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Contents and 00_Foreworda_15046.doc 13.02.07
SERVICE
MANUAL
PC5500
MACHINE MODEL SERIAL NUMBER
PC5500-6 Diesel 15045 to 15065
This service manual may contain attachments and optional
equipment that are not
available in your area.
Please consult your local Komatsu distributor for those items
you may require.
Materials and specifications are subject to change without
notice.
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Contents and 00_Foreworda_15046.doc 13.02.07
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Contents and 00_Foreworda_15046.doc 13.02.07
CONTENTS TABLE OF CONTENTS
00 Safety - Foreword 01 Technical DATA (Leaflet)
02 Assembly PROCEDURE (Brochure)
Section
1. Main assembly groups
2. Drive.
3. Hydraulic oil tank.
4. Hydraulic oil cooling.
5. Controlling.
6. Components
7. Main hydraulic pumps and pump regulation.
8. Operating hydraulic.
9. Hydraulic track tensioning system.
10. Hydraulic operated access ladder
11.
12. Hints for the hydraulic circuit diagram
13. Hints for the electric circuit diagram
14. ECS-T
15. Lubrication Systems
APPENDIX
) Each section includes a detailed table of contents.
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Contents and 00_Foreworda_15046.doc 13.02.07
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SAFTEY SAFTEY NOTICE
00-1
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 follow ing 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
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SAFTEY SAFTEY NOTICE
00-2
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
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SAFTEY SAFTEY NOTICE
00-3
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.
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SAFTEY SAFTEY NOTICE
00-4
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
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FOREWORD HOISTING INSTRUCTIONS
00-5
HOISTING INSTRUCTIONS HOISTING
Heavy parts (25 kg or more) must be lifted with a hoist etc.
) If a part cannot be smoothly remove d from the machine by
hoisting, the following checks should be made: 1. Check for removal
of all bolts fast ening 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.
continuedCont'd:
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FOREWORD HOISTING INSTRUCTIONS
00-6
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, w hich 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.
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FOREWORD STANDARD TIGHTENING TORQUE
00-7
STANDARD TIGHTENING TORQUE (1Kgm = 9,806Nm) STANDARD TIGHTENING
TORQUE OF BOLTS AND NUTS
Bolt Tightening torque dia.
Wrench size [mm] [Nm]
Quality grades
8.8 10.9 12.9 M 8 13 6 21 31 36 M 10 17 8 43 63 73 M 12 19 10 74
108 127 M 14 22 12 118 173 202 M 16 24 14 179 265 310 M 18 27 14
255 360 425 M 20 30 17 360 510 600 M 22 32 17 485 690 810 M 24 36
19 620 880 1030 M 27 41 19 920 1310 1530 M 30 46 22 1250 1770 2080
M 33 50 24 1690 2400 2800 M 36 55 27 2170 3100 3600 M 39 60 2800
4000 4700 M 42 65 32 3500 4950 5800 M 45 70 4350 6200 7200 M 48 75
35 5200 7500 8700 M 52 80 6700 9600 11200 M 56 85 41 8400 12000
14000 M 60 90 10400 14800 17400 M 64 95 46 12600 17900 20900 M 68
100 15200 21600 25500
Insert all bolts lubricated with MPG, KP2K
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FOREWORD CONVERSION TABLE
00-8
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE
The Conversion Table in this section is provided to enable
simple conversion of figures. For details of the method of using
the Conversion Table, see the example given below.
EXAMPLE
Method of using the Conversion Table to convert from millimeters
to inches.
1. Convert 55 mm into inches. (a) Locate the number 5 in the
vertical column at the left side, take this as (A),
then draw a horizontal line from (A). (b) Locate the number 5 in
the row across the top, take this as (B), then draw a
perpendicular line down from (B). (c) Take the point where the
two lines cross as (C). This point (C) gives the
value when converting from millimeters to inches. Therefore, 55
millimeters = 2.165 inches.
2. Convert 550 mm into inches.
(a) The number 550 does not appear in the table, so divide by 10
(move the decimal one place to the left) to convert it to 55
mm.
(b) Carry out the same procedure as above to convert 55 mm to
2.165 inches. (c) The original value (550 mm) was divided by 10, so
multiply 2.165 inches
by 10 (move the decimal one place to the right) to return to the
original value. This gives 550 mm = 21.65 inches.
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FOREWORD CONVERSION TABLE
00-9
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FOREWORD CONVERSION TABLE
00-10
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FOREWORD CONVERSION TABLE
00-11
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FOREWORD CONVERSION TABLE
00-12
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FOREWORD CONVERSION TABLE
00-13
Basic Values in Ohm according to DIN 43 76
For Measuring Resistor PT100
C -0 -1 -2 -3 -4 -5 -6 -7 -8 -9
-50 80,31 79,91 79,51 79,11 78,72 78,32 77,92 77,52 77,13
76,73
-40 84,27 83,88 83,48 83,08 82,69 82,29 81,89 81,50 81,10
80,70
-30 88,22 87,83 87,43 87,04 86,64 86,25 85,85 85,46 85,06
84,67
-20 92,16 91,77 91,37 90,98 90,59 90,19 89,80 89,40 89,01
88,62
-10 96,09 95,69 95,30 94,91 94,52 94,12 93,73 93,34 92,95
92,55
0 100,00 99,61 99,22 98,83 98,44 98,04 97,65 97,26 96,87
96,48
C 0 1 2 3 4 5 6 7 8 9
0 100,00 100,39 100,78 101,17 101,56 101,95 102,34 102,73 103,12
103,51
10 103,90 104,29 104,68 105,07 105,46 105,85 106,24 106,63
107,02 107,40
20 107,79 108,18 108,57 108,96 109,35 109,73 110,12 110,51
110,90 111,28
30 111,67 112,06 112,45 112,83 113,22 113,61 113,99 114,38
114,77 115,15
40 115,54 115,93 116,31 116,70 117,08 117,47 117,85 118,24
118,62 119,01
50 119,40 119,78 120,16 120,55 120,93 121,32 121,70 122,09
122,47 122,86
60 123,24 123,62 124,01, 124,39 124,77 125,16 125,54 125,92
126,31 126,69
70 127,07 127,45 127,84 128,22 128,60 128,98 129,37 129,75
130,13 130,51
80 130,89 131,27 131,66 132,04 132,42 132,80 133,18 133,56
133,94 134,32
90 134,70 135,08 135,46 135,84 136,22 136,60 136,98 137,36
137,47 138,12
100 138,50 138,88 139,26 139,64 140,02 140,39 140,77 141,15
141,53 141,91
110 142,29 142,66 143,04 143,42 143,80 144,17 144,55 144,93
145,31 145,68
120 146,06 146,44 146,81 147,19 147,57 147,94 148,32 148,70
149,07 149,45
130 149,82 150,20 150,57 150,95 151,33 151,70 152,08 152,45
152,83 153,20
140 153,58 153,95 154,32 154,70 155,07 155,45 155,82 156,19
156,57 156,94
150 157,31 157,69 158,06 158,43 158,81 159,18 159,55 159,93
160,30 16067
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FOREWORD CONVERSION TABLE
00-14
TEMPERATURE
Fahrenheit Centigrade Conversion; a simple way to convert a
Fahrenheit temperature reading into a Centigrade temperature
reading or vise versa is to enter the accompanying table in the
center or boldface column of figures. These figures refer to the
temperature in either Fahrenheit or Centigrade degrees. If it is
desired to convert from Fahrenheit to Centigrade degrees, consider
the center column as a table of Fahrenheit temperatures and read
the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees,
consider the center column as a table of Centigrade values, and
read the corresponding Fahrenheit temperature on the right.
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Main Assembly Groups
Section 1.0
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Table of contents section 1.0
Section Page
1.0 Main assembly groups
General lay out 2 1.1 Superstructure 3 1.1.1 Machine house 4
1.1.2 Hydraulic Oil Reservoir 5 1.1.3 Hydraulic Oil Cooler 6 1.1.4
Fuel Tank 7 1.1.5 Counter weight 8 1.1.6 Cab support 9 1.1.7
Operators cab 10 1.1.8 Control Blocks 11 1.1.9 Swing gears 12 1.2
Under carriage 13 1.3 Attachment 1.3.1. Backhoe Attachment (BHA) 14
1.3.2. Front Shovel Attachment (FSA) 15
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1.0
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Main Assembly Groups
Section 1.0
Page 2
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1. 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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Main Assembly Groups
Section 1.0
Page 3
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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
(16) Engine 1 (17) Flexible coupling, oil filled (18) PTO gear
with hydraulic pumps (19) Main hydraulic pumps 1, 2 and 3 (20)
Radiator for the engine cooling system
(21) Engine 2 (22) Flexible coupling, oil filled (23) PTO gear
with hydraulic pumps (24) Main hydraulic pumps 4, 5 and 6 (25)
Radiator for the engine cooling system
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1.0
4
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Main Assembly Groups
Section 1.0
Page 4
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1.1 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
Section 1.0
Page 5
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1.1 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
Section 1.0
Page 6
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Main Assembly Groups
Section 1.0
Page 6
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1.1 Superstructure
1.1.3 Hydraulic Oil Cooler
Legend for illustration (Z 22392):
(1) Cooler frame with swing out facility (2) Hydraulic motor of
upper fan (3) Upper fan (4) Fan guard (5) Outer part of the upper
radiator set (6) Inner part of the upper radiator set (7) Hydraulic
motor of lower fan (8) Lower fan (9) Fan guard (10) Outer part of
the lower radiator set (11) Inner part of the lower radiator (12)
Swing out doors (13) Locking bars to secure the swing out doors
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1.0 7
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Main Assembly Groups
Section 1.0
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1.1 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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Main Assembly Groups
Section 1.0
Page 8
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1.1 Superstructure
1.1.5 Counter weight
Legend for illustration (Z 21474): (1) Counter weight
Total weight
40000 kg
(2) Mounting bolts
Quantity
Bolt size (mm)
Grade SW* (mm)
Tightening torque (Nm)
16 M 48 x 380 10.9 75 7500
* SW = Wrench size (3) Lifting points
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1.0
9
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Main Assembly Groups
Section 1.0
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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 (mm)
Grade SW* (mm)
Tightening torque (Nm)
6 M 36 x 320 10.9 55 3100
* SW = Wrench size (3) Mounting bolts
Quantity
Bolt size (mm)
Grade SW* (mm)
Tightening torque (Nm)
6 M 36 x 160 10.9 55 3100
* SW = Wrench size (4) Door (5) Gasket (6) Door handle
(adjustable)
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1.0 10
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Main Assembly Groups
Section 1.0
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1.1 Superstructure
1.1.7 Operators cab
Legend for illustration (Z 21476):
(1) Monitor panel (2) Switch panel (3) Operators seat (E19)
Control lever
EURO Control KMG Control
(E20) Control lever EURO Control KMG Control
(E21a) Control pedal A - forward Left track B - reverse
(E21b) Control pedal A - forward Right track B - reverse
(E22) Control pedal - Swing brake (E23) Control pedal (left)
Clam closing (E24) Control pedal (right) Clam opening
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1.0 11
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Section 1.0
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1.1 Superstructure
1.1.8 Control blocks
Legend for illustration (Z 21477a):
(1) Control block carrier (2) Remote control valves (3) Main
control blocks (4) High pressure filter
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1.0 12
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Main Assembly Groups
Section 1.0
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1.1 Superstructure
1.1.9 Sw ing gears
Legend for illustration (Z 22395):
(1) Swing gear box (2) Swing parking brake Spring loaded multi
disk brake
(Released by oil pressure) (3) Parking brake Control port (X)
(4) Oil level gauge - gear box (5) Breather gear box (6) Oil
filling plug gear box (7) Oil level gauge motor adapter housing (8)
Breather motor adapter housing (9) Oil drain plug motor adapter
housing (10) Oil drain plug - gear box (20.1 + 20.2) Swing motor
(49.1 + 49.2) Swing brake valve block
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1.0
13
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Section 1.0
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1.2 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)
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1.0
14
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Main Assembly Groups
Section 1.0
Page 14
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1.3 Attachment
1.3.1 Backhoe attachment (BHA)
Legend for illustration (Z 21482):
(1) Boom (2) Boom Cylinders (3) Stick (4) Stick Cylinders (5)
Bucket (6) Bucket Cylinders (7) Control arm (8) Linkage
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Main Assembly Groups
Section 1.0
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Main Assembly Groups
Section 1.0
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1.3 Attachment
1.3.2 Front Shovel Attachment (FSA) Legend for illustration (Z
21483):
(1) Boom (2) Boom Cylinders (3) Stick (4) Stick Cylinders (5)
Bucket back wall (6) Bucket Cylinders (7) Bullclam (8) Bucket Clam
cylinders
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Drive
Section 2.0
Page 1
Table of contents section 2.0
Section Page
2.0 Prime drive assembly
General lay out 2 2.1 Engine and PTO mounts 3 + 4 2.2 Coupling 5
2.3 Air filter 6 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
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2.0
2
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Drive
Section 2.0
Page 2
2.0 Prime drive assembly
Legend for illustration (Z 22395):
(1) Engine 1 (2) Torsion type coupling (2) Pump distributor gear
(PTO)
(6) Engine 2 (7) Torsion type coupling (8) 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.
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2.0
3
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Section 2.0
Page 3
2.1 Engine and PTO mounts
Legend for illustration (Z 21601):
(1) Flexible bearing (2) Bolt with self locking nut
Quantity
Bolt size (mm)
Grade SW* (mm)
Tightening torque (Nm)
4 per mount M 10 x35 8.8 17 43
(3) Tie bolt Quantity
Bolt size (mm)
Grade SW* (mm)
Tightening torque (Nm)
4 M 24 x420 10.9 36 snugly
(4) Rubber-bounded metal bar (5) Self locking nut M24 (6) Bolt
M16 with self locking nut
Quantity
Bolt size (mm)
Grade SW* (mm)
Tightening torque (Nm)
2 M 16x 80 10.9 24 265
(7) Cup springs, seven per bolt (8) Stop bolt
Quantity
Bolt size (mm)
Grade SW* (mm)
Tightening torque (Nm)
2 M 36 x250 10.9 55 Not specified
(9) Nut (10) Bolt
Quantity
Bolt size (mm)
Grade SW* (mm)
Tightening torque (Nm)
10 M 24 x 230 10.9 36 880
(11) Bolt Quantity
Bolt size (mm)
Grade SW* (mm)
Tightening torque (Nm)
16 M 20 x 120 10.9 30 510
(12) Resilient sleeve (13) Bolt
Quantity
Bolt size (mm)
Grade SW* (mm)
Tightening torque (Nm)
4 M 30 x 200 10.9 46 1770
(14) Resilient sleeve
* SW = Wrench size
continued
-
2.0
4
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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.
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2.0
5
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Drive
Section 2.0
Page 5
2.2 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.
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2.0
6
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Drive
Section 2.0
Page 6
2.3 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.
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2.0
7
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Drive
Section 2.0
Page 7
2.4 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
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2.0 8
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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
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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).
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2.0 10
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Drive
Section 2.0
Page 10
2.5 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
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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
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2.0 12
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Section 2.0
Page 12
Cont'd
8. Loosen lock nut (2) of the relief valve (168.x), and decrease
the
pressure with set screw (3) until the correct fan speed is
obtained. 9. Tighten lock nut (2) and fix protection cap (3). Basic
Adjustment middle fan speed
10. Activate the 4/3 direction flow valve (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 (-).
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2.0 13
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Section 2.0
Page 13
2.6 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.
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2.0
14
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Section 2.0
Page 14
2.7 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.
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2.0 15
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Drive
Section 2.0
Page 15
2.8 PTO Lubrication and cooling
Legend for illustration (Z 22410e): 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 to PTO (relief line) (4)
Suction line from PTO oil pan to the pump (P) Connections to spray
nozzles (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
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Drive
Section 2.0
Page 16
Contd.:
2.8 PTO Lubrication and cooling
Legend for illustration (Z 22414)
(1) Pilot operated relief valve (8) Valve spring (2) Plug screw
(9) Seal rings (3) Valve piston (B27-x) Maintenance switch (4) Port
for pressure switch B17-1 (74.x) Pressure relief valve (6) Port for
pressure check stud (A) Pressure port (7) Jet bore (T) Return from
valve Adjustments:
The adjustment of the maximum permissible PTO lube pressure, has
to be carried out with cold oil to avoid serious damages to the
coolers.
The check for a sufficient PTO lube pressure has to be carried
out with warm oil to avoid serious damages gearbox.
Setting the pressure relief valve (74.x) at cold oil. 1. Connect
a pressure gauge to check point (M1.x). 2. Disconnect plug of
solenoid valve Y53-1/ Y53-2 3. Start the 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.
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2.0
17
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Section 2.0
Page 17
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 = 500
cm/rev
theoretical flow rate, each Qmax = 700 Liter/min Drive speed* n
= 1400 min-1
for all working motions
(10.1), (10.3) Axial piston pump Vg max = 80 cm/rev theoretical
flow rate Qmax = 158 Liter/min Drive speed* n = 1973 min-1
for radiator fan drive (10.2), (10.4) Axial piston pump Vg max =
80 cm/rev
theoretical flow rate Qmax = 142 Liter/min Drive speed* n = 1770
min-1
for oil cooler fan drive (8.1), (8.4) Gear pump Vg = 58,7
cm/rev
theoretical flow rate Qmax = 82,2 Liter/min Drive speed* n =
1400 min-1
for PTO gear lubrication (8.2), (8.5) Gear pump Vg = 58,7
cm/rev
theoretical flow rate Qmax = 82,2 Liter/min Drive speed* n =
1400 min-1
for hydraulic oil circulation (7.1), (7.2) Gear pump Vg = 85,7
cm/rev
theoretical flow rate Qmax = 120 Liter/min Drive speed* n = 1400
min-1
for pilot pressure supply
) * at 1800 min-1 input drive speed
-
Hydraulic Oil Reservoir
Section 3.0
Page 1
04.01.07 PC5500-6-E_Sec_3-0_rev2.doc
Table of contents section 3.0
Section Page
3.0 Hydraulic oil reservoir
General lay out 2 3.1 Main oil tank, location of switches,
sensors etc. 3 3.2 Suction oil tank with strainers 4 3.3 Return oil
collector tube with strainer 5 3.4 Back pressure valve 6 3.5 3.6
Return and Leak Oil Filter 8 3.7 Breather Filter 9
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3.0 2
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-
Hydraulic Oil Reservoir
Section 3.0
Page 2
04.01.07 PC5500-6-E_Sec_3-0_rev2.doc
3. General lay out
Legend for illustration (Z 22416b): (1) Filter cover retainer
(2) Filter cover (3) (A) Return oil filter 10 m (4x)
(B) Case drain filter 3 m (1x) (4) Man hole cover (5) Hydraulic
oil filler plug (6) Differential pressure switch, screen filter
monitoring (7) Test port, back pressure 8 bar (8) Test port, back
pressure swing motor 15 bar (24) Pressure switch B24 monitors item
(132.1+132.2) (39) Hydraulic oil level gauge (41) Main oil
reservoir (114) Return oil collector tube with pressure check point
M10 (115) Back pressure valve (118) Oil drain, quick release
coupling (128) Shut off valve (Gate valve) with monitoring switch
S31 (129) Compensator (132.1 + 132.2) Breather filter (178) Oil
cooler filter (screen filter)
The hydraulic oil tank is a welded sheet-metal construction. The
filling capacity is about 3800 litres. The tank contains four
return oil filters (3-A) and one case drain filter (3-B). The
breather filter (132.1 + 132.2) cleans the air that streams into
the tank. The back pressure valve (115) and the pressure check
point (M10) are located at the collector tube (114) for return oil.
The connection to the suction tank can be closed with the shut- off
valve (118) to prevent oil flow during repairs on the hydraulic
pumps. This unit is controlled by the switch S31, to prevent a
motor start with closed shut-off valve. Fault message Start blocked
because of main Shut-Off (gate) valve is displayed at the operators
dash board. The screen filter (178) protect the oil cooler for
internal contamination, the filter is monitored by differential
pressure switch (178). The back pressure valves (8) increase the
circulation pump pressure to 15 bar for cavitation protection of
the swing motors.
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3.0 3
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Hydraulic Oil Reservoir
Section 3.0
Page 3
04.01.07 PC5500-6-E_Sec_3-0_rev2.doc
3.1 Main oil tank, location of switches, sensors etc.
Legend for illustration (Z 21495a): (B4) Oil level sensor
Hydraulic oil level too low (B15) Hydraulic oil temperature
probe
Hydraulic oil temperature below: too hot (B24) Breather filter
pressure switch (B25) Pressure switch Pressure leak oil chamber
(B26) Pressure switch Pressure return oil chamber (B32) Hydraulic
oil temperature probe Temp. gauge cabin (B42) Oil level sensor Oil
level maximum (B50) Oil level sensor Hydraulic oil refill level
(Y101) Solenoid valve Back pressure reduction
-
3.0 4
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Hydraulic Oil Reservoir
Section 3.0
Page 4
04.01.07 PC5500-6-E_Sec_3-0_rev2.doc
3.2 Suction oil tank with strainers
Legend for illustration (Z 22418): (1) Suction oil reservoir (2)
Drain coupling (3) Bolt (4) Gaskets (5) Main suction oil strainer
(6) Gaskets (7) Intermediate pipe (8) Nut (9) Bolt (10) Compensator
(11) Suction strainer one for each main pump (12) Suction hose
connection pipe The suction oil tank (1) is a welded sheet-metal
construction. The capacity is 187 liters. The suction lines of all
hydraulic pumps are connected to the suction tank.
-
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Hydraulic Oil Reservoir
Section 3.0
Page 5
04.01.07 PC5500-6-E_Sec_3-0_rev2.doc
3.3 Return oil collector tube with strainer
Legend for illustration (Z 21497a): (1) Return oil collector
tube - Part 1 - (2) Return oil collector tube - Part 2 - (3) Return
oil collector tube - Part 3 - (4) Strainer (5) Bolt (6) Self
locking nut (7) Gasket (8) Differential pressure switch B165
Task:
The strainer is installed to prevent the hydraulic oil coolers
from getting clogged up in case of contamination in the main return
oil circuit. Excessive increase of the hydraulic oil temperature
can be an indication for a restricted strainer, i.e. bad cooling
performance due to insufficient oil flow through the coolers. In
case that main components such as cylinders or motors are internal
fragmentary damaged, the strainer should be inspected for metal
chips.
-
3.0 6
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Hydraulic Oil Reservoir
Section 3.0
Page 6
04.01.07 PC5500-6-E_Sec_3-0_rev2.doc
3.4 Back pressure valve
Legend for illustration (Z 21498): (1) Back pressure valve
assembly (2) Solenoid valve (Y101) Task:
The back pressure valve has to fulfill two functions in the
hydraulic system: 1. To ensure a sufficient pressure within the
return oil circuit, i.e. to supply
oil via the anticavitaton valves to the low pressure side of
cylinders, respectively motors.
2. To force the return oil through the coolers depending on the
present hydraulic oil temperature, controlled by solenoid valve
Y101. - Low temperature low volume through the coolers - High
temperature high volume through the coolers
) Further information about the function principle and
adjustments, refer to Section 4.0 this Manual.
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Hydraulic Oil Reservoir
Section 3.0
Page 7
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3.6 Return and Leak Oil Filter
Legend for illustration (Z 21500): (1) Filter cover retainer (2)
Filter cover with o-ring (3) Pre-tensioning spring (4) Retainer (5)
Filter assembly (6) Filter pot with machined cover (7) Main filter
element, 10 micron absolute (8) Safety filter element (200 micron
strainer) (9) By pass-valve, 2.3bar (9.1) Valve cone (9.2) Valve
spring (9.3) O-ring (10) Profile gasket (11) Seal ring (12) Self
locking nut (13) Self locking nut Function: The returning oil flows
into the filter chamber (A) of the hydraulic tank. (The sketch
shows one section only). The chamber is split into two sections;
one sections with 4 filters for the return oil and one for the leak
oil. But the five filters are all the same. The hydraulic oil
enters the filter at the top and passes then on its way to the
entire tank the filter-element (7). "Inside to outside filtration."
The filter element condition is monitored by a pressure switch
(B25, 0.5 bar for the leak oil filter) and (B26, 2 bar for the
return oil filter). As soon as the pressure inside the filter
chamber reaches the set pressure of those switches due to the
restriction of the filter-element which is caused by foreign
matters, the fault message Return oil filter restricted" or Leak
oil filter restricted is displayed at the operator's dash board The
filter elements must be replaced. For safety pre-cautions the
filter is equipped with a by-pass valve. As the filter chamber
pressure increases the by-pass valve opens at 2.3 bar and protects
the element from bursting. But the oil flows not totally unfiltered
into the tank because it must flow through the strainer (8).
) The switch point of the pressure switch for the leak oil has
been chosen so low with best intention to protect first of all the
radial seal rings of the hydraulic motors. Because the filter is
oversized for this purpose, the message Leak oil filter restricted
is displayed very seldom under normal circumstances.
Maintenance see MAINTENANCE MANUAL
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-
Hydraulic Oil Reservoir
Section 3.0
Page 8
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3.7 Breather filter
Legend for illustration (Z 21501a): (1) Nut (2) Cover (3) Filter
element (4) Filter pot A breather filter is installed to clean the
air that streams into the tank any time the oil level decreases
while extending attachment cylinders The filter element condition
is monitored by a vacuum type pressure switch (B24, 80mbar).
Maintenance see MAINTENANCE MANUAL
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Hydraulic Oil Cooling
Section 4.0
Page 1
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Table of contents section 4.0
Section Page
4.0 Hydraulic oil cooling
4.1 General 2 4.2 Function of the hydraulic oil cooling circuit
3 4.3 Adjustment of the Back Pressure Valve 4 4.4 Fan drive (Two
stage cooler fan RPM control) 5 + 6 4.5 Pressure relief valves and
solenoid valve 7 + 8 4.6 Fixed Displacement Pump, with variable
setting 9 4.7 Radiator fan drive speed adjustment 10
12
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Hydraulic Oil Cooling
Section 4.0
Page 2
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4.1 General
The hydraulic oil cooling system maintains the hydraulic oil at
a normal operating temperature. Legend for illustration (Z
21594)
(1) Noise shield (2) Cooler (Radiator) (3) Cooler frame (4) Fan
(5) Fan motor (Axial piston motor) (6) Bolt (7) Bolt (8) Drive
shaft (9) Shaft protecting Sleeve (10) Drive shaft seal (11) Ball
bearings (12) Seeger clip ring (13) Bearing group carrier (14) Oil
level plug (15) Breather filter Design:
There are four* hydraulic oil coolers in front of the hydraulic
tank on the R.H. side of the platform. They are in pairs mounted in
one frame, one above the other. The air stream needed for the
cooling is produced by hydraulic driven fans. The air flows from
inside to outside through the coolers. For a better cleaning, the
coolers can be moved to the side. (Swing out cooler) The bearing
group carrier is filled with oil to lubricate the bearings.
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Hydraulic Oil Cooling
Section 4.0
Page 3
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4.2 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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Hydraulic Oil Cooling
Section 4.0
Page 4
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4.3 Adjustment of the Back Pressure Valve
Checks and settings only at normal operating temperature of the
hydraulic oil, main pumps in maximum flow position and "Idle Time"
control eliminated (service switch S155in to pos.1 actuated)! 1.
Connect a pressure gauge to check point (M10). 2. Disconnect plug
connector (13) of solenoid valve Y101. 3. Actuate service switch
S155 (pos.1). 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 S155 pos.0.
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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-
Hydraulic Oil Cooling
Section 4.0
Page 5
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4.4 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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-
Hydraulic Oil Cooling
Section 4.0
Page 6
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Function:
From pump (10.x) flows the oil through the filter (68.x) to the
fan motor (22.x) and then back to the tank. The check valve (103.x)
act as an anti cavitation valve and is installed, because the fan
motor -driven by inertial force- is running for a short period
after the oil flow is interrupted by solenoid valve (Y6A-x/Y6B-x)
or if the 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
Section 4.0
Page 7
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4.5 Pressure relief valves and solenoid valves
Pressure relief valves (168.x)
Legend for illustration (Z 21598b)
(1) Valve cartridge (2) Spring (3) Spring chamber (4) "X" port
(5) Jet bore, Pilot poppet (6) Jet bore, Main piston (7) Main
piston (8) Valve housing (9) Pilot poppet (Y) External leak oil
port (A) Pressure port (B) Return oil port Function:
Pressure in line A affects the main piston (7). At the same time
there is pressure via the jet bore (6) on the spring-loaded side of
the main piston and via jet bore (5) at the pilot poppet (9) of the
relief valve cartridge (1). If system pressure in line A exceeds
the value set at the spring (2), pilot poppet (9) opens. The signal
for this comes from line A via the jet bores (6) and (5). The oil
on the spring-loaded side of the main piston (7) now flows via the
jet bore (5) and poppet (9) into the spring chamber (3). From here
it is fed internally by means of the control line (Y) to tank (port
B). Due to the state of equilibrium at the main piston (7), oil
flows from line A to line B, while the set operating pressure is
maintained. The pressure relief valve can be changed (Remote
controlled) by means of the port "X" and the function of the
solenoid valve Y6A-x / Y6B-x and pressure reduction valve 169.x. .(
Function see next page)
continued
-
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-
Hydraulic Oil Cooling
Section 4.0
Page 8
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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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-
Hydraulic Oil Cooling
Section 4.0
Page 9
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4.6 Fixed Displacement Pump, with variable setting
Legend for illustration (Z 21852)
(1) Drive shaft (2) Bearings (3) Cylinder with pistons (4)
Center pin (5) Control lens (6) Q-min adjustment bolt (7) Q-max
adjustment bolt (8) Pressure port (9) Tank port Description.
Pump type A7F0 is a variable displacement pump, designed to
operate in open circuits. It has an internal case drain return. The
rotary group is a robust self aspirating unit. External forces may
be applied to the drive shaft. Changing the swivel angle of the
rotary group is achieved by sliding the control lens along a
cylindrical formed track by means of an adjusting screw. With an
increase in the swivel angel, the pump output increase together
with necessary drive torque. With an decrease in the swivel
angel, the pump output decreases together
with the necessary drive torque.
When increasing to maximum swivel angle, there is a danger of
cavitation and over-speeding the hydraulic motor!
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-
Hydraulic Oil Cooling
Section 4.0
Page 10
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4.7 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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-
Hydraulic Oil Cooling
Section 4.0
Page 11
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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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Hydraulic Oil Cooling
Section 4.0
Page 12
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Cont'd
8. Loosen lock nut (2) of the relief valve (168.x), and decrease
the pressure with set screw (3) until the correct fan speed is
obtained.
9. Tighten lock nut (2) and fix protection cap (3). Basic
Adjustment middle fan speed
10. Activate the 4/3 direction flow valve (Y6B-x), by connecting
the solenoid plug (Y6B-x ) to permanent 24 V. Use 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). *) 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 (-).
-
Controlling
Section 5.0
Page 1
04.01.07 PC5500-6-D_Sec_5-0_rev4.doc
Table of contents section 5.0
Section Page
5.0 Controlling
General lay out 2 5.1 Control and filter panel location of
components
(valves, switches, sensors etc.) 3
5.2 Pilot Pressure Supply and Adjustments 4 7 5.3 Remote control
valves arrangement 8 5.4 Function principle of the
Electro-Hydraulic- Proportional Control 9 + 10
5.5 Potentiometer Control (Lever, Joy Stick) 11 5.6
Potentiometer Control (Pedal) 12 5.7 Proportional amplifier module,
Type A
(for swing brake only) 13
5.8 Proportional amplifier module, Type B (for Boom, Stick,
Bucket, Swing and Travel)
14
5.9 Ramp Time Module (Analogue command value module for Boom,
Stick, Travel and Swing function)
15
5.10 Adjustments of Amplifier Modules (General) 16 5.11
Adjusting the Amplifiers Type B 17 + 18 5.12 Adjusting the
Amplifiers Type A 19 + 20 5.13 Adjusting the Ramp Time Module 21 +
23
-
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04.01.07 PC5500-6-D_Sec_5-0_rev4.doc
X4 - pump support pressure
X2
to (45.2); (45.3) and (43)
pilot pressure pump regulation
X1 - pump regulation pressure
X3 remote control pressure (1/2Qmax; Qmin)
Z 22429
-
Controlling
Section 5.0
Page 2
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5.0 General lay out
Legend for illustration (Z 21631):
(7.1 / (7.2) Pumps for pilot pressure and pump regulation system
(84.1 / 84.2) Check valve (for combined operation) (68.1) Filter
(70.1) Pressure relief valve (X4 pressure) (70.2) Pressure relief
valve (X2 pressure) (85) Pressure accumulator (10 Liter, 10 bar
pre-charge
pressure) (91) Check valve (45.1; 45.2 ;45.3, 43) Remote control
valves (14; 15; 16; 13)) Control blocks General
The controlling includes the pilot pressure system and the pump
regulation system. The pumps (7.1 / 7.2) forcing the oil through
the filter (68.1) to all involved valves. The pressure accumulator
ensures that under any circumstances enough pilot pressure oil is
available. The accumulator (85) is also functioning as a hydraulic
battery for a certain time when the 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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-
Controlling
Section 5.0
Page 3
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5.1 Control and filter panel location of components Legend for
illustration (Z 22497): Solenoid valves
Engine 1 Engine 2 (Y5) Swing gear house brake (swing parking
brake)
(Y6A-1) (Y6B-1) Oil cooler fan RPM control(Y6A-2) (Y6B-2) Oil
cooler fan RPM control
(Y14A-1) (Y14A-2) Radiator fan RPM control, low speed (only
diesel drive) (Y14B-1) (Y14B-2) Radiator fan RPM control, middle
speed (only diesel drive)
(Y16) Travel gear house brake (travel parking brake)(Y17) Idle
time control (Qmin)(Y17a) Q-max (reduced oil flow at cold
oil)(Y127) Swing service brake control
(Y61.1) (Y61.2) XLR pressure, pumps 1 - 3, XLR pressure, pumps 4
- 6 (Y102.1) (Y102.2) X4 pressure, pumps 1 - 3, X4 pressure, pumps
4 - 6
(Y124A/B) Refilling arm up and down (only with diesel engines)
(Y124c) Refilling arm lock (only with diesel engines)(Y48) Swing
motor power/ speed control
(Y120) Emergency swing service brake control(Y123A/B) ladder up
and down
(Y125) ladder speed control Pressure switches:
(B16) Pilot pressure for Swing gear house brake (24 bar)(B21.1)
(B21.2) Radiator fan drive filter differential switch (filters
68.3+5) (only diesel)
(B22) Differential pressure switch, pilot pressure system filter
(B27.1) (B27.2) Differential pressure switch, PTO gear oil
filter(B28.1) (B28.2) Pressure switch, cooler fan drive filter
(B48) Pilot pressure for travel gear house brake (24 bar)(B97.1)
(B97.2) X4.1 pressure, pumps 1 - 3, X4.2 pressure, pumps 4 - 6
(B85.1) (B85.2) X1.1 pressure, pumps 1+2; X1.2 pressure pumps 4 -
6
(B86) X2 pressure sensor Pressure check points:
(M1.1) (M1.2) Pressure PTO gear lubrication (M2) X4 - pressure
(M3) X2 - pressure
(M5.1) (M5.2) Cooler fan drive pressure (M6) Pressure travel
gear house brake (M7) Pressure Swing gear house brake
(M11) Pressure swing brake (safety circuit ) (M18) Pressure for
hydraulic pump regulation (electronic out)
(M19.1) (M19.2) Radiator fan drive pressure (only with diesel
engines) (M20.1) (M20.2) X1 pressure pumps 1, 2, 4, 5, 6
(M30) X3 pressure for pumps at flow position (M32) X3 pressure
for pumps at flow position (M40) Pilot pressure, X-2
Filter: (68.1) Pilot pressure and pump regulation
(68.2) (68.4) Oil cooler fan drive(68.3) (68.5) Engine radiator
fan drive (only with diesel engines)(69.1) (69.2) PTO gear
lubrication
continued
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Controlling
Section 5.0
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5.2 Pilot Pressure Supply and Adjustments
Pilot Pressure Circuit The pilot pressure oil is used for the
following functions. To move the control block spools, to supply
the main pump regulation system, to lubricate the main pump
bearings, to release the travel- and swing gear house brakes
(spring loaded multi disk brakes), to drive the Lincoln Lubrication
pumps, to move the hydraulic operated ladder, to move the hydraulic
operated refilling arm and to supply the hydraulic track tensioning
system. Legend for illustration (Z 22498):
(7.1 / 7.2) Pilot pressure pumps (84.1 / 84.2) Check valve (for
combined operation) (68.1) Filter (70.1) Pressure relief valve 60
bar (70.2) Pressure relief valve 35 bar (85) Pressure accumulator
(43 + 45.x) Remote control valves (M2) 60 bar pressure check point
(X4-Pressure) (M3) 35 bar pressure check point (X2-Pressure) (M40)
35 bar pres. check point (X2-Pressure in front of accumulator)
Function:
Study together with the hydraulic circuit diagram
The pumps (7.1 and 7.2) are delivering the oil through the
filter (68.1) to port A of the pressure relief valve (70.1) and the
pressure relief valve (70.2) port A. The pressure relief valve
(70.1) maintains the adjusted pressure of 60 bar it is called
X4-pressure. X4 - pressure: Pump support pressure
Pump bearing lubrication Actuation of refilling arm and ladder
Lubrication system Track tensioning system
continued
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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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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.
) For the location and designation of the proportional and
directional solenoid valves of the remote control blocks see 5.3
Remote control valves arrangement in this section.
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5.2 Pilot Pressure Supply and Adjustments
Checks and Adjustment of Pilot Pressure Legend for illustration
(Z 21635a): (85) Bladder Accumulator 10 liter, 10 bar pre-charge
pressure (located underneath the catwalk in front of the PTO)
(70.1) Pressure relief valve for pump support pressure X4 (60 bar)
(70.2) Pressure relief valve for pilot pressure X2 (35 bar) (M2)
Pressure check point X4, pump support pressure (60 bar) (M3)
Pressure check point X2 pressure, pilot pressure (35 bar) (M40)
Pressure check point for accumulator (If not factory installed, fit
a T-union with test connector as shown in illustration Z
21635a)
) Since the X2 and the X4 pressure are influencing each other it
is always necessary to adjust both valves 70.1+70.2 alternately. 60
bar pressure X4, valve 70.1: 1. Connect pressure gauge to check
point (M2) 2. Start both engines and let them 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 both engines and let them 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.
) 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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5.3 Remote control valves arrangement
Legend for illustration (Z 21636)
Function No. Solenoid
valve
Proportional
valve 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)
45.1
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
45.2
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)
45.3
Y31a Y31b
Y31 Stick extending Stick retracting
43 Y32a
Y32b Y32 R.H. Swing
L.H. Swing
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5.4 Function principle of the Electro-Hydraulic- Proportional
Control
Legend for illustration (Z 21637)
(1) Pump (2) Filter (3) Pressure relief valve (4) Check valve
(5) Pressure Accumulator (6) Directional Solenoid valve, a side (7)
Directional Solenoid valve, b side (8) Proportional Solenoid valve
(9) Control valve block (10) Battery (11) Electronic units with
amplifiers etc. (12) Control lever
Function:
The electric-hydraulic control system is used to control the
direction and volume of oil flow to the operating cylinders and
motors via the control valve blocks. Hydraulically:
The oil volume of pump (1) flows through filter (2) into the
pilot pressure system. The pressure is limited by the pressure
relief valve (3). With the pressurized oil stored in accumulator
(5), a limited number of spool movements can be carried out with
the 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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Cont'd:
5.4 Function principle of the Electro-Hydraulic- Proportional
Control
(Exemplary illustration of the function of two a