<280bar).

As a result of decreasing operating pressure the motors are reducing their displacement so that the swing speed will increase.

If the operating pressure rises as a result of load torque, to the setting of the constant pressure control valve (280 bar), the motors are swiveled out to a greater angel (higher displacement) and the swing speed will decrease.

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Swing motor A6VM

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Section 8.2 Page 6

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Swing motor A6VM

8.2.2

Section 8.2 Page 7

Checks and Adjustments, illustration Z22432 Preconditions before starting checks and adjustments: 1. Main pump #3 must be in full flow position (x1-pressure = 35 bar) 2. MRV’s and SRV’s (pressure increasing valves) correctly adjusted.

3. Function of solenoid valve Y48 o.k. i.e. 35bar X2-pressure at the motor.

Checking the Q-max. and Q-min. stop bolt setting.

Q-max : The average outer length of 25.6mm must not be altered because the max. possible swivel angle is used.

Q-min : The Q-min. adjustment depends on the max. permissible swing speed (with reduced swivel angle). The average outer length is 21.3mm

)

• Because two motors are fitted, it is very 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 revolutions per minute after swinging one turn as an approach swing.

The speed must be 3.7±0.3 RPM. 3. If the speed is not correct: Turn off box nut (1) Loosen the lock-nut (3) Turn bolt (2) further in for less speed or further out for higher speed.

4. Re-check speed and tighten lock-nut and re-fit box nut (1) after setting is finished.

How to check the start of regulation.

1. Connect a pressure gauge (0-400 bar) to check point M12.2 at high pressure filter control block IV. 2. 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..

3. Start the motors.

4. Apply the swing parking brake.

5. Operate the control lever for swing and keep it in end position, to create the operating pressure of 310 bar.

6. Loosen look nut of MRV at single control block IV. 7. Decrease / increase alternately the operating pressure between 310 bar and 260 bar at MRV set screw. Check by turning the Q-max. stop bolt (2) by hand, if the motor control lens touches the Q-max. 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 8. Correct the start of regulation with valve (8) if necessary.

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Hydraulic for the Swing Circuit

Section 8.2 Page 8

8.2.3 Swing Gear Box Legend for illustration (Z 22438): (1) Drive housing (2) Drive shaft (3) Sun gear shaft (4) House brake (Multi disk brake) (5) Breather filter Drive shaft housing (6) Oil level gauge (dipstick) Drive shaft housing (7) Disk brake housing (8) Cylindrical roller bearing (9) Internal ring gear (10) Cylindrical roller bearing

(11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22)

Bearing ring Cartridge Spherical roller bearing Oil drain plug, gear box Cylindrical roller bearing Oil level gauge (dipstick) Gear box First planetary stage Drive shaft to second stage Second planetary stage Radial seal ring Drive pinion GreaseGrease line port

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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Hydraulic for the Swing Circuit

Section 8.2 Page 9

8.2.4 Swing Parking Brake (Gear house Brake) The Spring Loaded Multi-disk Brake is a safety brake; applied by spring force and released by oil pressure.

Legend for illustration (Z 22439): (1) Disk housing (2) Thrust washer (3) Inner disks (lamellas) (4) Outer disks (lamellas) (5) Sinus (spacing) ring (6) Piston (7) Quad-Rings with back- up rings (8) Quad-Rings with back- up rings (9) (10) (11) (12) (13)

Springs Piston back up ring and seal retainer Thrust washer Circlip Drive shaft Oil pressure port

Function: Brake applied: The outer disks (4) engaged to the housing by serration and the inner disks (3) in serrated connection with drive shaft (12) are pressed together by the springs (9).

This results in a fixed connection between housing and drive shaft.

Brake released: Oil pressure via port (13) reaches the bottom of the piston (6) and forces the piston upwards against the thrust washer (10).

This function eliminates the spring force onto the disks so that the sinus (spacing) rings can keep the outer disks (4) apart, thus the brake is released.

The releasing pressure is 19 - 20 bar, the maximum permissible pressure 60 bar.

This is a so named "Wet Brake" because the brake housing is partly filled with gear oil.

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Hydraulic for the Swing Circuit

Section 8.2 Page 10

8.2.5 Swing Brake Valve Legend for illustration (Z 21934): (1) Pressure increasing valve (items 6 - 13) (2) Check valve circuit A (3) Check valve circuit B (4) Anti-cavitation valve circuit B (5) Anti-cavitation valve circuit A (6) Jet bore, of main piston plug Ports: (Y) (T) (A) (A1) (B) (B1)

(7) (8) (9) (10) (11) (12) (13)

Spring of main piston Jet bore Valve poppet Spring Intermediate piston Pilot pressure piston Main piston

Leak oil Return oil Service line from control block Service line to the motor Service line from control block 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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Hydraulic for the Swing Circuit

Section 8.2 Page 11

Cont'd.: 8.2.5 Swing Brake Valve If after a swing motion the joy stick is released into neutral position without using the foot brake, the superstructure is turned by inertial force and the hydraulic motor acts as a pump because it is driven by the swing gear.

In this period the pressure in the service line is lower than the pressure in the return line, because there is a back pressure valve at the tank, and oil is forced through the anti-cavitation valves into the service line.

Function of the pressure increasing valve.

When ever a swing motion is carried out or the foot brake is used, pilot pressure arrives the pressure increasing valve (1) at port "X". The pilot pressure pre-loads these valves.

By applying pilot pressure via the external port X to piston (12), the pretensioning of the pressure spring (10) is increased by the amount of the piston stroke "S", which results in the actual valve setting.

The system pressure is in front of the main piston (13) and via the jet bore (6) also in the chamber of the spring (7) and via the jet bore (8) at the pressure relief valve poppet (9).

Due to the force balance the piston (13) is kept in its position supported by the spring (7).

Overcomes the system pressure the setting of the valve (9), this valve opens a channel to the dump line port (Y). Due to the drop of force the piston (13) is moved to the right.

The pressure line gets connected with the return line (T).

Damped opening and closing are obtained by the throttled volumetric change that is caused by the jet bores.

continued

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Hydraulic for the Swing Circuit

Section 8.2 Page 12

Cont'd.: 8.2.5

Swing Brake Valves Anticavitation prevention. Illustration Z 22672 (1) Return oil collector tube (2) Flange connection, return oil collector tube.

(3) Back pressure valve (195.1 + 195.2).

(4) Swing motor (20.1 + 20.2) (5) Brake valve blocks (49.1 + 49.2).

(6) Gear pump (8.2 + 8.5).

(7) Pressure check point M35.1 and M35.2 During the swing down phases the swing motors (4) are working as â&#x20AC;&#x153;pumpsâ&#x20AC;?.

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 additional valves (3) fitted. The valves increase the back pressure in the tank line (return oil line) up to 15 bar. This valves are supplyed by two gear pumps (6).

Adjustments - Measurements -Settings Setting of the swing circuit back pressure valves (3) 1. Connect pressure gauge (0 â&#x20AC;&#x201C; 25 bar) to the 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 the motors.

3. The pressure at the gauges should be 15 bar if the gauges shows a different value the pressure relieve valves in the back pressure valve must be adjusted. a) b) c)

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

Tighten look nut

4. Stop motors 5. Disconnect the gauges.

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Hydraulic for the Swing Circuit

Section 8.2 Page 13

8.2.6 Electric / Hydraulic flowchart “Swing Left” Legend for illustration (Z 22503): (E20) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (-X) Direction (axis) of joy stick (-10V) Signal voltage (Maximum) (ws/gn) Colour code of signal voltage cable ( Joy stick) (X2F...)

Terminal rail with number (E50) Ramp time module (A7) Amplifier module – Swing (Y32 + Y32a/b – Block IV) (K165) Relay counter lock (K250) Relay pressure increasing (E50A) Ramp time module – Swing brake (A16) Amplifier module – Swing brake (Y127) Proportional valve to pressure increasing valve (43) Remote control valve block (Y32) Proportional solenoid valve (Y32a + Y32b) Directional solenoid valve (13) Main control block IV (48) Distribution block (49.1 + 49.2) Swing brake valve blocks (20.1 + 20.2) Swing motors 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 to the proportional and directional solenoid valves of the remote control blocks (43).

In the same time signal voltage of joy stick arrives via K250 and ramp time module E50A to terminal 5 of the amplifier module A16.

Relay contact 2 / 10 of relay K165 opened if the excavator superstructure swing in a different direction as the lever direction. Relay contact 1 / 9 of relay K250 opened if the swing brake pedal is activated.

The hydraulic signal. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pressure ports of the main control blocks.

Proportional valve Y127 increase proportional to the lever deflection the pilot pressure to the pressure increasing valves.

The hydraulic oil flow Now the oil of the main pump 3 flows through the main control block (IV) and arrives via swing brake valves (49.1 + 49.2) at the swing motors (20.1 + 20.2).

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Hydraulic for the Swing Circuit

Section 8.2 Page 14

8.2.7 Electric / Hydraulic flowchart “Swing Right” Legend for illustration (Z 22504a): (E20) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (-X) Direction (axis) of joy stick (-10V) Signal voltage (Maximum) (ws/gn) Colour code of signal voltage cable ( Joy stick) (X2F...)

Terminal rail with number (E50) Ramp time module (A7) Amplifier module – Swing (Y32 + Y32a/b – Block IV) (K165) Relay counter lock (K250) Relay pressure increasing (E50A) Ramp time module – Swing brake (A16) Amplifier module – Swing brake (Y127) Proportional valve to pressure increasing valve (43) Remote control valve block (Y32) Proportional solenoid valve (Y32a + Y32b) Directional solenoid valve (13) Main control block IV (48) Distribution block (49.1 + 49.2) Swing brake valve blocks (20.1 + 20.2) Swing motors 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 to the proportional and directional solenoid valves of the remote control blocks (43).

In the same time signal voltage of joy stick arrives via K250 and ramp time module E50A to terminal 5 of the amplifier module A16.

Relay contact 2 / 10 of relay K165 opened if the excavator superstructure swing in a different direction as the lever direction. Relay contact 1 / 9 of relay K250 opened if the swing brake pedal is activated.

The hydraulic signal. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pressure ports of the main control blocks.

Proportional valve Y127 increase proportional to the lever deflection the pilot pressure to the pressure increasing valves.

The hydraulic oil flow Now the oil of the main pump 3 flows through the main control block (IV) and arrives via swing brake valves (49.1 + 49.2) at the swing motors (20.1 + 20.2).

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Hydraulic for the Swing Circuit

Section 8.2 Page 15

8.2.8 Swing Monitoring System, illustration (Z 21947a) There are two reasons why the swing monitoring system is installed: a) ⇒ To prevent adverse effects of a counter action. b) ⇒ To increase the swing speed, by reducing the swivel angel of the swing motor (lowering the required oil volume per motor rotation) Function of the swing monitoring system: The two sensors B98 and B99, (Proximity switches mounted into a housing near the ring-gear) sensing the direction of rotation.

How? Because the distance from sensor to sensor (B) is less than the distance of two teeth (A), one of the sensors recognizes first a swing action.

The signals of both sensors are used as input signals for the module (E42) which monitors the swing direction.

The same signals from sensor B99 are send to the module E43 for sensing the swing speed.

Proximity switch B99 together with module E43 monitors the swing speed to control via relay K154 and K153 solenoid valve (Y48).

• Activated solenoid valve Y48 allows full X2 pressure to swing motors (20.1 + 20.2) port X = if the working pressure is less then 260 bar increasing of swing speed is possible.

• De activated solenoid valve Y48 causes no X2 pressure to swing motor (20.1 + 20.2) port X = the motors are fixed in maximum swivel angel (max. volume = max. torque and min. speed) ⇒ Acceleration During the first acceleration phase the maximum torque by minimum speed is required, the motors must be in maximum swivel angel (x-port 0 bar). E43 detect the swing speed, if the speed is below 120 Imp./min. relays K154 and K153 are still de-energized and further solenoid valve Y48 de-energized (xport = 0 bar = max. motor swivel angel). After this first acceleration the torque and the 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 are the same. K153 energized and further K153 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, solenoid valve Y48 change over in neutral position and pilot line L18 release the pressure to the tank (port X = 0 bar). The swing motors move to maximum swivel angel. Now a maximum breaking torque is available.

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Hydraulic for the Swing Circuit

Section 8.2 Page 16

8.2.8 Swing Monitoring System, illustration (Z 21947a) 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 mm. b)

E42 for monitoring the slew direction E42 is an programmable module which is factory programmed with the parameters are shown on page 50 electric diagram. Therefore no adjustments or settings are required.

Settings: c)

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”

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

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Hydraulic for the Swing Circuit

Section 8.2 Page 17

8.2.9 Checks and adjustments for the swing circuit

)

â&#x20AC;˘ 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. â&#x20AC;˘ 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. â&#x20AC;˘ 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 the check point M12.2 at the high pressure filter units (153.3) of single control block IV. 2.

Disconnect the pilot pressure lines from the T-unions 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 motor 1.

5.

Lower attachment to ground and apply house 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.

7.

If the gauge shows a smaller or greater value the pressure increasing valves must be adjusted.

continue

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Hydraulic for the Swing Circuit

8.2.9

Section 8.2 Page 18

Checks and adjustments for the swing circuit Cont'd: High pressure check / adjustment Procedure: a) b) c) d) e) f) g) h) i) j) k)

Loosen lock nut (1) of the first pressure increasing valve PIV. 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.).

Secure by tightening lock nut (1).

Loosen lock nut (1) of the second PIV. Adjust pressure with set screw (2) to 330 –5 bar.

Secure adjusted set screw (2) by tightening lock nut (1) Loosen lock nut (1) of the first PIV. 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) Secure adjusted set screw (2) by tightening lock nut (1) Re-check pressure setting.

Re-set MRV to 310 + 5 bar after the check / adjustment is finished.

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

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

Re-connect the pilot pressure line.

9.

)

• For later one pressure checks the steps 2 + 3 must not be done.

• The Swinging down path may be extended, means the low pressure may be decreased, a little; e.g. for greater operating radius such as at strip Mining. But a little only otherwise disturbance due Swinging will occur.

• The Swinging down path may be shortened, means the low pressure may be increased approx. 20 bar; but not more because that means greater shocks in the systems which will shorten the life time of the components.

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Hydraulic for the Swing Circuit

8.2.10

Section 8.2 Page 19

Checks and adjustments for the swing circuit Cont'd: Brake pilot pressure - check / adjustment 1.

Connect the gauge to the check point M4.

2.

Start motor 1.

3.

Depress fully the foot brake pedal and read the pressure.

The pressure must be 19 +1 bar.

If adjustment is required: Alter the position of the potentiometer R2 of the amplifier A16 as long as the pressure is 19 +1 bar.

Basic adjustment for A16 see section 5

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Hydraulic for the travel circuit

Section 8.3 Page 1

Table of contents section 8.3 Section 8.3

Page Travel System 8.3.1 Travel Circuit (Brief description)

2+3

8.3.2 Rotary Distributor

4+5

8.3.3 Side Frame Components

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):

(40) (1; 2; 5; 6) (46.1+46.2) (M12.1 + M12.4) (14 / I) (16 / III) (34) (21.1- 21.4) (52.1 + 52.4) (M33.1, M33.2) (M33.3, M33.4) (28.1+28.2)

Suction tank Main pumps Double filter High pressure check points L.H. Control block R.H. Control block Rotary distributor Travel motors (A2FM 355) Travel gear house brakes High pressure check points left travel motors High pressure check points right travel motors Travel motors valve blocks

Brief description (Study together with the machine valid hydraulic and electric circuit diagram).

Control circuits, not shown By the function of the remote control valve (45.1 + 45.3) pilot pressure oil is sent to one side of each control block (14/I + 16/III) when operating the foot pedal for travelling "Forward or Reverseâ&#x20AC;&#x153;.

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Travel System

Section 8.3 Page 3

8.3.1 Service circuits ( Z22521) (Study together with the valid hydraulic and electric circuit diagram for the machine).

The travel motors (21.1 - 21.4) are driven by the pumps (1; 2; 5; 6).

The oil flows from the pumps through check valves and the filters (46.1 + 46.2) to the control blocks (14 / I + 16 / III).

In neutral position of the spools the oil flows via the return oil lines into the collector tube (35, not shown). From the collector tube (35) flows the oil via the return oil lines (L6 + L7, not shown) into the collector tube (114) and further to the tank. On its way to tank the oil must flow through the back pressure valve (115) or the oil coolers (106.1 â&#x20AC;&#x201C; 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 stopped. The brake release pressure is monitored by the pressure switch (B48).

The leak oil (case drain) flows through the line (L) and the leak oil filter (108) back to tank.

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Travel System

Section 8.3 Page 4

8.3.2 Rotary Distributor Task: The rotary distributor (joint) permits a hydraulic connection between the superstructure and the under- carriage, that means between the rotating and the stationary part.

Legend for illustration (Z 22522): (1) (2) (3) (4) (6) (8+9) (10) (11) (12) (13)

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

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

Service lines Leak oil Control oil „Travel break“ Control oil Track tensioning Track tensioning continued

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Travel System

Section 8.3 Page 5

Contâ&#x20AC;&#x2122;d.

Function (Z 22522): During operation superstructure and under carriage rotate towards each other.

The travel motors must be supplied with hydraulic oil in every position in which the superstructure is turned in regard to the undercarriage. Oil is directed by the control blocks to the ports (A-D) of the housing (2).

The oil flows to the outlet ports (A-D), of the rotor (1), via ring grooves as well as longitudinal and cross holes. The rotor is bolted to the under carriage and the housing (stator) is fixed by the upper structure. The sealing of the ring grooves among one another is done by seal rings (8) and o-rings (9).

The hydraulic connection for the travel motor case drain and the travel motor house brake is done via the ports (L) and (St).

The rotor (1) is at the top and bottom section guided in the housing by the guide rings (12).

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Travel System

Section 8.3 Page 6

8.3.3 Side Frame Components, Cross Sections Illustration Z 22523 A B C D

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Final drive Bottom and top roller Idler wheel Crawler tensioning cylinder

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Travel System

Section 8.3 Page 7

8.3.4 Travel Gear and Parking Brake Function principle ( illustration Z22524): 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 carrier (D) rotates in the same direction because of the planetary gears and the internal geared hollow wheel (G). The planetary gears of the second planetary stage are driven as well. The planetary carrier is connected by splines to the r.h. side frame flange, therefore rotates the hollow wheel (G) (means the complete gear rotates) in same direction as the drive shaft (A).

The drive sprocket is mounted to the hollow wheel flange (3).

For maintenance see MAINTENANCE MANUAL For more details see PARTS BOOK and REPAIR MANUAL

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Travel System

Section 8.3 Page 8

8.3.5 Parking Brake Illustration Z 22525 The Spring Loaded Multi-disk Brake is used as a safety brake (parking brake); applied by spring force and released by oil pressure.

Legend: (1) (2) (3) (4) (5) (6) (7) (8 + 9) (10 - 12) (13) (14) (16) (17) (19) (21 + 22)

Disk housing Piston Back-up ring with radial seal rings (15) Bach-up ring Coupler Inner disks (lamellas) Outer disks Springs O-ring Clip ring Clip ring Release pressure port Quad-Ring with back-up rings (18) Quad-Ring with back-up rings (20) Plug screw with seal ring

Function: Brake applied: The outer disks (7) engaged to the housing by serration and the inner disks (6) in serration connection with the coupler, are pressed together by the springs (8 + 9). This results in a fixed connection between housing and coupler.

Brake released: Oil pressure via port (16) reaches the left side of the piston (2) and forces the piston towards the back-up ring (4), as shown.

This function eliminates the spring force onto the disks thus the brake is released.

The releasing pressure is 18 bar, the maximum permissible pressure 60 bar.

This brake named "Wet Brake" because the brake housing is filled with gear oil.

For maintenance see MAINTENANCE MANUAL For more details see PARTS BOOK and REPAIR MANUAL

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Travel System

Section 8.3 Page 9

Electric / Hydraulic Flow Charts Illustration Z22526 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 â&#x20AC;&#x201C;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 hydraulic signal (pilot pressure) from the remote control blocks flow to the main control blocks (175 and 176) to the pilot pressure ports a1 or b1.

The high pressure hydraulic oil flow from the main control blocks via the rotary distributor (34) to the hydraulic motors (21.1 - 21.4).

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Travel System

Section 8.3 Page 10

Adjustments / Checks

)

â&#x20AC;˘ 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 one motor.

4.

Engage carefully desired travel motion and hold foot pedal in final position to built up max. pressure.

5.

Increase * slowly the MRV-pressure while observing the pressure gauge. Gauge value must remain at 310 +5 bar.

continued

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Travel System

Section 8.3 Page 11

Cont’d.

If the gauge shows a smaller or greater value and to be sure both SRVs are correct adjusted the SRVs (main valve block and brake valve block) must be adjusted.

)

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

• A faulty rotary distributor or motor gives the same problems.

Repair or replace faulty part.

6.

7.

8.

9.

10.

11.

12.

Procedure: Set MRV of main valve block I and III to a higher setting (~ 340 bar, for adjustment use the function “stick extending” Engage carefully desired travel motion and hold foot pedal in final position to built up max. pressure Adjust* the respective SRV to a higher setting (~330 bar) Connect pressure gauge to check points M33.1, M33.2, M33.3 and M33.4 at the travel valve block in the car body. The respective highe pressure check point is diagonal to the SRV. Adjust* the SRV at the desired travel function to 310 bar.

Reset the respective SRV at the main valve block to 310 bar, increase the setting from a lower pressure just to the point when the gauge stop increasing it should be 310 bar (provided setting from the SRV at the brake valve is correct).

Create max. pump pressure with “stick extending” to the max. position and re-set MRV to 310 + 5 bar after the check / adjustment is finished and re-plug solenoid valve Y16,.

* a) b) c) d) e)

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Remove dust cap of the SRV (1) Loosen lock nut (2).

Adjust pressure with set screw (3).

Secure adjustment by tightening lock nut (2).

Re-fit dust cap (1).

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Travel System

Section 8.3 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 one motor.

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 machine 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 the motor.

3.

Gauge must show common pilot pressure (norm. 35 + 1 bar).

4.

Set pilot pressure relief valve to 22 bar.

5.

Unplug solenoid valve Y16 to allow pressure release from the pressure line of the house brake.

6.

Reconnect solenoid valve Y16.

The text display must show „Travel gear house brake ON“ 7.

Increase the pilot pressure up to 26 bar „Travel gear house brake ON“ must disappear.

If not check the switch B48; in case it is an adjustable switch, adjust the switch point.( If necessary see SB 21-439 latest edition) 8.

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Reset pilot pressure to 35 bar.

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Hydraulic Track Tensioning System Section 9.0 Page 1

Table of contents section 9.0 Section 9.0

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Page 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

7â&#x20AC;&#x201C;9

9.5

Functional test

9

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9.0

General: Legend for illustration (Z 22453): (62.1 â&#x20AC;&#x201C; 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).

)

â&#x20AC;˘ For information about the preventative track inspection, refer to the Operation and Maintenance Manual.

Functional description on next page

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Hydraulic Track Tensioning System Section 9.0 Page 3

9.1

Functional description: Illustration Z 22454:

)

â&#x20AC;˘ 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 â&#x20AC;˘ 35 bar with motors stopped â&#x20AC;˘ 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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Hydraulic Track Tensioning System Section 9.0 Page 5

9.2

Pressure Increasing Valve

)

â&#x20AC;˘ The pressure increasing valve is a remote controlled pressure relief valve.

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

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

Function: The valve poppet (2) is connected via the jet bores (11) and (12) with the P port.

If static pressure increases above the set pressure value, the valve poppet (2) opens and allows oil to flow freely to tank (T1). This oil generates a pressure drop in the spring chamber of the main spool, the closing force of the spring (6) is cancelled, and the main piston (5) opens to allow the pump flow to flow to tank (T2).

Damped opening and closing is obtained by the throttled volumetric change.

By applying external pressure of Pst max = 60 bar to the main spool (9) via port X, the pre-tensioning of the pressure spring (3) is increased by the amount of the piston stroke "S" and system pressure is increased correspondingly.

The setting is fixed by means of the setting screw (7) and lock nut (13); 1 turn of the screw ~ 150 bar.

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Hydraulic Track Tensioning System Section 9.0 Page 6

9.3

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

Cylinder tube

(2)

Piston

(3)

Piston guide ring

(4)

Piston guide strap

(5)

Seal ring

(6)

O-ring

(7)

Scraper

(8)

Retracting device

(M) Bleeder port (P)

M

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Oil supply

â&#x20AC;˘ Maximum permissible piston stroke 350mm!

During bench test an external stroke limitation must be used!

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Hydraulic Track Tensioning System Section 9.0 Page 7

9.4

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

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

(M12.4)

Pressure check point – Operating pressure of main control block I

(M15.6)

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

(M15.5)

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

(M15.3)

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

(62.3+62.4)

Track tensioning cylinder R.H.

Checking / Setting the pressure increasing valve Pre-conditions: Correct MRV, SRV and pilot pressure setting and the system must be free of air.

The description is only for the R.H. track. The same procedure applies also for the L.H. side.

Basic Adjustment: 1.

Connect a pressure gauge (min.400 bar) to check point M12.4.

2.

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.

6.

7.

8.

9.

10.

:

Move the pressure gauge from M12.4 to M15.3 Connect pressure check point M12.4 with pressure check point M16.1, using a long pressure gauge hose. (required for the oil supply) Disconnect the pilot pressure line at port X of the pressure increasing valve (182) and close the hose (P) ith a plug.

Loosen lock nut (4) of the pressure increasing valve and screw in set sleeve (5) until piston (1) comes to stop. (substitution of X2 pressure) Start one motor.

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 â&#x20AC;&#x201C; 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 06.04.03

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Hydraulic Track Tensioning System Section 9.0 Page 9

Cont'd.: 9.4

Adjustments / Checks 12.

13.

Switch OFF the motor and open cock (54.1) to allow pressure relieve.

Re-connect the pilot pressure line to port X of the pressure increasing valve (182).

Remove the pressure gauge hose between pressure check point M12.4 and pressure check point M16.1.

Close the cock (54.1).

Re-set MRV to 310 + 5 bar after the check / adjustment is finished.

13.

15.

16.

9.5

Functional Test After all adjustments are finished, do the following: a) Bleed all air from the system b) Place shutoff and pressure relief cocks into correct operating position. c) Connect pressure gauge to check point (M15.3). d) Start 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.

)

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*

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

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Access ladder hydraulically operated

Section 10.0 Page 1

Table of contents section 10.0 Section 10.0

11.04.03

Page Access ladder hydraulic operated 10.0 General

2

10.1

3+4

Function of hydraulic operated access ladder

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Access ladder hydraulically operated 10.

Section 10.0 Page 2

Access ladder hydraulic operated General legend for Illustration Z22494 (A) Access ladder in lowered position (B) Access ladder way to upper position (C) Stop bar (Z) Hydraulic cylinder (S84) Ladder control switch (S84A) safety switch 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 engine can run or stand still only to move the ladder up the engine must running.

)

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If the ladder is out of the upper position the pilot control switch of and the solenoid valve Y120 activate the hydraulically swing brake. The ETM in the cab shows a message.

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Access ladder hydraulically operated 10.1

Section 10 Page 3

Function of hydraulic operated access ladder illustration (Z 22495): Legend: (7.1+7.2) (84.1+84.2) (68.1) (70.1) (70.2) (162.3 – 5) (171) (174) (172) Y125 Y123A Y123B

Pumps Check valves Filter with filter monitoring switch B22 Pressure relieve valve (60 bar) Pressure relieve valve (35 bar) Check valves Pressure relieve valve (70 bar) Ladder cylinder Orifice Solenoid valve: lower speed limit Solenoid valve: ladder up Solenoid valve: ladder down

The engine 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 11.04.03

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Section 10.0 Page 4

Access ladder hydraulically operated

9

Cont'd: The engine 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.

:

11.04.03

• 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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Special Equipment Cable drum

Section 11.0 Page 1

Table of contents section 11.0 Section 11.0

06.04.03

Page

Cable drum 11.0

General

2

11.1

Function

3

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Hydraulic Oil Reservoir

Section 11.0 Page 2

11.0 Cable drum General

)

Task: The cable drum, driven by a brake motor with slip ring rotor, is installed to wind up or wind off 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

Legend for Illustration (5M6) Brake motor (5S3) Rotation direction indicator (switch) (5R1) Resistor for brake motor torque adjustment (5S4) Gear type cam switch for resistor controlling (5S7) Safety switch to detect the last cable windings.

(5S6) Pendulum type cam switch, to detect slack or tight cable (5S8, 5S9) Proximity switch to detect cable deflection to right or left (0S15) Option, Emergency push button (shut down),

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Hints for Reading the Hydraulic Circuit Diagram

9

Section 12.0 Page 1

Table of contents section 11.0 Section 12.0

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Page Hints for reading the hydraulic circuit diagram 12.1 General

2

12.2

3

Symbols

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Hints for Reading the Hydraulic Circuit Diagram

9

12.1

Section 12.0 Page 3

Hints for reading the circuit diagram

Legend for Illustration Z22496

) Item

• • • • • • •

•

•

11.04.03

• •

The illustrations are used for exemplary explanations only.

Use original circuit diagram for detailed reading Description

Number / Code

Explanation

A

Diagram No. and Typ of

897 970 40

B

Respective Serial No.

15014/15

C

Sheet-No. / Quantity of sheets 01 / 3

1st of three sheets

D

Co-ordinates for discr . the

A 10

Main pump No. 6

E

Component-No. 14

14

L.H. control block

F

Line-No. with cross hint,

L19/2E7

Pressure line (Line No.19)

All the components drawn in neutral pressure less position.

Full wide continues black line shows a main component. (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 main pumps, pilot control valves, control blocks, distributor manifold and cylinders or motors. The text on coordinate C 1 explained the priority of the clam circuit.

Page 2 shows the auxiliary circuits, main pump control system, oil cooling system and the hydraulic tank. The diagram on coordinate A 12 shows the temperature switch points of different oil viscosity’s and circuits.

Page 3 shows the car body hydraulic with travel brakes, travel motors and track tensioning system. Additional on this page is the main pump control block arrangement drawn.

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Hints for Reading the Hydraulic Circuit Diagram

9

Section 12.0 Page 5

12.2 Symbols Line, union, valve Symbol

11.04.03

Description

Used as / at / on

Main line, can be a hose or a pipe.

Main high pressure line or pressurised line to secondary circuits.

Secondary line, can be a hose or a pipe.

Tank return line, drain line, pilot control line, regulation line and other secondary lines.

Connection point, is a connection with not defined position (can be at the end of a line or at any position) Component connection point, is a connection with a defined position at a component

Connection between three or more lines

Plugged connection point, can be plugged with any kind of plugs.

Not used connection points.

Quick coupling, is a special union with integrated check valve for easy and leak oil free coupling.

Blind, Orifice, not adjustable with orifice diameter

Tank drain couplings, often removed lines (at grease system with removal barrels).

Pressure check point With a special quick coupling.

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

Connection to each component like the valve blocks, tanks, pumps, ...

e.g. Oil cooler inlet,

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12.0 6

Line, union, valve Symbol

Description Compensator, Compensate line length differences depend on vibration and temperature.

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

Check valve spring loaded Opened in flow direction only against spring force = pressure Double check valve, in drawn pos.: opened only from the left to the bottom or from the right to bottom Screen filter, the screen size is written with 1.0 mm

11.04.03

Used as / at / on Oil tank outlet to the pumps

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

Swing brake control,

Suction line to the pumps, oil tank outlet, return oil collecting tube

Oil cooler,

Hydraulic oil cooler, PTO oil cooler

Breather filter,

On top of PTO or hydraulic tank

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Hints for Reading the Hydraulic Circuit Diagram

9

Section 12.0 Page 7

Line, union, valve Symbol

11.04.03

Description

Used as / at / on

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

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

Temperature sensor, Input = temperature Output = electric signal proportional to the temperature Level sensor, Input = fluid level Output = electrical signal analogue or digital

e.g. hydraulic tank

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

Main pumps

Accumulator, is filled with nitrogen gas with for the respective accumulator specified pressure Spray nozzles, inside of a case for cooling and lubricating

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

Valve with monitoring, the switch contacted monitors the valve position, itâ&#x20AC;&#x2122;s adjustable

Main gate valve at the outlet of the oil tank

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

Track tensioning system

Hydraulic tank, fuel tank

Gearbox (PTO) cooling and lubricating system

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Line, union, valve Symbol

11.04.03

Description

Used as / at / on

Variable throttle valve hydraulically controlled pressure less control port = maximum resistance

Travel brake valve, located in the car body

2 way 2 position valve manual controlled, 2/2 way valve

Track tensioning system

3 way 2 position valve manual controlled, 3/2 way valve

Change over valve for electronically or hydraulically pump regulation

4 way 2 position solenoid valve 4/2 way solenoid valve

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

3 way 2 position solenoid valve leak oil free 4/2 way solenoid valve

Service arm controlling

4 way 3 position solenoid valve 4/2 way solenoid valve, in neutral all ports closed

Ladder controlling, service arm controlling

Proportional pressure valve, reduce the pressure in port A proportional to the solenoid current.

3-way proportional pressure relief valves are direct operated by proportional solenoids.

Remote control valves

Pump regulation

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9

Section 12.0 Page 9

Line, union, valve Symbol

Description Pressure relief valve, mechanical adjustable

Pressure relief valve, mechanical and hydraulically via pilot port X adjustable, oil drain port Y Pressure relief valve with anti cavitation valve (check valve)

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

11.04.03

Used as / at / on e.g. primary relief valve, secondary relieve valve, ladder controlling, service arm controlling ....

Radiator and oil cooler fan drive

Secondary relieve valve at main control blocks

Distribution manifold at some sections

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Hints for reading the Electric Circuit Diagram

Section 13.0 Page 1

Table of contents section 13.0 Section 13.0

Page Hints for reading the electric circuit diagram 13.1

Designation of electrical devices

2

13.2

Symbols

3+4

13.3

General information

5+6

13.4

Reading a circuit diagram

7+8

Hints for reading the Electric Circuit Diagram

Section 13.0 Page 2

13.1 Designation of electrical devices Indicating letter A B

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

Kind of component System, subassembly, parts group, trigger boxes, control units Transducer for conversion of non-electrical variables to electrical variables, and vice versa.

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

13.0 3

Hints for reading the Electric Circuit Diagram

Section 13.0 Page 3

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

For this reason the following comparative chart.

1) Normally open contact

2) Maintained contact

4) Normally closed contact

5)

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

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

13) Contacts with time lag

14) Resistor general

16) Battery

17) Tapped resistor

18) Voltmeter

19) Inductive resistance

20) Continuously adjustable, general

21) Recording instrument

22) With iron core

23) Adjustable in steps

24) Signal lamps pilot lights

25) Continuously adjustable

26) Potentiometer rhesostat

27) Operating coil solenoid

28) Transformer

29) Capacitor general, continuously adjustable

30) Rectifier, semi conductor

Push-button switch

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

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Hints for reading the Electric Circuit Diagram

Section 13.0 Page 4

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

32) Thermal over load limit

33) Phase, 4-wire system

34) Current transformer

35) Undervoltage relay

36) Junction of conductors

37) Voltage transformer

38) Temperature relay

39) Junction

40) Circuit interrupter

41) Contactor

42) Terminal

43) Circuit breaker, three phase

44) Generator (G)Motor (M)

45) Terminal

46) Thermal over- ground, load protection

47) 3-phase-motor

48) Earthing, general

49) Magnetic over- socket current protection

50) 3-phase squirrel cage

51) Plug and

52) Slipring motor

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

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Hints for reading the Electric Circuit Diagram

Section 13.0 Page 5

13.3 General information Legend for illustration (Z 21823): Komatsu circuit diagrams Each sheet has the following information in the bottom right hand corner: Diagram Number example: 897 844 40 Machine Type example: PC4000-6 Sheet Number and Total Number of sheets 01/63 - 02/ . etc.

Each sheet is numbered from 8 (at the left corner) to 1 (at the right corner) along the top and bottom lines, and lettered down from F (at the top) to A (at the bottom) along the left and right side lines.

This coordinate system enables you to find components easily.

On the table of contents, page one, the individual circuits are listed up with the respective page number.

Example: The circuit for the superstructure lighting is shown on page 39.

Pages number two, three and four are cross reference lists of component codes related to page numbers.

Example: The relay with the component code “K1-1” is shown on page 8.

On page five is a list of answers to frequently asked questions (FAQ) concerning abbreviations, function of components (e.g. time relays) mathematical symbols etc. used in the diagram.

All electrical components are connected via cable harnesses to the main switch board “X2”. There is only one Plug connector in between, which is always located close to the respective component like sensors, solenoids etc.

All 24 volt wires are blue and have a printed code (every 10 cm) at each end of the wire. (see illustration) The first part of the code shows the required connection and the second part gives the information what is connected at the other side of the wire.

Example: going to coming from coming from going to

X2S 45

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

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

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

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Hints for reading the Electric Circuit Diagram

Section 13.0 Page 6

13.3 General information Legend for illustration (Z 21824): Explanation of the Drawing Concept (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16)

Drawing number Sheet number / quantity of sheets Designation of drawing Designation of component or assembly Column (vertical sections) Lines (horizontal sections) Component symbol Neutral wire / machine ground Designation of phase Phase strip Terminal strip and terminal Cable plug and pin number Relay coil Relay contacts, partially with detailed information Cross reference for the continuation, Page / Column Indication where the relay contact opens or closes

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

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Hints for reading the Electric Circuit Diagram

Section 13.0 Page 7

13.4 Reading a Circuit Diagram.

Legend for illustration (Z 21825): â&#x20AC;˘ Examples are shown by sectional drawings out of the electric circuit diagram 897 844 40 page 08.

) (1)

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

(2)

Section C4 / sheet 08 Shown is the relay coil K51-1 only and not its contacts.

The contacts are shown somewhere else in the diagram.

Switching and contact positions are shown below at the foot of that particular circuit in row C-C as shown below.

Example for K51-1: 08.5 : : :

1 5 2 6 3 7 4 8

9 10 11 12

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

When diodes are fitted to a relay, they are fitted to allow a current flow in one direction only. An LED* (Light Emitting Diode) indicates a current flow if it lights up.

When diodes ** are fitted anti-parallel to a relay coil, they absorb the high induced voltage caused by making and breaking the current flow through the coil.

This occurs each time we operate a switch supplying current to the coil. The diode effect allows the induced current to circulate within the coil windings and decay when the energy to the coil is cut. * **

LED between A1 and coil Diode between A1 and A2.

(3)

Section F7 / sheet 08 Connectors and Terminals are identified by a letter and number

Hints for reading the Electric Circuit Diagram

Section 13.0 Page 7

code. X2 o 23-28 = Terminal box X2 Terminals 23 to 28 are linked with a metal bridge. continued

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Hints for reading the Electric Circuit Diagram

Section 13.0 Page 8

Cont.: 13.4 Reading a Circuit Diagram.

Legend for illustration (Z 21826): (4)

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

S27 = Toggle switch (with non-automatic return)

a.

F11

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.

=

Circuit breaker (24V power supply)

Function: If switch S27 is actuated, terminal A and B are connected and 24VDC will energize the coils of K121 and K121a on page 08 and simultaneously via line S27 a digital input to the PLC on sheet 20 section 7.

Now the machine can be operated in emergency mode and a warning text appears on the display.

Section 14.0 Page 1

ECS

Table of contents section 14.0 Section 14.0

Page Table of contents and Safety instructions

1–5

14.1

General Design of the ECS-T System

7

14.1.1

Input and outputs of the PLC

9

14.1.2

Task

9

14.1.3

PLC DIGSY plus ®

11

14.1.4

Definitions; Symbols and Abbreviations

13

14.2

14.3

14.4

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How to Proceed due Maintenance and Installation

19

14.2.1

Meaning of the Status LED’s

23

14.2.2

Short Circuit Marker -LED “MK”

27

14.2.3

Diagnostic for Temperature-Module “TPM”

29

Front Connector Arrangement

31

14.3.1

Front Connector Arrangement BIM-Module

31

14.3.2

Front Connector Arrangement, TPM-Module

33

14.3.4

Four Wire (Conductor) Technique

35

14.3.5

Sensor Wire Breakage Monitoring

35

14.3.6

Earthing of the Control Unit

37

Power supply

41

14.4.1

Operation Voltages +24 V

41

14.4.2

Safety Precautions for Faultfinding

43

14.4.3

CPU Voltage Range

45

14.4.4

Electric Magnetic Strength

45

14.4.5

Fuse

45

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ECS

14.5

14.7

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Section 14.0 Page 3

Function explanations with electr diagram

47

14.5.1

General

47

14.5.2

Controlling

49

14.5.3

Pressure Measuring

53

14.5.4

Temperature Measuring

55

14.5.5

Temperature â&#x20AC;&#x201C; Resistance Chart PT100

56

Hints for reading the functional flow charts

57

14.7.1

General

57

14.7.2

Example 1

59

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ECS

) M : )

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Section 14.0 Page 5

• The following Symbols are used in the Manual to designate Instructions of particular Importance

• WARNING - Serious personal injury or extensive property damage can result if the warning instructions are not followed.

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

• NOTE - Refers to special information

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Section 14.0 Page 7

ECS 14.1

General Design of the ECS-T System ECS-T ?

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

)

•

Electronic Check System - Text (Display) Illust. Z 21407

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

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

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ECS 14.1.1

Section 14.0 Page 9

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.

)

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â&#x20AC;˘

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

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Section 14.0 Page 11

ECS

14.1.3

PLC DIGSY plus ® (circuit diagram code E6)

Legend for illustration Z21409a • • • • • • • • • • • • •

•

)

Central Processing Unit (CPU) board.

Binary Module (BIM) board.

Temperature Module (TPM) board.

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

• The quantity and configuration of the BIM and TPM 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 colours and duration of lightning (Continuos On or flashing). For detail information see Section 4.

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ECS 14.1.4

Section 14.0 Page 13

Definitions; Symbols and Abbreviations

≡ ≠ Bit

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

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).

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Section 14.0 Page 15

ECS

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 ÂŽ 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 ÂŽ.

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.

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Section 14.0 Page 17

ECS 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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ECS 14.2.

Section 14.0 Page 19

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

Section 14.0 Page 21

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

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

• Dispose batteries and accumulators as special waste.

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Section 14.0 Page 23

ECS 14.2.1

MEANING OF THE STATUS LED’S

ILLUST. Z 21431a

The DIGSY plus performs by the function of the Status LED’s (5V and DIAG) and the so named Diagnostic Words* (DW1 up to DW256) many data and statuses.

With a PC and the Program- and Diagnostic Software the. Diagnostic Words are visible on a monitor.

The following sections explain the diagnostic possibilities more in detail. * Can be called-up by PC assistance only.

Table: Statuses of the +5 V-LED and their meaning LED Effect Cause 5 V-LED Voltage green o.k.

5 V-LED CPU not working Supply red (RESET) < 4,65V DIAG-LED red 5 V-LED CPU not working Supply OFF (except the is missing LED is defect) Fuse S1 defect

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

LED defect (if DIAG LED is ON)

*)

others

*)

Watchdog in operation

*)

5 V-LED flashing red/green

cyclically new starts

red/ *) orange Continuos Reset Component fault ** For location refer to Section 3 page2 (Z 21428) Replacement only in after co-ordination with Komatsu Mining Germany, Dept. 8124.1 *) = Return SPS to manufacturer

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Section 14.0 Page 25

ECS Table: State of the DIAG-LED and their meaning LED Effect Cause DIAG-LED Program Communication via green in operation Interface COM-SP not active (interrupted) COM-SP<╪> Text display DIAG-LED ProgramTemperature orange state inside housing unchanged too high +24 VCPU < 14 V

Increase the voltage

Accumulator voltage too low

Replace the accumulator module

Fixed operands deleted

Check the accumulator connections

SPS in start loop after voltage ON

Program not running (stopped)

Stop the programming *1) Initialize EEPROM *1)

EEPROM not Initialized EEPROM- or RAM- fault

DIAG-LED OFF

Program not running (except LED defect)

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

Program stopped

No Program otherwise LED defect DIAG ProgramCommunication 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 SPS to manufacturer

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External cooling

wait

programming in operation DIAG-LED RED

Remedy Check the cable connection and the Interface port

Load program *1) *2)

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ECS

14.2.2

Section 14.0 Page 27

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 1 page 4

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ECS 14.2.3

Section 14.0 Page 29

Diagnostic for Temperature-Module â&#x20AC;&#x153;TPMâ&#x20AC;?

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:

Orderly 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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Section 14.0 Page 31

ECS 14.3

Front Connector Arrangement 14.3.1

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

Front Connector Arrangement, BIM Modul (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.

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

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

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

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14.0 32 Cont’d.: Pin 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

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

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

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

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

Ground / GND

UE/A = Voltage.

Input / Output

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

• • •

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E1, E2,...E7, E13 and E14 input port fix configured.

A2/E9, A4/E10, A6/E11, A8/E12 and A14/E21 variable input or output ports depend on software programming.

A1/A9, A3/A10, A5/A11, A7/A12 and A13/A21 output ports fix configured.

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ECS 14.3.2

Section 14.0 Page 33

Front Connector Arrangement, TPM-Module

)

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

• .This is an example for the first TPM slot. Additional TPM modules configuration can be vary depend on sensor configuration (temperature or pressure).

• The configuration for the respective excavator is written in the EAConfiguration chart (EA-Belegungsliste) see Apendix and the respective electric diagram.

PIN-NAME GND/UE1 GND/UE2 GND/UE3 GND/UE4 GND/UE5 GND/UE6 GND/UE7 GND/UE8 UE1 UE2 UE3 UE4 UE5 UE6 UE7 UE8 GND 1U+ 1UGND 2U+ 2UGND 3U+ 3U-

OPERAND

EW 1.1 EW 1.2 EW 1.3 EW 1.4 EW 13.1 EW 13.2 EW 13.3 EW 13.4 EW 1.1 EW 1.1 EW 1.2 EW 1.2 EW 1.3 EW 1.3

COMMENTARY Analogous GND of E1 Analogous GND of E2 Analogous GND of E3 Analogous GND of E4 Analogous GND of E5 Analogous GND of E6 Analogous GND of E7 Analogous GND of E8 Input 1, Volt. or current Input 2, Volt. or current Input 3, Volt. or current Input 4, Volt. or current Input 4, Volt. or current Input 4, Volt. or current Input 4, Volt. or current Input 4, Volt. or current Analogous - GND +Volt. - Input 1. Sensor -Volt. - Input 1. Sensor Analogous - GND +Volt. - Input 2. Sensor -Volt. - Input 2. Sensor Analogous - GND +Volt. - Input 3. Sensor -Volt. - Input 3. Sensor

All pins are internal connected All sensors of a PT 100 type

continued

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14.0 34 Cont’d.: Front Connector Arrangement, TPM-Module

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

PIN-NAME GND 4U+ 4UGND GND GND KG- Relay KG- Relay 1I+ 1IH 1I2I+ 2IH 2I3I+ 3IH 3I4I+ 4IH 4IGND KA - Relay KA - Relay KR - Relay KR - Relay

OPERAND EW 1.4 EW 1.4

COMMENTARY Analogous - GND +Volt. - Input 4. Sensor -Volt. - Input 4. Sensor Analogous - GND Analogous - GND Analogous - GND Combined relay contact Combined relay contact +Current 1. Sensor Aux. - Pin 1. Sensor -Current 1. Sensor +Current 2. Sensor Aux. - Pin 2. Sensor -Current 2. Sensor +Current 3. Sensor Aux. - Pin 3. Sensor -Current 3. Sensor +Current 4. Sensor Aux. - Pin 4. Sensor -Current 4. Sensor Analogous - GND Normally open contact Normally open contact Normally closed contact Normally closed contact

• All pins are internal connected • All sensors of a PT 100 type

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ECS

14.3.4

Section 14.0 Page 35

Four Wire (Conductor) Technique for analogue temperature input

Shield I+

Current

U+

Voltage

IH UI-

Voltage

R1 PT 100

Current

50 - pol.

SUB - D - Plug-connector

Connections must be as close as possible to the sensor !

With the four wire technique the length and the cross section of the wires are not important; because the ohmical resistance of the two current wires gets compensated in the manner that the measuring voltage of the sensor, via the two voltage wires (high ohmical), is picked-up direct at the sensor.

In the interest of safety must the wire length not exceed 25 m and the cross section must not be smaller than 0,14 mm². Additional the wires must be shielded according to the standards. The picture shows the wiring of a sensor to a 50 pol SUB D plug connector in four wire technique.

14.3.5

Sensor Wire Breakage Monitoring Each temperature measuring channel has wire breakage monitoring that is effectual for two- three- and four wire technique.

The respective measuring channel produces an internal maximum voltage (>+10 V, that means a temperature greater the nominal Max.-Temperature), in case that one of the wires breaks.

Measuring range TPM-Module = -50° C........+150° C.

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ECS 14.3.6

Section 14.0 Page 37

Earthing of the Control Unit

Attention: The complete shield of the analogous cable must be connected to the earthing bolt of the DIGSY. This bolt must be connected to GND by a cable (as short as possible) with 2,5 mm2 cross section.

When using plug connectors with metal boxes and connected shield the additional complete shielding of the analogous cable with the earthing bolt is not necessary. But attention must be played that the metal box is connected by screws with the DIGSY housing.

The twisted signal lines are pair wise shielded and already via the 50-pol female part of the connector connected to GND. The single shielding at the free end of the cable must not be connected with earth.

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ECS

Legend (1) (2) (3) (4) (5) (6) (7)

Illust. Z 21425a (Exemplary picture about what possible) Text display ECS Plug socket “X27” Laptop Field computer system control box Memory card system Portable printer Field dispatch system

Cables: VL3 VL4 VL5 VL6 VL7 VL8

X27 to Laptop X27 to Memory Card System 24V Power supply to Memory Card System X27 to Portable Printer 24V Power supply to Portable Printer X27 to Field Computer System

)

07.04.03 rev.2

Section 14.0 Page 39

• Data cables and/or communication systems are optional equipment.

• For more detailed information see OPERATION MANUAL of the shovel and the Software Program for the individual Communication System

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Section 14.0 Page 41

ECS 14.4

Power supply 14.4.1

Operation Voltages +24 V

Illust. Z 21426

Study together with the relevant circuit diagram 50-pin SUB Connector: + 24 V CPU-Supply: GND: + 24 V I/O-Supply:

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

This supply voltage is the operating voltage for the module outputs. It must be strong enough to carry the load current of all outputs.

It is provided with a LOAD-DUMP protection to protect (for short times) wrong polarity and over voltage peaks.

:

• Wrong polarity causes destroying of the module!

• External 24 V supply to the outputs causes destroying of the module!

See next page for more information

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Section 14.0 Page 43

ECS 14.4.2

Safety Precautions for Faultfinding

Illust. Z21427

• As already mentioned no external 24 V supply is allowed to the outputs of the BIM modules of the PLC. • If it is necessary while tracing faults, the cable to the PLC must be disconnected subsequent to a component check, thus as relays, solenoids or others by the PLC controlled components.

:

Procedure: Study together with the relevant circuit diagram 1.

Find the terminal between the component and the PLC. 2.

Example terminal 8X2-280 for the solenoid valve 8Y6.1.

3.

Disconnect the wire on one side of the terminal.

4.

Now supply 24 V to the solenoid and check function of it.

5.

Finally re-connect the wire to the terminal

Binary Outputs A 2A-Short circuit proof Each single Output of the Output group can withstand a load of 2A, but the total load must not exceed 10 A. The Output group will be switched OFF if one of the Output becomes overloaded (> 2 A), the short circuit marker will be set and the “MK”- LED comes ON. (A1¿ MK1, A3¿ MK3, A5¿ MK5)

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ECS 14.4.3

Section 14.0 Page 45

CPU Voltage Range • Electrical requirements +24 supply volt • 14 V up to 36 V without any restrictions regarding the max. current consumption of 4 amps out of the +5 V logic voltage.

• At voltage drops below 18 V the 2amps-outputs switched OFF due to safety reasons. The short circuit markers initiated.

• The +24 V CPU is monitored on the CPU plus DB16.1 After the diagnostic bit “Under-voltage UCPU “ DB16.1 has been set, all access to the EEPROM memory of the CPU plus is blocked • A drop below 9V results in a reset.

• During and after voltage drops according to DIN 40839 part 2 operates the CPU plus normally.

14.4.4

Electric classification The voltage supply meets the requirements according to: • ISO 7637-2 Automotive Technique 24V • DIN 0871-B • IEC 801-4 step 4, VDE 0843-4.

• DIN/VDE 0470 part1 (old DIN 40050)

14.4.5

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

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ECS 14.5

Section 14.0 Page 47

Function explanations with electr diagram 14.5.1 General Signal Status Voltage level: „1“ = 24 V* between E (Input) and GND „0“ =

0 V** between E (Input) and GND

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

The left half of the picture shows so named PULL-DOWN resistors and the right half PULL-UP resistors. The resistors are installed to get a low ohmical input. A system with contacts only leads to a (high ohmical) input if dust or moisture bridges the contacts.

PULL-DOWN resistors are installed with a normal NC contact (means with a de-energized relay or normal closed switch contact) thus the ECS recognize a fault after switching ON the system.

PULL-UP resistors are installed with a normal NO contact (means with a deenergized relay or normal open switch contact) thus the ECS recognize a fault after switching ON the system.

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Section 14.0 Page 49

ECS 14.5.2

Controlling (High pressure filter and Chip detector)

(sections out of a circuit diagram, study with the respective circuit diagram and flowchart) Example HP filter #1 Illust.: Z22800 Digital Input: E9.1, Differential pressure switch B5-1 monitoring and Chip detector B10A-1 Function: Condition A B5-1 closed, (normal condition) B10A-1 open, (normal condition) Input logic „1“, State LED E9.1 (green) ON Condition B B5-1 open, (Filter blocked or electrically defect) B10A-1 open, (normal condition) Input logic „0“, State LED E9.1 (green) OFF Condition C B5-1 closed, (normal condition) B10A-1 open, (Chips detected or electrically defect) Input logic „0“, State LED E9.1 (green) Off

With motor stand still Condition A: State LED A1.1 (red) OFF, Shut-Down relay K93 de-energized State LED A8.2 (red) OFF (emergency indication LED) Motor start possible With motor stand still, Condition B & C: State LED A1.1 (red) OFF, Shut-Down relay K93 de-energized State LED A8.2 (red) flashing (code 1 for filter 1) (emergency indication LED) Motor start blocked.

Text display shows: „Start of motor 1 blocked due to contamination pump 1 Differential pressure switch B5-1 not closed or B10A-1 closed - Check cables to differential pressure switch B5-1 and chip indicator B10A-1.“ continue

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Section 14.0 Page 51

ECS

Cont’d.: With motor running, Condition A: State LED A1.1 (red) ON, Shut-Down relay K93-1 energized State LED A8.2 (red) OFF (emergency indication LED) Motor running (normal condition) With motor running, Condition B & C (happened just in the moment): State LED A1.1 (red) OFF, Shut-Down relay K93 de-energized State LED A8.2(emergency indication LED red) flashing (code 1 for filter 1) Motor shutdown.

Text display shows: „High pressure filter 1 or pump 1 restricted. Stop the engine 1 Help: Differential pressure switch B5-1 not closed or chip indicator B10A-1 closed. - Clean or replace filter element. - Check pump.“ In case the text display shows the Fault messages: „Start of motor 1 blocked due to contamination pump #1 Differential pressure switch B5-1 not closed or B10A-1 closed - Check cables to differential pressure switch B5-1 and chip indicator B10A-1.“ or „High pressure filter 1 or pump 1 restricted. Stop the engine 1Help: Differential pressure switch B5-1 not closed or chip indicator B10A-1 closed. - Clean or replace filter element. - Check pump.“ Try to find the fault by using the Help Text and the Menu Control first.

(See Operation Manual „Menu-Control") Possible voltage checks: Inputs: 24 V Supply between supply line 15 (start at circuit breaker) and GND. Signal Voltage with closed switch contact 24 V (13 V up to Supply Voltage) between GND. Use respective circuit diagram for terminal numbers.

Signal Voltage with open switch contact 0 V (0 – 5 V) between GND and.

X2.167 - 168.

Output:K93.1 Control voltage24 V between GND and X2.237 - 238 with switched Output or 0 V without switched Output (Pay attention)

*(Program run see respective FLOWCHART) 07.04.03 rev.2

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Section 14.0 Page 53

ECS 14.5.3

Pressure Measuring

(Hydraulic System)

Illustration Z 22805

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

P = input pressure K = calculation factor for the respective pressure sensor.

Ua = (P x K) + 1 V Example for 200 bar and a 0 – 500 bar sensor: Ua = (200 x 0,02) + 1 V = 5 V

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Section 14.0 Page 55

ECS 14.5.4

Temperature Measuring (Hydraulic System)

Illustration Z22803 (study with the respective circuit diagram) (Program run see respective Flowchart) Analogous Inputs (eg.: Hydraulic oil temperature sensor B15) „EW 2.1“ (for Temperature sensor B15) Measuring channel: -50° C......+150° C Function: Continuously voltage supply to the sensor PT100: ECS Terminal 7.34 and 7.35-36 Return voltage (Signal) from PT100: 7.18 and 7.19

)

• With increasing resistance (Temperature) decreases the voltage

Possible measurements: PT100: Disconnect the wires at the resistor and measure the resistance across the resistor.

Compare the measured resistance with the values given in the table on next page.

At correspondences the PT100 resistor is OK.; otherwise replace resistor.

Wiring: Disconnect the wires at the resistor and inside X2-box.

(X2H.11 through X2H.12 and X2H.13 through X2H.14) Measure the wire resistance.

All single wire resistance must be the same.

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14.0 56 14.5.5

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

°C

-0

-1

-2

-3

-4

-5

-6

-7

-8

-9

-50

80,31

79,91

79,51

79,11

78,72

78,32

77,92

77,52

77,13

76,73

-40

84,27

83,88

83,48

83,08

82,69

82,29

81,89

81,50

81,10

80,70

-30

88,22

87,83

87,43

87,04

86,64

86,25

85,85

85,46

85,06

84,67

-20

92,16

91,77

91,37

90,98

90,59

90,19

89,80

89,40

89,01

88,62

-10

96,09

95,69

95,30

94,91

94,52

94,12

93,73

93,34

92,95

92,55

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

Example:

07.04.03 rev.2

84 ° C

Ì 80° + 4° = 132,42 Ω

124,4 Ω

Ì 124,4 ≈ 124,39 = 60° + 3° = 63 °C

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ECS 14.7

Section 14.0 Page 57

Hints for reading the functional flow charts 14.7.1

)

General

â&#x20AC;˘ Probably the best aid for trouble shooting is the confidence of knowing the system and how to use the ECS. Every component has a purpose in the system. The construction and operating characteristics of each one should be understood. â&#x20AC;˘ Use always the electric/hydraulic circuit diagram the flowchart and the operation manual for the specific machine.

1. Select on page 1 of the flow chart, (which contains the table of contents and the main program) the respective subprogram, for example the PowerMaster lube system.

2. Components in the flow chart, have the same identification code as in the electric/hydraulic circuit diagram, as shown in cross reference list (page 2-4).

For example: Relay K50 = ?

On page 2 (cross reference list) you find out that relay K50 is shown on page 40 of the flowchart.

3. On each page of the respective subprogram you will find the functional description in plain text.

In case of problems concerning reading the program loops, you may find answers in the frequently asked questions list on page 6 and 7 of the flow chart.

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ECS

Section 14.0 Page 59

14.7.2 Example 1: One complete lubrication cycle of the “lubrication system Superstructure ” automatically finished. (Manual lube switch not actuated) Designated in the flow chart as"u:=1" Presumed conditions: A) Both motors running B) Grease barrel full C) End-of-line switch closed.

For one complete lube cycle it is necessary to finish all four program loops one after the other: 1.

YELLOW LOOP (Pause time): Elapsing of the adjusted pause time after both motors have reached operating condition.

(Factory setting: 1 hour*) 2.

RED LOOP (Lubrication pump switched ON ⇒ pressure increasing phase): After the pause time is finished, lubrication is requested (2) ⇒ _press_increase will be set to “TRUE” (21), and the final pressure has to be reached within the adjusted monitoring time. (Factory setting: 5 minutes*)

3.

GREEN LOOP (Switch off pressure is reached ⇒ Lubrication pump is switched Off ⇒ start of pressure decreasing phase) When the final pressure is reached (3), _press_increase = “FALSE” (31) and at the same time _press_decrease = “ TRUE ”(32) will be set.

(Factory setting of the end-of-line switch B 43: p=190 bar)

BLUE LOOP (Pressure relieved,⇒ starting point of the pause time): When the pressure is low again (4) _press_decrease = “ FALSE ”(41) will be set and the lube counter will add one lube cycle (42).

The pressure has to be relieved within the adjusted relieve time.

(Factory setting: 2 minutes*) pause

) 07.04.03 rev.2

Pressure increase

Pressure decrease

settings

pause

The complete Lubrication cycle is finished and the Pause time starts again. * These factory time adjustments can be changed, with the menu control of the ECS system, in order to meet local requirements and operating conditions.

Adjustment procedure, refer to the Operation Manual.

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Section 14.0 Page 61

ECS

Detailed explanation of “u:=1” i.e. lube system superstructure.

1. Yellow loop Item query Yes a) Grease barrel empty?

0 V at E3.7 Fault message No 1028

No 24 V at E3.7

continued 07.04.03 rev.2

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ECS

Section 14.0 Page 63

Contâ&#x20AC;&#x2122;d.: 1. Yellow loop Item query b) Standstill_motor.all ?

Standstill_motor.1 ?

Standstill_motor.2 ?

Item c)

query Start or stop _motor.any ?

Start or stop _motor.1 ?

Start or stop _motor.2 ?

Yes

No

< 200 1/min < 200 1/min

>500 1/min at EW15.3 >500 1/min at EW15.4

Yes

No

E2.1 + 24 Volt or E2.3 + 24 Volt E2.2 + 24 Volt or E2.4 + 24 Volt

>500 1/min at EW15.3 or <200 1/min at EW15.3 >500 1/min at EW15.4 or <200 1/min at EW15.4

For more information about the operating conditions, refer to the flow chart. continued

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Section 14.0 Page 65

ECS Cont’d.: 1. Yellow loop Item query d) Key “manual lube” actuated ?

Item f)

g)

h)

Yes 24 V at E5.3

query press_increase_too_long.u = TRUE?

press_decrease_too_long.u = TRUE?

press_increase.u = TRUE?

Yes Fault message No 1034 Refer to Section 5.0 of the Operation Manual Fault message No 1040 Refer to Section 5.0 of the Operation Manual If the pause time is elapsed

No 0 V at E5.3

No pause time

pause time

During the pause time

continued

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ECS

Section 14.0 Page 67

Cont’d.: 1. Yellow loop Item i)

query press_decrease.u = TRUE?

j) k)

Manual_lub-u = True ? press_pause.u > user_set_ pause _time.u ?

Yes No If the switch off Still pause time ⇒ pressure is switch off pressure reached is not reached If actuated Pause time Pause time

⇓ l)

Switch off lube pump (No Voltage at output A5.7 and A13.1)

This yellow loop starts at point No 1, cycles again and again until the PAUSE TIME is elapsed and will be finished at point No 2.

Thereafter the Red loop with the pressure increasing phase starts at point No 2. (see next pages) continued

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Section 14.0 Page 69

ECS Cont’d.:

Detailed explanation of “u:=1” i.e. lube system superstructure.

2. Red loop As soon as the actual pause time is longer than the pre-adjusted pause time, the yellow loop will be interrupted at item “k”, because then the answer is “YES” and the program continues with the red loop.

Item k) n) o)

query Yes press_pause.u > user_set_ pause _time.u ?

Press_increase.u= TRUE Pressureincreasing-u= 0 sec ... _press_increase.u > user_set_increase_max_time ?

No

⇓ p)

Switch on lube pump Switch on pressure release valve (dump valve close) (24 Volt at output A5.7 and A13.1) And start with “item a” again

Item a)

query Grease barrel empty?

⇓

⇓

g)

press_decrease_too_long.u = TRUE?

Yes

No Refer to the information of the Yellow loop (page 3-6)

continued

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ECS

Section 14.0 Page 71

Contâ&#x20AC;&#x2122;d.: Item h)

query press_increase.u = TRUE?

q)

Increased up to switch off pressure?

Yes No During the During the pause pressure time increasing phase 24 V at E11.6 0 V at E11.6 switch off During the pressure is pressure reached increasing phase

Starting at point No 2, the Red loop cycles from point (21) to point (21) again and again until the switch off pressure is reached.

There after the Green loop with the pressure decreasing phase starts at point No 3. (see next pages)

continued

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Section 14.0 Page 73

ECS Cont’d.:

Detailed explanation of “u:=1” i.e. lube system superstructure.

3. Green loop As soon as the switch off pressure is reached, the red loop will be interrupted at item “q”, because than the answer is “YES” and the program continues with the green loop.

Item q)

query Increased up to switch off pressure?

q1)

press_increase-u=False press_decrease-u=True _press_pause : 0 sec Switch off lube pump

m)

Item m) a)

⇓ h)

Yes 24 V at E11.6 switch off pressure is reached If time is elapsed

No 0V at E11.6 During the pressure increasing phase

query Yes No Switch off lube pump Pressure release valve still active (dump valve still closed) (A5.7 = 0 Volt and A13.1 = 24 Volt) Grease barrel empty?

Refer to the information of the Yellow loop press_decrease-u = TRUE? (page 3-6)

⇓

continued

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14.0 74 Cont’d.: 3. Green loop As soon as the time “_press_pause” elapsed, the green loop will be interrupted at item “r”, because than the answer is “YES” and the program continues with the green interrupted loop.

Item i)

r) s)

query press_decrease.u = TRUE?

Yes If the switch off pressure is reached

Pressdecrease-u > 5 min?

Time is elapsed Lube system pressure relieved ? Contact of B43 is closed ⇒ 0 V at E13.1

No During pause time ⇒ switch off pressure is not reached Contact of 8B43 still open ⇒ 24 V at E13.1

Starting at point No 3, the Green loop cycles from point (32) to point (32) again and again until the pressure is relieved.

Thereafter the Blue loop starts at point No 4. (to set the pause time and the “4-hour last-lube monitoring” back to 0sec, and to add 1cycle to the lube counter at item “t”) (see next pages)

continued

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ECS

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14.0 76 Cont’d.: Detailed explanation of “u:=1” i.e. lube system superstructure.

4. Blue loop As soon as the pressure is relieved, the green loop will be interrupted at item “s”, because than the answer is “YES” and the program continues with the blue loop.

Item query s) Lube system pressure relieved ?

Yes No Contact of B43 Contact of 8B43 open closed ⇒ 0 V at E5.2 ⇒ 24 V at E5.2 settings Switch off lube pump (No Voltage at output A5.7)

t) m)

pause

Item a)

query Grease barrel empty?

⇓

⇓

i)

press_decrease.u = TRUE?

Pressure increase

Pressure decrease

Yes

settings

No Refer to the information of the Yellow loop

pause

The complete normal Lubrication cycle is finished and the Pause time starts i

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ECS

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Appendix Page 0

Appendix

Table of contents Appendix Section Appendix

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2

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