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Manual
PC5500-6
HYDRAULIC MINING SHOVEL
SERIAL NUMBERS
This material is proprietary to Komatsu Mining Germany GmbH and is not to be reproduced, used, or disclosed except
in accordance with written authorization from Komatsu Mining Germany GmbH.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on products
sold previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
December 2006
06.10.05
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.
APPENDIX
SAFTEY
SAFTEY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The
service and repair techniques recommended by Komatsu and described in this manual
are both effective and safe. Some of these techniques require the use of tools specially
designed by Komatsu for the specific purpose.
The following Symbols are used in this Manual to designate Instructions of
particular Importance.
WARNING -
CAUTION -
NOTE -
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE
MANUAL carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read all the precautions given on the decals
which are fixed to the machine.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons missing.
Always wear safety glasses when hitting parts with a hammer.
Always wear safety glasses when grinding parts with a grinder, etc.
continued
00-1
SAFTEY
SAFTEY NOTICE
Cont'd:
GENERAL PRECAUTIONS
3. If welding repairs are needed, always have a trained, experienced welder carry out the
work. When carrying out welding work, always wear welding gloves, apron, glasses, cap
and other clothes suited for welding work.
4. When carrying out any operation with two or more workers, always agree on the
operating procedure before starting. Always inform your fellow workers before starting
any step of the operation. Before starting work, hang UNDER REPAIR signs on the
controls in the operator's compartment.
5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the
tools and parts in their correct places. Always keep the work area clean and make sure
that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking.
Never smoke while working.
PREPARATIONS FOR WORK
7. Before adding oil or making repairs, park the machine on hard, level ground, and block
the wheels or tracks to prevent the machine from moving.
8. Before starting work, lower bucket, hammer or any other work equipment to the ground.
If this is not possible, insert the safety pin or use blocks to prevent the work equipment
from falling. In addition, be sure to lock all the control levers and hang warning signs on
them.
9. When disassembling or assembling, support the machine with blocks, jacks or stands
before starting work.
10. Remove all mud and oil from the steps or other places used to get on and off the machine.
Always use the handrails, ladders or steps when getting on or off the machine. Never
jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a
stand to provide safe footing.
PRECAUTIONS DURING WORK
11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs,
loosen
them
slowly
to
prevent
the
oil
from
spurting
out.
Before disconnecting or removing components of the oil, water or air circuits, first
remove the pressure completely from the circuit.
12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to
get burned.
Wait for the oil and water to cool before carrying out work on the oil or water circuits.
continued
00-2
SAFTEY
SAFTEY NOTICE
Cont'd:
PRECAUTIONS DURING WORK
13. Before starting work, remove the leads from the battery. ALWAYS remove the lead from
the negative (-) terminal first.
14. When raising heavy components, use a hoist or crane.
Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity.
Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly
to prevent the component from hitting any other part. Do not work with any part still
raised by the hoist or crane.
15. When removing covers which are under internal pressure or under pressure from a spring,
always leave two bolts in position on opposite sides. Slowly release the pressure, then
slowly loosen the bolts to remove.
16. When removing components, be careful not to break or damage the wiring, Damaged
wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to
the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can
even start fires.
18. As a general rule, do not use gasoline to wash parts.
19. Be sure to assemble all parts again in their original places. Replace any damaged part
with new parts.
When installing hoses and wires, be sure that they will not be damaged by contact
with other parts when the machine is being operated.
20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes
are dangerous, so be extremely careful when installing tubes for high pressure circuits.
Also check that connecting parts are correctly installed.
21. When assembling or installing parts, always use the specified tightening torques. When
installing protective parts such as guards, or parts which vibrate violently or rotate at high
speed, be particularly careful to check that they are installed correctly.
22. When aligning two holes, never insert your fingers or hand. Be careful not to get your
fingers caught in a hole.
23. When measuring hydraulic pressure, check that the measuring tool is correctly assembled
before taking any measurements.
24. Take care when removing or installing the tracks of track-type machines. When removing
the track, the track separates suddenly, so never let anyone stand at either end of the
track.
00-3
SAFTEY
SAFTEY NOTICE
FOREWORD
GENERAL
00-4
FOREWORD
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Heavy parts (25 kg or more) must be lifted with a hoist etc.
WIRE ROPES
1. Use adequate ropes depending on the weight of parts to be hoisted, referring
to the table below:
Wire ropes
(Standard "Z" or "S" twist ropes without galvanizing)
Rope diameter
[mm]
10,0
11,2 12,5 14,0 16,0 18,0 20,0 22,4 30,0 40,0 50,0 60,0
Allowable
load [tons]
1,0
1,4
1,6
2,2
2,8
3,6
4,4
5,6
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.
Cont'd:
00-5
continued
FOREWORD
HOISTING INSTRUCTIONS
WIRE ROPES
3. Do not sling a heavy load with one rope alone, but sling with two or more
ropes symmetrically wound on to the load.
Slinging with one rope may cause turning of the load during hoisting,
untwisting of the rope, or slipping of the rope from its original
winding position on the load, which can result in a dangerous
accident.
4. Do not sling a heavy load with ropes forming a wide hanging angle from the
hook. When hoisting a load with two or more ropes, the force subjected to
each rope will increase with the hanging angles. The table below shows the
variation of allowable load (kg) when hoisting is made with two ropes, each of
which is allowed to sling up to 1000 kg vertically, at various hanging angles.
When two ropes sling a load vertically, up to 2000 kg of total weight can be
suspended. This weight becomes 1000 kg when two ropes make a 120
hanging angle. On the other hand, two ropes are subject to an excessive force
as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150.
00-6
FOREWORD
Bolt
dia.
Wrench
size [mm]
Tightening torque
[Nm]
Quality grades
8.8
10.9
12.9
M 8
13
21
31
36
M 10
17
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
00-7
FOREWORD
CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE
The Conversion Table in this section is provided to enable simple conversion of
figures. For details of the method of using the Conversion Table, see the example
given below.
EXAMPLE
Method of using the Conversion Table to convert from millimeters to inches.
1. Convert 55 mm into inches.
(a) Locate the number 5 in the vertical column at the left side, take this as (A),
then draw a horizontal line from (A).
(b) Locate the number 5 in the row across the top, take this as (B), then draw a
perpendicular line down from (B).
(c) Take the point where the two lines cross as (C). This point (C) gives the
value
when
converting
from
millimeters
to
inches.
Therefore, 55 millimeters = 2.165 inches.
2. Convert 550 mm into inches.
(a) The number 550 does not appear in the table, so divide by 10 (move the
decimal one place to the left) to convert it to 55 mm.
(b) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(c) The original value (550 mm) was divided by 10, so multiply 2.165 inches
by 10 (move the decimal one place to the right) to return to the original
value. This gives 550 mm = 21.65 inches.
00-8
FOREWORD
00-9
CONVERSION TABLE
FOREWORD
CONVERSION TABLE
00-10
FOREWORD
00-11
CONVERSION TABLE
FOREWORD
CONVERSION TABLE
00-12
FOREWORD
CONVERSION TABLE
-0
-1
-2
-3
-4
-5
-6
-7
-8
-9
-50
80,31
79,91
79,51
79,11
78,72
78,32
77,92
77,52
77,13
76,73
-40
84,27
83,88
83,48
83,08
82,69
82,29
81,89
81,50
81,10
80,70
-30
88,22
87,83
87,43
87,04
86,64
86,25
85,85
85,46
85,06
84,67
-20
92,16
91,77
91,37
90,98
90,59
90,19
89,80
89,40
89,01
88,62
-10
96,09
95,69
95,30
94,91
94,52
94,12
93,73
93,34
92,95
92,55
100,00
99,61
99,22
98,83
98,44
98,04
97,65
97,26
96,87
96,48
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
124,77
125,16
125,54
125,92
126,31
126,69
70
127,07
127,45
127,84
128,22
128,60
128,98
129,37
129,75
130,13
130,51
80
130,89
131,27
131,66
132,04
132,42
132,80
133,18
133,56
133,94
134,32
90
134,70
135,08
135,46
135,84
136,22
136,60
136,98
137,36
137,47
138,12
100
138,50
138,88
139,26
139,64
140,02
140,39
140,77
141,15
141,53
141,91
110
142,29
142,66
143,04
143,42
143,80
144,17
144,55
144,93
145,31
145,68
120
146,06
146,44
146,81
147,19
147,57
147,94
148,32
148,70
149,07
149,45
130
149,82
150,20
150,57
150,95
151,33
151,70
152,08
152,45
152,83
153,20
140
153,58
153,95
154,32
154,70
155,07
155,45
155,82
156,19
156,57
156,94
150
157,31
157,69
158,06
158,43
158,81
159,18
159,55
159,93
160,30
16067
00-13
FOREWORD
CONVERSION TABLE
TEMPERATURE
Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit
temperature reading into a Centigrade temperature reading or vise versa is to enter
the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the
center column as a table of Fahrenheit temperatures and read the corresponding
Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the
center column as a table of Centigrade values, and read the corresponding
Fahrenheit temperature on the right.
00-14
Section 1.0
Page 1
Section
1.0
06.10.05
Page
Main assembly groups
General lay out
1.1
Superstructure
1.1.1
Machine house
1.1.2
1.1.3
1.1.4
Fuel Tank
1.1.5
Counter weight
1.1.6
Cab support
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.
14
1.3.2.
15
PC5500-6-D_Sec_1-0_rev4.doc
1.0
2
06.10.05
PC5500-6-D_Sec_1-0_rev4.doc
1.
Section 1.0
Page 2
General layout
Legend for illustration (Z 22387):
(1)
Superstructure
(2)
Under carriage
(3)
Front Shovel Attachment (FSA)
(4)
Backhoe Attachment (BHA)
06.10.05
PC5500-6-D_Sec_1-0_rev4.doc
1.0
3
06.10.05
PC5500-6-D_Sec_1-0_rev4.doc
Section 1.0
Page 3
1.1
Superstructure
Legend for illustration (Z 22386):
(1)
Operators Cab with integrated FOPS.
(2)
Exhaust
(3)
Air cleaner
(4)
Cab support (contains the electrical switch board)
(5)
Swing ring connection
(6)
Fuel reservoir
(7)
Hydraulic ladder
(8)
Counter weight
(9)
Hydraulic oil cooler with hydraulic driven fans
(10)
Hydraulic oil reservoir
(11)
Batteries
(12)
Swing Gear
(13)
Grease pump of the Central Lubrication System
(14)
Grease pump of the Swing gear pinion Lubrication System
(15)
Main Control blocks with high pressure filters
06.10.05
(16)
(17)
(18)
(19)
(20)
Engine 1
Flexible coupling, oil filled
PTO gear with hydraulic pumps
Main hydraulic pumps 1, 2 and 3
Radiator for the engine cooling system
(21)
(22)
(23)
(24)
(25)
Engine 2
Flexible coupling, oil filled
PTO gear with hydraulic pumps
Main hydraulic pumps 4, 5 and 6
Radiator for the engine cooling system
PC5500-6-D_Sec_1-0_rev4.doc
1.0
4
06.10.05
PC5500-6-D_Sec_1-0_rev4.doc
1.1
Section 1.0
Page 4
Superstructure
1.1.1
Machine house
06.10.05
PC5500-6-D_Sec_1-0_rev4.doc
1.0
5
06.10.05
PC5500-6-D_Sec_1-0_rev4.doc
1.1
Section 1.0
Page 5
Superstructure
1.1.2
06.10.05
PC5500-6-D_Sec_1-0_rev4.doc
06.10.05
Section 1.0
Page 6
PC5500-6-D_Sec_1-0_rev4.doc
1.1
Section 1.0
Page 6
Superstructure
1.1.3
06.10.05
PC5500-6-D_Sec_1-0_rev4.doc
1.0
7
06.10.05
PC5500-6-D_Sec_1-0_rev4.doc
1.1
Section 1.0
Page 7
Superstructure
1.1.4
06.10.05
PC5500-6-D_Sec_1-0_rev4.doc
1.0
8
06.10.05
PC5500-6-D_Sec_1-0_rev4.doc
Section 1.0
Page 8
1.1
Superstructure
1.1.5
Counter weight
Mounting bolts
Quantity
16
06.10.05
Bolt size
(mm)
M 48 x 380
SW = Wrench size
(3)
Lifting points
Grade
SW*
(mm)
10.9
75
Tightening
torque (Nm)
7500
PC5500-6-D_Sec_1-0_rev4.doc
1.0
9
06.10.05
PC5500-6-D_Sec_1-0_rev4.doc
Section 1.0
Page 9
1.1
Superstructure
1.1.6
Cab support
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)
06.10.05
Door
Gasket
Door handle (adjustable)
PC5500-6-D_Sec_1-0_rev4.doc
1.0
10
06.10.05
PC5500-6-D_Sec_1-0_rev4.doc
1.1
Section 1.0
Page 10
Superstructure
1.1.7
Operators cab
Monitor panel
Switch panel
Operators seat
Control lever
EURO Control
KMG Control
(E20)
Control lever
EURO Control
KMG Control
(E21a)
Control pedal
A - forward
Left track
B - reverse
(E21b)
Control pedal
A - forward
Right track
B - reverse
(E22)
(E23)
(E24)
06.10.05
Clam closing
Clam opening
PC5500-6-D_Sec_1-0_rev4.doc
1.0
11
06.10.05
PC5500-6-D_Sec_1-0_rev4.doc
1.1
Section 1.0
Page 11
Superstructure
1.1.8
Control blocks
06.10.05
PC5500-6-D_Sec_1-0_rev4.doc
1.0
12
06.10.05
PC5500-6-D_Sec_1-0_rev4.doc
1.1
Section 1.0
Page 12
Superstructure
1.1.9
Swing gears
06.10.05
PC5500-6-D_Sec_1-0_rev4.doc
1.0
13
06.10.05
PC5500-6-D_Sec_1-0_rev4.doc
1.2
Section 1.0
Page 13
Under carriage
Legend for illustration (Z 21481):
(1)
Undercarriage center body
(2)
Crawler carrier R.H.-side
(3)
Crawler carrier L.H.-side
(4)
Connecting bolts, between center body and crawler carriers
(5)
Crawler tracks
(6)
Rotary distributor
(7)
Brake valves
(8)
Travel motors
(9)
Parking brakes, spring loaded disk type brakes
(10) Travel gear
(11) Sprocket
(12) Track rollers
(13) Carrier rollers
(14) Guide wheel (Idler)
06.10.05
PC5500-6-D_Sec_1-0_rev4.doc
1.0
14
06.10.05
PC5500-6-D_Sec_1-0_rev4.doc
1.3
Section 1.0
Page 14
Attachment
1.3.1
06.10.05
PC5500-6-D_Sec_1-0_rev4.doc
06.10.05
Section 1.0
Page 15
PC5500-6-D_Sec_1-0_rev4.doc
1.3
Section 1.0
Page 15
Attachment
1.3.2
06.10.05
PC5500-6-D_Sec_1-0_rev4.doc
Drive
Section 2.0
Page 1
Section
2.0
Page
Prime drive assembly
General lay out
2.1
3+4
2.2
Coupling
2.3
Air filter
2.4
7+8
2.5
9 + 10
2.6
11
2.7
Pump-spline lubrication
12
2.8
13 + 14
2.9
15
2.0
2
Drive
2.0
Section 2.0
Page 2
Engine 2
Torsion type coupling
Pump distributor gear (PTO)
(5)
Power frame
General
The drive unit, consists of the two PTO gear and the two engines, are bolted
to the power frame.
The connection between engine and PTO gear is a flexible coupling.
2.0
3
Section 2.0
Page 3
Drive
2.1
4 per mount
(3)
Tie bolt
Quantity
4
(4)
(5)
(6)
Quantity
Quantity
Nut
Bolt
Quantity
10
(11)
Bolt
Quantity
16
(12)
(13)
Bolt size
(mm)
M 24 x420
Bolt size
(mm)
M 16x 80
(9)
(10)
M 10 x35
Grade
SW*
(mm)
8.8
17
Grade
SW*
(mm)
10.9
36
(7)
(8)
Bolt size
(mm)
Bolt size
(mm)
M 36 x250
Bolt size
(mm)
M 24 x 230
Bolt size
(mm)
M 20 x 120
Resilient sleeve
Bolt
Quantity
4
Bolt size
(mm)
M 30 x 200
(14)
Resilient sleeve
SW = Wrench size
Grade
SW*
(mm)
10.9
24
Grade
SW*
(mm)
10.9
55
Grade
SW*
(mm)
10.9
36
Grade
SW*
(mm)
10.9
30
Grade
SW*
(mm)
10.9
46
Tightening
torque (Nm)
43
Tightening
torque (Nm)
snugly
Tightening
torque (Nm)
265
Tightening
torque (Nm)
Not specified
Tightening
torque (Nm)
880
Tightening
torque (Nm)
510
Tightening
torque (Nm)
1770
continued
2.0
4
Drive
Section 2.0
Page 4
Cont'd
2.1
Check all flexible bearings (1) for engine and pump distributor gear.
Check the flexible bearings for damage and signs of fatigue. Make sure that there
is no contact between the upper and lower metal brackets of the flexible bearings
(1). Replace the bearings if necessary. Use new bolts and self locking nuts (2).
After new flexible bearings have been installed, check distance (B) on both torque
supports.
All flexible bearings (1) and all rubber-bounded metal bars (4) should
be replaced during engine overhaul.
Check distance (B) between torque support and stop bolt (8).
With setting of the flexible engine bearings (1) the distance (B) increases and
must be readjusted. To do this, loosen lock nut (9) and tighten stop bolt (8) until
the correct distance (B) is obtained. Tighten lock nut (9) and recheck distance (B).
If new flexible engine bearings (1) have been installed, replace also cup springs
(7) and adjust distance (B) to 29 mm.
Check tie bolts (3) on front and rear carrier units for looseness.
(four tie bolts)
Check to make sure that the self locking retainer nuts (5) are tight and that there is
no gap between nut and rubber-bounded metal bar (4). If necessary retighten
retainer nuts (5) snugly.
Check rubber-bounded metal bars (4) for signs of fatigue and damage.
Replace as necessary.
2.0
5
Drive
2.2
Section 2.0
Page 5
Coupling
Legend for illustration (Z 21602):
(1)
Coupling Assy.
(2)
Input drive flange
(3)
Leave spring assy.
(4)
Output drive flange
(5)
Dip stick
(6)
Bleeder plug
(7)
O-Rings
(8)
Spacers
E
Engine side
G
Gearbox side (PTO-side)
Task:
The coupling is the connecting link between the engine and the PTO
Function: "GEISLINGER COUPLING"
The combination of the high elasticity of its leaf springs with complimentary
viscous damping by oil displacement, ensures that the coupling reduces the
intensity of torsional vibrations effectively.
The widest engine speed range free of vibration periods and dangerous
resonances is thus obtained.
The springs (3) together with the inner driving and outer driven member form
chambers A and B which are filled with oil.
If the outer member is displaced in relation to the inner member, the
deflection of the leaf springs displaces oil from one chamber to the next, by
this action the relative movements of the two members of the coupling are
braked and the vibrations are dampened.
The spacers (8) limits the movement of the leaf springs.
2.0
6
Drive
2.3
Section 2.0
Page 6
Air Filter
Legend for illustration (Z 22396):
(1)
Wing nut
(2)
Washer
(3)
Seal ring
(4)
Main filter element
(5)
Cotter pin
(6)
Wing nut with service indicator
(7)
Safety element
(8)
Maintenance switch
(9)
Flap for pre-separator
(10)
Air intake with pre-separation
The air is filtered by a dry-air-filter with pre-separator for coarse impurities.
One filter housing includes 2 filter sets. Each one consists of a main filter
element (4) and a safety element (7).
The filter condition is monitored by the maintenance switch (8).
A fault message like Engine air filter restricted is displayed at the
operator's dash board as soon as the restriction is too high.
The wing nut (6) incorporates a service indicator.
Green indication = O.K.
Red indication
= safety element (7) needs maintenance.
The indication mark must be re-set by blowing through the nut opposite to the
normal air flow or by sucking at the other end, this can be done with the
mouth.
2.0
7
Drive
2.4
Section 2.0
Page 7
continued
2.0
8
Drive
Section 2.0
Page 8
Cont'd
2.4
2.0
9
Drive
Section 2.0
Page 9
Cont'd
(148.13 / 148.14) and the pressure reduction valve (169.1 / 169.4). The 4/3 direction
flow valve (148.13 / 148.14) with the solenoids (Y14A-1 and Y14B-1 / Y14A-2 and
Y14B-2) operates depending on engine coolant temperature.
The PLC (Programmable Logic Control) in the cab support controls the 4/3 direction
valve (148.13 / 148.14) by activating the solenoids (Y14A-1 and Y14B-1 / Y14A-2
and Y14B-2), depending on the engine coolant temperature.
With de-energized solenoids the fan turn with max. speed.
With activated solenoid (Y14A-1 / Y14A2) the fan is running with a very low speed,
caused by the flow resistance only.
With activated solenoid (Y14B-1 / Y14B2) the fan is running with middle setted
speed, caused by the reduced pilot pressure on port X of pressure relief valve (168.3 /
168.4) with the pressure reduction valve (169.1 / 169.4).
2.0
10
Drive
2.5
Section 2.0
Page 10
2.0
11
Drive
Section 2.0
Page 11
Cont'd
2.5
Increase the output flow of pump P ,by adjusting the swivel angle,
until the fan speed will be 20 min-1 higher than required:
To do this, loosen both lock nuts (6.1 + 7.1) and turn in bolt (6) and
turn out bolt (7) the same length.
This is necessary to avoid a loose positioning pin (10), resulting in
oscillating of the cylinder barrel.
Tighten the lock nuts (6.1 + 7.1).
Do not exceed the maximum permissible operating pressure of 230 bar
continued
2.0
12
Drive
Section 2.0
Page 12
Cont'd
8.
9.
Loosen lock nut (2) of the relief valve (168.x), and decrease the
pressure with set screw (3) until the correct fan speed is obtained.
Tighten lock nut (2) and fix protection cap (3).
If the speed can not be raised by increasing the pressure then increase the
output flow of pump (10.x).
*)
Prepare a test wire with a plug ET-No. 891 039 40, and a
plug ET-No. 440 305 99. Connect terminal 1 to positive (+)
(center off plug 440 305 99) and terminal 2 to ground (-).
2.0
13
Drive
2.6
Section 2.0
Page 13
2.0
14
Drive
2.7
Section 2.0
Page 14
Pump-spline lubrication
Drive shaft housings
Legend for illustration (Z 21608):
(1)
Oil filler plug with breather pipe of main pump drive shaft housing
(2)
Oil collector reservoir for auxiliary pump drive shaft housing
(M)
Configuration, main pump drives
(A)
Configuration, auxiliary pump drives
All drive shaft housings are filled with the same gear oil as the pump
distributor gear.
This is done for two reasons:
1. To lubricate the multi-spline connections, to prevent wear and corrosion.
2. It makes it easier to determine a seal ring leak at one of the drive shaft
connections.
Function:
M
If the oil level increases the oil drops out of the breather pipe (1).
If this oil is gear oil it indicates a possible leak at the gearbox side.
If the oil is a mixture of gear oil and hydraulic oil it shows a possible
leak at the pump side.
If at an oil level check a loss of oil is found it may be due to worn or
defective radial seal rings.
Function:
A
The oil is filled in via the oil collector reservoir (2). All auxiliary drive
shaft housings are connected by pipes with the reservoir. The reservoir
is filled approx. one half with oil.
If the oil level in the reservoir increases due to leakage the oil drops out
from the breather filter (with oil level gauge) on top of the reservoir.
Now a check has to be done to find out which one of the drive shafts
seals is damaged.
It can be done by disconnecting temporary the pipe to the reservoir.
Disconnect the pipe at the drive shaft housing, plug the pipe and leave
the union open.
If now at operation the oil still comes out of the union, this drive shaft
seal is gone.
Otherwise check sequential all auxiliary drives.
2.0
15
Drive
2.8
Section 2.0
Page 15
2.0
16
Section 2.0
Page 16
Drive
Contd.:
2.8
(8)
(9)
(B27-x)
(74.x)
(A)
(T)
Valve spring
Seal rings
Maintenance switch
Pressure relief valve
Pressure port
Return from valve
Adjustments:
The adjustment of the maximum permissible PTO lube pressure, has
to be carried out with cold oil to avoid serious damages to the coolers.
The check for a sufficient PTO lube pressure has to be carried out
with warm oil to avoid serious damages gearbox.
Setting the pressure relief valve (74.x) at cold oil.
1.
Connect a pressure gauge to check point (M1.x).
2.
Disconnect plug of solenoid valve Y53-1/ Y53-2
3.
Start the engine and let it run with max. speed.
4.
Maximum pressure: 7,5 bar.
If adjustment is required:
5.
Remove protection cap (1a).
6.
Loosen lock nut (1b).
7.
Set the pressure with set screw (1c).
8.
Tighten lock nut (1b) and re-install protection cap (1a)
9.
Reconnect plug of Y53-1/ Y53-2
If the pressure of 7,5 bar cannot be adj. 100 %, adj. to the highest
visible pressure.
2.0
17
Section 2.0
Page 17
Drive
2.9
= 500 cm/rev
= 700 Liter/min
= 1400 min-1
Vg max
Qmax
n
= 80 cm/rev
= 158 Liter/min
= 1973 min-1
Vg max
Qmax
n
= 80 cm/rev
= 142 Liter/min
= 1770 min-1
(8.1), (8.4)
Gear pump
theoretical flow rate
Drive speed*
for PTO gear lubrication
Vg
Qmax
n
= 58,7 cm/rev
= 82,2 Liter/min
= 1400 min-1
(8.2), (8.5)
Gear pump
theoretical flow rate
Drive speed*
Vg
Qmax
n
= 85,7 cm/rev
= 120 Liter/min
= 1400 min-1
Vg
Qmax
n
= 85,7 cm/rev
= 120 Liter/min
= 1400 min-1
Gear pump
theoretical flow rate
Drive speed*
for pilot pressure supply
Section 3.0
Page 1
Page
Hydraulic oil reservoir
General lay out
3.1
3.2
3.3
3.4
3.6
3.7
Breather Filter
3.5
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3.0
&2
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3.
Section 3.0
Page 2
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3.0
&3
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3.1
Section 3.0
Page 3
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3.0
&4
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3.2
Section 3.0
Page 4
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3.0
&5
25.03.03
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Section 3.0
Page 5
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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3.0
&6
25.03.03
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3.4
Section 3.0
Page 6
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 anticavitation 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
F
25.03.03
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3.0
&7
25.03.03
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3.6
Section 3.0
Page 7
25.03.03
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
PC5500-6-D_Sec_3-0_rev0.doc
3.0
&8
25.03.03
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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
25.03.03
PC5500-6-D_Sec_3-0_rev0.doc
Section 4.0
Page 1
Section
4.0
06.10.05
Page
Hydraulic oil cooling
4.1
General
4.2
4.3
4.4
5+6
4.5
7+8
4.6
4.7
9
10
12
PC5500-6-D_Sec_4-0_rev3.doc
4.0
2
06.10.05
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4.1
Section 4.0
Page 2
General
The hydraulic oil cooling system maintains the hydraulic oil at a normal
operating temperature.
Legend for illustration (Z 21594)
(1)
Noise shield
(1)
Cooler (Radiator)
(2)
Cooler frame
(3)
Fan
(4)
Fan motor (Axial piston motor)
(5)
Bolt
(6)
Bolt
(7)
Drive shaft
(8)
Shaft protecting Sleeve
(9)
Drive shaft seal
(10)
Ball bearings
(11)
Seeger clip ring
(12)
Bearing group carrier
(13)
Oil level plug
(14)
Breather filter
Design:
There are four* hydraulic oil coolers in front of the hydraulic tank on the
R.H. side of the platform.
They are in pairs mounted in one frame, one above the other. The air stream
needed for the cooling is produced by hydraulic driven fans. The air flows
from inside to outside through the coolers.
For a better cleaning, the coolers can be moved to the side. (Swing out
cooler)
The bearing group carrier is filled with oil to lubricate the bearings.
06.10.05
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4.0
3
06.10.05
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4.2
Section 4.0
Page 3
06.10.05
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4.0
4
06.10.05
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Section 4.0
Page 4
4.3
06.10.05
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4.0
5
06.10.05
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4.4
Section 4.0
Page 5
06.10.05
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4.0
6
06.10.05
PC5500-6-D_Sec_4-0_rev3.doc
Section 4.0
Page 6
Function:
From pump (10.x) flows the oil through the filter (68.x) to the fan motor (22.x) and
then back to the tank.
The check valve (103.x) act as an anti cavitation valve and is installed, because the
fan motor -driven by inertial force- is running for a short period after the oil flow is
interrupted by solenoid valve (Y6A-x/Y6B-x) or if the engine has been switched off.
The hydraulic circuit "Fan drive" is secured by the pilot controlled pressure relief
valves (168.x) and (169.x).
These valves are working together with the solenoid valve (Y6A-x/Y6B-x),
controlled by the PLC, depending on the hydraulic oil temperature:
With de-energized solenoids Y6A-x and Y6B-x the relief valve (168.x) is
functioning and the fans are running with max. adjusted speed (1300 RPM)
With solenoid Y6A-x energized the relief valve (168.x) is not functioning and
the fans are running with a very low speed caused by the flow resistance only.
With solenoid Y6b energized the relief valve (169.x) is controlling the relief
valve (168.x) and the fans are running with 1000 RPM only.
(See also description on next page)
06.10.05
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4.0
7
06.10.05
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4.5
Section 4.0
Page 7
continued
06.10.05
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4.0
8
06.10.05
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Section 4.0
Page 8
Contd.
4.5
06.10.05
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4.0
9
06.10.05
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4.6
Section 4.0
Page 9
06.10.05
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4.0
10
06.10.05
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4.7
Section 4.0
Page 10
A blocked cooler, restricted air flow, defect cooler seal or bend fan
influence the fan RPM and air volume.
Basic adjustment has to be carried out whenever one of the following
components has been replaced:
- pump
- relief valve
- hydraulic motor
continued
06.10.05
PC5500-6-D_Sec_4-0_rev3.doc
4.0
11
06.10.05
PC5500-6-D_Sec_4-0_rev3.doc
Section 4.0
Page 11
Cont'd
4.7
Increase the output flow of pump P ,by adjusting the swivel angle, until
the fan speed will be 20 min-1 higher than required:
To do this, loosen both lock nuts (6.1 + 7.1) and turn in bolt (6) and
turn out bolt (7) the same length.
This is necessary to avoid a loose positioning pin (10), resulting in
oscillating of the cylinder barrel.
Tighten the lock nuts (6.1 + 7.1).
Do not exceed the maximum permissible operating pressure of
230 bar
Note down the lengths L1 and L2 as reference measurements.
continued
06.10.05
PC5500-6-D_Sec_4-0_rev3.doc
4.0
12
06.10.05
PC5500-6-D_Sec_4-0_rev3.doc
Section 4.0
Page 12
Cont'd
8.
9.
Loosen lock nut (2) of the relief valve (168.x), and decrease the
pressure with set screw (3) until the correct fan speed is obtained.
Tighten lock nut (2) and fix protection cap (3).
If the speed can not be raised by increasing the pressure then increase the
output flow of pump (10.x).
*)
06.10.05
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 (-).
PC5500-6-D_Sec_4-0_rev3.doc
Controlling
Section 5.0
Page 1
Section
5.0
06.10.05
Page
Controlling
General lay out
5.1
5.2
47
5.3
5.4
9 + 10
5.5
11
5.6
12
5.7
13
5.8
14
5.9
15
5.10
16
5.11
17 + 18
5.12
19 + 20
5.13
21 + 23
PC5500-6-D_Sec_5-0_rev3.doc
5.0
2
X4 - pump support
pressure
X2
pilot pressure
X3 remote control
pressure (1/2Qmax; Qmin)
pump regulation
X1 - pump regulation
pressure
06.10.05
Z 22429
PC5500-6-D_Sec_5-0_rev3.doc
Controlling
5.0
Section 5.0
Page 2
06.10.05
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5.0
3
06.10.05
PC5500-6-D_Sec_5-0_rev3.doc
Section 5.0
Page 3
Controlling
5.1
Control and filter panel location of components Legend for illustration (Z 22497):
Solenoid valves
Engine 1
Engine 2
(Y5)
(Y6A-1)
(Y6A-2)
(Y14A-1)
(Y14B-1)
(Y6B-1)
(Y6B-2)
(Y14A-2)
(Y14B-2)
(Y16)
(Y17)
(Y17a)
(Y127)
(Y61.1)
(Y61.2)
(Y102.1)
(Y102.2)
(Y124A/B)
(Y124c)
(Y48)
(Y120)
(Y123A/B)
(Y125)
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)
(M1.2)
(M2)
(M3)
(M5.1)
(M5.2)
(M6)
(M7)
(M11)
(M18)
(M19.1)
(M20.1)
(M19.2)
(M20.2)
(M30)
(M32)
(M40)
Filter:
(68.1)
(68.2)
(68.3)
(69.1)
(68.4)
(68.5)
(69.2)
continued
06.10.05
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5.0
4
06.10.05
PC5500-6-D_Sec_5-0_rev3.doc
Controlling
5.2
Section 5.0
Page 4
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
06.10.05
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5.0
5
06.10.05
PC5500-6-D_Sec_5-0_rev3.doc
Controlling
Section 5.0
Page 5
Contd.:
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.
06.10.05
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5.0
6
06.10.05
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Controlling
Section 5.0
Page 6
Cont'd:
5.2
06.10.05
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5.0
7
06.10.05
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Controlling
5.2
Section 5.0
Page 7
06.10.05
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5.0
8
06.10.05
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Section 5.0
Page 8
Controlling
5.3
No.
45.1
45.2
45.3
43
06.10.05
Solenoid Proportional
valve
valve
Function
FSA
BHA
Y20a
Y20b
Y20
Y21a
Y21b
Y21
Stick extending
Stick retracting
Y22a
Y22b
Y22
Y23a
Y23b
Y23
Boom raising
Boom lowering
Y24a
X24b
Y24
Clam closing
Clam opening
Y25a
Y25b
Y25
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
Y29a
Y29b
Y29
Boom raising
Boom lowering
Y30a
Y30b
Y30
Y31a
Y31b
Y31
Stick extending
Stick retracting
Y32a
Y32b
Y32
R.H. Swing
L.H. Swing
PC5500-6-D_Sec_5-0_rev3.doc
5.0
9
06.10.05
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Controlling
5.4
Section 5.0
Page 9
06.10.05
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5.0
10
06.10.05
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Controlling
Section 5.0
Page 10
Cont'd:
5.4
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5.0
11
06.10.05
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Controlling
5.5
Section 5.0
Page 11
06.10.05
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5.0
12
06.10.05
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Section 5.0
Page 12
Controlling
5.6
06.10.05
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5.0
13
06.10.05
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Controlling
5.7
Section 5.0
Page 13
06.10.05
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5.0
14
06.10.05
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Controlling
5.8
Section 5.0
Page 14
06.10.05
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5.0
15
06.10.05
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Controlling
5.9
Section 5.0
Page 15
06.10.05
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5.0
16
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Section 5.0
Page 16
Controlling
5.10
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.
06.10.05
"a"
"b"
mA
VDC
"c" "d"
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Controlling
5.11
Section 5.0
Page 17
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18
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Controlling
Section 5.0
Page 18
Cont'd:
5.11
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.
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Controlling
5.12
Section 5.0
Page 19
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20
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Section 5.0
Page 20
Controlling
Cont'd:
5.12
)
10.
11.
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21
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Controlling
5.13
Section 5.0
Page 21
Basic Adjustment:
1.
Connect 0 VDC with a test lead from the red positive terminal of the
service module (6) to terminal 5 of the Ramp Time Module (3) and
adjust with "Pot Z" a value of 0 VDC measured at terminal 7.
Disconnect the test lead after the setting is done.
2.
Connect +10 VDC with a test lead from the red positive terminal of
the service module (6) to terminal 5 of the Ramp Time Module (3)
and adjust with "Pot G" a value of 10 VDC measured at terminal 7.
Check the negative voltage as well(- 10 VDC). Disconnect the test
lead after the setting is done.
Repeat settings of item 1 and 2 until both values are stabilized, because
"Pot Z" and "Pot G" influence each other.
The factory setting of potentiometer "w1" to "w4" for the command
value call-ups must not be adjusted.
continued
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Section 5.0
Page 22
Controlling
Cont'd:
5.13
Proportional-Amplifier-Module
Relay (Supply Voltage)
4.
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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23
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Section 5.0
Page 23
Controlling
Cont'd:
5.13
E48 Stick
24 Volt at
Pot
Terminal 9
0V to +10V
t1
Terminal 10
+10V to 0V
t2
5,00 Volt = 20 ms
Terminal 11
Neutral Stick in
0V to -10V
t3
Terminal 12
Stick in Neutral
-10V to 0V
t4
5,00 Volt = 20 ms
Pot
E49 Boom
24 Volt at
Terminal 9
Neutral Lower
0V to +10V
t1
Terminal 10
Lower Neutral
+10V to 0V
t2
5,00 Volt = 20 ms
Terminal 11
Neutral Lift
0V to -10V
t3
Terminal 12
Lift Neutral
-10V to 0V
t4
5,00 Volt = 20 ms
Pot
E50 Swing
24 Volt at
Terminal 9
Neutral Swing R
0V to +10V
t1
Terminal 10
Swing R Neutral
+10V to 0V
t2
Terminal 11
Neutral Swing L
0V to -10V
t3
Terminal 12
Swing L Neutral
-10V to 0V
t4
Pot
Terminal 9
Neutral counter
swing right
0V to +10V
t1
Terminal 10
t2
5,000 Volt = 20 ms
Terminal 11
Neutral counter
swing left
0V to -10V
t3
Terminal 12
-10V to 0V
t4
5,000 Volt = 20 ms
continued
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24
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Section 5.0
Page 24
Controlling
Pot
Terminal 9
Neutral Forward
0V to +10V
t1
Terminal 10
Forward Neutral
+10V to 0V
t2
Terminal 11
Neutral
Backward
0V to -10V
t3
Terminal 12
Backward
Neutral
-10V to 0V
t4
Pot
Terminal 9
Neutral
Backward
0V to +10V
t1
Terminal 10
Backward
Neutral
+10V to 0V
t2
Terminal 11
Neutral Forward
0V to -10V
t3
Terminal 12
Forward Neutral
-10V to 0V
t4
Pot
Terminal 9
Neutral Fill
0V to +10V
t1
Terminal 10
Fill Neutral
+10V to 0V
t2
5,00 Volt = 20 ms
Terminal 11
Neutral Dump
0V to -10V
t3
Terminal 12
Dump Neutral
-10V to 0V
t4
5,00 Volt = 20 ms
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Section 6.0
Page 1
Components
Section
6.0
Page
Components
6.1
06.10.05
Hydraulic
6.1.1
Main Control Blocks and High Pressure Filter FSA
2-3
6.1.2
4-5
6.1.3
6.1.4
6.1.5
6.1.6
6.1.7
10
6.1.8
11
6.1.9
12
6.1.10
13
6.1.11
6.1.12
18
6.1.13
19
6.1.14
20
6.1.15
21
6.1.16
22
14-17
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2
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Section 6.0
Page 2
Components
6.1.1
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3
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Section 6.0
Page 3
Components
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6.0
4
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Section 6.0
Page 4
Components
6.1.2
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5
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Section 6.0
Page 5
Components
Contd
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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6
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Components
6.1.3
Section 6.0
Page 6
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7
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Components
6.1.4
Section 6.0
Page 7
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8
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Components
6.1.5
Section 6.0
Page 8
Adjustment spindle
O-ring with back-up ring
Retainer
O-ring with back-up ring
Spring
(8)
(9)
(10)
(11
(12)
(13)
(14)
(15)
(16)
A+B
M
Y
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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9
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Components
6.1.6
Section 6.0
Page 9
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10
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Components
6.1.7
Section 6.0
Page 10
Function:
The electric-hydraulic control system is used to control the direction and
volume of oil flow to the operating cylinders and motors via the main control
valve blocks.
When a lever (or pedal) is actuated, a proportional solenoid valve (13) and
one of the directional solenoid valves (12 either a or b) are energized, and
allows the pilot pressure oil to flow to the spools of the main control blocks.
The proportional solenoid valve alters the pilot pressure, proportional to the
lever deflection, this results a spool movement between neutral and full
stroke position.
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Components
6.1.8
Section 6.0
Page 11
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12
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Components
6.1.9
Section 6.0
Page 12
(5)
(6)
(7)
(8)
Function:
In un-operated condition the control spool (2) is held in the neutral or starting
position by reset springs.
The control spool (2) is directly operated by the proportional solenoid (1).
If the solenoid is energized, it produces a force to operate the control spool (2) via
the pressure measuring spool (4) and moves the spool to the left. Oil flows from P
to A. As pressure in A increases, it passes via the radial borings in the control
spool (2) to the inner end of the pressure measuring spool (2).
The force generated by the pressure now works against the solenoid force and
pushes the control spool (2) to the right (closing direction) until a balance is
achieved between the two forces. In order to achieve this, the pressure measuring
spool (2) moves to the left until it is supported by the pin (5).
When the force balance is achieved, the connection between P and A is interrupted
and the pressure in line A is held constant.
Any reduction in the solenoid force leads to the pressure force exceeding the
solenoid force on the control spool (2). The control spool is then moved to the right
causing a connection from A to T allowing the pressure to fall until a balance is reestablished at a lower level.
At rest, when the solenoid is de-energized, ports A and B are open to tank, whilst
port P is blocked from both ports A and B.
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13
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Components
6.1.10
Section 6.0
Page 13
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14
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Components
6.1.11
Section 6.0
Page 14
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15
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Components
6.1.11
Section 6.0
Page 15
(B)
06.10.05
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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16
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Components
6.1.11
Section 6.0
Page 16
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6.0
17
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Components
6.1.11
Section 6.0
Page 17
(9)
(10
(11)
(12)
(13) + 16)
(14)
(15)
(17)
Set screw
Lock nut
Spring, pilot part
Poppet
Jet bore
Spring, main cone
Main valve cone
Pilot oil dump line to tank
MRVs and SRVs are pilot operated relief valves. The MRV limits the max.
Pump supply line pressure. The SRV limits the max. possible pressure peak in
the service-line.
The valves have an opening characteristic. That means, that in case of
contamination after the response procedure no further pressure increasing is
possible and damages are avoided.
Function:
The circuit pressure P forces with the force F1 on the piston surface A of the
main valve cone (15). Because there is via the jet bore (16) the same pressure on
the back side of the main cone, this results together with the spring (14) force in
a force F2 that keeps the main cone closed. Via the jet bore (13) the circuit
pressure is in front of the poppet (12). Exceeds the circuit pressure the setting
value of the spring (11), the poppet opens against the force of the spring (11).
This causes that the force F2 decreases and there is no more balance condition
between F1 and F2. Valve cone (15) is moved upwards by the greater force F1.
That means there is now a direct connection from port P to T (tank).
ACVs serve for compensation possible lack of feed when the SRV at the
opposite port is actuated (see circuit diagram) and for avoiding cavitation
damages. In addition, to supply a user in case it is continuously moved by
acceleration forces at zero position of the control spool.
Function:
The circuit pressure inside the spring chamber closes the valve cone (7).
The back pressure of the return line acts on the surface of the valve cone (7).
Whenever the pressure in the service-line is lower than the springs force the
valve cone opens by the force of the back pressure and hydraulic oil is additional
supplied.
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Components
6.1.12
Section 6.0
Page 18
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19
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Components
6.1.13
Section 6.0
Page 19
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20
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Components
6.1.14
Section 6.0
Page 20
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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Components
6.1.15
Section 6.0
Page 21
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6.0
22
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Components
6.1.16
Section 6.0
Page 22
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Section 7.0
Page 1
Page
Main hydraulic pumps and pump regulation system
General
7.1
7.2
25
Main Pumps
7.1.1
Location of Pumps
7.1.2
7.1.3
Operating Principles
8 15
7.1.4
16 20
21
7.2.2
22
7.2.3
23
Method A -
24
7.3
06.10.05
25 + 26
27 + 28
29 + 30
31 + 32
- Language selection
33
34
35
36
7.3.2
37
7.4
38+39
7.5
40
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2
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Section 7.0
Page 2
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7.0
3
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PC5500-6-D_Sec_7-
Section 7.0
Page 3
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7.0
4
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Section 7.0
Page 4
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7.0
5
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Section 7.0
Page 5
Note:
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Section 7.0
Page 6
Main Pumps
7.1.1. Location of Pumps
Legend for illustration (Z 22415a):
(1 - 6)
= 500 cm/rev
= 700 Liter/min
= 1400 min-1
Vg max
Qmax
n
= 80 cm/rev
= 158 Liter/min
= 1973 min-1
Vg max
Qmax
n
= 80 cm/rev
= 142 Liter/min
= 1770 min-1
Gear pump
pump volume
theoretical flow rate
Drive speed*
for PTO gear lubrication
Vg
Qmax
n
= 58,7 cm/rev
= 82,2 Liter/min
= 1400 min-1
Gear pump
pump volume
theoretical flow rate
Drive speed*
for hydraulic oil circulation
Vg
Qmax
n
= 58,7 cm/rev
= 82,2 Liter/min
= 1400 min-1
Gear pump
pump volume
theoretical flow rate
Drive speed*
for pilot pressure supply
Vg
Qmax
n
= 85,7 cm/rev
= 120 Liter/min
= 1400 min-1
(8.1), (8.4)
(8.2), (8.5)
(7.1), (7.2)
)
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7.1
Section 7.0
Page 7
Main Pumps
7.1.2. Pump bearing flushing / lubrication
The installed main pumps are provided with an external cooling and lubrication
system for flushing of drive shaft bearing and shaft seal.
Oil supply is provided from the X4-pressure circuit.
To reach the restricted guidance of the coolant for external bearing flushing, the
throttle screw (located behind the union at port U) must screwed in all the way.
An information sign is fixed at the pump.
Legend for illustration (Z 22443):
(1 4)
Main pumps
(147.1-147.6) Orifice (one for each main pump)
(33)
Filter for pilot pressure
(P)
Ports for X4-pressure (pump support pressure)
(U)
Port for the pump bearing flushing / lubrication
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Section 7.0
Page 8
Main Pumps
7.1.3 Operating Principles
Main hydraulic pump A4VSO 500 LR3DN / 30L
Type code explanation:
A4VSO 500 LR 3 D N / 30 L
Rotation
Series
Basic adjustment for minimum displacement
With pressure control
Hydraulic remote adjustment facility
Constant power with hyperbolic curve
Max displacement in cm3 at one (1) revolution
Axial piston pump series 4, variable displacement ,swash plate design for open circuits
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Section 7.0
Page 9
Cont'd:
7.1
Main Pumps
7.1.3 Operating Principles
Symbol of main hydraulic pump A4VSLO 750 LR3DN / 30L
Legend for illustration (Z 22447):
(1)
Main pump (swash plate pump, variable displacement)
(2)
Pump bearing group
(3)
Drive shaft
(4)
Non return valves
(5)
Remote control valve
(5.1)
Mechanical stroke limitation*
(5.2)
Remote pressure (PST) operated piston for item 6
(5.3)
Mechanical stroke limitation*
(6)
Spool valve (pressure balance valve)
(7)
Nozzle
(8)
Power control valve
(9)
Nozzle
(10)
Pressure cut-off valve
(11)
Auxiliary pump (Gear pump, fixed displacement
(12)
Positioning piston
(13)
Slipper pad piston
(14)
Lever
(15)
Cam
(16)
Through drive shaft
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 10
Cont'd:
7.1
Main Pumps
7.1.3
Operating Principles
continued
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Section 7.0
Page 11
Cont'd:
7.1
Main Pumps
7.1.3
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Section 7.0
Page 12
Cont'd:
7.1
Main Pumps
7.1.3 Operating Principles, illustration (Z 21553a)
Q-max position: (remember Q means volume)
When does the pumps move into Q-max position?
and
and
and
Engine running
hydraulic oil at normal operating temperature (> T2)
the controls frequently used within 20 sec.
(or Service switch S151 activated)
a pump pressure below start of de-stroking.
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13
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Section 7.0
Page 13
Cont'd:
7.1
Main Pumps
7.1.3 Operating Principles, illustration (Z 21554a)
12 Q-max position: (remember Q means volume)
When does the pumps move into half Q-max position?
and
and
and
Engine running
hydraulic oil below normal operating temperature (< T2)
the controls frequently used within 20 sec.
(or Service switch S151 activated)
a pump pressure below start of de-stroking.
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14
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Section 7.0
Page 14
Cont'd:
7.1
Main Pumps
7.1.3 Operating Principles, illustration (Z 21555a)
De-stroking: (Pump moves from Q-max. into of Q-min. direction)
When does the pumps start to de-stroke
Engine running
and hydraulic at normal operating temperature (> T2)
and Service switch S150 deactivated
and The load stalls the engine RPM below 1800 min-1
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15
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Section 7.0
Page 15
Cont'd:
7.1
Main Pumps
7.1.3
Pressure cut-off valve: (DR control valve, Pump moves into Q-min. position)
When is the pressure cut-off valve active?
Engine running
and With pump pressure above 300 bar
Example with the following conditions:
Engine running (> 1800 min-1)
Pump pressure 300 bar
X1 = 24 bar (pump regulation pressure)
X3 = 35 bar (remote control pressure)
X4 = 60 bar (pump support pressure)
Response of pump control mechanism:
Independent of the position of power control valve (8) the pressure cut-off
valve (10) causes the pump to de-stroke to the pre-adjusted Q-min position.
The operating pressure moves the pressure cut-off valve (10) (at set pressure)
into position "b" and flows to the large area side of positioning piston (12).
Because the large area side of positioning piston (12) is approximately three
times larger as the small area side, the operating pressure present on both
sides, resulting in stronger force at the large area side, moving the pump in Qmin position.
The pump moves into Q-min position
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16
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Section 7.0
Page 16
Main Pumps
7.1.4
Checks / Adjustments
Location of Adjustments
Legend for , illustration (Z21557)
(1)
Remote control valve
(2)
Q-min. stop bolt
(3)
Pressure balance valve
(4)
Start of de-stroking
(5)
Power curve correction
(6)
Pressure cut-off valve
(7)
Q-max. stop bolt
(8)
Angle indicator
The average length of the measurement "L" is: set crews (bolts )
location
length L (mm)
13.4
21.9
7.6
8.1
----
6.0
27.6
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Section 7.0
Page 17
Main Pumps
7.1.4
Checks / Adjustments
continued
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18
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Section 7.0
Page 18
Cont'd:
7.1
Main Pumps
7.1.4
Checks / Adjustments
Connect a 400 bar pressure gauge to the pressure check point at the
respective high pressure filter for the pumps being checked.
Connect a 25 bar pressure gauge to respective pressure check point
M20-1 or M20-2 at the control and filter panel (X1-pressure).
Change over the respective three way cock to electronic regulation.
Unplug the respective proportional valve Y61.1 / Y61.2.
Insert an Allen key into the angle indicator bolt (see illustration)
for better visibility of the start of.
Start the respective engine, let it run with max. speed. The X1pressure should be 0 bar.
Stall the hydraulic for the pump to be checked and alter the operating
pressure with the MRV between 140 and 160 bar.
Start of de-stroking should be at an operating pressure of 150 bar,
shown at the gauge connected to the high pressure filter.
9.
Re-adjust the operating pressure at the MRV to 310+10 bar and plug
on the Y61.1 resp. Y61.2
(For exact values refer to the final test report.)
Remove Allen key and gauges.
continued
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19
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Section 7.0
Page 19
Cont'd:
7.1
Main Pumps
7.1.4
Checks / Adjustments
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 destroking.
Start the respective engine, let it run with max. speed, stall the
hydraulic for the pump to be checked and alter the operating
pressure with the MRV between 280 and 310 bar.
The angle indicator must indicate Q-min. position at a pressure of
300 bar shown at the gauge connected to the high pressure filter.
continued
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20
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Section 7.0
Page 20
Cont'd:
7.1
Main Pumps
7.1.4
Checks / Adjustments
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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21
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Section 7.0
Page 21
The drive train of the excavator consists of two diesel engine, several
hydraulic pumps, which supply cylinders and hydraulic motors.
The load limiting control ensures optimum use of the power required for the
excavator under varying operating conditions and avoiding overload of the
diesel engine.
Illustration Z22448 shows the principle of the electronic load limiting control.
The MC7 (E32) processes the following input signals:
Diesel engine speed (Pin 52, 53 and 54) from magnetic pick-up (B64-1
and B64-2), adjustment see at the end of this section.
Switch signal (Pin 35) from engine control (3E14-1), 24V if n > 300 min-1
The MC7 (E32) processes the following output signals:
Signal value to control the proportional solenoid valve Y61-1 (Pin 28)
and Y61-2 (Pin 30).
Switch signals (Pin 32 and 33), diagnostic of the MC7 (E32-1)
The diesel engine drives three variable displacement pumps by means of a
PTO-gearbox.
Each pump is equipped with a hydraulic power controller (HPC).
This controller limits the input torque of the pump to an adjusted command
value (X1-pressure, for start of de-stroking).
The command value (X1-pressure) is present via proportional solenoid valve
Y61-1 and Y61-2 at the hydraulic power controllers of each pump.
The actual speed of the engine is measured with a speed sensor at the flywheel.
The control algorithm of the load limiting control always compares the actual
engine speed with the rated load speed.
With increasing load the engine torque will rise and the engine speed will
drop.
For this reason the electronic load limiting control will be initiated when the
load speed falls below 1800 min-1 , i.e. the torque of the main pumps will be
lowered (by reducing the X1-pressure) until the rated speed of 1800 min-1 is
attained again.
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22
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23
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Section 7.0
Page 23
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24
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Section 7.0
Page 24
Method A - X1-pressure with 24V supply to separating terminals at the X2switch board
Pre-conditions: Normal operating temperature, correct pilot pressure setting
and the system must be free of air.
1. Make sure the change over valves is in position Electronic Pump Regulation
2. Connect a pressure gauge to the respective check point (M20-1 or M20-2), using
a long pressure gauge hose to be able reading the pressure in front of the X2panel.
3. Selection of adjusting mode:
Turn the main key switch in on position, and activate the adjusting mode as
follows:
Connect 24V, simultaneously to terminal 127 and 128 for 10 seconds, using two
test leads and disconnect the voltage thereafter.
4. Selection of the required proportional solenoid valve:
With the main key switch still in on position, select the applying terminal (X2board) for proportional solenoid valve Y61-1 (engine1) or Y61-2 (engine2) as
follows:
Y 61-1 No connections at selecting terminals required.
Y 61-2 Connect 24V, to terminal 126, using one test lead.
5. Adjusting the X1-pressure:
Start the engine, let it run with maximum speed.
Read the pressure, required = 24 0,5 bar
If necessary increase the X1-pressure as follows:
Connect 24V temporarily to terminal 127.
As long as voltage is supplied, the X1-pressure drops to zero.
After interrupting the voltage supply, the gauge pointer will move
slowly to the new present X1-pressure.
Example:
Keeping voltage supply for two seconds , will increase the X1-pressure
of approximately 1 bar.
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25
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Section 7.0
Page 25
Method B -
Language selection
To change the language press simultaneously
the buttons ALT + Clear
continued
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26
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Section 7.0
Page 26
Method B
Cont'd:
Language selection
Press button 2
One of the four main menu items can be selected using the given keys. (Fig. 1)
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27
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Method B
Section 7.0
Page 27
continued
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28
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Section 7.0
Page 28
Method B
Cont'd:
Excavator Type selection:
Press MENU . Return to main menu.
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29
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Section 7.0
Page 29
Method B
X1-Pressure (maximum current) Adjustment:
Press F1 Config/Cal.
continued
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30
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Method B
Section 7.0
Page 30
Cont'd:
X1-Pressure (maximum current) Adjustment:
Press MENU . Return to main menu.
If all adjustments are correct and stored in the MC7, proceed as follow:
Stop the engine and turn key switch (S1) in OFF position
Disconnect the electronic service tool (BB-3) and the pressure gauge.
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Section 7.0
Page 31
continued
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32
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Method C
Cont'd:
Section 7.0
Page 32
8. The program starts (only) the first time with the Demo Version.
10. Start the program again. Now the computer is connected to the Micro controller.
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33
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Section 7.0
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Method C
Language selection
Open menu FILE Language , select the required language and confirm with OK .
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34
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Method C
Section 7.0
Page 34
After confirming the Excavator type, confirm saving the parameters with OK.
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35
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Method C
Section 7.0
Page 35
After adjusting the pressure, confirm saving the parameters with OK.
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36
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Section 7.0
Page 36
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37
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Section 7.0
Page 37
7.
8.
9.
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Section 7.0
Page 38
4.
5.
6.
7.
8.
9.
11.
12.
continued
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Section 7.0
Page 39
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40
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Section 7.0
Page 40
Avoid pick-up contact with the fly wheel while engine running..
The inductive AC voltage must be measured with connected pick up to
the RPM-module (RPM-relay).
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Section 8.0
Page 1
Operating Hydraulic
01.04.03
Page
Operating Hydraulic
General
8.0.1
Floating function of boom and stick cylinders
2
3+4
8.1
8.2
8.3
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8.0
&2
01.04.03
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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:
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
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8.0
&3
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8.0
&4
8.0
General
Cont'd:
8.0.1
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8.0
&4
01.04.03
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Operating Hydraulic
Section 8.0
Page 4
Boom:
S95 ON K160 ON Float position deactivated
A10 deactivated
A10A activated
A10A deactivated
Stick:
S98 ON K170 ON Float position deactivated
A8B deactivated
A8A activated
A8A deactivated
01.04.03
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
PC5500-6_Sec_8-0_rev1.doc
Section 8.1
Page 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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2
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Page 2
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8.1
3
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Page 3
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8.1
4
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Section 8.1
Page 4
8.1.2 Electric / Hydraulic flowchart Boom lowering FSA, Auto Float off
Legend for illustration (Z 22530):
(E19)
Control lever (Joy stick)
(D32)
Time relay Pilot control: Neutral position monitoring
(+Y)
Direction (axis) of joy stick
(+10V)
Signal voltage (Maximum)
(gn)
Color code of signal voltage cable ( Joy stick)
(X2...)
Terminal rail with number
(E49)
Ramp time module
(A10)
Amplifier module Boom
(A10A)
Amplifier module Boom
(A10B)
Amplifier module Boom
(K76A)
Relay pilot control:
Contacts 6 / 10 open while extending the stick.
(K79)
Relay pilot control:
Contacts 6 / 10 open while filling the bucket.
(K80)
Relay pilot control:
Contacts 8 / 12 closed while moving the boom up.
(K160)
Relay pilot control:
Contacts 2 / 10 closed and 5 / 9 open while auto floating on.
(K207C)
Relay pilot control:
Contacts 5 / 9 closed while warming up hydraulic oil (S205).
(45.1 45.3)
Remote control valves
(Y23, Y26, Y29)
Proportional solenoid valve
(Y23b, Y26b, Y29b) Directional solenoid valve
(I III)
Main control blocks I IV
Electrical signal flow (EURO control).
The auto float button in the right lever E19 is still engaged this will energize
relay K160. Signal voltage of joy stick (E19) arrives via ramp time module
(E49) only at terminal 5 of the amplifier modules (A10a and A10b) and further
to the proportional and directional solenoid valve of the remote control blocks
(45.2 and 45.3).
Hydraulic signal flow. (pilot pressure)
When the proportional and directional solenoid valves are energized pilot pressure
oil flows to the pilot pressure ports of the respective main control blocks.
Hydraulic oil flow
Only the oil of main pump 3 and 4 flows through the main control blocks (II)
and arrives via the distributor manifold at the boom hydraulic cylinders piston
rod side. Through main valve block III for boom lowering is no pressure oil
flow depend on a different valve spool with closed pressure port.
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5
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Page 5
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6
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Page 6
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7
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Page 7
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8.1
8
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Page 8
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9
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Section 8.1
Page 9
8.1.4 Electric / Hydraulic flowchart Stick retracting FSA Auto Float off
Legend for illustration (Z 22534):
(E20)
Control lever (Joy stick)
(D32)
Time relay Pilot control: Neutral position
monitoring
(YD)
Direction (axis) of joy stick
(-10V)
Signal voltage (Maximum)
(gn)
Color code of signal voltage cable ( Joy stick)
(X2...)
Terminal rail with number
(E48)
Ramp time module
(A8)
Amplifier module Stick
(A8a)
Amplifier module Stick
(A8b)
Amplifier module Stick
(K76A)
Relay pilot control:
Contacts 7 /11 and 8 / 12 open while retracting the stick.
(K80)
Relay pilot control:
Contacts 1 / 9 only open while bucket moving.
(K170)
Relay pilot control:
Contacts 1 / 9 closed and 3 / 11 open while auto floating
off.
(K207C)
Relay pilot control:
Contacts 5 / 9 closed while warming up hydraulic oil
(S205).
(45.1, 45.2, 45.3)
Remote control valves
(Y23, Y26, Y29)
Proportional solenoid valve
(Y23b, Y26b, Y29b) Directional solenoid valve
(I + III)
Main control blocks I + III
Electrical signal flow (EURO control).
Signal voltage of joy stick (E20) arrives via ramp time module (E48) at terminal 5
of the amplifier modules (A8, A8a) and further to the proportional and directional
solenoid valves of the remote control blocks (45.1 and 45.2).
Hydraulic signal flow. (pilot pressure)
When the proportional and directional solenoid valves are energized pilot pressure
oil flows to the pilot pressure ports of the control blocks ( I and II ).
Hydraulic oil flow
Only the oil of main pump 3 and 4 flows through the main control block (II)
and arrives via the distributor manifold at the stick hydraulic cylinders piston
side. Through main valve block I for stick retracting is no pressure oil flow
depend on a different valve spool with closed pressure port.
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8.1
10
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Section 8.1
Page 10
8.1.3 Electric / Hydraulic flowchart Stick retracting FSA, Auto Float active
Legend for illustration (Z 22535a):
(E20)
Control lever (Joy stick)
(D32)
Time relay Pilot control: Neutral position monitoring
(-Y)
Direction (axis) of joy stick
(-10V)
Signal voltage (Maximum)
(gn)
Color code of signal voltage cable ( Joy stick)
(X2...)
Terminal rail with number
(E48)
Ramp time module
(A8)
Amplifier module Stick
(A8a)
Amplifier module Stick
(A8b)
Amplifier module Stick
(45.1-45.3)
Remote control valves
(Y21, Y27, Y31)
Proportional solenoid valve
(Y21a, Y27a, Y27b) Directional solenoid valve
(I, II, III)
Main control blocks I, II III
Electrical signal flow (EURO control).
The auto float button in the left lever E20 is disengaged relay K170 is deenergized. Signal voltage of joy stick (E20) arrives via ramp time module
(E48) at terminal 5 of the amplifier modules (A8, A8a and A8b) and further to
the proportional and directional solenoid valve of the remote control blocks
(45.1 and 45.3). Amplifier module A8a disengaged with open K80 if bucket
filling is actuated..
Hydraulic signal flow. (pilot pressure)
When the proportional and directional solenoid valves are energized pilot pressure
oil flows to the pilot pressure ports of the respective main control blocks.
Hydraulic oil flow
Both pressure lines at valve block III section 4 (A4 and B4) are connected to the
same back pressure charged return line. Valve spool 4 of main valve block I
connect only port B2 to the return line. The return line, the piston side and the
piston rod side of the stick cylinders now connected together. The stick can move
forward and backward by external force.
If only the stick retracting function is active section 4 of main valve block II
opened additional port A4 and B4 to extend the max. oil flow for max. stick
speed.
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Page 12
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13
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Page 13
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Page 14
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Page 15
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17
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Page 17
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18
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Page 18
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19
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Section 8.1
Page 19
Pump circuit
I
Pump circuit
II
Pump circuit
III
Pump circuit
IV
MRV
block
Check
point
M12.1
travel
stick
bucket
boom
II
M12.3
clam
bucket
Boom
stick
III
M12.4
travel
boom
bucket
stick
IV
M12.2
Functions FSA
Extend or retract the cylinder to the stop position for the valve being
tested until the hydraulic system stalls.
4.
Read the pressure. Required: 310 + 5 bar
If the pressure is not correct, carry out a comparative measurement with an
other function, in order to avoid wrong measuring results caused by
wrongly adjusted SRV or other defects in the system.
When using the single function bucket fill, (gray shadow), all MRV
can be adjusted, because all four pump circuits are engaged.
Adjusting:
1.
Remove protective cap (a).
2.
Loosen lock nut (b).
3.
Turn set screw (c) -clockwise to increase pressure, Counter-clock
wise to decrease pressure.
4.
Tighten lock nut (b) and install cap (a).
)
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20
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Section 8.1
Page 20
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)
When using the single function bucket fill, (gray shadow), all MRV
can be adjusted, because all four pump circuits are engaged.
Adjusting:
1.
Remove protective cap (a).
2.
Loosen lock nut (b).
3.
Turn set screw (c) -clockwise to increase pressure, Counterclock wise to decrease pressure.
5.
Tighten lock nut (b) and install cap (a).
)
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21
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Section 8.1
Page 21
)
5.
6.
7.
8.
06.10.05
Location
Manifold section B
Manifold section N
Manifold section N
Double HP filter R.H.
Single HP filter, block II
Double HP L.H..
Single HP filter, block IV
Connect gauges to all above listed check points (min. 400 bar).
Start both motors..
Extend the boom cylinder to the stop position until the hydraulic
system stalls.
Increase slowly the pump supply line pressure, by turning in set screws (3)
of the MRVs 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
SRVs, 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 SRVs open during checks and adjustments
it is necessary to further increase the setting of both MRVs.
Remove protective cap (1) of MRV.
Loosen lock nut (2).
Turn set screw (3) of the MRVs 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-D_Sec_8-1_rev3.doc
8.1
22
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Section 8.1
Page 22
Cont'd:
8.1.10
Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 22482a):
Boom cylinder piston side FSA +BHA
9.
Adjust all three SRVs equally, until all gauges show a pressure of
360 bar.
Adjust in steps of turn of set screw (3) in the following sequence:
141.1 141.2 141.3
Remove protective cap (1) of SRVs.
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:
141.2 141.3
)
06.10.05
Reset the MRVs to 310 bar + 5 bar after the check / adjustment is finished,
as follows:
Remove protective cap (1).
Loosen lock nut (2).
Turn set screw (3) -clockwise to increase pressure, Counter-clock
wise to decrease pressure.
Tighten lock nut (2) and install cap (1).
It is important that the valve body of MRV-valve and the SRV-valve
are firmly tightened (with 300 Nm).
Otherwise, the internal sealing is not properly which results in loud
flow noises and wrong adjustments.
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8.1
23
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Section 8.1
Page 23
1.
2.
3.
4.
5.
6.
Location
Control block II, section A3 FSA
section A2 BHA
Single high pressure filter,
control block II
Single high pressure filter,
control block IV
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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24
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Section 8.1
Page 24
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8.1
25
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Section 8.1
Page 25
5.
6.
7.
8.
Location
Manifold section F
Manifold section F
Manifold section J
Double high pressure filter R.H.
Single HP filter, control block II
Double high pressure filter L.H..
Single HP filter, control block IV
06.10.05
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8.1
26
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Section 8.1
Page 26
Cont'd:
8.1.11
Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 22542):
Stick cylinder piston side FSA
9.
Adjust all three SRVs equally, until all gauges show a pressure of 360
bar.
Adjust in steps of turn of set screw (3) in the following sequence:
142.5 142.6 142.7
Remove protective cap (1) of SRVs.
Loosen lock nut (2).
Turn set screw (3) -clockwise to increase, Counter-clock wise to
decrease the setting.
Tighten lock nut (2) and install cap (1).
10.
Reduce the pressure at SRV 142.5 to a value below the required value,
and increase up to the required pressure (350 bar), while observing all
gauges.
)
11.
Now all gauges will show the same value of 350 bar,
but only SRV-65.2 has the correct setting.
Proceed with the other valves in the same manner in the following
sequence:
142.6 142.7
)
06.10.05
Reset the MRV to 310 bar + 5 bar (320 bar block IV) after the check /
adjustment is finished, as follows:
Remove protective cap (1).
Loosen lock nut (2).
Turn set screw (3) -clockwise to increase pressure, Counter-clock
wise to decrease pressure.
Tighten lock nut (2) and install cap (1).
It is important that the valve body of MRV-valve and the SRV-valve
are firmly tightened (with 300 Nm).
Otherwise, the internal sealing is not properly which results in loud
flow noises and wrong adjustments.
PC5500-6-D_Sec_8-1_rev3.doc
8.1
27
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Section 8.1
Page 27
)
5.
6.
7.
8.
06.10.05
Location
Control block I, section A2
Control block II, section A42
Control block I
Control block II
Control block IV
PC5500-6-D_Sec_8-1_rev3.doc
8.1
28
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Section 8.1
Page 28
Cont'd:
8.1.11
Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 22484):
Stick cylinder piston side BHA
9.
Adjust all two SRVs equally, until all gauges show a pressure of
360 bar.
Adjust in steps of turn of set screw (3) in the following sequence:
33.1 33.5
Remove protective cap (1) of SRVs.
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 33.5
)
06.10.05
Reset the MRV to 310 bar + 5 bar after the check / adjustment is finished,
as follows:
Remove protective cap (1).
Loosen lock nut (2).
Turn set screw (3) -clockwise to increase pressure, Counter-clock
wise to decrease pressure.
Tighten lock nut (2) and install cap (1).
It is important that the valve body of MRV-valve and the SRV-valve
are firmly tightened (with 300 Nm).
Otherwise, the internal sealing is not properly which results in loud
flow noises and wrong adjustments.
PC5500-6-D_Sec_8-1_rev3.doc
8.1
29
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Section 8.1
Page 29
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
06.10.05
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8.1
30
06.10.05
PC5500-6-D_Sec_8-1_rev3.doc
Section 8.1
Page 30
Cont'd:
8.1.11
Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 22543a):
Stick cylinder piston rod side FSA
Since the piston rod side of the stick cylinders are protected by
several SRVs, 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 SRVs open during checks and adjustments
it is necessary to further increase the setting of the MRVs.
7.
Turn set screw (3) of both MRVs turn further in, the gauge pointers
will remain at the value shown at item #6 (350 bar + 5 bar).
Adjust the SRVs equally, until all gauges show a pressure of 360 bar.
Adjust in steps of turn of set screw (1) (SRVs) in the following
sequence :
33.1 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 dont increase
turn set screw from the last setting max. turn in (c.w.).
Adjust pressure at the SRV 33.5 to ~350 bar.
8.
9.
10.
)
11.
06.10.05
Now all gauges will show the same value of 350 bar,
but only SRV-33.1 has the correct setting.
Reduce the pressure, at SRV 33.1 to a value below the required value and
then increase up to the required pressure (350 bar), while observing all
gauges.
PC5500-6-D_Sec_8-1_rev3.doc
8.1
31
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Section 8.1
Page 31
Cont'd:
8.1.11
Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 22543a):
Stick cylinder piston rod side FSA
Strong pulsation of the return line hoses, indicates deviation in
opening pressure of SRVs and must be avoided.
Repeat the adjusting procedure until the oil returns well-balanced
via all service line relief valves.
14.
15.
16.
06.10.05
Reset the MRVs to 310 bar + 5 bar after the check / adjustment is finished
Stop engine.
Install all protective cups (1).
It is important that the valve body of MRV-valve and the SRV-valve
are firmly tightened (with 300 Nm).
Otherwise, the internal sealing is not properly which results in loud
flow noises and wrong adjustments.
PC5500-6-D_Sec_8-1_rev3.doc
8.1
32
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Section 8.1
Page 32
)
5.
6.
7.
8.
Location
Manifold (42) section G
Manifold (42) section J
Manifold (42) section J
Double high pressure filter R.H.
Single high pressure filter,
control block II
Double high pressure filter L.H..
Single high pressure filter,
control block IV
06.10.05
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8.1
33
06.10.05
PC5500-6-D_Sec_8-1_rev3.doc
Section 8.1
Page 33
Cont'd:
8.1.11
Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 22485):
Stick cylinder Piston rod side BHA
9.
Adjust all SRVs equally, until all gauges show a pressure of
360 bar.
Adjust in steps of turn of set screw (3) in the following sequence:
142.5 142.6 142.7
Remove protective cap (1) of SRVs.
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:
142.6 142.7
)
06.10.05
Reset the MRVs 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.
PC5500-6-D_Sec_8-1_rev3.doc
8.1
34
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Section 8.1
Page 34
5.
6.
7.
8.
06.10.05
Location
Manifold (42) section C
Manifold (42) section C
Manifold (42) section D
Double high pressure (HP) filter R.H.
PC5500-6-D_Sec_8-1_rev3.doc
8.1
35
06.10.05
PC5500-6-D_Sec_8-1_rev3.doc
Section 8.1
Page 35
Cont'd:
8.1.11
Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 22544):
Bucket cylinder Piston rod side FSA
9.
Adjust all three SRVs equally, until all gauges show a pressure of
360 bar.
Adjust in steps of turn of set screw (3) in the following sequence:
142.1 142.2 142.3
Remove protective cap (1) of SRVs.
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:
142.2 142.3
)
06.10.05
Reset the MRVs 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.
PC5500-6-D_Sec_8-1_rev3.doc
8.1
36
06.10.05
PC5500-6-D_Sec_8-1_rev3.doc
Section 8.1
Page 36
)
5.
6.
7.
8.
06.10.05
Location
Manifold section C
Manifold section C
Manifold section D
Double high pressure filter R.H.
Single high pressure filter, block II
Double high pressure filter L.H..
Singe high pressure filter, block IV
PC5500-6-D_Sec_8-1_rev3.doc
8.1
37
06.10.05
PC5500-6-D_Sec_8-1_rev3.doc
Section 8.1
Page 37
Cont'd:
8.1.11
Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 22486):
Bucket cylinder Piston side BHA
9.
Adjust all three SRVs equally, until all gauges show a pressure of
360 bar.
Adjust in steps of turn of set screw (3) in the following sequence:
142.1 142.2 142.3
Remove protective cap (1) of SRVs.
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:
142.2 142.3 142.
)
06.10.05
Reset the MRVs to 310 bar + 5 bar after the check / adjustment is finished,
as follows:
Remove protective cap (1).
Loosen lock nut (2).
Turn set screw (3) -clockwise to increase pressure, Counter-clock
wise to decrease pressure.
Tighten lock nut (2) and install cap (1).
It is important that the valve body of MRV-valve and the SRV-valve
are firmly tightened (with 300 Nm).
Otherwise, the internal sealing is not properly which results in loud
flow noises and wrong adjustments.
PC5500-6-D_Sec_8-1_rev3.doc
8.1
38
06.10.05
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Section 8.1
Page 38
)
5.
6.
7.
8.
Location
Control block I, section A3
Control block I, section A2
Double high pressure filter R.H.
Single high pressure filter, block II
Double high pressure filter L.H..
Single high pressure filter, block IV
06.10.05
PC5500-6-D_Sec_8-1_rev3.doc
8.1
39
06.10.05
PC5500-6-D_Sec_8-1_rev3.doc
Section 8.1
Page 39
Cont'd:
8.1.11
Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 21999):
Bucket cylinder Rod side FSA
9.
Adjust both SRVs equally, until all gauges show a pressure of
360 bar.
Adjust in steps of turn of set screw (3) in the following sequence:
33,2 33.6
Remove protective cap (1) of SRVs.
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.
)
06.10.05
Reset the MRVs 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.
PC5500-6-D_Sec_8-1_rev3.doc
8.1
40
06.10.05
PC5500-6-D_Sec_8-1_rev3.doc
Section 8.1
Page 40
)
5.
6.
7.
8.
06.10.05
Since the piston rod side of the bucket cylinders are protected by
several SRVs, 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 SRVs 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 MRVs 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
PC5500-6-D_Sec_8-1_rev3.doc
8.1
41
06.10.05
PC5500-6-D_Sec_8-1_rev3.doc
Section 8.1
Page 41
Cont'd:
8.1.11
Checks and adjustments of the Service Line Relief Valves (SRV),
illustration (Z 22487):
Bucket cylinder Piston rod side BHA
9.
Adjust all SRVs equally, until all gauges show a pressure of 360 bar.
Adjust in steps of turn of set screw (3) in the following sequence:
142.8 142.9 142.10
Remove protective cap (1) of SRVs.
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:
142.9 142.10
)
06.10.05
Reset the MRVs to 310 bar + 5 bar after the check / adjustment is finished,
as follows:
Remove protective cap (1).
Loosen lock nut (2).
Turn set screw (3) -clockwise to increase pressure, Counter-clock
wise to decrease pressure.
Tighten lock nut (2) and install cap (1).
It is important that the valve body of MRV-valve and the SRV-valve
are firmly tightened (with 300 Nm).
Otherwise, the internal sealing is not properly which results in loud
flow noises and wrong adjustments.
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8.1
42
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Section 8.1
Page 42
5.
6.
7.
8.
9.
10.
)
06.10.05
Location
Manifold (42) section E
Control block II
Control block IV
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8.1
43
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Section 8.1
Page 43
06.10.05
Location
Manifold section K
Manifold section K
Control block II
4.
Since the piston side of the clam cylinders are protected by several
SRVs, the pressure gauges show the pressure of that valve with the
lowest setting.
Because of different wear packages the pressure can be between 150
bar and more as 200 bar.
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8.1
44
06.10.05
PC5500-6-D_Sec_8-1_rev3.doc
Section 8.1
Page 44
II.
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.
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8.1
45
06.10.05
PC5500-6-D_Sec_8-1_rev3.doc
Section 8.1
Page 45
Total time(s)
4,3
Adjustments / Checks:
I.
1.
2.
3.
4.
5.
If the lowering speed is too high, i.e. the measured time is less than the
permissible time, the speed must be reduced by altering the throttle valves
141.1 (section B) and 141.3 (section N, pointing to the attachment).
Adjust as follows:
To decrease the lowering speed loosen lock nut (1) and turn the bolt (2) cw.
To increase the lowering speed loosen lock nut (1) and turn the bolt (2) ccw.
Since there are several valves throttling the return oil flow the valves
must be set synchronously. The adjusting screws have to be turned in
by the same amount of revolutions.
O.K.
6.
7.
06.10.05
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8.1
46
06.10.05
PC5500-6-D_Sec_8-1_rev3.doc
Section 8.1
Page 46
Cont'd:
8.1.12
Checks and adjustments of the lowering speed,
illustration (Z 22489):
Boom cylinder FSA
Adjustments / Checks:
II.
1.
2.
3.
4.
5.
6.
The lowering speed will be the same as with floating position. If the lowering
speed is too high, i.e. the measured time is less than the permissible time, the
speed must be reduced by altering the throttle valve 141.1, 141.2 and
synchronous 141.3 at the distributor manifold section B and N.
Adjust as follows:
To decrease the lowering speed loosen lock nut (1) and turn the bolt (2) cw. To
increase the lowering speed loosen lock nut (1) and turn the bolt (2) ccw.
The adjusting screws have to be turned in by the same amount of
revolutions.
O.K.
7.
8.
06.10.05
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8.1
47
06.10.05
PC5500-6-D_Sec_8-1_rev3.doc
Section 8.1
Page 47
Boom BHA
Total time
(s)
5,0
Adjustments / Checks:
1.
Use a stop watch to measure the cylinder running time.
2.
Raise the fully extended attachment with empty bucket to the maximum
height position (A).
3.
Shift the engines to high idle speed.
4.
Rapidly move the control lever (E19) to the front end position (start the stop
watch) and hold it until the final position (B) is reached.(stop the stop
watch).
Lower the boom so, that the bucket stops just above the ground.
5.
If the lowering speed is too high, i.e. the measured time is less than the
permissible time, the speed must be reduced by altering the throttle valves
141.1, 141.2 and 141.3 at the distributor manifold.
Adjust as follows:
To decrease the lowering speed loosen the lock nut (1) and turn the bolt (2)
cw. To increase the lowering speed loosen the lock nut (1) and turn the bolt
(2) ccw.
Since there are several valves throttling the return oil flow of the boom
cylinder the valves must be set synchronously. The adjusting screws have
to be turned in by the same amount of revolutions.
O.K.
6.
06.10.05
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8.1
48
06.10.05
PC5500-6-D_Sec_8-1_rev3.doc
Section 8.1
Page 48
illustration (Z 22490):
Stick FSA
Total time
(s)
2,4
Adjustments / Checks:
I.
4.
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.
06.10.05
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8.1
49
06.10.05
PC5500-6-D_Sec_8-1_rev3.doc
Section 8.1
Page 49
Cont'd:
8.1.12
Checks and adjustments of the lowering speed, illustration (Z 22490):
Stick cylinder FSA
Adjustments / Checks:
II.
1.
2.
3.
4.
5.
6.
O.K.
7.
8.
06.10.05
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8.1
50
06.10.05
PC5500-6-D_Sec_8-1_rev3.doc
Section 8.1
Page 50
Stick BHA
Total time
(s)
1,5
Adjustments / Checks:
1.
Use a stop watch to measure the cylinder running time.
2.
Start both engines and let it run in high idle.
3.
Raise the fully extended attachment with empty bucket to the maximum
height position (A).
4.
Rapidly move the control lever (E20) to the rear end position (start the stop
watch) and hold it until close to the final position (B) is reached.(stop the
stop watch).
5.
If the lowering speed is too high, i.e. the measured time is less than the
permissible time, the speed must be reduced by altering the throttle valves
142.5, 142.6 and 142.7 at the distributor manifold.
Adjust as follows:
To decrease the lowering speed loosen the lock nut (1) and turn the bolt (2)
cw. To increase the lowering speed loosen the lock nut (1) and turn the bolt
(2) ccw.
Since there are several valves throttling the return oil flow of the stick
cylinder the valves must be set synchronously. The adjusting screws have
to be turned in by the same amount of revolutions.
O.K.
6.
7.
06.10.05
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8.1
51
06.10.05
PC5500-6-D_Sec_8-1_rev3.doc
Section 8.1
Page 51
Bucket FSA
Total time
(s)
3,0
Adjustments / Checks:
1.
Use a stop watch to measure the cylinder running time.
2.
Raise the fully extended attachment with empty bucket to the maximum
height position (A).
3.
Start both engines and let it run in high idle.
4.
Rapidly move the control lever (E19) to the r.h. end position (start the stop
watch) and hold it until the final position (B) is reached.(stop the stop
watch).
5.
If the lowering speed is too high, i.e. the measured time is less than the
permissible time, the speed must be reduced by altering the throttle valves
142.1, 142.2 and 142,3 at the distributor manifold section C and D.
Adjust as follows:
To decrease the lowering speed loosen lock nut (1) and turn the bolt (2) cw.
To increase the lowering speed loosen lock nut (1) and turn the bolt (2) ccw.
Since there are several valves throttling the return oil flow of the
bucket cylinder the valves must be set synchronously. The
adjusting screws have to be turned in by the same amount of
revolutions.
O.K.
6.
7.
06.10.05
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8.1
52
06.10.05
PC5500-6-D_Sec_8-1_rev3.doc
Section 8.1
Page 52
Bucket BHA
Total time
(s)
1,1
Adjustments / Checks:
1.
Use a stop watch to measure the cylinder running time.
2.
Raise the fully extended attachment with empty bucket to the maximum
height position (A).
3.
Start both engines and let it run in high idle.
4.
Rapidly move the control lever (E19) to the r.h. end position (start the stop
watch) and hold it until the final position (B) is reached.(stop the stop
watch).
5.
If the lowering speed is too high, i.e. the measured time is less than the
permissible time, the speed must be reduced by altering the throttle valves
142.1, 142.2, 142.3, 142.8, 142.9 and 142.10 at the distributor manifold.
Adjust as follows:
To decrease the lowering speed loosen the lock nut (1) and turn the bolt (2)
cw. To increase the lowering speed loosen the lock nut (1) and turn the bolt
(2) ccw.
Since there are several valves throttling the return oil flow of the bucket
cylinder the valves must be set synchronously. The adjusting screws have
to be turned in by the same amount of revolutions.
O.K.
6.
7.
06.10.05
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8.1
53
06.10.05
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Section 8.1
Page 53
5.
6.
7.
06.10.05
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8.1
54
06.10.05
PC5500-6-D_Sec_8-1_rev3.doc
Section 8.1
Page 54
06.10.05
PC5500-6-D_Sec_8-1_rev3.doc
Section 8.2
Page 1
Page
Hydraulic for the swing circuit
8.2.1 Swing Circuit (Brief description)
2+3
4-7
10+12
13
14
15 + 16
17 - 19
PC5500-6-D_Sec_8-2_rev4.doc
19
06.10.05
8.2
2
PC5500-6-D_Sec_8-2_rev4.doc
06.10.05
Section 8.2
Page 2
Main pumps
Single control block IV
Manifold
Swing motors
Manifold at the control and filter panel
Double check valve
Pressure increasing valve (swing brake valve)
Swing motors power control valve
Solenoid valve
Remote control valve block
Proportional valve of the remote control block
Directional solenoid valve of the remote control block
Control lever left hand
Ramp module
Amplifier module
PC5500-6-D_Sec_8-2_rev4.doc
06.10.05
8.2
3
PC5500-6-D_Sec_8-2_rev4.doc
06.10.05
Section 8.2
Page 3
Cont'd.:
8.2.1 Functional description:
Illustration (Z 22501b):
Brief description (Service circuits)
(Study together with the for the machine valid hydraulic and electric circuit
diagram).
The swing motors (20.1 + 20.2) are feed by the main pump (III). This pump is
at port XLR permanent with 35 bar X2- pressure fix adjusted to Qmax.
The oil flows from the pumps through check valve (47.3) and filter (153.3) to
the single control block (13 / IV).
In neutral position of the spool oil flows via port C into control block II for
additional oil volume from pump 3 to valve circuit II. If no function of
control block II is activated the oil flow via port T in to the collector tube (35)
and further via the return oil lines (L6 + L7) into the tank.
On its way to tank the oil must flow through the back pressure valve (115)
and the return oil filter (117.2 - 117.5). (Back pressure valve function see
chapt. 4.)
When operating the control lever for "Swinging" the pump line is connected
in the control block (33/IV) with the corresponding service line (A1 or B1) to
the swing motors (20.1 + 20.2).
The oil flows from the control block through each one of the swing brake
valves (49.1 + 49.2; description see page 6 and 7) and the swing motors (20.1
+ 20.2).
Each swing gear includes one spring loaded multi disk brake (House brake)
for locking the superstructure.
The leak oil (case drain) flows through the line (L11 + L12) and the leak oil
filter (108) back to tank.
PC5500-6-D_Sec_8-2_rev4.doc
06.10.05
8.2
4
PC5500-6-D_Sec_8-2_rev4.doc
06.10.05
Section 8.2
Page 4
PC5500-6-D_Sec_8-2_rev4.doc
06.10.05
8.2
5
PC5500-6-D_Sec_8-2_rev4.doc
06.10.05
Section 8.2
Page 5
Operating
pressure
bar
Torque
Motor
displacement
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
120-0
~170 0
Max.
Vg max
120-0
330 0
Max.
Vg max
Start swing
Standstill to low speed
Speed
Xindicator pressure
imp/min
bar
0-120
Continued
PC5500-6-D_Sec_8-2_rev4.doc
06.10.05
8.2
6
PC5500-6-D_Sec_8-2_rev4.doc
06.10.05
Section 8.2
Page 6
PC5500-6-D_Sec_8-2_rev4.doc
06.10.05
PC5500-6-D_Sec_8-2_rev4.doc
Section 8.2
Page 6
06.10.05
8.2.2
Section 8.2
Page 7
PC5500-6-D_Sec_8-2_rev4.doc
06.10.05
8.2
8
PC5500-6-D_Sec_8-2_rev4.doc
06.10.05
Section 8.2
Page 8
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).
PC5500-6-D_Sec_8-2_rev4.doc
06.10.05
8.2
9
PC5500-6-D_Sec_8-2_rev4.doc
06.10.05
Section 8.2
Page 9
PC5500-6-D_Sec_8-2_rev4.doc
06.10.05
8.2
10
PC5500-6-D_Sec_8-2_rev4.doc
06.10.05
Section 8.2
Page 10
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Leak oil
Return oil
Service line from control block
Service line to the motor
Service line from control block
Service line to the motor
PC5500-6-D_Sec_8-2_rev4.doc
06.10.05
8.2
11
PC5500-6-D_Sec_8-2_rev4.doc
06.10.05
Section 8.2
Page 11
Cont'd.:
8.2.5 Swing Brake Valve
If after a swing motion the joy stick is released into neutral position
without using the foot brake, the superstructure is turned by inertial force
and the hydraulic motor acts as a pump because it is driven by the swing
gear.
Both service lines (pump line and tank line) are blocked at the control
valve block. In this period the service line (previously pump line) acts now
as suction line and the return line (previously return line) acts now as
output line. Because of the closed service ports at the control block all oil
from the swing motor must pass the brake valve block. The pressure
increasing valve in the brake valve block acts now as a back pressure
valve. This variable back pressure is the brake force.
Function of the pressure increasing valve.
When ever a swing motion is carried out or the foot brake is used, pilot
pressure arrives the pressure increasing valve (1) at port "X". The pilot
pressure pre-loads these valves.
By applying pilot pressure via the external port X to piston (12), the pretensioning of the pressure spring (10) is increased by the amount of the piston
stroke "S", which results in the actual valve setting.
The system pressure is in front of the main piston (13) and via the jet bore (6)
also in the chamber of the spring (7) and via the jet bore (8) at the pressure
relief valve poppet (9).
Due to the force balance the piston (13) is kept in its position supported by
the spring (7).
Overcomes the system pressure the setting of the valve (9), this valve opens a
channel to the dump line port (Y). Due to the drop of force the piston (13) is
moved to the right.
The pressure line gets connected with the return line (T).
Damped opening and closing are obtained by the throttled volumetric change
that is caused by the jet bores.
continued
PC5500-6-D_Sec_8-2_rev4.doc
06.10.05
8.2
12
PC5500-6-D_Sec_8-2_rev4.doc
06.10.05
Section 8.2
Page 12
Cont'd.:
8.2.5
4. Stop engines
5. Disconnect the gauges.
PC5500-6-D_Sec_8-2_rev4.doc
06.10.05
8.2
13
PC5500-6-D_Sec_8-2_rev4.doc
06.10.05
Section 8.2
Page 13
PC5500-6-D_Sec_8-2_rev4.doc
06.10.05
8.2
14
PC5500-6-D_Sec_8-2_rev4.doc
06.10.05
Section 8.2
Page 14
PC5500-6-D_Sec_8-2_rev4.doc
06.10.05
8.2
15
PC5500-6-D_Sec_8-2_rev4.doc
06.10.05
Section 8.2
Page 15
PC5500-6-D_Sec_8-2_rev4.doc
06.10.05
8.2
16
PC5500-6-D_Sec_8-2_rev4.doc
06.10.05
Section 8.2
Page 16
c)
Function
nominal setting
12 imp/min (i.e.120)
---
Set to III
X x 10 imp/min
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06.10.05
8.2
17
PC5500-6-D_Sec_8-2_rev4.doc
06.10.05
Section 8.2
Page 17
continue
PC5500-6-D_Sec_8-2_rev4.doc
06.10.05
8.2
18
PC5500-6-D_Sec_8-2_rev4.doc
06.10.05
8.2.9
Section 8.2
Page 18
Actuate either l.h. or r.h. rotation until the hydraulic system stalls.
a)
loosen lock nut (3) at the first PIV and turn out set screw (4)
until 150 +5 bar is reached.
b)
Tighten lock nut (3).
c)
Loosen lock nut (3) at the second PIV and turn out set screw
(4) until the gauge start lowering the pressure.
d)
Re-check pressure setting.
Re-connect the pilot pressure line. Proceed like item 2.
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.
PC5500-6-D_Sec_8-2_rev4.doc
06.10.05
8.2
19
PC5500-6-D_Sec_8-2_rev4.doc
06.10.05
8.2.10
Section 8.2
Page 19
PC5500-6-D_Sec_8-2_rev4.doc
06.10.05
Section 8.3
Page 1
Page
Travel System
8.3.1 Travel Circuit (Brief description)
2+3
4+5
10 + 12
PC5500-6-D_Sec_8-3_rev2.doc
06.10.05
8.3
2
PC5500-6-D_Sec_8-3_rev2.doc
06.10.05
Travel System
Section 8.3
Page 2
Travel Circuit
Legend for illustration (Z 22521):
(1; 2; 5; 6)
(14 / I)
(16 / III)
(21.1- 21.4)
(28.1+28.2)
(34)
(40)
(46.1+46.2)
(52.1 + 52.4)
Main pumps
L.H. Control block
R.H. Control block
Travel motors (A2FM 355)
Travel motors valve blocks
Rotary distributor
Suction tank
Double filter
Travel gear house brakes
(M12.1 + M12.4)
(M33.1, M33.2)
(M33.3, M33.4)
Brief description
(Study together with the machine valid hydraulic and electric circuit diagram).
Control circuits, not shown
By the function of the remote control valve (45.1 + 45.3) pilot pressure oil is
sent to one side of each control block (14/I + 16/III) when operating the foot
pedal for travelling "Forward or Reverse.
PC5500-6-D_Sec_8-3_rev2.doc
06.10.05
8.3
3
PC5500-6-D_Sec_8-3_rev2.doc
06.10.05
Travel System
Section 8.3
Page 3
PC5500-6-D_Sec_8-3_rev2.doc
06.10.05
8.3
4
PC5500-6-D_Sec_8-3_rev2.doc
06.10.05
Travel System
Section 8.3
Page 4
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
Verschluschraube mit Loctite gesichert = Plug screw sealed with Loctite
mit Krnerschlag gesichert = sealed with punch mark
Kammer mit Fett gefllt = Chamber grease filled
Ports:
A-D
L
ST
X
K1
K2
Service lines
Leak oil
Control oil Travel break
Control oil (travel motor flushing)
Track tensioning
Track tensioning
continued
PC5500-6-D_Sec_8-3_rev2.doc
06.10.05
8.3
5
PC5500-6-D_Sec_8-3_rev2.doc
06.10.05
Travel System
Section 8.3
Page 5
Contd.
Function (Z 22522):
During operation superstructure and under carriage rotate towards each other.
The travel oil motors must be supplied with hydraulic oil in every position in
which the superstructure is turned in regard to the undercarriage. Oil is directed by the control blocks to the ports (A-D) of the housing (2).
The oil flows to the outlet ports (A-D), of the rotor (1), via ring grooves as
well as longitudinal and cross holes. The rotor is bolted to the under carriage
and the housing (stator) is fixed by the upper structure. The sealing of the ring
grooves among one another is done by seal rings (8) and o-rings (9).
The hydraulic connection for the travel motor case drain and the travel motor
house brake is done via the ports (L) and (St).
The rotor (1) is at the top and bottom section guided in the housing by the
guide rings (12).
PC5500-6-D_Sec_8-3_rev2.doc
06.10.05
8.3
6
PC5500-6-D_Sec_8-3_rev2.doc
06.10.05
Travel System
Section 8.3
Page 6
A
B
C
D
PC5500-6-D_Sec_8-3_rev2.doc
06.10.05
8.3
7
PC5500-6-D_Sec_8-3_rev2.doc
06.10.05
Travel System
Section 8.3
Page 7
PC5500-6-D_Sec_8-3_rev2.doc
06.10.05
8.3
8
PC5500-6-D_Sec_8-3_rev2.doc
06.10.05
Travel System
Section 8.3
Page 8
Disk housing
Piston
Back-up ring with radial seal rings (15)
Bach-up ring
Coupler
Inner disks (lamellas)
(7)
(8 + 9)
(10 - 12)
(13)
(14)
(16)
(17)
(19)
(21 + 22)
Outer disks
Springs
O-ring
Clip ring
Clip ring
Release pressure port
Quad-Ring with back-up rings (18)
Quad-Ring with back-up rings (20)
Plug screw with seal ring
Function:
Brake applied:
The outer disks (7) engaged to the housing by serration and the inner disks (6) in
serration connection with the coupler, are pressed together by the springs (8 +
9). This results in a fixed connection between housing and coupler.
Brake released:
Oil pressure via port (16) reaches the left side of the piston (2) and forces the
piston towards the back-up ring (4), as shown.
This function eliminates the spring force onto the disks thus the brake is released.
The releasing pressure is 18 bar, the maximum permissible pressure 60 bar.
This brake named "Wet Brake" because the brake housing is filled with gear oil.
For maintenance see MAINTENANCE MANUAL
For more details see PARTS BOOK
PC5500-6-D_Sec_8-3_rev2.doc
06.10.05
8.3
9
PC5500-6-D_Sec_8-3_rev2.doc
06.10.05
Travel System
Section 8.3
Page 9
PC5500-6-D_Sec_8-3_rev2.doc
06.10.05
8.3
10
PC5500-6-D_Sec_8-3_rev2.doc
06.10.05
Travel System
Section 8.3
Page 10
Adjustments / Checks
Motor 2
continued
PC5500-6-D_Sec_8-3_rev2.doc
06.10.05
8.3
11
PC5500-6-D_Sec_8-3_rev2.doc
06.10.05
Travel System
Section 8.3
Page 11
Contd.
If the gauge shows a lower or higher value and to be sure both SRVs are correct
adjusted the SRVs (main valve block and brake valve block) must be adjusted.
A faulty anti cavitation valve (32.1; 32.2; 32.13; 32.14) can influence
the SRV pressure reading / setting. In a doubt inspect the valve. Repair or replace faulty valve if necessary.
A faulty rotary distributor or motor gives the same problems.
Repair or replace faulty part.
Procedure:
6.
7.
8.
9.
10.
11.
12.
13.
Set MRV of main valve block I and III to a higher setting (~ 340 bar,
for adjustment use the function stick extending
Engage carefully desired travel motion and hold foot pedal in final position to built up max. pressure
Adjust* the respective SRV to a higher setting (~330 bar)
Connect pressure gauge to check points M33.1, M33.2, M33.3 and
M33.4 at the travel valve block in the car body. The respective high
pressure check point is on the other side diagonal to the SRV.
Adjust* the SRV at the desired travel function to 310 bar.
Reset the respective SRV at the main valve block to 310 bar, increase
the setting from a lower pressure just to the point when the gauge stop
increasing it should be 310 bar (provided setting from the SRV at the
brake valve is correct).
Create max. pump pressure with stick extending to the max. position
and re-set MRV to 310 + 5 bar after the check / adjustment is finished
and re-plug solenoid valve Y16
Stop enignes.
*
a)
b)
c)
d)
e)
PC5500-6-D_Sec_8-3_rev2.doc
06.10.05
8.3
12
PC5500-6-D_Sec_8-3_rev2.doc
06.10.05
Travel System
Section 8.3
Page 13
1.
2.
3.
4.
5.
PC5500-6-D_Sec_8-3_rev2.doc
06.10.05
26.03.03
Page
Hydraulic Track Tensioning System
General
9.1
Functional description
3+4
9.2
9.3
Tensioning Cylinder
9.4
Adjustments / Checks
79
9.5
Functional test
PC5500-6-D_Sec_9-0_rev0.doc
9.0
2
26.03.03
PC5500-6-D_Sec_9-0_rev0.doc
9.0
General:
Legend for illustration (Z 22453):
(62.1 62.4)
Track tensioning cylinders
(M15.3 + M15.4) Bleeder and hydraulic pressure check points at the
R.H.- tensioning cylinders.
(M15.1 + M15.2) Bleeder and hydraulic pressure check points at the
L.H.- tensioning cylinders.
(M15.5)
Bleeder and hydraulic pressure check point at the bladder
accumulator (59.1) for the L.H.-side.
(M15.6)
Bleeder and hydraulic pressure check point at the bladder
accumulator (59.2) for the R.H.-side.
(60.1 + 60.2)
Membrane accumulator, 1,3 liter (pre-charge pressure 31bar)
(54.2)
Service shut-off cock for the L.H.-side
(54.3)
Service shut-off cock for the R.H.-side
* "O" = open - "C" = closed
(59.1 + 59.2)
Bladder accumulator, 5 liter (pre-charge pressure 150bar)
(34)
Rotary joint
L3 (St)
Supply line from solenoid valve Y16 over rotary joint port St
The hydraulic track tensioning system ensures automatically the correct track
tension.
The pilot pressure pumps (7.1+7.2, see hydraulic diagram page 02) will supply
oil to all four tensioning cylinders (62.1-62.4).
The maximum pressure is limited by the pressure increasing valve (182), one
for both sides.
The pressure in the tensioning cylinders transmits the required force to move
the guide wheels to the front, until the correct track tension is obtained.
External forces acting at the guide wheels will be absorbed through the
pressure accumulators (60.1 + 60.2, first stage) and (59.1 + 59.2, second stage).
26.03.03
PC5500-6-D_Sec_9-0_rev0.doc
9.0
3
26.03.03
PC5500-6-D_Sec_9-0_rev0.doc
9.1
Functional description:
Illustration Z 22454:
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
continued
26.03.03
PC5500-6-D_Sec_9-0_rev0.doc
9.0
4
26.03.03
PC5500-6-D_Sec_9-0_rev0.doc
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:
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.
26.03.03
PC5500-6-D_Sec_9-0_rev0.doc
9.0
5
26.03.03
PC5500-6-D_Sec_9-0_rev0.doc
9.2
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.
26.03.03
PC5500-6-D_Sec_9-0_rev0.doc
9.0
6
26.03.03
PC5500-6-D_Sec_9-0_rev0.doc
9.3
Tensioning cylinder:
Legend for illustration (Z 21929):
(1)
Cylinder tube
(2)
Piston
(3)
(4)
(5)
Seal ring
(6)
O-ring
(7)
Scraper
(8)
Retracting device
26.03.03
Oil supply
PC5500-6-D_Sec_9-0_rev0.doc
9.0
7
26.03.03
PC5500-6-D_Sec_9-0_rev0.doc
9.4
Adjustments / Checks
Legend for illustration (Z 22455):
(182)
(54.3)
(54.2)
(59.2)
(60.2)
(MRV)
(M12.4)
(M15.6)
(M15.5)
(M15.3)
(62.3+62.4)
26.03.03
PC5500-6-D_Sec_9-0_rev0.doc
9.0
8
26.03.03
PC5500-6-D_Sec_9-0_rev0.doc
Cont'd.:
9.4
Adjustments / Checks
5.
6.
7.
8.
9.
10.
If the gauge shows a lower or higher value the pressure increasing valve
must be adjusted.
Setting procedure, high pressure stage (Valve 58.2)
a)
Loosen lock nut (2).
b)
Adjust pressure with set screw (3).
c)
d)
11.
The low pressure setting of the pressure increasing valve must now be
reset (with the pilot pressure line at port X still disconnected):
Setting procedure, low pressure stage (Valve 58.2)
a)
Stall the hydraulic with the bucket filling function (bucket
cylinders completely extended) and observe pressure at check
point M15.3.
b)
c)
d)
loosen lock nut (4) and turn set screw (5) ccw until gauge at
check-point M15.8 shows 35 bar.
Tighten lock nut (4).
Re-check pressure setting.
continued
26.03.03
PC5500-6-D_Sec_9-0_rev0.doc
9.0
9
26.03.03
PC5500-6-D_Sec_9-0_rev0.doc
Cont'd.:
9.4
Adjustments / Checks
12.
13.
Switch OFF the engine and open cock (54.1) to allow pressure relieve.
Re-connect the pilot pressure line to port X of the pressure increasing
valve (182).
Remove the pressure gauge hose between pressure check point M12.4
and pressure check point M16.1.
Close the cock (54.1).
Re-set MRV to 310 + 5 bar after the check / adjustment is finished.
13.
15.
16.
9.5
Functional Test
After all adjustments are finished, do the following:
a)
Bleed all air from the system
b)
Place shutoff and pressure relief cocks into correct operating position.
c)
Connect pressure gauge to check point (M15.3).
d)
Start engine and let it run with max. speed.
e)
Travel approx. 10 m with the shovel. The pressure should be rise to a
higher value.
f)
Stop the engine.
g)
The pressure must drop to 35 bar.
If the pressure remains at a higher or lower pressure*, re-adjust the low
pressure setting at the pressure increasing valve (182) is necessary.
26.03.03
The pressure may drop below 35 bar after a longer time, this is o.k.
because of internal leakage.
PC5500-6-D_Sec_9-0_rev0.doc
Access ladder
hydraulically operated
Section 10.0
Page 1
05.10.04
Page
Access ladder hydraulic operated
10.0 General
10.1
3+4
PC5500-6-D_Sec_10-0_rev1.doc
10.0
2
05.10.04
PC5500-6-D_Sec_10-0_rev1.doc
Access ladder
hydraulically operated
10.
Section 10.0
Page 2
05.10.04
If the ladder is out of range R3 the pilot control will cut off to prevent
any machine movement . At the same time the hydraulical swing brake
will be applied and the text display in the cab will show a message.
PC5500-6-D_Sec_10-0_rev1.doc
10.0
3
05.10.04
PC5500-6-D_Sec_10-0_rev1.doc
Access ladder
hydraulically operated
10.1
Section 10.0
Page 3
Pilot pumps
Check valves
Filter with filter monitoring switch B22
Pressure relieve valve X4 pressure = 60 bar
Pressure relieve valve X2 pressure = 35 bar
Check valves
Pressure relieve valve (70 bar)
Ladder cylinder
Orifice
Solenoid valve: flow reduction (slow speed)
Solenoid valve: ladder up
Solenoid valve: ladder down
60 bar auxiliary & control oil pressure
Function:
The engine is running
In addition to the hydraulic diagram Z 22495 also the electric diagram 897 899 40
on next page.
The pumps (7.1) and (7.2) are delivering oil through filter (68.1) to port P of the
solenoid valve Y123A/B (3 way- 4 port valve), and to the pressure relief valve
(70.1) port A. The pressure relief valve (70.1) maintains the adjusted pressure of
60 bar.
With solenoid valve Y123A/B in neutral position ports A, B, P and T are blocked.
If one of the solenoids is energised the valve directs pump oil to the cylinder.
Depending on the activated solenoid the cylinder gets pump oil to the piston or
rod side and the ladder move up or down.
The pressure relief valve (171) limits the pressure of the ladder cylinder to
maximal 70 bar.
With activated solenoid valve Y123A/B the return oil from the cylinder must pass
solenoid valve Y125. With de-energised solenoid valve Y125 the return oil flow
is restricted through orifice (172) resulting in a reduced speed of ladder
movement. More over, the combined function of sensors S22 / S91 and solenoid
valve Y125 provides smooth and cushioned approach of the ladder to the upper
and lower final stops. In the main movement range R2 the ladder speed is faster
because the energised solenoid valve Y125 allows unrestricted oil flow back to
the tank.
continued
05.10.04
PC5500-6-D_Sec_10-0_rev1.doc
10.0
4
05.10.04
PC5500-6-D_Sec_10-0_rev1.doc
Access ladder
hydraulically operated
Section 10.0
Page 4
Cont'd:
Y125 is energised when both proximity switches S22 and S91 are not activated
(ladder in R2.range)
If the ladder is in position B the activated sensor S22 de-energised Y125 and
energised Y123A, now unrestricted pump pressure is connected to the cylinder
piston side to keep the ladder pressurerized in the upper final stop position B.
If switch S84 is in neutral position and the ladder moves out of the R3 range all
solenoids (Y125; Y123 A+B) are de-energised and the ladder stops.
Engine off and the ladder in position C
With activated switch S84 in position 2 (ladder down) solenoid valve Y123B
and relay K132 are energised. Y123B connects the cylinder piston side via
solenoid valve Y125 to the tank. K132 activate Y125 so that the oil can flow
without resistance to the tank. Now, the ladder can move down only by its
own weight. The operator have to push the ladder slightly until it starts
moving.
The rod side of the cylinder receives oil via anti-cavitation valve (162.3).
The ladder controlling is independent to the main electric key switch S1 and
the battery master switch. The ladder circuit is directly supplied by the
battery via circuit breaker F17.
There is an additional pull switch S84A below the ladder support.
Make sure that there are no obstacles in the moving range of the
ladder. Stop raising the ladder by releasing the control switch (S84) if
there are any obstacles in the moving range.
Mount the ladder only in completely lowered position.
Do not lift persons or objects (tools) with the hydraulic access ladder.
Serious injury or death can be the result.
05.10.04
PC5500-6-D_Sec_10-0_rev1.doc
Hydraulic operated
refilling arm
Section 11.0
Page 1
26.03.03
Page
Hydraulic operated refilling arm
11.0 General
11.1
Function
PC5500-6-D_Sec_11-0_rev0.doc
11.0
2
26.03.03
PC5500-6-D_Sec_11-0_rev0.doc
Section 11.0
Page 2
26.03.03
If the refilling arm swing out of the upper position the pilot control will
stop all working functions and activate the swing brake. The text
display show a message.
PC5500-6-D_Sec_11-0_rev0.doc
11.0
3
26.03.03
PC5500-6-D_Sec_11-0_rev0.doc
10.1
Section 11.0
Page 3
Refilling arm
Control switch (pull switch) S87
Hydraulic cylinder
Limit switch S23
Pilot Pump
Pilot filter with filter monitoring switch B22
Pressure relieve valve (60 bar)
Pressure relieve valve (35 bar)
Check valves
Solenoid valve: refilling arm up
Solenoid valve: refilling arm down
Solenoid valve: security valve refilling arm locking
Hydraulic cylinder
26.03.03
PC5500-6-D_Sec_11-0_rev0.doc
Section 12.0
Page 1
Page
Hints for reading the hydraulic circuit diagram
General
12.1
22.12.04
Symbols
12.1.1 Lines, unions
12.1.2 Components, valves
12.1.3 Sensors
12.1.4 Valves, valve components
12.1.5 Pumps, motors, cylinders
12.1.6 Assemblies and main components
2
5
5-6
7
8
9-12
13-14
15-16
PC5500-6_Sec_12-0_rev3.doc
12.0
2
22.12.04
PC5500-6_Sec_12-0_rev3.doc
Section 12.0
Page 3
12.0 General:
Legend for Illustration Z22987
)
Item
22.12.04
Number / Code
Explanation
Component-No. 127
12041
1 C 10
127
L37/3B9
PC5500-6_Sec_12-0_rev3.doc
12.0
4
22.12.04
PC5500-6_Sec_12-0_rev3.doc
Section 12.0
Page 5
Symbols
Illustration Z 22988
12.1.1 Lines, unions
Symbol
Description
Used as / at / on
Crossed lines
Connection point, is a
connection of hydraulic
lines without definite
position
Component connection
point, is a connection with
a definite position at a
component
Plugged connection point,
can be plugged with any
kind of plugs.
Connection between
several lines
22.12.04
Connection to components
like, valve blocks, tanks,
pumps, ...
Not used connection
points.
PC5500-6_Sec_12-0_rev3.doc
12.0
6
12.1
Symbols
12.1.1 Line, union
Symbol
10
Description
Used as / at / on
Compensator,
Compensate line length
differences depend on
vibration and temperature.
Quick coupling,
is a special union with
integrated check valve
12
Blind, Orifice,
not adjustable with
orifice diameter in mm
13
14
Distributor block
11
22.12.04
PC5500-6_Sec_12-0_rev3.doc
Section 12.0
Page 7
Symbols
12.1.2 Components, valves
Symbol
Description
Used as / at / on
Accumulator,
is filled with nitrogen gas
with for the respective
accumulator specified
pressure
Screen filter,
the screen size is 1.0 mm
17
Oil cooler,
18
Breather filter,
On top of PTO or
hydraulic tank
19
Spray nozzles,
inside of a case for
cooling and lubricating
15
16
continued
22.12.04
PC5500-6_Sec_12-0_rev3.doc
12.0
8
12.1
Symbols
12.1.3 Sensors
Symbol
Description
Used as / at / on
20
21
Pressure switch
Input = pressure
Output = digital electrical
The switch point is 24 bar
22
Temperature sensor,
Input = temperature
Output = electric signal
proportional to the
temperature
23
Level sensor,
Input = fluid level
Output = electrical signal
analogue or digital
24
Chip sensor,
Input = contaminate oil
Output = electrical digital
signal
Main pumps
22.12.04
PC5500-6_Sec_12-0_rev3.doc
Section 12.0
Page 9
Symbols
12.1.4 Valves, valve components
Symbol
Description
Used as / at / on
25
26
Electric / magnetic
operated unit
Solenoid
Solenoid valve
27
Pilot pressure
controlled unit
28
Spring,
with fixed force
Solenoid valves,
29
Spring adjustable
spring force is adjustable
30
Check valve
In drawn pos.: from right
to left free flow, from left
to right blocked flow.
31
32
22.12.04
PC5500-6_Sec_12-0_rev3.doc
12.0
10
12.1
33
Symbols
Symbol
34
35
36
37
38
39
40
22.12.04
Ladder controlling,
service arm controlling
PC5500-6_Sec_12-0_rev3.doc
Section 12.0
Page 11
Symbols
12.1.4 Valves and valve components
Symbol
Description
Used as / at / on
41
42
43
44
22.12.04
Emergency mode
pressure (X3-pressure),
pilot oil pressure
PC5500-6_Sec_12-0_rev3.doc
12.0
12
12.1
Symbols
12.1.4 Valves and valve components
Symbol
Description
Used as / at / on
45
46
47
48
Proportional pressure
valve, reduce the
pressure in port A
proportional to the
solenoid current.
4 port proportional
pressure relief valve,
direct operated by a
proportional solenoids.
50
51
Distribution manifold
normally in the line to the
cylinder piston side.
49
22.12.04
PC5500-6_Sec_12-0_rev3.doc
Section 12.0
Page 13
Symbols
12.1.5 Pump, motor, cylinder
Symbol
Description
Used as / at / on
52
53
54
55
56
Main pumps
57
Hydraulic pump
assembly
with pump bearing
lubrication, one direction
and external case drain
Main pumps
22.12.04
PC5500-6_Sec_12-0_rev3.doc
12.0
14
12.1
Symbols
12.1.5 Pump, motor, cylinder
Symbol
Description
Used as / at / on
58
Variable hydraulic
pump with charge
pump
and external drive shaft
bearing lubrication
Main pump
59
Hydraulic motor
can be used in both
direction, with external
case drain L
Fan motor
60
Travel motor
61
22.12.04
PC5500-6_Sec_12-0_rev3.doc
Section 12.0
Page 15
Symbols
12.1.6 Assembly and main components
Symbol
Description
Used as / at / on
62
63
64
Rotary joint
Upper part with
connections drawn to
the top, lower part with
connections drawn to
the bottom
Hydraulical connection
between superstructure
and car body
65
22.12.04
PC5500-6_Sec_12-0_rev3.doc
12.0
16
12.1
Symbols
12.1.6 Assembly and main components
Symbol
Description
Used as / at / on
66
67
68
22.12.04
PC5500-6_Sec_12-0_rev3.doc
Section 13.0
Page 1
Page
Hints for reading the electric circuit diagram
13.1
13.2
Symbols
3+4
13.3
General information
5+6
13.4
7+8
Section 13.0
Page 2
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
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
14) Resistor
general
16) Battery
17) Tapped
resistor
18) Voltmeter
19) Inductive
resistance
20) Continuously
adjustable,
general
21) Recording
instrument
23) Adjustable in
steps
25) Continuously
adjustable
26) Potentiometer
rhesostat
28) Transformer
29) Capacitor
general,
continuously
adjustable
Push-button
switch
3) Single pole
two way contact
break before make
6) Limit switch
NO contact
NC contact
9) Pressure
operated switch
12) Indicating
instrument
(general) symbol
15) Ammeter
13.0
4
Section 13.0
Page 4
13.2 Symbols
Legend for illustration (Z 21817):
31) Rectifier bridge
39) Junction
41) Contactor
42) Terminal
45) Terminal
47) 3-phase-motor
13.0
5
Section 13.0
Page 5
X2S
45
All circuits are shown currentless and all relays and switches are in neutral position.
13.0
6
Section 13.0
Page 6
Drawing number
Sheet number / quantity of sheets
Designation of drawing
Designation of component or assembly
Column (vertical sections)
Lines (horizontal sections)
Component symbol
Neutral wire / machine ground
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
Designation of phase
Phase strip
Terminal strip and terminal
Cable plug and pin number
Relay coil
Relay contacts, partially with detailed information
Cross reference for the continuation, Page / Column
Indication where the relay contact opens or closes
13.0
7
Section 13.0
Page 7
)
(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.
1
5
2
6
3
7
4
8
9
10
11
12
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.
*
**
(3)
Section F7 / sheet 08
Connectors and Terminals are identified by a letter and number
code. X2 o 23-28 = Terminal box X2 Terminals 23 to 28 are linked
with a metal bridge.
continued
13.0
8
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 =
c.
S27 / 20.7 =
Function:
If switch S27 is actuated, terminal A and B are connected and 24VDC will
energize the coils of K121 and K121a on page 08 and simultaneously via line
S27 a digital input to the PLC on sheet 20 section 7.
Now the machine can be operated in emergency mode and a warning text
appears on the display.
Section 14.0
Page 1
Page
Electronic Control System ECS
14.1
14.2
14.3
14.4
14.5
14.6
PC5500-6-D_Sec_14-0_rev2.doc
14.1.1
14.1.2
14.1.3
14.1.4
3
3
4
5 + 6 +7
8+9
14.2.1
14.2.2
14.2.3
10 + 11
12
13
14
14.3.1
14.3.2
14.3.3
14.3.4
14 + 15
16 + 17
18
19
Power supply
20
14.4.1
14.4.2
14.4.3
14.4.4
14.4.5
20
21
22
22
22
23
14.5.1
14.5.2
14.5.3
14.5.4
23
24
25 + 26
27
General
Pressure Measuring
Temperature Measuring
Temperature Resistance Chart PT100
28
14.6.1
14.6.2
28
29
General
Example
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14.0
2
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Section 14.0
Page 2
Legend:
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
I/ O
Illust. Z 21407a
BIM
Binary Module
ANM
Analogous Module
MK
Short Circuit Memory
A
Digital Output
E
Digital Input
DIAG
Diagnostic
More in detail see page 4
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14.0
3
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Section 14.0
Page 3
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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14.0
4
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Section 14.0
Page 4
The quantity and configuration of the BIM and ANM Module can be
vary, depend on the excavator typ and additional options.
MK-LED, The short circuit marker are used to indicate an external short to GND
MK1, MK3, MK5, MK7 & MK9- LED for outputs A1.1 - A1.8
A3.1 - A3.8, A5.1 - A5.8, A7.1 - A7.8 & A13.1 A13.8
MK2, MK4 , MK6, MK8 and MK10 if there groups as outputs used
A MK-marker is placed, if an output (e.g. A1.1) gets from the program an output signal
and at the same output happens an external short. The red MK 1-LED lights ON
If there is a short all outputs of the resp. Output group i.e.. A1.1 - A1.8)
are switched Off
The short circuit marker remains until the control system gets switched
Off/ON (after eliminating the short).
PC5500-6-D_Sec_14-0_rev2.doc
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Section 14.0
Page 5
Bit
Boolean algebra Mathematical rules for binary variables and conditions. For Boolean
equations the following signs are used:
Logical AND operation (AND or &)
Byte
Unit for Information unit comprised of 8 bits. A byte can assume a value
between 0 and 255.
Word
Clock
Signal pulse
VWP
AWP
AWL
CMOS
Complementary Metal-Oxide Semiconductor: Complementary metaloxide semiconductor technology with very low-level closed circuit
current. These semiconductors are used above all for accumulator and
battery buffering.
RAM
EPROM
PC5500-6-D_Sec_14-0_rev2.doc
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Section 14.0
Page 6
Cont'd:
EEPROM
Loop
Program loop.
Off-Line
On-Line
PC
Cycle Time
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Section 14.0
Page 7
Cont'd:
Coding Types and Number Systems
ASCII
Digital
Analogue
Numeral
A value expressed in one digit: from 0 to 9 in the decimal system and 0-F
in the hexadecimal system.
Number
Baud
Baud Rate
Binary
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06.10.05
Section 14.0
Page 8
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
PC5500-6-D_Sec_14-0_rev2.doc
06.10.05
Section 14.0
Page 9
Contd.:
Serious damage may happen at irrelevant opening and improper repair.
Open always the resp. circuit breaker before opening a unit.
I/O cables may only be connect or disconnect in a powerless state.
A BIM module will be damaged while supplying an external power
of 24VDC to the inputs and/ or outputs. If it is necessary for
faultfinding or external unit checks the connection to the PLC has to be
interrupted.
Without power interruption the interface cable are only allowed to be
disconnect or connect when following preconditions are given:
1. The cable must be shielded and the shield must be connected to the
cover of the plug-in connector.
2. A potential balance must be made by connecting the GND
potential parts of the plug connector parts before connecting
the cables.
Replace the fuses only by fuses which matches the values given in the
technical dates
Do not through batteries into open flame and do not solder at their cell
body, explosion can occur (max. Temperature 100 C). Do not open and
do not recharge batteries that contain lithium or mercury. Replace
them by same type only!
Dispose batteries and accumulators as special waste.
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14.0
10
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06.10.05
Section 14.0
Page 10
Remedy
Check the
+24 V Supply
if not o.k. *)
Check the
+24 Volt
Replace the **
Fuse F1
LED defect
(if DIAG
LED is ON)
*)
others
*)
Watchdog
in operation
*)
5 V-LED
flashing
red/green
cyclically
new starts
red/
orange
Continuos Reset
Component fault
*)
** Replacement only after co-ordination with Komatsu Mining Germany, Dept. 8124.1
*) = Return PLC to manufacturer
continued
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14.0
11
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Section 14.0
Page 11
14.2.1
Meaning of the Status LEDs, Illust. Z 21431b
Contd.:
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
Accumulator voltage
too low
Replace the
accumulator module
Fixed operands
deleted
Check the
accumulator
connections
wait
programming in
operation
EEPROM not
Initialized
Stop the
programming *1)
Initialize
EEPROM *1)
EEPROM- or
RAM- fault
Initialize
EEPROM *1)
if the fault is
still present *2)
Start program *1)
DIAG-LED
RED
DIAG-LED
OFF
Program
not running (stopped)
Program
not running
(except LED
defect)
Program
stopped
No Program
otherwise LED
defect
DIAG
ProgramCommunication via
flashing
state
Interface COM-SP
or COM-SK active
unchanged
Color State
COM-SP Text
depending
Display
COM-SK (PC)
*1) Function of the Programming Software PROSYD
*2) = Return PLC to manufacturer
PC5500-6-D_Sec_14-0_rev2.doc
Remedy
Check the cable
connection and the
Interface port
External cooling
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14.0
12
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Section 14.0
Page 12
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14.0
13
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Section 14.0
Page 13
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06.10.05
Section 14.0
Page 14
.This is an example for the first Slot. Additional BIM Modules can
be vary depend on configuration of the variable input/output port
A2/E9/ A4E10, A6/E11, A8/E12 or A14/E21.
The configuration for the respective excavator is written in the
EA-Configuration chart (EA-Belegungsliste) see Apendix.
Pin
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Symbol
Input 1.1
Input 1.2
Input 1.3
Input 1.4
Input 1.5
Input 1.6
Input 1.7
Input 1.8
Input 9.1
Input 9.2
Input 9.3
Input 9.4
Input 9.5
Input 9.6
Input 9.7
Input 9.8
0 V (GND)
Input 2.2
Input 2.4
Input 2.6
Input 2.8
Operand
E 1.1
E 1.2
E 1.3
E 1.4
E 1.5
E 1.6
E 1.7
E 1.8
E 9.1
E 9.2
E 9.3
E 9.4
E 9.5
E 9.6
E 9.7
E 9.8
E2.2
E2.4
E2.6
E2.8
Definition
Input 1 of the input group. 1
Input 2 of the input group. 1
Input 3 of the input group 1
Input 4 of the input group 1
Input 5 of the input group 1
Input 6 of the input group 1
Input 7 of the input group 1
Input 8 of the input group 1
Input 1 of the output group 2
Input 2 of the output group 2
Input 3 of the output group 2
Input 4 of the output group 2
Input 5 of the output group 2
Input 6 of the output group 2
Input 7 of the output group 2
Input 8 of the output group 2
Ground
Input 2 of the input group 2
Input 4 of the input group 2
Input 6 of the input group 2
Input 8 of the input group 2
continued
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Section 14.0
Page 15
Contd.:
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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Section 14.0
Page 16
PIN
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
PIN-NAME
KR
KG
KA
GND/ANA
GND/ANA
GND/ANA
GND/ANA
A1I
A1U
A2I
A2U
A3I
A3U
A4I
A4U
A4G
A3G
A2G
GND/ANA
GND/ANA
GND/ANA
E8G
E7G
E6G
E5G
OPERAND
AW Z.1
AW Z.1
AW Z.2
AW Z.2
AW Z.3
AW Z.3
AW Z.4
AW Z.4
COMMENTARY
Relay contact
Relay contact
Relay contact
Analogous GND
Analogous GND
Analogous GND
Analogous GND
Current output 1
Tension output 1
Current output 2
Tension output 2
Current output 3
Tension output 3
Current output 4
Tension output 4
GND Output 4
GND Output 3
GND Output 2
Analogues - GND
Analogues - GND
Analogues - GND
GND input 8
GND input 7
GND input 6
GND input 5
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Section 14.0
Page 17
Contd.:
PIN
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
PIN-NAME
A1G
4U+E4G
A2G
E3G
A3G
E2G
A4G
E1G
GND/ANA
E8
GND/ANA
E7
GND/ANA
E6
GND/ANA
E5
A1G
E4
E4
E3
E3
E2
E2
E1
E1
OPERAND
EW Z+1.4
EW Z +1.3
EW Z +1.3
EW Z +1.3
EW Z.4
EW Z.4
EW Z.3
EW Z.3
EW Z.2
EW Z.2
EW Z.1
EW Z.1
COMMENTARY
GND - Output 1
GND - Input 4
GND - Output 2
GND - Input 3
GND - Output 3
GND - Input 2
GND - Output 4
GND - Input 1
Analogues GND
Input (U/I) 8
Analogues GND
Input (U/I) 7
Analogues GND
Input (U/I) 6
Analogues GND
Input (U/I) 5
GND Output 1
Input (U/I) 4
Input (U/I) 4
Input (U/I) 3
Input (U/I) 3
Input (U/I) 2
Input (U/I) 2
Input (U/I) 1
Input (U/I) 1
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Section 14.0
Page 18
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14.0
19
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Section 14.0
Page 19
Interface-connection COM SK / SP
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
Communication interface:
COM-SK => Programming interface (Baud rate 19200)
COM-SP => Communication with text display (Baud rate 9600)
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14.0
20
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Section 14.0
Page 20
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!
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14.0
21
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Section 14.0
Page 21
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)
PC5500-6-D_Sec_14-0_rev2.doc
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Section 14.0
Page 22
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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Section 14.0
Page 23
General
Signal Status
Voltage level:
1 = 24 V* between E (Input) and GND
0 =
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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14.0
24
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Section 14.0
Page 24
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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14.0
25
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Section 14.0
Page 25
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26
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Section 14.0
Page 26
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Section 14.0
Page 27
ECS
14.5 Function explanations with electrical diagram
14.5.4
-0
-1
-2
-3
-4
-5
-6
-7
-8
-9
-50
80,31
79,91
79,51
79,11
78,72
78,32
77,92
77,52
77,13
76,73
-40
84,27
83,88
83,48
83,08
82,69
82,29
81,89
81,50
81,10
80,70
-30
88,22
87,83
87,43
87,04
86,64
86,25
85,85
85,46
85,06
84,67
-20
92,16
91,77
91,37
90,98
90,59
90,19
89,80
89,40
89,01
88,62
-10
96,09
95,69
95,30
94,91
94,52
94,12
93,73
93,34
92,95
92,55
100,00
99,61
99,22
98,83
98,44
98,04
97,65
97,26
96,87
96,48
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
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:
84 C
80 + 4 = 132,42
124,4
124,4 124,39 = 60 + 3 = 63 C
PC5500-6-D_Sec_14-0_rev2.doc
06.10.05
Section 14.0
Page 28
General
Probably the best aid for trouble shooting is the confidence of knowing
the system and how to use the ECS. Every component has a purpose in
the system. The construction and operating characteristics of each one
should be understood.
Use always the electric/hydraulic circuit diagram the flowchart and
the operation manual for the specific machine.
1. Select on page 1 of the flow chart, (which contains the table of contents
and the main program) the respective subprogram, for example the
Power-Master lube system.
2. Components in the flow chart, have the same identification code as in the
electric/hydraulic circuit diagram, as shown in cross reference list (page 2-4).
For example: Relay K50 = ?
On page 2 (cross reference list) you find out that relay K50 is shown on
page 43 of the flowchart.
3. On each page of the respective subprogram you will find the functional
description in plain text.
In case of problems concerning reading the program loops, you may find
answers in the frequently asked questions list on page 6 and 7 of the flow
chart.
PC5500-6-D_Sec_14-0_rev2.doc
06.10.05
14.0
29
PC5500-6-D_Sec_14-0_rev2.doc
06.10.05
Section 14.0
Page 29
query
Sensor or cable
defect?
Yes
No
B85-X : 5 sec. < --6bar
B85-X : 5 sec. : Voltage
between 1V and 11V at
i.e. <1V at EW13.3
or
EW13.3
B85-X : 5 sec. > +55,3bar
i.e. > 11V at EW13.3
2)
3)
_running_motor-x
> 15 sec ?
X1-pressure to
high?
PC5500-6-D_Sec_14-0_rev2.doc
06.10.05
Section 15.0
Page 1
Lubrication System
Table of contents
Page
General Function
Oscillation Cylinder and Control Block
Adjustments
One line system
Electrical function
Capacitive analog sensor for lubricant level monitoring
Adjustments
End Line pressure switch
Injectors
Function Pinion type (dummy wheel) system
Electrical Function (dummy wheel) system
Capacitive analog sensor for lubricant level monitoring
Adjustments
End-Of-Line Switch setting
Injectors
Components
Hydraulically driven lube pump
Injectors
End-Line Switch
In line Filter
Vent valve (Solenoid valve)
05.10.04 rev.5
3
9
11
13
17
21
23
25
27
31
35
37
39
41
45
51
53
55
PC5500-6-D_Sec_15-0_rev1.doc
15.0
2
Lubrication System
Section 15.0
Page 3
Lubrication System
General Function
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
Lubricant barrel
Pump mechanism
Lubricant filter
Hydraulic pressure test plug (Operating pressure)
Lubricant pressure gauge (Operating pressure)
Vent line to barrel
Breather
Electrical terminal box
continued
05.10.04 rev.5
PC5500-6-D_Sec_15-0_rev1.doc
15.0
4
Lubrication System
Cont'd.
X-axis
Y-axis
Time
Lubricant supply line pressure
PI
S+
PH
SPR
PT
Pressure Increasing
Switch point ON of the end of line pressure switch
Pressure Holding
Switch point OFF of the end of line pressure switch
Pressure Relieve
Pause Time
Lubrication System
Section 15.0
Page 5
PT-phase
With the pump and controller system in a rest state a pre-set pause time interval
occurs as determined by the PLC.
Diagram position (a):
A 24 VDC signal from the PLC activate solenoid valve (2) that opens and activate
the lubrication pump. (*). As solenoid valve (2) opens hydraulic oil flows through
the pressure reducing valve (4), it lowers the hydraulically pilot oil pressure to the
operating range of the hydraulic driven lube pump. The reduced pilot oil pressure
operates now the grease pump. The oil cylinder shuttles the grease cylinder at 18
20 double strokes per minute and delivering 612 680 cm (37.3 41.5 in) of
lubricant per minute (approx. 550 612 g / 19.64 21.45 oz.)
At the same time a 24 V signal energize release valve (7), it close now the release
line to the lubrication container.
PI-phase
With energized release valve (7) (*) and solenoid valve (2) the pump continues to
cycle until maximum pressure is achieved and the injectors have metered
lubricant to the bearings.
S+ point, diagram position (b)
When the maximum system pressure is reached the end-of-line switch (*) open its
contact. In the normal application is the end-of-line switch adjusted to 185 bar
(2630 psi. ).The pressure increasing phase is now finished.
The open pressure switch (*) signals the controller to stop the pumping cycle and
the controller terminates the signal to the solenoid valves (2) The pilot oil flow to
the pump stops.
Solenoid valve 2
Y7, CLS
Vent valve 7
Y7a, CLS (1)
end-of-line switch
B43, CLS
Y9a, SLS
B46, SLS
PC5500-6-D_Sec_15-0_rev1.doc
15.0
6
Lubrication System
Cont'd.
X-axis
Y-axis
Time
Lubricant supply line pressure
PI
S+
PH
SPR
PT
Pressure Increasing
Switch point ON of the end of line pressure switch
Pressure Holding
Switch point OFF of the end of line pressure switch
Pressure Relieve
Pause Time
Lubrication System
Section 15.0
Page 7
Cont'd.
PH-phase
Release valve (7) is still energized to keep the pressure in the lubricant line for a
fix adjusted time (pressure holding time normally 5 min).
Diagram position (c):
With expired pressure holding time vent valve (7) de-energize. It opens the
release line to the lubricant container. The lubricant line pressure drop to zero so
the injectors can recharge for the next lubricant injection. (PR-phase).
PR-phase
In the pressure relieve phase the end of line switch (*) move back to neutral
contact position it signals the PLC that the lube pressure relieve phase is now
active.
PT-phase
The system is now at rest (pause time), ready for another lube cycle and the
sequence repeats itself.
05.10.04 rev.5
PC5500-6-D_Sec_15-0_rev1.doc
15.0
8
Lubrication System
Section 15.0
Page 9
Lubrication System
Description:
Oscillation cylinder (6) is auto directional controlled, non pressure related. This
differential cylinder is connected to the pilot pressure suppliy line (P) and a tank
line (T). The speed is contolled by a flow contol valve (3) and the maximum
working pressure is controlled by a pressure reducing valve (2).
Function:
The Oscillatin cylinder (6) starts as soon pilot pressure is send via the connection
(P) to the control block (1). Design related the cylinder (6) retract always first
after start or from any position the piston has stopped before. When the cylinder
reaches the fully retracted position the flow will be redirected automatically and
the cylinders moves in the extending position. If the cylinder comes to an stop in
between the end positions weather the oil supply get stopped or the cylinder is
hold back by a higher work resistance than the supply pressure, the cylinder
changes direction and retracts.
05.10.04 rev.5
PC5500-6-D_Sec_15-0_rev1.doc
15.0
10
Lubrication System
Lubrication System
Adjustments
Section 15.0
Page 11
(illustration Z21175b):
Stroke speed
For a sufficient lube pump operation 18 20 double strokes / min for the pump
drive cylinder are required. Therefore the flow reducing valve (3) has to be
adjusted accordingly.
Procedure:
1. Remove electrical plug connection form the discharge valve (7), so no
pressure built up will take place during the following test.
2. Start engine and run at high idle.
3. Switch ON the lube system annually and count strokes per minute, visible
on the moving up and down of pipe (1).
If adjustment is required:
a. Loosen lock nut (3.1)
b. Turn adjustment (3) until the right number of strokes is achieved.
turn set screw ccw for more speed and cw to reduce the speed
c. Tighten lock nut (3.1).
Working pressure
The pressure reducing valve (2) mounted in the oscillation control block reduce
the supply pressure internally to maximal allowed 45 bar.
The pressure ration is 6,55 to 1, that means 45 bar supply pressure result in 295 bar
maximum lubricant pressure.
At the end of line pressure switch the pressure should be 180 0,5 bar. With the
lubricant line resistance and different lubricant viscosity the pressure at the
lubricant pump output must be higher as 180 bar. For standard condition adjust the
maximum pump pressure to 220 bar 250 bar, depend on lubricant line resistance
and different lubricant viscosity.
Procedure:
1. Disconnect quick coupling (8), so the pump will be blocked when started.
2. Start engine and run at high idle.
3. Switch ON the lube system manually, the gauge should show 220-250 bar.
If adjustment is required:
a. Loosen lock nut (2.1)
d. Turn adjustment (2) until the right pressure is shown at the gauge.
turn set screw ccw for lower pressure and cw to increase the pressure
b. Tighten lock nut (2.1).
c. Reconnect quick coupling (8).
)
05.10.04 rev.5
15.0
12
Lubrication System
Section 15.0
Page 13
Lubrication System
Function:
As soon as the adj. "Pause-Time" is finished the solenoid valves
(2) and (7) are energized. The lubricant pump (1) start to pump lubricant in
the lubricant supply line.
By the function of the solenoid valve (7) the port to the vent line (15) (return
line to the lubricant container) is closed, thus a pressure built up is possible.
The high-pressure barrel pump (1) supplies lubricant into the supply line (8). It
continuos through the lubricant filter (12) to the injectors (metering valves) (18).
The picture shows an example only. The hole system includes much
more injectors which are connected via pipes or hoses to the supply
line (8).
In the Injectors the lubricant forced with full pump pressure via the feed lines
(19) to the lube points.
The actual operating pressure can be monitored at the pressure gauge (14)
and checked at the pressure check point (17).
continued
05.10.04 rev.5
PC5500-6-D_Sec_15-0_rev1.doc
15.0
14
Lubrication System
Lubrication System
Section 15.0
Page 15
Cont'd.
Illustr. Z 21176
When all injectors pistons have reached there final position no more lubricant
is accepted from the supply line which causes a pressure increase in the
supply line (8).
As soon as the pressure reaches the adjusted value of the end-of-line switch
(16) the solenoid valves (2) de-energized and the lubricant pump switched
Off. Depend on different factory settings vent valve (7) de energize together
with solenoid valve (2) or after a fix adjusted time of max. 5 minutes.
With de-energized solenoid valve (7) the port to vent line (15) ( return line to
the lubricant container ) opened and release the lubricant and lubricant
pressure in to the container.
With the diminishing pressure in the main line the pistons of the injector (18)
are forced by spring force in their initial position and the discharge chambers
are filled with grease for the following lubrication cycle.
The system is now prepared for a new lubrication cycle. The operation is reinitiated after the next "Pause Time" is elapsed.
The proper build-up of the pressure in the supply line (8) is monitored by the
end-of-line switch (16).
If the pressure adjusted at the end-of-line switch will not reached within the
adjusted "Monitoring Time" the fault message Central lubrication system
fault comes up on the text display and the system switch off
05.10.04 rev.5
PC5500-6-D_Sec_15-0_rev1.doc
15.0
16
Lubrication System
Lubrication System
Section 15.0
Page 17
05.10.04 rev.5
PC5500-6-D_Sec_15-0_rev1.doc
15.0
18
Lubrication System
Lubrication System
Section 15.0
Page 19
Cont'd:
Illustr. Z 21177a
The next lubrication cycle starts after the decreasing time and pause time has
expired.
With the switch S24 an additional lubrication can be carried out any time provided
the end of line pressure switch (B43) contact is closed.
Monitoring:
The orderly built-up of the pressure in the lubricant supply line is monitored by
the end-of-line switch (B43 or B46).
If the pressure adjusted at the end-of-line switch is not reached within the adjusted
maximal increasing time the PLC switch off both solenoid (Y7 and Y7A or Y9
and Y9A) valves and send the fault message Central lubrication system fault or
Swing ring lubrication system fault to the text display at the dash board.
If the excavator is still working additional four hours with faulty lubrication
system the PLC stop the bucket function. This function is to prevent trouble
depend on a lack of lubricant.
Continued
05.10.04 rev.5
PC5500-6-D_Sec_15-0_rev1.doc
15.0
20
Lubrication System
Section 15.0
Page 21
Lubrication System
05.10.04 rev.5
PC5500-6-D_Sec_15-0_rev1.doc
15.0
22
Lubrication System
Lubrication System
Section 15.0
Page 23
Adjustments
End line switch setting. Illustration Z 21180
1.
Start engine.
Start a lube cycle with the dashboard switch S24.
+
Watch pressure gauge. At a pressure of 180 10 bar the end-line switch
must react and the lubricants pump must stop.*
If at the same time the pressure shown at the built-in gauge is noted
down, this pressure can be taken for later on checks as a reference
pressure.
180 bar is the normal setting.
Under particular circumstances it may be necessary to increase the
pressure slightly
If re-setting is required:
5.
Screw out screw 1 and take off cover 2.
6.
Alter the spring tension with adjustment screw 3 that the switch
operates at 180 bar.
7.
Install cover 2 and screw 1.
continued
05.10.04 rev.5
PC5500-6-D_Sec_15-0_rev1.doc
15.0
24
Lubrication System
Section 15.0
Page 25
Lubrication System
Cont'd:
Injectors, illustr. 21181:
Series SL-1 injector:
Lubricant output adjustable from 0.13 up to 1.3 cm per cycle. Hydraulic type
fitting with screw type cover cap is provided for initial filling of feeder line, and
may also be used for visual check of injector operation.
Series SL-1 injectors incorporate a stainless steel visual indicator.
Series SL-11 injector:
Lubricant output adjustable from 0.82 up to 8.2 cm per cycle.
Designed for systems where a high amount of lubricant is required.
Principle of operation similar to series SL-1.
Adjusting the lubricant output:
1.
Loosen lock nut (C).
2.
Turn adjusting screw (A) counterclockwise (OUT) for more lubricant
output or clockwise (IN) for less lubricant output.
3.
Tighten lock nut (C).
05.10.04 rev.5
The max. lubricant output is adjusted if the indicator stem (B) moves
not more further outwards
PC5500-6-D_Sec_15-0_rev1.doc
15.0
26
Lubrication System
Section 15.0
Page 27
Lubrication System
Z 21183a
Lubricant pump drive (Hydraulic cylinder)
Solenoid valve Y9 (Oil pressure supply)
Flow control valve
Pressure reducing valve
Hydraulic oil supply line (Pilot pressure)
Hydraulic oil return line
Vent valve Y9A (Solenoid valve, de-energized open)
Grease supply line to injectors
Lubricant level indication
Lubricant barrel
Pump mechanism
Lubricant filter
Hydraulic pressure test plug (Operating pressure)
Lubricant pressure gauge (Operating pressure)
Vent line to barrel
Breather
Electrical terminal box
Principle of operation:
By the lubricant pump, the lubricant is supplied to the centered bore hole (B) of the
lubrication type pinion (R). Bore hole (B) must be perfectly aligned to the center of
the lubrication type pinion (A) to be greased, so that lubricant leaves the tooth flank
always when the gear tooth is in contact. The grease outlet (D) of the lubricating type
pinion is arranged at a different angle for each tooth, so that the lubricant is distributed
in a uniform and perfect manners on the tooth flank of the drive pinion to be
lubricated.
Function:
As soon as the adjusted "Pause-Time" elapse the solenoid valves (2 + 7). energized
and the lubricant pump (1) start to pump lubricant.
By the function of the solenoid valve (8) the port to the vent line (15) (return line to
the lubricant container) closed, thus a pressure built up is possible.
The high-pressure lubricant pump (1) supplies lubricant into the supply line (8). It
continuos through the lubricant filter (12) to the injectors (metering valves) (18).
The picture shows an example with one pinion only. There are also
machines which have more lubrication type pinion (dummy wheel).
By the injectors the lubricant is forced with full pump pressure via the feed line
(19) to the centered bore hole (B) of the lubricating type pinion (R).
continued
05.10.04 rev.5
PC5500-6-D_Sec_15-0_rev1.doc
15.0
28
Lubrication System
Lubrication System
Section 15.0
Page 29
Cont'd.
Illustr. Z 21183a
The actual operating pressure can be monitored at the pressure gauge (14)
and checked at the pressure check point (17). When all injector pistons have
reached there final position no more lubricant will accepted from the supply
line (8) which causes a pressure increase in the supply line.
Depend on different factory settings vent valve (7) de energize together with
solenoid valve (2) or after a fix adjusted time of max. 5 minutes.
With de-energized solenoid valve (7) the port to vent line (15) ( return line to
the lubricant container ) opened and release the lubricant and lubricant
pressure in to the container.
With the diminishing pressure in the main line the pistons of the injector (18)
are forced by spring force in their initial position and the discharge chambers
fill up with grease for the following lubrication cycle.
The system is prepared for the next lubrication cycle. The operation is
reinitiated after the next "Pause Time".
The proper build-up of the pressure in the supply line (8) is monitored by the
end-of-line switch (16).
If the pressure adjusted at the end-of-line switch is not reached within the
adjusted "Monitoring Time" the fault message Slew ring gear lubrication
system fault is shown on the text display and the pump switch off.
05.10.04 rev.5
PC5500-6-D_Sec_15-0_rev1.doc
15.0
30
Lubrication System
Lubrication System
Electrical function.
Section 15.0
Page 31
Illustration Z 21177b
05.10.04 rev.5
PC5500-6-D_Sec_15-0_rev1.doc
15.0
32
Lubrication System
Lubrication System
Section 15.0
Page 33
Cont'd:
Illustr. Z 21177b
The next lubrication cycle starts after the decreasing time and pause time has
expired.
With the switch S26 an additional lubrication can be carried out any time provided
the end of line pressure switch (B46) contact is closed.
Monitoring:
The orderly built-up of the pressure in the lubricant supply line is monitored by
the end-of-line switch (B46).
If the pressure adjusted at the end-of-line switch is not reached within the adjusted
maximal increasing time the PLC switch off both solenoid valves (Y9 and Y9A)
and send the fault message Central lubrication system fault to the text display at
the dash board.
If the excavator was working additional four hours with faulty lubrication system
the PLC stop the bucket function. This function is to prevent trouble depend on a
lack of lubricant.
Continued
05.10.04 rev.5
PC5500-6-D_Sec_15-0_rev1.doc
15.0
34
Lubrication System
Section 15.0
Page 35
Lubrication System
05.10.04 rev.5
PC5500-6-D_Sec_15-0_rev1.doc
15.0
36
Lubrication System
Lubrication System
Section 15.0
Page 37
Adjustments
End of line switch setting, illustration Z 21185
1.
Connect pressure gauge to check point close to the end of line pressure
switch.
Block the swing function with the swing ring parking, use the switch at
the dash board.
Start engine.
Start a lube cycle with the dashboard switch S26 and activate for a short
time the swing function to the left or right.
+
Watch pressure gauge. At a pressure of 180 10 bar the end of line
switch must react and the lubricants pump must be stopped.*
If at the same time the pressure shown at the built-in gauge is noted
down, this pressure can be taken for later on checks as a reference
pressure.
But be careful this pressure is higher than the pressure shown at the test
gauge because of the long distance between pump and end of the
supply line.
05.10.04 rev.5
PC5500-6-D_Sec_15-0_rev1.doc
15.0
38
Lubrication System
Section 15.0
Page 39
Lubrication System
Cont'd:
Injectors, illustr. 21181:
Series SL-1 injector:
Lubricant output adjustable from 0.13 up to 1.3 cm per cycle. Hydraulic type
fitting with screw type cover cap is provided for initial filling of feeder line, and
may also be used for visual check of injector operation.
Series SL-1 injectors incorporate a stainless steel visual indicator.
Series SL-11 injector:
Lubricant output adjustable from 0.82 up to 8.2 cm per cycle.
Designed for systems where a high amount of lubricant is required.
Principle of operation similar to series SL-1.
Adjusting the lubricant output:
1.
Loosen lock nut (C).
2.
Turn adjusting screw (A) counterclockwise (OUT) for more lubricant
output or clockwise (IN) for less lubricant output.
3.
Tighten lock nut (C).
05.10.04 rev.5
The max. lubricant output is adjusted if the indicator stem (B) moves
not more further outwards
PC5500-6-D_Sec_15-0_rev1.doc
15.0
40
Lubrication System
Section 15.0
Page 41
Lubrication System
Breather plug
Ball, outlet check valve
Ball and seat, check valve
Main piston and plunger
Piston rod set
Inlet valve
Scoop piston
Grease inlet
HINT:
Loss of pressure or to short pump strokes indicates:
A
05.10.04 rev.5
PC5500-6-D_Sec_15-0_rev1.doc
15.0
42
Lubrication System
Lubrication System
Section 15.0
Page 43
05.10.04 rev.5
PC5500-6-D_Sec_15-0_rev1.doc
15.0
44
Lubrication System
Section 15.0
Page 45
Lubrication System
TASK:
A readjusted (at the injector) volume of grease is pushed with the injectors to
the bearings or to the progressive distributors.
Design: (model SL1)
(01+02)
Metering valve, assy.
(03+04)
Injector bar
(05)
Adjusting screw
(06)
(07)
Nut
Plug screw
(04)
(05)
Plug screw
O-ring
(08)
(09)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
Seal ring
Disk
Seal ring
Bolt with nut
Disk
Seal ring
Piston
Compression spring
Spring retainer
Seal ring
Disk
Seal ring
Disk
Piston
(06)
(07)
(08)
(09)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
Disk
Seal ring
Disk
Guide
Indicator pin
Seal ring
Piston
Seal ring
Pin
Compression spring
Spring retainer
Bolt with piston
Seal ring
Valve housing
(22)
(23)
(24)
(25)
Seal
Adapter bolt
Valve housing
Union
(20)
Union
continued
05.10.04 rev.5
PC5500-6-D_Sec_15-0_rev1.doc
15.0
46
Lubrication System
Lubrication System
Section 15.0
Page 47
Cont'd:
Function: illustr. Z 21188
Pos. 1
The injector piston (2) is in its normal or rest position. The discharge
chamber (9) is filled with lubricant from the previous cycle.
Under the pressure of incoming lubricant the slide valve (4) is about
to open the passage (5) leading to the piston.
Pos. 2
When the slide valve (4) uncovers the passage lubricant is admitted to
the top of piston (2) forcing the piston down. The piston force
lubricant from the discharge chamber (9) through the outlet port (10)
to the bearing or progressive distributor.
The lubricant pressure at the bearing or the progressive distributor is
always the same as the pump pressure.
Pos. 3
As the piston completes its stroke, it pushes the slide valve (4) past the
passage, cutting off further admission of lubricant to the passage.
Piston and slide valve remain in this position until lubricant pressure
in the supply line is vented (relieved) at the pump.
This is indicated by the injector stem (8). (fully in)
Pos. 4
After pressure is relieved the compressed spring (3) moves the slide
valve (4) to closed position.
This opens the port from the measuring chamber and permits the
lubricant to be transferred from the top of the piston to the discharge
chamber.
This is also indicated by the injector stem (8) (fully out)
continued
05.10.04 rev.5
PC5500-6-D_Sec_15-0_rev1.doc
15.0
48
Lubrication System
Lubrication System
Section 15.0
Page 49
Cont'd:
Connection of one or more injectors, illustr. Z 21189
The injectors are designed so that the lubricant out- put of two or more
injectors can be combined without the use of tees.
The injector body (1) has two outlets ports (a + b), one above the other.
The connector tube (2) is used to couple the injectors together.
Lubricant from injector No. 1 is directed through the connector tube into the
discharge chamber of injector No. 2 but simply combines with the lubricant
delivery of injector No. 2 to yield double output from the out- let of injector
No. 2.
This does not interfere with the operation of injector No. 2.
05.10.04 rev.5
PC5500-6-D_Sec_15-0_rev1.doc
15.0
50
Lubrication System
Lubrication System
Section 15.0
Page 51
End-line switch
TASK:
The pressure control unit is monitoring and controlling the centralized lube
system.
Design:
(1)
(2)
(3)
(4)
illustr. Z 21190
Piston
Disk
Switch contact
Spring
(5)
(6)
(7)
(8)
Pressure switch
Adjustment sleeve
Connection to pressure circuit
Electrical connection
Function:
One pressure control unit is installed in each greasing circuit. The grease
pressure, produced by the pneumatic barrel pump, is with his force also at the
piston (1)
If the grease pressure reaches the tension of the spring (4), the piston (1) is
forced against the disk (2), thus that the contacts of the switch (5) are
operated and a electric impulse is given to the electronic control unit of the
greasing equipment.
Adjusting has to be done with the sleeve (6). Clockwise - higher switch point,
counterclockwise - lower switch point.
05.10.04 rev.5
PC5500-6-D_Sec_15-0_rev1.doc
15.0
52
Lubrication System
Lubrication System
Section 15.0
Page 53
In-line filter
A clogged filter element will be moved against the spring force by the
lubricant pressure and unfiltered lubricant reaches the system!
For maintenance proceed as follows:
1.
Remove plug screw (1) using 36 mm width wrench.
2.
Remove plug screw gasket (2).
3.
Take out spring (6), spring guide (5) and filter element (3).
4.
Clean all parts and inspect for damage.
Replace as necessary.
5.
Insert filter element, spring guide (5) and spring.
6.
Install plug screw (1) with gasket (2) and tighten with a wrench.
05.10.04 rev.5
PC5500-6-D_Sec_15-0_rev1.doc
15.0
54
Lubrication System
Lubrication System
Section 15.0
Page 55
05.10.04 rev.5
PC5500-6-D_Sec_15-0_rev1.doc
Appendix
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Appendix
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01
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Appendix
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PC5500-6-D_Sec_Appendix_rev0.doc
3&B)URQWVKRYHO 6HU1R'DWH
b a
- - - - 0 I
b a
- - - - 0 II
0
b
0
IV
a
b
a
III
b
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P
IV
a
b
a
III
b
P
IV
a
b
a
O
III
b
-
IV
a
b
a
III
02 Right forw
b a
- - - - - I
b a
- - - - - II
03 Right back
b a
- - - - - I
b a
- - - - - II
04 Left forw
b a
- - - - O
P I
PC5500_6_FS.xls
b a
- - - - - II
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3&B)URQWVKRYHO 6HU1R'DWH
05 Left back
b
O
P
a
I
b a
- - - - - II
b
-
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a
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b
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06 Boom up
b
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a
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07 Boom down
b a
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b a
- - O
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08 Stick out
b
O
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PC5500_6_FS.xls
a
I
b
O
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a
II
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3&B)URQWVKRYHO 6HU1R'DWH
09 Stick in
b a
- - - O
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b a
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- - - - II
b
-
IV
a
b
a
O
III
P
b
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10 Bucket fill
b
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11 Bucket empty
b a
- - O
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b a
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12 Clam open
b a
- - - - - I
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- - - - O
P II
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3&B)URQWVKRYHO 6HU1R'DWH
13 Clam close
b a
- - - - - I
b
O
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a
II
P
b
-
IV
a
b
a
III
P
O
b
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a
b
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a
b
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14 Swing right
b a
- - - - - I
b a
- - - - - II
15 Swing left
b a
- - - - - I
b a
- - - - - II
b a
- - - - - I
PC5500_6_FS.xls
b a
- - - - - II
b
-
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a
b
a
III
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3&B)URQWVKRYHO 6HU1R'DWH
b
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PC5500_6_FS.xls
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6 / 11
3&B)URQWVKRYHO 6HU1R'DWH
b a
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b a
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b
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a
b
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PC5500_6_FS.xls
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b
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b
a
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III
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3&B)URQWVKRYHO 6HU1R'DWH
b a
- - - O
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b a
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P
b
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a
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b a
- - - - - I
b a
- - - - - II
b
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a
b
a
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28 Boom down, Stick in, Bucket empty, Clam close, Swing right
b
P
PC5500_6_FS.xls
a
O
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b
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a
O
O
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II
P
O
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IV
a
b
a
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Stand_12.08.2005
8 / 11
3&B)URQWVKRYHO 6HU1R'DWH
b
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PC5500_6_FS.xls
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Stand_12.08.2005
9 / 11
3&B)URQWVKRYHO 6HU1R'DWH
b
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b
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a
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PC5500_6_FS.xls
a
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II
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b
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a
b
a
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III
Stand_12.08.2005
10 / 11
3&B)URQWVKRYHO 6HU1R'DWH
37 Boom up, Stick out, Bucket empty, Clam open, Swing right
b
O
O
P
PC5500_6_FS.xls
a
I
b
O
O
P
a
O
O
II
P
O
b
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O
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IV
a
b
a
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III
Stand_12.08.2005
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Appendix
Page 1
1.
The fault message LED (H138 at the X2 panel) send a flash code (blink code) after a MC7
fault occurs.
The regulation active LED (H63) light on when the MC7 (electronic pump control) is
active (reduced X1-pressure = reduced current signal to Y61 proportional valve).
Blink
Code
1
Error Message
Working Pump 1
Sav
e
yes
Low Speed 52
no
Low Speed 53
no
High Speed 1
yes
Low Battery
yes
MC7 Calibration
yes
MC7 ADC
yes
Working Pump 2
yes
10
Low Speed 54
no
11
High Speed 2
yes
Possible Cause
Effect
Fixing
Reduction of
hydraulic power
Check
connection to
motor controller
Reduction of
hydraulic power
Check
connection to
motor controller
Check
mechanical
high idle
limitation
Check voltage
generator
Replace MC7
Adjustable current
range is different
Check
connection to
motor controller
Check
mechanical
high idle
limitation
- All output ports of the MC7 are protected against short circuit.
- It is not allowed to connect 24 Volt to the output terminals.