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SMPC550015035

Shop
Manual

PC5500-6
HYDRAULIC MINING SHOVEL
SERIAL NUMBERS

PC5500-6 15031,15035 & UP

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

Copyright 2006 Komatsu


Printed in U.S.A.
Komatsu Mining Germany

Contents and 00_Foreworda_15031.doc

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.

Main assembly groups


Drive.
Hydraulic oil tank.
Hydraulic oil cooling.
Controlling.
Components
Main hydraulic pumps and pump regulation.
Operating hydraulic.
Hydraulic track tensioning system.
Hydraulic operated access ladder
Refilling Arm

Hints for the hydraulic circuit diagram


Hints for the electric circuit diagram
ECS-T
Lubrication Systems

APPENDIX

Each section includes a detailed table of contents.

SAFTEY

SAFTEY NOTICE

SAFETY

SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The
service and repair techniques recommended by Komatsu and described in this manual
are both effective and safe. Some of these techniques require the use of tools specially
designed by Komatsu for the specific purpose.
The following Symbols are used in this Manual to designate Instructions of
particular Importance.

WARNING -

Serious personal injury or extensive property damage can


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

CAUTION -

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


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

NOTE -

Refers to special information

GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE
MANUAL carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read all the precautions given on the decals
which are fixed to the machine.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons missing.
Always wear safety glasses when hitting parts with a hammer.
Always wear safety glasses when grinding parts with a grinder, etc.
continued
00-1

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

With this SERVICE MANUAL KOMATSU provides you with the


description of the construction and the function of the major systems of the
Hydraulic Excavator PC5500-E.
We describe for you all functions and how to carry out the inspections and
adjustments.
How do you find "your" desired information?
In the table of CONTENT all the functions and components are shown in
their sequence of the description.
If after reading this SERVICE MANUAL you can give us suggestions and
comments for improvements - please do not hesitate to contact us.
Komatsu Mining Germany GmbH
- Service Training Postfach 180361
40570 Dsseldorf
Tel.:0211 / 7109 - 206
Fax.:0211 / 74 33 07
The editorial staff will be pleased about your co-operation.
- FROM THE PRACTICE - FOR THE PRACTICE -

This service manual corresponds to the state of development of the


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

00-4

FOREWORD

HOISTING INSTRUCTIONS

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

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


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

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

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

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


strength of the rope used.

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

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

STANDARD TIGHTENING TORQUE

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


STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS

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

Insert all bolts lubricated with MPG, KP2K

00-7

FOREWORD

CONVERSION TABLE

CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE
The Conversion Table in this section is provided to enable simple conversion of
figures. For details of the method of using the Conversion Table, see the example
given below.
EXAMPLE
Method of using the Conversion Table to convert from millimeters to inches.
1. Convert 55 mm into inches.
(a) Locate the number 5 in the vertical column at the left side, take this as (A),
then draw a horizontal line from (A).
(b) Locate the number 5 in the row across the top, take this as (B), then draw a
perpendicular line down from (B).
(c) Take the point where the two lines cross as (C). This point (C) gives the
value
when
converting
from
millimeters
to
inches.
Therefore, 55 millimeters = 2.165 inches.
2. Convert 550 mm into inches.
(a) The number 550 does not appear in the table, so divide by 10 (move the
decimal one place to the left) to convert it to 55 mm.
(b) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(c) The original value (550 mm) was divided by 10, so multiply 2.165 inches
by 10 (move the decimal one place to the right) to return to the original
value. This gives 550 mm = 21.65 inches.

00-8

FOREWORD

00-9

CONVERSION TABLE

FOREWORD

CONVERSION TABLE

00-10

FOREWORD

00-11

CONVERSION TABLE

FOREWORD

CONVERSION TABLE

00-12

FOREWORD

CONVERSION TABLE

Basic Values in Ohm according to DIN 43 76


For Measuring Resistor PT100

-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

123,62 124,01, 124,39

124,77

125,16

125,54

125,92

126,31

126,69

70

127,07

127,45

127,84

128,22

128,60

128,98

129,37

129,75

130,13

130,51

80

130,89

131,27

131,66

132,04

132,42

132,80

133,18

133,56

133,94

134,32

90

134,70

135,08

135,46

135,84

136,22

136,60

136,98

137,36

137,47

138,12

100

138,50

138,88

139,26

139,64

140,02

140,39

140,77

141,15

141,53

141,91

110

142,29

142,66

143,04

143,42

143,80

144,17

144,55

144,93

145,31

145,68

120

146,06

146,44

146,81

147,19

147,57

147,94

148,32

148,70

149,07

149,45

130

149,82

150,20

150,57

150,95

151,33

151,70

152,08

152,45

152,83

153,20

140

153,58

153,95

154,32

154,70

155,07

155,45

155,82

156,19

156,57

156,94

150

157,31

157,69

158,06

158,43

158,81

159,18

159,55

159,93

160,30

16067

00-13

FOREWORD

CONVERSION TABLE

TEMPERATURE
Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit
temperature reading into a Centigrade temperature reading or vise versa is to enter
the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the
center column as a table of Fahrenheit temperatures and read the corresponding
Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the
center column as a table of Centigrade values, and read the corresponding
Fahrenheit temperature on the right.

00-14

Main Assembly Groups

Section 1.0
Page 1

Table of contents section 1.0

Section
1.0

06.10.05

Page
Main assembly groups
General lay out

1.1

Superstructure

1.1.1

Machine house

1.1.2

Hydraulic Oil Reservoir

1.1.3

Hydraulic Oil Cooler

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.

Backhoe Attachment (BHA)

14

1.3.2.

Front Shovel Attachment (FSA)

15

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1.0
2

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Main Assembly Groups

1.

Section 1.0
Page 2

General layout
Legend for illustration (Z 22387):
(1)
Superstructure
(2)
Under carriage
(3)
Front Shovel Attachment (FSA)
(4)
Backhoe Attachment (BHA)

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1.0
3

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Section 1.0
Page 3

Main Assembly Groups

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

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1.0
4

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Main Assembly Groups

1.1

Section 1.0
Page 4

Superstructure
1.1.1

Machine house

Legend for illustration (Z 22390):


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

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1.0
5

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Main Assembly Groups

1.1

Section 1.0
Page 5

Superstructure
1.1.2

Hydraulic Oil Reservoir

Legend for illustration (Z 22391):


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

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Main Assembly Groups

06.10.05

Section 1.0
Page 6

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Main Assembly Groups

1.1

Section 1.0
Page 6

Superstructure
1.1.3

Hydraulic Oil Cooler

Legend for illustration (Z 22392):


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

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1.0
7

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Main Assembly Groups

1.1

Section 1.0
Page 7

Superstructure
1.1.4

Fuel tank (Fuel reservoir)

Legend for illustration (Z 21473):


(1)
Fuel tank
(2)
Fuel tank breather valve
(3)
Main shut-off solenoid valves
(4)
Drain coupling with protection cap
(5)
Shut-off cock for fuel pressure transducer
(6)
Fuel pressure transducer

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1.0
8

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Section 1.0
Page 8

Main Assembly Groups

1.1

Superstructure
1.1.5

Counter weight

Legend for illustration (Z 21474):


(1)
Counter weight
Total weight
40000 kg
(2)

Mounting bolts
Quantity
16

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

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1.0
9

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Section 1.0
Page 9

Main Assembly Groups

1.1

Superstructure
1.1.6

Cab support

Legend for illustration (Z 21475):


(1)
Cab support (Location of electrical switch board X2)
(2)
Mounting bolts
Quantity
Bolt size
Grade SW*
Tightening
(mm)
(mm) torque (Nm)
6

M 36 x 320

10.9

55

Grade

SW*
(mm)

10.9

55

3100

* SW = Wrench size
(3)

Mounting bolts
Quantity
Bolt size
(mm)
6

M 36 x 160

Tightening
torque (Nm)
3100

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

06.10.05

Door
Gasket
Door handle (adjustable)

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1.0
10

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Main Assembly Groups

1.1

Section 1.0
Page 10

Superstructure
1.1.7

Operators cab

Legend for illustration (Z 21476):


(1)
(2)
(3)
(E19)

Monitor panel
Switch panel
Operators seat
Control lever
EURO Control

KMG Control

(E20)

Control lever
EURO Control

KMG Control

(E21a)

Control pedal

A - forward
Left track
B - reverse

(E21b)

Control pedal

A - forward
Right track
B - reverse

(E22)
(E23)
(E24)

06.10.05

Control pedal - Swing brake


Control pedal (left)
Control pedal (right)

Clam closing
Clam opening

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1.0
11

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Main Assembly Groups

1.1

Section 1.0
Page 11

Superstructure
1.1.8

Control blocks

Legend for illustration (Z 21477a):


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

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

Main Assembly Groups

1.1

Section 1.0
Page 12

Superstructure
1.1.9

Swing gears

Legend for illustration (Z 22395):


(1)
Swing gear box
(2)
Swing parking brake
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(20.1 + 20.2)
(49.1 + 49.2)

06.10.05

Spring loaded multi disk brake


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

PC5500-6-D_Sec_1-0_rev4.doc

1.0
13

06.10.05

PC5500-6-D_Sec_1-0_rev4.doc

Main Assembly Groups

1.2

Section 1.0
Page 13

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

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Main Assembly Groups

1.3

Section 1.0
Page 14

Attachment
1.3.1

Backhoe attachment (BHA)

Legend for illustration (Z 21482):


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

06.10.05

PC5500-6-D_Sec_1-0_rev4.doc

Main Assembly Groups

06.10.05

Section 1.0
Page 15

PC5500-6-D_Sec_1-0_rev4.doc

Main Assembly Groups

1.3

Section 1.0
Page 15

Attachment
1.3.2

Front Shovel Attachment (FSA)

Legend for illustration (Z 21483):


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

06.10.05

PC5500-6-D_Sec_1-0_rev4.doc

Drive

Section 2.0
Page 1

Table of contents section 2.0

Section
2.0

Page
Prime drive assembly
General lay out

2.1

Engine and PTO mounts

3+4

2.2

Coupling

2.3

Air filter

2.4

Fan drive and radiator assembly

7+8

2.5

Radiator fan drive speed adjustment

9 + 10

2.6

Pump distributor gearbox (PTO)

11

2.7

Pump-spline lubrication

12

2.8

PTO Lubrication and cooling

13 + 14

2.9

Hydraulic pumps location, drive speed and flow rates

15

2.0
2

Drive

2.0

Section 2.0
Page 2

Prime drive assembly


Legend for illustration (Z 22395):
(1)
Engine 1
(2)
Torsion type coupling
(2)
Pump distributor gear (PTO)
(6)
(7)
(8)

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

Engine and PTO mounts


Legend for illustration (Z 21601):
(1)
Flexible bearing
(2)
Bolt with self locking nut
Quantity

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

Cup springs, seven per bolt


Stop bolt

(9)
(10)

M 10 x35

Grade

SW*
(mm)

8.8

17

Grade

SW*
(mm)

10.9

36

Rubber-bounded metal bar


Self locking nut M24
Bolt M16 with self locking nut

(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

Engine and PTO mounts


General
The flexible bearings are installed to take the vibrations and the torsion forces
and they carry the total weight of the engine, the pump distributor gear with
all hydraulic pumps.
Check mounting and security of Diesel engine and pump distributor gear,
illustration (Z 21601)

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.

Check all bolt connections for correct tightening torque.


Check condition of engine carrier and brackets. If any damages, failures
or wrong condition are found, corrective action must be taken.
For more information, refer to Parts & Service News REF NO AH01521.

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.

For service intervals and procedure refer to the OPERATION AND


MAINTENANCE MANUAL of the corresponding machine.

2.0
7

Drive

2.4

Section 2.0
Page 7

Fan drive and radiator assembly

Legend for illustration (Z 22398):


(1)
Radiator
(2)
Fan motor (Axial piston motor)
(3)
Intake air fan
(4)
Bearing group carrier
(5)
Ball bearings
(6)
Breather filter
(7)
Oil level plug
(8)
Check valve (Anti-cavitation valve)

For service intervals and procedure refer to the OPERATION AND


MAINTENANCE MANUAL of the corresponding machine.

continued

2.0
8

Drive

Section 2.0
Page 8

Cont'd
2.4

Fan drive and radiator assembly


Legend for illustration (Z 22399):
(1)
Radiator
(2)
Intake air fan
(10.1)
Axial piston pump Engine 1 (fixed displacement pump, with
variable setting)
(10.3)
Axial piston pump Engine 2 (fixed displacement pump, with
variable setting)
(23.1)
Fan motor (Axial piston motor)
(23.2)
Fan motor (Axial piston motor)
(41)
Main oil reservoir
(168.3)
Pressure relief valve Engine 1 radiator fan drive
(168.4)
Pressure relief valve Engine 2 radiator fan drive
(68.3)
Pressure filter with pressure differential switch B21-1 (Engine 1)
(68.5)
Pressure filter with pressure differential switch B21-2 (Engine 2)
(103.3)
Check valve engine 1 (Anti cavitation valve for fan drive motor)
(103.4)
Check valve engine 2 (Anti cavitation valve for fan drive motor)
(148.13) 4/3 direction flow valve Engine 1 radiator fan speed (stop, low and
high speed)
(148.14) 4/3 direction flow valve Engine 2 radiator fan speed (stop, low and
high speed)
(169.3) pressure reduction valve (low fan speed adjusting) engine 1
(169.4) pressure reduction valve (low fan speed adjusting) engine 2
(L)
Leak oil (case drain) to tank
(P)
Pressure to motor
(R)
Return oil to tank
Function:
From pump (10.1 / 10.3) flows the oil through the filter (68.3 / 68.5) to the fan motor
(23.1 / 23.2) and then back to the tank.
The check valve (103.3 / 103.4) 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
engine has been switched off.
The hydraulic circuit "Fan drive" is secured by the pilot controlled pressure relief
valve (168.3 / 168.4). This valve works together with the 4/3 direction flow valve
continued

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

Radiator fan drive speed adjustment


Basic Adjustment
Legend for illustration (Z 22400):
(1)
Dust cap
(2)
Lock nut
(3)
Set screw
(P)
Axial piston pump (fixed displacement pump, with variable
setting)
(6)
Qmin stop bolt
(6.1)
Lock nut
(7)
Qmax stop bolt
(7.1)
Lock nut
(10)
Positioning pin (mover)
(168.3)
Pressure relief valve - Engine radiator fan drive (Engine 1)
(168.4)
Pressure relief valve - Engine radiator fan drive (Engine 2)
(169.3)
pressure reduction valve - Engine radiator fan drive (Engine 1)
(169.4)
pressure reduction valve - Engine radiator fan drive (Engine 2)
(Y14A-1 /Y14B-1))
4/3 direction flow valve Engine 1
(Y14A-2 /Y14B-2))
4/3 direction flow valve Engine 2
(L1)
Measurement of Qmin stop bolt
(L2)
Measurement of Qmax stop bolt
(M19-1) Pressure check points - Engine 1 radiator fan drive operating pressure
(M19-2) Pressure check points - Engine 2 radiator fan drive operating pressure

Basic adjustment has to be carried out whenever one of the following


components has been replaced:
- pump
- relief valve
- hydraulic motor
continued

2.0
11

Drive

Section 2.0
Page 11

Cont'd
2.5

Radiator fan drive speed adjustment


Basic Adjustment max fan speed
1.
Reduce the output flow of the respective pump (P),by adjusting the
minimum possible swivel angle, to avoid over speeding the fan:
To do this, loosen both lock nuts (6.1 + 7.1) and turn out bolt (6)
and turn in bolt (7) the same length.
This is necessary to avoid a loose positioning pin (10), resulting in
oscillating of the cylinder barrel.
Tighten the lock nuts.
2.
Remove protection cap (1) from relief valve (168.x), loosen lock nut (2)
and turn set screw (3) fully clockwise and then a half turn counter
clockwise.
3.
Disconnect the plug connectors (Y14A-x and Y14B-x) of the 4/3
direction flow valve, to ensure that the full flow of pump P will be
delivered to the fan motor. The valve is in neutral position and all ports
are blocked.
4.
Connect a pressure gauge to check point (M19-x).
5.
Start the engine and let it run with max. speed.
6.
Check the fan speed with a non-contact rev counter
Required fan speed: 1250 min-1
Be careful not to get caught in the fan or other rotating parts
7.

Increase the output flow of pump P ,by adjusting the swivel angle,
until the fan speed will be 20 min-1 higher than required:
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

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).

Basic Adjustment middle fan speed


10.
Activate the 4/3 direction flow valve (Y14B-x), by connecting the
solenoid plug (Y14B-x ) to permanent 24 V. Use the 24V socket at
the PTO *).
11.
Check the fan speed with a non-contact rev counter Required fan
speed: 1000 min-1
12.
If adjustment is necessary loosen lock nut (5) of the relief valve
(169.x), and decrease the pressure with set screw (4) until the correct
fan speed is obtained.
13.
Stop engine and reconnect the plugs to the correct positions.
14.
Disconnect the pressure gauge from check point (M7).
Fan speed check
If the maximum fan speed is out of adjustment, increase or decrease first the
pressure at relief valve (168.x), to change the speed.
Do not exceed the maximum permissible operating pressure of 230 bar

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

*)

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

2.0
13

Drive

2.6

Section 2.0
Page 13

Pump distributor gearbox (PTO)


Legend for illustration (Z 22409):
(1)
Oil level gauge
(2)
Oil filler plug
(3)
Breather filter
(4)
Oil collector reservoir for auxiliary pump drive shaft housing
(5)
Breather filter with oil level gauge (drive shaft housing)
(6)
Main pump drive shaft housings
(7)
Oil level plug of main pump drive shaft housing
(8)
Oil filler plug with breather pipe of main pump drive shaft housing
(9)
Oil drain plug of main pump drive shaft housing
(10)
Oil drain plug of PTO gear
(11)
Flange for heater studs
(12)
Gear oil temperature probe mounting bore
(13)
Thermostat switch mounting bore cover plate
(14)
Suction line connection for gear oil cooling
(15)
Return line connection from gear oil cooler
(D)
Drive flange
(M)
Power take off for main pumps
(R)
Power take off for engine radiator fan drive pump
(C)
Power take off for hydraulic oil cooler fan drive pump
Description
The pump distribution gear (PTO gear) is a spur gear design and driven by an
diesel engine.
The PTO gear runs in anti friction bearings and has been provided with a
splash lubrication system. The oil supply of the bearings and tooth contacts
takes place by an injection. The gearwheels are of case-hardened steel.
The hydraulic pumps are directly attached to the gearbox. O-rings included in
the supply enable the unit to be reliably sealed statically.
The gearbox housing is a one-piece design and made of Grey cast iron.
Gearbox design allows a direct attachment to the engine via connection flange.
The gearbox has been provided with connections for a separate cooling system
resp. for heating rods. For more information refer to the REPAIR MANUAL
Description for the lubrication see next pages.

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

PTO Lubrication and cooling


Legend for illustration (Z 22410c):
The machine is equipped with two engines and gearboxes. The engine close to the
counter weight is called engine 1 and the engine to the front is called engine 2.
The extension of the component designation shows the mounted position.
Example: Pressure filter (69.1) is the pressure filter for the PTO lubrication of
engine 1 and (69.2) for engine 2.
(1)
Line to the cooler (hot oil)
(2)
Return line from the cooler (cooled oil)
(3)
Return line from valve
(4)
Suction line from PTO oil pan to the pump
(P)
Pressure port
(8.1)(8.4)
Gear pump PTO-gearbox lubrication
(69.1)(69.2)
Pressure filter - PTO gear lubrication
(74.1)(74.2)
Pressure relief valve, 7,5 bar
(78.14)(78.15) Solenoid valve (Y53-x), (reduction of relief valve pressure)
(105.3+105.4) Oil cooler, part of hydraulic oil cooler engine 1
(105.1+105.2) Oil cooler, part of hydraulic oil cooler engine 2
(M1-1)(M1-2) Pressure check point
(B17-1)(B17-2) Pressure switch, 0,5 bar
(B27-1)(B27-2) Maintenance switch, 5 bar
(B49-1)
Temperature sensor
Function:
Pump (8.1)/(8.4) forces the gear oil from the gear oil pan through filter
(69.1)/(69.2)) to pressure relief valve (74.1/74.2). This pressure relief valve acts
as a back pressure valve causing that most of the oil passes through the gear oil
coolers (105.3+105.4)/(105.1+105.2).
The gear oil coolers are a small part of the hydraulic oil coolers, thus the gear oil
gets cooled by the same air stream as the hydraulic oil. From the coolers the oil
flows to the port (P) of the gear and internally via a system of pipes to the several
spray nozzles. The spray nozzles in the gear case ensure proper and adequate
distribution of the lube oil. The circuit is monitored by the pressure switches
(B17-1). At too low lube oil pressure (0.5 bar), a fault message will be displayed
on the monitor at the dash board.
The gear oil temperature is monitored by the sensor unit (B49-1) (B49-2). At too
high oil temperature a fault message will be displayed on the monitor at the dash
board.
If the oil temperature is to low, solenoid valve (Y53-1) (Y53-2) energized and
opened port X of the pressure relive valve (74.1) (74.2). This reduced the relieve
valve pressure setting. The main gear oil flow direct back to the PTO to quick
warm up of the gear oil.
continued

2.0
16

Section 2.0
Page 16

Drive

Contd.:
2.8

PTO Lubrication and cooling


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

(8)
(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.

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


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

2.0
17

Section 2.0
Page 17

Drive

2.9

Hydraulic pumps location, drive speed and flow rates


Legend for illustration (Z 22415a):
(1 - 6)

Axial piston pump (swash plate type) Vg max


theoretical flow rate, each
Qmax
Drive speed*
n
for all working motions

= 500 cm/rev
= 700 Liter/min
= 1400 min-1

(10.1), (10.3) Axial piston pump


theoretical flow rate
Drive speed*
for radiator fan drive

Vg max
Qmax
n

= 80 cm/rev
= 158 Liter/min
= 1973 min-1

(10.2), (10.4) Axial piston pump


theoretical flow rate
Drive speed*
for oil cooler fan drive

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

for hydraulic oil circulation


(7.1), (7.2)

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

* at 1800 min-1 input drive speed

Hydraulic Oil Reservoir

Section 3.0
Page 1

Table of contents section 3.0


Section
3.0

Page
Hydraulic oil reservoir
General lay out

3.1

Main oil tank, location of switches, sensors etc.

3.2

Suction oil tank with strainers

3.3

Return oil collector tube with strainer

3.4

Back pressure valve

3.6

Return and Leak Oil Filter

3.7

Breather Filter

3.5

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Hydraulic Oil Reservoir

3.

Section 3.0
Page 2

General lay out


Legend for illustration (Z 22416a):
(1)
Filter cover retainer
(2)
Filter cover
(3)
Filter location
(A) Return oil filter 10 m (4x)
(B) Case drain filter 3 m (1x)
(4)
Man hole cover
(5)
Hydraulic oil filler plug
(24)
Pressure switch B24 monitors item (132.1+132.2)
(39)
Hydraulic oil level gauge
(41)
Main oil reservoir
(114)
Return oil collector tube with pressure check point M10
(115)
Back pressure valve
(118)
Oil drain, quick release coupling
(128)
Shut off valve (Gate valve) with monitoring switch S31
(129)
Compensator
(132.1 + 132.2) Breather filter
(178)
Return pipe filter (screen filter)
The hydraulic oil tank is a welded sheet-metal construction.
The capacity is about 3800 litres. The tank contains four return oil filters (3A) and one case drain filter (3-B).
The breather filter (132.1 + 132.2) cleans the air that streams into the tank.
The back pressure valve (115) and the pressure check point (M10) are located
at the collector tube (114) for return oil.
The connection to the suction tank can be closed with the shut- off valve (118)
to prevent oil flow during repairs on the hydraulic pumps. This unit is
controlled by the switch S31, to prevent a engine start with closed shut-off
valve. Fault message Start blocked because of main Shut-Off (gate) valve is
displayed at the operators dash board

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Hydraulic Oil Reservoir

3.1

Section 3.0
Page 3

Main oil tank, location of switches, sensors etc.


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

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Hydraulic Oil Reservoir

3.2

Section 3.0
Page 4

Suction oil tank with strainers


Legend for illustration (Z 22418):
(1)
Suction oil reservoir
(2)
Drain coupling
(3)
Bolt
(4)
Gaskets
(5)
Main suction oil strainer
(6)
Gaskets
(7)
Intermediate pipe
(8)
Nut
(9)
Bolt
(10)
Compensator
(11)
Suction strainer one for each main pump
(12)
Suction hose connection pipe
The suction oil tank (1) is a welded sheet-metal construction.
The capacity is 187 liters.
The suction lines of all hydraulic pumps are connected to the suction tank.

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Hydraulic Oil Reservoir

Section 3.0
Page 5

3.3 Return oil collector tube with strainer


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

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

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Hydraulic Oil Reservoir

3.4

Section 3.0
Page 6

Back pressure valve


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

Task:
The back pressure valve has to fulfill two functions in the hydraulic system:
1. To ensure a sufficient pressure within the return oil circuit, i.e. to supply oil
via the 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
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Further information about the function principle and adjustments,


refer to Section 4.0 this Manual.

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Hydraulic Oil Reservoir

3.6

Section 3.0
Page 7

Return and Leak Oil Filter


Legend for illustration (Z 21500):
(1)
Filter cover retainer
(2)
Filter cover with o-ring
(3)
Pre-tensioning spring
(4)
Retainer
(5)
Filter assembly
(6)
Filter pot with machined cover
(7)
Main filter element, 10 micron absolute
(8)
Safety filter element (200 micron strainer)
(9)
By pass-valve, 2.3bar
(9.1)
Valve cone
(9.2)
Valve spring
(9.3)
O-ring
(10)
Profile gasket
(11)
Seal ring
(12)
Self locking nut
(13)
Self locking nut
Function:
The returning oil flows into the filter chamber (A) of the hydraulic tank. (The
sketch shows one section only).
The chamber is split into two sections; one sections with 4 filters for the return oil
and one for the leak oil. But the five filters are all the same. The hydraulic oil
enters the filter at the top and passes then on its way to the entire tank the filterelement (7). "Inside to outside filtration."
The filter element condition is monitored by a pressure switch (B25, 0.5 bar for
the leak oil filter) and (B26, 2 bar for the return oil filter).
As soon as the pressure inside the filter chamber reaches the set pressure of those
switches due to the restriction of the filter-element which is caused by foreign
matters, the fault message Return oil filter restricted" or Leak oil filter
restricted is displayed at the operator's dash board The filter elements must be
replaced. For safety pre-cautions the filter is equipped with a by-pass valve. As the
filter chamber pressure increases the by-pass valve opens at 2.3 bar and protects
the element from bursting.
But the oil flows not totally unfiltered into the tank because it must flow through
the strainer (8).

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The switch point of the pressure switch for the leak oil has been
chosen so low with best intention to protect first of all the radial seal
rings of the hydraulic motors.
Because the filter is oversized for this purpose, the message Leak
oil filter restricted is displayed very seldom under normal
circumstances.
Maintenance see chapter. 6.5 of MAINTENANCE MANUAL

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3.7

Section 3.0
Page 8

Breather filter
Legend for illustration (Z 21501):
(1)
Nut
(2)
Cover
(3)
Filter element
(4)
Filter pot
A breather filter is installed to clean the air that streams into the tank any time
the oil level decreases while extending attachment cylinders
The filter element condition is monitored by a vacuum type pressure switch
(B24, 80mbar).
Maintenance see chapter 6.5 of MAINTENANCE MANUAL

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Hydraulic Oil Cooling

Section 4.0
Page 1

Table of contents section 4.0

Section
4.0

06.10.05

Page
Hydraulic oil cooling
4.1

General

4.2

Function of the hydraulic oil cooling circuit

4.3

Adjustment of the Back Pressure Valve

4.4

Fan drive (Two stage cooler fan RPM control)

5+6

4.5

Pressure relief valves and solenoid valve

7+8

4.6

Fixed Displacement Pump, with variable setting

4.7

Radiator fan drive speed adjustment

9
10
12

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2

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Hydraulic Oil Cooling

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.

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3

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Hydraulic Oil Cooling

4.2

Section 4.0
Page 3

Function of the hydraulic oil cooling circuit


Legend for illustration (Z 22419)
(107.1-107.4)
Restrictor, shock absorbers for the hydraulic oil cooler
(106.1-106.4)
Hydraulic oil cooler
(41)
Main oil reservoir
(114)
Return oil collector tube
(115)
Back pressure valve
(L6 + L7)
Return line from control blocks
(L8 + L9)
Supply line for the anticavitation circuit of the swing
motors
(M10)
Pressure check point
(Y101)
Solenoid valve 4/2-directional control valve
(H)
Lines to cooler (hot oil)
(C)
Lines to tank (cold oil)
Function:
The returning oil from the system flows via the lines (L6 - L7) into the
collector tube (114). On the top of it is the Back Pressure Valve (115)
installed.
The back pressure valve (115) causes a back pressure which forces most of
the relative hot oil through the lines (H) to the cooler (106.1-106.4).
On its flow through the cooler the hydraulic oil gets cooled and flows than
through the restrictors (107.1-107.4) and the lines (C) into the filter chamber
of the main oil reservoir (41).
The restrictors are acting like shock absorbers to prevent cooler cracking at
pressure peaks.
Besides the back pressure valve acts as an oil flow control valve as far as the
oil temperature has not reached its steady temperature.
During the warm up period (1/2 Qmax) the back pressure valve (115) is wide
open, because solenoid valve Y101 is energized, which results in less oil
flows through the cooler which causes that the oil gets quicker its optimum
operating temperature.
With increasing oil temperature the oil gets thinner, so that the main pumps
can be shifted to Qmax position and simultaneously solenoid valve Y101 will
be de-energized, so that the valve piston will be more closed by the force of
the spring thus that more oil passes the cooler.
(See sectional drawing on next page.)

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4

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Section 4.0
Page 4

Hydraulic Oil Cooling

4.3

Adjustment of the Back Pressure Valve


Checks and settings only at normal operating temperature of the hydraulic oil,
main pumps in maximum flow position and "Idle Time" control eliminated
(service switch S151 actuated)!
1.
Connect a pressure gauge to check point (M10).
2.
Disconnect plug connector (13) of solenoid valve Y101.
3.
Actuate service switch S151 ().
4.
Start the engine and let it run with maximum speed.
5.
Required pressure: 8 0,5 bar
If adjustment is required:
a) Take off protective cap (12).
b) Loosen lock nut (5).
c) Adjust the pressure with the set screw (6).
d) Tighten lock nut (5) and refit protective cap (12).
6.
Disconnect the pressure gauge, reconnect solenoid valve Y101 and
switch back service switch S151.
Legend for illustration (Z 21596):
(1)
Control oil port
(2)
"Y"- port (external return to tank)
(2a)
"X"- port (external return to tank via solenoid valve Y101)
(3)
Poppet
(4)
Valve spring
(5)
Lock nut
(6)
Set screw
(7)
Jet bore (large)
(8)
Valve spring
(9)
Valve piston
(10)
Jet bore (small)
(11)
Plug screw
(12)
Protective cap
(13)
Plug connector
(A)
Return to tank (Filter chamber)
(Z)
Pressure oil to valve

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5

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Hydraulic Oil Cooling

4.4

Section 4.0
Page 5

Fan drive (Two stage cooler fan RPM control)


Legend for illustration (Z 22420)
(10.2)
Axial piston pump Engine 1 (fixed displacement pump, with
variable setting)
(10.4)
Axial piston pump Engine 2 (fixed displacement pump, with
variable setting)
(22.1)
Fan motor (Axial piston motor)
(22.2)
Fan motor (Axial piston motor)
(41)
Main oil reservoir
(168.1)
Pressure relief valve Engine 1 radiator fan drive
(168.2)
Pressure relief valve Engine 2 radiator fan drive
(68.1)
Pressure filter with pressure differential switch B28-1 (Engine 1)
(68.2)
Pressure filter with pressure differential switch B28-2 (Engine 2)
(103.1)
Check valve engine 1 (Anti cavitation valve for fan drive motor)
(103.2)
Check valve engine 2 (Anti cavitation valve for fan drive motor)
(148.11) 4/3 direction flow valve Engine 1 radiator fan speed (stop, low and
high speed), solenoid Y6A-1 + Y6B-1
(148.12) 4/3 direction flow valve Engine 2 radiator fan speed (stop, low and
high speed), solenoid Y6A-2 + Y6B-2
(169.1)
pressure reduction valve (low fan speed adjusting) engine 1
(169.2)
pressure reduction valve (low fan speed adjusting) engine 2
(L)
Leak oil (case drain) to tank
(P)
Pressure to motor
(R)
Return oil to tank
1
Engine 1
2
Engine 2

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6

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Hydraulic Oil Cooling

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)

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Hydraulic Oil Cooling

4.5

Section 4.0
Page 7

Pressure relief valves and solenoid valves


Pressure relief valves (168.x)
Legend for illustration (Z 21598b)
(1)
Valve cartridge
(2)
Spring
(3)
Spring chamber
(4)
"X" port
(5)
Jet bore, Pilot poppet
(6)
Jet bore, Main piston
(7)
Main piston
(8)
Valve housing
(9)
Pilot poppet
(Y)
External leak oil port
(A)
Pressure port
(B)
Return oil port
Function:
Pressure in line A affects the main piston (7). At the same time there is pressure
via the jet bore (6) on the spring-loaded side of the main piston and via jet bore (5)
at the pilot poppet (9) of the relief valve cartridge (1).
If system pressure in line A exceeds the value set at the spring (2), pilot poppet (9)
opens. The signal for this comes from line A via the jet bores (6) and (5).
The oil on the spring-loaded side of the main piston (7) now flows via the jet bore
(5) and poppet (9) into the spring chamber (3).
From here it is fed internally by means of the control line (Y) to tank (port B).
Due to the state of equilibrium at the main piston (7), oil flows from line A to line
B, while the set operating pressure is maintained.
The pressure relief valve can be changed (Remote controlled) by means of the
port "X" and the function of the solenoid valve Y6A-x / Y6B-x and pressure
reduction valve 169.x. .( Function see next page)

continued

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8

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Section 4.0
Page 8

Hydraulic Oil Cooling

Contd.
4.5

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


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

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9

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Hydraulic Oil Cooling

4.6

Section 4.0
Page 9

Fixed Displacement Pump, with variable setting


Legend for illustration (Z 21852)
(1)
Drive shaft
(2)
Bearings
(3)
Cylinder with pistons
(4)
Center pin
(5)
Control lens
(6)
Q-min adjustment bolt
(7)
Q-max adjustment bolt
(8)
Pressure port
(9)
Tank port
Description.
Pump type A7F0 is a variable displacement pump, designed to operate in open
circuits. It has an internal case drain return. The rotary group is a robust self
aspirating unit. External forces may be applied to the drive shaft.
Changing the swivel angle of the rotary group is achieved by sliding the
control lens along a cylindrical formed track by means of an adjusting screw.
With an increase in the swivel angel, the pump output increase together
with necessary drive torque.
With an decrease in the swivel angel, the pump output decreases together
with the necessary drive torque.
When increasing to maximum swivel angle, there is a danger of
cavitation and over-speeding the hydraulic motor!

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Hydraulic Oil Cooling

4.7

Section 4.0
Page 10

Radiator fan drive speed adjustment


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

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

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11

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Hydraulic Oil Cooling

Section 4.0
Page 11

Cont'd
4.7

Radiator fan drive speed adjustment


Basic Adjustment max fan speed
1.
Reduce the output flow of the respective pump (P),by adjusting the
minimum possible swivel angle, to avoid over speeding the fan:
To do this, loosen both lock nuts (6.1 + 7.1) and turn out bolt (6)and
turn in bolt (7) up to final stop.
This is necessary to avoid a loose positioning pin (10), resulting in
oscillating of the cylinder barrel.
Tighten the lock nuts.
2.
Remove protection cap (1) from relief valve (168.x), loosen lock nut
(2) and turn set screw (3) fully clockwise and then a half turn
counter clockwise.
3.
Disconnect the plug connectors (Y6A-x and Y6B-x) of the 4/3
direction flow valve, to ensure that the full flow of pump P will be
delivered to the fan motor. The valve is in neutral position and all
ports are blocked.
4.
Connect a pressure gauge to check point (M5-x).
5.
Start the respective engine and let it run in high idle.
6.
Check the fan speed with a non-contact rev counter
Required fan speed: 1250 min-1
Be careful not to get caught in the fan or other rotating parts
7.

Increase the output flow of pump P ,by adjusting the swivel angle, until
the fan speed will be 20 min-1 higher than required:
To do this, loosen both lock nuts (6.1 + 7.1) and turn in bolt (6) and
turn out bolt (7) the same length.
This is necessary to avoid a loose positioning pin (10), resulting in
oscillating of the cylinder barrel.
Tighten the lock nuts (6.1 + 7.1).
Do not exceed the maximum permissible operating pressure of
230 bar
Note down the lengths L1 and L2 as reference measurements.

continued

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12

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Section 4.0
Page 12

Hydraulic Oil Cooling

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).

Basic Adjustment middle fan speed


10.
Activate the 4/3 direction flow valve (Y6B-x), by connecting the
solenoid plug (Y6B-x ) to permanent 24 V. Use the 24V socket at
the PTO *).
11.
Check the fan speed with a non-contact rev counter Required fan
speed: 1000 min-1
12.
If adjustment is necessary loosen lock nut (5) of the relief valve
(169.x), and decrease the pressure with set screw (4) until the correct
fan speed is obtained.
13.
Stop engine and reconnect the plugs to the correct positions.
14.
Disconnect the pressure gauge from check point (M5-x).
Fan speed check
If the maximum fan speed is out of adjustment, increase or decrease first the
pressure at relief valve (168.x), to change the speed.
Do not exceed the maximum permissible operating pressure of 230 bar

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

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 (-).

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Controlling

Section 5.0
Page 1

Table of contents section 5.0

Section
5.0

06.10.05

Page
Controlling
General lay out

5.1

Control and filter panel location of components


(valves, switches, sensors etc.)

5.2

Pilot Pressure Supply and Adjustments

47

5.3

Remote control valves arrangement

5.4

Function principle of the


Electro-Hydraulic- Proportional Control

9 + 10

5.5

Potentiometer Control (Lever, Joy Stick)

11

5.6

Potentiometer Control (Pedal)

12

5.7

Proportional amplifier module, Type A


(for swing brake only)

13

5.8

Proportional amplifier module, Type B


(for Boom, Stick, Bucket, Swing and Travel)

14

5.9

Ramp Time Module


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

15

5.10

Adjustments of Amplifier Modules (General)

16

5.11

Adjusting the Amplifiers Type B

17 + 18

5.12

Adjusting the Amplifiers Type A

19 + 20

5.13

Adjusting the Ramp Time Module

21 + 23

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2

X4 - pump support
pressure

X2
pilot pressure

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

X1 - pump regulation
pressure

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

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Z 22429
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5.0

Section 5.0
Page 2

General lay out


Legend for illustration (Z 21631):
(7.1 / (7.2)
Pumps for pilot pressure and pump regulation system
(84.1 / 84.2)
Check valve (for combined operation)
(68.1)
Filter
(70.1)
Pressure relief valve (X4 pressure)
(70.2)
Pressure relief valve (X2 pressure)
(85)
Pressure accumulator (10 Liter, 10 bar pre-charge
pressure)
(91)
Check valve
(45.1; 45.2 ;45.3, 43)
Remote control valves
(14; 15; 16; 13))
Control blocks
General
The controlling includes the pilot pressure system and the pump regulation
system.
The pumps (7.1 / 7.2) forcing the oil through the filter (68.1) to all involved
valves.
The pressure accumulator ensures that under any circumstances enough pilot
pressure oil is available. The accumulator (85) is also functioning as a
hydraulic battery for a certain time when the engine was shut down or to
pressure relive the system for repair works.
When the operator is using his controls an electrical signal causes energizing
of the selected solenoid valve of the remote control valves(14).
By the function of the remote control valves pilot pressure oil is send to the
relevant control block spools which in turn allows operating hydraulic oil to
the users.

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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)

Swing gear house brake


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

Pressure switches:
(B16)
(B21.1)

(B21.2)
(B22)

(B27.1)
(B28.1)

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

(B97.1)
(B85.1)

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

Pilot pressure for Swing gear house brake (24 bar)


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

Pressure check points:


(M1.1)

(M1.2)
(M2)
(M3)

(M5.1)

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

(M19.1)
(M20.1)

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

Pressure PTO gear lubrication


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

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

(68.4)
(68.5)
(69.2)

Pilot pressure and pump regulation


Oil cooler fan drive
Engine radiator fan drive (only with diesel engines)
PTO gear lubrication

continued

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Controlling

5.2

Section 5.0
Page 4

Pilot Pressure Supply and Adjustments


Pilot Pressure Circuit
The pilot pressure oil is used for the following functions.
To move the control block spools, to supply the main pump regulation
system, to lubricate the main pump bearings, to release the travel- and swing
gear house brakes (spring loaded multi disk brakes), to drive the Lincoln
Lubrication pumps, to move the hydraulic operated ladder, to move the
hydraulic operated refilling arm and to supply the hydraulic track tensioning
system.
Legend for illustration (Z 22498):
(7.1 / 7.2)
Pilot pressure pumps
(84.1 / 84.2) Check valve (for combined operation)
(68.1)
(70.1)
(70.2)
(85)
(43 + 45.x)
(M2)
(M3)
(M40)

Filter
Pressure relief valve 60 bar
Pressure relief valve 35 bar
Pressure accumulator
Remote control valves
60 bar pressure check point (X4-Pressure)
35 bar pressure check point (X2-Pressure)
35 bar pres. check point (X2-Pressure in front of accumulator)

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

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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.

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Controlling

Section 5.0
Page 6

Cont'd:
5.2

Pilot Pressure Supply and Adjustments


Pilot Pressure Circuit
Legend for illustration (Z 22500):
(41)
Main oil reservoir
(91)
Check valve
(85)
Bladder Accumulator 10 liter, 10 bar (located behind the filter and
valve panel of engine 2 on top of the PTO)
(PX2)
Pilot pressure line
(LX2) Leak / return oil line from the remote control blocks
Function:
The pilot pressure oil flows via line (PX2) to port (P) of each remote control
block and is present via a gallery at all proportional and directional solenoid
valves.
These solenoid valves are energized by the function of the Electro
proportional controls (Joy sticks or pedals) and direct the pilot pressure oil to
the respective spools of the main control blocks with a variable pilot pressure
proportional to the deflection of the controls.

06.10.05

For the location and designation of the proportional and directional


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

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5.2

Section 5.0
Page 7

Pilot Pressure Supply and Adjustments


Checks and Adjustment of Pilot Pressure
Legend for illustration (Z 21635a):
(85)
Bladder Accumulator 10 liter, 10 bar pre-charge pressure
(located underneath the catwalk in front of the PTO)
(70.1) Pressure relief valve for pump support pressure X4 (60 bar)
(70.2) Pressure relief valve for pilot pressure X2 (35 bar)
(M2) Pressure check point X4, pump support pressure (60 bar)
(M3) Pressure check point X2 pressure, pilot pressure (35 bar)
(M40) Pressure check point for accumulator (If not factory installed, fit a
T-union with test connector as shown in illustration Z 21635a)
Since the X2 and the X4 pressure are influencing each other it is
always necessary to adjust both valves 70.1+70.2 alternately.
60 bar pressure X4, valve 70.1:
1.
Connect pressure gauge to check point (M2)
2.
Start engine and let it run with max. speed
3.
Read pressure, required = 60 -2 bar
If readjustment is required *:
35 bar pressure X2, valve 70.2:
1.
Connect pressure gauge to check point (M3)
2.
Start engine and let it run with max. speed
3.
Read pressure, required = 35+3 bar
If readjustment is required *:
* Valve adjustment:
a
Remove dust cap (1).
b.
Loosen lock nut (2).
c.
Set pressure with set screw (3).
d.
Tighten lock nut (2) and re-fit dust cap (1).
Checking of Accumulator Function
1.
Connect pressure gauge to check point (M40).
2.
Start one engine and let it run with maximum speed.
3.
After build-up of pressure stop the engine, but do not turn the
key switch to zero position.
4.
Watch pressure gauge. Pressure should remain constant for at
least 5 minutes.

06.10.05

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


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

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Section 5.0
Page 8

Controlling

5.3

Remote control valves arrangement


Legend for illustration (Z 21636)

No.

45.1

45.2

45.3

43

06.10.05

Solenoid Proportional
valve
valve

Function
FSA

BHA

Y20a
Y20b

Y20

L.H. Crawler forward


L.H. Crawler reverse

Y21a
Y21b

Y21

Stick extending
Stick retracting

Y22a
Y22b

Y22

Bucket filling (curl)


Bucket emptying (dump)

Y23a
Y23b

Y23

Boom raising
Boom lowering

Y24a
X24b

Y24

Clam closing
Clam opening

Bucket filling (curl)


Bucket emptying (dump)

Y25a
Y25b

Y25

Bucket filling (curl)


Bucket emptying (dump)

Boom raising
Boom lowering

Y26a
Y26b

Y26

Boom raising
Boom lowering

Reserved
Reserved

Y27a
Y27b

Y27

Stick extending
Stick retracting

Stick extending
Stick retracting

Y28a
Y28b

Y28

R.H. Crawler reverse


R.H. Crawler forward

Y29a
Y29b

Y29

Boom raising
Boom lowering

Y30a
Y30b

Y30

Bucket filling (curl)


Bucket emptying (dump)

Y31a
Y31b

Y31

Stick extending
Stick retracting

Y32a
Y32b

Y32

R.H. Swing
L.H. Swing

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Controlling

5.4

Section 5.0
Page 9

Function principle of the Electro-Hydraulic- Proportional Control


Legend for illustration (Z 21637)
(1)
Pump
(2)
Filter
(3)
Pressure relief valve
(4)
Check valve
(5)
Pressure Accumulator
(6)
Directional Solenoid valve, a side
(7)
Directional Solenoid valve, b side
(8)
Proportional Solenoid valve
(9)
Control valve block
(10)
Battery
(11)
Electronic units with amplifiers etc.
(12)
Control lever
Function:
The electric-hydraulic control system is used to control the direction and
volume of oil flow to the operating cylinders and motors via the control valve
blocks.
Hydraulically:
The oil volume of pump (1) flows through filter (2) into the pilot pressure
system. The pressure is limited by the pressure relief valve (3).
With the pressurized oil stored in accumulator (5), a limited number of spool
movements can be carried out with the engines at standstill.
When a lever (or pedal) is actuated, proportional solenoid valve (8) and one
of the directional solenoid valves (either 6 or 7) are energized, and allows the
pilot pressure oil to flow to the spools of the control blocks.
Electrical
Whenever a lever or a pedal is moved out of its neutral position, an amplifier
will created a current between 0 and 1000 mA. (For detailed information refer
to page 10 in this section)
Depending on the lever direction, simultaneously one of the directional
solenoid valves (either 6 or 7) is energized.
The proportional solenoid valve alters the pilot pressure, proportional to the
lever deflection, this results a spool movement between neutral and full
stroke position.
continued

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Controlling

Section 5.0
Page 10

Cont'd:
5.4

Function principle of the Electro-Hydraulic- Proportional Control


(Exemplary illustration of the function of two axis with one Amplifier only)
Legend for illustration (Z 21638a)
(1)
Control lever (joystick)
(2)
Capacitor-Module
(3)
Ramp time module
(4)
Proportional-Amplifier-Module
(5)
Relay (Supply Voltage)
(6)
Proportional solenoid valve-(Pressure-Reducing Valve)
(7)
Directional solenoid valve
(8)
Control block spool
General Function
Control lever (1) is supplied with 24 VDC battery voltage for the switch contacts
and for the internal electronics to create the signal voltage.
When moving lever (1) out of its neutral position, 24 VDC battery voltage arrives
at relay (5) and energizes the Proportional Amplifier (4) with capacitor
supported 24 VDC via terminal 1.
Depending on the function of the control lever, 1 to 4 Amplifiers can be involved
for the Y-axis (forward/ backwards direction) and 1 to 4 Amplifiers for the Xaxis (left/right direction.)
The polarity of the Output Signal from joystick (1), either positive or negative,
between 0 and 10 VDC indicates the direction of the lever movement and is
proportional to the lever deflection. This is the Input Signal to the ramp time
module (3) at terminal 5 which will arrive after the adjusted ramp time delay via
terminal 7 to the proportional amplifier (4) at terminal 5.
This Input Signal (between 0 and 10 VDC) is amplified to an Output Signal
between 0 to 1000 mA and is simultaneously send via terminal 7 (negative) or
terminal 8 (positive) to the Proportional Solenoid valve (6) and to the
Directional solenoid valve (7) via terminal 3 (negative) or terminal 9 (positive)
to the a or b-side.
The proportional Solenoid valve (6) alters the pilot pressure (X2) of 35 bar to a
value proportional to the Current Signal.
This pressure controls the movement of the control block spool (8) between
neutral and full stroke position.

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Controlling

5.5

Section 5.0
Page 11

Potentiometer Control (Lever, Joy Stick)


Legend for illustration (Z 21639b)
(1)
Push button *
(2)
Toggle switch *
(3)
Inductive linear transmitter
(4)
Universal joint
(5)
Electronics
(6)
Push pin
(7)
Shaft seal
(8)
Reset spring
(9)
Coil core
(10)
Coil
* Alternative application
The non-contacting lever control (inductive linear transmitter) contains both
the electronic and mechanical components which converts the lever
movement into a proportional electrical voltage. The lever can be operate in
two axes:
Axis "Y", splitted into the half axis Y- and Y + (backward and forward)
Axis "X", splitted into the half axis X- and X + (left and right)
Of course the lever can be moved in any other direction (Joy stick function)
In order to be able to monitor the direction of the lever movement and the
neutral position, the electronics (8) sends a 24V signal as soon as the lever
gets moved out of its neutral position.
For one axis are used two inductive linear transmitter (3). The motion of the
coil core (9) connected to the push pin (6) causes a variation of the induction
in the coils (10). The electronics convert this inductive signal into a
proportional output signal of 10...0...+10 V for the amplifiers.
The electronic part of the lever is equipped with a internal fault detector. In
case of a internal electronic fault the electronic send a 24V signal to the test
output. The test input is used for a lever system check before engine start.
The inductive system is designed as a redundant system with two separate
coils.

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Section 5.0
Page 12

Controlling

5.6

Potentiometer Control (Pedal)


Legend for illustration (Z 21300)
(1)
Potentiometer Control Unit
(2)
Pedal
(3)
Standard cable
(4)
Connection cable for combined operation
Application for:
(A)
Swing foot brake
(B)
Clam Opening/closing, (only face shovel attachment)
(C)
Travelling
The Potentiometer Control (inductive linear transmitter) contains both the
electronic and mechanical components which converts the pedal movement
into a proportional electrical voltage.
In order to be able to electrically monitor the pedal (2) action a neutral
position switch is fitted.
This switch closes when the pedal is moved out of the rest position.
When using the double unit (B) (combined operation) only the signal output
from one unit is used for the Clam Operation.
Due to the cross lined connection via the connection cable (4) the signal is
once positive and once negative (inverted), depending on the Pedal used.

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5.7

Section 5.0
Page 13

Proportional Amplifier Module, Type A


Legend for illustration (Z 21516)
Type A (for swing brake only)
(LED) LED for Solenoid A or B
(P)
Set Potentiometer
R1 for the lowest current value
R2 for the highest current value
The amplifier module is snapped onto mounting rails inside the X2-box.
The amplifier module contains the necessary electronics for the control of
two proportional solenoids. Depending on the input polarity, either solenoid
A or solenoid B is operated.
The solenoid current (solenoid A - solenoid B) is measured and compared
with the external input value. Differences between feed-back and input
values, for example caused by changes in solenoid temperature or supply
voltage, are compensated.
The module also generates a direction-dependent voltage signal (solenoid A solenoid B) as soon as the solenoid current reaches the lowest set value.
The lowest and highest values are set externally via the potentiometer R1 + R2.
The brightness of the LED's changes with the current.
This function should not be used for setting.

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5.8

Section 5.0
Page 14

Proportional Amplifier Module, Type B


Legend for illustration (Z 21640)
Type B (for Boom, Stick, Bucket, Clam, Swing and Travel)
(LED)
(P) Set Potentiometer:
AX: Proportional output AX active
- 10% for the lowest current value
AS: Switched output AS active
- J2 for the highest current value
BX: Proportional output BX active (Pt) Set Potentiometer for the Ramp
BS: Switched output BS active
Time
Power: Internal supply voltage
Fault: Fault indication
The amplifier module is snapped onto mounting rails inside the X2-box.
The amplifier module contains the necessary electronics for the control of
two proportional solenoids and two directional solenoids. The outputs for
proportional solenoids Ax and Bx and the switched outputs As and Bs are
activated by connecting a minimum of approx. 10 % signal voltage at the
amplifier input.
A positive signal voltage controls outputs A, a negative signal voltage
controls output B.
A signal voltage of approx. 10% with respect to +/- 10 V input voltage at the
amplifier, produces a stepped output voltage. The height of this 10% jump
may be set separately for proportional outputs Ax and Bx via external
potentiometer. As the signal voltage rises the solenoid current for the
proportional outputs increases linearly.
A further step in output current occurs at approx. 90% signal voltage.
The maximum current or the 90% jump may be set separately for outputs Ax
and Bx via external potentiometers and hence the gradient of the output curve
may be influenced.
LEDs indicate the current output to each proportional and switched output,
whereby the brightness is approx. proportional to the solenoid current in Ax
and Bx. This function should not be used for setting.
A Ramp Time function is included in the amplifier which may be externally
changed by a set potentiometer. The setting range for the ramp time is
approx. from 80 ms to 1s. The time setting applies to both up and down
ramps and to both proportional solenoids.
A fault is indicated by the LED Fault.

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5.9

Section 5.0
Page 15

Ramp Time Module


(Analogue command value module for Boom, Stick, Travel and Swing
function)
Legend for illustration (Z 21518)
Potentiometer:
"t1" to "t5"
Ramp times
"w1" to "w4" Command value call-ups
"G"
Zero point matching
"Z"
Amplitude attenuation for the differential input
LED displays:
(1)
green Operational power
(2)
"4-Q" Quadrant recognition
(3)
"INV" Inversion active
(4)
yellow display for potentiometer t1 to t4
(5)
yellow display for potentiometer w1 to w4
(6)
Measurement sockets: "t" Actual ramp time
"w" Internal adjustment variable
"" Reference potential / GND
General
The Ramp Time Module is snapped onto mounting rails inside the X2-box.
The electrical connection is done via screw terminals.
The module is operated with 24 VDC. A power supply provides the internally
required positive and negative supply voltages.
As soon as the power supply is in operation the green LED (power) lights up.
Internal command values
The internal command value signal is generated from the external command
value signal which is being applied to the differential input, a called-up signal
and an offset signal (zero point potentiometer "Z").
The external command value signal can, via potentiometer "G", changed from
0 % to approx. 110 %.
Command value call-ups
The call-up signals w1 to w4 also have an adjustment range of 0 % to 110 %.
No settings required. (factory set to 100 %).
Ramp time call up
If the quadrant recognition is not activated, then each command value call-up
"w1" to "w4" is allocated its own ramp time "t1" to "t4".
As long as there is a signal change, the LED allocated to the actual ramp time
is alight.

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Section 5.0
Page 16

Controlling

5.10

Adjustments of Amplifier Modules (General)


Legend for illustration (Z 21641)
(1)
Potentiometer control
(2)
Terminal with a separating possibility
(3)
Ramp time module
(4)
Amplifier
(5)
Solenoid valve
(6)
Service module
Introduction:
The illustration shows simplified the route of the signal voltage from
Potentiometer Control (1) to Solenoid-Valve (5):
A.
With ramp time module,
i.e. Boom,- Stick,- Travel,- and Swing Function.
B.
Without ramp time module,
i.e. Bucket and Clam Function.
The ramp time modules (3) and the amplifiers (4) are adjustable.
Adjustments are required:
Ramp time modules
When commissioning the machine
When replacing a module

Amplifiers
When replacing a solenoid valve
When replacing an amplifier

For Checking and Setting the Signal Current at the Proportional-Amplifier (4),
both separating terminal (2) before and behind the Amplifier (4) must be opened.
For the setting procedure the signal voltage from the potentiometer control (1) can
be simulated with the potentiometer of Service-Module (6),which is installed on
the X2-panel.
Accessories required for the adjustments:
a) A multimeter, good readable for
values between 0 and 1000 mA.
b) More convenient is a second meter
for reading voltage simultaneously.
c) A simple wire, 1m length, or better
a prepared test lead same length
d) Four test leads, 1m length, with
banana type connectors on each
end.

06.10.05

"a"

"b"

mA

VDC

"c" "d"

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Controlling

5.11

Section 5.0
Page 17

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


Procedure applicable for all amplifiers except the one for the swing
brake:
(Do not start the engines turn only the key switch in ON position.)
1.
Open* the respective separating terminal (T1) between the lever unit and
the amplifier module to be set.
2.
Open* the respective separating terminal (T2) between the amplifier module
to be set and the proportional solenoid valve.
3.
Disconnect the wire from terminal five.
4.
Connect the positive output of the service module with terminal five of the
amplifier module, using test lead (2).
5.
Attach a multimeter for voltage reading to the service module, using test
lead (3).
6.
Attach a multimeter (in series) for Amp reading to the terminal between
amplifier module and solenoid valve, using test leads (3).
7.
Move the lever of the Potentiometer Control into its final position; or
override manual the relay which allows 24 V operating voltage to the
amplifier module; thus the amplifier gets 24 V operating voltage. The
power LED and simultaneously LED A(+) or B(-) lights up, depending on
the polarity.
8.
Turn the potentiometer (P) of the Service-Module until the multimeter
shows 1 VDC (it may be either positive or negative); the multimeter for the
current reading will show a value which should correspond to the value
giving in the circuit diagram e.g. 330 mA. (The first step (10 %) value)
If necessary correct the value with potentiometer (R1).
9.
Turn the potentiometer (P) of the Service-Module further until the
multimeter shows 9 VDC; the multimeter for the current reading will show
a value which should correspond to the value giving in the circuit diagram
e.g. 660 mA. (The second step (90 %) value).
If necessary correct the value with potentiometer (R2).
10. Repeat settings of item 8 and 9 until both mA values are stabilized, because
R1 and R2 influence each other.
* How to open and close the terminal:
Push the yellow stud (1) down with a screw driver and turn it 90 to the left to
open or to the right to close the terminal. A spring pushes then the stud
outwards and the contacts are either open or closed.
continued

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Controlling

Section 5.0
Page 18

Cont'd:
5.11

Adjusting the Amplifiers Type B, illustration (Z 21642)


11.

12.
13.

If the setting with either positive or negative potential was successful, turn
the potentiometer (P) of the service module into the opposite direction and
check the settings with the other polarity i.e. if the first setting was done
with positive potential then turn the pot into negative direction; otherwise
vice versa.
Repeat the setting as described under item 7 to 10.
Remove multimeter, test wire, close* the terminals and reconnect the wire
to terminal 5 of the amplifier module.

Adjusting the Ramp Time


1.
2.

Turn potentiometer (Rt) 30 revolutions counter clockwise, to guarantee the


correct start position at the complete left side.
Turn potentiometer (Rt) so many revolutions clockwise as shown in the
table below (part of the electrical circuit diagram).

* How to open and close the terminal:


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

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19

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Controlling

5.12

Section 5.0
Page 19

Adjusting the Amplifiers Type B, illustration (Z 21643)


The amplifiers for the crawler foot pedals are adjustable in the same way as
the amplifiers for the joy sticks.(refer to page 17 and 18 in this section)
The amplifier for the swing foot brake is similar.
Procedure for the swing foot brake:
1.
Open* the respective separating terminal (T1) between the pedal unit and
the amplifier module to be set.
2.
Open* the respective separating terminal (T2) between the amplifier module
to be set and the proportional solenoid valve.
3.
Disconnect the wire from terminal five.
4.
Connect the positive output of the service module with terminal five of the
amplifier module, using test lead (2).
5.
Attach a multimeter for voltage reading to the service module, using test
lead (3).
6.
Attach a multimeter (in series) for Amp reading to the terminal between
amplifier module and solenoid valve, using test lead (3).
7.
Press the pedal fully down ; or manual override the relay which allows 24 V
operating voltage to the amplifier module; thus the amplifier gets 24 V
operating voltage.
8.
Turn the potentiometer (P) of the Service-Module until the multimeter
shows 1 VDC ; the multimeter for the current reading will show a value
which should correspond to the value giving in the circuit diagram e.g. 10
mA. (10 % value)
If necessary correct the value with potentiometer (R1).
* How to open and close the terminal:
Push the yellow stud (1) down with a screw driver and turn it 90 to the left to
open or to the right to close the terminal. A spring pushes then the stud
outwards and the contacts are either open or closed.
continued

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20

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Section 5.0
Page 20

Controlling

Cont'd:
5.12

Adjusting the Amplifiers Type B, illustration (Z 21643)


9.

)
10.
11.

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


multimeter shows 10 VDC; the multimeter for the current reading will show
a value which should correspond to the value giving in the circuit diagram
e.g. 500 mA. (100 % value).
If necessary correct the value with potentiometer (R2).
It is important that the pilot pressure for the pressure increasing valve
is 19 1 bar.
For more information refer to section 8.2 Swing Circuit
Repeat settings of item 8 and 9 until both mA values are stabilized, because
R1 and R2 influence each other.
Remove multimeter, test wire, close* the terminals and reconnect the wire
to terminal 5 of the amplifier module.

* How to open and close the terminal:


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

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Controlling

5.13

Section 5.0
Page 21

Adjusting the Ramp Time Module


Legend for illustration (Z 21644)
(2)
Capacitor-Module
(3)
Ramp time module
(6)
Service module
(P)
Potentiometer

The following adjustments have to be done when commissioning the


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

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

Repeat settings of item 1 and 2 until both values are stabilized, because
"Pot Z" and "Pot G" influence each other.
The factory setting of potentiometer "w1" to "w4" for the command
value call-ups must not be adjusted.

continued

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22

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Section 5.0
Page 22

Controlling

Cont'd:
5.13

Adjusting the Ramp Time Module


Legend for illustration (Z 21645)
(1)
Control lever (joystick)
(2)
Capacitor-Module
(3)
Ramp time module
(4)
(5)

Proportional-Amplifier-Module
Relay (Supply Voltage)

Ramp time adjustment in relation to the operating movements:


3.

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


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

4.

To check the adjustments under operating conditions reconnect terminal


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

5.

If the above mentioned values are not suitable for the local working
conditions, for example due to, different Attachments or different
operation feeling of the operator,
the ramp time can be changed according to the NOTE on illustration
Z 21645, to ensure smooth and efficient working cycles.

continued

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23

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Section 5.0
Page 23

Controlling

Cont'd:
5.13

Adjusting the Ramp Time Module

E48 Stick
24 Volt at

Joy stick Signal

Pot

Value to be measured at socket "t"

Terminal 9

Neutral Stick out

0V to +10V

t1

0,10 Volt = 1000 ms

Terminal 10

Stick out Neutral

+10V to 0V

t2

5,00 Volt = 20 ms

Terminal 11

Neutral Stick in

0V to -10V

t3

0,10 Volt = 1000 ms

Terminal 12

Stick in Neutral

-10V to 0V

t4

5,00 Volt = 20 ms

Pot

Value to be measured at socket "t"

E49 Boom
24 Volt at

Joy stick Signal

Terminal 9

Neutral Lower

0V to +10V

t1

0,10 Volt = 1000 ms

Terminal 10

Lower Neutral

+10V to 0V

t2

5,00 Volt = 20 ms

Terminal 11

Neutral Lift

0V to -10V

t3

0,10 Volt = 1000 ms

Terminal 12

Lift Neutral

-10V to 0V

t4

5,00 Volt = 20 ms

Pot

Value to be measured at socket "t"

E50 Swing
24 Volt at

Joy stick Signal

Terminal 9

Neutral Swing R

0V to +10V

t1

0,10 Volt = 1000 ms

Terminal 10

Swing R Neutral

+10V to 0V

t2

0,10 Volt = 1000 ms

Terminal 11

Neutral Swing L

0V to -10V

t3

0,10 Volt = 1000 ms

Terminal 12

Swing L Neutral

-10V to 0V

t4

0,10 Volt = 1000 ms

Pot

Value to be measured at socket "t"

E50B Swing brake


24 Volt at

Joy stick Signal

Terminal 9

Neutral counter
swing right

0V to +10V

t1

0,067 Volt 1500 ms

Terminal 10

Counter swing right +10V to 0V


Neutral

t2

5,000 Volt = 20 ms

Terminal 11

Neutral counter
swing left

0V to -10V

t3

0,067 Volt 1500 ms

Terminal 12

Counter swing left


Neutral

-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

E51 Left crawler


24 Volt at

Joy stick Signal

Pot

Value to be measured at socket "t"

Terminal 9

Neutral Forward

0V to +10V

t1

0,10 Volt = 1000 ms

Terminal 10

Forward Neutral

+10V to 0V

t2

0,10 Volt = 1000 ms

Terminal 11

Neutral
Backward

0V to -10V

t3

0,10 Volt = 1000 ms

Terminal 12

Backward
Neutral

-10V to 0V

t4

0,10 Volt = 1000 ms

Pot

Value to be measured at socket "t"

E52 Right crawler


24 Volt at

Joy stick Signal

Terminal 9

Neutral
Backward

0V to +10V

t1

0,10 Volt = 1000 ms

Terminal 10

Backward
Neutral

+10V to 0V

t2

0,10 Volt = 1000 ms

Terminal 11

Neutral Forward

0V to -10V

t3

0,10 Volt = 1000 ms

Terminal 12

Forward Neutral

-10V to 0V

t4

0,10 Volt = 1000 ms

Pot

Value to be measured at socket "t"

E59 Bucket (only BHA)


24 Volt at

Joy stick Signal

Terminal 9

Neutral Fill

0V to +10V

t1

0,10 Volt = 1000 ms

Terminal 10

Fill Neutral

+10V to 0V

t2

5,00 Volt = 20 ms

Terminal 11

Neutral Dump

0V to -10V

t3

0,10 Volt = 1000 ms

Terminal 12

Dump Neutral

-10V to 0V

t4

5,00 Volt = 20 ms

06.10.05

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Section 6.0
Page 1

Components

Table of contents section 6.0

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

Main Control Blocks and High Pressure Filter BHA

4-5

6.1.3

Distributor Manifold Restrictor blocks FSA

6.1.4

Distributor Manifold Restrictor blocks BHA

6.1.5

Restrictor Block with Pressure Relief Valve

6.1.6

Anti Cavitation Valve Block

6.1.7

Remote Control Valves

10

6.1.8

Directional Solenoid Valves (4 way / 3 positions)

11

6.1.9

Proportional Solenoid Valves

12

6.1.10

High Pressure Filter

13

6.1.11

Control Blocks and Valves

6.1.12

Load Holding Valve

18

6.1.13

Travel Brake Valve

19

6.1.14

Pressure Reducing Valve

20

6.1.15

Directional Solenoid Valves (2 positions / 4-ways)

21

6.1.16

Pressure Increasing Valve

22

14-17

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2

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Section 6.0
Page 2

Components

6.1.1

Main Control Blocks and High Pressure Filter


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

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3

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Section 6.0
Page 3

Components

Pump circuit No. III


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

06.10.05

There is one MRV in each control block.

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4

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Section 6.0
Page 4

Components

6.1.2

Main Control Blocks and High Pressure Filter


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

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6.0
5

06.10.05

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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

06.10.05

There is one MRV in each control block.

PC5500-6-D_Sec_6-0_rev1.doc

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6

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Components

6.1.3

Section 6.0
Page 6

Distributor Manifold - Location of restrictor blocks and anti cavitation


valves
Front Shovel Attachment (FSA)
Legend for illustration (Z 22434):
(1)
Distributor manifold
(2)
Synchronization (Equalization) lines
(3)
Synchronization (Equalization) lines
(4)
Anti Cavitation Valve Block (ACV)
(5)
Restrictor Block (Throttle valve)
(6)
Restrictor Block (Throttle valve)
(7)
Service-line Relief Valve

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6.0
7

06.10.05

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Components

6.1.4

Section 6.0
Page 7

Distributor Manifold - Location of restrictor blocks and anti cavitation


valves
Backhoe Attachment
Legend for illustration (Z 22434):
(1)
Distributor manifold
(2)
Synchronization (Equalization) lines
(3)
Synchronization (Equalization) lines
(5)
Service-line Relief Valve
(4)
ACV Block Section A ,Boom cylinder rod side
(6)
Service-line Relief Valve
Pressure check point
(7)
Restrictor blocks

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6.0
8

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Components

6.1.5

Section 6.0
Page 8

Restrictor Block with Pressure Relief Valve

A restrictor block is used for limiting cylinder lowering speeds.


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

Legend for illustration (Z 21834):


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

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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6.0
9

06.10.05

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Components

6.1.6

Section 6.0
Page 9

Anti Cavitation Valve Block

ACVs are installed to avoid cavitation damages on users (hydraulic


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

Legend for illustration (Z 21835):


(Type 64.1 to 64.9 of the hydraulic circuit diagram)
(1)
Housing
(2)
Valve cone
(3)
Spring
(4)
O-ring
(5)
Control and leak oil bore
(6)
Cap screw (torque 900 Nm)
S
Supply line
(Return oil pressurized to approximately 10 bar by
back pressure valve)
A and B Line connections
Function:
The circuit pressure in the line A and B hold the valve cone (2) closed. The
pressure of the supply line S forces onto the valve cone.
The valve cone opens, whenever the pressure at the A and B side is lower
than the back pressure at return oil port S, to allow necessary oil supply into
the circuit.

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6.0
10

06.10.05

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Components

6.1.7

Section 6.0
Page 10

Remote control valves

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

Legend for illustration (Z 21838):


(1 - 8)
(9)
(10)
(11)
(12)
(13)

Pilot pressure lines to the control block


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

Function:
The electric-hydraulic control system is used to control the direction and
volume of oil flow to the operating cylinders and motors via the main control
valve blocks.
When a lever (or pedal) is actuated, a proportional solenoid valve (13) and
one of the directional solenoid valves (12 either a or b) are energized, and
allows the pilot pressure oil to flow to the spools of the main control blocks.
The proportional solenoid valve alters the pilot pressure, proportional to the
lever deflection, this results a spool movement between neutral and full
stroke position.

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6.0
11

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Components

6.1.8

Section 6.0
Page 11

Directional Solenoid Valves


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

This solenoid operated directional spool valves are installed to control


the start, stop and direction of an oil flow.

Legend for illustration (Z 21839):


(1)
Housing
(2)
Solenoids
(3)
Control spool
(4)
Reset springs
(5)
Plunger
(6)
End cover
Function:
In un-operated condition the control spool (3) is held in the neutral or
starting position by the reset springs (4). Operation of the control spool is by
means of oil immersed solenoids (2).
The force of the solenoid (2) acts via the plunger (5) on the control spool (3)
and pushes its from its resting position into the required end position. This
results in the required free flow from P to A and B to T or from P to B and
A to T.
When the solenoid (2) is de-energised, the control spool (3) is returned to its
original position by the reset springs (4).

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Components

6.1.9

Section 6.0
Page 12

Proportional Solenoid Valve

This valves are responsible for the creation of a variable control


pressure proportional to the electrical signal output of an amplifier.

Legend for illustration (Z 21697):


(1)
Proportional solenoid
(2)
Control piston
(3)
Valve housing
(4)
Pressure measuring spool

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

Pressure measuring spool


Connection plug
Return spring
Bleed screw

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


when commissioning:
- Supply pressure to the valve
- Remove plug 8
- When no more air bubbles appear screw in plug 8.

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Components

6.1.10

Section 6.0
Page 13

High Pressure Filter

There is one filter in each pump line installed.

Legend for illustration (Z 21696):


(1)
Filter head
(2)
Drain plug
(3)
Filter case
(4)
Hexagon
(5)
Filter element
(6)
Seal
(7)
O-ring
(8)
Back-up ring
(9)
O-ring
(10)
Spring
(11)
Differential pressure switch
P1
Input pressure
P2
Output pressure
a
Electrical connection
b
REED contact
c
Permanent magnet piston
d
Spring
e
Plug screw
Function:
High-pressure in-line filters prevent contamination from entering the
hydraulic circuits. The high pressure filters are installed between the main
hydraulic pumps and main control blocks. All hydraulic components, behind
the pumps, are effectively protected from damage and undue wear. Each filter
is equipped with a differential pressure switch to monitor the filter flow
restriction. If the pressure reaches an unsafe difference of 8.5 bar, a
visual/acoustic warning appears on the display in the cab and the engines will
be shifted automatically to low idle.

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Components

6.1.11

Section 6.0
Page 14

Control Blocks and Valves

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

Legend for illustration (Z 22436):


(1)
Control block housing
(2)
Cab ("A side)
(3)
Cap ("B" side)
(4)
Solid spool
(5)
"B" side service line ports
(6)
Centering springs
(7)
MRV, main relief valve
(8)
Port A, to cylinder/motor
(9)
Port B, to cylinder / motor
(10)
Fine controlling grooves
(11)
Port P, from pumps
(12)
Port T, to tank
(13)
Load holding valves
Control blocks with "Open Center and Closed Ports".
Control blocks I, II and III are 4 spool blocks and IV is a 1 spool block.
See hydraulic circuit diagram for spool details.
Each spool is provided with "Fine Controlling Grooves" and ring grooves for
hydraulically centering of the spool.
Between 8 and 19 bar pilot pressure the spools are moved in their fine control
range.
Spool number 4 of block I, 2 of block II and 4 of block III are special
designed, to keep the pressure channel connected to the center channel during
the floating function is activated, so that pump flow is available for other
functions. This spools are marked in the hydraulic diagram with (# or $)
symbol.
The Load Holding Valves are installed inside of the spool, for each port to
the cylinder or motor one valve. The hydraulic diagram shows only one.
The MRV is a pilot operated pressure relief valve.

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Components

6.1.11

Section 6.0
Page 15

Control Blocks and Valves


Legend for illustration (Z 22440):
(1)
Main relief valve (MRV)Control block housing
(2)
Load holding valve
(3)
Anti cavitation valve (ACV)
(4)
Service line relief valve (SRV)
Explanation of the schematic drawing of the control block:
The hydraulic oil flows through the control block from port P to T, if all
spools are in neutral position ("pressure-less circuit" or Free circulation).

(A) 4 valve block


E.g. the spools moves up when pilot pressure is build up in the control pipe
line a1. (Imagine the lower symbol box moves to the center position.)
Now pump oil flows through holding valve (2) to the user port A1 because
the free flow circulation to the hydraulic reservoir is closed. The main relief
valve (1) limits the maximum operation pressure in this circuit. Via port B1
the return oil from the user is flowing back to the hydraulic reservoir.
During down hill travelling motion and stopping procedure (e.g. travel
motors) the anti cavitation valves (3) prevents cavitation on the hydraulic
motors. Because during these short periods of time the hydraulic motor needs
a higher oil supply than the pump can deliver.
E.g. the spool (4) moves up when pilot pressure is build up in the control pipe
A4. Now the user port A4 is connected to the pump pressure line and the free
circulation to the tank. There is no high pressure build up only 8 bar from the
back pressure valve and line resistance. Via port B4 the return oil from the
user is flowing back to the hydraulic reservoir. Service line relief valve (4) is
additional installed in this circuit to protect the circuit for extreme pressure.
The shortly extreme pressure closes also the holding valve (2) which secures
the hydraulic pump from extreme pressure peaks.

(B)

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

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Components

6.1.11

Section 6.0
Page 16

Control Blocks and Valves


Legend for illustration (Z 22441):
(1)
Spool
(2)
Reset springs
(3)
Load holding valve
Function:
Reset springs (2) moves the spool (1) in neutral position.
Fine control grooves provide for sensitive controlling, because a motion is
started always while the pressure oil and the return oil first passes this fine
control grooves before spool (1) is inter connecting the entire groove to the
user channel.
In neutral position of spool (1) the pump oil is flowing back via port PU to the
tank.
Lower picture:
Example. The spool is moved by pilot pressure on the left spool side to right
position: Port PU is closed and the connection through the holding valve (3)
to the user (port A) is open. Also the connection from the other user side (port
B return)is connected to the port T (return line to tank).

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Components

6.1.11

Section 6.0
Page 17

Control Blocks and Valves


Legend for illustration (Z 21705):
(01)
Service -Line Relief Valve
(02)
Anti Cavitation Valve
(03)
Main Relief Valve
(04)
Closing plate
(5)
Plug screw
(6)
Spring
(7)
Valve cone
(8)
Dust cap

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

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

MRVs and SRVs are pilot operated relief valves. The MRV limits the max.
Pump supply line pressure. The SRV limits the max. possible pressure peak in
the service-line.
The valves have an opening characteristic. That means, that in case of
contamination after the response procedure no further pressure increasing is
possible and damages are avoided.
Function:
The circuit pressure P forces with the force F1 on the piston surface A of the
main valve cone (15). Because there is via the jet bore (16) the same pressure on
the back side of the main cone, this results together with the spring (14) force in
a force F2 that keeps the main cone closed. Via the jet bore (13) the circuit
pressure is in front of the poppet (12). Exceeds the circuit pressure the setting
value of the spring (11), the poppet opens against the force of the spring (11).
This causes that the force F2 decreases and there is no more balance condition
between F1 and F2. Valve cone (15) is moved upwards by the greater force F1.
That means there is now a direct connection from port P to T (tank).
ACVs serve for compensation possible lack of feed when the SRV at the
opposite port is actuated (see circuit diagram) and for avoiding cavitation
damages. In addition, to supply a user in case it is continuously moved by
acceleration forces at zero position of the control spool.
Function:
The circuit pressure inside the spring chamber closes the valve cone (7).
The back pressure of the return line acts on the surface of the valve cone (7).
Whenever the pressure in the service-line is lower than the springs force the
valve cone opens by the force of the back pressure and hydraulic oil is additional
supplied.

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18

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Components

6.1.12

Section 6.0
Page 18

Load Holding Valve


Legend for illustration (Z 22441):
(1)
Spool
(2)
Reset springs
(3)
Load holding valve
Control Blocks I to IV (4 spool blocks and single spool block)
Two load holding valves are fitted into each spool of the control blocks, one
valve for each port (A and B).
They have three tasks:
1.
When circuit pressure due to attachment weight is higher than pump
pressure these valves prevent dropping of the attachment, within their
sensitive (fine controlling) range.
2.
Due suddenly pressure peaks in the service lines the valves also protect
the pump.
3.
When two pumps flows are used for one user they ensure that at least
the flow of one pump reaches the user in case one MRV is defect or not
more correct adjusted.
That means: Up to the max. Pressure of the defective valve both load holding
valves are open allowing the flow of both pumps to the user, then one valve will
be closed by the higher pressure and the flow of one pump only flows to the
user.
Function:
The system pressure forces onto the front area of the valve cone (1). This force
moves the valve cone against the spring and allows the oil to flow from the
pump through the spool centre to the port.
In neutral position of the spool no further flow is possible. (see circuit diagram)
If the spool is not more in neutral the flow continues to the user.
If due to an external force the pressure directed to the pump overcomes the
pump line pressure, this pressure forces the valve onto its seat (closed position)

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Components

6.1.13

Section 6.0
Page 19

Travel Brake Valve


Illustration Z 21695
Task:
Travel brake valves control the oil flow from the hydraulic motor to the tank
depending on operating pressure. This braking action prevents the motors from
over speeding.
Function:
Spring force keeps the spool in the lowest flow position. with increasing
operating pressure the opening for the return oil flow becomes larger.
On its way to the hydraulic motor the oil flows from A to A1 respectively from
B to B1 depending on the selected travel motion.
Example:
Operating pressure at port A moves spool (1) against the force of the spring (2)
and opens the way for the return oil (B1 to B).
Holding valve (3) prevents a direct oil flow from B1 to B.
If the operating pressure decreases to such an extend that the spring force
overcomes the pressure, the flow to the tank becomes restricted, resulting in
braking of the machine.
For more information and adjustment see section 8.3.

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20

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Components

6.1.14

Section 6.0
Page 20

Pressure Reducing Valve

Pressure reducing valves are installed to reduce the common 35 bar


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

Legend for illustration (Z 21844):


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

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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21

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Components

6.1.15

Section 6.0
Page 21

Directional Solenoid Valves (2 positions / 4-ways)

This solenoid operated directional spool valves are installed to control


the start, stop or direction of an oil flow.

Legend for illustration (Z 21845):


(1)
Housing
(2)
Solenoid
(3)
Control spool
(4)
Return spring
(5)
Plunger
(6)
Dust cap with stem for manual operation
Function:
When there is no flow through the valve, control spool (3) is held in neutral
or output position by means of the return springs (4). The control spool (3) is
operated by means of oil immersed solenoid (2).
The force of the solenoid (2) effects control spool (3) by means of the plunger
(5) and pushes it from its resting position to the required end position.
This results in free flow from P to B and A to T.
When solenoid (2) is de-energized, control spool (3) is moved back to its
resting position by means of return springs (4).
An optional hand emergency (6) allows movement of the control spool (3)
without energizing the solenoid.

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22

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Components

6.1.16

Section 6.0
Page 22

Pressure Increasing Valve

The pressure increasing valve is a remote controlled pressure relief


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

Legend for illustration (Z 21846):


(1)
Pilot valve with valve seat
(2)
Valve poppet
(3)
Compression spring
(4)
Main valve with sleeve
(5)
Main piston
(6)
Closing spring
(7+8)
Set screws
(9)
Piston
(10)
Pin
(11+12) Jet bore
(13+14) Lock nut
Function:
The valve poppet (2) is connected via the jet bores (11) and (12) with the
pressure port (P).
If static pressure increase above the set pressure value, the valve poppet (2)
opens and allows oil to flow freely via port (T1) to tank. This out flowing oil
generates a pressure drop in the spring chamber of the main spool (5). The
closing force of the spring (6) is now lower as the oil pressure from the
pressure port (P) and the main piston (5) opens to release pressurized oil to the
tank via port (T2).
Damped opening and closing is obtained by the throttled volumetric change.
By applying external pressure of Pst max = 35 bar to the main spool (9) via
port X, the pre-tensioning of the pressure spring (3) is increased by the amount
of the piston stroke "S" and system pressure is increased correspondingly.
The maximal possible pressure (P) adjustment is 440 bar with max. control
pressure at port X.
The lower setting is fixed by means of the setting screw (7) and lock nut (13);
1 turn of setting screw reduce or increase the pressure about ~150 bar.

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Main Hydraulic Pumps


and
Pump Regulation System

Section 7.0
Page 1

Table of contents section 7.0


Section
7.0

Page
Main hydraulic pumps and pump regulation system
General
7.1

7.2

25

Main Pumps
7.1.1
Location of Pumps

7.1.2

Pump bearing flushing / lubrication

7.1.3

Operating Principles

8 15

7.1.4

Checks and Adjustments

16 20

Electronic Pump Regulation System


7.2.1
Electronic load limiting control - General

21

7.2.2

Micro controller MC7

22

7.2.3

Checks and adjustments - General

23

Method A -

24

X1-pressure adjustment with 24V


supply to separating terminals at
the X2-switch board.

Method B - With the electronic service tool BB-3


- Language selection

7.3

06.10.05

25 + 26

- Excavator Type selection

27 + 28

- X1-pressure (max. current) adjust.

29 + 30

Method C - With a laptop and BODEM software


- Starting the program

31 + 32

- Language selection

33

- Excavator Type selection

34

- X1-pressure (max. current) adjust.

35

Hydraulic Constant Regulation System


7.3.1
General

36

7.3.2

37

X1-pressure adjustment (constant-pressure)

7.4

Determination of the Peak point

38+39

7.5

Engine speed sensor (pick up)


7.5.1
Engine speed sensor (pick up) adjustment

40

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2

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Main Hydraulic Pumps


and
Pump Regulation System
7.0

Section 7.0
Page 2

Main hydraulic pumps and pump regulation system


General layout (Hydraulic only)
Legend for illustration (Z 22442a):
(1 - 6) Main hydraulic pumps
(7.1)
Pilot pressure pumps, engine 1
(7.2)
Pilot pressure pumps, engine 2
(68.1) Pilot pressure filter unit
(70.1) 60 bar pressure relief valve
(70.2) 35 bar pressure relief valve
(81.1) Pressure reducing valve: "Remote control pressure" Q-max flow
reduction for the warming-up period
(81.2) Pressure reducing valve: "Pump regulation pressure X1 at hydraulic
pump regulation" (Hydraulic constant regulation mode)
(Y17) Solenoid valve: "Idle time control and low hydraulic oil temperature"
Q-min flow for all main pumps
(Y17a) Solenoid valve: "Remote control pressure"
Q-max flow reduction for all main pumps (low hydraulic oil
temperature)
(Y61-1) Proportional solenoid valve: "Pump regulation pressure X1 at electronic
pump regulation, engine 1" (Standard operation mode)
(Y61-2) Proportional solenoid valve: "Pump regulation pressure X1 at electronic
pump regulation, engine 1" (Standard operation mode)
(79.1) Change over valve: "Electronic or Hydraulic pump regulation",
engine 1
(79.2) Change over valve: "Electronic or Hydraulic pump regulation",
engine 2
(Y102-1) Solenoid valve:
"Pump regulation support pressure and pump bearing lubrication"
(Y102-2) Solenoid valve:
"Pump regulation support pressure and pump bearing lubrication"

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PC5500-6-D_Sec_7-

Main Hydraulic Pumps


and
Pump Regulation System
7.0

Section 7.0
Page 3

Main hydraulic pumps and pump regulation system


Pump regulation system
General
Controlled output flow of the main pumps is necessary:
To utilize the available engine power most efficiently in every operating
mode.
To limit the power consumption of the hydraulic pumps depending of the load
of the engine. (Electronic pump regulation with micro-controller MC7)
For additional functions, such as swing dependent or temperaturedependent flow control.
Function:
X1 pump regulation pressure (0 25 bar):
The power controller of the main pumps can be remotely controlled by
applying an external pilot pressure (X1 ) at port X LR to the spring chamber of
the power control valve. The start of destroking can be varied in proportion to
the applied X1 - pressure.
X2 pilot pressure (35 bar):
Constant pilot pressure to regulate the main pumps at special circumstances,
e.g. to fix pump 3 in Q-max position activated by the swing control (pump for
swinging controlled by Y48) .
X3 remote control pressure (0 / 16 / 35 bar):
Basic setting Q-min (0 bar), the flow rate increases with the
pilot pressure X3 at port Pst, up to Q-max (35 bar).
The hyperbolic power control is superimposed on the pilot pressure
signal and keeps the specified drive power constant. (px Vg = constant).
The flow rates are:
Q-min.:
X3 = 0 bar
Q-max.: X3 = 16 bar
Q-max.:
X3 = 35 bar
X4 pump support pressure (60 bar):
Constant pilot pressure to support the regulation function at low operating
pressure and to lubricate the main pump bearings.

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Main Hydraulic Pumps


and
Pump Regulation System
7.0

Section 7.0
Page 4

Main hydraulic pumps and pump regulation system


Pump regulation system general
Function:
Solenoid valve Y17:
(33/7)*
If solenoid valve Y17 is de-energized pumps (1-6) are in Q-min position. It
gets energized as soon as one of the control levers/pedals has been operated
and de-energized when ever all controls are in neutral position for more than
20 seconds (exception: high oil temperature >T3).
Solenoid valve Y17a: (33/5)*
The solenoid is de-energized as long the hydraulic oil temperature is below
the values of temperature range T2 (depending on the filled in hydraulic
oil) shown in the table. ( pumps (1-6) are in Q-max. position)

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7.0
5

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Main Hydraulic Pumps


and
Pump Regulation System
7.0

Section 7.0
Page 5

Main hydraulic pumps and pump regulation system


Pump regulation system general
Function:
Proportional Solenoid valve Y61-1 and Y61-2: (49/2)*
This valves, connected to the MC7 micro-controller E32 (electronic pump
regulation), creates a X1-pressure depending on the load of the engine.
This X1-pressure is the pumps regulation signal to de-stroke from Q-max. into
Q-min. position, to keep the engine at rated speed of approx. 1800 RPM.
Pressure reducing valve 81.1:
"Remote control pressure" (X3)
Q-max flow reduction during the warming-up period for all pumps by the
function of solenoid valve Y17a.
Pressure reducing valve 81.2:
Pump regulation pressure X1 at "hydraulic pump regulation" (Hydraulic
constant regulation mode) by the function of change over valve (79.1 / 79.2).
One valve for both engines. This valve create a constant X1 pressure, the
pressure can be change for different pump regulation checks and adjustments.
Change over valve 79.1 and 79.2:
Change over three way cock valve to select "Electronic or constant regulation
mode", one for each engine.

Note:

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* Electric circuit diagram page / column (based on Id # 897 889 40)

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Main Hydraulic Pumps


and
Pump Regulation System
7.1

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

(10.1), (10.3) Axial piston pump


pump volume
theoretical flow rate
Drive speed*
for radiator fan drive

Vg max
Qmax
n

= 80 cm/rev
= 158 Liter/min
= 1973 min-1

(10.2), (10.4) Axial piston pump


pump volume
theoretical flow rate
Drive speed*
for oil cooler fan drive

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)

)
06.10.05

Axial piston pump (swash plate type)


pump volume
Vg max
theoretical flow rate, each
Qmax
Drive speed*
n
for all working motions

* at 1800 min-1 input drive speed

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7

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Main Hydraulic Pumps


and
Pump Regulation System

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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Main Hydraulic Pumps


and
Pump Regulation System
7.1

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

Function and characteristics:


The A4VSO variable displacement axial piston pump in swash plate
design is intended for drives in open circuit operation.
The flow volume is proportional to the drive speed and the displacement.
By adjusting the swash plate a infinitely variable flow adjustment is
possible.
Pumps of the same nominal size can be built onto the trough drive.
Combinations with gear pumps are also possible.
Legend for illustration (Z 22446):
The lower illustration shows only a principle pump construction
(1)
Drive shaft
(2)
Cylindrical roller bearing
(3)
Slipper pad
(4)
Swivel angle indicator
(5)
Positioning piston
(6)
Swivel pin
(7)
Cylinder with pistons
(8)
Final connecting plate
(9)
Cylindrical roller bearing
(10)
Splints for the through drive coupling (Aux. pump drive)
(11)
Swivel cradle
(12)
Q-min stop bolt
(13)
Power control valve
(14)
Pressure balance valve
(15)
Power curve correction
(16)
Pressure cut off valve
(17)
Q-max. stop bolt
(18)
Remote control valve
continued

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Main Hydraulic Pumps


and
Pump Regulation System

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

* Factory side adjusted, no field adjustment required

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

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

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Main Hydraulic Pumps


and
Pump Regulation System

Section 7.0
Page 10

Cont'd:
7.1
Main Pumps
7.1.3

Operating Principles

Sectional drawing of Power Controller LR3DN / 30L


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

Refer also to illustration Z 22447 on the previous page.

continued

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11

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Main Hydraulic Pumps


and
Pump Regulation System

Section 7.0
Page 11

Cont'd:
7.1
Main Pumps
7.1.3

Operating Principles, illustration (Z 21552a)

Q-min position: (remember Q means volume)


When are the pumps in Q-min position?
A: Engine at standstill
B: Engine running and the controls are not used for 20 sec. or longer
at normal operating temperature
C: Engine running and service switch S150 activated
Example C with the following conditions:
Engine running (high idle)
Pump pressure smaller than X4 = 60 bar (pump support pressure)
X1 = 24 bar (pump regulation pressure), this pressure will not influence
the Q-min position under these conditions.
X3 = 0 bar (remote control pressure); Y17 de-energized (S150 activated)
for pumps (1, 2,4, 5 and 6).
Pump #3 is not connected in the regulation circuit its port XLR is
permanent charged with X2-pressure
X4 = 60 bar (pump support pressure)
Pump support pressure is present at valve (6), the slipper pad of
piston (13) and the small area side of the positioning piston (12).
Response of pump control mechanism:
Valve (6) moves to position "b" because the X4-pressure will overcome the
spring force, since the oil behind nozzle (7) flows through valve (5) (which is
in position "a", due to the missing remote control pressure X3) back to tank.
Pump support pressure X4 passes valve (6) position "b" and flows via power
control valve (8) position "a" to the large area side of positioning piston (12).
Because the large area side of positioning piston (12) is approximately three
times larger as the small area side, the pump support pressure X4 of 60 bar
present on both sides, resulting in stronger force at the large area side, keeps
the pump in Q-min position.
The pump remains in Q-min position
continued

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12

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Main Hydraulic Pumps


and
Pump Regulation System

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.

Example with the following conditions:


Engine running (> 1800 min-1)
Pump pressure between 60 bar and 300 bar, present at the slipper pad
of piston (13) and the small area side of the positioning piston (12)
X1 = 24 bar (pump regulation pressure)
X3 = 35 bar (remote control pressure); Y17 and Y17a energized
for all six pumps.
X4 = 60 bar (pump support pressure), present at valve (6).
Response of pump control mechanism:
Valve (6) moves to position "a" because the spring force is supported by the
X4-pressure, since the oil flow back to tank is blocked at valve (5) (which is
in position "b", due to the 35 bar remote control pressure X3).
The large area side of positioning piston (12) is connected, via power control
valve (8) position "a" and pressure balance valve (6) position "a", to the
return oil line.
The pump moves into Q-max position, because the pump pressure acts only
at the small area side of positioning piston (12).
The pump moves into Q-max position
continued

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13

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Main Hydraulic Pumps


and
Pump Regulation System

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.

Example with the following conditions:


Engine running (> 1800 min-1)
Pump pressure between 60 bar and 300 bar, present at the slipper pad
of piston #14 and the small area side of the positioning piston #13
X1 = 24 bar (pump regulation pressure)
X3 = 16 bar (remote control pressure); Y17 energized and Y17a deenergized
for all six pumps.
X4 = 60 bar (pump support pressure), present at valve #6.
Response of pump control mechanism:
Valve (6) moves to an intermediate position (in-between "a" and "b"), since a
certain amount of oil behind nozzle (7) flows through valve (5) (which is also
in an intermediate position, due to the 16 bar remote control pressure X3)
back to tank.
The large area side of positioning piston (12) is connected, via power control
valve (8) position "a" and pressure balance valve (6), to the return oil line.
The pump moves into Q-max position, because the return oil flow through
pressure balance valve (6) is restricted (due to its intermediate position),
resulting in a pressure at the large area side of the positioning piston (12).
The pump moves into 12 Q-max position
continued

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14

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Main Hydraulic Pumps


and
Pump Regulation System

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

(The electronic pump regulation system will reduce the X1-pressure)


or
With pump pressure above 150 bar (Hydraulic constant regulation)
(Constant X1-pressure of approximately 8 bar)
Example with the following conditions:
Engine running (> 1800 min-1)
Pump pressure 260 bar adjustable at main relief valve, present at the slipper
pad of piston (13) and the small area side of the positioning piston (12)
X1 = 12 bar (constant regulation pressure adjustable at pressure reducing
valve 81.2) Change over valve (79.1 / 73.2) switched to hydraulic mode
X3 = 35 bar (remote control pressure); Y17 energized and Y17a energized
X4 = 60 bar (pump support pressure), present at valve (7).
Response of pump control mechanism:
Valve (6) moves to position "a" because the spring force is supported by the
X4-pressure, since the oil flow back to tank is blocked at valve (5) (which is
in position "b", due to the 35 bar remote control pressure X3).
The operating pressure (with the value for start of de-stroking) at the slipper
pad of piston (13) moves the power control valve (8) into position "b"
(against the spring force supported by the X1-pressure).
This in turn connects the operating pressure to the large area side of
positioning piston (12).
Because the large area side of positioning piston (12) is approximately three
times larger as the small area side, the operating pressure present on both sides,
resulting in stronger force at the large area side, moving the pump in Q-min
direction.
The pump de-strokes until the forces at positioning piston (12) are
balanced
continued

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15

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Main Hydraulic Pumps


and
Pump Regulation System

Section 7.0
Page 15

Cont'd:
7.1
Main Pumps
7.1.3

Operating Principles, illustration (Z 21556a)

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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Main Hydraulic Pumps


and
Pump Regulation System
7.1

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

The measurement "L" is an orientation only if the adjustment is


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

Further information see next pages

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17

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Main Hydraulic Pumps


and
Pump Regulation System
7.1

Section 7.0
Page 17

Main Pumps
7.1.4

Checks / Adjustments

Pressure balance valve, illustration (Z 21558b)

The pressure balance valve is bench adjusted. There is no field


setting with a sufficient result possible.

continued

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18

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Main Hydraulic Pumps


and
Pump Regulation System

Section 7.0
Page 18

Cont'd:
7.1
Main Pumps
7.1.4

Checks / Adjustments

Start of de-stroking(LR valve), illustration (Z21559)


The reason of this check is to make sure, the pump starts de-stroking at an
operating pressure of 150 bar with a pump regulation pressure X1 = 0 bar.
1.
2.
3.
4.
5.
6.
7.

Connect a 400 bar pressure gauge to the pressure check point at the
respective high pressure filter for the pumps being checked.
Connect a 25 bar pressure gauge to respective pressure check point
M20-1 or M20-2 at the control and filter panel (X1-pressure).
Change over the respective three way cock to electronic regulation.
Unplug the respective proportional valve Y61.1 / Y61.2.
Insert an Allen key into the angle indicator bolt (see illustration)
for better visibility of the start of.
Start the respective 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.

If readjustment is required proceed as follow:


a)
Adjust with the MRV an operating pressure of 150 bar.
b)
Loosen lock nut (6) (Power control valve).
c)
Turn set bolt (7), so that the pump is still in Q-max. position,
but just at the beginning of de-stroking.
d)
Tighten lock nut (6).
8.

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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Main Hydraulic Pumps


and
Pump Regulation System

Section 7.0
Page 19

Cont'd:
7.1
Main Pumps
7.1.4

Checks / Adjustments

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


The sense of this check is to make sure that the pump is in Q-min. position at
an operating pressure between 300 bar and 310 bar.
1.
2.
3.

4.

Connect a 400 bar pressure gauge to the pressure check point at the
respective high pressure filter for the pumps being checked.
Insert an Allen key into the angle indicator bolt (see illustration) for
better visibility of the start of 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.

If readjustment is required proceed as follow:


a)
Loosen lock nut (8).
b)
Turn set bolt (9), so that the pump is in Q-min. position at
the required value.
c)
Tighten lock nut (8).
5.
6.

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


Remove Allen key and gauges.

continued

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20

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Main Hydraulic Pumps


and
Pump Regulation System

Section 7.0
Page 20

Cont'd:
7.1
Main Pumps
7.1.4

Checks / Adjustments

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


1.
2.
3.
5.

Unscrew box nut (10 or 14).


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

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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Main Hydraulic Pumps


and
Pump Regulation System
7.2

Section 7.0
Page 21

Electronic Pump Regulation System


7.2.1

Electronic load limiting control - general, illustration (Z 22448)

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 auxiliary hydraulic pumps and other consumers can be operated


without being directly affected by the load limiting control.

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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Main Hydraulic Pumps


and
Pump Regulation System
7.2

Section 7.0
Page 22

Electronic Pump Regulation System


7.2.2
Micro controller MC7, illustration (Z 21716)
The MC7 micro controller is used for the programmable control of a maximum of
four proportional solenoids and two additional switching functions.
As input signals, the microprocessor processes analog voltages in the 0V to 5V
range and switching information. All inputs are protected against over voltage and
electrical interference.
As output signals, the output stages of the MC7 deliver closed loop controlled
currents for the connection of proportional solenoids.
The analog voltage output is suitable for the simple forwarding of analog
information to other electronic circuits.
Characteristics
Closed loop control of solenoid currents, i.e. independent of voltage and
temperature.
Pulse width modulated (PWM) solenoid currents for minimal hysteresis.
Internal buzzer for programmable monitoring of functions or errors.

Setting and Display Facilities


All calibration operations and the display of functions, faults and system variables
are connected via the serial interface to the BB-3 control panel or to a PC running
the BODEM software.
MC7 - Unit Dimensions
Plug Contacts

MC7 - Block Circuit Diagram

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23

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Main Hydraulic Pumps


and
Pump Regulation System
7.2

Section 7.0
Page 23

Electronic Pump Regulation System


7.2.3
Checks and adjustments
Micro controller MC7, illustration (Z 21714a)
The adjustment of the X1-pressure can be done with three different methods:
A.
With 24V supply to separating terminals at the X2-switch board
or
B.
With the electronic service tool (EST) BB-3 connected to the serial
interface X13-1 (located in the operators cab)
or
C.
With a laptop, running the BODEM software, connected to the serial
interface X13-1 (located in the operators cab)

06.10.05

Procedure B and C should only be carried out by authorized


personnel. [ Dealer or KMG-factory staff ]
Because it is possible to influence the behavior of the pump regulation
system.
On the following pages are only the necessary setups described.
If additional information is required, please contact KMG-Service
department.

PC5500-6-D_Sec_7-0_rev5c.doc

7.0
24

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Main Hydraulic Pumps


and
Pump Regulation System
7.2

Section 7.0
Page 24

Electronic Pump Regulation System


7.2.3

Checks and adjustments Micro controller MC7,


illustration (Z 21717a)

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.

6. To decrease the X1-pressure connect 24V to terminal 128 and proceed as


described under item 5, keeping voltage supply for two seconds , will
decrease the X1-pressure of approximately 1 bar.
7. After the adjustment is finished, remove the test leads and pressure gauge and
turn the main key switch in OFF position to deactivate the adjusting mode.

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7.0
25

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Main Hydraulic Pumps


and
Pump Regulation System
7.2

Section 7.0
Page 25

Electronic Pump Regulation System


7.2.3

Checks and adjustments Micro controller MC7,


illustration (Z 22357a)

Method B -

With the electronic service tool (EST) BB-3 connected to the


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

Language selection
To change the language press simultaneously
the buttons ALT + Clear

The language selection menu appears

continued

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7.0
26

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Main Hydraulic Pumps


and
Pump Regulation System
7.2

Section 7.0
Page 26

Electronic Pump Regulation System


7.2.3

Checks and adjustments Micro controller MC7,


illustration (Z 22357)

Method B
Cont'd:
Language selection
Press button 2

The language will change to English

One of the four main menu items can be selected using the given keys. (Fig. 1)

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7.0
27

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Main Hydraulic Pumps


and
Pump Regulation System
7.2

Electronic Pump Regulation System


7.2.3

Method B

Section 7.0
Page 27

Checks and adjustments Micro controller MC7,


illustration (Z 22357)

Excavator Type selection:


Press F1 Config/Cal.

Press 4 Device List.

Press 1 Device List.

Select the excavator type by pressing


or . PC4000/5500/8000

Press ENTER . Accept value/condition

Press MENU . Return to sub menu.

continued

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7.0
28

06.10.05

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Main Hydraulic Pumps


and
Pump Regulation System
7.2

Section 7.0
Page 28

Electronic Pump Regulation System


7.2.3

Checks and adjustments Micro controller MC7,


illustration (Z 22357)

Method B
Cont'd:
Excavator Type selection:
Press MENU . Return to main menu.

Press 1 . Save Params. This menu item permits


storage of all edited parameters in the EEPROM
of the MC electronics.

Press TEACH . Activate storage menu.

Press ENTER . Store parameters.

Press MENU .Abort.

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7.0
29

06.10.05

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Main Hydraulic Pumps


and
Pump Regulation System
7.2

Section 7.0
Page 29

Electronic Pump Regulation System


7.2.3

Checks and adjustments Micro controller MC7,


illustration (Z 22357)

Method B
X1-Pressure (maximum current) Adjustment:
Press F1 Config/Cal.

Press 2 Max current

Start the respective diesel engine and let it run


with maximum speed. (high free idle)
Do not load the diesel engine.
Press 1 Valve 1. (Engine 1) or
Press 2 Valve 2 (Engine 2)

Press ENTER . Acceptance of new value

Check the X1-pressure with a pressure


gauge and set it to the
desired value by pressing or .

Press MENU . Return to sub menu.

continued
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7.0
30

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Main Hydraulic Pumps


and
Pump Regulation System
7.2

Electronic Pump Regulation System


7.2.3

Method B

Section 7.0
Page 30

Checks and adjustments Micro controller MC7,


illustration (Z 22357)

Cont'd:
X1-Pressure (maximum current) Adjustment:
Press MENU . Return to main menu.

Press 1 . Save Params. This menu item permits


storage of all edited parameters in the EEPROM
of the MC electronics.

Press TEACH . Activate storage menu.

Press ENTER . Store parameters.

Press MENU .Abort.

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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7.0
31

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Main Hydraulic Pumps


and
Pump Regulation System
7.2

Section 7.0
Page 31

Electronic Pump Regulation System

7.2.3 Checks and adjustments Micro controller MC7,


illustration (Z 22358)
Method C - With a laptop computer and BODEM software connected to the
serial interface X13 (located in the operators cab)
Pre-conditions: Normal operating temperature, correct pilot pressure setting and the
system must be free of air.
1. Make sure the change over valve is in position Electronic Pump Regulation
2. Connect a pressure gauge to the respective check point (M20-x), using a long pressure
gauge hose to be able reading the pressure inside the operators cab.
3. Connect the laptop computer to the data link adapter X13,
with key switch (S1) in OFF position.
4. Make sure that the dongle is connected to the laptop computer. If not

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


6. Start the computer.
7. Click on the Bodem - icon to start the program.

continued

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32

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Main Hydraulic Pumps


and
Pump Regulation System
7.2

Electronic Pump Regulation System


7.2.3

Method C
Cont'd:

Section 7.0
Page 32

Checks and adjustments Micro controller MC7,


illustration (Z 22358)

8. The program starts (only) the first time with the Demo Version.

9. Open menu FILE INTERFACE , select the required interface connection


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

10. Start the program again. Now the computer is connected to the Micro controller.

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33

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Main Hydraulic Pumps


and
Pump Regulation System
7.2

Section 7.0
Page 33

Electronic Pump Regulation System


7.2.3

Method C

Checks and adjustments Micro controller MC7,


illustration (Z 22358)

Language selection
Open menu FILE Language , select the required language and confirm with OK .

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34

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Main Hydraulic Pumps


and
Pump Regulation System
7.2

Electronic Pump Regulation System


7.2.3

Method C

Section 7.0
Page 34

Checks and adjustments Micro controller MC7,


illustration (Z 22358)

Excavator Type selection:


Open menu
Display/Edit parameters Device list , select the required Excavator type and
confirm with OK .

After confirming the Excavator type, confirm saving the parameters with OK.

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35

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Main Hydraulic Pumps


and
Pump Regulation System
7.2

Electronic Pump Regulation System


7.2.3

Method C

Section 7.0
Page 35

Checks and adjustments Micro controller MC7,


illustration (Z 22358)

X1-Pressure (maximum current) Adjustment:


Open menu
Display/Edit parameters Max current , adjust the required pressure with the
slide bar and confirm with OK .

After adjusting the pressure, confirm saving the parameters with OK.

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36

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Main Hydraulic Pumps


and
Pump Regulation System
7.3

Section 7.0
Page 36

Hydraulic Constant Regulation System


7.3.1. General
The pilot pressure pump (7.1 and 7.2) delivers the oil through the pressure
filter (68.1) to port A of the pressure relief valve (70.1) for limiting the pilot
pressure (X2). The 35 bar limited pilot pressure oil flows through the solenoid
manifold to the pressure reducing valve (81.2), which reduces the X2 pressure
to the necessary constant X1 pressure, to prevent the engine from overloading.

For testing purposes the pump regulation system can be changed to


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

Legend for illustration (Z 22449):


(1 - 6) Main hydraulic pumps
(7.1)
Pilot pressure pump, engine 1
(7.2)
Pilot pressure pump, engine 2
(68.1) Pilot pressure filter unit
(70.1) 60 bar pressure relief valve
(70.2) 35 bar pressure relief valve
(81.1) Pressure reducing valve: "Remote control pressure" Q-max flow
reduction for the warming-up period.
(81.2) Pressure reducing valve: " Pump regulation pressure X1 at hydraulic
pump regulation" (Hydraulic constant regulation mode)
(Y61.1) Proportional solenoid valve: "Pump regulation pressure X1.1 at electronic
pump regulation " (Standard operation mode), pump 1 and 2.
(Y61.2) Proportional solenoid valve: "Pump regulation pressure X1.2 at electronic
pump regulation " (Standard operation mode), pump 4, 5 and 6.
(79.1) Change over valve engine 1: "Electronic or Hydraulic pump regulation"
(79.2) Change over valve engine 1: "Electronic or Hydraulic pump regulation"
(Y102-1) Solenoid valve Pump support pressure and pump bearing flushing,
engine 1
(Y102-2) Solenoid valve Pump support pressure and pump bearing flushing,
engine 2

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7.0
37

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Main Hydraulic Pumps


and
Pump Regulation System
7.3

Section 7.0
Page 37

Hydraulic Constant Regulation System


7.3.2.
1.
2.
3.
4.
5.
6.

7.
8.
9.

X1-pressure adjustment (constant-pressure) , illustration (Z 22360a)


Connect gauges (min. 400 bar) to check points (M12.1, M12.2, M12.3 and
M12.4).
Start only one engines and let it run with max. speed.
Check High Idle speed = 1900+35 min-1.
Shift the respective three way cock valves (79.1 and 79.2) to position
Hydraulic regulation
Set the X1-pressure at pressure reducing valve (81.2) to approx. 4 bar **.
Apply max. load to all pumps (e.g. extend the bucket cylinder to the
stop position until the hydraulic system stalls), and increase the
pressure at the 3 MRVs (Block I, II, and III) equally to 260 bar*.
Check the engine speed. Required = 1850+10 min-1.
If necessary correct the X1-pressure at pressure reducing valve (81.2) until
the required engine speed is obtained. Record this pressure for other tests.
Stop engine and start the other engine and repeat from position 3.
Shift the three way cock valves (79.1 and 79.2) to position Electronic
regulation
Reset the MRVs to 310 bar+5bar , and remove the gauges.

A slightly deviation between the two X -1 pressures is normal, caused


by tolerances of the pumps and engines.

*Altering the MRV-Setting:


Remove dust cap (a).
Loosen lock nut (b).
Turning the set screw (c) cw the pressure will increase.
Turning the set screw
ccw the pressure will decrease.
**Altering the X1-Setting:
Remove dust cap (d).
Loosen the lock nut (e).
Turning the set screw (f) cw the pressure will increase.
Turning the set screw
ccw the pressure will decrease.

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7.0
38

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Main Hydraulic Pumps


and
Pump Regulation System
7.4

Section 7.0
Page 38

Determination of the Peak point (Engine performance) ,


illustration (Z 22360a)
1.
2.
3.

4.

5.
6.
7.
8.
9.
11.

12.

Connect pressure gauges to check points (M12.1, M12.2, M12.3 and


M12.4) at the high pressure filter.
Connect a pressure gauge to the X1.1 and X1.2 pressure check point M201 and M20-2.
Unplug solenoid valves Y6A-1, Y6B-1, and Y6A-2, Y6B-2, for engine 2,
to ensure that the hydraulic oil cooler fans are running with maximum
speed.
Unplug the solenoid valve Y14A-1, Y14B-1 for engine 1 and Y14A-2,
Y14B-2 for engine 2 to ensure that the engine radiator fan is running with
maximum speed.
Start one engine and let it run with max. speed.
Check High Idle speed = 1900+35 min-1.
Set the MRV of main valve block I, II and III individually to approx. 120 bar
*, to prevent the engine from overloading during the test.
Shift the three way cock valves (79.1, 79.2) to position Hydraulic regulation.
Set the X1-pressure at pressure reducing valve (81.2) > 24 bar **, to
ensure that the pumps remaining in Q-max. flow position during the test.
Apply max. load to all pumps (e.g. extend the bucket cylinder to the final
stop position keep the ), and increase the pressure at the 3 MRVs *
(block I, II, III) equally until the engine speed is 180010 min-1.
Record this pressure for other tests. Required: 3 times 2205 bar.
Stop engine and start the other one. Repeat from step 6.
If the operating pressure respectively the engine speed is higher than
required there is probably not the full volume available.
If the operating pressure respectively the engine speed is lower than
required there is probably not the full engine power available.

continued

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7.0
39

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Main Hydraulic Pumps


and
Pump Regulation System
7.4

Section 7.0
Page 39

Determination of the Peak point (Engine performance) ,


illustration (Z 22360a)
13.
14.
15.
16.

Re-set the X1-pressure at pressure reducing valve (81.2) as recorded **.


Shift the three way cock valve (22) to position Electronic regulation
Reset the MRVs to 310 bar+5bar , and remove the gauges.
Check MRV on single valve block IV
*Altering the MRV-Setting:
Remove dust cap (a).
Loosen lock nut (b).
Turning the set screw (c) cw the pressure will increase.
Turning the set screw
ccw the pressure will decrease.
**Altering the X1-Setting:
Remove dust cap (d).
Loosen the lock nut (e).
Turning the set screw (f) cw the pressure will increase.
Turning the set screw
ccw the pressure will decrease

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7.0
40

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Main Hydraulic Pumps


and
Pump Regulation System
7.5

Section 7.0
Page 40

Engine speed sensor (pick up)


Legend for illustration (Z 22360a)
1.
Speed sensor (pick up)
2.
Fly wheel housing
3.
Fly wheel
4.
Look nut
5.
RPM-module (RPM-relay)
General:
The engine speed sensor (pick up) together with the RPM-Module use the fly
wheel teeth to count the engine RPM. With engine running create each tooth
a inductive tension in the pick up coil. That cause a alternative tension at the
pick up coil wire. With engine stand still there is no tension at the pick up
wire. The frequency of this alternative tension increase or decrease
proportional to the engine RPM. The RPM-module convert the frequency in
to a proportional voltage signal. This signal is used for different components
e.g. pump regulation, display, ECS.
7.5.1.

Engine speed sensor (pick up) adjustment


1.
Stop engine.
2.
Disconnect plug at the pick-up wire.
3.
Loosen look nut
4.
Turn out the pick-up completely ccw.
5.
Check front end of the pick up and clean it from magnetic chips and dirt.
6.
Turn the pick-up completely in ( cw ) until it touch the fly wheel Fig. A.
7.
Turn the pick-up turn out ( ccw ) Fig. B.
8.
Secure the pick up with look nut Fig. C.
9.
Connect the plug.
Final Check
10. Start engine and let them run in high idle
11. Check the tension (AC Voltage) of the pick-up. Use the terminals 1
and 2 of the RPM-module (RPM-relay) or respective terminals at the
X2 panel.
E.g.: Pick up B64-1 is connected to terminal X2M 7 and X2M 8 and
further to RPM-module (RPM-relay) K55-1 terminal 1 and 2.
(excavator S/N 15017).
12. The tension should be 1+ 0,5 Volt AC

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

Table of contents section 8.0


Section
8.0

01.04.03

Page

Operating Hydraulic
General
8.0.1
Floating function of boom and stick cylinders

2
3+4

8.1

Hydraulic for the attachment cylinder FSA and BHA

8.2

Hydraulic for the swing circuit

8.3

Hydraulic for the travel circuit

PC5500-6_Sec_8-0_rev1.doc

8.0
&2

01.04.03

PC5500-6_Sec_8-0_rev1.doc

Operating Hydraulic

8.0

Section 8.0
Page 2

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

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

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

Study together with the circuit diagram.


The following numbering refers to the hydraulic circuit diagram.

Each main pump (1 to 6) delivers oil trough the high pressure filter (44.1,
44.2, 46.1 and 46.2) to port P of the main control blocks (FSA 14, 15, 16
and 13) (BHA - 175, 15,176 and 13). The single valve block IV (13) is in line
to valve block II (15) connected.
This results in three main circuits.
If all spools of the control blocks (1 to 6) are in neutral position, the oil leaves
the block at port T and returns via return oil pipes, return oil collector
manifold (35), return oil pipes (L6 and L7), return oil collector tube (114),
back pressure valve (115) and the return oil filters (117.1-117.4) into the tank
(41).
The function of back pressure valve (115) ensures:
- sufficient oil supply for all anti-cavitation valves
- and that sufficient oil is forced through the oil coolers.
If a control lever or pedal is actuated, pilot pressure oil moves the spools of the
control blocks, directing the oil flow from the main pumps to one side of the
user (either cylinders or motors). From the opposite side of the user the oil
returns to the control block and from there via the return oil circuit back into
the tank.
Each circuit is provided with one MRV (also called primary valve, at least one
SRV (also called secondary valve) and at least one flow restrictor.
continued
01.04.03

PC5500-6_Sec_8-0_rev1.doc

8.0
&3

01.04.03

PC5500-6_Sec_8-0_rev1.doc

8.0
&4
8.0

General
Cont'd:
8.0.1

Floating function of boom and stick cylinders FSA:


illustration (Z 22568):
The Excavator (only front shovel attachment) operates automatically with the float
position for boom and stick activated.
That means the lowering movement of boom and stick is always done in the float
position.
For deactivation of the float position, two push buttons are installed:
a) S95 in the right joy stick (E19) for the Boom function
b) S95a in the left joy stick (E20) for the Stick function
Press the respective button and keep it depressed as long as the float position shall
be deactivated.
When releasing the button the float position is activated again.
Function:
There are different main valve spools in the three main valve blocks (14, 15 and
16) for boom and stick installed. Only by lowering of the boom or retracting of the
stick is the floating function active if the button on the lever is not pushed. The
piston and rod side of the respective cylinders are in floating position direct
connect to the return line (tank). The pressure free pump circulation is still active
there is no pump pressure to the respective cylinders. By external force the
cylinder can move up or down with negligible hydraulically resistance.
In floating position of the boom only valve spool 4 of main valve block I and 2 of
block III active.
In floating position of the stick only valve spool 2 of Main valve block I and 4 of
block III active.
To push down the boom or retract the stick by hydraulically force the respective
button on the lever must by activated.
S98 for the Stick cylinders
S95 for the Boom cylinders
In normal operation mode (i.e. float position) the piston side, the rod side and the
tank are connected together when lowering the boom or retracting the stick.
If a pressurised lowering of the boom or retracting of the stick cylinders is
required the connection of piston side, rod side and tank must be disconnected and
the rod side must be connected to the pump pressure. This is done by
disconnecting the respective special floating valve spool and activating the
respective standard valve spool. Now pressurised pump oil can flow to the
cylinder rod side.

01.04.03

PC5500-6_Sec_8-0_rev1.doc

8.0
&4

01.04.03

PC5500-6_Sec_8-0_rev1.doc

Operating Hydraulic

Section 8.0
Page 4

Boom:
S95 ON K160 ON Float position deactivated
A10 deactivated
A10A activated

Floating spool block I section 4 off


Standard spool block II section 3 ON

S95 OFF K160 OFF Float position activated


A10 activated

A10A deactivated

Floating spool block I section 4 ON


Standard spool block II section can be on or off

Stick:
S98 ON K170 ON Float position deactivated
A8B deactivated
A8A activated

Floating spool block III section 4 off


Standard spool block II section 4 ON

S98 OFF K170 OFF Float position activated


A8B activated

A8A deactivated

01.04.03

Floating spool block III section 4 ON


Standard spool block II section can be on or off

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

PC5500-6_Sec_8-0_rev1.doc

Hydraulic for the


Attachment Cylinders

Section 8.1
Page 1

Table of contents section 8.1


Section
8.1

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

06.10.05

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

PC5500-6-D_Sec_8-1_rev3.doc

8.1
2

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Hydraulic for the


Attachment Cylinders

Section 8.1
Page 2

8.1.1 Electric / Hydraulic flowchart Boom raising FSA


Legend for illustration (Z 22493):
(E19)
Control lever (Joy stick)
(D32)
Time relay Pilot control: Neutral position monitoring
(Y-)
Direction (axis) of joy stick
(-10V)
Signal voltage (Maximum)
(gn)
Color code of signal voltage cable ( Joy stick)
(X2...)
Terminal rail with number
(E49)
Ramp time module
(A10)
Amplifier module Boom
(A10A)
Amplifier module Boom
(A10B)
Amplifier module Boom
(K79)
Relay pilot control:
Contacts 8 / 12 only closed while lifting the boom.
(K160)
Relay Floating control:
Contacts 2 / 10 closed auto floating active .
(K80)
Relay pilot control:
Contacts 2 / 10 open while bucket filling (priority function).
(K76A)
Relay pilot control:
Contacts 2 / 10 open while stick extending (priority
function).
(45.1 45.3)
Remote control valves
(Y23, Y26, Y29)
Proportional solenoid valve
(Y23a, Y26a, Y29a) Directional solenoid valve
(I III)
Main control blocks I III
Electrical signal flow (EURO control).
Signal voltage of joy stick (E19) arrives via ramp time module (E49) and the
relay contacts (K79, K160) at terminal 5 of the three amplifier modules (A10,
A10a and A10b) and further to the proportional and directional solenoid valves
of the remote control blocks (45.1, 45.2, and 45.3).
Hydraulic signal flow. (pilot pressure)
When the respective proportional and directional solenoid valves are energized
pilot pressure oil flows to the pilot pressure ports of the main control blocks.
Hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (I to IV)
and arrives via the distributor manifold at the hydraulic cylinders.

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Hydraulic for the


Attachment Cylinders

Section 8.1
Page 3

8.1.1 Electric / Hydraulic flowchart Boom raising BHA


Legend for illustration (Z 22471):
(E19)
Control lever (Joy stick)
(D32)
Time relay Pilot control: Neutral position
monitoring
(YD)
Direction (axis) of joy stick
(-10V)
Signal voltage (Maximum)
(gn)
Color code of signal voltage cable ( Joy stick)
(X2...)
Terminal rail with number
(E49)
Ramp time module
(A10)
Amplifier module Boom
(A10a)
Amplifier module Boom
(A10b)
Amplifier module Boom
(45.1 45.3)
Remote control valves
(Y23, 25 + Y29)
Proportional solenoid valve
(Y23a, Y25a, Y29a) Directional solenoid valve
(175, 15, 176)
Main control blocks I IV
Electrical signal flow (EURO control).
Signal voltage of joy stick (E19) arrives via ramp time module (E49) at
terminal 5 of the amplifier modules (A10 to A10b) and further to the
proportional and directional solenoid valves of the remote control blocks (45.1,
45.2, 45.3).
Hydraulic signal flow. (pilot pressure)
When the proportional and directional solenoid valves are energized pilot
pressure oil flows to the pilot pressure ports of the main control blocks.
Hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (I to III)
and arrives via distributor manifold at the hydraulic cylinders piston side.
The piston extend and the boom move up.

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Hydraulic for the


Attachment Cylinders

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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Hydraulic for the


Attachment Cylinders

Section 8.1
Page 5

8.1.2 Electric / Hydraulic flowchart Boom lowering FSA, Auto Float on


Legend for illustration (Z 22531):
(E19)
Control lever (Joy stick)
(D32)
Time relay Pilot control: Neutral position monitoring
(+Y)
Direction (axis) of joy stick
(+10V)
Signal voltage (Maximum)
(gn)
Color code of signal voltage cable ( Joy stick)
(X2...)
Terminal rail with number
(E49)
Ramp time module
(A10)
Amplifier module Boom
(A10A)
Amplifier module Boom
(A10B)
Amplifier module Boom
(K76A)
Relay pilot control:
Contacts 6 / 10 open while extending the stick.
(K79)
Relay pilot control:
Contacts 6 / 10 open while filling the bucket.
(K80)
Relay pilot control:
Contacts 8 / 12 closed while moving the boom up.
(K160)
Relay pilot control:
Contacts 2 / 10 closed and 5 / 9 open while auto floating on.
(K207C)
Relay pilot control:
Contacts 5 / 9 closed while warming up hydraulic oil (S205).
(45.1 45.3)
Remote control valves
(Y23, Y26, Y29)
Proportional solenoid valve
(Y23b, Y26b, Y29b) Directional solenoid valve
(I III)
Main control blocks I III
Electrical signal flow (EURO control).
The auto float button in the right lever E19 is disengaged and relay K160 is deenergized. Signal voltage of joy stick (E19) arrives via ramp time module
(E49) only at terminal 5 of the amplifier modules (A10 and A10b) and further
to the proportional and directional solenoid valve of the remote control blocks
(45.1 and 45.3).
Hydraulic signal flow. (pilot pressure)
When the proportional and directional solenoid valves are energized pilot pressure
oil flows to the pilot pressure ports of the respective main control blocks.
Hydraulic oil flow
Now the pump oil flow still back to the return line. Both pressure lines at valve
block I section 3 (A3 and B3) are connected to the same back pressure charged
return line. Valve spool 2 of main valve block III connect only port B2 to the
return line. The return line, the piston side and the piston rod side of the boom
cylinders now connected together. The boom can moved up and down by external
force.

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Hydraulic for the


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Section 8.1
Page 6

8.1.2 Electric / Hydraulic flowchart Boom lowering BHA


Legend for illustration (Z 22473):
(E19)
Control lever (Joy stick)
(D32)
Time relay Pilot control: Neutral position monitoring
(+Y)
Direction (axis) of joy stick
(+10V)
Signal voltage (Maximum)
(gn)
Color code of signal voltage cable ( Joy stick)
(X2...)
Terminal rail with number
(E49)
Ramp time module
(A10)
Amplifier module Boom
(A10a)
Amplifier module Boom
(A10b)
Amplifier module Boom
(45.1 45.3)
Remote control valves
(Y23, 25 + Y29)
Proportional solenoid valve
(Y23a, Y25a, Y29a) Directional solenoid valve
(175, 15, 176)
Main control blocks I IV
Electrical signal flow (EURO control).
Signal voltage of joy stick (E19) arrives via ramp time module (E49) at terminal 5
of the amplifier modules (A10, A10a and A10b) and further to the proportional
and directional solenoid valves of the remote control blocks (45.1 45.3).
Hydraulic signal flow. (pilot pressure)
When the proportional and directional solenoid valves are energized pilot pressure
oil flows to the pilot pressure ports of the main control blocks.
Hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (I to III)
and arrives via distributor manifold at the hydraulic cylinders piston rod side.
The piston retract extend and the boom move down..

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Hydraulic for the


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Section 8.1
Page 7

8.1.3 Electric / Hydraulic flowchart Stick extending FSA


Legend for illustration (Z 22532):
(E20)
Control lever (Joy stick)
(D32)
Time relay Pilot control: Neutral position
monitoring
(YC)
Direction (axis) of joy stick
(+10V)
Signal voltage (Maximum)
(gn)
Color code of signal voltage cable ( Joy stick)
(X2...)
Terminal rail with number
(E48)
Ramp time module
(A8)
Amplifier module Stick
(A8a)
Amplifier module Stick
(A8b)
Amplifier module Stick
(K76A)
Relay pilot control:
Contacts 7 / 11 and 8 / 12 closed while extending the stick.
(K80)
Relay pilot control:
Contacts 1 / 9 open while bucket filling.
(K170)
Relay pilot control:
Contacts 5 / 9 closed and 7 / 11 opened while floating
system active.
(45.1, 45.2, 45.3)
Remote control valves
(Y21, Y27, Y31)
Proportional solenoid valve
(Y21a, Y27a, Y31a) Directional solenoid valve
(I, II + III)
Main control blocks I III
Electrical signal flow (EURO control).
Signal voltage of joy stick (E20) arrives via ramp time module (E48) at terminal 5
of the amplifier modules (A8, A8a and A8b) and further to the proportional and
directional solenoid valves of the remote control blocks (45.1, 45.2 and 45.3).
Hydraulic signal flow. (pilot pressure)
When the proportional and directional solenoid valves are energized pilot pressure
oil flows to the pilot pressure ports of the main control blocks .
Hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (I, II, III)
and arrives via the distributor manifold at the hydraulic cylinders.

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Hydraulic for the


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Section 8.1
Page 8

8.1.3 Electric / Hydraulic flowchart Stick extending BHA


Legend for illustration (Z 22474):
(E20)
Control lever (Joy stick)
(D32)
Time relay Pilot control: Neutral position monitoring
(Y+)
Direction (axis) of joy stick
(+10V)
Signal voltage (Maximum)
(gn)
Color code of signal voltage cable ( Joy stick)
(X2...)
Terminal rail with number
(E48)
Ramp time module
(A8)
Amplifier module Stick
(A8a)
Amplifier module Stick
(A8b)
Amplifier module Stick
(45.1-45.3)
Remote control valves
(Y21, Y27, Y31)
Proportional solenoid valve
(Y21a, Y27a, Y27b) Directional solenoid valve
(I, II, III)
Main control blocks I, II III
Electrical signal flow (EURO control).
Signal voltage of joy stick (E20) arrives via ramp time module (E48) at terminal 5
of the amplifier modules (A8, A8a and A8b) and further to the proportional and
directional solenoid valves of the remote control blocks (45.1, 45.2, and 45.3).
Hydraulic signal flow. (pilot pressure)
When the proportional and directional solenoid valves are energized pilot pressure
oil flows to the pilot pressure ports of the main control blocks .
Hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (I, II, III)
and arrives via distributor manifold at the hydraulic cylinders.

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Hydraulic for the


Attachment Cylinders

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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Hydraulic for the


Attachment Cylinders

Section 8.1
Page 10

8.1.3 Electric / Hydraulic flowchart Stick retracting FSA, Auto Float active
Legend for illustration (Z 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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Hydraulic for the


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Section 8.1
Page 11

8.1.4 Electric / Hydraulic flowchart Stick retracting BHA


Legend for illustration (Z 22475):
(E20)
Control lever (Joy stick)
(D32)
Time relay Pilot control: Neutral position
monitoring
(Y-)
Direction (axis) of joy stick
(-10V)
Signal voltage (Maximum)
(gn)
Color code of signal voltage cable ( Joy stick)
(X2...)
Terminal rail with number
(E48)
Ramp time module
(A8)
Amplifier module Stick
(A8a)
Amplifier module Stick
(A8b)
Amplifier module Stick
(45.1-45.3)
Remote control valves
(Y21, Y27, Y31)
Proportional solenoid valve
(Y21b, Y27b, Y31a) Directional solenoid valve
(I, II, III)
Main control blocks I, II, III
Electrical signal flow (EURO control).
Signal voltage of joy stick (E20) arrives via ramp time module (E48) at terminal 5
of the amplifier modules (A8, A8a and A8b) and further to the proportional and
directional solenoid valves of the remote control blocks (45.1, 45.2 and 45.3).
Hydraulic signal flow. (pilot pressure)
When the proportional and directional solenoid valves are energized pilot pressure
oil flows to the pilot pressure ports of the main control blocks .
Hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (I, II, III)
and arrives via distributor manifold at the hydraulic cylinders.

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Hydraulic for the


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Section 8.1
Page 12

8.1.5 Electric / Hydraulic flowchart Bucket filling FSA


Legend for illustration (Z 22536):
(E19)
Control lever (Joy stick)
(D32)
Time relay Pilot control: Neutral position
monitoring
(-X)
Direction (axis) of joy stick
(-10V)
Signal voltage (Maximum)
(ws / gn)
Color code of signal voltage cable ( Joy stick)
(X2...)
Terminal rail with number
(A9)
Amplifier module Bucket
(A9a)
Amplifier module Bucket
(A9b)
Amplifier module Bucket
(K50)
Relay pilot control: Bucket cut-off
Contacts 6 / 10 only closed if the hydraulic oil is in normal
operating temperature.
(K78)
Relay pilot control:
Contacts 1 / 9 only open while bucket dump.
(K79)
Relay pilot control:
Contacts 1 / 9 only open while lifting the boom.
(45., 45.2, 45.3)
Remote control valves
(Y22, Y24, Y30)
Proportional solenoid valve
(Y22A, Y24A, Y30A) Directional solenoid valve
(I III)
Main control blocks I III
Electrical signal flow (EURO control).
Signal voltage of joy stick (E19) arrives via relay contacts K50 at terminal 5 of
the amplifier modules (A9, A9a, A9b) and further to the proportional and
directional solenoid valves of the remote control blocks (45.1, 45.2, 45.3).
Hydraulic signal flow. (pilot pressure)
When the proportional and directional solenoid valves are energized pilot
pressure oil flows to the pilot pressure ports of the main control blocks.
Hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (I to III)
and arrives via the distributor manifold at the hydraulic cylinders.

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Hydraulic for the


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Section 8.1
Page 13

8.1.5 Electric / Hydraulic flowchart Bucket filling BHA


Legend for illustration (Z 22476):
(E19)
Control lever (Joy stick)
(D32)
Time relay Pilot control: Neutral position
monitoring
(XB)
Direction (axis) of joy stick
(-10V)
Signal voltage (Maximum)
(ws / gn)
Color code of signal voltage cable ( Joy stick)
(X2...)
Terminal rail with number
(K50)
Relay pilot control: Bucket cut-off
Contacts 6 / 10 only closed if the hydraulic oil is
overheated.
(A9)
Amplifier module Bucket
(A9a)
Amplifier module Bucket
(A9b)
Amplifier module Bucket
(45.1-45.3)
Remote control valves
(Y22, Y24, Y30)
Proportional solenoid valve
(Y22a, Y24a, Y30a) Directional solenoid valve
(I, II, III)
Main control blocks I, II, III
Electrical signal flow (EURO control).
Signal voltage of joy stick (E19) arrives terminal 5 of the amplifier modules (A9,
A9a, A9b) and further to the proportional and directional solenoid valves of the
remote control blocks (45.,45.2 and 45.3).
Hydraulic signal flow. (pilot pressure)
When the proportional and directional solenoid valves are energized pilot pressure
oil flows to the pilot pressure ports of the main control blocks .
Hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (I, II, III)
and arrives via distributor the manifold at the hydraulic cylinders.

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Hydraulic for the


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Section 8.1
Page 14

8.1.6 Electric / Hydraulic flowchart Bucket dump FSA


Legend for illustration (Z 22537):
(E19)
Control lever (Joy stick)
(D32)
Time relay Pilot control: Neutral position
monitoring
(+X)
Direction (axis) of joy stick
(+10V)
Signal voltage (Maximum)
(ws / gn)
Color code of signal voltage cable ( Joy stick)
(X2...)
Terminal rail with number
(A9)
Amplifier module Bucket
(A9a)
Amplifier module Bucket
(A9b)
Amplifier module Bucket
(K50)
Relay pilot control: Bucket cut-off
Contacts 6 / 10 only closed if the hydraulic oil is in normal
operating temperature.
(K78)
Relay pilot control:
Contacts 1 / 9 only open while bucket dump.
(K79)
Relay pilot control:
Contacts 1 / 9 only open while lifting the boom.
(K205)
Relay pilot control:
Contacts 1 / 3 only open while S205 activated (hydraulic
oil warming up)
(45., 45.2, 45.3)
Remote control valves
(Y22, Y24, Y30)
Proportional solenoid valve
(Y22A, Y24A, Y30A) Directional solenoid valve
(I III)
Main control blocks I III
Electrical signal flow (EURO control).
Signal voltage of joy stick (E19) arrives via relay contacts K50 at terminal 19 of
the ELB modules. From ELB modules the signal voltage arrives at terminal 5 of
the amplifier modules (A9, A9a, A9b) and further to the proportional and
directional solenoid valves of the remote control blocks (45.1, 45.2, 45.3). Only
while bucket dump together with boom up K78 and K79 opened the contacts 1 / 9
and deactivate amplifier module A9 (priority to the boom).
Hydraulic signal flow. (pilot pressure)
When the proportional and directional solenoid valves are energized pilot
pressure oil flows to the pilot pressure ports of the main control blocks.
Hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (I to III)
and arrives via the distributor manifold at the hydraulic cylinders. There is no oil
flow through main control block I to the bucket cylinder if bucket dump and boom
up is activated.

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Hydraulic for the


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Section 8.1
Page 15

8.1.6 Electric / Hydraulic flowchart Bucket dump BHA


Legend for illustration (Z 22477):
(E19)
Control lever (Joy stick)
(D32)
Time relay Pilot control: Neutral position monitoring
(+X)
Direction (axis) of joy stick
(+10V)
Signal voltage (Maximum)
(ws / gn)
Color code of signal voltage cable ( Joy stick)
(X2...)
Terminal rail with number
(A9)
Amplifier module Bucket
(A9a)
Amplifier module Bucket
(A9b)
Amplifier module Bucket
(K50)
Relay pilot control: Bucket cut-off
Contacts 6 / 10 only closed if the hydraulic oil is overheated.
(14.1 + 14.3)
Remote control valves
(15)
Remote control valves
(Y64)
Proportional solenoid valve
(Y71 + Y75)
Proportional solenoid valve
(Y23 + Y45)
Directional solenoid valve
(Y37)
Directional solenoid valve
(II, III + IV)
Main control blocks II, III + IV
(42)
Distributor manifold
Electrical signal flow (EURO control)
Signal voltage of joy stick (E19) arrives via relay contacts K50 at terminal 5 of
the amplifier modules (A9, A9a, A9b) and further to the proportional and
directional solenoid valves of the remote control blocks (45.1, 45,2 and 45.3).
Hydraulic signal flow. (pilot pressure)
When the proportional and directional solenoid valves are energized pilot pressure
oil flows to the pilot pressure ports of the main control blocks .
Hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (II, III, IV)
and arrives via distributor manifold (42) at the hydraulic cylinders.

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Hydraulic for the


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Section 8.1
Page 17

8.1.8 Electric / Hydraulic flowchart Clam opening FSA


Legend for illustration (Z 21970):
(E24)
Control pedal
(D32)
Time relay Pilot control: Neutral position monitoring
(-10V)
Signal voltage (Maximum)
(rs)
Color code of signal voltage cable ( Joy stick)
(X2...)
Terminal rail with number
(A11)
Amplifier module Clam
(K76)
Relay pilot control:
Contacts 7 / 11 only closed while traveling the left crawler.
(15)
Remote control valves
(Y72)
Proportional solenoid valve
(Y39)
Directional solenoid valve
(II)
Main control block II
(42)
Distributor manifold
Electrical signal flow (EURO control).
Signal voltage of control pedal (E24) arrives via relay contact at terminal 5 of the
amplifier module (A11) and further to the proportional and directional solenoid
valves of the remote control block (15).
Hydraulic signal flow. (pilot pressure)
When the proportional and directional solenoid valves are energized pilot pressure
oil flows to the pilot pressure port of the main control block .
Hydraulic oil flow
Now the oil of the main pump flows through the main control block (II) and
arrives via distributor manifold (42) at the hydraulic cylinders.

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18

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Hydraulic for the


Attachment Cylinders

Section 8.1
Page 18

8.1.9 Electric / Hydraulic flowchart Clam closing FSA


Legend for illustration (Z 21971):
(E23)
Control pedal
(D32)
Time relay Pilot control: Neutral position monitoring
(+10V)
Signal voltage (Maximum)
(rs)
Color code of signal voltage cable ( Joy stick)
(X2...)
Terminal rail with number
(A11)
Amplifier module Clam
(K76)
Relay pilot control:
Contacts 7 / 11 only closed while traveling the left crawler.
(15)
Remote control valves
(Y72)
Proportional solenoid valve
(Y38)
Directional solenoid valve
(II)
Main control block II
(42)
Distributor manifold
Electrical signal flow (EURO control).
Signal voltage of control pedal (E23) arrives via relay contact at terminal 5 of the
amplifier module (A11) and further to the proportional and directional solenoid
valves of the remote control block (15).
Hydraulic signal flow. (pilot pressure)
When the proportional and directional solenoid valves are energized pilot pressure
oil flows to the pilot pressure port of the main control block .
Hydraulic oil flow
Now the oil of the main pump flows through the main control block (II) and
arrives via distributor manifold (42) at the hydraulic cylinders.

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Hydraulic for the


Attachment Cylinders
8.1.10

Section 8.1
Page 19

Checks and adjustments of the Main Relief Valves (MRV),


illustration (Z 22481):
There are four main relief valves (primary valves) installed, one in each main
control block, to limit the maximum pump supply line pressure (operating
pressure).

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

MRV
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

Swing, (if no swing active circuit II)

Each Pump circuit can be checked or adjusted individually by selecting one


function of the required pump circuit.
Checking:
1.
Connect the gauge to the required check point M12.1 - M12.4.
2.
Start both motors.
3.

Extend or retract the cylinder to the stop position for the valve being
tested until the hydraulic system stalls.
4.
Read the pressure. Required: 310 + 5 bar
If the pressure is not correct, carry out a comparative measurement with an
other function, in order to avoid wrong measuring results caused by
wrongly adjusted SRV or other defects in the system.

When using the single function bucket fill, (gray shadow), all MRV
can be adjusted, because all four pump circuits are engaged.

Adjusting:
1.
Remove protective cap (a).
2.
Loosen lock nut (b).
3.
Turn set screw (c) -clockwise to increase pressure, Counter-clock
wise to decrease pressure.
4.
Tighten lock nut (b) and install cap (a).

)
06.10.05

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

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Hydraulic for the


Attachment Cylinders
8.1.10

Section 8.1
Page 20

Checks and adjustments of the Main Relief Valves (MRV),


illustration (Z 22481):
There are four main relief valves (primary valves) installed, one in each main
control block, to limit the maximum pump supply line pressure (operating
pressure).

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

MRV in
control block
I
II
III
IV

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

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

Each Pump circuit can be checked or adjusted individually by selecting one


function of the required pump circuit.
Checking:
1.
Connect the gauge to the required check point M12.1 M12.4.
2.
Start both motors..
3.
Extend or retract the cylinder to the stop position for the valve being
tested until the hydraulic system stalls.
4.
Read the pressure. Required: 310 + 5 bar
If the pressure is not correct, carry out a comparative measurement with an
other function, in order to avoid wrong measuring results caused by
wrongly adjusted SRV or other defects in the system.

When using the single function 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).

)
06.10.05

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
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Hydraulic for the


Attachment Cylinders
8.1.11

Section 8.1
Page 21

Checks and adjustments of the Service Line Relief Valves (SRV),


illustration (Z 22482):
Boom cylinder piston side FSA + BHA
There are three service line relief valves (secondary valves) installed, all three
at the distributor manifold, to limit the maximum possible pressure peaks in
the service line.
Since the opening pressure of the SRVs is higher than the setting of the Main
Relief Valves (MRVs) it is necessary to increase the main relief pressure for
testing and adjusting purposes.
SRV FSA SRV BHA
141.1
138.1
141.2
138.2.
141.3
138.3
MRV I
MRV II
MRV III
MRV IV
1.
2.
3.
4.

)
5.
6.
7.
8.

06.10.05

Press. check point


M23
M29.1
M29.2
M12.1 (at HP filter)
M12.3 (at HP filter)
M12.4 (at HP filter)
M12.2 (at HP filter)

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

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Hydraulic for the


Attachment Cylinders

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

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 six service line relief valves.
12.

)
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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Hydraulic for the


Attachment Cylinders
8.1.11

Section 8.1
Page 23

Checks and adjustments of the Service Line Relief Valves (SRV),


illustration (Z 22483b):
Boom cylinder piston rod side FSA +BHA
There is one service line relief valve (secondary valve) installed in the main
control block II, to limit the maximum possible pressure peaks in the service
line. Since the opening pressure of the SRV is higher than the setting of the
Main Relief Valves (MRVs) it is necessary to increase the main relief pressure
for testing and adjusting purposes.
Valve
Press. check point
SRV 33.4 FSA M12.3 (High pressure filter)
SRV 33.6 BHA
MRV circuit II M12.3 (High pressure filter)
MRV circuit IV M12.2 (High pressure filter)

1.
2.
3.

4.

5.
6.

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

Connect gauges to all above listed check points.


Start both motors..
Press floating system button S95 at the lever with the boom function
and retract the boom cylinder to the stop position until the hydraulic
system stalls.
Increase slowly the pump supply line pressure, by turning in set
screws (3) of the MRV in control blocks II, while observing the
pressure gauges. Stop as soon the pressure does not raise any further.
The gauge pointers should remain at 350 bar + 5 bar.
If there is a setting required follow
Turn set screw (3) of the MRV turn further in, the gauge pointers
will remain at the value shown at item #4 .
Tighten lock nut (2).

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

continued

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Hydraulic for the


Attachment Cylinders
8.1.11

Section 8.1
Page 24

Checks and adjustments of the Service Line Relief Valves (SRV),


illustration (Z 22483b):
Cont'd:
7.
Adjust the SRV until the gauges show a pressure of 350 bar.
8.
Tighten lock nut (2).
9.
Reset the MRV to 310 bar + 5 bar after the check / adjustment is finished
10.
Tighten lock nut (2).
11.
Stop engine.
12.
Install all protective cups (1).

06.10.05

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
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Hydraulic for the


Attachment Cylinders
8.1.11

Section 8.1
Page 25

Checks and adjustments of the Service Line Relief Valves (SRV),


illustration (Z 22542):
Stick cylinder piston side FSA
There are three service line relief valves (secondary valves) installed, all three
at the distributor manifold, to limit the maximum possible pressure peaks in
the service line.
Since the opening pressure of the SRVs is higher than the setting of the Main
Relief Valves (MRVs) it is necessary to increase the main relief pressure for
testing and adjusting purposes.
Valve
SRV 142.5
SRV 142.6
SRV 142.7
MRV circuit I
MRV circuit II
MRV circuit III
MRV circuit IV
1.
2.
3.
4.

5.
6.
7.
8.

Press. check point


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

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

Connect gauges to all above listed check points.


Start both motors..
Extend the stick cylinder to the stop position until the hydraulic
system stalls.
Increase slowly the pump supply line pressure, by turning in set screws (3)
of the MRV in control block IV, while observing the pressure gauges.
Stop as soon the pressure does not raise any further.
The gauge pointers should remain at 350 bar + 5 bar.
Since the piston side of the stick cylinders are protected by several
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 MRVs.
Remove protective cap (1) of MRV.
Loosen lock nut (2).
Turn set screw (3) of the MRV turn further in, the gauge
pointers will remain at the value shown at item #4 (350 bar + 5 bar).
Tighten lock nut (2) and install cap (1).
continued

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Hydraulic for the


Attachment Cylinders

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

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 three service line relief valves.
12.

)
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

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Hydraulic for the


Attachment Cylinders
8.1.11

Section 8.1
Page 27

Checks and adjustments of the Service Line Relief Valves (SRV),


illustration (Z 22484):
Stick cylinder piston side BHA
There are two service line relief valves (secondary valves) installed, in main
control blocks I and II, to limit the maximum possible pressure peaks in the
service line.
Since the opening pressure of the SRVs is higher than the setting of the Main
Relief Valves (MRVs) it is necessary to increase the main relief pressure for
testing and adjusting purposes.
Valve
SRV 33.1
SRV 33.5
MRV circuit I
MRV circuit II
MRV circuit IV
1.
2.
3.
4.

)
5.
6.
7.
8.

06.10.05

Press. check point


M12.1 (High pressure filter)
M12.3 (High pressure filter)
M12.1 (High pressure filter)
M12.3 (High pressure filter)
M12.2 (High pressure filter)

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

Connect gauges to all above listed check points.


Start both motors..
Extend the stick cylinder (stick retracting) to the stop position until
the hydraulic
system stalls.
Increase slowly the pump supply line pressure, by turning in set screws (3)
of the MRVs in the control blocks, while observing the pressure gauges.
Stop as soon the pressure does not raise any further.
The gauge pointers should remain at 350 bar + 5 bar.
Since the piston side of the stick cylinders are protected by several
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 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) and install cap (1).
continued

PC5500-6-D_Sec_8-1_rev3.doc

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28

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Hydraulic for the


Attachment Cylinders

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

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 three service line relief valves.
12.

)
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
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Hydraulic for the


Attachment Cylinders
8.1.11

Section 8.1
Page 29

Checks and adjustments of the Service Line Relief Valves (SRV),


illustration (Z 22543a):
Stick cylinder piston rod side FSA
There are two service line relief valves (secondary valves) installed, in main
control blocks I and II, to limit the maximum possible pressure peaks in the
service line.
Since the opening pressure of the SRVs is higher than the setting of the Main
Relief Valves (MRVs) it is necessary to increase the main relief pressure for
testing and adjusting purposes.
Valve
SRV 33.1
SRV 33.5
MRV circuit I
MRV circuit II
MRV circuit IV
1.
4.
5.
6.

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

Connect gauges to all above listed check points.


Start both motors..
Retract the stick cylinder to the stop position until the hydraulic
system stalls.
Increase slowly the pump supply line pressure, by turning in set screws (3)
of MRVs in all above listed control blocks I, II, IV, while observing the
respective pressure gauges. Stop as soon the pressure does not raise any
further. The gauge pointers should remain at 350 bar + 5 bar.
a)
b)
c)
d)

06.10.05

Press. check point


M12.1 (High pressure filter)
M12.3 (High pressure filter)
M12.1 (High pressure filter)
M12.3 (High pressure filter)
M12.2 (High pressure filter)

Remove protective cap (1).


Loosen lock nut (2).
Turn set screw (3) -clockwise to increase pressure, Counterclock wise to decrease pressure.
Tighten lock nut (2).
continued

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30

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Hydraulic for the


Attachment Cylinders

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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Hydraulic for the


Attachment Cylinders

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
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Hydraulic for the


Attachment Cylinders
8.1.11

Section 8.1
Page 32

Checks and adjustments of the Service Line Relief Valves (SRV),


illustration (Z 22485):
Stick cylinder Piston rod side BHA
There are three service line relief valves (secondary valves) installed at the
distributor manifold, to limit the maximum possible pressure peaks in the
service line.
Since the opening pressure of the SRVs is higher than the setting of the Main
Relief Valves (MRVs) it is necessary to increase the main relief pressure for
testing and adjusting purposes.
Valve
SRV 142.5
SRV 142.6
SRV 142.7
MRV circuit I
MRV circuit II

Press. check point


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

MRV circuit III M12.4 (High pressure filter)


MRV circuit IV M12.2 (High pressure filter)
1.
2.
3.
4.

)
5.
6.
7.
8.

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

Connect gauges to all above listed check points.


Start both motors..
Retract the stick cylinder (extend the stick) to the stop position until
the hydraulic system stalls.
Increase slowly the pump supply line pressure, by turning in set screws (3)
of MRVs in the control blocks, while observing the pressure gauges. Stop
as soon the pressure does not raise any further. The gauge pointers should
remain at 350 bar + 5 bar.
Since the piston rod side of the stick cylinders are protected by
several 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 both MRVs turn further in, the gauge
Tighten lock nut (2) and install cap (1).
continued

06.10.05

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Hydraulic for the


Attachment Cylinders

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

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.
12.

)
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.

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Hydraulic for the


Attachment Cylinders
8.1.11

Section 8.1
Page 34

Checks and adjustments of the Service Line Relief Valves (SRV),


illustration (Z 22544):
Bucket cylinder Piston side FSA
There are three service line relief valves (secondary valves) installed, all three
at the distributor manifold, to limit the maximum possible pressure peaks in
the service line.
Since the opening pressure of the SRVs is higher than the setting of the Main
Relief Valves (MRVs) it is necessary to increase the main relief pressure for
testing and adjusting purposes.
Valve
SRV 142.1
SRV 142.2
SRV 142.3
MRV circuit I
MRV circuit II
MRV circuit III
MRV circuit IV
1.
2.
3.
4.

5.
6.
7.
8.

06.10.05

Press. check point


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

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

Single HP filter, control block II


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

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


Start both motors..
Extend the Bucket cylinder to the stop position until the hydraulic
system stalls.
Increase slowly the pump supply line pressure, by turning in set screws (3)
of all four MRVs in control block I to IV, while observing the
pressure gauges. Stop as soon the pressure does not raise any further.
The gauge pointers should remain at 350 bar + 5 bar.
Since the piston side of the bucket cylinders are protected by several
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 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

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35

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Hydraulic for the


Attachment Cylinders

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

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 six service line relief valves.
12.

)
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.

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8.1
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Hydraulic for the


Attachment Cylinders
8.1.11

Section 8.1
Page 36

Checks and adjustments of the Service Line Relief Valves (SRV),


illustration (Z 22486):
Bucket cylinder Piston side BHA
There are three service line relief valves (secondary valves) installed at the
distributor manifold, to limit the maximum possible pressure peaks in the service
line.
Since the opening pressure of the SRVs is higher than the setting of the Main Relief
Valves (MRVs) it is necessary to increase the main relief pressure for testing and
adjusting purposes.
Valve
SRV 142.1
SRV 142.2
SRV 142.3
MRV circuit I
MRV circuit II
MRV circuit III
MRV circuit IV
1.
2.
3.
4.

)
5.
6.
7.
8.

06.10.05

Press. check point


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

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

Connect gauges to all above listed check points.


Start both engines and let them run with max. speed.
Extend the bucket cylinder (Bucket filling) to the stop position until
the hydraulic system stalls.
Increase slowly the pump supply line pressure, by turning in set screws (3)
of MRV in control block I, II, III and IV, while observing the pressure
gauges. Stop as soon the pressure does not raise any further. The gauge
pointers should remain at 350 bar + 5 bar.
Since the piston side of the bucket cylinders are protected by several
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 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

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37

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Hydraulic for the


Attachment Cylinders

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.

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 three service line relief valves.
12.

)
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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Hydraulic for the


Attachment Cylinders
8.1.11

Section 8.1
Page 38

Checks and adjustments of the Service Line Relief Valves (SRV),


illustration (Z 22545):
Bucket cylinder Rod side FSA
There are two service line relief valves (secondary valves) installed, one in
main control block I section 3 and one in block II section 2, to limit the
maximum possible pressure peaks in the service line.
Since the opening pressure of the SRVs is higher than the setting of the Main
Relief Valves (MRVs) it is necessary to increase the main relief pressure for
testing and adjusting purposes.
Valve
SRV 33.2
SRV 33.6
MRV circuit I
MRV circuit II
MRV circuit III
MRV circuit IV
1.
2.
3.
4.

)
5.
6.
7.
8.

Press. check point


M12.1 (High pressure filter)
M12.3 (High pressure filter)
M12.1 (High pressure filter)
M12.3 (High pressure filter)
M12.4 (High pressure filter)
M12.2 (High pressure filter)

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

Connect gauges to all above listed check points.


Start both motors..
Stall the system with full retracted bucket cylinder in final stop position.
Increase slowly the pump supply line pressure, by turning in set screws (3)
of MRVs in the control blocks, while observing the pressure gauges.
Stop as soon the pressure does not raise any further.
The gauge pointers should remain at 350 bar + 5 bar.
Since the piston rod side of the bucket cylinders are protected by
several 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 MRVs.
Remove protective cap (1) of MRV.
Loosen lock nut (2).
Turn set screw (3) of both MRVs turn further in, the gauge
Tighten lock nut (2) and install cap (1).
continued

06.10.05

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8.1
39

06.10.05

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Hydraulic for the


Attachment Cylinders

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.

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.
12.

)
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

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Hydraulic for the


Attachment Cylinders
8.1.11

Section 8.1
Page 40

Checks and adjustments of the Service Line Relief Valves (SRV),


illustration (Z 22487):
Bucket cylinder Piston rod side BHA
There are three service line relief valves (secondary valves) installed at the
distributor manifold, to limit the maximum possible pressure peaks in the
service line.
Since the opening pressure of the SRVs is higher than the setting of the Main
Relief Valves (MRVs) it is necessary to increase the main relief pressure for
testing and adjusting purposes.
Valve
Press. check point
Location
SRV 142.8
M34.1
Manifold section L
SRV 142.9
M34.2
Manifold section L
SRV 142.10
M34.3
Manifold section M
MRV circuit I M12.1 (High pressure filter) Double high pressure filter R.H.
MRV circuit II M12.3 (High pressure filter) Single high pressure filter, block II
MRV circuit III M12.4 (High pressure filter) Double high pressure filter L.H..
MRV circuit IV M12.2 (High pressure filter) Single high pressure filter, block IV
1.
Connect gauges to all above listed check points.
2.
Start both engines and let it run with max. speed.
3.
Retract the Bucket cylinder (Bucket dump) to the stop position until
the hydraulic system stalls.
4.
Increase slowly the pump supply line pressure, by turning in set screws (3)
of MRVs in control block I, I, III and IV, while observing the pressure
gauges. Stop as soon the pressure does not raise any further.
The gauge pointers should remain at 350 bar + 5 bar.

)
5.
6.
7.
8.

06.10.05

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

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Hydraulic for the


Attachment Cylinders

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

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 three service line relief valves.
12.

)
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
42

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Hydraulic for the


Attachment Cylinders
8.1.11

Section 8.1
Page 42

Checks and adjustments of the Service Line Relief Valves (SRV),


illustration (Z 22546):
Clam cylinder Rod side (clam opening) FSA
There is one service line relief valve (secondary valve) installed at the distributor
manifold section E, to limit the maximum possible pressure peaks in the service line.
Since the opening pressure of the SRV is higher than the setting of the Main Relief
Valves (MRVs) it is necessary to increase the main relief pressure for testing and
adjusting purposes.
Valve
SRV 142.4
MRV circuit II
MRV circuit IV
1.
2.
3.
4.

5.
6.
7.
8.
9.
10.

)
06.10.05

Press. check point


M26
M12.3 (High pressure filter)
M12.2 (High pressure filter)

Location
Manifold (42) section E
Control block II
Control block IV

Connect gauges to the above listed check points.


Start engine 2 and let it run in high idle.
Retract the clam cylinder (open the bucket) to the stop position until the
hydraulic system stalls.
Increase slowly the pump supply line pressure, by turning in set screws (3) of
MRV in control block II and IV, while observing the pressure gauges.
Stop as soon the pressure does not raise any further.
The gauge pointers should remain at 350 bar + 5 bar.
If necessary correct the adjustment as follows:
Remove protective cap (1) of MRV.
Loosen lock nut (2).
Turn set screw (3) of the MRV turn further in, the gauge pointers will
remain at the value shown at item #4 (350 bar + 5 bar).
Tighten lock nut (2) and install cap (1).
Reduce the pressure, at SRV 142.4 to a value below the required value, and
then increase up to the required pressure (350 bar), while observing all auges.
Reset the MRV to 310 bar + 5 bar after adjustment is finished, as follows:
Remove protective cap (1).
Loosen lock nut (2).
Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to
decrease pressure.
Tighten lock nut (2) and install cap (1).
It is important that the valve body of MRV and the SRV are firmly
tightened (with 300 Nm).
Otherwise, the internal sealing is not properly which results in loud
flow noises and wrong adjustments.

PC5500-6-D_Sec_8-1_rev3.doc

8.1
43

06.10.05

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Hydraulic for the


Attachment Cylinders
8.1.11

Section 8.1
Page 43

Checks and adjustments of the Service Line Relief Valves (SRV),


illustration (Z 22561):
Clam cylinder Piston side (clam closing) FSA
There are three service line relief valves (secondary valves) installed, two at
distributor manifold section K and one at main control block II section 1, to
limit the maximum possible pressure in the service line when closing the
bucket.
To avoid damages at the clam shell, due to wrong operation, the SRVs
should be adjusted in a way that the pressure is just sufficient to close the
clam with horizontal back wall.
Valve
SRV 144 (1)
SRV 144 (2)
SRV 32.10
1.
2.
3.

06.10.05

Location
Manifold section K
Manifold section K
Control block II

Connect gauges to all above listed check points.


Start engine 2 and let them run in high idle.
Raise the attachment and bring the back wall of the bucket in a
horizontal position (bucket dump).
Press carefully pedal bucket closing. The clam should close complete
and must stay closed after pedal in neutral position.
Adjust the SRVs as follows:
Remove protective cap (1) of SRVs.
Loosen lock nut (2).
Turn set screw (3) -clockwise to increase pressure,
Counter-clock wise to decrease pressure while
depressed pedal clam closing.
Tighten lock nut (2) and install cap (1).
Adjust all three SRVs equally, until the gauges show a pressure of 220 bar.
Now reduce the pressure at one SRV in steps of 5 bar until the bucket opens
by gravity (check with released pedal).
Now read the pressure and adjust 10% plus the reading to compensate the
weight of material stuck at the clam shell.

4.

Press. check point


M22
M22
MM12.3 (High pressure filter)

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.

PC5500-6-D_Sec_8-1_rev3.doc

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44

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Hydraulic for the


Attachment Cylinders

Section 8.1
Page 44

8.1.12 Checks and adjustments of the lowering speed,


illustration (Z 22489):
General
On excavators equipped with Face Shovel Attachment (FSA) there are two
different operation modes for lowering the boom and stick:
I.

Float position activated the lowering speed has to be adjusted by altering


the flow restrictors (throttle valves) at the distributor manifold section B,
throttle valve 141.1 and section N, throttle valve 141.3.

II.

Float position deactivated the lowering speed has to be adjusted by


altering the flow restrictor (throttle valve) at the distributor manifold
section N, throttle valve 141.2.

On excavators equipped with Backhoe Attachment (BHA) the lowering speed has
to be adjusted at all flow restrictors on distributor manifold section B and N,
throttle valves 141.1, 141.2 and 141.3.
Purpose of the Flow Restrictors:
To avoid an interruption of the pump delivery.
To provide an uniform and smooth cylinder travel.
To limit the return oil flow through the control block to the maximum
permissible volume.

Checks and Adjustments:


Activate service switch S151 (located in the cab base) during the checks and
adjustments, to ensure that the main pumps are in Qmax position.
Standard test method is measuring the total cylinder running time by using a
stop watch. If it is impossible to move the cylinder over the whole way, mark a
distance of one meter with permanent pen P/N 621 566 40 on the piston rod
and measure the time for only one meter movement.
Adjust the restrictor as follows:
For easy turning of set screw (2) lower the attachment to ground, stop engines
and allow pressure equalizing by moving the lever several times.
Loosen the lock nut (1) and turn the bolt (2) cw for more restriction and ccw
for less restriction. If more than one restrictor is used for one movement make
sure all set screws are equally adjusted.
During commissioning, a throttle adjustment has to be carried out on
all machines. For safety reasons, the throttle valves are completely
screwed in before each machine is leaving the factory.
For more information refer to the respective newest Service Bulletin

06.10.05

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8.1
45

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Hydraulic for the


Attachment Cylinders
8.1.12

Section 8.1
Page 45

Checks and adjustments of the lowering speed,


illustration (Z 22489):
Boom cylinder FSA
Due to the two different operation modes for lowering the boom, the lowering
speed must be adjusted twice:
I.
Float position activated
II.
Float position deactivated
Maximum permissible lowering speed for both operation modes:
Boom FSA

Cylinder retracting time/meter (s /m)


1,4

Total time(s)
4,3

Adjustments / Checks:
I.

1.
2.
3.
4.

Float position activated:


Use a stop watch to measure the cylinder running time.
Raise the fully extended attachment with empty bucket to the maximum
height position (A).
Shift both engines to high idle speed.
Rapidly move the control lever (E19) to the front end position (start the stop
watch) and hold it until the final position (B) is reached.(stop the stop
watch).
Lower the boom so, that the bucket stops just above the ground.

5.

If the lowering speed is too high, i.e. the measured time is less than the
permissible time, the speed must be reduced by altering the throttle valves
141.1 (section B) and 141.3 (section N, pointing to the attachment).
Adjust as follows:
To decrease the lowering speed loosen lock nut (1) and turn the bolt (2) cw.
To increase the lowering speed loosen lock nut (1) and turn the bolt (2) ccw.
Since there are several valves throttling the return oil flow the valves
must be set synchronously. The adjusting screws have to be turned in
by the same amount of revolutions.

O.K.

6.
7.

06.10.05

Check lowering speed again and repeat the adjustment if necessary.


If the adjustment is finished tighten lock nut (1).
continued

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8.1
46

06.10.05

PC5500-6-D_Sec_8-1_rev3.doc

Hydraulic for the


Attachment Cylinders

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.

Float position deactivated (with push button S95):


Adjust the throttle adjustment bold of throttle valve 141.2 to the same amount
of revolutions as the valve 141.1 and 141.3.
Use a stop watch to measure the cylinder running time.
Raise the fully extended attachment with empty bucket to the maximum
height position (A).
Shift the engines to high idle speed.
Press push button S95 and keep it depressed while lowering the attachment.
Rapidly move the control lever (E19) to the front end position (start the stop
watch) and hold it until the final position (B) is reached.(stop the stop watch).
Lower the boom so, that the bucket stops just above the ground.

6.

The lowering speed will be the same as with floating position. If the lowering
speed is too high, i.e. the measured time is less than the permissible time, the
speed must be reduced by altering the throttle valve 141.1, 141.2 and
synchronous 141.3 at the distributor manifold section B and N.
Adjust as follows:
To decrease the lowering speed loosen lock nut (1) and turn the bolt (2) cw. To
increase the lowering speed loosen lock nut (1) and turn the bolt (2) ccw.
The adjusting screws have to be turned in by the same amount of
revolutions.

O.K.

7.
8.

06.10.05

Check lowering speed again and repeat the adjustment if necessary.


If the adjustment is finished tighten lock nut (1).

PC5500-6-D_Sec_8-1_rev3.doc

8.1
47

06.10.05

PC5500-6-D_Sec_8-1_rev3.doc

Hydraulic for the


Attachment Cylinders
8.1.12

Section 8.1
Page 47

Checks and adjustments of the lowering speed,


illustration (Z 22488):
Boom cylinder BHA
Maximum permissible lowering speed:

Boom BHA

Cylinder retracting time/meter


(s /m)
1,4

Total time
(s)
5,0

Adjustments / Checks:
1.
Use a stop watch to measure the cylinder running time.
2.
Raise the fully extended attachment with empty bucket to the maximum
height position (A).
3.
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

Check lowering speed again and repeat the adjustment if necessary.


If the adjustment is finished tighten lock nut (1).

PC5500-6-D_Sec_8-1_rev3.doc

8.1
48

06.10.05

PC5500-6-D_Sec_8-1_rev3.doc

Hydraulic for the


Attachment Cylinders
8.1.12

Checks and adjustments of the lowering speed,

Section 8.1
Page 48

illustration (Z 22490):

Stick cylinder FSA


Due to the two different operation modes for lowering the stick, the lowering
speed must be adjusted twice:
I.
Float position activated
II.
Float position deactivated
Maximum permissible lowering speed for both operation modes:

Stick FSA

Cylinder retracting time/meter


(s /m)
0,9

Total time
(s)
2,4

Adjustments / Checks:
I.

Float position activated:


1.
2.
3.

4.

Use a stop watch to measure the cylinder running time.


Raise the fully extended attachment with empty bucket to the maximum
height position (A).
Rapidly move the control lever (E20) to the rear end position (start the stop
watch until the stick start moving) and hold it until close to the final position
(B) is reached.(stop the stop watch).
If the lowering speed is too high, i.e. the measured time is less than the
permissible time, the speed must be reduced by altering the throttle valves
142.5 and 142.7 at the distributor manifold.
Adjust as follows:
To decrease the lowering speed loosen lock nut (1) and turn the bolt (2) cw. To
increase the lowering speed loosen lock nut (1) and turn the bolt (2) ccw.

Since there are several valves throttling the return oil flow of the stick
cylinder the valves must be set synchronously. The adjusting screws have
to be turned in by the same amount of revolutions.

O.K.

5.

Check lowering speed again and repeat the adjustment if necessary.


If the adjustment is finished tighten lock nut (1).
continued

06.10.05

PC5500-6-D_Sec_8-1_rev3.doc

8.1
49

06.10.05

PC5500-6-D_Sec_8-1_rev3.doc

Hydraulic for the


Attachment Cylinders

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.

Float position deactivated (with push button S95a):


Adjust the throttle adjustment bold of throttle valve 142.6 to the same amount
of revolutions as the valve 142.5 and 142.7.
Use a stop watch to measure the cylinder running time.
Start both engines and let it run in high idle.
Raise the fully extended attachment with empty bucket to the maximum
height position (A).
Press push button S95a and keep it depressed while lowering the stick.
Rapidly move the control lever (E20) to the rear end position (start the stop
watch) and hold it until the final position (B) is reached.(stop the stop watch).
The lowering speed will be the same as with floating position. If the lowering
speed is too high, i.e. the measured time is less than the permissible time, the
speed must be reduced by altering the throttle valve 142.5, 142.6 and
synchronous 142.7 at the distributor manifold section F and J.
Adjust as follows:
To decrease the lowering speed loosen lock nut (1) and turn the bolt (2) cw.
To increase the lowering speed loosen lock nut (1) and turn the bolt (2) ccw.
Since there are several valves throttling the return oil flow of the
stick cylinder the valves must be set synchronously. The adjusting
screws have to be turned in by the same amount of revolutions.

O.K.

7.
8.

06.10.05

Check lowering speed again and repeat the adjustment if necessary.


If the adjustment is finished tighten lock nut (1).

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8.1
50

06.10.05

PC5500-6-D_Sec_8-1_rev3.doc

Hydraulic for the


Attachment Cylinders
8.1.12

Section 8.1
Page 50

Checks and adjustments of the lowering speed,


illustration (Z 22491):
Stick cylinder BHA
Maximum permissible lowering speed:

Stick BHA

Cylinder extending time/meter


(s /m)
0,6

Total time
(s)
1,5

Adjustments / Checks:
1.
Use a stop watch to measure the cylinder running time.
2.
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

Check lowering speed again and repeat the adjustment if necessary.


If the adjustment is finished tighten lock nut (1).

PC5500-6-D_Sec_8-1_rev3.doc

8.1
51

06.10.05

PC5500-6-D_Sec_8-1_rev3.doc

Hydraulic for the


Attachment Cylinders
8.1.12

Section 8.1
Page 51

Checks and adjustments of the lowering speed,


illustration (Z 22562):
Bucket cylinder FSA
Maximum permissible lowering speed:

Bucket FSA

Cylinder retracting time/meter


(s /m)
1,1

Total time
(s)
3,0

Adjustments / Checks:
1.
Use a stop watch to measure the cylinder running time.
2.
Raise the fully extended attachment with empty bucket to the maximum
height position (A).
3.
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

Check lowering speed again and repeat the adjustment if necessary.


If the adjustment is finished tighten lock nut (1).

PC5500-6-D_Sec_8-1_rev3.doc

8.1
52

06.10.05

PC5500-6-D_Sec_8-1_rev3.doc

Hydraulic for the


Attachment Cylinders
8.1.12

Section 8.1
Page 52

Checks and adjustments of the lowering speed,


illustration (Z 22492):
Bucket cylinder BHA
Maximum permissible lowering speed:

Bucket BHA

Cylinder retracting time/meter


(s /m)
0,5

Total time
(s)
1,1

Adjustments / Checks:
1.
Use a stop watch to measure the cylinder running time.
2.
Raise the fully extended attachment with empty bucket to the maximum
height position (A).
3.
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

Check lowering speed again and repeat the adjustment if necessary.


If the adjustment is finished tighten lock nut (1).

PC5500-6-D_Sec_8-1_rev3.doc

8.1
53

06.10.05

PC5500-6-D_Sec_8-1_rev3.doc

Hydraulic for the


Attachment Cylinders
8.1.12

Section 8.1
Page 53

Checks and adjustments of the lowering speed,


illustration (Z 22563):
Clam cylinder FSA
Maximum permissible lowering speed:
Adjustments / Checks:
1.
2.
3.
4.

5.

6.
7.

06.10.05

Use a stop watch to measure the cylinder running time.


Start both engines and let it run in high idle.
Open the clam of the empty bucket to the maximum position (A).
Rapidly push the control pedal (E23) to the end position (start the stop
watch) and hold it until the final position (B) is nearly reached.(stop the stop
watch).
If the lowering speed is too high, i.e. the speed is uncomfortable, the speed
must be reduced by altering the throttle valve 142.4 at the distributor
manifold section E.
Adjust as follows:
To decrease the lowering speed loosen lock nut (1) and turn the bolt (2) cw.
To increase the lowering speed loosen lock nut (1) and turn the bolt (2) ccw.
Check lowering speed again and repeat the adjustment if necessary.
If the adjustment is finished tighten lock nut (1) and write down the adjusted
running time for later checks.

PC5500-6-D_Sec_8-1_rev3.doc

8.1
54

06.10.05

PC5500-6-D_Sec_8-1_rev3.doc

Hydraulic for the


Attachment Cylinders
8.1.13

Section 8.1
Page 54

Checks for the valve control logic


Legend for illustration (Z 22582a):
(1)
Main pump condition P = pressurized outlet
(2)
Main pump condition (-) = free flow to reservoir
(3)
Pilot ports a = outlet ports a
(4)
Pilot ports b = outlet ports b
(5)
Port condition (-) = closed port
(6)
Port condition O = open port
(7)
Respective function
(8)
Single control valve block for swing
(9)
control valve block number
(10)
Swing parking brake switch S29
General:
For harmonic attachment motion and well working floating function the valve
spools must be activated with different priorities. The whole valve control logic is
a arrangement of electric relay controlling and the main hydraulic control valve
sequence.
The correct function of the valve control logic can be checked by pressure gauges
(0 -50bar) connected to the pressure test ports at the control valve cabs.
Checks:
a)
Connect the pressure gauges (0-50 bar) to all test ports at the pilot control
cabs (26 gauges necessary *) and (0-400 bar) to the high pressure filter
test ports M44.1, 44.2, 46.1, 46.2
b)
Mark the control cab with the respective function and port designation.
c)
Use the Check list for the Valve Logic in the appendix in this binder.
d)
Unplug solenoid valve Y16 (travel parking brake closed) and activate the
swing brake with the switch at the dash board. The ladder and the
refilling arm are in high position (working position) the operator sits on
the operators seat. Make sure that the machine can move hazardless all
functions
e)
Start one motor.
f)
The operator activate carefully step for step the respective lever or pedal
as shown in the check list. Compare each step with the pressure condition
of the control cabs and main pressure to the check list.
If there is a wrong result, check the respective electric circuit and hydraulic
pilot circuit.

06.10.05

PC5500-6-D_Sec_8-1_rev3.doc

Hydraulic for the Swing Circuit

Section 8.2
Page 1

Table of contents section 8.2


Section
8.2

Page
Hydraulic for the swing circuit
8.2.1 Swing Circuit (Brief description)

2+3

8.2.2 Swing Motor

4-7

8.2.3 Swing Gear Box

8.2.4 Swing Parking Brake (Gear house Brake)

8.2.5 Swing Brake Valve

10+12

8.2.6 Electric / Hydraulic flowchart Swing Left

13

8.2.7 Electric / Hydraulic flowchart Swing Right

14

8.2.8 Swing Monitoring System

15 + 16

8.2.9 Adjustments for the swing circuit

17 - 19

8.2.10 Checks and adjustments for the swing circuit

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

Hydraulic for the Swing Circuit

Section 8.2
Page 2

8.2.1 Swing Circuit (Brief description)


Legend for illustration (Z 22501b):
(I - VI)
(13)
(48)
(20.1+ 20.2)
(71.1+ 71.2)
(25.2)
(49.1 + 49.2)
(Y48)
(Y120)
(43)
(Y32)
(Y32a/b)
(20)
(50)
(A7)

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

Brief description (Control circuits)


(Study together with the for the machine valid hydraulic and electric circuit
diagram).
When the lever (E20) is moved out of its neutral position, proportional
solenoid valves Y32 are energized. Simultaneously the directional solenoid
valves Y32a (R.H.-swing) or Y32b (L.H.-swing) are energized.
By the function of the remote control valve (43) pilot pressure oil is sent to
one side of the control block (13/IV) when operating the control lever for
"Swinging". At the same time by the function of the proportional valve
(Y127) pilot pressure (proportional to the lever deflection) is present at port
X pressure increasing valve (PIV)of each brake valve block (49.1+ 49.2)
thus a internal pressure built up (higher as 150 bar) in the service lines is
possible.
continued

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06.10.05

8.2
3

PC5500-6-D_Sec_8-2_rev4.doc

06.10.05

Hydraulic for the Swing Circuit

Section 8.2
Page 3

Cont'd.:
8.2.1 Functional description:
Illustration (Z 22501b):
Brief description (Service circuits)
(Study together with the for the machine valid hydraulic and electric circuit
diagram).
The swing motors (20.1 + 20.2) are feed by the main pump (III). This pump is
at port XLR permanent with 35 bar X2- pressure fix adjusted to Qmax.
The oil flows from the pumps through check valve (47.3) and filter (153.3) to
the single control block (13 / IV).
In neutral position of the spool oil flows via port C into control block II for
additional oil volume from pump 3 to valve circuit II. If no function of
control block II is activated the oil flow via port T in to the collector tube (35)
and further via the return oil lines (L6 + L7) into the tank.
On its way to tank the oil must flow through the back pressure valve (115)
and the return oil filter (117.2 - 117.5). (Back pressure valve function see
chapt. 4.)
When operating the control lever for "Swinging" the pump line is connected
in the control block (33/IV) with the corresponding service line (A1 or B1) to
the swing motors (20.1 + 20.2).
The oil flows from the control block through each one of the swing brake
valves (49.1 + 49.2; description see page 6 and 7) and the swing motors (20.1
+ 20.2).
Each swing gear includes one spring loaded multi disk brake (House brake)
for locking the superstructure.
The leak oil (case drain) flows through the line (L11 + L12) and the leak oil
filter (108) back to tank.

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

Swing motor A6VM

8.2.2 Swing Motor

Section 8.2
Page 4

Axial Piston Motor A6VM355 HD1D

Legend for illustration (Z 22430):


(1)
Check valve
(2)
Check valve
(3)
Governor valve
(4)
Positioning piston
(5)
Boost pressure valve
(6)
Flushing valve (16l/min)
(7)
Flow control valve
(8)
Constant pressure control valve (adjusted: 280 bar)
General:
A6VM355 HD1D is a variable displacement motor with an axial piston rotary
group of bent axis design for hydrostatic drives.
Its control range allows the variable displacement motor to meet both, high speed
and torque requirements. The output speed is proportional to its displacement.
The output speed increases with decreased displacement trough lower
operating pressure.
The output torque increases with increased displacement trough higher
operating pressure.

PC5500-6-D_Sec_8-2_rev4.doc

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8.2
5

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06.10.05

Section 8.2
Page 5

Swing motor A6VM

8.2.1 Swing Motor

Axial Piston Motor A6VM355 HD1D

Hydraulic control, illustration Z22430


By switching pilot pressure to port X at the motor (0 bar or 35 bar) the displacement is
fixed in Vg max or variable.
Without pilot pressure at port X (0 bar) the displacement is fixed to Vg max .
With pilot pressure at port X (35 bar) the displacement is variable from
Vg min (175 cm3/rpm) to Vg max (355 cm3/rpm).
With a swing speed of 0 up to 120 impulses per minute (measured by a proximity
switch located at the swing gear) the motors are in maximum displacement position,
i.e. min. speed and max. torque available.
With a swing speed of more as 120 imp./min. pilot pressure is directed via a solenoid
valve to port X at the motors, to actuate governor valve (3). Now the output speed is
variable depending on the operating pressure, controlled by the function of control
valve (8).
As a result of decreasing operating pressure the motors are reducing their
displacement so that the swing speed will increase.
If the operating pressure rises as a result of load torque, to the setting of the constant
pressure control valve (280 bar), the motors are swiveled out to a greater angel (higher
displacement) and the swing speed will decrease.
Function

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

Swing down path

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

Reduced Vg max Vg min


variable

Control lever in neutral

Counter Swing (braking)


Control lever moved to the
opposite side of swing direction

Continued

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8.2
6

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06.10.05

Swing motor A6VM

8.2.2 Hydraulic Motor

Section 8.2
Page 6

Axial Piston Motor A6VM355 HD1D

Hydraulic control, illustration Z22431b


Cont'd:

Flow from A to B without X-pressure (slow swing speed) :


The operating pressure opens check valve (1) and closes the opposite valve (2). The
same pressure is present at the control port of pressure control valve (8) and inside
the small area side of the positioning piston (4). The large area side is connected via
the governor valve (3) to tank (port T2).
The motor remains in Vgmax position. = max. torque by low speed.

Flow from A to B, with X-pressure (higher swing speed),


operating pressure 0 280 bar:
Operating pressure opens check valve (1) and closes the opposite valve (2). The
same pressure is present at the control port of pressure control valve (8) and inside
the small area side of the positioning piston (4).
Because of the X pressure at the control port of governor valve (3) a connection
is made from the operating pressure to the large area side of positioning piston (4).
Same pressure on both sides but different areas causes a greater force at the piston
side moving the motor into the Vgmin position.
The motor is in regulation mode due to 35 bar X-pressure
Motor displacement to Vgmin position (<280bar).

Flow from A to B, with X-pressure (higher swing speed),


operating pressure 280-310 bar:
Depending on the system pressure (more as 280 bar), valve (8) connect the large
area side of the positioning piston (4) with the pressure less return line (T2). Low
pressure at the large side cause a greater force at the pressurized small area side of
the positioning piston (4) moving the motor into the Vgmax position.
The motor is in regulation mode due to high operating pressure (>280bar) :
Motor displacement to Vgmax position (>280bar).
As a result of decreasing operating pressure the motors are reducing their
displacement so that the swing speed will increase.
If the operating pressure rises as a result of load torque, to the setting of the constant
pressure control valve (280 bar), the motors are swiveled out to a greater angel (higher
displacement) and the swing speed will decrease.

PC5500-6-D_Sec_8-2_rev4.doc

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Swing motor A6VM

PC5500-6-D_Sec_8-2_rev4.doc

Section 8.2
Page 6

06.10.05

Swing motor A6VM

8.2.2

Section 8.2
Page 7

Checks and Adjustments, illustration Z22432


Preconditions before starting checks and adjustments:
1. Main pump 3 must be in full flow position (X1-pressure = 35 bar), no action
required because stabilized X1 pressure is automatic activated during swinging
2. MRVs and SRVs (pressure increasing valves) correctly adjusted.

Checking the Q-max. and Q-min. stop bolt setting.


Q-max : The average outer length of 25.1 mm must not be altered because the
max. possible swivel angle is used.
Q-min : The Qmin. adjustment depends on the max. permissible swing speed (with
reduced swivel angle). The average outer length is 36.1 mm

It is important that the adjustment is equal on both motors!

How to check the Q-min. adjustment.


1. Lift the extended attachment to horizontal position.
2. Measure the time for 5 revolutions after swinging one turn as an approach swing.
The time should be t5rev = 90+5 sec .
3. If a adjustment is required:
Turn off box nut (1) and loosen lock nut (3)
Turn bolt (2) further in for less speed or further out for higher speed.
One turn of the Qmin bolt (2) cause a change of approx. t5rev = 4.6 sec.
4. Re-check speed and tighten lock nut and re-fit box nut (1) after setting is finished.
How to check / adjust the start of regulation.
1. Activate manually relay K153 to energize Y48 to pressurized swing motor port
X with X2-pressur.
2. Connect a pressure gauge (0-400 bar) to check point M12.2 at high pressure
filter of single control block IV.
3. Measure and note outer length (L) of Qmax stop bolt (2) (for resetting later on)
Loosen lock nut (3) approx. turn without turning the stop bolt..
4. Start engine 1 and let it run in high idle.
5. Apply the swing parking brake.
6. Operate carefully the control lever for swing in one direction and keep it in end
position. The resulting operating pressure should be 320 bar.
7. Loosen look nut of MRV at single control block IV.
8. Decrease / increase alternately the operating pressure between 300 bar and 260 bar
at MRV set screw. Check by turning the Qmax stop bolt (2) by hand, if the motor
control lens touches the Qmax stop bolt:
The lens must touch the stop bolt with a pressure higher than 280 bar.
The lens must not touch the stop bolt with a pressure lower than 280 bar
9. Correct the start of regulation with valve (8) if necessary.
10. Reset MRV. Stop engine and deactivate K153

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8

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Hydraulic for the Swing Circuit

Section 8.2
Page 8

8.2.3 Swing Gear Box


Legend for illustration (Z 25305), manufacturer: Siebenhaar
(1) Drive housing
(11) Bearing ring
(2) Drive shaft
(12) Cartridge
(3) Sun gear shaft
(13) Spherical roller bearing
(4) Multi disc brake, spring
(14) Oil drain plug, gear box
loaded pilot pressure released
(15) Cylindrical roller bearing
(5) Breather filter motor adapter
(16) Oil level gauge (dipstick)
housing
for gear box
(6) Oil level gauge (dipstick)
(17) First planetary stage
for drive shaft housing
(18) Drive shaft to second stage
(7) Disk brake housing
(19) Second planetary stage
(8) Cylindrical roller bearing
(20) Radial seal ring
(9) Internal ring gear
(21) Drive pinion
(10) Cylindrical roller bearing
(22) Grease line port
(23) Centering circle

The swing gear is of compact design with a two stage planetary gear including a
multi disk house brake.
The gear is bolted to the superstructure and fits firmly due to the machined
diameter (A) and the bolt torque.
The torque loaded on the hydraulic motor is transmitted by drive shafts (2)
and sun gear shaft (3) to the first planetary stage (17).
The sun shaft (17) of the first planetary stage transmits the torque into the
second planetary stage (19). By the planetary gears the output drive shaft is
rotated and transmits the torque to the pinion (21).
The drive housing, and the gearbox are filled with gear oil.
Aeration is done by breather filters.
A grease nipple is via a hose connected to the bearing lubrication port (22).

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9

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Hydraulic for the Swing Circuit

Section 8.2
Page 9

8.2.4 Swing Parking Brake (Gear house Brake)


The Spring Loaded Multi-disk Brake is a safety brake; applied by
spring force and released by oil pressure.
Legend for illustration (Z 22439):
(1)
Clip ring (circlip)
(2)
Thrust washer
(3)
Outer discs
(4)
Inner discs
(5)
Piston
(6)
Quad ring with back up ring
(7)
Quad ring with back up ring
(8)
Springs
(9)
Piston back up ring and seal retainer
(10)
O ring
(11)
Clip ring (circlip)
(12)
Oil pressure port
Function:
Brake applied:
The outer disks (3) engaged to the housing by serration and the inner disks (4) in
serrated connection with drive shaft are pressed together by the springs (8). This
results in a fixed connection between housing and drive shaft.
Brake released:
Oil pressure via port (12) reaches the bottom of the piston (5) and forces the
piston upwards against the thrust washer (2).
This function eliminates the spring force to the disc (3) and (4) thus the brake is
released.
The releasing pressure is 12 - 20 bar, the maximum permissible pressure
60 bar.
This is a so named "Wet Brake" because the brake housing is filled with oil.

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10

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Hydraulic for the Swing Circuit

Section 8.2
Page 10

8.2.5 Swing Brake Valve


Legend for illustration (Z 21934):
(1) Pressure increasing valve
(items 6 - 13)
(2) Check valve circuit A
(3) Check valve circuit B
(4) Anti-cavitation valve circuit B
(5) Anti-cavitation valve circuit A
(6) Jet bore, of main piston plug
Ports:
(Y)
(T)
(A)
(A1)
(B)
(B1)

(7)
(8)
(9)
(10)
(11)
(12)
(13)

Spring of main piston


Jet bore
Valve poppet
Spring
Intermediate piston
Pilot pressure piston
Main piston

Leak oil
Return oil
Service line from control block
Service line to the motor
Service line from control block
Service line to the motor

Pressure check points:


(MA) Circuit A
(MB) Circuit B
Explanation of the function by the symbol:
When ever a swing motion is carried out or the foot brake is used, pilot
pressure arrives the pressure increasing valve (1) at port "X".
The pilot pressure pre-loads these valves.
The oil for the hydraulic motor from the control block arrives the service line
port A or B, depending if a R.H. or a L.H. swing motion is carried out.
The ports A and B are internally connected to the ports A1 and B1 and these
ports in turn with the hydraulic motor.
The operating pressure, at either port A or B closes the anti-cavitation valves
(4 or 5) and opens the check valves (2 or 3).
That means by the check valves (2 or 3) the service lines are connected to the
pressure increasing valve.
When ever the pressure is higher than the setting of the pressure increasing
valve, this valves opens and dumps the oil into the return line (T) to tank.
The pressure can be checked at the check points MA or MB.
continued

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11

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Hydraulic for the Swing Circuit

Section 8.2
Page 11

Cont'd.:
8.2.5 Swing Brake Valve
If after a swing motion the joy stick is released into neutral position
without using the foot brake, the superstructure is turned by inertial force
and the hydraulic motor acts as a pump because it is driven by the swing
gear.
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

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12

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Hydraulic for the Swing Circuit

Section 8.2
Page 12

Cont'd.:
8.2.5

Swing Brake Valves


Anti cavitation prevention. Illustration Z 22672a
(1)
Return oil collector tube
(2)
Main back pressure valve
(3)
Gear pump (8.2 + 8.5)..
(4)
Swing motor back pressure valve blocks (195.1 + 195.2)
(5)
Swing brake valve blocks (49.1 + 49.2).
(6)
Swing motor (20.1 + 20.2)
(7)
Pressure relieve valve (swing motor back pressure)
(8)
Check valve
(9)
Pressure check point M35.1 and M35.2
(10)
Valve drain connection
A
Input from gear pump
B
Output to swing brake block
T
Tank connection to return oil collector tube
During the swing down phases the swing motors (6) are working as pumps.
It means that the pressure side change to a suction side and the suction side
change to a pressure side. To prevent cavitation in the swing motors during
this change there are two back pressure valves (4) fitted. The valves (4)
together with the gear pumps (3) increase the main back pressure up to 15
bar. Port B is direct connected to the tank port (return line) of the swing brake
valve block (5).
Adjustments - Measurements -Settings
Setting of the swing circuit back pressure valves (3)
1. Connect pressure gauge (0 25 bar) to check points M35.1 and M35.2
at the valve blocks (195.1 +195.2). The valve blocks fitted at the return
oil collector tube in front of the hydraulic tank.
2. Start both engines and let them run in high idle.
3. The pressure at the gauges should be 15 bar if the gauges shows a
different value the pressure relieve valves in the back pressure valve
must be adjusted.
a)
b)
c)

Loosen look nut


Turn in or out set screw to increase or decrease the pressure.
Tighten look nut

4. Stop engines
5. Disconnect the gauges.

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13

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Hydraulic for the Swing Circuit

Section 8.2
Page 13

8.2.6 Electric / Hydraulic flowchart Swing Left


Legend for illustration (Z 22503a):
(-10V)
Signal voltage (Maximum)
(13)
Main control block IV
(20.1 + 20.2)
Swing motors
(43)
Remote control valve block
(48)
Distribution block
(49.1 + 49.2)
Swing brake valve blocks
(A7)
Amplifier module Swing (Y32 + Y32a/b Block IV)
(A16)
Amplifier module Swing brake
(D32)
Time relay Pilot control: Neutral position monitoring
(E20)
Control lever (Joy stick)
(E50)
Ramp time module
(E50B)
Ramp time module Swing brake
(K165)
Relay counter lock (option)
(K253)
Relay controlled by swing brake (foot brake)
(ws/gn)
Colour code of signal voltage cable ( Joy stick)
(-X)
Direction (axis) of joy stick (minus x = left)
(X2F...)
Terminal rail with number
(Y32)
Proportional solenoid valve
(Y32a + Y32b)
Directional solenoid valve
(Y127)
Proportional valve, controlling pressure increasing valve
The electrical signal.
Signal voltage of joy stick (E20) arrives via ramp time module (E50) at
terminal 5 of the amplifier module (A7) and further via relay K165 (if
equipped) to the proportional and directional solenoid valves of the remote
control blocks (43). In the same time signal voltage of joy stick arrives via
K253 and ramp time module E50B to terminal 5 of the amplifier module A16.
Relay contact 2 / 10 of relay K165 (if equipped) opened if the excavator
superstructure swing in a different direction as the lever direction (counter
look). Relay K253 energized if the swing brake pedal is activated this
eliminate the ramp time function of E50B.
The hydraulic signal. (pilot pressure)
When the proportional and directional solenoid valves are energized pilot
pressure oil flows to the pressure ports of the main control blocks.
Proportional valve Y127 increase proportional to the lever deflection the pilot
pressure to the pressure increasing valves.
The hydraulic oil flow
Now the oil of the main pump 3 flows through the main control block (IV) and
arrives via swing brake valves (49.1 + 49.2) at the swing motors (20.1 + 20.2).

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Hydraulic for the Swing Circuit

Section 8.2
Page 14

8.2.7 Electric / Hydraulic flowchart Swing Right


Legend for illustration (Z 22504a):
(+10V)
Signal voltage (Maximum)
(13)
Main control block IV
(20.1 + 20.2)
Swing motors
(43)
Remote control valve block
(48)
Distribution block
(49.1 + 49.2)
Swing brake valve blocks
(A7)
Amplifier module Swing (Y32 + Y32a/b Block IV)
(A16)
Amplifier module Swing brake
(D32)
Time relay Pilot control: Neutral position monitoring
(E20)
Control lever (Joy stick)
(E50)
Ramp time module
(E50B)
Ramp time module Swing brake
(K165)
Relay counter lock (option)
(K253)
Relay controlled by swing brake (foot brake)
(ws/gn)
Colour code of signal voltage cable ( Joy stick)
(+X)
Direction (axis) of joy stick (plus x = right)
(X2F...)
Terminal rail with number
(Y32)
Proportional solenoid valve
(Y32a + Y32b)
Directional solenoid valve
(Y127)
Proportional valve, controlling pressure increasing valve
The electrical signal.
Signal voltage of joy stick (E20) arrives via ramp time module (E50) at
terminal 5 of the amplifier module (A7) and further via relay K165 K165 (if
equipped) to the proportional and directional solenoid valves of the remote
control blocks (43). In the same time signal voltage of joy stick arrives via
K253 and ramp time module E50B to terminal 5 of the amplifier module A16.
Relay contact 2 / 10 of relay K165 (option) opened if the excavator
superstructure swing in a different direction as the lever direction (counter
look). Relay K253 energized if the swing brake pedal is activated this
eliminate the ramp time function of E50B.
The hydraulic signal. (pilot pressure)
When the proportional and directional solenoid valves are energized pilot
pressure oil flows to the pressure ports of the main control blocks.
Proportional valve Y127 increase proportional to the lever deflection the pilot
pressure to the pressure increasing valves.
The hydraulic oil flow
Now the oil of the main pump 3 flows through the main control block (IV) and
arrives via swing brake valves (49.1 + 49.2) at the swing motors (20.1 + 20.2).

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15

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Hydraulic for the Swing Circuit

Section 8.2
Page 15

8.2.8 Swing Monitoring System, illustration (Z 21947a)


There are two reasons why the swing monitoring system is installed:
a) To prevent adverse effects of a counter action.
b) To increase the swing speed, by reducing the swivel angel of the
swing motor (lowering the required oil volume per motor rotation)
Function of the swing monitoring system:
The two sensors B98 and B99, (Proximity switches mounted into a housing
near the ring-gear) sensing the direction of rotation.
How?
Because the distance from sensor to sensor (B) is less than the distance of two
teeth (A), one of the sensors recognizes first a swing action.
The signals of both sensors are used as input signals for the module (E42)
which monitors the swing direction.
The same signals from sensor B99 are send to the module E43 for sensing the
swing speed.
Proximity switch B99 together with module E43 monitors the swing speed to
control via relay K154 and K153 solenoid valve (Y48).
Activated solenoid valve Y48 allows full X2 pressure to swing motors
(20.1 + 20.2) port X = if the working pressure is less then 280 bar
increasing of swing speed is possible.
De activated solenoid valve Y48 causes no X2 pressure to swing motor
(20.1 + 20.2) port X = the motors are fixed in maximum swivel angel
(max. volume = max. torque and min. speed)
Acceleration
During the first acceleration phase the maximum torque by minimum speed is
required, the motors must be in maximum swivel angel (x-port 0 bar). E43
detect the swing speed, if the speed is below 120 Imp./min. relays K154 and
K153 are still de energized and further solenoid valve Y48 de-energized (xport = 0 bar = max. motor swivel angel = max torque). After this first
acceleration the required torque and hydraulic pressure droops and the swing
speed increase. E43 detect more as 120 Imp./min and energize relay K154. If
the lever direction and the swing direction is the same K153 energized and
further D153 energized solenoid valve Y48 (x-port = 35 bar = variable motor
swivel angel is possible).
Braking with counter position of the lever
If the operator release the lever or move the lever to counter position relay
K153 opened contact 5 / 9 it de energize time relay D153. After the time is
elapsed (one second) solenoid valve Y48 de energize and change over in
neutral position so that pilot line L18 release the pressure to the tank (port X =
0 bar). The swing motors move to maximum swivel angel. Now a maximum
breaking torque is available.

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16

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Hydraulic for the Swing Circuit

Section 8.2
Page 16

8.2.8 Swing Monitoring System, illustration (Z 21947a)


(Study together with the valid hydraulic and electric circuit diagram for the
machine)
Adjustments - Measurements -Settings
a)
Distance between Swing ring teeth and the switches B98 and B99
The sensors B98 and B99 are inductive switches with own electronic.
Sensor B98 switches 24V via cable Sig to terminal 4 of E42 and
Sensor B99 switches 24V via cable Sig to terminal 11 of E42 if a
tooth comes close to the sensor head.
Simultaneously these signal arrives at E43 terminal 4.
Adjust the distance C of the sensors B98 and B99 to 51 mm.
b)

E42 for monitoring the slew direction


E42 is an programmable module which is factory programmed with the
parameters are shown in the electric diagram. Therefore no adjustments
or settings are required.
The indication light (In1 from B98 / In2 from B99) lights/pulses if a
input signal comes up. The indication light (Out1 for swing left / Out2
for swing right) lights if the module indicates a swing direction.

c)

E43 for monitoring the slew direction


E43 is an programmable module which is factory programmed with the
parameters are shown in the electric diagram below.
Settings:
E43 (speed monitor) counter prevention
No

Function

nominal setting

Setting the start up delay

Not used set to 0

Fine setting of the preset value (pulses / min.)

12 imp/min (i.e.120)

Setting the hysteresis

Not used set to 0

LED: lights when the output relay is energised

---

Setting the switching function

Set to III

Coarse setting of the preset value (pulses / min)

X x 10 imp/min

If necessary increase or decrease the imp/min with set screw no. 2


until a smooth slew operation is possible.

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17

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Hydraulic for the Swing Circuit

Section 8.2
Page 17

8.2.9 Checks and adjustments for the swing circuit

It is important that the complete MRV-valve and the Pressure


Increasing Valve is firmly (with 300 Nm) tightened.
Otherwise, the internal sealing sealed not properly which results in:
difficulty setting, loud flow noises and abnormal temperatures.
Whenever pressure checks are carried out, they must be carried out
for both, r.h. and l.h. swing, to make sure the check valves in the brake
valve are in good shape.
Because the Swing motors are working hydraulically in combined
operation, the pressure gauge shows the pressure of the pressure
increasing valve with the lowest setting. Even when the gauge shows
the required pressure it is possible that one valve has a higher setting.
Therefore lower the pressure on one valve below the required pressure
and then increase up to required pressure. Proceed with next valve in
the same manner.

High pressure check / adjustment


1.
Connect the gauge (0-400 bar) to check point M12.2 at the high
pressure filter units (153.3) of single control block IV.
2.
Release the pilot pressure by several movements of the lever with
motor / engine stand still. The key switch S1 must be on the ladder and
service arm must be in up position. Disconnect carefully the pilot
pressure lines from the pressure increasing valves and close the lines
with a suitable plug.
3.
Loosen lock nut (3) of both pressure increasing valves (PIV) and screw
in set screw (4) until piston (5) comes to stop.
4.
Start engine and let it run with max. speed.
5.
Lower attachment to ground and apply house brake (swing parking
brake).
6.
Actuate either l.h. or r.h. rotation until the hydraulic system stalls and
increase slowly the MRV-pressure while observing the pressure gauge.
Gauge value must remain at 330 -5 bar. Increase MRV setting
additional 1/8 turn cw..
7.
If the gauge shows a lower or higher value the pressure increasing
valves must be adjusted.

continue

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18

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Hydraulic for the Swing Circuit

8.2.9

Section 8.2
Page 18

Checks and adjustments for the swing circuit


Cont'd:
High pressure check / adjustment
Pressure Increasing Valve (PIV) high pressure adjustment
Procedure:
a)
Loosen lock nut (1) of the first pressure increasing valve PIV.
b)
Adjust pressure with set screw (2) to ~340 bar if the pressure dont
increase turn set crew from the last setting max. turn in (c.w.).
c)
Secure by tightening lock nut (1).
d)
Loosen lock nut (1) of the second PIV.
e)
Adjust pressure with set screw (2) to 330 5 bar.
f)
Secure adjusted set screw (2) by tightening lock nut (1)
g)
Loosen lock nut (1) of the first PIV.
h)
Adjust pressure with set screw (2) of the first PIV to 330 5 bar
(lower pressure c.c.w. just as the pressure gauge show a reaction)
i)
Secure adjusted set screw (2) by tightening lock nut (1)
j)
Re-check pressure setting.
k)
Re-set MRV to 310 + 5 bar after the check / adjustment is finished.

Low pressure check / adjustment (Swinging down path (drifting)


(with still disconnected pilot pressure line )
8.

Actuate either l.h. or r.h. rotation until the hydraulic system stalls.
a)
loosen lock nut (3) at the first PIV and turn out set screw (4)
until 150 +5 bar is reached.
b)
Tighten lock nut (3).
c)
Loosen lock nut (3) at the second PIV and turn out set screw
(4) until the gauge start lowering the pressure.
d)
Re-check pressure setting.
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.

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19

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Hydraulic for the Swing Circuit

8.2.10

Section 8.2
Page 19

Checks and adjustments for the swing circuit


Cont'd:
Brake pilot pressure - check / adjustment
1.
Connect the gauge to the check point M4.
2.
Start engine and let it run with max. speed.
3.
Depress fully the foot brake pedal and read the pressure.
The pressure must be 19 +3 bar.
If adjustment is required:
Alter the position of the potentiometer R2 of the amplifier A16 as long as the
pressure is 19 +3 bar.
Basic adjustment for A16 see section 5

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Hydraulic for the travel circuit

Section 8.3
Page 1

Table of contents section 8.3


Section
8.3

Page
Travel System
8.3.1 Travel Circuit (Brief description)

2+3

8.3.2 Rotary Distributor

4+5

8.3.3 Side Frame Components

8.3.4 Travel Gear and Parking Brake

8.3.5 Parking Brake

8.3.6 Electric / Hydraulic Flow Chart

8.3.7 Adjustment / Checks

10 + 12

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8.3
2

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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)

High pressure check points


High pressure check points left travel motors
High pressure check points right travel motors

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.

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8.3
3

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Travel System

Section 8.3
Page 3

8.3.1 Service circuits ( Z22521)


(Study together with the valid hydraulic and electric circuit diagram for the
machine).
The travel motors (21.1 - 21.4) are driven by the pumps (1; 2; 5; 6).
The oil flows from the pumps through check valves and the filters (46.1 + 46.2)
to the control blocks (14 / I + 16 / III).
In neutral position of the spools the oil flows via the return oil lines into the collector tube (35, not shown). From the collector tube (35) flows the oil via the return oil lines (L6 + L7, not shown) into the collector tube (114) and further to
the tank. On its way to tank the oil must flow through the back pressure valve
(115) or the oil coolers (106.1 106.4) and the return oil filter (117.1 - 117.4).
(Back pressure valve function see section 4.)
When operating the foot pedal for "Travelling" the pump line of each control
block is connected with the corresponding service line (A1 or B1) via the rotary
distributor (34) and the valve blocks (175 + 176) to the travel motors (21.1 21.4).
The oil flows from the travel motors via the rotary distributor back to the control
blocks and further to tank.
Each travel gear includes two spring loaded multi disk brakes (House brakes)
(52.1 - 52.4). They are used as parking brakes, automatically applied (by the
function of Y16) whenever both motors stoped. The brake release pressure is
monitored by the pressure switch (B48).
The leak oil (case drain) flows through the line (L) and the leak oil filter (108)
back to tank.

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8.3
4

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06.10.05

Travel System

Section 8.3
Page 4

8.3.2 Rotary Distributor


Task:
The rotary distributor (joint) permits a hydraulic connection between the superstructure and the under- carriage, that means between the rotating and the
stationary part.
Legend for illustration (Z 22522):
(1)
(2)
(3)
(4)
(6)
(8+9)
(10)
(11)
(12)
(13)

Rotor
Rotary distributor housing
Cover
Thrust washer
Sealing plunger
Seal ring and O-ring
PTFE Sealing
V Sealing
Rotor guide rings
O-ring

Translations:
Schnitt = Cross section
Versetzt gezeichnet = Offset drawn
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

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8.3
5

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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).

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8.3
6

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Travel System

Section 8.3
Page 6

8.3.3 Side Frame Components, Cross Sections


Illustration Z 22523

A
B
C
D

PC5500-6-D_Sec_8-3_rev2.doc

Under carriage view from the back side


Final drive with
Side frame with top and bottom roller
Track tensioning cylinder

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8.3
7

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06.10.05

Travel System

Section 8.3
Page 7

8.3.4 Travel Gear and Parking Brake


Function principle ( illustration Z22524a):
The spur gear stage (B) is driven by two hydraulic motors via two drive
shafts (A). This in turn causes that by the shaft (C) the first planetary stage
(D) is driven; opposite the input drive direction.
The planetary gears of the second planetary stage are connected to the hollow
shaft (G).
The drive sprocket is mounted to the hollow shaft (G).

For maintenance see MAINTENANCE MANUAL


For more details see PARTS BOOK.

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8.3
8

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Travel System

Section 8.3
Page 8

8.3.5 Parking Brake


Illustration Z 22525
The Spring Loaded Multi-disk Brake is used as a safety brake (parking
brake); applied by spring force and released by oil pressure.
Legend:
(1)
(2)
(3)
(4)
(5)
(6)

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

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8.3
9

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06.10.05

Travel System

Section 8.3
Page 9

Electric / Hydraulic Flow Charts


Illustration Z 22526
On the following pages are shown the electric / hydraulic flow charts for the
travel circuit.
The electrical signal created by the foot pedals (E21a and E21b) reach first
of all the ramp modules (E51 and E52) and further the amplifier modules
(A12 and A13). It is a voltage signal from 10 up to +10 Volt dependent to
the pedal deflection and direction. The amplifier modules changes this signal
in a current signal from 0 to 1000 mA and a directional signal (0 or 24 V).
The current signal activate the proportional valve and the directional signal
the directional solenoid valve of the remote control block (45.1 and 45.3).
The valves in case activate the pilot pressure to the main control valve blocks.
This hydraulic signal (pilot pressure) from the remote control valves flow to
the main control blocks (175 and 176) to the pilot pressure ports a1 or b1
which in case push the main control valve spool to control the main hydraulic
oil flow from the main pump.
The main hydraulic oil flows now from the main control blocks via the rotary distributor (34) to the hydraulic motors (21.1 - 21.4).

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8.3
10

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Travel System

Section 8.3
Page 10

Adjustments / Checks

It is important that the complete MRV-valve is firmly (with 300 Nm)


tightened.
Otherwise, the internal sealing sealed not properly which results in:
difficulty setting, loud flow noises and abnormal temperatures.

High pressure check / adjustment (illustration Z 22528)


1.
Connect the gauge (0-400 bar) to the check points M12.1. and M12.4
at the double high pressure filters.
2.
Unplug solenoid valve Y16 (Z 22529, filter and valve panel motor 2) to
3.
4.
5.

keep the parking brake applied.


Start both engines and let it run in high idle.
Engage carefully desired travel motion and hold foot pedal in final position to built up max. pressure.
Increase * slowly the MRV-pressure while observing the pressure
gauge. Gauge value must remain at 310 +5 bar.

Motor 2

continued

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8.3
11

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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

Remove dust cap of the SRV (1)


Loosen lock nut (2).
Adjust pressure with set screw (3).
Secure adjustment by tightening lock nut (2).
Re-fit dust cap (1).

06.10.05

8.3
12

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06.10.05

Travel System

Section 8.3
Page 13

Function Check of the Travel Gear House Brake


Illustration Z 22529
Connect pressure gauge to check point (M6) at the filter and valve
panel motor 2.
Start both engines and let it run in high idle.
Read the pressure. Gauge must show common pilot pressure (norm.
35 + 1 bar). If not check the pilot pressure. If the pressure is below
24 bar, the text display must show Travel gear house brake ON.
Operate the travel foot pedals, the machine must travel.
In case the machine doesnt travel the text display must show
Travel gear house brake ON
Unplug solenoid (Y16) and operate the travel foot pedals, the machine must not travel.
The text display must show Travel gear house brake ON

1.
2.
3.

4.

5.

In a case of malfunctioning check the electrical controlling and the


solenoid valve Y16.

Function check of the pressure switch (B48)


1.
Connect pressure gauge to check point (M6).
2.
Start one motor. The gauge must show common pilot pressure (norm.
35 + 1 bar).
3.
Set pilot pressure relief valve (70.2) to 22 bar X2 pressure.
4.
Unplug solenoid valve Y16 to allow pressure release from the pressure line of the house brake.
5.
Reconnect solenoid valve Y16.
The text display must show Travel gear house brake ON
6.
Increase the pilot pressure up to 26 bar
Travel gear house brake ON must disappear
If not check the pressure switch B48 and exchange it if it is out of
the range.
7.
Reset pilot pressure to 35 bar

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06.10.05

Hydraulic Track Tensioning System Section 9.0


Page 1

Table of contents section 9.0


Section
9.0

26.03.03

Page
Hydraulic Track Tensioning System
General

9.1

Functional description

3+4

9.2

Pressure Increasing Valve

9.3

Tensioning Cylinder

9.4

Adjustments / Checks

79

9.5

Functional test

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9.0
2

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Hydraulic Track Tensioning System Section 9.0


Page 2

9.0

General:
Legend for illustration (Z 22453):
(62.1 62.4)
Track tensioning cylinders
(M15.3 + M15.4) Bleeder and hydraulic pressure check points at the
R.H.- tensioning cylinders.
(M15.1 + M15.2) Bleeder and hydraulic pressure check points at the
L.H.- tensioning cylinders.
(M15.5)
Bleeder and hydraulic pressure check point at the bladder
accumulator (59.1) for the L.H.-side.
(M15.6)
Bleeder and hydraulic pressure check point at the bladder
accumulator (59.2) for the R.H.-side.
(60.1 + 60.2)
Membrane accumulator, 1,3 liter (pre-charge pressure 31bar)
(54.2)
Service shut-off cock for the L.H.-side
(54.3)
Service shut-off cock for the R.H.-side
* "O" = open - "C" = closed
(59.1 + 59.2)
Bladder accumulator, 5 liter (pre-charge pressure 150bar)
(34)
Rotary joint
L3 (St)
Supply line from solenoid valve Y16 over rotary joint port St

The hydraulic track tensioning system ensures automatically the correct track
tension.
The pilot pressure pumps (7.1+7.2, see hydraulic diagram page 02) will supply
oil to all four tensioning cylinders (62.1-62.4).
The maximum pressure is limited by the pressure increasing valve (182), one
for both sides.
The pressure in the tensioning cylinders transmits the required force to move
the guide wheels to the front, until the correct track tension is obtained.
External forces acting at the guide wheels will be absorbed through the
pressure accumulators (60.1 + 60.2, first stage) and (59.1 + 59.2, second stage).

For information about the preventative track inspection, refer to the


Operation and Maintenance Manual.

Functional description on next page

26.03.03

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9.0
3

26.03.03

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Hydraulic Track Tensioning System Section 9.0


Page 3

9.1

Functional description:
Illustration Z 22454:

Under normal operating condition the shut-off cock (54.1) located on


the valve block (181) in the car body are closed. The shut-off cock
(184) located on the valve block (181) in the car body and (54.2 and
54.3) located inside the side frames are open.

The oil flow of the pilot pressure pumps (7.1 + 7.2), filtered by pressure filter
(68.1) enters port "P" of the solenoid valves Y16 via hydraulic line L3 and
the rotary joint to the track tensioning valve block (181) in the car body.
If solenoid valves Y16 is actuated (i.e. pressure at sensor B48), the oil flows
(X2-pressure with 35 bar) via the pressure relive valve (83), rotary joint (34), the
shut-off cock (184) and check valves (180.1+180.2) into the tensioning cylinders
(62.1 - 62.4).
The resulting force moves the guide wheels toward the front, until the correct
track tension is obtained.
Simultaneously the system is connected to the pressure increasing valve (182).
External forces acting at the guide wheels will be absorbed through the pressure
accumulators (60.1 + 60.2, first stage) and (59.1 + 59.2, second stage).
Purpose of the pressure increasing valve
The two system pressures

35 bar with engine stopped


315 bar with engine running
are controlled by the pressure increasing valve as follows.
With stopped engine and switched off ignition there is no pilot pressure (X2) at
the pressure increasing valve (182) and only the lowest adjusted pressure of 35
bar remains in the system.
As soon as the engine has been started, the pilot pressure (X2) of 35 bar act
on the pressure increasing valve. As a result the system pressure can rise to
the adjusted pressure of 315 bar.

continued

26.03.03

PC5500-6-D_Sec_9-0_rev0.doc

9.0
4

26.03.03

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Hydraulic Track Tensioning System Section 9.0


Page 4

Cont'd.:
9.1

Functional description:
Illustration (Z 22454):
Cushioning Function
When the tensioning cylinders (62.1 - 62.4) are moved in by external forces,
the none return valves (179.1 + 179.2) will be closed.
A certain amount from the displaced oil of the tensioning cylinders is taken
up by the pressure accumulators.
First stage:

at a pressure higher than 31 bar, is taken up by the side frame


accumulators (60.1.1 + 60.2).

Second stage: at a pressure higher than 150 bar, is taken up by the center section
accumulators (59.1 + 59.2).
The system pressure can rise up to 315 bar pressure increasing valve (182)
setting.
With reduction of external forces, the oil is pushed back by the accumulator
pressure into the tensioning cylinders.
If the displaced oil volume was higher than the accumulators could take up,
oil is added from the pilot pressure circuit (X2), as soon as the pressure in the
lines to the tensioning cylinder is lower than 35 bar.

26.03.03

PC5500-6-D_Sec_9-0_rev0.doc

9.0
5

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Hydraulic Track Tensioning System Section 9.0


Page 5

9.2

Pressure Increasing Valve

The pressure increasing valve is a remote controlled pressure relief


valve.

Legend for illustration (Z 21846):


(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11+12)
(13+14)

Pilot valve with valve seat


Valve poppet
Compression spring
Main valve with sleeve
Main piston
Closing spring
Set screw - low pressure 35 bar
Set screw - high pressure 310bar
Piston
Pin
Jet bore
Lock nut

Function:
The valve poppet (2) is connected via the jet bores (11) and (12) with the P
port.
If static pressure increases above the set pressure value, the valve poppet (2)
opens and allows oil to flow freely to tank (T1). This oil generates a pressure
drop in the spring chamber of the main spool, the closing force of the spring
(6) is cancelled, and the main piston (5) opens to allow the pump flow to flow
to tank (T2).
Damped opening and closing is obtained by the throttled volumetric change.
By applying external pressure of Pst max = 60 bar to the main spool (9) via
port X, the pre-tensioning of the pressure spring (3) is increased by the amount
of the piston stroke "S" and system pressure is increased correspondingly.
The setting is fixed by means of the setting screw (7) and lock nut (13); 1 turn
of the screw ~ 150 bar.

26.03.03

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9.0
6

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Hydraulic Track Tensioning System Section 9.0


Page 6

9.3

Tensioning cylinder:
Legend for illustration (Z 21929):
(1)

Cylinder tube

(2)

Piston

(3)

Piston guide ring

(4)

Piston guide strap

(5)

Seal ring

(6)

O-ring

(7)

Scraper

(8)

Retracting device

(M) Bleeder port


(P)

26.03.03

Oil supply

Maximum permissible piston stroke 350mm!


During bench test an external stroke limitation must be used!

PC5500-6-D_Sec_9-0_rev0.doc

9.0
7

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Hydraulic Track Tensioning System Section 9.0


Page 7

9.4

Adjustments / Checks
Legend for illustration (Z 22455):
(182)
(54.3)
(54.2)
(59.2)
(60.2)
(MRV)

Pressure increasing valve


Service shut-off cock for the R.H.-side
Service shut-off cock for the L.H.-side (not illustrated)
Bladder accumulator 150 bar
Accumulator 31 bar
Main relief valve Operating pressure of main control
block I

(M12.4)

Pressure check point Operating pressure of main control


block I

(M15.6)

Bleeder and hydraulic pressure check point at the bladder


accumulator (59.2) for the R.H.-side.

(M15.5)

Bleeder and hydraulic pressure check point at the bladder


accumulator (59.1) for the L.H.-side (not illustrated).

(M15.3)

Pressure check point - track tensioning system


operating pressure R.H.

(62.3+62.4)

Track tensioning cylinder R.H.

Checking / Setting the pressure increasing valve


Pre-conditions: Correct MRV, SRV and pilot pressure setting and the system
must be free of air.
The description is only for the R.H. track. The same procedure applies also
for the L.H. side.
Basic Adjustment:
1.
Connect a pressure gauge (min.400 bar) to check point M12.4.
2.
3.
4.

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


Increase the MRV-setting (Block I), ~ 330 to 340 bar.
Switch OFF the engine, open cock valve (54.1) to allow pressure
relieve of the R.H. track, and close it again.
continued

26.03.03

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9.0
8

26.03.03

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Hydraulic Track Tensioning System Section 9.0


Page 8

Cont'd.:
9.4

Adjustments / Checks
5.
6.
7.
8.
9.
10.

Move the pressure gauge from M12.4 to M15.3


Connect pressure check point M12.4 with pressure check point M16.1,
using a long pressure gauge hose. (required for the oil supply)
Disconnect the pilot pressure line at port X of the pressure increasing
valve (182) and close the hose (P) ith a plug.
Loosen lock nut (4) of the pressure increasing valve and screw in set
sleeve (5) until piston (1) comes to stop. (substitution of X2 pressure)
Start the engine and let it run with max. speed.
Stall the hydraulic with the bucket filling function (bucket cylinders
completely extended) and observe pressure at check point M15.3.
A pressure of 315 + 5 bar must reached within a time period of 10 15
minutes and must remain at this value.
The maximum pressure will be shown only after the accumulators are
completely filled with oil.
When the pressure reaches the pre-charge gas pressure ( 31 bar and
150 bar) the gauge pointer moves slower depending on the gas
compression.

If the gauge shows a lower or higher value the pressure increasing valve
must be adjusted.
Setting procedure, high pressure stage (Valve 58.2)
a)
Loosen lock nut (2).
b)
Adjust pressure with set screw (3).
c)
d)

Secure adjustment by tightening lock nut (2).


Re-check pressure setting.

11.

The low pressure setting of the pressure increasing valve must now be
reset (with the pilot pressure line at port X still disconnected):
Setting procedure, low pressure stage (Valve 58.2)
a)
Stall the hydraulic with the bucket filling function (bucket
cylinders completely extended) and observe pressure at check
point M15.3.
b)
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

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9.0
9

26.03.03

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Hydraulic Track Tensioning System Section 9.0


Page 9

Cont'd.:
9.4

Adjustments / Checks
12.
13.

Switch OFF the 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

Table of contents section 10.0


Section
10.0

05.10.04

Page
Access ladder hydraulic operated
10.0 General

10.1

3+4

Function of hydraulic operated access ladder

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

Access ladder hydraulic operated


General
Legend for Illustration Z22494a
(A)
Access ladder in lowered position
(B)
Access ladder in upper position
(C)
Stop bar
(R1)
Slow ladder movement in both directions
(R2)
Fast ladder movement in both directions
(R3)
Slow ladder movement only towards final stop (C).
(Z)
Hydraulic cylinder
(S84) Ladder control switch for lowering
(S84a) Ladder control switch for raising.
(S84A) Pull switch for emergency lowering of the ladder.
(S22) Monitor and control sensor : Cut off of the pilot control system and
actuation of the slew brake as soon as the ladder leaves the range R3.
(S91) Control sensor. This sensor controls the moving speed in range R1.
The access ladder is hydraulic driven by the hydraulic cylinder (Z) via the 60
bar X4 pressure. S84 is the control switch to move the ladder up and down. It
is possible to lower the ladder without engine running. For lifting the ladder
the engine must run.

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

Function of hydraulic operated access ladder


illustration (Z 22495):
Legend:
(7.1+7.2)
(84.1+84.2)
(68.1)
(70.1)
(70.2)
(162.3 5)
(171)
(174)
(172)
Y125
Y123A
Y123B
X4

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

Table of contents section 11.0


Section
11.0

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

Hydraulic Oil Reservoir

Section 11.0
Page 2

11.0 Hydraulic operated refilling arm


General
Legend for Illustration Z22496
(A)
Refilling arm
(B)
Control switch (pull switch)
(B)
Hydraulic cylinder
(D)
Limit switch S23
(7.1+7.2)
Pilot Pump
(68.1)
Pilot filter with filter monitoring switch B22
(70.1)
Pressure relieve valve (60 bar)
(70.2)
Pressure relieve valve (35 bar)
(162.1+161.22) Check valves
Y124A
Solenoid valve: refilling arm up
Y124B
Solenoid valve: refilling arm down
Y125C
Solenoid valve: security valve refilling arm locking
(163)
Hydraulic cylinder
The excavator is equipped with a central refilling system for easy service and
maintenance. One part of this system is the movable refilling arm. This arm is
hydraulic driven by the hydraulic cylinder (C) and mounted below the power
frame.
The refilling arm can moved up or down by pull switch S23. For correct
operation of the refilling arm see OPERATION MANUAL:

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

Hydraulic Oil Reservoir

10.1

Section 11.0
Page 3

Function of hydraulic operated refilling arm


illustration (Z 22496):
Legend:
(A)
(B)
(C)
(D)
(7.1+7.2)
(68.1)
(70.1)
(70.2)
(162.1+161.22)
Y124A
Y124B
Y125
(163)

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

The engine is running


Additional to the hydraulic diagram from illustration Z22496 use the respective
electric diagram.
The pumps (7.1) and (7.2) are delivering oil through filter (68.1) to port P of the
solenoid valve Y124A/B and the pressure relief valve (70.1) port A. The pressure
relief valve (70.1) maintains the adjusted pressure of maximum 60 bar.
If the solenoid valves Y124A together with solenoid valve Y124C is energised
pressurised oil flows to the arm cylinder piston side and the refilling arm will
move up. If the solenoid valves Y124B together with solenoid valve Y124C is
energised pressurised oil flows to the arm cylinder rod side and the refilling arm
will move down.
Solenoid valve Y124C act as a security lock to prevent a uncontrolled down
moving of the refilling arm. This valve is a special 100% leek oil free valve.
All solenoid valves Y124A/B and C are PLC controlled. Control switch B (S87)
is connected to the PLC and act as a remote control. The refilling arm can only
moved down or up with activated key contact (key switch S1 in the cabin). Only
down moving is possible by gravity with engines stand still.

26.03.03

PC5500-6-D_Sec_11-0_rev0.doc

Hints for reading the


Hydraulic Circuit Diagram

Section 12.0
Page 1

Table of contents section 12.0


Section
12.0

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

Hints for reading the


Hydraulic Circuit Diagram

Section 12.0
Page 3

12.0 General:
Legend for Illustration Z22987

)
Item

22.12.04

The illustrations are used for exemplary explanations only.


Use original circuit diagram for detailed reading
There are more symbols on the following pages shown as in the
diagrams drawn. Some symbols of the diagrams not shown in the
following pages.
Description

Number / Code

Explanation

Diagram No. and Type of the 897 895 40 a


respective machine
PC8000-E

Respective Serial No.

Sheet-No. / Quantity of sheets 01 / 04

1st of four sheets

Co-ordinates to describe the


location of a component

Page 1 on co-ordinate C vertical


and 10 horizontal Remote control
valve 102.1

Component-No. 127

Line-No. with cross hint,

Diagram No. only for the


respective machine

12041
1 C 10

127
L37/3B9

Main control block I


Case drain line (Line No.37)
comes from / goes to sheet 2
coordinate E7

All the components drawn in neutral and pressure less position.


Full wide continues black line shows a main component or assembly. (Ex.: Valve
and Filter panel, Main pump, Hydraulic tank, ...)
Continues black line shows a main hydraulic line. This lines are temporary or
continues load with high or pilot pressure.
Broken line shows a return, drain or control oil line.
Black dot shows a connection point. The position of this connection is not definitely
fixed.
White dot shows a connection or port of a component with a fix definitely position
or port number.
Page 1 shows the high pressure main hydraulic circuits with all pilot control valves,
control blocks, distributor manifold and cylinders or motors.
Page 2 shows all main pumps and pilot pressure pumps with the main pump control
system, all other auxiliary pilot pressure circuits as lubrication system and ladder and
the auxiliary circuits with the fan drive and the oil cooling system with the hydraulic
tank and aspiration tank.
Page 3 shows the car body hydraulic with travel brakes, travel motors and track
tensioning system.

PC5500-6_Sec_12-0_rev3.doc

12.0
4

22.12.04

PC5500-6_Sec_12-0_rev3.doc

Hints for reading the


Hydraulic Circuit Diagram
12.1

Section 12.0
Page 5

Symbols
Illustration Z 22988
12.1.1 Lines, unions
Symbol

Description

Used as / at / on

Oil supply line, can be a


hose or a pipe.

Return oil line, can be a


hose or a pipe.

Case drain (leak) oil line,


can be a hose or a pipe.

Control oil line, can be a


hose or a pipe.

Crossed lines

Pipes or hoses not


connected

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

Plugged line inside of a


manifold, can be plugged
with different kind of plugs.

Not used connection


points.

22.12.04

Suction line or pressurized


line of main hydraulic circuit
or pilot pressure circuit or
auxiliary circuits (e.g. fan
drive).
Return lines, connected to
the return oil filter chamber
of the main oil reservoir.
Return lines, connected to
the case drain (leak) oil filter
chamber of the main oil
reservoir.
Pilot control line, pump
regulation line and parking
brake control lines.

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

Oil tank outlet to the


pumps

12

Blind, Orifice,
not adjustable with
orifice diameter in mm

e.g. Oil cooler inlet,

13

Pressure check point


With a special quick
coupling.

HP Filter, Fan valve


block....at all important
circuits

14

Distributor block

Connection of lines with


the same destination e.g.
return lines to tank

11

22.12.04

Tank drain couplings, often


removed lines (e.g. at grease
systems with removable
barrels).

PC5500-6_Sec_12-0_rev3.doc

Hints for reading the


Hydraulic Circuit Diagram
12.1

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

Input line to the remote


control valves, return oil
collecting tube, track
tensioning system

17

Oil cooler,

Hydraulic oil cooler,


PTO oil cooler

18

Breather filter,

On top of PTO or
hydraulic tank

19

Spray nozzles,
inside of a case for
cooling and lubricating

Gearbox (PTO) cooling


and lubricating system

15

16

Installed in suction lines to


the pumps, oil tank outlet,
return oil collecting tube

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

Pressure switch / sensor


Input = pressure
Output = electrical signal
analogue or digital

e.g. return / leak oil


chamber (digital), high
pressure filter (analogue)

21

Pressure switch
Input = pressure
Output = digital electrical
The switch point is 24 bar

e.g. swing or travel


detection PC3000,

22

Temperature sensor,
Input = temperature
Output = electric signal
proportional to the
temperature

e.g. hydraulic tank

23

Level sensor,
Input = fluid level
Output = electrical signal
analogue or digital

Hydraulic tank, fuel tank

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

Hints for reading the


Hydraulic Circuit Diagram
12.1

Symbols
12.1.4 Valves, valve components
Symbol

Description

Used as / at / on

25

Manuel operated unit


Lever

Valve in track tensioning


system,

26

Electric / magnetic
operated unit
Solenoid

Solenoid valve

27

Pilot pressure
controlled unit

Pressure relief valve, disc


brake, ...

28

Spring,
with fixed force

Solenoid valves,

29

Spring adjustable
spring force is adjustable

Pressure relieve valves,....

30

Check valve
In drawn pos.: from right
to left free flow, from left
to right blocked flow.

31

Check valve spring


loaded
Opened in flow direction
only against spring force
= pressure
Double check valve,
in drawn pos.: opened
only from the left to the
bottom or from the right
to bottom

e.g. main pump outlet,


swing brake valve block,
anti cavitation valves at
main control blocks or
distribution manifold
By pass of the return oil
filter, by pass of
secondary filter

32

22.12.04

Swing brake control,

PC5500-6_Sec_12-0_rev3.doc

12.0
10
12.1

33

Symbols

Symbol

12.1.4 Valves, valve components


Description
Used as / at / on
Shut-off Valve with
Gate valve between main oil
monitoring switch,
reservoir and suction tank
the adjustable switch
monitors the valve position

34

2/2 control valve


manual operated,
2/2 cock valve

Track tensioning system

35

3/2 control valve


manual operated,
3/2 cock valve

Change over valve from


electronically pump
regulation to emergency
mode (hydraulically
pump regulation)

36

4/2 directional control valve


as solenoid valve
4/2 way solenoid valve,
electrically controlled.
Neutral position:
P-A and B-T connected.
Variable throttle valve
hydraulically controlled
pilot control port pressure
less = maximum restriction
3/2 directional control
solenoid valve, seat
design = leak oil free
3/2 way solenoid valve,
neutral = port P-A open
4/3 directional control
solenoid valve
4/2 way solenoid valve,
in neutral all ports closed
External pilot
controlled proportional
floating valve

e.g. swing parking brake,


travel parking brake,
ladder controlling,,

37

38

39

40

22.12.04

Travel brake valve,


located in the car body

Service arm controlling

Ladder controlling,
service arm controlling

PC 3000 and PC4000


with floating system

PC5500-6_Sec_12-0_rev3.doc

Hints for reading the


Hydraulic Circuit Diagram
12.1

Section 12.0
Page 11

Symbols
12.1.4 Valves and valve components
Symbol

Description

Used as / at / on

41

Main control valve


Standard control valve for
standard function
two directions of cylinder or
In neutral position:
motor.
open pump flow (P-PU) and
control port flushing (T a, T
b), in position a or b closed
circulation port (P- PU)

42

Main control valve


pressure less lowering
Neutral position: open pump
flow (P-PU), control port
flushing (T a, T b)
Position b: closed circulation
port (P-PU), normal function
P B and B - T,
Position a: open circulation
port P PU, only port B T
connected
Main control valve floating
function
Neutral position: open pump
flow (P-PU), control port
flushing (T a, T b),
Position b: closed circulation
port (P-PU), normal function
P B and B - T,
Position a: open circulation
port (P PU) = A, B, T, P
connected together via tank
Pressure reducing valve,
assembly
Variable inlet pressure at port
B and constant lower output
pressure at port A, output
pressure is adjustable.

43

44

22.12.04

Control valve for pressure


less lowering. Used to assist
the floating function of boom
and stick,

Control valve with floating


function in position a,
e.g. floating valve for boom
or stick, .

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

Pressure relief valve,


direct controlled and
adjustable

e.g. ladder controlling,


service arm controlling ..

46

Pressure relief valve


with anti cavitation
valve (check valve)
Assembly, external drain
at port Y

Secondary relieve valve


at main control blocks

47

Pressure increasing valve


pressure relieve valve with
variable setting, pilot
pressure controlled via port
X. Low pilot pressure = low
relieve pressure

Swing brake block, track


tensioning system.

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.

Remote control valves to


control the main control
blocks,

50

Pressure relief valve,


mechanical and
hydraulically via pilot
port X adjustable, oil
drain port Y

Radiator and oil cooler


fan drive

51

Throttle check valve


with secondary relieve
valve, throttle and
secondary valve
mechanical adjustable,
external drain at port Y.

Distribution manifold
normally in the line to the
cylinder piston side.

49

22.12.04

Pump regulation, only


output port A is used for
our systems

PC5500-6_Sec_12-0_rev3.doc

Section 12.0
Page 13

Hints for reading the


Hydraulic Circuit Diagram
12.1

Symbols
12.1.5 Pump, motor, cylinder
Symbol

Description

Used as / at / on

52

Single acting Cylinder,


pressurised moving only
in one direction, return by
external force

Track tensioning system

53

Double acting Cylinder,


Cylinder in which the fluid
pressure operates alternately
in both directions (forward
and backward strokes)
A = Piston side
B = Rod side

Attachment i.e. boom,


stick, bucket or clam
cylinder

54

Drive shaft of a motor


or pump with one
direction

Main pumps, swing


motor, fan drive, travel
drive

55

Hydraulic pump with fix


volume per revolution
suction port S and pressure
outlet P

Fan pump, circulation


pump, pilot pump, PTO
lubrication pump

56

Hydraulic pump with


variable output volume
per revolution
with external case drain

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

Motor with disc brake


disc brake is spring
loaded it means:
pressure less pilot line =
maximal brake torque

Travel motor

61

Variable swing motor


with integrated control
valves and flushing
valves

Swing motor PC5500

22.12.04

PC5500-6_Sec_12-0_rev3.doc

Hints for reading the


Hydraulic Circuit Diagram
12.1

Section 12.0
Page 15

Symbols
12.1.6 Assembly and main components
Symbol

Description

Used as / at / on

62

Lubricant pump drive


differential cylinder with
integrated control valves
to propel the grease pump

Lubricant pump station


for central lubrication
system and swing ring
lubrication system

63

Swing brake valve


assembly,
act as a hydraulical back
pressure system parallel
to a motor with variable
pressure setting and
independent pressure
side. Input port A or B
and outlet on the opposite
connection to the motor..

Swing brake system.

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

Travel brake valve block


with secondary pressure
relieve valve
is connected in the line to
the travel motors. The
return oil flow is restricted
according to the pressure
inlet.

mounted in the supply


line to the travel motors,
is located in the car body

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

Remote control lever to


control the main control
blocks

Control lever in the


operators cabin

67

Remote control pedal to


control the main control
blocks

Control lever in the


operators cabin

68

Hydraulic oil tank with


leak and return oil filter,
back pressure valve and
sensors

Main hydraulic tank

22.12.04

PC5500-6_Sec_12-0_rev3.doc

Hints for reading the


Electric Circuit Diagram

Section 13.0
Page 1

Table of contents section 13.0


Section
13.0

Page
Hints for reading the electric circuit diagram
13.1

Designation of electrical devices

13.2

Symbols

3+4

13.3

General information

5+6

13.4

Reading a circuit diagram

7+8

Hints for reading the


Electric Circuit Diagram

Section 13.0
Page 2

13.1 Designation of electrical devices

Indicating letter
A
B

C
D
E
F
G
H
K
L
M
N
P
Q
R
S
T
U
V
W
X
Y
Z

Kind of component
System, subassembly, parts group, trigger boxes, control units
Transducer for conversion of non-electrical variables to electrical
variables, and vice versa.
Speed sensors, pressure sensors, pressure switches, oil-pressure
switches, temperature sensors
Condenser, capacitor, Condensers and capacitors, general
Elements with time lag, memory elements, binary elements
Various devices and equipment
Protection device
Fuses, current protection circuits
Power supply, generator
Batteries, generators, alternators
Monitor, alarm, signaling device
Indicator lights, signal lights, headlights, warning buzzers, horn
Relay, contactors
Inductor
Coils, windings
Motor
Regulators, amplifiers
Measuring instrument
High voltage switching units
Resistors, heating devices
Switches, selectors
Transformer
Modulator, converter from one electrical in an other electrical value
Semiconductor, electron tubes, diodes, rectifiers, zener diodes
Transmission path, conductor, antenna
Terminal, Plug, Plug and socket connection
Electrically actuated mechanical device
Solenoid-operated valves
Compensating units, filters, limiters cable connection

13.0
3

Hints for reading the


Electric Circuit Diagram

Section 13.0
Page 3

13.2 Symbols
Legend for illustration (Z 21816):
Our common used symbols in accordance to VDE/IEC (Association of
German Electrical Engineers DIN 40710 - 40716 and the International
Electrical Commission) differ for the most part from the symbols in
accordance to JIC/ASA (Joint Industrial Concil and American Standard
Association) USA and Canada JIC EMP-1-1967 and ASA 2 32-3).
For this reason the following comparative chart.
1) Normally open
contact

2) Maintained
contact

4) Normally
closed contact

5)

7) Manual operated
switch isolator,
disconnect switch
10) NO contact with
time lag

8) Foot-operated
push-button
switch
11) Multi-position
switch selector

13) Contacts with


time lag

14) Resistor
general

16) Battery

17) Tapped
resistor

18) Voltmeter

19) Inductive
resistance

20) Continuously
adjustable,
general

21) Recording
instrument

22) With iron core

23) Adjustable in
steps

24) Signal lamps


pilot lights

25) Continuously
adjustable

26) Potentiometer
rhesostat

27) Operating coil


solenoid

28) Transformer

29) Capacitor
general,
continuously
adjustable

30) Rectifier, semi


conductor

Push-button
switch

3) Single pole
two way contact
break before make
6) Limit switch
NO contact
NC contact
9) Pressure
operated switch
12) Indicating
instrument
(general) symbol
15) Ammeter

13.0
4

Hints for reading the


Electric Circuit Diagram

Section 13.0
Page 4

13.2 Symbols
Legend for illustration (Z 21817):
31) Rectifier bridge

32) Thermal over load limit

33) Phase, 4-wire system

34) Current transformer

35) Undervoltage relay

36) Junction of conductors

37) Voltage transformer

38) Temperature relay

39) Junction

40) Circuit interrupter

41) Contactor

42) Terminal

43) Circuit breaker, three


phase

44) Generator (G)Motor (M)

45) Terminal

46) Thermal over- ground,


load protection

47) 3-phase-motor

48) Earthing, general

49) Magnetic over- socket


current protection

50) 3-phase squirrel cage

51) Plug and

52) Slipring motor

53) Fuse with bolted contacts 54) 3-phase squirrel cage


induction motor in
Star-delta starting
55) Thermal over- load relay 55) Two speed motor
(tapped windings)
(for ex. 8 to 4 poles)

13.0
5

Hints for reading the


Electric Circuit Diagram

Section 13.0
Page 5

13.3 General information


Legend for illustration (Z 21823):
Komatsu circuit diagrams
Each sheet has the following information in the bottom right hand corner:
Diagram Number
example: 897 844 40
Machine Type
example: PC4000-6
Sheet Number and Total Number of sheets 01/63 - 02/ . etc.
Each sheet is numbered from 8 (at the left corner) to 1 (at the right corner) along the
top and bottom lines, and lettered down from F (at the top) to A (at the bottom)
along the left and right side lines.
This coordinate system enables you to find components easily.
On the table of contents, page one, the individual circuits are listed up with the
respective page number.
Example: The circuit for the superstructure lighting is shown on page 39.
Pages number two, three and four are cross reference lists of component codes
related to page numbers.
Example: The relay with the component code K1-1 is shown on page 8.
On page five is a list of answers to frequently asked questions (FAQ) concerning
abbreviations, function of components (e.g. time relays) mathematical symbols etc.
used in the diagram.
All electrical components are connected via cable harnesses to the main switch
board X2. There is only one Plug connector in between, which is always located
close to the respective component like sensors, solenoids etc.
All 24 volt wires are blue and have a printed code (every 10 cm) at each end of the
wire. (see illustration)
The first part of the code shows the required connection and the second part gives
the information what is connected at the other side of the wire.
Example:
going to
coming from
coming from
going to

X2S
45

= X2-Board, terminal group S


= Terminal No 45

Y136 = Plug connector to solenoid


.1 = Terminal 1 of connector

All circuits are shown currentless and all relays and switches are in neutral position.

13.0
6

Hints for reading the


Electric Circuit Diagram

Section 13.0
Page 6

13.3 General information


Legend for illustration (Z 21824):
Explanation of the Drawing Concept
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)

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

Location of the Main Terminal Boxes


(X1)
Dashboard inside the cabin
(X2)
Main switch board inside the cab base
(3E14-1) Electronic control module (ECM- Quantum) left bank of the engine
(3E54-1) Electronic control module (ECM- Cense) flywheel end of the engine

13.0
7

Hints for reading the


Electric Circuit Diagram

Section 13.0
Page 7

13.4 Reading a Circuit Diagram.


Legend for illustration (Z 21825):
Examples are shown by sectional drawings out of the electric circuit
diagram 897 844 40 page 08.

)
(1)

Section F8 / sheet 08
The hint F11/06.1 indicates that the wire from F11 is continued on
sheet 06 column 1.

(2)

Section C4 / sheet 08
Shown is the relay coil K51-1 only and not its contacts.
The contacts are shown somewhere else in the diagram.
Switching and contact positions are shown below at the foot of that
particular circuit in row C-C as shown below.

Example for K51-1:


08.5
:
:
:

1
5
2
6
3
7
4
8

9
10
11
12

opens on sheet 8 section 5 when relay is energized


Not used
Not used
Not used

When diodes are fitted to a relay, they are fitted to allow a current flow in one
direction only. An LED* (Light Emitting Diode) indicates a current flow if it
lights up.
When diodes ** are fitted anti-parallel to a relay coil, they absorb the high
induced voltage caused by making and breaking the current flow through the
coil.
This occurs each time we operate a switch supplying current to the coil. The
diode effect allows the induced current to circulate within the coil windings and
decay when the energy to the coil is cut.
*
**

LED between A1 and coil


Diode between A1 and A2.

(3)

Section F7 / sheet 08
Connectors and Terminals are identified by a letter and number
code. X2 o 23-28 = Terminal box X2 Terminals 23 to 28 are linked
with a metal bridge.
continued

13.0
8

Hints for reading the


Electric Circuit Diagram

Section 13.0
Page 8

Cont.:
13.4 Reading a Circuit Diagram.
Legend for illustration (Z 21826):
(4)

Section E 1 sheet 08
The components have a letter and a number prefix, and these are
explained below in rows A and B.
Components are depicted in a system unique to VDE/IEC
(Association of German Electrical Engineers DIN 40710-40716 and
the International Electrical Commission) or to KMG standard.
S27 = Toggle switch (with non-automatic return)

a.

F11

b.

F11 / 10.5 =

Power line F11, comes from circuit breaker F11, sheet


08 section 8 and continues on sheet 10 section 5.

c.

S27 / 20.7 =

Line S27, comes from switch S27, sheet 08 section 1


and continues on sheet 20 section 7.

Circuit breaker (24V power supply)

Function:
If switch S27 is actuated, terminal A and B are connected and 24VDC will
energize the coils of K121 and K121a on page 08 and simultaneously via line
S27 a digital input to the PLC on sheet 20 section 7.
Now the machine can be operated in emergency mode and a warning text
appears on the display.

Electronic Control System


ECS

Section 14.0
Page 1

Table of contents section 14.0


Section
14.0

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

General Design of the ECS-T System

14.1.1
14.1.2
14.1.3
14.1.4

3
3
4
5 + 6 +7

Input and outputs of the PLC


Task
PLC DIGSY plus
Definitions; Symbols and Abbreviations

How to Proceed due Maintenance and Installation

8+9

14.2.1
14.2.2
14.2.3

10 + 11
12
13

Meaning of the Status LEDs


Short Circuit Marker -LED MK
Diagnostic for Temperature-Module ANM

Front Connector Arrangement

14

14.3.1
14.3.2
14.3.3
14.3.4

14 + 15
16 + 17
18
19

Front Connector Arrangement BIM-Module


Front Connector Arrangement, ANM-Module
Ground connection of the Control Unit
Interface-Connection COM SP /SK

Power supply

20

14.4.1
14.4.2
14.4.3
14.4.4
14.4.5

20
21
22
22
22

Operation Voltages +24 V


Safety Precautions for Faultfinding
CPU Voltage Range
Electric Classification
Fuse

Function explanations with electrical diagram

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

Hints for reading the functional flow charts

28

14.6.1
14.6.2

28
29

General
Example

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14.0
2

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Electronic Control System


ECS

Section 14.0
Page 2

14.1 General Design of the ECS System


ECS

Electronic Control System

Legend:
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
I/ O

Illust. Z 21407a

PLC Programmable Logic Control (DIGSY plus )


Text display
Keys for function control and pre-adjustments
Outlet X27 for data transfer
Field computer system (like MODULAR MINING)
Printer
Memory card unit
Laptop
Input / Output data transfer
Items 5 to 8 are optional equipment

Meaning of the PLC front cover codes

BIM
Binary Module

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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Electronic Control System


ECS
14.1.1

Section 14.0
Page 3

Input and Output of the PLC, Illust. Z 21408


PLC = Programmable Logic Control
(Programmable Logic Control = Control system with a write-readingmemory, whose content can be altered (via an serial interface) by a PC and
the resp. Software.
No mechanical action necessary.)

14.1.2

Task
The PLC receives from the monitored excavator components the actual
values and does an evaluation.
The evaluation results in a control and display function.
See I / O connection table (chapter 10) and electric circuit diagram for I / O
levels and ports.

PC5500-6-D_Sec_14-0_rev2.doc

The picture shows as an example the application for a two motor


version.

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14.0
4

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Electronic Control System


ECS
14.1.3

Section 14.0
Page 4

PLC DIGSY plus (circuit diagram code E6)


Legend for illustration Z 21409b
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

Central Processing Unit (CPU) board.


Binary Module (BIM) board.
Analogues Module (ANM) board.
MK Output short circuit marker LED red
Input state-LED green, Inputs E1.1 - E1.8 up to E14.1-E14.8
Input or Output State-LED red (A2/ E9, Af/E10, A6/E11,
A8/E12, A14/E21) Can be used as Inputs or Outputs
Output state-LED red, Output A1.1 - A1.8 up to A13.1-E13.8
Diagnostic-LED (DIAG), (green flashing = OK.)
5Volt Voltage-LED (+5V), (green = OK.)
Diagnostic LED for ANM
COM SP Interface (COM SP) (Text display connection)
COM SK Interface (COM SK) (PC-Connection)
Binary Module BIM-plug-in location (slots) (X1-X5)
Analogous Module ANM-plug-in location (slots) (X6-X8)
Ground Connection (GND)

The quantity and configuration of the BIM and ANM Module can be
vary, depend on the excavator typ and additional options.

MK-LED, The short circuit marker are used to indicate an external short to GND
MK1, MK3, MK5, MK7 & MK9- LED for outputs A1.1 - A1.8
A3.1 - A3.8, A5.1 - A5.8, A7.1 - A7.8 & A13.1 A13.8
MK2, MK4 , MK6, MK8 and MK10 if there groups as outputs used
A MK-marker is placed, if an output (e.g. A1.1) gets from the program an output signal
and at the same output happens an external short. The red MK 1-LED lights ON

If there is a short all outputs of the resp. Output group i.e.. A1.1 - A1.8)
are switched Off
The short circuit marker remains until the control system gets switched
Off/ON (after eliminating the short).

State-LED Input lights up with a present 24 Volt signal.


State-LED Output lights up with a switched On output.
5V-LED, indicate specified operation states by different colors and duration of
lightning (Continuos On or flashing). For detail information see Section 4.
DIAG-LED, indicate specified operation states by different colors and duration of
lightning (Continuos On or flashing). For detail information see Section 4.

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Electronic Control System


ECS
14.1.4

Section 14.0
Page 5

Definitions; Symbols and Abbreviations

Bit

Sign used for corresponds to


Sign used for not equal to
A bit is the smallest unit for information. It can assume only two
conditions: logical 0 or logical 1 ( also referred to as logical L-Level and
logical H-Level).

Boolean algebra Mathematical rules for binary variables and conditions. For Boolean
equations the following signs are used:
Logical AND operation (AND or &)

Logical OR operation (OR or >=1)

Logical Negation (NOT or 0)

Byte

Unit for Information unit comprised of 8 bits. A byte can assume a value
between 0 and 255.

Word

Memory unit comprised of 2 byte or 16 bit. A word covers the numeric


range from 32767 to +32767.

Clock

Signal pulse

VWP

VerWaltungProgramm: (management program) A control program


created by the user.

AWP

AnWender Program: (Application program, user program) A control


program created by the user.

AWL

AnWeisungsListe: (instruction sequence) Representation of a program


using alphanumeric signs and symbols as defined in DIN 19239.
Programming in AWL (selection logic) is the at present widely applied
method of programming.

CMOS

Complementary Metal-Oxide Semiconductor: Complementary metaloxide semiconductor technology with very low-level closed circuit
current. These semiconductors are used above all for accumulator and
battery buffering.

RAM

Random Access Memory: Read-write memory in which each memory cell


can be addressed in order to read, write or delete at any time. RAM losses
all of its information when the computer is turned off which is why it is
often buffered by accumulators or batteries.

EPROM

Erasable Programmable Read Only Memory: Read-only memory erasable


by ultraviolet light and electrically programmable. With this memory type,
the contents remain intact in the event of a power failure. In the case of
DIGSY plus this memory contains the management program (firmware).
continued

PC5500-6-D_Sec_14-0_rev2.doc

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Electronic Control System


ECS
14.1.4

Section 14.0
Page 6

Definitions; Symbols and Abbreviations

Cont'd:
EEPROM

Electrically Erasable Programmable Read-Only Memory (also called


E2PROM):Electrically erasable and programmable memory. In the event
of a power failure, the contents of this type of memory remain intact. The
DIGSY plus application program (AWP) is loaded into this type of
memory.

COMPILER A program that translates the instructions of a programming language


(e.g. instruction sequence [AWL]) into machine code (processor
instructions).
EDITOR

Utility program for the creation and changing of programs.

Loop

Program loop.

Off-Line

Operational method of a programming device without attached


automation device.

On-Line

Operational method of a programming device (PC) is connected to the


automation device thereby enabling data and programs to be read or
changed.

PC

Personal Computer: Programmable unit for the DIGSY plus .

Watch-Dog: Internal supervisory unit in computers and automation devices used to


recognize system and memory errors.
CPU

Central Processing Unit: Control and central unit in an automation


device usually based on a microprocessor. It can read the application
program code and run the instructions contained therein.

Cycle Time

Time required for the application program to run through once.


continued

PC5500-6-D_Sec_14-0_rev2.doc

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Electronic Control System


ECS
14.1.4

Section 14.0
Page 7

Definitions; Symbols and Abbreviations

Cont'd:
Coding Types and Number Systems
ASCII

American Standard Code for Information Interchange: A standardized


information processing code developed in the USA based on
7 bits = 0 127 (7-bit code), (extended ASCII-code of 8-bit = 0 - 255)

Digital

(Eng. Digit) is the representation of a continuos value or a physical


quantity (e.g. voltage) in several levels as a numeric value.
With regard to automation devices one also refers to word processing
in which case a word is a number (e.g. 573).

Analogue

is the representation of a continuos physical quantity (e.g. current or


voltage) which corresponds to the value of a proportional condition
(e.g. rotational speed, routing, temperature, etc.)
For an automation device this physical value converted into 1024 levels,
for example (10-bit analogues-digital conversion). The digitalized value
thus acts within a defined range (e.g. 0 0 volts to 1024 10 volts) in
proportion to a certain input quantity (e.g. voltage). Conversely, by using
a digital-analog conversion, a digitalized value can be converted into a
continuous output signal (current, voltage).

Numeral

A value expressed in one digit: from 0 to 9 in the decimal system and 0-F
in the hexadecimal system.

Number

Value consisting of one or more numeric characters.

Baud

Unit used in serial transmission of data: bits per second (bit/s).

Baud Rate

Modulation rate or transmission speed of serial transmission of binary


numbers. The DIGSY plus uses a baud rate of 2400 baud for
communication and down-loading.

Binary

Numbers, data and information which are exclusively expressed using


the two values 0 and 1 are bivalent = binary dates and information,
exclusive with the use of digits 0 and 1 (e.g. 1 = current 0 = no current).

Dual(Binary) Number (Dual = 2) is the simplest binary numeric expression. Each


position is arranged according to increasing powers of 2.
Example: 13463dec. = 0011 0100 1001 0111dual

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Electronic Control System


ECS
14.2

Section 14.0
Page 8

How to Proceed due Maintenance and Installation

Keep in mind
- BE CAREFUL
- BE ALERT
- THINK ABOUT WHAT YOU ARE DOING
Any PERSON doing any work in or around the machine must be familiar
with the local SAFETY INSTRUCTIONS and with the specific SAFETY
INSTRUCTIONS REGARDING TO HIS OCCUPATION.
Serious damage may happen at unqualified actions at the System or
Unit or when not paying attention to the hints given in this manual or
on labels at the units
Qualified persons in sense of the safety relevant hints in this manual or on the
product, are persons which are
either as project engaged person familiar with the safety concept for
automatic control systems;
or as operating personal for the use of an automatic control system being
instructed;
or having the authorization and occupation to put such systems into operation
or doing repair work as well as having the authorization and occupation to put
such systems/units into operation regarding the power
circuits and there safety standards and, to earth and to mark it.
continued

PC5500-6-D_Sec_14-0_rev2.doc

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Electronic Control System


ECS
14.2

Section 14.0
Page 9

How to Proceed due Maintenance and Installation

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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Electronic Control System


ECS
14.2.1

Section 14.0
Page 10

Meaning of the Status LEDs, Illust. Z 21431b


The DIGSY plus performs by the function of the Status LEDs (5V and DIAG) and
the so named Diagnostic Words* (DW1 up to DW256) many data and statuses.
With a PC and the Program- and Diagnostic Software the. Diagnostic Words are
visible on a monitor.
The following sections explain the diagnostic possibilities more in detail.
* Can be called-up by PC assistance only.
Table: Statuses of the +5 V-LED and their meaning
LED
Effect
Cause
5 V-LED
Voltage
green
o.k.
5 V-LED
CPU not working
Supply
red
(RESET)
< 4,65V
DIAG-LED red
5 V-LED
CPU not working
Supply
OFF
(except the
is missing
LED is defect)
Fuse S1
defect

Remedy
Check the
+24 V Supply
if not o.k. *)
Check the
+24 Volt
Replace the **
Fuse F1

LED defect
(if DIAG
LED is ON)

*)

others

*)

Watchdog
in operation

*)

5 V-LED
flashing
red/green

cyclically
new starts

red/
orange
Continuos Reset
Component fault
*)
** 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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Electronic Control System


ECS

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

Increase the voltage

Accumulator voltage
too low

Replace the
accumulator module

Fixed operands
deleted

Check the
accumulator
connections

SPS in start loop


after voltage ON

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

Load program *1)


*2)

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14.0
12

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Electronic Control System


ECS
14.2.2

Section 14.0
Page 12

Short Circuit Marker -LED MK


The short circuit markers are used to indicate a short of the outputs at an external
short to GND.
A MK marker will be initialized if by the user-program an output signal is
given and at the same output is an external short present.
The MK marker remains until (after short elimination) the control system is
switched OFF and ON.
See also Section 14.1.3 page 4

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13

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Electronic Control System


ECS
14.2.3

Section 14.0
Page 13

Diagnostic for Temperature-Module ANM


For the function control a two-color LED is used, visible at the front cover.
The diagnostic - LED indicates following states:
- LED red:
System in reset mode or range overflow of
one or more analogous outputs.
- LED green:

Ordinary operation, no range overflow.

- LED red/green flashing (2Hz) Watch-dog timer response or cyclically


overflow of one ore more analogous outputs.

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Electronic Control System


ECS

Section 14.0
Page 14

14.3 Front Connector Arrangement


14.3.1

Front Connector Arrangement, BIM Module (Digital Input / Output)

.This is an example for the first Slot. Additional BIM Modules can
be vary depend on configuration of the variable input/output port
A2/E9/ A4E10, A6/E11, A8/E12 or A14/E21.
The configuration for the respective excavator is written in the
EA-Configuration chart (EA-Belegungsliste) see Apendix.

Pin
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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Electronic Control System


ECS

Section 14.0
Page 15

14.3 Front Connector Arrangement


14.3.1

Front Connector Arrangement, BIM Module (Digital Input / Output)

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).

E1, E2,...E7, E13 and E14 input port fix configured.


A2/E9, A4/E10, A6/E11, A8/E12 and A14/E21 variable input or output
ports depend on software programming.
A1/A9, A3/A10, A5/A11, A7/A12 and A13/A21 output ports fix
configured.

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Electronic Control System


ECS

Section 14.0
Page 16

14.3 Front Connector Arrangement


14.3.2

Front Connector Arrangement, ANM-Module (Analogues Input)


.This is an example for the first ANM slot. Additional ANM modules
configuration can be vary depend on configuration (temperature or
pressure).
The configuration for the respective excavator is written in the EAConfiguration chart (EA-Belegungsliste) see Appendix and the
respective electric diagram.

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

All pins are internal connected


continued

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Electronic Control System


ECS

Section 14.0
Page 17

14.3 Front Connector Arrangement


14.3.2

Front Connector Arrangement, ANM-Module (Analogues Input)

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

All pins are internal connected

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Electronic Control System


ECS

Section 14.0
Page 18

14.3 Front Connector Arrangement


14.3.3

Ground connection of the Control Unit


Attention: The complete shield of the analogous cable must be connected to the
ground (GND) bolt of the PLC housing. This bolt must be connected to the
X2 frame / machine ground by a cable (as short as possible) with 2,5 mm2
cross section.
When using plug connectors with metal boxes and connected shield the
additional complete shielding of the analogous cable with the ground bolt
is not necessary. But attention must be played that the metal box is
connected by screws with the PLC housing.
The twisted signal lines are pair wise shielded and already via the 50-pol
female part of the connector connected to ground. The single shielding at
the free end of the cable must not be connected with earth.

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14.0
19

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Electronic Control System


ECS

Section 14.0
Page 19

14.3 Front Connector Arrangement


14.3.4

Interface-connection COM SK / SP

Legend for illustration Z 21425a (Exemplary picture about what possible)


(1)
Text display
(2)
PLC
(3)
Plug socket X27
(4)
Laptop computer
(5)
Memory card system
(6)
Portable printer
(7)
Field dispatch system
Cables:
VL3
VL4
VL5
VL6
VL7
VL8

X27 to Laptop
X27 to Memory Card System
24V Power supply to Memory Card System
X27 to Portable Printer
24V Power supply to Portable Printer
X27 to Field Computer System

Communication interface:
COM-SK => Programming interface (Baud rate 19200)
COM-SP => Communication with text display (Baud rate 9600)

Data cables and/or communication systems are optional equipment.


For more detailed information see OPERATION MANUAL of the
shovel
and the Software Program for the individual Communication System

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20

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Electronic Control System


ECS

Section 14.0
Page 20

14.4 Power supply


14.4.1
Operation Voltages +24 V, Illust. Z 21426
Study together with the relevant circuit diagram
50-pin SUB Connector:
+ 24 V CPU-Supply:
GND:
+ 24 V I/O-Supply:

Pin 33 and 49
Pin 17 and 50
Pin 30 - 32, 46 48

This supply voltage is the operating voltage for the module outputs. It must
be strong enough to carry the load current of all outputs.
It is provided with a LOAD-DUMP protection to protect (for short times)
wrong polarity and over voltage peaks.
Wrong polarity causes destroying of the module!
External 24 V supply to the outputs causes destroying of the module!

See next page for more information

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21

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Electronic Control System


ECS

Section 14.0
Page 21

14.4 Power supply


14.4.2

Safety Precautions for Faultfinding, Illust. Z21427

As already mentioned no external 24 V supply is allowed to the


outputs of the BIM modules of the PLC.
If it is necessary while tracing faults, the cable to the PLC must be
disconnected subsequent to a component check, thus as relays,
solenoids or others by the PLC controlled components.
Procedure: Study together with the relevant circuit diagram
1.
Find the terminal between the component and the PLC.
2.
Example terminal 8X2-280 for the solenoid valve 8Y6.1.
3.
Disconnect the wire on one side of the terminal.
4.
5.

Now supply 24 V to the solenoid and check function of it.


Finally re-connect the wire to the terminal

Binary Outputs A
2A-Short circuit proof
Each single Output of the Output group can withstand a load of 2A, but the
total load must not exceed 10 A. The Output group will be switched OFF if
one of the Output becomes overloaded (> 2 A), the short circuit marker will
be set and the MK- LED comes ON.
(A1 MK1, A3 MK3, A5 MK5)

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Electronic Control System


ECS

Section 14.0
Page 22

14.4 Power supply


14.4.3
CPU Voltage Range
Electrical requirements +24 supply volt
14 V up to 36 V without any restrictions regarding the max. current
consumption of 4 amps out of the +5 V logic voltage.
At voltage drops below 18 V the 2amps-outputs switched OFF due to
safety reasons. The short circuit markers initiated.
The +24 V CPU is monitored on the CPU plus
DB16.1
After the diagnostic bit Under-voltage UCPU DB16.1 has been set, all
access to the EEPROM memory of the CPU plus is blocked
A drop below 9V results in a reset.
During and after voltage drops according to DIN 40839 part 2 operates the
CPU plus normally.

14.4.4
Electric classification
The voltage supply meets the requirements according to:
ISO 7637-2 Automotive Technique 24V
DIN 0871-B
IEC 801-4 step 4, VDE 0843-4.
DIN/VDE 0470 part1 (old DIN 40050)

14.4.5
Fuse
TR5 / 2.5AT IEC 127-3 Manufacturer Wickmann,

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Electronic Control System


ECS

Section 14.0
Page 23

14.5 Function explanations with electrical diagram


14.5.1

General

Signal Status
Voltage level:
1 = 24 V* between E (Input) and GND
0 =

0 V** between E (Input) and GND

* 13 V up to actual supply voltage


** 0V up to 5 V

The left half of the picture shows so named PULL-DOWN resistors and the
right half PULL-UP resistors. The resistors are installed to get a low ohmical
input. A system with contacts only leads to a (high ohmical) input if dust or
moisture bridges the contacts.
PULL-DOWN resistors are installed with a normal NC contact (means with a
de-energized relay or normal closed switch contact) thus the ECS recognize a
fault after switching ON the system.
PULL-UP resistors are installed with a normal NO contact (means with a deenergized relay or normal open switch contact) thus the ECS recognize a fault
after switching ON the system.

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14.0
24

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Electronic Control System


ECS

Section 14.0
Page 24

14.5 Function explanations with electrical diagram


14.5.2

Pressure Measuring (Hydraulic System), Illustration Z 22805


(study with the respective circuit diagram)
(Program run see Flowchart)

Analogous Inputs:
EW 14.1 for pressure sensor B87A (0 up to 500 bar)
Measuring channel: 0......10 V
Function:
- Voltage supply for the pressure sensor: 24 V
- Output voltages Ua (OUT+, pin 2) of the pressure sensors:
Sensor 0 0,4 bar
K= 25 V / bar
Sensor 0 60 bar
K= 0,1667 V / bar
Sensor 0 500 bar
K= 0,02 V / bar
(Pressure sensors with +1 V Offset)
Possible voltage checks:
24 V Supply between supply line 15 (start at circuit breaker) and GND.
Output voltage OUT (pin 2) of the sensor
between GND. Use respective circuit diagram for terminal numbers.
* How to calculate the Output voltage Ua:
Ua = output voltage proportional to the pressure input.
P = input pressure
K = calculation factor for the respective pressure sensor.
Ua = (P x K) + 1 V
Example for 200 bar and a 0 500 bar sensor:
Ua = (200 x 0,02) + 1 V = 5 V

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25

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Electronic Control System


ECS

Section 14.0
Page 25

14.5.3 Temperature Measuring and trouble shooting Illustration Z22803a


General:
(study with the respective circuit diagram)
The signal of the PT100 temperature probe cant connect direct to the ANM
Module (Analog input of the PLC). A temperature transducer module change
the PT100 signal (Ohm) into a suitable current (mA) signal for the ANM
Module. The temperature probe is connected with a four wire technique to
compensate the line resistance of the long wire between the X2 switch board
and the temperature probe.
Analogous Inputs (eg.: Hydraulic oil temperature sensor B15)
The temperature probe B15 is with 4-wire technology (distorting compensation)
connected to the transducer U15 terminal 1, 4, 2, and 3 (measuring range: -50
C......+150 C). The output terminal 5 and 6 of the transducer is connected to the
ECS analogues input EW 2.1 (input range 4 20 mA). The transducer need 24
V power supply via terminal 7 and 8 (+24V, ground).
Function:
The temperature transducer convert the
measured values from the PT100 temperature
probe into electrically standardized analog
signals. With the four wire technique the length
and the cross section of the wires are not
important; because the electrical resistance of the
two current lines gets compensated. The sensor
is supplied with a low electrical current from the
temperature transducer (I+ and I-). Additional to
the temperature probe (PT100) resistance the
line resistance influence the current flow what
falsified the PT100 measurement. To
compensate the line resistance there are two
additional lines (U+ and U-) close to the PT100
connected. Via this lines the transducer measure
exact a tension drop between in- and output of
the PT100 probe witch is only created by the
PT100 resistance. Because there is no current flow through this lines witch
are influenced by the line resistance (compared to hydraulic system- its like
a test hose with a pressure gauge). The module convert this tension drop into
a current signal (4-20mA) which is proportional to the temperature.
In the interest of proper function must the line resistance not exceed 50 .
Additional the lines must be shielded according to the standards. The picture
shows the wiring of a PT100 probe to a temperature transducer in four wire
technique.
continued

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14.0
26

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Electronic Control System


ECS
14.5.3

Section 14.0
Page 26

Temperature Measuring and trouble shooting, illustration Z22803a


Contd.:
Possible measurements PT100:
Disconnect the wires at the resistor and measure the resistance across the
resistor.
Compare the measured resistance with the values given in the table on next
page.
If the value correspond to the temperature measured with an other temperature
gauge the PT100 resistor is OK.; otherwise replace resistor.
Wiring:
Disconnect the wires at the resistor and inside X2-box at the temperature
transducer terminal 1, 2, 3, and 4.
Measure the line resistance to the ground.
All single wire resistance must be the same.
Transducer:
Connect a Ampere-meter in line between terminal 5 of the transducer and the
disconnected wire to the ECS. Select mA range and check the current. The value
must compare to the PT100 resistance with the following calculation:
I = [( 50 + t ) x 0,08 ] + 4
t = temperature [C]
(Check temperature via PT100 resistance and temperature chart next page)
I = current [mA] to the ECS

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Electronic Control System

Section 14.0
Page 27

ECS
14.5 Function explanations with electrical diagram
14.5.4

Temperature Resistance Chart PT100


Basic Values in Ohm according to DIN 43 76
For Measuring Resistor PT100

-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

123,62 124,01, 124,39

124,77

125,16

125,54

125,92

126,31

126,69

70

127,07

127,45

127,84

128,22

128,60

128,98

129,37

129,75

130,13

130,51

80

130,89

131,27

131,66

132,04

132,42

132,80

133,18

133,56

133,94

134,32

90

134,70

135,08

135,46

135,84

136,22

136,60

136,98

137,36

137,47

138,12

100

138,50

138,88

139,26

139,64

140,02

140,39

140,77

141,15

141,53

141,91

110

142,29

142,66

143,04

143,42

143,80

144,17

144,55

144,93

145,31

145,68

120

146,06

146,44

146,81

147,19

147,57

147,94

148,32

148,70

149,07

149,45

130

149,82

150,20

150,57

150,95

151,33

151,70

152,08

152,45

152,83

153,20

140

153,58

153,95

154,32

154,70

155,07

155,45

155,82

156,19

156,57

156,94

150

157,31

157,69

158,06

158,43

158,81

159,18

159,55

159,93

160,30

16067

Example:

84 C

80 + 4 = 132,42

124,4

124,4 124,39 = 60 + 3 = 63 C

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Electronic Control System


ECS

Section 14.0
Page 28

14.6 Hints for reading the functional flow charts


14.6.1

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.

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29

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Electronic Control System


ECS

Section 14.0
Page 29

14.6 Hints for reading the functional flow charts


14.6.2

Example: Monitoring the X1-pressure for pump control,


illustration Z25072
Grey shaded fields in the table below shows the normal way , used from the program,
if the excavator is in standard condition.
Item
1)

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?

Fault message No 1190


Motor X is running for
more than 15 seconds
B85-X : 2 sec. > 40bar
i.e. > 6,5V at EW13.3

Motor X is not running


B85-X : 5 sec. : Voltage
below 6,5V at EW13.3

Fault message No 962

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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

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15.0
2

Lubrication System

Section 15.0
Page 3

Lubrication System

General Function

Legend: illustration Z 24042a


(1)
Lubricant pump drive (Hydraulic cylinder)
(2)
Solenoid valve (Oil pressure supply)
(3)
Flow control valve
(4)
Pressure reducing valve
(5)
Hydraulic oil supply line (Pilot pressure)
(6)
Hydraulic oil return line
(7)
Vent valve (Solenoid valve, de-energized open to barrel)
(8)
(9)

Grease supply line to injectors


Lubricant level indication (capacitively analog sensor)

(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

Cylinder pressure must not exceed 650 psi (45 bar)

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

Function of a lubrication cycle

Section 15.0
Page 5

illustration Z24042c and Z22023a

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

Y8a, CLS (2)


Y9, SLS

Y9a, SLS

B46, SLS

SLS = Slew Ring Teeth Lubrication System


CLS = Central Lubrication System
(*) check respective circuit diagram
continued
05.10.04 rev.5

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

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8

Lubrication System

Section 15.0
Page 9

Lubrication System

Oscillation Cylinder and Control Block, illustration Z 21174

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

If the required pressure cant be adjusted, check adjustment of the 60


bar pilot pressure valve (X-4 pressure) at the filter and control panel in
the machinery house.
PC5500-6-D_Sec_15-0_rev1.doc

15.0
12

Lubrication System

Section 15.0
Page 13

Lubrication System

One line system


Legend: illustr. Z 21176
(1)
Lubricant pump drive (Hydraulic cylinder)
(2)
Solenoid valve (Oil pressure supply)
(3)
Flow control valve
(4)
Pressure reducing valve
(5)
Hydraulic oil supply line (Pilot pressure)
(6)
Hydraulic oil return line
(7)
Vent valve (Solenoid valve, de-energized open to barrel)
(8)
Grease supply line to injectors
(9)
Lubricant level indication (capacitively analog sensor)
(10)
Lubricant barrel
(11)
Pump mechanism
(12)
Lubricant filter
(13)
Hydraulic pressure test plug (Operating pressure)
(14)
Lubricant pressure gauge (Operating pressure)
(15)
Vent line to barrel
(16)
End-of-line switch
(17)
(Pressure check point)
(18)
Injector block
(19)
Lubricant feed line to bearing

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

Grease qualities to be used:


According to NLGI classes 000, 00, 0 and 1 according to the lowest
ambient temperature in the operation area

1. The content of molybdenum must not exceed 5 %.


2. Only synthetic graphite allowed in graphite contained lubricants

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

Electrical function. illustr. Z 21177a

It follows an exemplary explanation for a central lubrication system


for machines equipped with PLC System. For details see the circuit
diagram of the respective machine. The Lubrication Systems are
PLC controlled. No relay adjustment necessary.
Central lubrication system controlling :
The PLC from the ECS System controls the whole lubrication systems.
The solenoid valves (Y7, Y7A or Y9, Y9A) on top of the lubrication stations are
direct connected to digital output ports of the PLC.
On a few machines there are additional relays between PLC outputs and the
solenoid valves.
Depend on a PLC input from the end-of-line pressure switch (B43 or B46) and a
PLC internal time counter the grease system start a lubrication cycle.
The lubrication cycle starts.
If the pause time elapsed the PLC energize both solenoid valves (Y7, Y7A or
Y9, Y9A) of the respective lubrication system. The engine must run in high idle.
The pilot pump pressure activate now the lubrication pump and the lubrication
pressure to the injectors increase.
If the lubricant pressure reach the adjusted pressure of the end-of-line pressure
switch (B43 or B46) its contact change and the PLC input signal change.
The PLC de energize the respective lubrication pump supply valve (Y7 or Y9) to
stop the pump. For the next 5 min the respective pressure releasing valve (Y7A
or Y9A) are continued energized to keep the lubricant pressure still on a high
level to be able all injectors inject the hole adjusted amount of lubricant.
After the 5 min. pressure holding time the PLC de energize the respective
pressure releasing valve (Y7A or5 Y9A) The lubricant pressure drops and the
injectors move by spring load back in its initial position. A PLC internal counter
is still counting a additional decreasing time to monitor the end-of-line pressure
switch (B43 or B46) position. The PLC internal time counter is still counting up
to the next lubrication cycle.
The lubrication cycle is finished.
continued

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

Capacitive analog sensor for lubricant level monitoring,


Illustration Z 21179f
Task:
A lubricant (L) maximum filling level monitoring is necessary to prevent an
overfilling of the grease barrel (C) via the refilling system (only systems with
refilling arm). The PLC use the analog level signal from the sensor to activate a
lamp at the refilling arm just in the moment when the lubricant container is full.
The sensor (S) is mounted on top of the lubricant container and reaches into the
lubricant.
The refilling level activate only a message at the text display to inform that the
lubricant level must be filled up. The message comes up if the lubricant level
reach 5% (910 mm from the cover plate).
The minimum level stop the respective lubrication pump and release the
lubricant pressure until the lubricant level reach the 0% mark (950 mm from the
cover plate). It is necessary to stop the lubrication system with empty lubricant
container to prevent the lubrication pump from running dry. With empty
lubricant container the bucket motion will be switched off after four hours.
Function:
The capacitively level sensor (S) check continuous the lubricant level (L) and
convert the capacitive signal into a current signal between 4 and 20mA. The
current signal increase with increasing lubricant level.
Use the specific electric circuit diagram and program flow charts.

05.10.04 rev.5

The capacitively proximity switch used in our machines are


programmed by the supplier and therefor no adjustment or settings
required.

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.

Connect pressure gauge to check point.

Use an other gauge as for checking hydraulic pressures because the


gauge remains filled with grease after the test
2.
3.
4.

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

Function Pinion type (dummy wheel) system.


Legend:
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)

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.

Grease qualities to be used:


According to NLGI classes 000, 00, 0 and 1 according to the lowest
ambient temperature in the operation area

05.10.04 rev.5

1. The content of molybdenum must not exceed 5 %.


2. Only synthetic graphite must be contained in graphic lubricants

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

It follows an exemplary explanation for a Slew Ring Lubrication


System for machines equipped with ECS System. For details see the
circuit diagram of the respective machine. The Lubrication Systems
are controlled through the ECS. No relay adjustment required.
Slew Ring Gear Lubrication (Teeth lubrication) controlling :
The PLC from the ECS System control the whole lubrication systems.
Solenoid valves (Y9, Y9A) on top of the lubrication container are direct
connected to digital output ports of the PLC.
On few machines there are additional relays between PLC and the solenoid
valves.
Depend on a PLC input from the end-of-line pressure switch (B43 or B46) and a
PLC internal time counter the grease system start a lubrication cycle.
The lubrication cycle starts.
If the pause time elapsed and the swing function was activated for a short time
the PLC energize both solenoid valves ( Y9 , Y9A ). To start one swing ring
gear lubrication cycle the swing function must be activated one time.
If the lubricant pressure reach the adjusted pressure of the end of line pressure
switch its contact change the position now the input port of the PLC change.
The PLC de energize the respective lubrication pump supply valve (Y9) to stop
the pump. For the next 5 min the respective pressure releasing valve (Y9A) are
continued energized to keep the lubricant pressure still on a high level to be able
all injectors inject the hole amount of lubricant.
After 5 min. pressure holding time the PLC de energize the respective pressure
releasing valve (Y9A) The lubricant pressure drops and the injectors move by
spring load back in its initial position. A internal counter is still counting a
additional decreasing time to prevent a to early new lubrication cycle with the
risk of not complete reset injectors.
The lubrication cycle is finished.
continued

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

Capacitive analog sensor for lubricant level monitoring,


Illustration Z 21179f
Task:
A lubricant (L) maximum filling level monitoring is necessary to prevent an
overfilling of the grease barrel (C) via the refilling system (only systems with
refilling arm). The PLC use the analog level signal from the sensor to activate a
lamp at the refilling arm just in the moment when the lubricant container is full.
The sensor (S) is mounted on top of the lubricant container and reaches into the
lubricant.
The refilling level activate only a message at the text display to inform that the
lubricant level must be filled up. The message comes up if the lubricant level
reach 5% (910 mm from the cover plate).
The minimum level stop the respective lubrication pump and release the
lubricant pressure until the lubricant level reach the 0% mark (950 mm from the
cover plate). It is necessary to stop the lubrication system with empty lubricant
container to prevent the lubrication pump from running dry. With empty
lubricant container the bucket motion will be switched off after four hours.
Function:
The capacitively level sensor (S) check continuous the lubricant level (L) and
convert the capacitive signal into a current signal between 4 and 20mA. The
current signal increase with increasing lubricant level.
Use the specific electric circuit diagram and program flow charts.

05.10.04 rev.5

The capacitively proximity switch used in our machines are


programmed by the supplier and therefor no adjustment or settings
required.

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.

Use an other gauge as for checking hydraulic pressures because the


gauge remains filled with grease after the test
2.
3.
4.
5.

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.

180 bar is the normal setting.


Under particular circumstances it may be necessary to increase the
pressure slightly
If re-setting is required:
6.
7.
8.

Screw out screw (1) and take off cover (2).


Alter the spring tension with adjustment screw (3) that the switch
operates at 180 bar.
Install cover (2) and screw (1).
continued

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

Hydraulically driven Power Master III lube pump, illustr. Z 21186


Legend: (more detailed see parts list 90-0781) Fig.: 12
(P)
Hydraulic oil supply
(T)
Hydraulic oil return
(Pr)
Pressure reducing valve
(Q)
Flow regulator valve
(1)
Hydr. actuator piston
(2)
Oscillator control block
(3)
Pump tube
(4)
Breather port
(5)
Grease outlet port
(6)
Piston rod
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)

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

Foreign material lodged under Piston Ball Checks or between Upper


and Lower Inlet Checks (8 + 9).
To correct this problem the upper lower inlet checks (8 + 9) and inlet
valve (13) should be removed and cleaned thoroughly.
If sealing surfaces between upper and lower inlet checks (8 + 9) are
rough or pitted, replace or resurface if damages are slight.

Shovel rod packing worn or damaged. Before installing new packing,


inspect surface of shovel rod and replace if rough or pitted.
Do not grip shovel rod when disassembling lower pump tube assembly.
continued

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

Trouble shooting, illustr. Z 21186


If the following procedures do not correct the problem, contact a factory
authorized service center.
PROBLEMS:
CYLINDER PRESSURE GAUGE DOES NOT REGISTER PRESSURE.
A.
Check system pressure to pump.
B.
Check for 24 VDC signal at solenoids.
C.
Pressure reducing valve set too low. Check pressure.
PUMP PRESSURE BUILT UP VERY SLOWLY OR NOT AT ALL.
A.
B.
C.
D.
E.
F.
G.
H.

05.10.04 rev.5

No oscillation of pump, check oscillation control block (2).


Pressure reducing valve (Pr) may be setting too low.
Grease viscosity may be too high for the actual ambient temperature.
If pressure is not building up at all, solenoid valve (pilot pressure
supply solenoid) may be inoperative.
Pump piston (11) and inlet checks may have foreign matter trapped
causing leakage. Remove, inspect and clean if necessary.
Inspect sealing surface on upper and lower checks (8 + 9). Replace if
rough or pitted.
Replace scoop piston if rough or pitted. Replace rod packing (15) if
it is leaking.
Inspect lubricant supply line for leaks or breaks.

PC5500-6-D_Sec_15-0_rev1.doc

15.0
44

Lubrication System

Section 15.0
Page 45

Lubrication System

Lubricant Injector (metering valve), illustr. Z 21187

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

Design: (model SL11)


(01)
Metering valve, assy.
(02)
Adjusting screw
(03)
Nut

(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

Legend: illustr. Z 21191


(1)
Plug screw
(2)
Plug screw gasket
(3)
Filter element
(4)
Filter housing
(5)
Spring guide
(6)
Spring
Before servicing stop the motor and remove ignition key in order to
prevent operation of the system.

A clogged filter element will be moved against the spring force by the
lubricant pressure and unfiltered lubricant reaches the system!
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

For service intervals see SERVICE LITERATURE chapter 6.6

PC5500-6-D_Sec_15-0_rev1.doc

15.0
54

Lubrication System

Lubrication System

Section 15.0
Page 55

Vent valve, illustr. Z 21192


TASK:
By the function of the vent valve the lubricant supply line gets pressurerelieved, after the lubrication cycle is finished. The injector pistons can move
into their initial position.
Legend: (Valve VP1 S-G). Fig. 19
(1)
Solenoid
(2)
Valve assy.
(3)
Solenoid stem
(4)
Lever
(5)
Main valve cone
(6)
Auxiliary valve cone
(7)
Reset spring
Function:
The solenoid gets energized. When the lubrication starts.
The connection from A to B gets closed, thus a pressure build-up is possible.
The solenoid gets de-energized, as soon as the lubrication cycle is finished.
This causes opening of the connection A to B, thus the supply line to the
lubricant barrel is open. The lubricant flows from A to B or vice versa
along the main valve cone (5).

05.10.04 rev.5

PC5500-6-D_Sec_15-0_rev1.doc

Appendix
Page 0

Appendix

Table of contents Appendix


Section
Appendix

26.03.03

Page
01

Check list valve logic

PC5500-6-D_Sec_Appendix_rev0.doc

Appendix

26.03.03

Appendix
Page 1

PC5500-6-D_Sec_Appendix_rev0.doc

Appendix

26.03.03

Appendix
Page 2

PC5500-6-D_Sec_Appendix_rev0.doc

Appendix

26.03.03

Appendix
Page 3

PC5500-6-D_Sec_Appendix_rev0.doc

Appendix

26.03.03

Appendix
Page 4

PC5500-6-D_Sec_Appendix_rev0.doc

Appendix

26.03.03

Appendix
Page 5

PC5500-6-D_Sec_Appendix_rev0.doc

Appendix

26.03.03

Appendix
Page 6

PC5500-6-D_Sec_Appendix_rev0.doc

Appendix

26.03.03

Appendix
Page 7

PC5500-6-D_Sec_Appendix_rev0.doc

Appendix

26.03.03

Appendix
Page 8

PC5500-6-D_Sec_Appendix_rev0.doc

Appendix

26.03.03

Appendix
Page 9

PC5500-6-D_Sec_Appendix_rev0.doc

Appendix

26.03.03

Appendix
Page 10

PC5500-6-D_Sec_Appendix_rev0.doc

Appendix

26.03.03

Appendix
Page 11

PC5500-6-D_Sec_Appendix_rev0.doc

Appendix

26.03.03

Appendix
Page 12

PC5500-6-D_Sec_Appendix_rev0.doc

Appendix

26.03.03

Appendix
Page 13

PC5500-6-D_Sec_Appendix_rev0.doc

Appendix

26.03.03

Appendix
Page 14

PC5500-6-D_Sec_Appendix_rev0.doc

Appendix

26.03.03

Appendix
Page 15

PC5500-6-D_Sec_Appendix_rev0.doc

Appendix

26.03.03

Appendix
Page 16

PC5500-6-D_Sec_Appendix_rev0.doc

Appendix

26.03.03

Appendix
Page 17

PC5500-6-D_Sec_Appendix_rev0.doc

3&B)URQWVKRYHO 6HU1R'DWH

01 Check Single Movement (title)

b a
- - - - 0 I

b a
- - - - 0 II

0
b
0

IV
a
b
a
III

b
O
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

Stand_12.08.2005

1 / 11

3&B)URQWVKRYHO 6HU1R'DWH

PC5500_6_FS.xls

Stand_12.08.2005

2 / 11

3&B)URQWVKRYHO 6HU1R'DWH

05 Left back

b
O
P

a
I

b a
- - - - - II

b
-

IV
a
b
a
III

P
b
O
P

IV
a
b
a
III

b
-

IV
a
b
a
O
III

P
b
O
P

IV
a
b
a
III

06 Boom up

b
O
P

a
I

b
O
P

a
II

07 Boom down

b a
- O
- - - - I

b a
- - O
- - - II

08 Stick out

b
O
P

PC5500_6_FS.xls

a
I

b
O
P

a
II

Stand_12.08.2005

3 / 11

3&B)URQWVKRYHO 6HU1R'DWH

09 Stick in

b a
- - - O
- - I

b a
- O
- - - - II

b
-

IV
a
b
a
O
III

P
b
O
P

IV
a
b
a
III

b
P

IV
a
b
a
O
III

P
b
-

IV
a
b
a
III

10 Bucket fill

b
O
P

a
I

b
O
P

a
II

11 Bucket empty

b a
- - O
- - P I

b a
- - - O
- - II

12 Clam open

b a
- - - - - I

PC5500_6_FS.xls

b a
- - - - O
P II

Stand_12.08.2005

4 / 11

3&B)URQWVKRYHO 6HU1R'DWH

13 Clam close

b a
- - - - - I

b
O
P

a
II

P
b
-

IV
a
b
a
III

P
O
b
-

IV
a
b
a
III

P
O
b
-

IV
a
b
a
III

14 Swing right

b a
- - - - - I

b a
- - - - - II

15 Swing left

b a
- - - - - I

b a
- - - - - II

16 Check Automatic Priority (title)

b a
- - - - - I

PC5500_6_FS.xls

b a
- - - - - II

b
-

IV
a
b
a
III

Stand_12.08.2005

5 / 11

3&B)URQWVKRYHO 6HU1R'DWH

17 Boom up, Bucket empty

b
O
P

a
I

b
O
P

a
O
II

P
b
O
P

IV
a
b
a
O
III

18 Boom up, Bucket fill

b
O
O
P

a
I

b
O
P

a
II

P
b
O
O
P

IV
a
b
a
III

19 Check Unfloat Switch Function (title)

b a
- - - - - I

b a
- - - - - II

b
-

IV
a
b
a
III

20 Boom down, Stick Unfloat switch pressed

b a
- O
- - - - I

PC5500_6_FS.xls

b a
- - O
- - - II

b
-

IV
a
b
a
O
III

Stand_12.08.2005

6 / 11

3&B)URQWVKRYHO 6HU1R'DWH

21 Boom down, Boom Unfloat switch pressed

b a
- - - - - I

b a
- - O
- - P II

P
b
-

IV
a
b
a
O
III

22 Boom down, Boom Unfloat switch pressed, Bucket fill

b
O
P

a
I

b
O
P

a
O
II

P
b
O
P

IV
a
b
a
O
III

23 Boom down, Boom Unfloat switch pressed, Stick out

b
O
P

a
I

b
O
P

a
O
II

P
b
O
P

IV
a
b
a
O
III

24 Stick in, Boom Unfloat switch pressed

b a
- - - O
- - I

PC5500_6_FS.xls

b a
- O
- - - - II

b
-

IV
a
b
a
O
III

Stand_12.08.2005

7 / 11

3&B)URQWVKRYHO 6HU1R'DWH

25 Stick in, Stick Unfloat switch pressed

b a
- - - O
- - I

b a
- O
- - - P II

P
b
-

IV
a
b
a
III

26 Stick in, Stick Unfloat switch pressed, Bucket fill

b
O
P

a
O
I

b
O
P

a
O
II

P
b
O
P

IV
a
b
a
III

27 Check Operating Situations (title)

b a
- - - - - I

b a
- - - - - II

b
-

IV
a
b
a
III

28 Boom down, Stick in, Bucket empty, Clam close, Swing right

b
P

PC5500_6_FS.xls

a
O
O
O
I

b
O
P

a
O
O
O
II

P
O
b
P

IV
a
b
a
O
O
O
III

Stand_12.08.2005

8 / 11

3&B)URQWVKRYHO 6HU1R'DWH

29 Boom down, Stick out, Bucket fill

b
O
O
P

a
O
I

b
O
O
P

a
II

P
b
O
O
P

IV
a
b
a
O
III

30 Boom down, Stick out, Bucket empty

b
O
P

a
O
O
I

b
O
P

a
O
II

P
b
O
P

IV
a
b
a
O
O
III

31 Boom down, Stick in, Bucket fill

b
O
P

a
O
O
I

b
O
P

a
II

P
b
O
P

IV
a
b
a
O
O
III

32 Boom up, Stick in, Bucket empty, Swing left

b
O
P

PC5500_6_FS.xls

a
O
I

b
O
P

a
O
O
II

P
O
b
O
P

IV
a
b
a
O
O
III

Stand_12.08.2005

9 / 11

3&B)URQWVKRYHO 6HU1R'DWH

33 Boom up, Stick out, Bucket empty, Swing left

b
O
O
P

a
I

b
O
O
P

a
O
II

P
O
b
O
O
P

IV
a
b
a
O
III

34 Boom up, Stick in, Bucket fill, Swing left

b
O
O
P

a
O
I

b
O
P

a
II

P
O
b
O
O
P

IV
a
b
a
O
III

35 Boom up, Stick out, Bucket fill, Swing left

b
O
O
O
P

a
I

b
O
O
P

a
II

P
O
b
O
O
O
P

IV
a
b
a
III

36 Boom up, Stick out, Bucket empty, Clam open

b
O
O
P

PC5500_6_FS.xls

a
I

b
O
O
P

a
O
O
II

P
b
O
O
P

IV
a
b
a
O
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
O
O
P

IV
a
b
a
O
III

Stand_12.08.2005

11 / 11

Appendix
Page 1

1.

MC7 Fault Code, Diagnostic

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

Working pump solenoid


circuit open or shorted to
ground
Diesel engine is not
running or engine rpm too
low or no signal from
motor controller because
of short cut or break
Diesel engine is not
running or engine rpm too
low or no signal from
motor controller because
of short cut or break
Diesel engine defect or
rpm too high

Pump has maximum Check DRE


power
valve

Battery voltage is below


17V
MC7 was not precalibrated at
BRUENINGHAUS
HYDROMATIK
Internal MC7 fault

Engine lug too large

Working pump solenoid


circuit open or shorted to
ground
Diesel engine is not
running or engine rpm too
low or no signal from
motor controller because
of short cut or break
Diesel engine defect or
rpm too high

Fixing

Reduction of
hydraulic power

Check
connection to
motor controller

Reduction of
hydraulic power

Check
connection to
motor controller

Load limiting control


malfunction

Check
mechanical
high idle
limitation
Check voltage
generator
Replace MC7

Adjustable current
range is different

Analog input signals Replace MC7


can be wrong
Pump has maximum Check DRE
power
valve
Reduction of
hydraulic power

Check
connection to
motor controller

Load limiting control


malfunction

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.