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SHOP 08199-upD-GB-1
Shop Manual
HYDRAULIC EXCAVATOR
PC4000-6 Diesel Serial Number 08199 and up
HYDRAULIC MINING EXCAVATOR PC4000-6D
Machine model
Serial numbers
PC4000-6D
08199 and up
00 Foreword
® Copyright 2009 KOMATSU MINING GERMANY GmbH
PC4000-6D
1
2
PC4000-6D
1.1 CONTENTS OF THE BINDER
1.1
CONTENTS OF THE BINDER
Assembled in this file are the Operation- and Maintenance Manuals for your KOMATSU Mining Shovel.
4
INTRODUCTION
INTRODUCTION
1.2
1.2 DIVISION OF THE BINDER
DIVISION OF THE BINDER
Part 1: Operation Manual Part 2: Maintenance Manual Part 3: Depending on the volume of Part 3 a second Binder "Volume 2" is being delivered with the Shovel. This Binder contains the General Assembly Procedure Manual for the Shovel, Specification Booklet, Service Literature for the Power Unit (Diesel Engine or Electric Motor) and for Special Equipment. The Electrical- and Hydraulic Diagrams are attached in the pocket of the front cover. Refer to the -TABLE OF CONTENTS VOLUME 2 BINDERfor details.
Read the Manuals before You Start the Engine. Before operating the machine, familiarize yourself with its instruments and controls. Observe the instructions in these manuals for: ●
your Personal SAFETY
●
Operating SAFETY, and
●
READY and EFFICIENT KOMATSU Shovel.
PERFORMANCE
of
your
Periodic preventive inspections and maintenance are the surest means of keeping the machine in proper working order. Prompt detection and correction of minor irregularities, and immediate replacement of worn out or broken parts will prevent failures and avoid expenses. Replace damaged graphics and symbols. Observe safety precautions to prevent injury and damage. If you have any questions concerning this literature please contact Komatsu Mining Germany GmbH Service Information Department 8151.30 P.O. Box 18 03 61 D - 40570 Düsseldorf GERMANY
5
1.3 DESIGNATED USE OF THE SHOVEL
1.3
DESIGNATED USE OF THE SHOVEL
This machine has been manufactured in accordance with advanced and up-to-date technology standards including recognized safety rules. Nevertheless, its use may constitute a risk to life and limb of the user or of third parties, or cause damage to the machine and to other material property. The machine must only be used in technically perfect condition in accordance with its designated use and the instructions set out in the operation manual. Only trained safety-conscious operators who are fully aware of the risks involved should operate the machine. Any functional disorders, especially those affecting the safety of the machine, should, therefore, be rectified immediately. The hydraulic Shovel is designed exclusively for excavating, i.e. excavation of bulk material and natural soil structure (e.g. earth, clay, sand and stones ashore and off-shore). Observe local and national safety regulations. Special conditions at the worksite require additional safe working precautions, follow your company's safety instructions. Short traveling distances for changing the working site are considered as part of the designated use of the Shovel. Using the Shovel for purposes other than those mentioned above (such as object handling and use as a transport vehicle) is considered contrary to its designated use. The manufacturer/supplier cannot be held liable for any damage resulting from such use. The risk of such misuse lies entirely with the user. WARNING Special use of the Shovel beyond its designated use, e.g. object handling operations, require written agreement from the manufacturer and retrofitment of the Shovel with respective safety related equipment before such special applications are permitted.
6
INTRODUCTION
INTRODUCTION
1.4
1.4 DELIVERY OF THE SHOVEL
DELIVERY OF THE SHOVEL
The Shovel is being delivered disassembled into its main components. For assembling the Shovel refer to the ”General Assembly Procedure Manual” in Volume 2 Service Literature Binder. WARNING ●
Improper assembling of the Shovel can cause serious accidents with personal injury or death.
●
Personnel entrusted with work on the machine must have read the Assembly Manual, the Operation- and Maintenance Manual and in particular the section on safety before beginning work. Reading the instructions after work has begun is too late. If there are any questions concerning safe assembling procedure, contact your local Komatsu Service Organization.
Prior to first operation, inspect the Shovel thoroughly with the Service Engineer responsible for the erection of the machine. Check all fluid levels according to the Lubrication and Maintenance Schedule. Damages and defects caused by incorrect operation and maintenance are not covered by the manufacturers guarantee. NOTICE If the Shovel is equipped with a fire suppression system, make sure that the system is ready for operation.
SPARE PARTS For your spare part orders refer to the Parts Catalogue. In order to keep your Shovel in first-class operating condition use only genuine spare and wear parts. The use of any part other than the genuine part releases the KOMATSU MINING GERMANY GmbH from any guarantee.
SERVICE For all questions related to your Shovel please contact your local Service Center. In all your written or phoned inquiries please indicate the model and serial number of your Shovel.
7
1.5 EXPLANATION OF ABBREVIATIONS
1.5
EXPLANATION OF ABBREVIATIONS
ABB
Definition
A
Ampere
AC
Alternating Current
API
American Petroleum Institute
cSt
Centistoke
°C
Degree Celsius
CENSE
Engine Monitoring System
CLS
Central Lubrication System
DC
Direct Current
DIN
German Institute for Standardization
EBL
Electronic Bucket Levelling System
ECM
Electronic Control Module (Engine)
FGPS
Front Guard Protective Structure
FOPS
Falling-Object Protective Structure
GL
Gear Lubricant
h
hours of operation
HPF
High Pressure Filter (Hydraulic Oil)
HT
High Tension
LED
Light Emitting Diode
LT
Low Tension
N
Newton
Nm
Newton meter
QSK
Type of Engine Fuel System
PLC
Programmable Logic Controller
PM
Planned Maintenance
ppm
parts per million
PTO
Power Take-Off (Pump Distributor Gear)
SLS
Swing circle pinion Lubrication System
V
Volt
VHMS
Vehicle Health Monitoring System
1/min
Revolutions Per Minute (RPM)
8
INTRODUCTION
SAFETY
2 SAFETY
IGNORING THE INSTRUCTIONS IN THIS MANUAL COULD LEAD TO SERIOUS INJURY OR DEATH. Please read and make sure that you fully understand the precautions described in this section and the safety labels on the machine. When operating or servicing the machine, always follow these precaution strictly.
2 -1
SAFETY
CONTENTS 2.1
SAFETY INFORMATION ................................................................................................................... 2-3
2.2
OVERVIEW......................................................................................................................................... 2.2.1 NORMAL OPERATIONS ....................................................................................................... 2.2.2 REGULAR MAINTENANCE................................................................................................... 2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR ....................................................... 2.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR.........................................................................
2-4 2-4 2-4 2-4 2-4
2.3
SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB. .............................................................. 2-5
2.4
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR........................... 2-6 2.4.1 UNDERSTANDING THE MACHINE ...................................................................................... 2-6 2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR ...................... 2-6 2.4.2.1 ENSURING SAFE OPERATION............................................................................ 2-6 2.4.3 PREPARATIONS FOR SAFE OPERATION.......................................................................... 2-6 2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT........................ 2-6 2.4.3.2 INSPECTING THE MACHINE................................................................................ 2-6 2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT.................. 2-7 2.4.3.4 KEEP MACHINE CLEAN ....................................................................................... 2-7 2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT ................................... 2-7 2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT ........................................ 2-8 2.4.3.7 IF A PROBLEM IS FOUND .................................................................................... 2-8 2.4.4 FIRE PREVENTION............................................................................................................... 2-8 2.4.4.1 PRECAUTIONS TO PREVENT FIRE .................................................................... 2-8 2.4.4.2 ACTION IF FIRE OCCURS.................................................................................... 2-9 2.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB................................................. 2-10 2.4.5 PRECAUTIONS WHEN CLEANING CAB GLASS .............................................................. 2-10 2.4.6 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE ....................................... 2-10 2.4.6.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE............................................................................................................. 2-10 2.4.6.2 NO JUMPING ON OR OFF THE MACHINE ........................................................ 2-10 2.4.6.3 NO PEOPLE ON THE ATTACHMENT ................................................................ 2-10 2.4.6.4 WORKING IN HIGH PLACES .............................................................................. 2-10 2.4.6.5 LEAVING OPERATOR’S SEAT WITH LOCK ...................................................... 2-11 2.4.6.6 LEAVING THE MACHINE .................................................................................... 2-11 2.4.7 BURN PREVENTION........................................................................................................... 2-11 2.4.7.1 HOT COOLANT .................................................................................................. 2-11 2.4.7.2 HOT OIL .............................................................................................................. 2-12 2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES .......................................... 2-12 2.4.8.1 UNAUTHORIZED MODIFICATION...................................................................... 2-12 2.4.9 PRECAUTIONS AT JOBSITE.............................................................................................. 2-14 2.4.9.1 VISIBILITY FROM OPERATOR’S SEAT ............................................................. 2-15 2.4.9.2 CAMERA SYSTEM WITH MONITORS................................................................ 2-15 2.4.9.3 ENSURE GOOD VISIBILITY................................................................................ 2-15 2.4.9.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS............................................ 2-15 2.4.9.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS.................................... 2-16 2.4.9.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES .......................................... 2-16 2.4.9.7 WORKING ON LOOSE GROUND ....................................................................... 2-17 2.4.9.8 GAS, DUST, STEAM AND SMOKE ..................................................................... 2-17 2.4.9.9 VENTILATION OF ENCLOSED AREAS.............................................................. 2-18
2 -2
SAFETY
2.5
2.6
2.4.10 STARTING ENGINE ............................................................................................................ 2.4.10.1 WARNING TAG ................................................................................................... 2.4.10.2 CHECKS BEFORE STARTING ENGINE ............................................................ 2.4.10.3 PRECAUTION WHEN STARTING ENGINE........................................................ 2.4.10.4 PRECAUTION IN COLD AREAS ......................................................................... 2.4.11 OPERATION........................................................................................................................ 2.4.11.1 CHECKS BEFORE OPERATION ........................................................................ 2.4.11.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE ............... 2.4.11.3 PRECAUTIONS WHEN TRAVELLING ................................................................ 2.4.11.4 TRAVELLING ON SLOPES ................................................................................. 2.4.11.5 OPERATIONS ON SLOPES................................................................................ 2.4.11.6 PROHIBITED OPERATIONS............................................................................... 2.4.11.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES....................... 2.4.11.8 PARKING THE MACHINE ................................................................................... 2.4.11.9 TRANSPORTATION ............................................................................................
2-19 2-19 2-19 2-19 2-20 2-20 2-20 2-21 2-22 2-23 2-24 2-24 2-25 2-25 2-25
PRECAUTION FOR MAINTENANCE.............................................................................................. 2.5.1 GENERAL PRECAUTIONS ................................................................................................. 2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES ............................................................................................ 2.5.1.2 STOP ENGINE FOR MAINTENANCE ................................................................. 2.5.1.3 WARNING TAG ................................................................................................... 2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY ............................................................. 2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS ..................................... 2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING ............................................................................................................ 2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS ............................... 2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT........................................................................................................ 2.5.1.9 NOISE .................................................................................................................. 2.5.1.10 WHEN USING A HAMMER ................................................................................. 2.5.1.11 PROPER TOOLS................................................................................................. 2.5.1.12 ACCUMULATOR ................................................................................................. 2.5.1.13 PERSONNEL ....................................................................................................... 2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE................................................ 2.5.2.1 PRECAUTION WHEN WELDING ........................................................................ 2.5.2.2 BATTERY HANDLING ......................................................................................... 2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID............................................................... 2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE ................................................ 2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES .......................................... 2.5.3.3 REPLACEMENT OF HOSE LINES...................................................................... 2.5.3.4 INSPECTION OF HOSE LINES........................................................................... 2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ............................ 2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE............................................................... 2.5.3.7 AIR CONDITIONING MAINTENANCE ................................................................ 2.5.3.8 COMPRESSED AIR............................................................................................. 2.5.3.9 WASTE MATERIALS ...........................................................................................
2-26 2-26 2-27 2-28 2-28 2-29 2-30 2-30 2-30 2-31 2-31 2-31 2-32 2-32 2-32 2-32 2-32 2-33 2-34 2-34 2-34 2-34 2-35 2-35 2-36 2-36 2-36 2-37
ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS............................................................................................................................... 2-38 2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM ................................................................... 2-38 2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING
2 -3
SAFETY
2.6.3 2.7
2 -4
ADJUSTMENTS................................................................................................................... 2-38 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR...................................... 2-38
SPECIAL SAFETY EQUIPMENT..................................................................................................... 2.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB ................ 2.7.2 OBJECT HANDLING ........................................................................................................... 2.7.3 LIGHTING ............................................................................................................................ 2.7.4 WARNING BEACON............................................................................................................ 2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) ........... 2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) .................................................................................. 2.7.5.2 INSTRUCTIONS FOR USE ................................................................................. 2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL ......................... 2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS OF THE SAFETY HARNESS (1), .................................... 2.7.5.5 INSTRUCTIONS FOR USE .................................................................................
2-40 2-41 2-41 2-41 2-41 2-41 2-41 2-43 2-45 2-45 2-47
SAFETY
2.1
SAFETY INFORMATION
SAFETY INFORMATION
To enable you to use this machine safely, and to prevent injury to operators, service personnel or bystanders, the precautions and warnings included in this manual and the safety signs attached to the machine must always be followed. To identify important safety messages in the manual and on the machine labels, the following signal words are used. The "Safety Alert Symbol" identifies important safety messages on machines, in manuals, and elsewhere. When you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety message.
DANGER This signal word indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING This signal word indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION This signal word indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
NOTICE This signal word is used to alert you to information that must be followed to avoid damage to the machine. This precaution is given where the machine may be damaged or the service life reduced if the precaution is not followed.
2 -5
OVERVIEW
2.2
SAFETY
OVERVIEW
The appropriate safety information for specific working modes on the excavator can be found in the following:-
2.2.1
NORMAL OPERATIONS
–
For normal operating procedures, refer to the OPERATION section of the Operation and Maintenance Manual.
–
For operational safety information, refer to section 2.4 on page 3-8.
–
For on site safety information, refer to section 2.4.9 on page 3-16.
2.2.2
REGULAR MAINTENANCE
–
For information on regular maintenance, including maintenance intervals, refer to the MAINTENANCE section of the Operation and Maintenance Manual.
–
For maintenance safety information, refer to section 2.5 on page 3-28.
2.2.3
TROUBLESHOOTING, ADJUSTMENTS AND REPAIR
–
For additional safety information for troubleshooting and adjustments refer to section 2.6 on page 3-40.
–
For maintenance solutions, refer to the separate manuals TROUBLESHOOTING manual. Available through Komatsu Mining Germany.
–
For servicing information and adjustments, refer to the separate SERVICE MANUAL. Available through Komatsu Mining Germany.
2.2.4 –
ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR
Prior to starting assembling, disassembling and transportation of the excavator read and follow the additional safety precautions given in the ASSEMBLY PROCEDURE MANUAL.
2 -6
SAFETY
2.3
SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB.
SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB.
Fig. 3-1 The sound pressure level in the operator’s cab is measured according to ISO 6396 (Dynamic test method). The sound pressure value is also shown on the decal attached to the wall inside the operator’s cab, see Fig. 3-1.
2 -7
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR
2.4
SAFETY
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR
WARNING WHEN MISUSED, THESE MACHINES ARE DANGEROUS. Mistakes in operation, inspection, or maintenance may result in personal injury or death. Before carrying out operation, inspection, or maintenance, always read this manual and the safety labels on the machine carefully and obey the warnings.
2.4.1
UNDERSTANDING THE MACHINE
Before operating the machine, read this manual thoroughly. If there are any places in this manual that you do not understand, ask the person in charge of safety to give an explanation.
2.4.2
PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR
2.4.2.1 ENSURING SAFE OPERATION –
Only trained and authorized personnel can operate and maintain the machine.
–
During operations, personnel are not allowed outside of the operator’s cabin.
–
Follow all safety rules, precautions and instructions when operating or performing inspection or maintenance on the machine.
–
If you are not feeling well, or are under the influence of alcohol or medication, your ability to safely operate or repair your machine may be severly impaired putting yourself and everyone else on your jobsite in danger.
–
When working with another operator or with a person on worksite traffic duty, discuss the content of the operation beforehand and use pre-determined signals when carrying out these operations.
2.4.3
PREPARATIONS FOR SAFE OPERATION
2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT –
Be sure that all guards, covers and mirrors are in their proper positions. Have guards and covers repaired immediately if they are damaged.
–
Understand the method of use of safety features and use them properly.
–
Never remove any safety features. Always keep them in good operating condition.
2.4.3.2 INSPECTING THE MACHINE Check the machine before starting operations. If any abnormality is found, do not operate the machine until repairs of the problem location have been completed.
2 -8
SAFETY
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR
2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT –
Do not wear loose clothing and accessories. If these catch on the control levers or moving parts, there is a danger that it may cause the machine to move unexpectedly.
–
Always wear a hard hat and safety shoes when working on the machine outside of the cabin. If the nature of the work requires it, wear safety glasses, mask, gloves, ear plugs and a safety belt when operating or maintaining the machine (Fig. 3-2).
–
If you have long hair and it hangs out from your hard hat, there is a hazard that it may get caught up in the machine, so tie your hair up and be careful not to let it get caught.
–
Check that all protective equipment functions properly before using it.
Fig. 3-2
2.4.3.4 KEEP MACHINE CLEAN –
If you get on or off the machine or carry out inspection or maintenance when the machine is dirty with mud or oil, there is a hazard that you will slip and fall. Wipe off any mud or oil from the machine. Always keep the machines clean.
–
If water gets into the electrical system (Fig. 3-3), there is a hazard that it will cause malfunctions or a misoperation. If there is any misoperation, there is a danger that the machine may move unexpectedly and cause serious personal injury or death. When washing the machine with water or steam, do not allow the water or steam to come into direct contact with electrical components. Fig. 3-3
2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT –
When entering the operator’s compartment, always remove all mud and oil from your shoes. If you operate the pedal with mud or oil affixed to your shoes, you may slip and this may cause a serious accident.
–
Do not leave tools or machine parts lying around inside the operator’s compartment. If tools or parts get into the control devices, they may obstruct operation and cause the machine to move unexpectedly, resulting in serious personal injury or death.
–
Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.
–
Do not use a cell phone when driving or operating the machine. This may lead to mistakes in operation, which could cause serious personal injury or death.
–
Never bring any dangerous objects such as flammable or explosive items into the operator’s compartment.
2 -9
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR
SAFETY
2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT Always follow the precautions below to prepare for action if any injury or fire should occur. –
Be sure that fire extinguishers have been provided and read the labels to ensure that you know how to use them in emergencies.
–
Carry out periodic inspection and maintenance to ensure that the fire extinguisher can always be used.
–
Provide a first aid kit. Carry out periodic checks and add to the contents if necessary (Fig. 3-4).
Fig. 3-4
2.4.3.7 IF A PROBLEM IS FOUND If you find any problems in the machine during operation and maintenance (noise, vibration, smell, incorrect gauges, smoke, oil, leakage, etc., or any abnormal display on the warning devices or monitor), report to the person in charge and have the necessary action taken. Do not operate the machine until the problem has been corrected.
2.4.4
FIRE PREVENTION
2.4.4.1 PRECAUTIONS TO PREVENT FIRE Fire caused by fuel, oil, antifreeze, or window washer fluid. Do not bring any flame or fire close to flammable substances such as fuel, oil, antifreeze, or window washer fluid. There is a danger they may catch fire. To prevent fire, always observe the following: – Do not smoke or use any flame near fuel or other flammable substances. (Fig. 3-5) – Stop the engines before adding fuel. – Do not leave the machine while adding fuel or oil. – Tighten all fuel and oil caps securely. – Be careful not to spill fuel on overheated surfaces or on parts of the electrical system. – After adding fuel or oil, wipe up any spillage. – Put greasy rags and other flammable materials into a safe container to maintain safety in the workplace. – When washing parts with oil, use a non-flammable oil. Do not use diesel oil or gasoline. There is a danger that they may catch fire.
Fig. 3-5
– Do not weld or use a cutting torch to cut any pipe or tubes that contain flammable liquids. – Determine well ventilated areas for storing oil and fuel. Keep the oil and fuel in the determined place and do not allow unauthorised persons to enter. REMARKS: Before carrying out grinding or welding work on the machine, remove any flammable materials.
2 - 10
SAFETY
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR
–
Fire caused by accumulation of flammable material. Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or affixed around the engines, exhaust manifold, muffler or battery, or inside the undercovers.
–
Fire coming from electrical wiring Short circuits in the electrical system can cause fire. To prevent fire, always observe the following: – Keep all electrical connections clean and securely tightened. – Check the wiring every day for looseness or damage. Tighten any loose connectors or wiring clamps. Repair or replace any damaged wiring.
–
Fire coming from piping Check that all hose and tube clamps, guards, and cushions are securely fixed in position. If they are loose, they may vibrate during operation and rub against other parts. There is a danger that this may lead to damage to the hoses and cause high pressure oil to spurt out, leading to fire, personal injury, or death.
–
Explosion caused by lighting equipment – When checking fuel, oil, battery electrolyte, or coolant, always use lighting with anti-explosion specifications. – When taking the electrical power for the lighting from the machine itself, follow the instructions of this manual.
2.4.4.2 ACTION IF FIRE OCCURS –
Activate the STOP switch to stop the engine.
–
Use the access ladders and steps to get off the machine.
–
If it is impossible to escape from the rear of the cab, use the rope ladder provided for emergency escape to escape from the side of the cab. (Fig. 3-6.)
Fig. 3-6
–
After escaping with the emergency escape ladder, activate the engine stop chains (1 on Fig. 3-7) to shut down the engine if they are equipped on your shovel.
Fig. 3-7
2 - 11
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR
SAFETY
2.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB If the cab door does not open, use the sliding window for an emergency escape. On machines without a sliding window, use the emergency escape hammer to break the window glass and use the window as an emergency escape.
2.4.5
PRECAUTIONS WHEN CLEANING CAB GLASS
Always keep the cab glass clean to ensure good visibility when operating. Use an ethyl alcohol based washer liquid. Methyl alcohol based liquid may irritate your eyes, so do not use it. If the cab glass on the work equipment side is broken, there is a hazard that the intruding objects may contact the operator's body directly. Stop operation immediately and replace the glass.
2.4.6
PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE
2.4.6.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE To prevent personal injury caused by slipping or falling off the machine, always do as follows. –
Always use the handrails and steps when getting on or off the machine.
–
To ensure safety, always face the machine and maintain three-point contact (both feet and one hand, or both hands and one foot - see Fig. 3-8). with the handrails and steps to ensure that you support yourself.
–
When walking around the machine, where possible, move only in areas that have non-slip padded walkways and nonslip gratings. Extra care is to be taken when moving around outside of these areas.
–
Before getting on or off the machine, check the handrails and steps. If there is any oil, grease, or mud on the handrails or steps, wipe it off immediately. Always keep these parts clean. Repair any damage and tighten any loose bolts.
Fig. 3-8
2.4.6.2 NO JUMPING ON OR OFF THE MACHINE –
Never jump on or off the machine. Never get on or off a moving machine.
–
If the machine starts to move when there is no operator on the machine, do not jump onto the machine and try to stop it.
2.4.6.3 NO PEOPLE ON THE ATTACHMENT Never let any person mount the boom, arm, bucket, or other attachment without appropriate safety equipment. There is danger of falling and suffering serious personal injury. For further information refer to section 2.7 on page 3-42.
2.4.6.4 WORKING IN HIGH PLACES When working in high places, use safety harness and fall absorber to ensure that the work can be carried out safely. For further information refer to section 2.7 on page 3-42.
2 - 12
SAFETY
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR
2.4.6.5 LEAVING OPERATOR’S SEAT WITH LOCK –
Before standing up from the operator's seat in order to adjust the seat, always lower the work equipment to the ground, turn off the engine, relieve the pressure in the hydraulic system and set lock lever to LOCK position (L, Fig. 3-9.). If the lock is not applied, there is danger of serious personal injury if the work equipment control levers are touched by mistake and the machine moves suddenly. For information on relieving the pressure in the hydraulic system, refer to chapter ’RELIEVING THE PRESSURE IN THE HYDRAULIC SYSTEM’ in the ’OPERATION’ part of this manual.
Fig. 3-9
2.4.6.6 LEAVING THE MACHINE –
When leaving the machine, always lower the work equipment completely to the ground, turn off the engine, relieve the pressure in the hydraulic system and set lock lever (1) securely to the LOCK position (L), then stop the engine. Use the key to lock all the equipment. Always remove the key, take it with you, and keep it in the specified place (Fig. 3-10). For information on relieving the pressure in the hydraulic system, refer to chapter ’RELIEVING THE PRESSURE IN THE HYDRAULIC SYSTEM’ in the ’OPERATION’ part of this manual.
Fig. 3-10
2.4.7
BURN PREVENTION
2.4.7.1 HOT COOLANT –
To prevent burns from hot water or steam spurting out when checking or draining the coolant, wait for the water to cool to a temperature where it is possible to touch the radiator cap (Fig. 3-11 and Fig. 3-12) by hand before starting the operation. Even when the coolant has cooled down, loosen the cap slowly to relieve the pressure inside the radiator before removing the cap.
Fig. 3-11
2 - 13
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR
SAFETY
2.4.7.2 HOT OIL –
To prevent burns from hot oil spurting out when checking or draining the oil, wait for the oil to cool to a temperature where it is possible to touch the cap or plug by hand before starting the operation (Fig. 3-12). Even when the oil has cooled down, loosen the cap or plug slowly to relieve the internal pressure before removing the cap or plug.
Fig. 3-12
2.4.8
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES
On jobsites where there is a hazard that falling objects (Fig. 3-13), flying objects (Fig. 3-14), or intruding objects may hit or enter the operator's cab, consider the operating conditions and install the necessary guards to protect the operator. –
When carrying out operations in mines or quarries where there is danger of falling or flying rocks, order/use the optionally available front guard.
–
When carrying out the above operations, always ensure that bystanders are a safe distance away and are not in hazard from falling or flying objects.
–
The above recommendations assume that the conditions are Fig. 3-13 for standard operations, but it may be necessary to add additional guards according to the operating conditions on the jobsite. Always contact your Komatsu distributor for advice.
Fig. 3-14
2.4.8.1 UNAUTHORIZED MODIFICATION –
Komatsu will not be responsible for any injuries, accidents, product failures or other property damage resulting in modifications made without authorisation from Komatsu.
–
Any modifications made without authorisation from Komatsu can create hazards. Before making a modification, consult your komatsu distributor.
–
Any injuries, accidents, or product failures resulting from the use of unauthorized attachments or parts will not be the responsibility of Komatsu.
2 - 14
SAFETY
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR
Please continue reading on the next page.
2 - 15
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR
2.4.9
Fig. 3-15
2 - 16
PRECAUTIONS AT JOBSITE
SAFETY
SAFETY
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR
2.4.9.1 VISIBILITY FROM OPERATOR’S SEAT
WARNING THE AREA AROUND THE EXCAVATOR DURING OPERATION IS EXTREMELY DANGEROUS! Death and serious injury can occur. Make sure the job site is organized in such a way, that the safety of man and equipment is always ensured.
Fig. 3-15 shows an example of general blind areas of large Komatsu hydraulic mining shovels. The grey shaded areas (A) show the areas where the view is blocked when the operator is sitting in the operator’s seat, and the shovel is equipped with standard mirrors. The boundary line (B) shows the distance of 1 meter from outside surface of the shovel. Please be fully aware that there are places that can not seen when operating the machine. REMARKS: The blind areas (A) differ depending on the machine type, attachment and position of attachment. The International Standard ISO 5006 defines criteria for Operator’s visibility. This standard is not met and does not apply to large hydraulic mining shovels.
2.4.9.2 CAMERA SYSTEM WITH MONITORS Komatsu Mining Germany offers optionally camera systems and monitors to improve the overall visibility. See latest version of the OMM for typical arrangement of cameras and monitors. The camera system can be installed ex works and can also be retrofitted in the field. If you need more information, please contact your local Komatsu distributor.
2.4.9.3 ENSURE GOOD VISIBILITY When operating or travelling in places with poor visibility, if it is impossible to confirm the condition of the job side or obstacle is in the area around the machine, there is danger that the machine may suffer damage or the operator may suffer serious personal injury. When operating or travelling in places with poor visibility, always observe the following items strictly. –
If the visibility cannot be sufficiently assured, position a flagman if necessary. The operator should pay careful attention to the signs and follow the instructions of the flagman.
–
The signals should be given only by one flagman.
–
When working in dark places, turn on the working lamps and front lamps of the machine, and if necessary, set up additional lighting in the area.
–
Stop operations if there is poor visibility, such as in fog, snow, rain, or sand storms.
–
Check the mirrors on the machine before starting operations every day. Clean off any dirt and adjust the view to ensure good visibility.
–
In areas where it is impossible to confirm the area around the machine and observation cameras have been set up, clean off any dirt from the lens and make sure that the cameras give a clear view of the working area of the machine.
2.4.9.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS –
Set up signs to inform of road shoulders or soft ground. If the visibility is not good, position a signalman if necessary. Operators should pay careful attention to the signs and follow the instructions from the signalman.
–
Only one signalman should give signals.
Make sure that all workers understand the meaning of all signals and signs before starting work.
2 - 17
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR
SAFETY
2.4.9.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS On the jobsite, there are various hidden dangers that may lead to personal injury or death. Before starting operations, always check the following to confirm there are no dangers on the jobsite. –
When carrying out operations near combustible materials, there is a hazard of fire, so be careful when operating.
–
Check the terrain and condition of the ground at the worksite, and determine the safest method of operation. Do not operate where there is a hazard of landslides or falling rocks.
–
If water lines, gas lines, or high-voltage electrical lines may be buried under the worksite, contact each utility and identify their locations. Be careful not to sever or damage any of these lines (Fig. 3-16).
–
Take necessary measures to prevent any unauthorized person from entering the operating area.
–
If there is a fire near the machine, there is danger of sparks being sucked in and causing a fire on the machine.
–
When travelling or operating in shallow water or on soft ground, check the shape and condition of the bedrock, and the depth and speed of flow of the water before starting operations.
–
Maintain the travel path on the jobsite so that there is no obstruction to travel operations.
Fig. 3-16
2.4.9.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES
DANGER HIGH VOLTAGE! Do not travel or operate the machine near electric cables (Fig. 3-17). There is a hazard of electric shock, which may cause serious injury or property damage. Even going close to high-voltage cables can cause an electric shock, which may cause serious burns or even death.
Fig. 3-17
2 - 18
SAFETY
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR
On jobsites where the machine may go close to electric cables, always do as follows. –
Before starting work near electric cables, inform the local power company of the work to be performed, and ask them to take the necessary action.
–
Always maintain a safe distance (see the table on the right) between the machine and the electric cable. Check with the local power company about safe operating procedure before starting operations.
–
To prepare for any possible emergencies, wear rubber shoes and gloves. Lay a rubber sheet on top of the seat, and be careful not to touch the chassis with any exposed part of your body.
–
Use a signalman to give warning if the machine approaches too close to the electric cables.
–
When carrying out operations near high voltage cables, do not let anyone near the machine.
–
If the machine should come too close or touch the electric cable, to prevent electric shock, the operator should not leave the operator's compartment until it has been confirmed that the electricity has been shut off. Also, do not let anyone near the machine.
Voltage of Cables 100 V - 200 V 6,600 V 22,000 V 66,000 V 154,000 V 187,000 V 275,000 V 500,000 V
Safety Distance Over 2 m (7 ft) Over 2 m (7 ft) Over 3 m (10 ft) Over 4 m (14 ft) Over 5 m (17 ft) Over 6 m (20 ft) Over 7 m (23 ft) Over 11 m (36 ft)
2.4.9.7 WORKING ON LOOSE GROUND –
Avoid travelling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine, there is a hazard that the machine may fall or tip over. Remember that the soil after heavy rain or blasting or after earthquakes is weak in these areas.
–
When working on embankments or near excavated ditches, there is a hazard that the weight and vibration of the machine will cause the soil to collapse. Before starting operations, take steps to ensure that the ground is safe and to prevent the machine from rolling over or falling.
2.4.9.8 GAS, DUST, STEAM AND SMOKE
WARNING RISK OF EXPOLSION AND FIRE! Welding, flame-cutting and grinding work on the machine increases the risk of explosion and fire which may result in serious injury or death. All relevent safety measures must be followed and only under expressly obtained authorization. Special care must be taken before welding, flame-cutting and grinding operations are carried out on the counterweight. The filling of the counterweight chambers can create explosive gases which will accumulate in the chambers of the counterweight. These gases must be expelled before welding, flame-cutting and grinding operations are carried out on the counterweight. Follow the instructions given in PARTS & SERVICE NEWS No. AH04518 for expelling the gases from the counterweight chambers. (See Volume 2 binder)
2 - 19
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR
SAFETY
WARNING RISK OF EXPLOSION! Substances and objects igniting can lead to fire or explosion resulting in serious injury or death. Before carrying out welding, flame-cutting and grinding operations, clean the machine and its surroundings from dust and other inflammable substances and make sure that the premises are adequately ventilated as there is a risk of explosion.
2.4.9.9 VENTILATION OF ENCLOSED AREAS
WARNING POISONOUS FUMES! Unventilated areas where poisonous fumes can accumulate can kill. Always ensure adequate ventilation.
–
Operate internal combustion engines and fuel operated heating systems only on adequately ventilated premises. Before starting the machine on enclosed premises, make sure that there is sufficient ventilation (Fig. 3-18). Observe the regulations in force at the respective site.
–
If it is necessary to start the engine within an enclosed area, or when handling fuel, flushing oil, or paint, open the doors and windows to ensure that adequate ventilation is provided to prevent gas poisoning.
Fig. 3-18
2 - 20
SAFETY
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR
2.4.10 STARTING ENGINE 2.4.10.1 WARNING TAG –
If there is a "DANGER DO NOT OPERATE!" warning tag displayed, it means that someone is carrying out inspection and maintenance on the machine (Fig. 3-19). If the warning sign is ignored and the machine is operated, there is a danger that the person carrying out the inspection or maintenance may be caught in the rotating parts or moving parts and suffer personal injury or death. Do not start the engine or touch the levers.
Fig. 3-19
2.4.10.2 CHECKS BEFORE STARTING ENGINE Carry out the following checks before starting the engine at the beginning of the day's work to ensure that there is no problem with the operation of the machine. If this inspection is not carried out properly, problems may occur with the operation of the machine, and there is the danger that this could lead to serious personal injury or death. –
Remove all dirt from the surface of the window glass to ensure a good view.
–
Completely remove all flammable materials accumulated around the engine and battery, and remove any dirt from the windows, mirrors, handrails, access ladder and steps.
–
Check the coolant levels, fuel levels, and oil levels, and check for damage to the electric wiring.
–
Adjust the operator's seat to a position where it is easy to carry out operations, check the camera system functions and check that there is no damage or wear to the seat belt or mounting clamps.
–
Check the operation of the instruments and gauges, check the angle of the mirror, and check that the control levers are all at the Neutral position.
–
Before starting the engine, check that lock lever (Fig. 3-20) is in LOCK position (L).
–
Adjust the mirrors so that the rear of the machine can be seen clearly from the operator's seat.
–
Check that there are no persons or obstacles above, below, or in the area around the machine.
Fig. 3-20
2.4.10.3 PRECAUTION WHEN STARTING ENGINE –
Start and operate the machine only while seated.
–
Do not short circuit the starting motor circuit to start the engine. Short circuiting can cause fire.
–
When starting the engine, sound the horn as a warning.
2 - 21
HYDRAULIC MINING EXCAVATOR PC4000-6D
Machine model
Serial numbers
PC4000-6D
08199 and up
01 Specification
® Copyright 2009 KOMATSU MINING GERMANY GmbH
PC4000-6D
1
2
PC4000-6D
OPERATING WEIGHT 385-397 ton 850,000-875,000 lb 22
m3
SHOVEL CAPACITY 29 yd3 SAE 2:1 heaped
BACKHOE CAPACITY 22 m3 29 yd3 SAE 1:1 heaped
PC4000 PC
4000
SUPER SHOVEL
PC 4000
S UPER S HOVEL
WALK-AROUND Quality ● Quality management ISO 9001 certified. ● Environmental Management ISO 14001 certified. ● High consistent quality through continuous investment in personnel, design and manufacturing systems and processes.
Reliability and Durability Designed for lower operating costs ● Robust structural design developed from field experience and finite element analaysis. ● Extended life undercarriage wear parts; Big diameter rollers, idlers and sprockets. Large surface area and extensive precision hardening. Hardened track link pin bores.
Productivity Designed for more tons per hour ● Powerful digging forces. ● Ease of bucket filling. ● Proven attachment design. ● All cylinders mounted under the shovel attachment for additional protection. ● Buckets and Wear Packages to suit all material densities and ground conditions.
2
PC 4000
SUPER SHOVEL
MATCHED FOR 150 to 240 U.S. ton TRUCKS
Large Comfortable Cab Full shift comfort ● Komatsu low noise cab on multiple viscous mounts for reduced noise and vibration. ● Large volume cab with deep wide front window. ● Comprehensive climate control with pressurised filtered air ventilation and air conditioning. ● High specification multi-adjustable air suspension seat. ● Well elevated operator position giving good all round view.
SHOVEL AND BACKHOE BUCKET CAPACITY 22 m3 29 yd3
Advanced Hydraulics Extended reliability and precise control ● Comprehensive monitored filtration. ● Simple open circuit hydraulic system with high efficency swing out oil coolers.
Powerful Diesel Engine Single Komatsu SDA16V160 engine ● Rated 1400 kW 1875 HP, at 1800 rpm. ● Electronic engine management. ● Low engine emission levels meet EPA regulations. ● Time saving oil management system fitted as standard; Centinel Engine Oil Management, Reserve Engine Oil Supply and Eliminator Oil Filter systems.
Easy Maintenance Simple, common-sense design gives quick safe access to all major components ● Generous access to all major service points from machinery house floor level. ● Enclosed, internally lit machinery house with firewall separating engine from pump area. ● Automatic central lubrication. ● VHMS electronic monitoring system providing real time information about the operating status of the machine. ● Ground-level access to hydraulically powered swing down service arm with Wiggins connections.
3
PC 4000
S UPER S HOVEL
SPECIFICATIONS DIESEL DRIVE Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Komatsu SDA16V160 Type . . . . . . . . . . . . . . . . . . . 4-cycle, water-cooled, direct injection Aspiration . . . . . . . . . . . . . . . . . . . . . Turbocharged and aftercooled Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Rated power . . . . . . . . . . . . . . . . . . 1400 kW 1875 HP @ 1800 rpm (SAE 1995/J1349)
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . All-speed, electronic The integrated engine oil and filter system combining the oil stabilising systems, Reserve and Centinel, with the Eliminator self cleaning oil filter extends, with oil analysis, the oil change interval to 4000 hours. (not available in Australia)
ELECTRIC DRIVE Type . . . . . . . . . . . . . . . . . . . . . . . . . Squirrel-cage induction motor Power output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1350 kW Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6600 V* Amperage (approximate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 A Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Soft start Frequency (standard) . . . . . . . . . . . . . . . . . . . . . 50 Hz @ 1500 rpm Optional frequency . . . . . . . . . . . . . . . . . . . . . . . 60 Hz @ 1800 rpm *Other voltages available on request
UNDERCARRIAGE ELECTRICS System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 V Batteries (series/parallel) . . . . . . . . . . . . . . . . . . . . . . . . 2x 3 x 12 V Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 A Standard working lights. . . . . . . . . . . . . . . . . . . . . . . 8 Xenon lights Standard service lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 lights
HYDRAULICS The power train consists of one main drive. Diesel engine or electric motor can be supplied. One gearbox drives four identical main pumps which draw hydraulic oil from an unpressurized hydraulic tank. Open circuit hydraulics provide maximum cooling and filtering efficiency. Rated flow (total output) . . . . . . . . . . . . 4140 ltr/min 1096 U.S. gal Relief valve setting . . . . . . . . . . . . . . . . . . . . . . . . 310 bar 4,495 psi Swing flow rate . . . . . . . . . . . . . . . . . . . . 1590 ltr/min 420 U.S. gal High pressure in line filters . . . . . . . . . . . . . . . . . . . . . . 200 microns
Undercarriage consists of one center carbody and two track frames, each side attached by 62 high torque bolts. Center frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-type Track frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steel box-section
CRAWLER ASSEMBLY Track adjustment . . . . . . . . . . . . . . . . . . . Automatic hydraulic type Number of shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 each side Number of top rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . 3 each side Number of bottom rollers. . . . . . . . . . . . . . . . . . . . . . . . 7 each side
COOLING SYSTEM The high capacity engine radiators are cooled by hydraulically driven fans for superior cooling efficiency and require little maintenance. The hydraulic system includes two large swing-out vertical air-to-oil hydraulic coolers with temperature-regulated hydraulically driven fans.
one per pump located at the valve blocks
Full flow return line filters (8 double elements) . . . . . . . . 10 microns at head of hydraulic tank
Case drain/by-pass return line filters . . . . . . . . . . . . . . . . 3 microns The four-circuit system features a load-limiting governor with oil delivery summation to the working circuits and incorporates pressure cut-off control. Hydropilot prioritizes hydraulic flow giving smooth hydraulic response, simple hydraulic system layout, and a reduced number of components. The hydraulic system includes four large swing-out vertical air-to-oil hydraulic coolers with temperatureregulated hydraulically driven fans.
DRIVES AND BRAKES Travel control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 foot pedals Gradeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Up to 50% Travel speed (maximum) . . . . . . . . . . . . . . . . . . . 2.1 km/h 1.3 mph Service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic brake Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . Wet, multiple-disc
SWING SYSTEM Hydraulic motors and drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Swing brake, service . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic brake Swing brake, parking. . . . . . . . . . . . . . . . . . . . . . Wet, multiple-disc Swing ring teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Swing speed (maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 rpm
4
AUTOMATIC CENTRALISED LUBRICATION Two hydraulically powered Lincoln single line automatic lubrication systems are provided as standard, complete with time and volume variable controls. Activity and malfunction events are linked to the VHMS. The central lube grease system is supplied from a refillable 200 litre 53 gal. barrel. A second, identical system supplies open gear lubricant to the swing ring teeth through a lube pinion. Replenishment of the barrels is through the service arm.
SERVICE CAPACITIES Hydraulic oil tank . . . . . . . . . . . . . . . . . . . 3900 ltr Hydraulic system . . . . . . . . . . . . . . . . . . . 5900 ltr Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6400 ltr Engine coolant . . . . . . . . . . . . . . . . . . . . . . 475 ltr Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . 290 ltr Centinel engine oil make up tank . . . . . . . 460 ltr
1,030 U.S. gal 1,559 U.S. gal 1,691 U.S. gal 125 U.S. gal 77 U.S. gal 122 U.S. gal
PC 4000
SUPER SHOVEL
CAB Cab engineering standards are; • ISO 3449 Falling Objects Protection Structure • ISO 6396 Noise in operator´s cab is 73 dB(A) • ISO 2631-1/ 5349-1 Vibration and Shock • Air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . .10kW 34120 Btu • Heater/Demister (Diesel version) . . . . . . . . . . . . .10kW 34120 Btu
The large welded steel safety cab is mounted with 18 viscous damping pads and sound insulated. It is equipped with automatic climate control and is pressurised. The operator’s seat is fully adjustable, air suspended, electrically heated and has a lap seat belt. There is a trainer’s seat. Low effort joy stick controls are electric over hydraulic and foot controls are for front shovel clam, crawler and swing brake. Full instrumentation and VHMS are provided. Space in the console is provided for an additional monitor. AM/FM radio is fitted. The windshield wash wiper has two speed and intermittent operation. (Water reservoir 7 litres 1.8 gal.) Amenities include a wash basin with running water, water reservoir, (50 litres 13 gal.), refrigerator and storage cabinets. Powered mirrors are adjusted from inside the cab. There are left and right hand sliding windows. All windows are tinted parsol green. External metal louvres are provided on the cab side windows.
CS
VEHICLE HEALTH MONITORING SYSTEM
VHMS is designed for Komatsu mining equipment to provide real time and stored information about the status of the operating machine. A touch sensitive flat screen color monitor gives a continuous display or can be activated to provide operator or service data. Non serious and critical faults are automatically announced, while for major malfunctions the engine is also shut down. The integrated digital storage provides a full event history, which can be down loaded by laptop computer or by wireless link. The ability to provide real time service information as messages, snap-shot or trend data automatically to mine control programmes can improve mechanical utilisation and reduce costs. (Electric drive version fitted with ECS Health Monitor)
OPERATING WEIGHTS PC 4000 Backhoe:
PC 4000 Front Shovel:
Operating weight including 9750 mm 32’0’’ boom, 4500 mm 14’9’’ stick, 22 m3 29 yd3 backhoe bucket, operator, lubricant, coolant, full fuel tank and standard equipment.
Operating weight including 7150 mm 23’6’’ boom, 4900 mm 16’1’’ stick, 22 m3 29 yd3 shovel bucket, operator, lubricant, coolant, full fuel tank and standard equipment.
Shoe Width
Operating Weight
Ground Pressure
Shoe Width
Operating Weight
Ground Pressure
1200 mm 47’’
392 t 865,000 lb
2.19 kg/cm2 31.2 psi
1200 mm 47’’
385 t 850,000 lb
2.15 kg/cm2 30.6 psi
1500 mm 59’’
397 t 875,000 lb
1.78 kg/cm2 25.3 psi
1500 mm 59’’
390 t 860,000 lb
1.75 kg/cm2 24.8 psi
4
5
3
Explanation 1 Operator´s Cab
7
10
2 Power Train 3 Hydraulic Pumps
6
4 Hydraulic Tank
2
9
5 Hydraulic Coolers 6 Valve Blocks 7 Swing Motor
7
10
8 Fuel Tank
8
9 Counterweight 10 Autolube System
6
1
11 Secondary Egress
11
Lower-Level Upper-Level SKZ4006_68
5
PC 4000
S UPER S HOVEL
PRODUCTIVITY-FEATURES
4006078
DIGGING FORCES Break-out force Tear-out force
1155 kN 1050 kN
260,000 lb 236,000 lb
Maximum reach at ground level . . . . . . . . .16.650 mm 54’8’’ Maximum digging depth . . . . . . . . . . . . . . . .8000 mm 26’3’’
BACKHOE BUCKET, STICK AND BOOM COMBINATION Bucket Capacity
Width
SAE Heaped 1 : 1 22 m3 29 yd3
Teeth
including Wear package -2 3790 mm 12’5’’
Alternative buckets / wear packages are available
6
Weight
23.4 t 51,590 lb
Boom Length 9750 mm 32’ 0’’ Stick Length 4500 mm 14’ 9’’
6
Material weight to 1.8 t/m3 3000 lb/yd3
SUPER SHOVEL
PC 4000
4006077
DIGGING FORCES Break-out force Crowd force
1250 kN 1330 kN
280,000 lb 300,000 lb
Level crowd at ground level . . . . . . . . . . . . . .5700 mm 18’8’’ Maximum dumping height . . . . . . . . . . . . . .12.000 mm 39’4’’
SHOVEL BUCKET, STICK AND BOOM COMBINATION Bucket Capacity SAE / CECE Heaped 2 : 1
Heaped 1 : 1
22 m3 29 yd3
25 m3 32.7 yd3
Width
Weight
Teeth
including Wear package-3 4020 mm 13’2’’
38.8 t 76,700 lb
Boom Length 7150 mm 23’ 6’’ Stick Length 4900 mm 16’ 1’’
5
Material weight to 1.8 t/m3 3000 lb/yd3
Alternative buckets / wear packages are available
7
STANDARD EQUIPMENT Hydraulic Mining Shovel with Diesel Drive will comprise: ● FRONT SHOVEL ATTACHMENT 7.15 m 23'6" boom and 4.9 m 16'1" stick complete with cylinders. 22 m3 29 yd3 (SAE 2:1) shovel bucket with mechanical teeth and lip system. OR ● BACKHOE ATTACHMENT 9.75 m 32'0" boom and 4.5 m 14'9" stick with 22 m3 29 yd3 (SAE 1:1) bucket. ● CRAWLER UNDERCARRIAGE Heavy-duty shovel type undercarriage consisting of a center carbody and 2 heavy box-type track frames, each having 7 bottom rollers, 3 top rollers, and 1200 mm 47" cast steel track shoes. Hydraulic track adjustment and parking brake provided.
● SUPERSTRUCTURE Main frame mounted over an externally toothed swing circle carries the main drive module, including Komatsu SDA16V160 diesel engine, oil and fuel reservoirs, counterweight, operator’s cab and base.
AM-FM radio. Washbasin with running water (reservoir 50 ltr 13 gal). Refrigerator and storage cabinets. Left and right hand sliding windows. All windows tinted parsol green. ● LUBRICATION LINCOLN central lubrication for basic machine, attachment, and bucket. 200 ltr 53 gal refillable barrel. LINCOLN automatic pinion lubrication system for swing circle teeth with 200 ltr 53 gal refillable barrel.
● LIGHTING 8 Xenon high performance working lights. 11 service lights throughout platform. ● OPERATOR’S CAB Fully enclosed steel cab which incorporates the ISO 3449 standard FOPS structure and CARRIER SÜTRAK air-conditioning unit. Mounted on viscous pads. GRAMMER fully suspended seat with lap-belt. Fold-away auxiliary seat. Full selection of controls, switches, and VHMS (Vehicle Health Monitoring System). Joystick and pedal-operated controls are electric over hydraulic. Windshield wash wipers with two speed and intermittent operation. (reservoir 7 ltr 1.8 gal).
Service point (diesel version only as standard) on hydraulic arm carrying WIGGINS fluid receiving connectors for filling of fuel, engine oil and coolant, hydraulic oil, grease, cabwater and the evacuation of coolant, and hydraulic and engine oils. ● ACCESSORIES Acoustic travel alarm Hydraulically actuated ground access ladder Electric air horn Engine oil management System. (Centinel, Reserve & Eliminator Systems)
OPTIONAL EQUIPMENT • 1500 mm 59’’ track shoes • Extra or alternative, lighting
• Electric drive • Cable reel (Electric Version)
• Low temperature package • Fire suppression system
DIMENSIONS
BASIC MACHINE WITH COUNTERWEIGHT
N M
OR
L
A B CA CB D E F G
1200mm 1500mm 6750mm 7050mm 2480mm 3380mm 6700mm 8842mm
47" 59" 22'2" 23'2" 8'2" 11'1" 22'0" 29'0"
H I J K L M N O OR
3017mm 3085mm 7600mm 8300mm 3175mm 4700mm 7975mm 6095mm 6500mm
9'11" 10'2" 24'11" 27'3" 10'5" 18'6" 26'2" 20'0" 21'4"
O
K
H
D
E
A B
F
CA
G
CB
Ground Clearance: 930mm 3'0"
QESS0046 01
I J
SKZ4006_67
SKZ4006_66
©2006 Komatsu Printed in Germany
www.komatsu-mining.com
Materials and specifications are subject to change without notice. is a trademark of Komatsu Ltd. Japan.
HYDRAULIC MINING EXCAVATOR PC4000-6D
Machine model
Serial numbers
PC4000-6D
08199 and up
10 Structure, Function
® Copyright 2009 KOMATSU MINING GERMANY GmbH
PC4000-6D
1
2
PC4000-6D
I.
II.
INTRODUCTION ............................................................................ I-1 I.I
CONTENTS OF THE BINDER ........................................................................................... I-2
I.II
FOREWORD ...................................................................................................................... I-3 1.2.1 IMPORTAND NOTE.............................................................................................. I-5
I.III
EXPLANATION OF ABBREVATIONS .............................................................................. I-7
SAFETY ......................................................................................... II-1 II.I
SAFETY INSTRUCTIONS ................................................................................................. II-2
II.II
GENERAL PREAUCTIONS .............................................................................................. II-3
II.III
PREPARATIONS FOR WORK ......................................................................................... II-4
II.IV
PRECAUTIONS DURING WORK ..................................................................................... II-5
II.V
PRECAUTIONS AFTER WORK ....................................................................................... II-6
1
1
III.
2
MAIN ASSEMBLY GROUPS............................................................ 1-1 1.1
GENERAL LAYOUT .......................................................................................................... 1-2
1.2
SUPERSTRUCTURE ......................................................................................................... 1-4
1.3
MACHINE HOUSE ............................................................................................................ 1-6
1.4
HYDRAULIC OIL RESERVOIR ......................................................................................... 1-8
1.5
HYDRAULIC OIL COOLER ............................................................................................. 1-10
1.6
FUEL TANK .................................................................................................................... 1-12
1.7
COUNTERWEIGHT.......................................................................................................... 1-14
1.8
CAB SUPPORT................................................................................................................ 1-16
1.9
OPERATOR’S CAB ......................................................................................................... 1-18
1.10
CONTROL BLOCKS ........................................................................................................ 1-20
1.11
SWING GEARS ................................................................................................................ 1-22
1.12
UNDERCARRIAGE.......................................................................................................... 1-24
1.13
BACKHOE ATTACHMENT (BHA) .................................................................................. 1-26
1.14
FRONT SHOVEL ATTACHMENT (FSA) ......................................................................... 1-28
SPECIFICATIONS ........................................................................ III-1 III.I
LIFTING GEARS .............................................................................................................. III-2
III.II
STANDARD TIGHTENING TORQUE CHART ................................................................ III-4
III.III
CONVERSION TABLE ..................................................................................................... III-5
III.IV
GENERAL SPECIFICATIONS ....................................................................................... III-12
2.
DRIVE............................................................................................... 2-1 2.1
PRIME DRIVE ASSEMBLY ............................................................................................... 2-2
2.2
ENGINE AND PTO MOUNTS ............................................................................................ 2-4 2.2.1 FLEXIBLE MOUNTS ............................................................................................ 2-5 2.2.2 TORQUE SUPPORT............................................................................................ 2-7
2.3
FAN DRIVE AND RADIATOR ASSEMBLY....................................................................... 2-8 2.3.1 RADIATOR FAN DRIVE SPEED ADJUSTMENT .............................................. 2-12
2.4
PUMP DISTRIBUTOR GEARBOX (PTO)........................................................................ 2.4.1 SPLINE SHAFT HOUSING ................................................................................ 2.4.2 PTO LUBRICATION AND COOLING................................................................. 2.4.3 HYDRAULIC PUMPS – LOCATION, DRIVE SPEED AND FLOW RATES .......
2.5
GEISLINGER COUPLING................................................................................................ 2-28
2.6
AIR FILTER ...................................................................................................................... 2-30
2-16 2-18 2-20 2-26
3
3.
4
HYDRAULIC OIL RESERVOIR ........................................................ 3-1 3.1
GENERAL LAYOUT ......................................................................................................... 3-2
3.2
MAIN OIL TANK, LOCATION OF ELECTRIC EQUIPMENT. ........................................... 3-4
3.3
SUCTION OIL RESERVOIR WITH STRAINERS ............................................................. 3-6
3.4
RETURN OIL COLLECTOR TUBE WITH STRAINER ..................................................... 3-8
3.5
BACK PRESSURE VALVE ............................................................................................. 3-10
3.6
TRANSFER PUMP .......................................................................................................... 3-12 3.6.1 EVACUATION OF THE SUCTION OIL RESERVOIR........................................ 3-15 3.6.2 EVACUATION OF THE RETURN OIL COLLECTOR PIPES AND COOLER CIRCUIT 3-17
3.7
RETURN AND LEAK OIL FILTER .................................................................................. 3-18
3.8
BREATHER FILTER ....................................................................................................... 3-20
4.
HYDRAULIC OIL COOLING ............................................................ 4-1 4.1
4.2 CIRCUIT 4.3
GENERAL .......................................................................................................................... 4-2 FUNCTION OF THE HYDRAULIC OIL COOLING 4-4 ADJUSTMENT OF THE BACK PRESSURE VALVE........................................................ 4-6
4.4 FAN DRIVE (TWO STAGE COOLER FAN RPM CONTROL) 4-8 4.4.1 FIXED DISPLACEMENT PUMP, WITH VARIABLE SETTING ......................... 4-10 4.4.2 PRESSURE RELIEF VALVES .......................................................................... 4-12 4.4.3 FAN SPEED CONTROL VALVE ARRANGEMENT........................................... 4-14 4.5
ADJUSTMENT OF THE COOLER FAN DRIVE SPEED ................................................. 4-16 4.5.1 FUNCTION CHECK OF FAN SPEED CONTROL ............................................. 4-21
5
5.
CONTROLLING.............................................................................. 5-23 5.1
GENERAL LAYOUT ........................................................................................................ 5-24
5.2 CONTROL AND FILTER PANEL LOCATION OF COMPONENTS 5-26 5.3
PILOT PRESSURE SUPPLY AND ADJUSTMENTS ...................................................... 5.3.1 PILOT PRESSURE CIRCUIT (PPC) .................................................................. 5.3.2 CHECKS AND ADJUSTMENT OF PILOT PRESSURE..................................... 5.3.3 REMOTE CONTROL VALVES ARRANGEMENT..............................................
5-32 5-33 5-36 5-38
5.4 FUNCTION ELECTRO HYDRAULIC CONTROL SYSTEM 5-40
6
5.5
POTENTIOMETER CONTROL (LEVER, JOY STICK).................................................... 5-44
5.6
POTENTIOMETER CONTROL (PEDAL) ........................................................................ 5-46
5.7
PROPORTIONAL AMPLIFIER MODULE, TYPE A ......................................................... 5-48
5.8
PROPORTIONAL AMPLIFIER MODULE, TYPE B ......................................................... 5-50
5.9
RAMP TIME MODULE .................................................................................................... 5-52
5.10
ADJUSTMENTS OF AMPLIFIER MODULES ................................................................. 5.10.1 GENERAL .......................................................................................................... 5.10.2 ADJUSTING THE AMPLIFIERS TYPE B........................................................... 5.10.3 ADJUSTING THE AMPLIFIERS TYPE A...........................................................
5.11
ADJUSTING THE RAMP TIME MODULE ....................................................................... 5-62
5-54 5-55 5-56 5-60
6.
COMPONENTS ................................................................................ 6-1
6.1 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER (FSA) 6-2 6.2 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER (BHA) 6-4 6.3 DISTRIBUTOR MANIFOLD - LOCATION OF RESTRICTOR BLOCKS AND ANTI CAVITATION VALVES (FSA) 6-6 6.4 DISTRIBUTOR MANIFOLD - LOCATION OF RESTRICTOR BLOCKS AND ANTI CAVITATION VALVES (BHA) 6-8 6.5
SINGLE CONTROL BLOCKS (FLOATING) FOR STICK AND BOOM (FSA)................ 6-10
6.6
RESTRICTOR BLOCK WITH PRESSURE RELIEF VALVE........................................... 6-12
6.7
ANTI CAVITATION VALVE BLOCK................................................................................ 6-14
6.8
REMOTE CONTROL VALVES ........................................................................................ 6-16
6.9 DIRECTIONAL SOLENOID VALVES (THREE POSITIONS / 4-WAYS) 6-18 6.10
PROPORTIONAL SOLENOID VALVE ............................................................................ 6-20
6.11
HIGH PRESSURE FILTER .............................................................................................. 6-22
6.12
CONTROL BLOCKS AND VALVES................................................................................ 6-24
6.13
TRAVEL BRAKE VALVE................................................................................................. 6-36
6.14
PRESSURE REDUCING VALVE..................................................................................... 6-38
6.15 DIRECTIONAL SOLENOID VALVES (TWO POSITIONS / 4-WAYS) 6-40 6.16
PRESSURE INCREASING VALVE ................................................................................. 6-42
6.17
HYDRAULIC CYLINDER ................................................................................................. 6-44
6.18
SWING RING.................................................................................................................... 6-48
7
7.
MAIN HYDRAULIC PUMPS AND PUMP REGULATION................. 7-1 7.1
GENERAL .......................................................................................................................... 7-2
7.2
MAIN PUMPS ................................................................................................................... 7.2.1 LOCATION OF PUMPS ..................................................................................... 7.2.2 PUMP BEARING FLUSHING / LUBRICATION.................................................. 7.2.3 OPERATING PRINCIPLE .................................................................................. 7.2.4 CHECKS / ADJUSTMENTS ...............................................................................
7-12 7-13 7-14 7-16 7-34
7.3
ELECTRONIC PUMP REGULATION SYSTEM .............................................................. 7.3.1 ELECTRONIC LOAD LIMITING CONTROL - GENERAL .................................. 7.3.2 MICROCONTROLLER RC4-4............................................................................ 7.3.3 CHECKS AND ADJUSTMENTS ........................................................................
7-44 7-45 7-47 7-49
7.4
HYDRAULIC CONSTANT REGULATION SYSTEM ....................................................... 7-76 7.4.1 GENERAL .......................................................................................................... 7-77 7.4.2 X1-PRESSURE ADJUSTMENT (CONSTANT-PRESSURE)............................. 7-78
7.5 DETERMINATION OF THE PEAK POINT (ENGINE PERFORMANCE) 7-80
8
7.6
ENGINE SPEED SENSOR (PICK UP)............................................................................. 7-82 7.6.1 GENERAL .......................................................................................................... 7-83 7.6.2 ENGINE SPEED SENSOR (PICK UP) ADJUSTMENT ..................................... 7-83
7.7
ENERGY EFFICIENCY .................................................................................................... 7-84 7.7.1 GENERAL .......................................................................................................... 7-85 7.7.2 CHECKS AND ADJUSTMENTS ........................................................................ 7-86
8.
OPERATING HYDRAULIC............................................................... 8-1 8.1
GENERAL .......................................................................................................................... 8-2 8.1.1 FLOATING SYSTEM............................................................................................ 8-4
8.2
HYDRAULIC FOR THE ATTACHMENT CYLINDER FSA AND BHA............................... 8-6 8.2.1 ELECTRIC / HYDRAULIC FLOWCHART "BOOM RAISING" FSA...................... 8-6 8.2.2 ELECTRIC / HYDRAULIC FLOWCHART "BOOM RAISING" BHA ..................... 8-8 8.2.3 ELECTRIC / HYDRAULIC FLOWCHART "BOOM LOWERING" FSA ............... 8-10 8.2.4 ELECTRIC / HYDRAULIC FLOWCHART "BOOM LOWERING" BHA............... 8-12 8.2.5 ELECTRIC / HYDRAULIC FLOWCHART "STICK EXTENDING" FSA .............. 8-14 8.2.6 ELECTRIC / HYDRAULIC FLOWCHART "STICK EXTENDING" BHA.............. 8-16 8.2.7 ELECTRIC / HYDRAULIC FLOWCHART "STICK RETRACTING" FSA............ 8-18 8.2.8 ELECTRIC / HYDRAULIC FLOWCHART "STICK RETRACTING" BHA ........... 8-20 8.2.9 ELECTRIC / HYDRAULIC FLOWCHART "BUCKET FILLING" FSA ................. 8-22 8.2.10 ELECTRIC / HYDRAULIC FLOWCHART "BUCKET FILLING" BHA ................. 8-24 8.2.11 ELECTRIC / HYDRAULIC FLOWCHART "BUCKET EMPTYING" FSA ............ 8-26 8.2.12 ELECTRIC / HYDRAULIC FLOWCHART "BUCKET EMPTYING" BHA............ 8-28 8.2.13 ELECTRIC / HYDRAULIC FLOWCHART "CLAM OPENING" FSA ................... 8-30 8.2.14 ELECTRIC / HYDRAULIC FLOWCHART "CLAM CLOSING" FSA ................... 8-32 8.2.15 CHECKS AND ADJUSTMENTS OF THE MAIN RELIEF VALVES (FSA) ......... 8-34 8.2.16 CHECKS AND ADJUSTMENTS OF THE MAIN RELIEF VALVES (BHA)......... 8-36 8.2.17 CHECKS AND ADJUSTMENTS OF THE SERVICE LINE RELIEF VALVES (SRV) 8-38 8.2.17.1 BOOM CYLINDER "PISTON SIDE" FSA + BHA .............................. 8-39 8.2.17.2 BOOM CYLINDER "PISTON ROD SIDE" FSA +BHA ...................... 8-43 8.2.17.3 STICK CYLINDER "PISTON SIDE" FSA .......................................... 8-47 8.2.17.4 STICK CYLINDER "PISTON SIDE" BHA.......................................... 8-51 8.2.18 STICK CYLINDER "PISTON ROD SIDE" FSA .................................................. 8-55 8.2.18.1 STICK CYLINDER "PISTON ROD SIDE" BHA................................. 8-59 8.2.18.2 BUCKET CYLINDER "PISTON SIDE" FSA ...................................... 8-63 8.2.18.3 BUCKET CYLINDER "PISTON SIDE" BHA...................................... 8-67 8.2.18.4 BUCKET CYLINDER "PISTON ROD SIDE" FSA ............................. 8-71 8.2.18.5 BUCKET CYLINDER "PISTON ROD SIDE" BHA............................. 8-75 8.2.18.6 CLAM CYLINDER "PISTON ROD SIDE" FSA.................................. 8-79 8.2.18.7 CLAM CYLINDER "PISTON SIDE" FSA........................................... 8-81 8.2.18.8 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED ....... 8-83 8.2.18.9 BUCKET CYLINDER FSA ................................................................ 8-97 8.2.18.10 BUCKET CYLINDER BHA ................................................................ 8-99 8.2.18.11 CLAM CYLINDER BHA .................................................................. 8-101
8.3
HYDRAULIC FOR THE SWING CIRCUIT ..................................................................... 8.3.1 SWING CIRCUIT.............................................................................................. 8.3.2 SWING MOTOR .............................................................................................. 8.3.3 SWING GEAR BOX ......................................................................................... 8.3.4 SWING PARKING BRAKE (GEAR HOUSE BRAKE) ...................................... 8.3.5 SWING BRAKE VALVE ................................................................................... 8.3.6 ELECTRIC / HYDRAULIC FLOWCHART "SWING LEFT" .............................. 8.3.7 ELECTRIC / HYDRAULIC FLOWCHART "SWING RIGHT" ............................ 8.3.8 CHECKS AND ADJUSTMENTS FOR THE SWING CIRCUIT......................... 8.3.9 FUNCTION CHECK FOR HYDRAULIC SWING BRAKE ................................ 8.3.10 FUNCTION CHECK FOR THE SWING PARKING BRAKE .............................
8-102 8-102 8-106 8-108 8-110 8-112 8-114 8-116 8-118 8-124 8-126
9
8.4
10
HYDRAULIC FOR THE TRAVEL CIRCUIT ................................................................... 8.4.1 TRAVEL CIRCUIT ............................................................................................ 8.4.2 TRAVEL MOTOR ............................................................................................. 8.4.3 ROTARY DISTRIBUTOR ................................................................................. 8.4.4 TRAVEL GEAR ................................................................................................ 8.4.5 TRAVEL PARKING BRAKE (GEAR HOUSE BRAKE)..................................... 8.4.6 TRAVEL BRAKE VALVE.................................................................................. 8.4.7 ELECTRIC / HYDRAULIC FLOWCHART “TRAVELING FORWARD”............. 8.4.8 ELECTRIC / HYDRAULIC FLOWCHART “TRAVELING BACKWARD”........... 8.4.9 CHECKS AND ADJUSTMENTS FOR THE TRAVEL CIRCUIT ....................... 8.4.10 FUNCTION CHECK FOR THE TRAVEL PARKING BRAKE ...........................
8-128 8-128 8-132 8-134 8-136 8-138 8-140 8-142 8-144 8-146 8-148
9.
HYDRAULIC TRACK TENSIONING SYSTEM ................................ 9-1 9.1
GENERAL .......................................................................................................................... 9-2
9.2
PRESSURE INCREASING VALVE ................................................................................... 9-6
9.3
TENSIONING CYLINDER .................................................................................................. 9-8
9.4
ADJUSTMENTS / CHECKS............................................................................................. 9-10
9.5
FUNCTIONAL TEST ........................................................................................................ 9-12
11
10. ACCESS LADDER HYDRAULICALLY OPERATED ...................... 10-1
12
10.1
GENERAL ........................................................................................................................ 10-2
10.2
FUNCTION OF HYDRAULICALLY OPERATED ACCESS LADDER............................. 10-4
10.3
ADJUSTMENTS / CHECKS............................................................................................. 10-8
11. CENTRAL REFILLING SYSTEM (SERVICE ARM) ....................... 11-1 11.1
GENERAL ........................................................................................................................ 11-2
11.2
FUNCTION ....................................................................................................................... 11-4
13
12. HINTS FOR READING THE HYDRAULIC DIAGRAM ................... 12-1
14
12.1
GENERAL ........................................................................................................................ 12-2
12.2
SYMBOLIC....................................................................................................................... 12-4 12.2.1 LINES, UNIONS ................................................................................................. 12-5 12.2.2 COMPONENTS, VALVES.................................................................................. 12-6 12.2.3 SENSORS .......................................................................................................... 12-7 12.2.4 VALVES, VALVE COMPONENTS ..................................................................... 12-8 12.2.5 PUMP, MOTOR, CYLINDER............................................................................ 12-12
13. HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM....... 13-1 13.1
DESIGNATION OF ELECTRICAL COMPONENTS ........................................................ 13-3
13.2
ELECTRIC SYMBOLS ..................................................................................................... 13-4
13.3
SYMBOLS ........................................................................................................................ 13-6
13.4
DRAWING CONCEPT...................................................................................................... 13-8
13.5
READING A CIRCUIT DIAGRAM.................................................................................. 13-12
13.6
COMPONENT LIST........................................................................................................ 13-16
15
14 VEHICLE HEALTH MONITORING SYSTEM ................................. 14-1
16
14.1
GENERAL ........................................................................................................................ 14-2
14.2
SPECIFICATIONS FOR OPERATORS .......................................................................... 14-4 14.2.1 SEQUENCE OF DISPLAYS............................................................................... 14-5 14.2.2 OPENING SCREEN ........................................................................................... 14-5 14.2.3 MAIN GAUGE SCREENS 1 TO 3 ...................................................................... 14-6 14.2.4 FUEL CONSUMPTION SCREEN .................................................................... 14-10 14.2.5 FAILURE MESSAGE HISTORY SCREEN FOR OPERATOR......................... 14-13 14.2.6 MAIN SCREEN - CHANCE TIME SMR DATE ................................................. 14-13 14.2.7 MAINTENANCE MONITOR ............................................................................. 14-14 14.2.8 SETTINGS FOR OPERATOR.......................................................................... 14-16 14.2.9 AUTOMATIC MESSAGES ............................................................................... 14-22 14.2.10 TABLE OF ALL TOP MESSAGES PROVIDED BY THE SYSTEM.................. 14-26 14.2.11 TABLE OF AVAILABLE INSTRUCTION MESSAGES ..................................... 14-36
14.3
SPECIFICATIONS FOR SERVICE ................................................................................ 14.3.1 MAIN SCREEN FLOW CHART FOR THE OPERATER MODE ...................... 14.3.2 MAIN SCREEN FLOW CHART FOR THE SERVICE MODE .......................... 14.3.3 ENTERING THE SERVICE MENU .................................................................. 14.3.4 SERVICE MENU SELECT SCREEN ............................................................... 14.3.5 REAL TIME MENU SELECT SCREEN ............................................................ 14.3.5.1 ENGINE .......................................................................................... 14.3.5.2 PTO 1.............................................................................................. 14.3.5.3 HYDRAULIC ................................................................................... 14.3.5.4 ELECTRICAL EQUIPMENT............................................................ 14.3.5.5 EMERGENCY STOP ...................................................................... 14.3.5.6 MANUAL SW .................................................................................. 14.3.5.7 CENTRAL LUBRICATION SYSTEM 1 ........................................... 14.3.5.8 SLEW RING GEAR LUBE SYSTEM............................................... 14.3.5.9 OTHER............................................................................................ 14.3.5.10 OUTPUT SIGNALS......................................................................... 14.3.5.11 OUTPUT SIGNALS WITH DEACTIVATED PLC-EVALUATION .... 14.3.6 PM-CLINIC ....................................................................................................... 14.3.6.1 GENERAL ....................................................................................... 14.3.6.2 POWER CHECK ............................................................................. 14.3.7 SERIAL/GCC NO. SETTING............................................................................ 14.3.8 MEMORY CLEAR ............................................................................................ 14.3.8.1 INPUT MEMORY CLEAR ID........................................................... 14.3.8.2 MEMORY CLEAR SCREEN ........................................................... 14.3.9 FAILURE HISTORY ......................................................................................... 14.3.10 MAINTENANCE MONITOR ............................................................................. 14.3.11 SNAPSHOT...................................................................................................... 14.3.12 SETTINGS........................................................................................................ 14.3.12.1 CENTRAL LUBRICATION SYSTEM (CLS) .................................... 14.3.12.2 SWING LUBRICATION SYSTEM (SLS)......................................... 14.3.12.3 OTHER SETTINGS 1...................................................................... 14.3.12.4 OTHER SETTINGS 2...................................................................... 14.3.12.5 SHUTDOWN ON/OFF ....................................................................
14.4
WIRING OF THE MAIN COMPONENTS ....................................................................... 14-74
14-38 14-39 14-40 14-44 14-46 14-47 14-47 14-48 14-48 14-50 14-50 14-51 14-52 14-52 14-53 14-54 14-56 14-57 14-57 14-58 14-59 14-60 14-60 14-61 14-62 14-64 14-65 14-66 14-66 14-67 14-68 14-70 14-71
14.4.1 14.4.2 14.4.3 14.4.4
WIRING OF THE ENGINE ............................................................................... WIRING OF THE VHMS-CONTROLLER......................................................... WIRING OF THE CGD-MONITOR................................................................... WIRING OF THE PLC......................................................................................
14-76 14-78 14-82 14-84
14.5
GENERAL DESIGN OF THE PLC ................................................................................. 14.5.1 INPUT AND OUTPUT OF THE PLC ................................................................ 14.5.2 TASK ................................................................................................................ 14.5.3 PLC DIGSY PLUS ® ........................................................................................
14-86 14-89 14-89 14-90
14.6
HOW TO PROCEED THE MAINTENANCE AND INSTALLATION .............................. 14.6.1 MEANING OF THE +5 V STATUS LED........................................................... 14.6.2 MEANING OF THE DIAG STATUS LED ......................................................... 14.6.3 SHORT CIRCUIT MARKER-LED “MK”............................................................ 14.6.4 DIAGNOSTIC FOR ANALOGUE-MODULE “ANM” .........................................
14-92 14-93 14-95 14-98 14-98
14.7
FRONT CONNECTOR ARRANGEMENT...................................................................... 14-99 14.7.1 FRONT CONNECTOR ARRANGEMENT, BIM MODULE (DIGITAL INPUT / OUTPUT) 14-
99 14.7.2 14.7.3 14.7.4
FRONT CONNECTOR ARRANGEMENT, ANM-MODULE (ANALOGUES INPUT) 14-101 GROUND CONNECTION OF THE CONTROL UNIT .................................... 14-103 INTERFACE-CONNECTION VHMS-CONTROLLER .................................... 14-104
14.8
POWER SUPPLY......................................................................................................... 14.8.1 OPERATION VOLTAGES +24 V ................................................................... 14.8.2 SAFETY PRECAUTIONS FOR TROUBLESHOOTING................................. 14.8.3 CPU VOLTAGE RANGE AND ELECTRIC CLASSIFICATION ...................... 14.8.4 FUSE..............................................................................................................
14-106 14-107 14-108 14-109 14-109
14.9
FUNCTION EXPLANATIONS WITH ELECTRICAL DIAGRAM.................................. 14.9.1 GENERAL ...................................................................................................... 14.9.2 PRESSURE MEASURING (HYDRAULIC SYSTEM) ..................................... 14.9.3 TEMPERATURE MEASURING AND TROUBLESHOOTING........................ 14.9.4 TEMPERATURE – RESISTANCE CHART PT100 ........................................
14-111 14-111 14-112 14-114 14-116
14.10 HINTS FOR READING THE FUNCTIONAL FLOW CHARTS..................................... 14-117 14.10.1 GENERAL ...................................................................................................... 14-117 14.10.2 EXAMPLE: MONITORING THE X1-PRESSURE FOR PUMP CONTROL .... 14-118
17
15. LUBRICATION SYSTEMS ............................................................. 15-1
18
15.1
INTRODUCTION .............................................................................................................. 15-3
15.2
CENTRAL LUBRICATION SYSTEM (CLS) .................................................................... 15-4 15.2.0.1 CLS LUBRICATION SYSTEM ELECTRIC LAYOUT ........................ 15-8
15.3
LUBRICATION PUMP STATION (SLS) ........................................................................ 15.3.0.1 SLS LUBRICATION SYSTEM ELECTRIC LAYOUT ...................... 15.3.1 HYDRAULICALLY DRIVEN LUBE PUMP........................................................ 15.3.2 VENT VALVE ................................................................................................... 15.3.3 END OF LINE SWITCH.................................................................................... 15.3.4 IN-LINE FILTER ............................................................................................... 15.3.5 LUBRICANT LEVEL SENSOR......................................................................... 15.3.6 LUBRICANT PRESSURE SENSOR ................................................................ 15.3.7 LUBRICANT INJECTOR .................................................................................. 15.3.7.1 FUNCTION STEPS:........................................................................ 15.3.7.2 INLINE CONNECTION OF INJECTORS ........................................ 15.3.8 LUBRICATION PINION ....................................................................................
15.4
OPERATING AND CONTROLLING .............................................................................. 15-33 15.4.1 OPERATING FLOW, ELECTRICAL FLOW ..................................................... 15-34
15.5
ADJUSTMENTS ............................................................................................................. 15.5.1 PUMP SPEED AND WORKING PRESSURE .................................................. 15.5.1.1 ADJUSTMENTS LUBRICATING PUMP SPEED............................ FIG. 15-20ADJUSTMENTS LUBRICATING PUMP PRESSURE .................... 15.5.2 INJECTORS ..................................................................................................... 15.5.3 END OF LINE SWITCH SETTING CLS ........................................................... 15.5.4 END OF LINE SWITCH SETTING SLS ...........................................................
15.6
TROUBLESHOOTING ................................................................................................... 15-48
15.7
COMMISSIONING .......................................................................................................... 15.7.1 COMMISSIONING OF THE CLS ..................................................................... 15.7.2 FINE ADJUSTMENT ........................................................................................ 15.7.3 COMMISSIONING OF THE SLS......................................................................
15-10 15-14 15-16 15-18 15-20 15-22 15-24 15-25 15-26 15-28 15-30 15-31
15-38 15-39 15-39 15-41 15-42 15-44 15-46 15-52 15-52 15-53 15-53
Table of Contents I.
INTRODUCTION ............................................................................ I-1 I.I
CONTENTS OF THE BINDER ........................................................................................... I-2
I.II
FOREWORD ...................................................................................................................... I-3
I.III
RECOMMENDATIONS FOR ENVIRONMENTALLY FRIENDLY OPERATION AND MAINTENANCE OF HYDRAULIC MINING SHOVELS ...................................................... I-4
I.IV
EXPLANATION OF ABBREVATIONS .............................................................................. I-5
I.V
DIAGRAMS AND ILLUSTRATIONS IN THIS MANUAL ................................................... I-6
SAFETY............................................................................................ II-1 CONTENTS ........................................................................................................................ II-2 OVERVIEW ........................................................................................................................ NORMAL OPERATIONS ..................................................................................... REGULAR MAINTENANCE................................................................................. TROUBLESHOOTING, ADJUSTMENTS AND REPAIR...................................... ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR ................
II-3 II-3 II-3 II-3 II-3
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR........... II-4 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR .... II-4 PREPARATIONS FOR SAFE OPERATION ........................................................ II-4 FIRE PREVENTION............................................................................................. II-6 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE........................ II-8 BURN PREVENTION........................................................................................... II-9 PRECAUTIONS WHEN CLEANING CAB GLASS............................................... II-9 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES ........................ II-10 PRECAUTIONS AT JOBSITE............................................................................ II-11 STARTING ENGINE .......................................................................................... II-17 OPERATION ...................................................................................................... II-18 PRECAUTION FOR MAINTENANCE.............................................................................. II-24 PRECAUTIONS FOR INSPECTION AND MAINTENANCE .............................. II-30 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS................................................................................................................ II-36 SPECIAL SAFETY EQUIPMENT..................................................................................... II-38
III.
SPECIFICATIONS ........................................................................ III-1 III.I
LIFTING GEARS .............................................................................................................. III-2
III.II
SAFETY HINTS FOR SLING ACCESSORY ................................................................... III-4
III.III
STANDARD TIGHTENING TORQUE CHART ................................................................ III-5
III.IV
CONVERSION TABLE ..................................................................................................... III-6
III.V
BLIND PLUGS ............................................................................................................... III-13
III.VI
CLASSIFICATION OF THREADS TO THE NOMINAL WIDTH .................................... III-15
III.VII PLUGS AND FITTINGS ACCORDING TO ISO 8434-1 / DIN 2353 .............................. III-16
3
1.
2.
3.
4
MAIN ASSEMBLY GROUPS............................................................ 1-1 1.1
GENERAL LAYOUT .......................................................................................................... 1-2
1.2
SUPERSTRUCTURE ......................................................................................................... 1-4
1.3
MACHINE HOUSE ............................................................................................................ 1-6
1.4
HYDRAULIC OIL TANK..................................................................................................... 1-8
1.5
HYDRAULIC OIL COOLER ............................................................................................. 1-10
1.6
FUEL TANK ..................................................................................................................... 1-12
1.7
COUNTERWEIGHT.......................................................................................................... 1-14
1.8
CAB SUPPORT................................................................................................................ 1-16
1.9
OPERATOR’S CAB ......................................................................................................... 1-18
1.10
CONTROL BLOCKS ........................................................................................................ 1-20
1.11
SWING MACHINERY....................................................................................................... 1-22 1.11.1 SWING MACHINERY L&S ................................................................................. 1-22 1.11.2 SWING MACHINERY SIEBENHAAR................................................................. 1-24
1.12
UNDERCARRIAGE.......................................................................................................... 1-26
1.13
BACKHOE ATTACHMENT (BHA) .................................................................................. 1-28
1.14
FRONT SHOVEL ATTACHMENT (FSA) ......................................................................... 1-30
DRIVE............................................................................................... 2-1 2.1
PRIME DRIVE ASSEMBLY ............................................................................................... 2-2
2.2
ENGINE AND PTO MOUNTS ............................................................................................ 2-4 2.2.1 ENGINE MOUNTS ............................................................................................... 2-5 2.2.2 TORQUE SUPPORT............................................................................................ 2-6
2.3
GEISLINGER COUPLING.................................................................................................. 2-8
2.4
FAN DRIVE AND RADIATOR ASSEMBLY..................................................................... 2-10 2.4.1 RADIATOR FAN DRIVE SPEED ADJUSTMENT .............................................. 2-14
2.5
PUMP DISTRIBUTOR GEARBOX (PTO) ........................................................................ 2.5.1 PUMP DRIVE SHAFT HOUSING....................................................................... 2.5.2 PTO LUBRICATION AND COOLING................................................................. 2.5.3 HYDRAULIC PUMPS – LOCATION, DRIVE SPEED AND FLOW RATES .......
2.6
AIR FILTER ...................................................................................................................... 2-28
2-18 2-20 2-22 2-26
HYDRAULIC OIL TANK.................................................................... 3-1 3.1
GENERAL LAYOUT ......................................................................................................... 3-2
3.2
HYDRAULIC OIL TANK, LOCATION OF THE ELECTRIC EQUIPMENT ........................ 3-4
3.3
SUCTION OIL TANK WITH STRAINERS ......................................................................... 3-6
3.4
RETURN OIL COLLECTOR PIPE WITH STRAINER ....................................................... 3-8
3.5
BACK PRESSURE VALVE ............................................................................................. 3-10
3.6
TRANSFER PUMP FOR HYDRAULIC OIL ..................................................................... 3-12
3.7
RETURN AND LEAK OIL FILTER .................................................................................. 3-14
3.8
BREATHER FILTER ....................................................................................................... 3-16
4.
5.
6.
HYDRAULIC OIL COOLING ............................................................ 4-1 4.1
OVERALL VIEW OF THE HYDRAULIC OIL COOLING ................................................... 4-2
4.2
FUNCTION OF THE HYDRAULIC OIL COOLING CIRCUIT ............................................ 4-4
4.3
ADJUSTMENT OF THE BACK PRESSURE VALVE........................................................ 4-6
4.4
FAN DRIVE (TWO STAGE COOLER FAN RPM CONTROL)........................................... 4-8 4.4.1 FIXED DISPLACEMENT PUMP, WITH VARIABLE SETTING ......................... 4-10 4.4.2 PRESSURE RELIEF VALVE ............................................................................ 4-12 4.4.3 SOLENOID VALVE ............................................................................................ 4-14
4.5
ADJUSTMENT OF THE COOLER FAN DRIVE SPEED ................................................. 4.5.1 MAXIMUM SPEED............................................................................................. 4.5.2 MEDIUM SPEED................................................................................................ 4.5.3 FUNCTION CHECK OF FAN SPEED CONTROL .............................................
4-16 4-16 4-19 4-20
CONTROLLING.............................................................................. 5-23 5.1
GENERAL LAYOUT ........................................................................................................ 5-24
5.2
VALVE CARTRIDGE BLOCK.......................................................................................... 5-26
5.3
PILOT PRESSURE SUPPLY AND ADJUSTMENTS ...................................................... 5.3.1 PILOT PRESSURE CONTROL (PPC) CIRCUIT ............................................... 5.3.2 CHECKS AND ADJUSTMENT OF PILOT PRESSURE .................................... 5.3.3 REMOTE CONTROL VALVES ARRANGEMENT .............................................
5.4
FUNCTION OF THE ELECTRO HYDRAULIC CONTROL SYSTEM .............................. 5-40
5.5
HAND LEVER (JOYSTICK) CONTROL .......................................................................... 5-44
5.6
FOOT PEDAL CONTROL................................................................................................ 5-46
5.7
PROPORTIONAL AMPLIFIER MODULE, TYPE A......................................................... 5-48
5.8
PROPORTIONAL AMPLIFIER MODULE, TYPE B......................................................... 5-50
5.9
RAMP TIME MODULE ..................................................................................................... 5-52
5.10
ADJUSTMENTS OF AMPLIFIER MODULES ................................................................. 5.10.1 GENERAL .......................................................................................................... 5.10.2 ADJUSTING THE AMPLIFIERS TYPE A........................................................... 5.10.3 ADJUSTING THE AMPLIFIERS TYPE B...........................................................
5.11
ADJUSTING THE RAMP TIME MODUL ......................................................................... 5-60
5-32 5-33 5-36 5-38
5-54 5-55 5-56 5-58
COMPONENTS ................................................................................ 6-1 6.1
MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER (FSA)................................ 6-2
6.2
MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER (BHA) ............................... 6-4
6.3
DISTRIBUTOR MANIFOLD - LOCATION OF RESTRICTOR BLOCKS AND ANTI CAVITATION VALVES (FSA) ................................................................................... 6-6
6.4
DISTRIBUTOR MANIFOLD - LOCATION OF RESTRICTOR BLOCKS AND ANTI CAVITATION VALVES (BHA)................................................................................... 6-8
6.5
SINGLE CONTROL BLOCKS (FLOATING) FOR STICK AND BOOM (FSA)................ 6-10
6.6
RESTRICTOR BLOCK WITH PRESSURE RELIEF VALVE........................................... 6-12
6.7
ANTI CAVITATION VALVE BLOCK................................................................................ 6-14
6.8
REMOTE CONTROL VALVES ........................................................................................ 6-16 5
7.
8.
6
6.9
4/3 DIRECTIONAL SOLENOID VALVES ........................................................................ 6-18
6.10
PROPORTIONAL SOLENOID VALVES.......................................................................... 6-20
6.11
HIGH PRESSURE FILTER .............................................................................................. 6-22
6.12
CONTROL BLOCKS AND VALVES................................................................................ 6-24
6.13
TRAVEL BRAKE VALVE................................................................................................. 6-36
6.14
PRESSURE REDUCING VALVE ..................................................................................... 6-38
6.15
4/2 DIRECTIONAL SOLENOID VALVES ........................................................................ 6-40
6.16
PRESSURE DOUBLE STAGE VALVE ........................................................................... 6-42
6.17
HYDRAULIC CYLINDER ................................................................................................. 6-44
6.18
SLEW RING ..................................................................................................................... 6-48
MAIN HYDRAULIC PUMPS AND PUMP REGULATION................. 7-1 7.1
GENERAL .......................................................................................................................... 7-2
7.2
MAIN PUMPS ................................................................................................................... 7.2.1 LOCATION OF PUMPS ..................................................................................... 7.2.2 PUMP BEARING FLUSHING / LUBRICATION.................................................. 7.2.3 OPERATING PRINCIPLE .................................................................................. 7.2.4 CHECKS / ADJUSTMENTS ...............................................................................
7-10 7-11 7-12 7-14 7-30
7.3
ELECTRONIC PUMP REGULATION SYSTEM .............................................................. 7.3.1 ELECTRONIC LOAD LIMITING CONTROL - GENERAL .................................. 7.3.2 MICROCONTROLLER RC4-4............................................................................ 7.3.3 CHECKS AND ADJUSTMENTS ........................................................................
7-38 7-39 7-41 7-43
7.4
HYDRAULIC CONSTANT REGULATION SYSTEM ....................................................... 7-50 7.4.1 GENERAL .......................................................................................................... 7-51 7.4.2 X1 PRESSURE ADJUSTMENT (CONSTANT PRESSURE) ............................. 7-52
7.5
DETERMINATION OF THE PEAK POINT (ENGINE PERFORMANCE) ........................ 7-54
7.6
ENGINE SPEED SENSOR (PICK-UP) ............................................................................ 7-56 7.6.1 GENERAL .......................................................................................................... 7-57 7.6.2 ENGINE SPEED SENSOR (PICK-UP) ADJUSTMENT ..................................... 7-57
7.7
ENERGY EFFICIENCY .................................................................................................... 7-58 7.7.1 GENERAL .......................................................................................................... 7-59 7.7.2 CHECKS AND ADJUSTMENTS ........................................................................ 7-60
OPERATING HYDRAULICS ............................................................ 8-1 8.1
GENERAL .......................................................................................................................... 8-2 8.1.1 FLOATING SYSTEM............................................................................................ 8-4
8.2
HYDRAULICS FOR THE ATTACHMENT CYLINDER FSA AND BHA ............................ 8-6 8.2.1 ELECTRIC / HYDRAULIC FLOWCHART "BOOM RAISE" FSA .......................... 8-6 8.2.2 ELECTRIC / HYDRAULIC FLOWCHART "BOOM RAISE" BHA ......................... 8-8 8.2.3 ELECTRIC / HYDRAULIC FLOWCHART "BOOM LOWERING" FSA ............... 8-10 8.2.4 ELECTRIC / HYDRAULIC FLOWCHART "BOOM LOWERING" BHA............... 8-12 8.2.5 ELECTRIC / HYDRAULIC FLOWCHART "STICK EXTEND" FSA .................... 8-14 8.2.6 ELECTRIC / HYDRAULIC FLOWCHART "STICK EXTEND" BHA .................... 8-16 8.2.7 ELECTRIC / HYDRAULIC FLOWCHART "STICK RETRACT" FSA .................. 8-18
8.2.8 8.2.9 8.2.10 8.2.11 8.2.12 8.2.13 8.2.14 8.2.15 8.2.16 8.2.17
8.2.18
ELECTRIC / HYDRAULIC FLOWCHART "STICK RETRACT" BHA.................. ELECTRIC / HYDRAULIC FLOWCHART "BUCKET CURL" FSA ..................... ELECTRIC / HYDRAULIC FLOWCHART "BUCKET CURL" BHA..................... ELECTRIC / HYDRAULIC FLOWCHART "BUCKET DUMP" FSA .................... ELECTRIC / HYDRAULIC FLOWCHART "BUCKET DUMP" BHA .................... ELECTRIC / HYDRAULIC FLOWCHART "CLAM OPEN" FSA ......................... ELECTRIC / HYDRAULIC FLOWCHART "CLAM CLOSE" FSA ....................... CHECKS AND ADJUSTMENTS OF THE MAIN RELIEF VALVES (FSA) ......... CHECKS AND ADJUSTMENTS OF THE MAIN RELIEF VALVES (BHA)......... CHECKS AND ADJUSTMENTS OF THE SECONDARY RELIEF VALVES (SRV)................................................................................................... 8.2.17.1 BOOM CYLINDER "PISTON SIDE" FSA + BHA .............................. 8.2.17.2 BOOM CYLINDER "PISTON ROD SIDE" FSA +BHA ...................... 8.2.17.3 STICK CYLINDER "PISTON SIDE" FSA .......................................... 8.2.17.4 STICK CYLINDER "PISTON SIDE" BHA.......................................... STICK CYLINDER "PISTON ROD SIDE" FSA .................................................. 8.2.18.1 STICK CYLINDER "PISTON ROD SIDE" BHA................................. 8.2.18.2 BUCKET CYLINDER "PISTON SIDE" FSA ...................................... 8.2.18.3 BUCKET CYLINDER "PISTON SIDE" BHA...................................... 8.2.18.4 BUCKET CYLINDER "PISTON ROD SIDE" FSA ............................. 8.2.18.5 BUCKET CYLINDER "PISTON ROD SIDE" BHA............................. 8.2.18.6 CLAM CYLINDER "PISTON ROD SIDE" FSA.................................. 8.2.18.7 CLAM CYLINDER "PISTON SIDE" FSA........................................... 8.2.18.8 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED .......
8-20 8-22 8-24 8-26 8-28 8-30 8-32 8-34 8-36 8-38 8-39 8-43 8-47 8-51 8-55 8-59 8-63 8-67 8-71 8-75 8-79 8-81 8-83
8.3
HYDRAULICS FOR THE SWING CIRCUIT................................................................... 8.3.1 SWING CIRCUIT.............................................................................................. 8.3.2 SWING MOTOR .............................................................................................. 8.3.3 SWING GEARBOX (L&S)................................................................................ 8.3.4 SWING GEARBOX (SIEBENHAAR)................................................................ 8.3.5 SLEW PARKING BRAKE (L&S) ...................................................................... 8.3.6 SLEW PARKING BRAKE (SIEBENHAAR) ...................................................... 8.3.7 SWING BRAKE VALVE ................................................................................... 8.3.8 ELECTRIC / HYDRAULIC FLOWCHART "SWING LEFT" .............................. 8.3.9 ELECTRIC / HYDRAULIC FLOWCHART "SWING RIGHT" ............................ 8.3.10 CHECKS AND ADJUSTMENTS FOR THE SWING CIRCUIT......................... 8.3.11 FUNCTION CHECK FOR THE HYDRAULIC SWING BRAKE ........................ 8.3.12 FUNCTION CHECK FOR THE SLEW PARKING BRAKE...............................
8-102 8-102 8-106 8-108 8-110 8-112 8-114 8-116 8-118 8-120 8-122 8-128 8-130
8.4
HYDRAULICS FOR THE TRAVEL CIRCUIT ................................................................ 8.4.1 TRAVEL CIRCUIT............................................................................................ 8.4.2 TRAVEL MOTOR ............................................................................................. 8.4.3 ROTARY JOINT ............................................................................................... 8.4.4 TRAVEL GEARBOX (L&S).............................................................................. 8.4.5 TRAVEL GEARBOX (ZOLLERN)..................................................................... 8.4.6 TRAVEL PARKING BRAKE (GEAR HOUSE BRAKE) .................................... 8.4.7 TRAVEL BRAKE VALVE.................................................................................. 8.4.8 ELECTRIC / HYDRAULIC FLOWCHART “TRAVEL FORWARD” ................... 8.4.9 ELECTRIC / HYDRAULIC FLOWCHART “TRAVEL BACKWARDS” .............. 8.4.10 CHECKS AND ADJUSTMENTS FOR THE TRAVEL CIRCUIT ....................... 8.4.11 FUNCTION CHECK FOR THE TRAVEL PARKING BRAKE ...........................
8-132 8-132 8-136 8-138 8-140 8-142 8-144 8-146 8-148 8-150 8-152 8-154
7
9.
HYDRAULIC TRACK TENSIONING SYSTEM................................. 9-1 9.1
GENERAL .......................................................................................................................... 9-2
9.2
FUNCTIONAL DESCRIPTION ........................................................................................... 9-4
9.3
PRESSURE DOUBLE STAGE VALVE ............................................................................. 9-6
9.4
TENSIONING CYLINDER .................................................................................................. 9-8
9.5
ADJUSTMENTS / CHECKS............................................................................................. 9-10
10. ACCESS LADDER, HYDRAULICALLY OPERATED ..................... 10-1 10.1
GENERAL ........................................................................................................................ 10-2
10.2
FUNCTION OF HYDRAULICALLY OPERATED ACCESS LADDER............................. 10-4
10.3
ADJUSTMENTS / CHECKS............................................................................................. 10-8
11. CENTRAL REFILLING SYSTEM (SERVICE ARM) ....................... 11-1 11.1
GENERAL ........................................................................................................................ 11-2
11.2
FUNCTION ....................................................................................................................... 11-4
12. HINTS FOR READING THE HYDRAULIC DIAGRAM ................... 12-1 12.1
GENERAL ........................................................................................................................ 12-2
12.2
HYDRAULIC SYMBOLS .................................................................................................. 12-4 12.2.1 LINES, UNIONS ................................................................................................. 12-5 12.2.2 COMPONENTS, VALVES.................................................................................. 12-7 12.2.3 SENSORS .......................................................................................................... 12-7 12.2.4 VALVES, VALVE COMPONENTS ..................................................................... 12-8 12.2.5 PUMP, MOTOR, CYLINDER............................................................................ 12-12
13. HINTS FOR READING THE ELECTRIC WIRING DIAGRAM........ 13-1
8
13.1
GENERAL ........................................................................................................................ 13-2
13.2
REFERENCE DESIGNATION OF THE ELECTRICAL COMPONENTS ......................... 13-3 13.2.1 AREA CODE ...................................................................................................... 13-3 13.2.2 COMPONENT IDENTIFYING LETTER.............................................................. 13-5
13.3
GRAPHICAL SYMBOLS.................................................................................................. 13-6
13.4
DRAWING CONCEPT.................................................................................................... 13-10
13.5
CABLE MARKING ......................................................................................................... 13-20
13.6
TABLE OF NEW AND OLD COMPONENT DESIGNATIONS ...................................... 13-21
14. VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM ...................................................................... 14-1 14.1
GENERAL ........................................................................................................................ 14-2
14.2
SPECIFICATIONS FOR OPERATORS ........................................................................... 14-4 14.2.1 SEQUENCE OF DISPLAYS............................................................................... 14-5 14.2.2 OPENING SCREEN........................................................................................... 14-5 14.2.3 MAIN GAUGE SCREENS 1 TO 3 ...................................................................... 14-6 14.2.4 FUEL CONSUMPTION SCREEN .................................................................... 14-11 14.2.5 FAILURE MESSAGE SCREEN FOR THE OPERATOR ................................. 14-13 14.2.6 MAIN GAUGE SCREENS - CHANGING OF TIME / SMR / DATE .................. 14-15 14.2.7 MAINTENANCE MONITOR ............................................................................. 14-16 14.2.8 SETTINGS FOR OPERATORS ....................................................................... 14-18 14.2.9 AUTOMATIC MESSAGES ............................................................................... 14-26 14.2.10 TABLES OF ALL MESSAGES PROVIDED BY THE SYSTEM ....................... 14-29 14.2.10.1 TABLE OF G-CODES .................................................................... 14-30 14.2.10.2 TABLE OF C-CODES - DIESEL ENGINES WITH EMISSION STANDARD TIER 2 ..................................................... 14-39 14.2.10.3 TABLE OF C-CODES - DIESEL ENGINES WITH EMISSION STANDARD TIER 1 ..................................................... 14-46 14.2.10.4 TABLE OF AVAILABLE INSTRUCTION MESSAGES ................... 14-52
14.3
FLOW CHARTS (1-4) VHMS MAIN SCREENS............................................................. 14-55
14.4
VHMS SERVICE LEVEL ................................................................................................ 14.4.1 EXPLANATION OF THE BUTTON SYMBOLS (SERVICE LEVEL) ................ 14.4.2 SERVICE MENU SELECT SCREEN ............................................................... 14.4.3 REAL TIME MENU SELECT SCREEN............................................................ 14.4.3.1 REAL TIME MENU, OPTION: 01 ENGINE 1 .................................. 14.4.3.2 REAL TIME MENU, OPTION: 02 PTO 1 ........................................ 14.4.3.3 REAL TIME MENU, OPTION: 03 HYDRAULIC .............................. 14.4.3.4 REAL TIME MENU, OPTION: 04 SLEW ........................................ 14.4.3.5 REAL TIME MENU, OPTION: 05 ELECTRICAL EQUIPMENT ...... 14.4.3.6 REAL TIME MENU, OPTION: 06 EMERGENCY STOP................. 14.4.3.7 REAL TIME MENU, OPTION: 07 MANUAL SWITCH .................... 14.4.3.8 REAL TIME MENU, OPTION: 08 CENTRAL LUBE SYSTEM 1..... 14.4.3.9 REAL TIME MENU, OPTION: 09 SLEW RING GEAR LUBE SYSTEM ............................................................................... 14.4.3.10 REAL TIME MENU, OPTION: 10 WINDSCREEN WIPER ............. 14.4.3.11 REAL TIME MENU, OPTION: 11 LADDER .................................... 14.4.3.12 REAL TIME MENU, OPTION: 12 SERVICE ARM .......................... 14.4.3.13 REAL TIME MENU, OPTION: 13 PILOT CONTROL...................... 14.4.3.14 REAL TIME MENU, OPTION: 14 OTHER ITEMS .......................... 14.4.3.15 REAL TIME MENU, OPTION: 15 OUTPUT SIGNALS ................... 14.4.3.16 OUTPUT SIGNALS WITH DEACTIVATED MTC-EVALUATION.... 14.4.4 PM-CLINIC ....................................................................................................... 14.4.4.1 GENERAL ....................................................................................... 14.4.4.2 POWER CHECK ............................................................................. 14.4.5 SERIAL/GCC NO. SETTING............................................................................ 14.4.6 MEMORY CLEAR ............................................................................................ 14.4.6.1 INPUT MEMORY CLEAR ID .......................................................... 14.4.6.2 MEMORY CLEAR SCREEN ...........................................................
14-59 14-60 14-61 14-62 14-62 14-63 14-64 14-65 14-65 14-65 14-66 14-67 14-67 14-68 14-68 14-69 14-70 14-71 14-72 14-77 14-78 14-78 14-79 14-80 14-81 14-81 14-82 9
14.4.7 14.4.8 14.4.9 14.4.10
FAILURE HISTORY ......................................................................................... MAINTENANCE MONITOR ............................................................................. SNAPSHOT...................................................................................................... SETTINGS........................................................................................................ 14.4.10.1 CENTRAL LUBRICATION SYSTEM (CLS 1), SCREEN 1/8 .......... 14.4.10.2 SWING LUBRICATION SYSTEM (SLS), SCREEN 2/8.................. 14.4.10.3 QMIN - QMAX - SETTING, SCREEN 3/8 ....................................... 14.4.10.4 OTHER SETTINGS 1/2, SCREEN 4/8............................................ 14.4.10.5 OTHER SETTINGS 2/2, SCREEN 5/8............................................ 14.4.10.6 SHUTDOWN BYPASS ON/OFF .....................................................
14-83 14-84 14-85 14-86 14-86 14-87 14-88 14-88 14-90 14-92
14.5
INTERFACE-CONNECTION VHMS-CONTROLLER .................................................... 14-94 14.5.1 VHMS-CONTROLLER ..................................................................................... 14-95
14.6
WIRING OF THE VHMS-CONTROLLER....................................................................... 14-96
14.7
GLOBAL LAYOUT OF THE MTC CONTROL SYSTEM ............................................. 14.7.1 MTC (MASTER TURBO CONTROLLER) ...................................................... 14.7.1.1 MTC-FLOWCHART ...................................................................... 14.7.1.2 MTC FEATURES .......................................................................... 14.7.1.3 MTC-FIRMWARE AND SOFTWARE............................................ 14.7.1.4 VIEW ONTO THE MTC UNIT AND ITS CONNECTORS .............
14-100 14-102 14-102 14-102 14-103 14-104
14.8
GLOBAL LAYOUT OF THE INTERNAL CAN BUS .................................................... 14.8.1 GENERAL INFORMATION ABOUT A CAN BUS SYSTEM........................... 14.8.1.1 GENERAL CAN BUS DESCRIPTION .......................................... 14.8.1.2 CAN BUS TROUBLESHOOTING ................................................. 14.8.1.3 CAN BUS WIRING........................................................................ 14.8.1.4 CAN BUS END RESISTOR ..........................................................
14-106 14-106 14-107 14-107 14-108 14-110
14.9
THE NODES IN THE CAN BUS SYSTEM ................................................................... 14.9.1 GLOBAL LAYOUT.......................................................................................... 14.9.2 INTRODUCTION ............................................................................................ 14.9.2.1 ICN-V FEATURES ........................................................................ 14.9.2.2 ICN-D FEATURES ........................................................................ 14.9.3 NODE DIP-SWITCHES .................................................................................. 14.9.4 NODE BOX..................................................................................................... 14.9.5 NODE LOCATIONS ON THE MACHINE ....................................................... 14.9.5.1 NODE & LOCATION CHART........................................................ 14.9.5.2 EXEMPLARY VIEW ONTO LOCATION 11 (CAB BASE).............
14-112 14-112 14-113 14-114 14-115 14-116 14-117 14-118 14-119 14-120
15. AUTOMATIC LUBRICATION SYSTEMS ....................................... 15-1
10
15.1
GENERAL OVERVIEW CLS & SLS ................................................................................ 15-2 15.1.1 GENERAL DESCRIPTION................................................................................. 15-3
15.2
BASIC FUNCTION OF THE LUBRICATION SYSTEMS ................................................. 15-4
15.3
CENTRAL LUBRICATION SYSTEM (CLS) .................................................................... 15-6 15.3.1 GENERAL INFORMATION ON CLS.................................................................. 15-8
15.4
LUBRICATION PUMP STATION (SLS) ........................................................................ 15-10 15.4.1 GENERAL INFORMATION ON SLS ................................................................ 15-12
15.5
LUBRICATION CYCLE.................................................................................................. 15.5.1 OPERATION AND CONTROL ......................................................................... 15.5.2 LUBRICATION CYCLE - COMPONENTS ....................................................... 15.5.3 LUBRICATION CYCLE - PROCESSING ......................................................... 15.5.4 TIME SEGMENTS & SWITCH POINTS OF A LUBRICATION CYCLE ........... 15.5.5 LUBRICATION MODES ................................................................................... 15.5.5.1 AUTOMATIC LUBRICATION MODE .............................................. 15.5.5.2 MANUAL LUBRICATION MODE .................................................... 15.5.5.3 VHMS SERVICE MODE .................................................................
15-13 15-13 15-14 15-16 15-17 15-18 15-18 15-18 15-18
15.6
HYDRAULICALLY DRIVEN LUBE PUMP .................................................................... 15.6.1 ADJUSTMENT OF LUBE PUMP SPEED & WORKING PRESSURE ............. 15.6.1.1 STROKE SPEED ADJUSTMENT ................................................... 15.6.1.2 WORKING PRESSURE ADJUSTMENT ........................................
15-20 15-22 15-23 15-23
15.7
LUBRICANT INJECTORS ............................................................................................. 15.7.1 TIGHTENING TORQUE FOR FITTINGS AT THE GREASE INCETORS ....... 15.7.2 DESCRIPTION................................................................................................. 15.7.3 ADJUSTMENT OF THE LUBRICANT OUTPUT .............................................. 15.7.4 OPERATION PRINCIPLE OF LUBRICANT INJECTORS ............................... 15.7.4.1 FUNCTION DESCRIPTION ............................................................ 15.7.5 CONNECTION OF ONE OR MORE INJECTORS...........................................
15-24 15-25 15-25 15-25 15-26 15-28 15-29
15.8
VENT VALVE ................................................................................................................. 15-30 15.8.1 DESCRIPTION................................................................................................. 15-31
15.9
END-LINE SWITCH........................................................................................................ 15.9.1 DESCRIPTION................................................................................................. 15.9.2 CLS END-LINE SWITCH ADJUSTMENT ........................................................ 15.9.3 SLS END-LINE SWITCH ADJUSTMENT ........................................................
15-32 15-33 15-34 15-36
15.10 IN-LINE FILTER ............................................................................................................. 15-38 15.10.1 DESCRIPTION................................................................................................. 15-39 15.10.2 MAINTENANCE PROCEDURE ....................................................................... 15-39 15.11 LUBRICANT LEVEL SENSOR ...................................................................................... 15-40 15.11.1 DESCRIPTION................................................................................................. 15-41 15.11.1.1 LEDS AT THE SONAR SENSOR ................................................... 15-41 15.12 LUBRICATION PINION (SLS) ....................................................................................... 15-44 15.12.1 DESCRIPTION................................................................................................. 15-45 15.13 COMMISSIONING.......................................................................................................... 15.13.1 COMMISSIONING OF THE CLS LUBRICATION SYSTEM ............................ 15.13.2 FINE ADJUSTMENT ........................................................................................ 15.13.3 COMMISSIONING OF THE SLS LUBRICATION SYSTEM ............................
15-46 15-46 15-47 15-48
11
12
I. INTRODUCTION
Version 2010/1
I-1
I.I
CONTENTS OF THE BINDER
Assembled in this file are the Service Manual with explanation and adjustment of the major components and circuits for your KOMATSU Hydraulic Mining Shovel PC4000-6 Diesel with X2 controller and the enhanced VHMS system.
I-2
Version 2010/1
I.II
FOREWORD
Observe the instructions in these manuals for: WARNING z
your Personal SAFETY
z
Operating SAFETY, and
z
READY and EFFICIENT PERFORMANCE of your KOMATSU Hydraulic Mining Shovel.
With this SERVICE MANUAL KOMATSU provides you with the description of the construction and the function of the major systems of the Hydraulic Excavator PC 4000-6D. 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. CAUTION Periodic preventive inspections and maintenance are the surest means of keeping the machine in proper working order. Prompt detection and correction of minor irregularities, and immediate replacement of worn out or broken parts will prevent failures and avoid expenses.
Personnel entrusted with work on the machine must have read the Assembly Manual, the Operation,- Lubrication- and Maintenance Manual and in particular the section on Safety before beginning to work. Reading the instructions after work has begun is too late.
Damages and defects caused by incorrect operation and maintenance are not covered by the manufacturers guarantee. NOTICE If the Shovel is equipped with a fire suppression system, make sure that the system is ready for operation. In order to keep your Shovel in first-class operating condition use only genuine spare and wear parts. The use of any part other than the genuine part releases the KOMATSU MINING GERMANY GmbH from any guarantee.
SERVICE For all questions related to your Shovel please contact your local Service Center. In all your written or phoned inquiries please indicate the model and serial number of your Shovel.
Replace damaged graphics and symbols at the machine. Observe safety precautions to prevent injury and damage. 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 Buscherhofstr. 10 40599 Düsseldorf GERMANY
FROM THE PRACTICE - FOR THE PRACTICE -
Version 2010/1
I-3
I.III
RECOMMENDATIONS FOR ENVIRONMENTALLY FRIENDLY OPERATION AND MAINTENANCE OF HYDRAULIC MINING SHOVELS
Operation z
Avoid engine idling over long periods. Long periods of idling, more than 10 minutes, will not only waste fuel, but is also harmful to the engine.
z
Avoid operation against the main relief valves of the hydraulic system. Move control lever to neutral position before the loader attachment stalls due to overload.
z
Position trucks in such a way, that loading operation can be carried out in a safe and economic manner. Avoid swing angeles over 90°.
Maintenance and repair z
Preserve our environment. To prevent environmental pollution, pay careful attention to the method of disposing waste materials.
z
Always drain fluids from your machine into containers. Never drain fluids onto the ground or dump it into the sewage system rivers, the sea, or lakes.
z
Dispose of harmful material, such as oil, fuel, coolant, solvent, filters and batteries in accordance with environmental regulations and laws.
.
I-4
Version 2010/1
I.IV
EXPLANATION OF ABBREVATIONS
Abbre.
Definition
AC
Alternating Current
A/C
Air Condition
ACV
Anti-Cavitation Valve
API
American Petroleum Institute
BHA
Backhoe Attachment
°C
Degree Celsius
CCW
Counterclockwise
CW
Clockwise
CLS
Central Lubrication System
CO
Cut off function (main pump)
DC
Direct Current
FSA
Front Shovel Attachment
GET
Ground Engaging Tools
HP
High Pressure
LED
Light Emitting Diode
L.H.
Left Hand
MH801
VHMS monitor
MRV
Main Relief Valve
MTC
Master Turbo Controller
PTO
Power Take-Off (Pump Distributor Gear)
Qmax
Maximum pump delivery = maximum swash plate angle
Qmin
Minimum pump delivery = minimum swash plate angle
1/2 Qmax
1/2 pump delivery
R.H.
Right Hand
RPM
Revolutions Per Minute
SLS
Swing circle pinion Lubrication System
SRV
Secondary Relief Valve
VHMS
Vehicle Health Monitoring System
Version 2010/1
I-5
I.V
DIAGRAMS AND ILLUSTRATIONS IN THIS MANUAL
Wiring Diagrams & Hydraulic Diagrams z
During work or troubleshooting always make sure to use your Wiring Diagrams and Hydraulic Diagrams which are assigned to your machine.
z
Due to variable requirements in many respects, the samples of diagrams shown in this manual can not meet the actual state of each machine in every case.
Illustrations & technical drawings
I-6
z
The illustrations and technical drawings shown in this manual correspond to state of the technology at the time of press date.
z
Modifications of shown components are possible prior notice.
Version 2010/1
This page was left blank intentionally.
Version 2010/1
I-7
I-8
Version 2010/1
III. SPECIFICATIONS
Version 2010/1
III-1
III.I
LIFTING GEARS CAUTION
Heavy parts (25 kg or more) must be lifted with a hoist etc.
CAUTION If any part cannot be smoothly removed from the machine by hoisting, the following checks should be made: Check for removal of all bolts fastening the part to the relative parts. Check for existence of another part causing interference with the part to be removed.
WIRE ROPES Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below:
z
Wire popes (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
CAUTION The allowable load value is estimated to be 1/6 or 1/7 of the breaking strength of the rope used.
z
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.
z
Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load.
Fig. III-1 III-2
Version 2010/1
WARNING 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.
z
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) where hoisting g is made with two ropes, each of which is allowed to sling up to 1000kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000kg of total weight can be suspended. This weight becomes 1000kg when two ropes make a 120° hanging angle. On the other hand two ropes are subject to an excessive force as large as 4000kg if they sling a 2000kg load at a lifting angel of 150°.
Fig. III-2
Version 2010/1
III-3
III.II
SAFETY HINTS FOR SLING ACCESSORY WARNING
Always attend to local standards when using sling accessory.
z
Do not use rigid eye bolts from steel C 15 for lifting (e.g. ISO 580). These eye bolts may only be loaded vertically or with a maximum permissible angle of 45° to the ring.
z
Always use suitable swivel hoist rings according to local standards or Vario-Starpoint hoist rings recommended by Komatsu, see following table: Thread
Komatsu Part Number
Tightening Torque
M8
941 650 40
10 Nm
M10
941 651 40
10 Nm
M12
906 519 40
25 Nm
M16
906 780 40
60 Nm
M20
906 782 40
115 Nm
M24
906 783 40
190 Nm
M30
906 421 40
330 Nm
M36
906 233 40
590 Nm
DANGER Vario-Starpoint hoist rings are not suited for turning under load. After installing a Starpoint hoist ring disengage the star key. Adjust the ring plane in direction of pull before attaching any sling accessory.
DANGER Eye bolts or sling accessory which is not suitable can result in serious accidents.
z
Check that the wire rope, chains, and hooks are free from damage.
z
Always use lifting equipment which has ample capacity.Install the lifting equipment at the correct places.
z
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.
III-4
Version 2010/1
III.III STANDARD TIGHTENING TORQUE CHART
Bolt diameter
Wrench size [mm]
Tightening torque [Nm] Bolt quality grades
metric regular
8.8
10.9
12.9
M 8
13
6
21
31
36
M 10
17
8
43
63
73
M 12
19
10
74
108
127
M 14
22
12
118
173
202
M 16
24
14
179
265
310
M 18
27
14
255
360
425
M 20
30
17
360
510
600
M 22
32
17
485
690
810
M 24
36
19
620
880
1030
M 27
41
19
920
1310
1530
M 30
46
22
1250
1770
2080
M 33
50
24
1690
2400
2800
M 36
55
27
2170
3100
3600
M 39
60
2800
4000
4700
M 42
65
3500
4950
5800
M 45
70
4350
6200
7200
M 48
75
5200
7500
8700
M 52
80
6700
9600
11200
M 56
85
8400
12000
14000
M 60
90
10400
14800
17400
M 64
95
12600
17900
20900
M 68
100
15200
21600
25500
32
35
41
46
z
(1 kgm = 9,806 Nm)
z
Insert all bolts lubricated with multi purpose grease MPG (Multi Purpose Grease) (same grease as used in the central lubrication system)
Version 2010/1
III-5
III.IV CONVERSION TABLE Millimeter - Inch & Kilogram - Pound 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. Convert 55 mm into inches: z
Locate the number 5 in the vertical column at the left side, take this as (A), then draw a horizontal line from (A).
z
Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B).
z
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.
Convert 550 mm into inches. z
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.
z
Carry out the same procedure as above to convert 55 mm to 2.165 inches.
z
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.
III-6
Version 2010/1
Version 2010/1
III-7
Liter - U.S. Gallon & Liter - U.K. Gallon
III-8
Version 2010/1
Nm - ft.lb 0
1
2
3
4
5
6
7
8
9
0
0
0.74
1.47
2.21
2.95
3.69
4.42
5.16
5.90
6.63
10
7.37
8.11
8.84
9.58
10.32
11.06
11.79
12.53
13.27
14.00
20
14.74
15.48
16.21
16.95
17.69
18.43
19.16
19.90
20.64
21.37
30
22.11
22.85
23.58
24.32
25.06
25.80
26.53
27.27
28.01
28.74
40
29.48
30.22
30.95
31.69
32.43
33.17
33.90
34.64
35.38
36.11
50
36.85
37.59
38.32
39.06
39.80
40.54
41.27
42.01
42.75
43.48
60
44.22
44.96
45.69
46.43
47.17
47.91
48.64
49.38
50.12
50.85
70
51.59
52.33
53.06
53.08
54.54
55.28
56.01
56.75
57.49
58.22
80
58.96
59.07
60.43
61.17
61.91
62.65
63.38
64.12
64.86
65.59
90
66.33
67.07
67.80
68.54
69.28
70.02
70.75
71.49
72.23
72.96
100
73.70
74.44
75.17
75.91
76.65
77.39
78.12
78.86
79.60
80.33
110
81.07
81.81
82.54
83.28
84.02
84.76
85.49
86.23
86.97
87.70
120
88.44
89.18
89.91
90.65
91.39
92.13
92.86
93.60
94.34
95.07
130
95.81
96.55
97.28
98.02
98.76
99.50
100.23
100.97
101.71
102.44
140
103.18
103.92
104.65
105.39
106.13
106.87
107.60
108.34
109.08
109.81
150
110.55
111.29
112.02
112.76
113.50
114.24
114.97
115.71
116.45
117.18
160
117.92
118.66
119.39
120.13
120.87
121.61
122.34
123.08
123.82
124.55
170
125.29
126.03
126.76
127.50
128.24
128.98
129.71
130.45
131.19
131.92
180
132.66
133.40
134.13
134.87
135.61
136.35
137.08
137.82
138.56
139.29
190
140.03
140.77
141.50
142.24
142.98
143.72
144.45
145.19
145.93
146.66
200
147.40
148.14
148.87
149.61
150.35
151.09
151.82
152.56
153.30
154.03
1 Nm = 0.737 ft.lb
Version 2010/1
III-9
bar - PSI / PSI - bar
Conversion Table bar / PSI bar - PSI bar 1 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
PSI 14,5033 73 145 218 290 363 435 508 580 653 725 798 870 943 1015 1088 1160 1233 1305 1378 1450 1523 1595 1668 1740 1813 1885 1958 2030 2103 2175 2248 2321 2393 2466 2538 2611 2683 2756 2828 2901
PSI - bar bar 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 325 330 335 340 345 350 355 360 365 370 375 380 385 390 395 400
PSI 2973 3046 3118 3191 3263 3336 3408 3481 3553 3626 3698 3771 3843 3916 3988 4061 4133 4206 4278 4351 4424 4496 4569 4641 4714 4786 4859 4931 5004 5076 5149 5221 5294 5366 5439 5511 5584 5656 5729 5801
PSI 1 75 150 225 300 375 450 525 600 675 750 825 900 975 1050 1125 1200 1275 1350 1425 1500 1575 1650 1725 1800 1875 1950 2025 2100 2175 2250 2325 2400 2475 2550 2625 2700 2775 2850 2925 3000
bar 0,06895 5,17 10 16 21 26 31 36 41 47 52 57 62 67 72 78 83 88 93 98 103 109 114 119 124 129 134 140 145 150 155 160 165 171 176 181 186 191 197 202 207
PSI 3075 3150 3225 3300 3375 3450 3525 3600 3675 3750 3825 3900 3975 4050 4125 4200 4275 4350 4425 4500 4575 4650 4725 4800 4875 4950 5025 5100 5175 5250 5325 5400 5475 5550 5625 5700 5775 5850 5925 6000
bar 212 217 222 228 233 238 243 248 253 259 264 269 274 279 284 290 295 300 305 310 315 321 326 331 336 341 346 352 357 362 367 372 378 383 388 393 398 403 409 414
PSI bar
x
14,5033 = PSI
=
bar
14,5033
III-10
Version 2010/1
Basic values in Ohm according to IEC 751 / EN 60751 Conversion table - Ohm to Centigrade of PT100 sensors °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
160.67
Version 2010/1
III-11
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 degrees Fahrenheit or Centigrade . If it is desired to convert from degrees Fahrenheit to Centigrade, 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 degrees Centigrade to Fahrenheit, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.
III-12
Version 2010/1
III.V BLIND PLUGS Dummy plates for SAE–flanges
Fig. III-3
Forms / types of dummy plates for SAE–flanges
Up to 3000 PSI (207 bar)
SAE size
Form / type according to Fig. III-3
Part Number
DN (Diameter Nominal) (hose / pipe)
1/2"
A
506 521 98
12
3/4"
A
506 583 98
20
1 1/4"
A
506 584 98
32
1 1/2"
A
506 522 98
40
2"
A
506 523 98
50
2 1/2"
A
506 585 98
65
3"
A
512 570 98
80
3/4"
B
516 826 98
20
1 1/4
B
517 479 98
32
1 1/2"
B
506 528 98
40
2"
B
506 529 98
50
2 1/2"
B
506 530 98
65
3"
B
512 571 98
80
Version 2010/1
III-13
Up to 6000 PSI (414 bar)
III-14
SAE size
Form / type according to Fig. III-3
Part Number
DN (Diameter Nominal) (hose / pipe)
3/4"
A
506 580 98
20
1"
A
506 519 98
25
1 1/4"
A
506 520 98
32
1 1/2"
A
506 581 98
40
2"
A
506 582 98
50
1"
B
506 524 98
25
1 1/4"
B
506 525 98
32
1 1/2"
B
506 526 98
40
2"
B
506 527 98
50
1 1/4"
C
516 499 98
32
1 1/2"
C
509 375 98
40
2"
C
509 376 98
50
Version 2010/1
III.VI CLASSIFICATION OF THREADS TO THE NOMINAL WIDTH Heavy class (up to 6000 PSI / 414 bar)
Light class (up to 3000 PSI / 207 bar)
Size
Ra
DN (nominal width)
Ra
DN (nominal width)
M 12 x 1.5
-
-
6
5
M 14 x 1.5
-
-
8
6
M 16 x 1.5
8
5
10
8
M 18 x 1.5
10
6
12
10
M 20 x 1.5
12
8
-
-
M 22 x 1.5
14
10
15
12
M 24 x 1.5
16
12
-
-
M 26 x 1.5
-
-
18
16
M 30 x 1.5
-
-
-
-
M 30 x 2
20
16
22
20
M 36 x 2
25
20
28
25
M 38 x 1.5
-
-
-
-
M 42 x 2
30
25
-
-
M 45 x 1.5
-
-
-
-
M 45 x 2
-
-
35
32
M 52 x 1.5
-
-
-
-
M 52 x 2
38
32
42
40
M 65 x 2
-
-
-
-
Method of using the above table to find appropriate plugs and fittings according to Table III.VII on page 16. EXAMPLE: To cover up a hose / tube with a diameter of 25 mm, for a pressure up to 3000 PSI perform the following steps: z
Locate the 25 in the column "DN" in the category "up to 3000 PSI".
z
Check the digit in the column "Ra" next to DN 25 in the same row and category. For this example the proper plug and fitting is BUZ 28-L and ROV 28-L, refer to Table III.VII on page 16.
NOTE: The column "Size" indicates the thread-size for the ROV-fittings.
Version 2010/1
III-15
III.VII PLUGS AND FITTINGS ACCORDING TO ISO 8434-1 / DIN 2353 Up to 3000 PSI / 207 bar BUZ (plugs)
Part Number
ROV (fittings)
Part Number
8-L
501 692 98
8-L
518 113 98
10-L
371 852 99
10-PL
513 789 98
12-L
371 854 99
12-PL
513 547 98
15-L
371 855 99
15-PL
507 051 98
18-L
371 856 99
18-PL
513 787 98
22-L
371 857 99
22-PL
513 788 98
28-L
371 858 99
28-PL
509 377 98
35-L
371 859 99
35-PL
516 770 98
42-L
371 860 99
42-PL
513 790 98
Up to 6000 PSI / 414 bar
III-16
BUZ (plugs)
Part Number
ROV (fittings)
Part Number
-
-
8-PS
515 921 98
-
-
10-PS
507 023 98
-
-
12-PS
507 022 98
16-S
371 866 99
-
-
20-S
371 853 99
20-PS
512 005 98
25-S
371 867 99
25-PS
508 033 98
30-S
371 868 99
30-PS
507 021 98
38-S
371 869 99
38-PS
507 020 98
Version 2010/1
This page was left blank intentionally.
Version 2010/1
III-17
III-18
Version 2010/1
MAIN ASSEMBLY GROUPS
1. MAIN ASSEMBLY GROUPS
Version 2010/1
1-1
General Layout
1.1
GENERAL LAYOUT
Fig. 1-1
General layout
1-2
MAIN ASSEMBLY GROUPS
Version 2010/1
MAIN ASSEMBLY GROUPS
General Layout
Legend for Fig. 1-1: (1)
Superstructure
(2)
Undercarriage
(3)
Front shovel attachment (FSA)
(4)
Backhoe attachment (BHA)
Version 2010/1
1-3
Superstructure
1.2
SUPERSTRUCTURE
Fig. 1-2
Superstructure
1-4
MAIN ASSEMBLY GROUPS
Version 2010/1
MAIN ASSEMBLY GROUPS
Superstructure
Legend for Fig. 1-2: (1)
Hydraulically operated access ladder
(2)
Battery main switches (batteries G1-G4)
(2a)
Battery main switches (batteries G8-G9)
(3)
Lift cylinder for access ladder
(4)
Batteries, location below the catwalk (batteries G1-G4)
(5)
Control switch for access ladder
(6)
Emergency engine shut down switch
(7)
Fuel tank
(8)
Cab base, contains the electronic components of the VHMS system, the electrical switch boards, and the batteries G8 & G9
(9)
Side window of operator’s cab
(10)
Swing circle guard
(11)
Emergency escape ladder
(12)
Engine air cleaners
(13)
Exhaust mufflers
(14)
Air duct
(15)
Extinguishing agent tank assemblies, only on machines equipped with a fire detection, actuation and suppression system.
(16)
Counterweight
(17)
Main control valves & remote control valves with high pressure in-line filters
(18)
Hydraulic oil reservoir
(19)
Return oil filters and leak oil filter
(20)
Hydraulic oil cooler
(21)
Swing machinery
(22)
Distributor manifold
(23)
Swing circle pinion Lubrication System (SLS)
(24)
Central Lubrication System (CLS)
(25)
Node box, location 40
(26)
Node box, location 51
(27)
Node box, location 56
Version 2010/1
1-5
Machine House
1.3
MACHINE HOUSE
Fig. 1-3
Machine house
1-6
MAIN ASSEMBLY GROUPS
Version 2010/1
MAIN ASSEMBLY GROUPS
Machine House
Legend for Fig. 1-3: (1)
Engine air cleaners
(2)
Exhaust air duct
(3)
Exhaust muffler housing
(4)
Rain cap for exhaust muffler
(5)
Expansion tank for radiator
(6)
Coolant radiator
(7)
Hydraulic motor for radiator fan drive
(8)
Oil tank for engine oil reserve system
(9)
Engine oil filler tube
(10)
Engine oil eliminator filter
(11)
Diesel engine
(12)
Flexible coupling, oil-filled (Geislinger)
(13)
Suction oil manifold
(14)
Hydraulic pump for the hydraulic oil cooler fan drive
(15)
Hydraulic pump for the coolant radiator fan drive
(16)
Gear pumps, installed at the drive through shaft of the main hydraulic pumps
(17)
Main hydraulic pumps
(18)
Pump distributor gear (PTO)
(19)
Valve cartridge block
(20)
Node box, location 40
Version 2010/1
1-7
Hydraulic Oil tank
1.4
HYDRAULIC OIL TANK
Fig. 1-4
Hydraulic oil tank
1-8
MAIN ASSEMBLY GROUPS
Version 2010/1
MAIN ASSEMBLY GROUPS
Hydraulic Oil tank
Legend for Fig.1-4: (1)
Breather filter
(2)
Back pressure valve, temperature controlled
(3)
Drain coupling of the hydraulic oil tank
(4)
Return oil filters
(5)
Leak oil filter
(6)
Main shut-off valve (gate valve) with compensator
(7)
Return oil collector pipe
(8)
Drain coupling of the return oil collector pipe
Version 2010/1
1-9
Hydraulic Oil Cooler
1.5
HYDRAULIC OIL COOLER
Fig. 1-5
Hydraulic oil cooler
1-10
MAIN ASSEMBLY GROUPS
Version 2010/1
MAIN ASSEMBLY GROUPS
Hydraulic Oil Cooler
Legend for Fig. 1-5: (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)
Lock bars to secure the swing out doors in open position
Version 2010/1
1-11
Fuel Tank
MAIN ASSEMBLY GROUPS
1.6
FUEL TANK
Fig. 1-6
Fuel tank
1-12
Version 2010/1
MAIN ASSEMBLY GROUPS
Fuel Tank
Legend for Fig. 1-6 : (1)
Fuel tank
(2)
Fuel tank breather valve
(3)
Main shut-off cock valve
(4)
Drain coupling with protection cap
(5)
Shut-off cock valve for fuel pressure transducer
(6)
Fuel pressure transducer (31B063)
(7)
Fuel shut-off solenoid (31Q599)
Version 2010/1
1-13
Counterweight
1.7
COUNTERWEIGHT
Fig. 1-7
Counterweight
1-14
MAIN ASSEMBLY GROUPS
Version 2010/1
MAIN ASSEMBLY GROUPS
Counterweight
Legend for Fig. 1-7: (1)
Counterweight
(2)
Mounting bolts
(3)
Instruction label
(4)
Lifting points for horizontal transport
(5)
Lifting points for vertical transport
(6)
Lifting points for raising up the counterweight
NOTE: For information about bolt connections see OPERATION & MAINTENANCE MANUAL, section Maintenance.
Version 2010/1
1-15
Cab Support
1.8
CAB SUPPORT
Fig. 1-8
Cab support
1-16
MAIN ASSEMBLY GROUPS
Version 2010/1
MAIN ASSEMBLY GROUPS
Cab Support
Legend for Fig. 1-8: (1)
Cab support (location of the electrical switch board “X2”)
(2)
Mounting bolts
(3)
Mounting bolts
(4)
Door
(5)
Door seal
(6)
Door handle (adjustable)
NOTE: For information about bolt connections see OPERATION & MAINTENANCE MANUAL, section Maintenance.
Version 2010/1
1-17
Operator’s Cab
1.9
OPERATOR’S CAB
Fig. 1-9
Operator’s cab
1-18
MAIN ASSEMBLY GROUPS
Version 2010/1
MAIN ASSEMBLY GROUPS
Operator’s Cab
Legend for Fig. 1-9: (1)
VHMS monitor (20P047)
(2)
Switch panel
(3)
Operator’s seat
(4)
Lock lever (20S105)
(20S019)
Control lever
(20S020)
Control lever
(20S021a)
Control pedal: left track
(20S021b)
Control pedal: right track
(20S022)
Control pedal: swing brake
(20S023)
Control pedal: clam closing
(20S024)
Control pedal: clam opening
Version 2010/1
1-19
Control Blocks
MAIN ASSEMBLY GROUPS
1.10 CONTROL BLOCKS
Fig. 1-10 Control blocks 1-20
Version 2010/1
MAIN ASSEMBLY GROUPS
Control Blocks
Legend for Fig. 1-10: (1)
Control block carrier
(2)
Remote control valves
(3)
Main control blocks
(4)
High pressure filter
Version 2010/1
1-21
Swing machinery
MAIN ASSEMBLY GROUPS
1.11 SWING MACHINERY 1.11.1 SWING MACHINERY L&S
Fig. 1-11 Swing machinery (L&S) 1-22
Version 2010/1
MAIN ASSEMBLY GROUPS
Swing machinery
Legend for Fig. 1-11: (1)
Oil dip stick (gearbox)
(2)
Oil filler plug (gearbox)
(3)
Breather filter (gearbox)
(4)
Oil dip stick (motor adapter housing)
(5)
Breather filter (motor adapter housing)
(6)
Oil drain plug (motor adapter housing)
(7)
Drain plug (gearbox)
(8)
Pinion
(60.1 + 60.2)
Swing motors
(61.1 + 61.2)
Swing brake valve blocks
(48.1 + 48.2)
Swing gearbox (L&S) with integrated spring loaded multi disc brakes
Version 2010/1
1-23
Swing machinery
MAIN ASSEMBLY GROUPS
1.11.2 SWING MACHINERY SIEBENHAAR
Fig. 1-12 Swing machinery (Siebenhaar)
1-24
Version 2010/1
MAIN ASSEMBLY GROUPS
Swing machinery
Legend for Fig. 1-12: (1)
Swing gearbox SIEBENHAAR
(2)
Oil drain coupling
(3)
Compensator oil tank for swing machinery
(4)
Brake housing
(5)
Oil level gauge, motor adaper housing
(6)
Oil level gauge and oil drain plug, brake housing
(7)
Oil drain plug and breather filter, motor adapter housing
(8)
Breather filter, brake housing
(9)
Dipstick, swing machinery housing
(10)
Breather filter, oil tank
(48.1 + 48.2)
Multi-disc slew parking brake
(60.1 + 60.2)
Swing motor
(61.1 + 61.2)
Hydraulic swing brake
Version 2010/1
1-25
Undercarriage
MAIN ASSEMBLY GROUPS
1.12 UNDERCARRIAGE
Fig. 1-13 Undercarriage
1-26
Version 2010/1
MAIN ASSEMBLY GROUPS
Undercarriage
Legend for Fig. 1-13: (1)
Undercarriage center body
(2)
Crawler carrier R.H.-side
(3)
Crawler carrier L.H.-side
(4)
Screws, connecting center body and crawler carriers
(5)
Crawler tracks
(6)
Rotary joint
(7)
Travel brake valves
(8)
Travel motors
(9)
Parking brakes, spring loaded disk type brakes
(10)
Travel gearbox
(11)
Sprocket
(12)
Track rollers
(13)
Carrier rollers
(14)
Guide wheel (idler)
(15)
Track tensioning cylinder
Version 2010/1
1-27
Backhoe Attachment (BHA)
MAIN ASSEMBLY GROUPS
1.13 BACKHOE ATTACHMENT (BHA)
Fig. 1-14 Backhoe attachment (BHA)
1-28
Version 2010/1
MAIN ASSEMBLY GROUPS
Backhoe Attachment (BHA)
Legend for Fig. 1-14: (1)
Boom
(2)
Boom cylinders
(3)
Stick
(4)
Stick cylinders
(5)
Bucket
(6)
Bucket cylinders
(7)
Steering
(8)
Rod
Version 2010/1
1-29
Front Shovel Attachment (FSA)
MAIN ASSEMBLY GROUPS
1.14 FRONT SHOVEL ATTACHMENT (FSA)
Fig. 1-15 Front shovel attachment (FSA)
1-30
Version 2010/1
MAIN ASSEMBLY GROUPS
Front Shovel Attachment (FSA)
Legend for Fig. 1-15: (1)
Boom
(2)
Boom cylinders
(3)
Stick
(4)
Stick cylinders
(5)
Bucket backwall
(6)
Bucket cylinders
(7)
Clam
(8)
Clam cylinders
Version 2010/1
1-31
Front Shovel Attachment (FSA)
1-32
MAIN ASSEMBLY GROUPS
Version 2010/1
DRIVE
2. DRIVE
Version 2010/1
2-1
Prime Drive Assembly
2.1
PRIME DRIVE ASSEMBLY
Fig. 2-1
Prime drive assembly
2-2
DRIVE
Version 2010/1
DRIVE
Prime Drive Assembly
Legend for Fig. 2-1: (1)
Engine, Komatsu SDA16V160
(2)
Front damper
(3)
Coupling adapter flange
(4)
Coupling (Geislinger)
(5)
Pump distributor gear (PTO)
(6)
Power frame
General description The drive unit consists of the Komatsu engine SDA16V160, the fexible coupling, the front damper, and the PTO gear. The drive unit is bolted to the power frame with engine mounts and PTO mounts. Two damping elements, which complement each other, are installed at the prime drive in order to eliminate exessive rotation torques at the crankshaft of the engine (Fig. 2-1, Pos. 1). The damping elements are the front damper (Fig. 2-1, Pos. 3) at the front and rear side of the engine as well as the flexible coupling (Fig. 2-1, Pos. 4) which is connected to the PTO (Fig. 2-1, Pos. 5). It is very important that both damping elements are working properly. In case of any damage or wear at either the front damper or at the flexible coupling also always check the damping element at the opposite side of the engine for proper function as well. For further information about the Geislinger coupling refer to section 2.3 GEISLINGER COUPLING.
Version 2010/1
2-3
Engine and PTO Mounts
2.2
ENGINE AND PTO MOUNTS
Fig. 2-2
Engine and PTO mounts
2-4
DRIVE
Version 2010/1
DRIVE
Engine and PTO Mounts
Legend for Fig. 2-2: Quantity
Size
Grade
WS*
Torque
(1)
Flexible bearing
14
(2)
Bolt with self-locking nut
4 per mount
M10x35
8.8
17
43
(3)
Tie bolt
4
M24x400
10.9
36
handtight
(4)
Rubber-bounded metal bar
4
(5)
Self locking nut
4
M24
8
36
handtight
(6)
Bolt with self locking nut
28
M16x80
10.9
24
265
(7)
Cup springs
7 per bolt
(8)
Stop bolt
2
M36x250
10.9
55
-
(9)
Nut
2
M36
10
55
-
(10)
Bolt
10
M24x200
10.9
36
880
(11)
Bolt
16
M20x120
10.9
30
510
(12)
Resilient sleeve
16
(13)
Bolt
4
M30x200
10.9
46
1770
(14)
Resilient sleeve
4 * Wrench Size
2.2.1
ENGINE MOUNTS
The flexible mounts are installed to absorb the vibrations and the torsional forces. They carry the total weight of the engine and the pump distributor gear with all hydraulic pumps. For this reason, all connections must be checked frequently (every 3000 hs) according to PARTS & SERVIVE NEWS "AH01521b" (latest edition), or after the engine, the coupling, or the PTO has been replaced. In the case of wear or damage of any metal rubber guide (Fig. 2-2, Pos. 1), all metal rubber guides and their fastening bolts (Fig. 2-2, Pos. 2) including nuts must be replaced. Also inspect the metal-rubber-bar (Fig. 2-2, Pos. 4) for wear or damage and replace if necessary. The bolt (Fig. 2-2, Pos. 3) should not have any axial play. If necessary, re-tighten the nut (Fig. 2-2, Pos. 5) until the rubber is squeezed slightly out of the rubber bar (Fig. 2-2, Pos. 4).
Version 2010/1
2-5
Engine and PTO Mounts
2.2.2
DRIVE
TORQUE SUPPORT
To absorb the torque force, the front engine support is additionally supported by a cup spring package. Check the cup springs (Fig. 2-2, Pos. 7) of both supports for fatigue or damage regularly and replace them if necessary. Turn the bolt (Fig. 2-2, Pos. 8) down until it slightly pre-stresses the cup spring and secure it with the lock nut. (Distance between engine torque support and bolt head "B" = 29 mm)
2-6
Version 2010/1
Engine and PTO Mounts
DRIVE
This page was left blank intentionally.
2-7
Version 2010/1
Geislinger Coupling
2.3
GEISLINGER COUPLING
Fig. 2-3
Geislinger coupling
2-8
DRIVE
Version 2010/1
DRIVE
Geislinger Coupling
Legend for Fig. 2-3: (1)
Coupling assembly
(2)
Input drive flange
(3)
Leaf spring assembly
(4)
Output drive flange
(5)
Dip stick
(6)
Bleeder plug
(7)
O-rings
(8)
Spacer
(E)
Engine input flange
(G)
Gearbox output flange
Description of the oil-filled GEISLINGER coupling The combination of the high elasticity of the leaf springs together with viscous damping by oil displacement ensures that the GEISLINGER-COUPLING removes major critical speeds outside the engine speed range and dampens minor torsional vibrations effectively. The widest engine speed range free of vibration periods and dangerous resonance is thus obtained. Furthermore, the employment of this coupling with its highly dampening characteristics generally results in lower stress in all engine driving shafts and gears as well as in the crankshaft, permitting further power development on standard components. In any similar application, a simple vibration damper and/or a pure flexible coupling would not confer the same advantages. The springs (Fig. 2-3, Pos. 3) together with the inner driving and outer driven member, form the chambers A and B (Fig. 2-3, Pos. 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 spacer (Fig. 2-3, Pos. 8) limits the movement of the leaf springs.
Version 2010/1
2-9
Fan Drive and Radiator Assembly
2.4
FAN DRIVE AND RADIATOR ASSEMBLY
Fig. 2-4
Fan drive and radiator assembly
2-10
DRIVE
Version 2010/1
DRIVE
Fan Drive and Radiator Assembly
Legend for Fig. 2-4: (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)
NOTE: For service intervals and procedures refer to the OPERATION & MAINTENANCE MANUAL of the corresponding machine. The fan direction is counterclockwise viewed from the engine to the radiator. The fan aspirates air through the cooler into the engine house => The air flows from the outside to inside.
Version 2010/1
2-11
Fan Drive and Radiator Assembly
Fig. 2-5
2-12
DRIVE
Fan drive and radiator assembl
Version 2010/1
DRIVE
Fan Drive and Radiator Assembly
Legend for Fig. 2-5: (1)
Radiator
(2)
Intake air fan
(5.2)
Axial piston pump (fixed displacement pump, with variable setting)
(23)
Fan motor (axial piston motor)
(31.2)
Pressure relief valve - engine radiator fan drive
(34.2)
Pressure filter
(41)
Hydraulic oil tank
(52)
Check valve – (anti cavitation valve for fan drive motor)
(57K636-1)
Proportional solenoid valve - Engine radiator fan speed (infinitely variable)
(L)
Leak oil tank
(P)
Pressure to motor
(R)
Return oil to tank
Function description From the pump (Fig. 2-5, Pos. 5.2) the oil flows through the filter (Fig. 2-5, Pos. 34.2) to the fan motor (Fig. 2-5, Pos. 23) and then back to the oil tank. The check valve (Fig. 2-5, Pos. 52) acts as an anti-cavitation valve and is installed, because the fan motor drive is stopped by a cutt-off of the pressure and the fan keeps on running for a short period due to its own torque. The hydraulic circuit "Fan drive" is secured by the pilot controlled pressure relief valve (Fig. 2-5, Pos. 31.2). This valve works together with the proportional solenoid valve (Fig. 2-5, Pos. 57K636-1). The proportional solenoid valve (Fig. 2-5, Pos. 57K636-1) operates dependent on the engine coolant temperature. The ECM (Electronic Control Module) passes the engine coolant temperature on to the MTC controller, which regulates the fan speed via proportional solenoid valve (Fig. 2-5, Pos. 57K636-1) by sending variable current signals. With a low current signal to the proportional solenoid the fans are running with the max. set-speed. With a high current signal to the proportional solenoid the fans are running with a very low speed.
Version 2010/1
2-13
Fan Drive and Radiator Assembly
2.4.1
RADIATOR FAN DRIVE SPEED ADJUSTMENT
Fig. 2-6
Radiator fan drive speed adjustment
2-14
DRIVE
Version 2010/1
DRIVE
Fan Drive and Radiator Assembly
Legend for Fig. 2-6: (1)
Dust cap
(2)
Lock nut
(3)
Set screw
(5.2)
Axial piston pump (fixed displacement pump, with variable setting)
(6)
Torque adjustment bolt
(6.1)
Lock nut
(7)
Qmax stop bolt
(7.1)
Lock nut
(10)
Positioning pin (mover)
(31.2)
Pressure relief valve - engine radiator fan drive
(57K636-1)
Proportional solenoid valve - engine radiator fan speed
(L1)
Measurement of torque adjustment bolt
(L2)
Measurement of Qmax stop bolt
(M7)
Pressure check point - engine radiator fan drive operating pressure
Basic Adjustment NOTE: Basic adjustment has to be carried out whenever one of the following components has been replaced: z
pump
z
relief valve
z
hydraulic motor
1. Reduce the output flow of pump (Fig. 2-6, Pos. 5.2) by adjusting the minimum possible swivel angle, to avoid over speeding the fan: To do this, loosen both lock nuts (Fig. 2-6, Pos. 6.1+7.1) and turn out bolt (Fig. 2-6, Pos. 6) and turn in bolt (Fig. 2-6, Pos. 7) the same length. This is necessary to avoid a loose positioning pin (Fig. 2-6, Pos. 10), resulting in oscillating of the cylinder barrel. Tighten the lock nuts. 2. Remove the protection cap (Fig. 2-6, Pos. 1) from the relief valve (Fig. 2-6, Pos. 31.2), loosen the lock nut (Fig. 2-6, Pos. 2) and turn the set screw (Fig. 2-6, Pos. 3) fully clockwise and then half turn counterclockwise. 3. Isolate the function of the proportional solenoid valve (Fig. 2-6, Pos. 57K636-1), by disconnecting the plug connector, to ensure that the full flow of the pump (Fig. 2-6, Pos. 5.2) will be delivered to the fan motor. 4. Connect a pressure gauge to the check point (Fig. 2-6, Pos. M7). 5. Start the engine and let it run at high idle. 6. Check the fan speed with a non-contact rev counter, required fan speed: 1200 ± 50 rpm
WARNING Be careful not to get caught in the fan or other rotating parts.
Version 2010/1
2-15
Fan Drive and Radiator Assembly
DRIVE
7. If the speed can not be raised by increasing the pressure then increase the output flow of the pump (Fig. 2-6, Pos. 5.2). If necessary increase the output flow of the pump (Fig. 2-6, Pos. 5.2), by adjusting the swivel angle, until the fan speed will be 20 rpm higher than required: To do this, loosen both lock nuts (Fig. 2-6, Pos. 6.1 + 7.1), turn in the bolt (Fig. 2-6, Pos. 6), and turn out the bolt (Fig. 2-6, Pos. 7) the same length. This is necessary to avoid a loose positioning pin (Fig. 2-6, Pos. 10), resulting in oscillating of the cylinder barrel. Tighten the lock nuts (Fig. 2-6, Pos. 6.1 + 7.1).
WARNING Do not exceed the maximum permissible operating pressure of max 230 bar.
NOTE: Note down the lengths (Fig. 2-6, Pos. L1) and (Fig. 2-6, Pos. L2) as reference measurements. 8. Loosen the lock nut (Fig. 2-6, Pos. 2) of the relief valve (Fig. 2-6, Pos. 31.2), and decrease the pressure with the set screw (Fig. 2-6, Pos. 3) until the correct fan speed is obtained. 9. Tighten the lock nut (Fig. 2-6, Pos. 2) and fix the protection cap (Fig. 2-6, Pos. 3). 10. Activate the function of the proportional solenoid valve (Fig. 2-6, Pos. 57K636-1), by connecting the connector (fan speed is controlled in relation to the engine temperature). 11. Disconnect the pressure gauge from the check point (Fig. 2-6, Pos. M7). Fan speed check If the fan speed is out of the adjustment range, first increase or decrease the pressure at the relief valve (Fig. 2-6, Pos. 31.2), in order to change the speed.
2-16
Version 2010/1
DRIVE
Fan Drive and Radiator Assembly
This page was left blank intentionally.
Version 2010/1
2-17
Pump Distributor Gearbox (PTO)
2.5
PUMP DISTRIBUTOR GEARBOX (PTO)
Fig. 2-7
Pump distributor gearbox (PTO)
2-18
DRIVE
Version 2010/1
DRIVE
Pump Distributor Gearbox (PTO)
Legend for Fig. 2-7: (1)
Oil level dip stick
(2)
Oil filler plug
(3)
Breather filter
(4)
Oil collector reservoir for auxiliary pump drive shaft housing
(5)
Breather filter with oil level dip stick
(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)
Mounting bore for sensor "Trouble totally loss gear oil" (option)
(13)
Gear oil temperatur sensor mounting bore
(14)
Suction line connection for gear oil cooling
(15)
Return line connection from gear oil cooler
(16)
Return line connection from cooling system relief valve
(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 a Diesel engine. The PTO gear runs in anti-friction bearings and it 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. The gearbox has been provided with connections for a separate cooling system or, as an option, a heating system.
Version 2010/1
2-19
Pump Distributor Gearbox (PTO)
2.5.1
PUMP DRIVE SHAFT HOUSING
Fig. 2-8
Pump drive shaft housing
2-20
DRIVE
Version 2010/1
DRIVE
Pump Distributor Gearbox (PTO)
Legend for Fig. 2-8: (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
The gear oil in the drive shaft housings is different to the gear oil in the pump distributor gear. There are two reasons for to have seperate housings: 1. To lubricate the multi-spline connections in order to prevent wear and corrosion. 2. It makes it easier to determine a seal ring leak at one of the drive shaft connections.
Function description z
(Fig. 2-8, Pos. M): If the oil level increases, the oil drops out of the breather pipe (Fig. 2-8, Pos. 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 during an oil level check a loss of oil is found, the cause may be worn or defective radial seal rings.
z
(Fig. 2-8, Pos. A): The oil is filled in via the oil collector reservoir (Fig. 2-8, Pos. 2). All auxiliary drive shaft housings are connected to the reservoir by pipes. 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. In this case a check has to be done, to find out which one of the drive shafts seals is damaged. It can be done by disconnecting the pipe to the reservoir temporarily. Disconnect the pipe at the drive shaft housing, plug the pipe and leave the union open. Start the motor or engine and run it at high idle. After a while monitor the open drive shaft housings. The housing with continuous oil leak has a pump seal defect. Otherwise check all auxiliary drives one after the other.
Version 2010/1
2-21
Pump Distributor Gearbox (PTO)
2.5.2
PTO LUBRICATION AND COOLING
Fig. 2-9
PTO Lubrication and cooling
2-22
DRIVE
Version 2010/1
DRIVE
Pump Distributor Gearbox (PTO)
Legend for Fig. 2-9: (1)
Line to the cooler (hot oil)
(2)
Return line from the cooler (cooled oil)
(3)
Return line from the valve (cooler by-pass)
(4)
Control line (x)
(5)
Leak oil line (y)
(P)
Spray nozzle port
(8.2)
Gear pump - PTO gearbox lubrication
36
Pressure filter - PTO gearbox lubrication
(57B027-1)
Filter clogging sensor (5 bar)
(29)
Pressure relief valve (10 bar)
(M3)
Pressure check point
(57B017-1)
Pressure switch (0.5 bar)
(51.1 & 51.2)
Oil cooler, part of the hydraulic oil cooler
(57B049-1)
Temperature sensor
(M34)
Pressure check point
(57K553-1)
Solenoid valve (by-pass control)
Function description An external gear pump (Fig. 2-9, Pos. 8.2) feeds gear oil from the gearbox sump and pumps it through the oil coolers (Fig. 2-9, Pos. 51.1 & 51.2) back to the gearbox. The lubrication and cooling circuit is protected by a filter (Fig. 2-9, Pos. 36) and a pressure relief valve (Fig. 2-9, Pos. 29). The gear oil coolers (Fig. 2-9, Pos. 51.1 & 51.2) are small parts of the hydraulic oil cooler elements, thus the gear oil is getting cooled by the same air stream as the hydraulic oil. From the coolers the oil flows to the spray nozzle port (Fig. 2-9, Pos. P) of the gearbox via return line (Fig. 2-9, Pos. 2). The spray nozzle insures proper and adequate distribution of the oil in order to lubricate and cool down the gears and bearings. The circuit is monitored by the pressure switch (Fig. 2-9, Pos. 57B017-1). If the lube oil pressure is too low ( low volume through the coolers
z
High temperature => high volume through the coolers
NOTE: For further information about the function principle, refer to section 4.2 on page 4-4. For further information about adjustment, refer to section 4.3 on page 4-6.
Version 2010/1
3-11
Transfer Pump for hydraulic oil
3.6
TRANSFER PUMP FOR HYDRAULIC OIL
Fig. 3-8
Transfer pump for hydraulic oil
3-12
HYDRAULIC OIL TANK
Version 2010/1
HYDRAULIC OIL TANK
Transfer Pump for hydraulic oil
REMARK The illustration shows the transfer pump arrangement viewed from the center of the platform. Legend for Fig. 3-8 1
Cock for the suction oil tank (11)
2
Cock for the collector pipe (13)
3
Cock for the return oil collector pipe (12)
4
Electric motor of the transfer pump (40G018)
5
Transfer pump (40G018)
6
Operating switch (40S035) for the transfer pump (5)
7
Suction line to the suction oil manifold (11)
8
Suction line to the collector pipe (13)
9
Suction line to the return oil manifold (12)
10
Hand wheel of the main shut-off gate valve
11
Suction oil manifold
12
Return oil manifold
13
Collector pipe
14
Back pressure valve
General description 1. Transfusing oil from the suction manifold into the main hydraulic oil tank. This is required for the evacuation of the suction oil manifold when replacing the hydraulic oil. Before servicing the main hydraulic pumps, it is recommended to empty the suction oil manifold partially. 2. Transfusing oil from the return oil manifold and from the collector pipe into the main hydraulic oil tank. This is required when replacing the hydraulic oil and before servicing the high-pressure filters, the main control valves, or the hydraulic oil cooler (oil return system). NOTE: For the operating instructions of the transfer pump refer to the OPERATION & MAINTENANCE MANUAL.
Version 2010/1
3-13
Return and Leak Oil Filter
3.7
RETURN AND LEAK OIL FILTER
Fig. 3-9
Return and leak oil filter
3-14
HYDRAULIC OIL TANK
Version 2010/1
HYDRAULIC OIL TANK
Return and Leak Oil Filter
Legend for Fig. 3-9: (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 for return oil 3 micron absolute for leak oil
(8)
Safety filter element (200 micron strainer), same for return and leak oil
(9)
Bypass valve, 2.3 bar
(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
(A)
Filter chamber
Function The return oil flows into the filter chamber (Fig. 3-9, Pos. A) of the hydraulic oil tank (the drawing is showing a section of it only). The chamber is split into two sections; one section with 4 filter elements for the return oil (10 micron) and another section with one filter element for the leak oil (3 micron). But the structure of the five filter assemblies is basically the same. The hydraulic oil enters the filter at the top and then passes on its way to the tank the filter element (Fig. 3-9, Pos. 7) "Inside to outside filtration". The filter element condition is monitored by pressure switches (40B164 for the leak oil filter and 40B163 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 VHMS monitor. In this case the filter elements must be replaced. For safety precautions the filter is equipped with a bypass valve. As the filter chamber pressure increases the by-pass valve opens at 2.3 + 0.5 bar and protects the element from bursting. But the oil does not flow totally unfiltered into the tank because it is forced to flow through the strainer (Fig. 3-9, Pos. 8).
Version 2010/1
3-15
Breather Filter
3.8
HYDRAULIC OIL TANK
BREATHER FILTER
Fig. 3-10 Breather filter 3-16
Version 2010/1
HYDRAULIC OIL TANK
Breather Filter
Legend for Fig. 3-10: (1)
Nut
(2)
Cover
(3)
Filter element
(4)
Filter pot
(5)
Pressure sensor
Two breather filters are installed in order to clean the air which streams into the tank at any time when the oil level decreases during the extension of the attachment cylinders. The filter element condition is monitored by a vacuum type pressure switch (40B024, 0.08 bar). NOTE: Refer to the OPERATION & MAINTENANCE MANUAL for further information.
CAUTION Only use steel filter elements.
Version 2010/1
3-17
Breather Filter
3-18
HYDRAULIC OIL TANK
Version 2010/1
HYDRAULIC OIL COOLING
4. HYDRAULIC OIL COOLING
Version 2010/1
4-1
Overall view of the hydraulic oil cooling
HYDRAULIC OIL COOLING
4.1
OVERALL VIEW OF THE HYDRAULIC OIL COOLING
Fig. 4-1
Overall view of the hydraulic oil cooling
4-2
Version 2010/1
HYDRAULIC OIL COOLING
Overall view of the hydraulic oil cooling
Legend for Fig. 4-1: (1)
Cooler door
(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
(16)
Bolt
The hydraulic oil cooling system keeps the hydraulic oil in the normal operating temperature range. 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 the inside to the outside through the coolers. For cleaning, the cooler frame must be moved to the side ("swing out cooler"). The bearing group carrier is filled with oil (CLP 220) in order to lubricate the bearings and the spline shaft connection. The oil change interval is 3000 hours.
Version 2010/1
4-3
Function of the Hydraulic Oil Cooling Circuit
HYDRAULIC OIL COOLING
4.2
FUNCTION OF THE HYDRAULIC OIL COOLING CIRCUIT
Fig. 4-2
Function of the hydraulic oil cooling circuit
4-4
Version 2010/1
HYDRAULIC OIL COOLING
Function of the Hydraulic Oil Cooling Circuit
Legend for Fig. 4-2: (32.1 - 32.4)
Restrictor, shock absorbers for the hydraulic oil cooler 22mm.
(39.1 + 39.2)
Hydraulic oil cooler
(41)
Main oil reservoir
(54)
Return oil collector pipe
(55)
Back pressure valve
(L6 + L7)
Return line from control blocks
(L13 + L14)
Supply line for the anti cavitation circuit of the swing motors
(M10)
Pressure check point
(40K601)
Solenoid valve – 4/2-directional control valve
(H)
Lines to cooler (hot oil)
(C)
Lines to tank (cold oil)
Function description The returning oil from the system flows via the lines (Fig. 4-2, Pos. L6 - L7) into the return oil collector pipe (Fig. 4-2, Pos. 54). A pressure relief valve, also called back pressure valve (Fig. 4-2, Pos. 55) is installed on top of it. The back pressure valve (Fig. 4-2, Pos. 55) causes a back pressure which forces most of the relative hot oil through the lines (Fig. 4-2, Pos. H) to the cooler (Fig. 4-2, Pos. 39.1 - 39.2). During its flow through the coolers the oil gets cooled and then it flows through the restrictors (Fig. 4-2, Pos. 32.1 - 32.4) and the lines (Fig. 4-2, Pos. C) into the filter chamber of the main hydraulic oil tank (Fig. 4-2, Pos. 41). The restrictors are acting as shock absorbers in order to prevent cooler cracking at pressure peaks. The back pressure valve (Fig. 4-2, Pos. 55) also acts as an oil flow control valve as long as the oil temperature has not reached its normal operating temperature. During the warm up period (1/2 Qmax) the back pressure valve (Fig. 4-2, Pos. 55) is wide open because the solenoid valve 40K601 is energized. As a results smaller oil flow volume passes through the coolers, which causes the oil to reach its optimum operating temperature faster. With increasing oil temperature the oil gets thinner, so that the main pumps can be shifted to Qmax position and simultaneously the solenoid valve 40K601 will be de-energized. As a result the valve piston is more closed by the force of the spring so that a larger oil volume may pass the coolers. NOTE: Refer to the sectional drawing in (Fig. 4-3).
Version 2010/1
4-5
Adjustment of the Back Pressure Valve
HYDRAULIC OIL COOLING
4.3
ADJUSTMENT OF THE BACK PRESSURE VALVE
Fig. 4-3
Back pressure valve
4-6
Version 2010/1
HYDRAULIC OIL COOLING
Adjustment of the Back Pressure Valve
Legend for Fig. 4-3: (1)
Control oil port
(2)
"Y"- port (external return to tank)
(2a)
"X"- port (external return to tank via solenoid valve 40K601)
(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
Checks and settings only at normal operating temperature of the hydraulic oil and main pumps in maximum flow position (Qmax activated via VHMS). 1. Connect a pressure gauge to the check point (Fig. 4-3, Pos. M10). 2. Disconnect the plug connector (Fig. 4-3, Pos. 13) of the solenoid valve 40K601. 3. Activate the Qmax function via VHMS. 4. Start the engine and run it at high idle. 5. Required pressure: 10 ± 1.0 bar If adjustment is required: z
Remove the protective cap (Fig. 4-3, Pos. 12).
z
Loosen the lock nut (Fig. 4-3, Pos. 5).
z
Adjust the pressure with the set screw (Fig. 4-3, Pos. 6).
z
Tighten the lock nut (Fig. 4-3, Pos. 5) and refit the protective cap (Fig. 4-3, Pos. 12).
6. Disconnect the pressure gauge, reconnect the solenoid valve 40K601, and switch off the Qmax function via VHMS.
Version 2010/1
4-7
Fan Drive (Two Stage Cooler Fan RPM Control)
HYDRAULIC OIL COOLING
4.4
FAN DRIVE (TWO STAGE COOLER FAN RPM CONTROL)
Fig. 4-4
Fan drive
4-8
Version 2010/1
HYDRAULIC OIL COOLING
Fan Drive (Two Stage Cooler Fan RPM Control)
Legend for Fig. 4-4: (5.1)
Axial piston pump (fixed displacement pump with variable setting)
(31.1)
Pressure relief valve, pilot controlled (maximum fan speed)
(34.1)
Pressure filter
(37.1)
Fan motor top (axial piston motor)
(37.2)
Fan motor bottom (axial piston motor)
(38)
Check valve – (anti-cavitation valve for fan drive motor)
(124)
Pressure relief valve (medium fan speed)
(57K506a/b-1)
Solenoid valve
(M6)
Pressure check point
Function From the pump (Fig. 4-4, Pos. 5.1) the oil flows through the pressure filter (Fig. 4-4, Pos. 34.1) to the fan motors (Fig. 4-4, Pos. 37.1 + 37.2) and then back to the tank. The check valve (Fig. 4-4, Pos. 38) acts as an anti-cavitation valve. It is installed because the fan motor (driven by inertial force) keeps on running for a short period after the oil flow is interrupted by the solenoid valve (Fig. 4-4, Pos. 57K506a/b-1). The fan drive circuit is protected by the pilot controlled pressure relief valves ( Fig. 4-4, Pos. 31.1) and (Fig. 4-4, Pos. 124). These valves are working together with the solenoid valve (Fig. 4-4, Pos. 57K506a/b-1), controlled by the VHMS system, depending on the hydraulic oil temperature. z
With de-energized solenoids 57K506a-1 and 57K506b-1 the relief valve (Fig. 4-4, Pos. 31.1) is operating and the fans are running with max. adjusted speed (1250 ± 50 rpm).
z
With solenoid 57K506a-1 energized the relief valve (Fig. 4-4, Pos. 31.1) is not operating and the fans are running with a very low speed caused by the flow resistance only.
z
With solenoid 57K506b-1 energized the relief valve (Fig. 4-4, Pos. 124) is controlling the relief valve (Fig. 4-4, Pos. 31.1) and the fans are running with medium speed (1000 ± 10 rpm) only.
Version 2010/1
4-9
Fan Drive (Two Stage Cooler Fan RPM Control)
HYDRAULIC OIL COOLING
4.4.1
FIXED DISPLACEMENT PUMP, WITH VARIABLE SETTING
Fig. 4-5
Fixed displacement pump
4-10
Version 2010/1
HYDRAULIC OIL COOLING
Fan Drive (Two Stage Cooler Fan RPM Control)
Legend for Fig. 4-5: (1)
Drive shaft
(2)
Bearings
(3)
Cylinder with pistons
(4)
Center pin
(5)
Control lens
(6)
Torque adjustment bolt
(7)
Qmax 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 into the suction port. The rotary group is a robust self aspirating unit. 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. z
With an increase in the swivel angel, the pump output increases together with the necessary drive torque.
z
With an decrease in the swivel angel, the pump output decreases together with the necessary drive torque.
WARNING When increasing to the maximum swivel angle, there is a danger of cavitation and over-speeding the hydraulic motors!
Version 2010/1
4-11
Fan Drive (Two Stage Cooler Fan RPM Control)
4.4.2
PRESSURE RELIEF VALVE
Fig. 4-6
Pressure relief valve
4-12
HYDRAULIC OIL COOLING
Version 2010/1
HYDRAULIC OIL COOLING
Fan Drive (Two Stage Cooler Fan RPM Control)
Legend for Fig. 4-6: (1)
Valve cartridge
(2)
Spring
(3)
Spring chamber
(4)
"X" port
(5)
Jet bore, pilot poppet
(6)
Jet bore, main piston
(7)
Main valve piston
(8)
Valve housing
(9)
Pilot valve cone
(A)
Pressure port
(B)
Return oil port
(X)
Remote control port
(Y)
External leak oil port
Function description Pressure input (A) affects the main piston (Fig. 4-6, Pos. 7). At the same time pressure acts via the jet bore (Fig. 4-6, Pos. 6) onto the spring-loaded side of the main piston, and via the jet bore (Fig. 4-6, Pos. 5) onto the pilot poppet (Fig. 4-6, Pos. 9) of the relief valve cartridge (Fig. 4-6, Pos. 1). If the system pressure in line (A) exceeds the value which is set at the spring (Fig. 4-6, Pos. 2), the pilot poppet (Fig. 4-6, Pos. 9) opens. The signal for this action comes from line (A) via the jet bores (Fig. 4-6, Pos. 6) and (Fig. 4-6, Pos. 5). The oil on spring-loaded side of the main piston (Fig. 4-6, Pos. 7) now flows via the jet bore (Fig. 4-6, Pos. 5) and poppet (Fig. 4-6, Pos. 9) into the spring chamber (Fig. 4-6, Pos. 3). From here it is fed internally by means of the control line (Fig. 4-6, Pos. Y) to the tank (Fig. 4-6, Pos. B). Due to the state of equilibrium at the main piston (Fig. 4-6, Pos. 7), the oil flows from line (A) to (B), while the adjusted operating pressure is maintained. The pressure relief valve can be unloaded (remote controlled) by means of the port (X) and the function of the solenoid valve (Fig. 4-7, Pos. 124). For the operating function of the solenoid valve refer to section 4.4.3 on page 4-14.
Version 2010/1
4-13
Fan Drive (Two Stage Cooler Fan RPM Control)
4.4.3
SOLENOID VALVE
Fig. 4-7
Solenoid valve
4-14
HYDRAULIC OIL COOLING
Version 2010/1
HYDRAULIC OIL COOLING
Fan Drive (Two Stage Cooler Fan RPM Control)
Function description With de-energized solenoids (Fig. 4-7, Pos. 57K506a/b-1) the spool (Fig. 4-7, Pos. 3) keeps the "X" connection of valve (Fig. 4-7, Pos. 31.1) and port “B“ to port “P“ closed. The pressure relief valve (Fig. 4-7, Pos. 31.1) operates normally. • Fan speed: maximum speed. The energized solenoid 57K506b-1 operates the spool (Fig. 4-7, Pos. 3) and a connection is made between port “P“ and port “B“ and port "X" of the valve (Fig. 4-7, Pos. 31.1) The system pressure now opens the main piston (Fig. 4-6, Pos. 7) of the pressure relief valve (Fig. 4-7, Pos. 31.1), because via the solenoid 57K506b-1 (P to B) the oil from the rear side of the piston (Fig. 4-6, Pos. 7) flows from the "X"-port to the “P“ connection of the valve (Fig. 4-7, Pos. 124). The normal valve function is now remote controlled by the pressure adjusted at the valve (Fig. 4-7, Pos. 124). • Fan speed: medium speed The energized solenoid 57K506a-1 operates the spool (Fig. 4-7, Pos. 3) and a connection is made between port “P“ and port “A” and port "X" of the relief valve (Fig. 4-7, Pos. 31.1). The system pressure now opens the main piston (Fig. 4-6, Pos. 7) of the relief valve (Fig. 4-7, Pos. 31.1) because via the "X"-port the oil from the rear side of piston (Fig. 4-6, Pos. 7) flows to the tank. The normal relief valve function is eliminated. • Fan speed: minimum speed
Version 2010/1
4-15
Adjustment of the Cooler Fan Drive Speed
HYDRAULIC OIL COOLING
4.5
ADJUSTMENT OF THE COOLER FAN DRIVE SPEED
4.5.1
MAXIMUM SPEED
Fig. 4-8
Adjustment of the cooler fan drive maximum speed
4-16
Version 2010/1
HYDRAULIC OIL COOLING
Adjustment of the Cooler Fan Drive Speed
Legend for Fig. 4-8: (a + d)
Dust cap
(b + e)
Lock nut
(c + f)
Set screw
(5.1)
Axial piston pump (fixed displacement pump, with variable setting)
(6)
Torque adjustment bolt
(6.1)
Lock nut
(7)
Qmax stop bolt
(7.1)
Lock nut
(10)
Positioning pin (mover)
(31.1)
Pressure relief valve – Hydraulic oil cooler fan drive
(34.1)
Pressure filter
(124)
Pressure relief valve (medium fan speed)
(57K506a/b-1)
Solenoid valve
(L1)
Measurement of torque adjustment bolt
(L2)
Measurement of Qmax stop bolt
(M6)
Pressure check point
NOTE: Basic adjustment has to be carried out whenever one of the following components has been replaced: z
pump
z
relief valve
z
hydraulic motor
Precaution when the fan pump was replaced: The pump must be bleeded properly and the spline housing must be filled with oil, refer to the OPERATION & MAINTENANCE MANUAL. Basic Adjustment – Maximum Speed 1. For safety reason reduce the output flow of the pump (Fig. 4-8, Pos. 5.1) by adjusting the minimum possible swivel angle, to avoid over-speeding the fan: To do this, loosen both lock nuts (Fig. 4-8, Pos. 6.1 + 7.1), turn out the torque adjustment bolt (Fig. 4-8, Pos. 6). Turn in the Qmax bolt (Fig. 4-8, Pos. 7) the same length. This is necessary to avoid a loose positioning pin (Fig. 4-8, Pos. 10) which would result in oscillating of the cylinder barrel. Tighten the lock nuts. Adjust the relief valve to a higher setting as required in order to eliminate the pressure relief valve influence. 2. Remove the protection cap (Fig. 4-8, Pos. a) from the relief valve (Fig. 4-8, Pos. 31.1), loosen the lock nut (Fig. 4-8, Pos. b) and turn the set screw (Fig. 4-8, Pos. c) fully clockwise and then a half turn counterclockwise. 3. Isolate the function of the solenoid valve (Fig. 4-8, Pos. 57K506a/b-1) by disconnecting both connectors, to ensure that the full flow capacity of pump 5.1 will be delivered to the fan motor. 4. Connect a pressure gauge to the check point (Fig. 4-8, Pos. M6).
Version 2010/1
4-17
Adjustment of the Cooler Fan Drive Speed
HYDRAULIC OIL COOLING
5. Start the engine and run it at high idle. 6. Check the fan speed with a non-contact revolution counter.
WARNING Be careful not to get caught in the fan or other rotating parts.
7. Increase the output flow of pump (Fig. 4-8, Pos. 5.1) by adjusting the swivel angle, until the fan speed will be 20 - 50 rpm higher as required: To do this, loosen both lock nuts (Fig. 4-8, Pos. 6.1 + 7.1) and turn in the bolt (Fig. 4-8, Pos. 6). Turn out the bolt (Fig. 4-8, Pos. 7) the same length while the engine and the fan are in operation. This is necessary to avoid a loose positioning pin (Fig. 4-8, Pos. 10) which would result in oscillating of the cylinder barrel. Tighten the lock nuts (Fig. 4-8, Pos. 6.1 + 7.1).
WARNING Do not exceed the maximum permissible operating pressure of p = 230 +30 bar.
NOTE: Note down the lengths ”L1” and ”L2” as reference measurements. 8. Loosen the lock nut (Fig. 4-8, Pos. b) of the relief valve (Fig. 4-8, Pos. 31.1), and decrease the pressure with the set screw (Fig. 4-8, Pos. c) until the correct fan speed is obtained. 9. Tighten the lock nut (Fig. 4-8, Pos. b) and fix the protection cap (Fig. 4-8, Pos. a). NOTE: Both fans have to be checked. A speed difference of 50 rpm is normal due to the higher resistance of the air stream for the lower fan. If the speed difference between both fans is higher than 50 rpm, a possible cause could be a worn hydraulic motor or defective bearings.
4-18
Version 2010/1
HYDRAULIC OIL COOLING
4.5.2
MEDIUM SPEED
Fig. 4-9
Adjustment of the cooler fan drive medium speed
Version 2010/1
Adjustment of the Cooler Fan Drive Speed
4-19
Adjustment of the Cooler Fan Drive Speed
HYDRAULIC OIL COOLING
Basic Adjustment – Medium Speed 10. Activate the function of the pressure relief valve (Fig. 4-9, Pos. 124) by connecting the connector of the solenoid valve 57K506b-1 only. 11. Use the REAL TIME MONITOR of the VHMS system and check the condition of the solenoid valve 57K506b-1 (0 or 1).
Fig. 4-10 VHMS screen with 57K506b-1 NOTE: For the operating instructions of the VHMS system refer to section 14. 12. Loosen the lock nut (Fig. 4-9, Pos. e) of the relief valve (Fig. 4-9, Pos. 124) and turn the set screw (Fig. 4-9, Pos. f) fully counterclockwise and then clockwise until the correct fan speed is obtained. z
Required fan speed: 1000 ± 10 rpm.
13. Tighten the lock nut (Fig. 4-9, Pos. e) and fix the protection cap (Fig. 4-9, Pos. d). 14. Note down the pressure as reference value (expected ~ 150 bar). 15. Disconnect the pressure gauge from the check point (Fig. 4-9, Pos. M6). 16. Connect the connector of the solenoid valve 57K506a-1.
4.5.3
FUNCTION CHECK OF FAN SPEED CONTROL
Connect/disconnect the plugs of the solenoids 57K506a/b-1 and check the following fan speeds: 57K506a-1 - 0 57K506b-1 - 0
nmaximum ≈ 1250 ± 50 rpm
57K506a-1 - 0 57K506b-1 - 1
nmedium ≈ 1000 ± 10 rpm
57K506a-1 - 1 57K506b-1 - 0
nminimum ≈ 0 - 50 rpm
NOTE: At minimum speed condition the fan may spin at low revolution or it may stop completely.
4-20
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HYDRAULIC OIL COOLING
Adjustment of the Cooler Fan Drive Speed
This page was left blank intentionally.
Version 2010/1
4-21
Adjustment of the Cooler Fan Drive Speed
4-22
HYDRAULIC OIL COOLING
Version 2010/1
CONTROLLING
5. CONTROLLING
Version 2010/1
5-23
General layout
5.1
GENERAL LAYOUT
Fig. 5-1
Overall view of the controlling system
5-24
CONTROLLING
Version 2010/1
CONTROLLING
General layout
Legend for Fig. 5-1 (20S019)
Electro proportional joystick control
(20S020)
Electro proportional joystick control
(20S021a)
Electro proportional pedal control, travelling of left crawler
(20S021b)
Electro proportional pedal control, travelling of right crawler
(20S022)
Electro proportional pedal control, swing brake
(20S023)
Electro proportional pedal control, closing of the clam
(20S024)
Electro proportional pedal control, opening of the clam
(M1.1)
Pressure test port, X4 pressure. (Pump bearing lubrication, pump support pressure (60 bar)) CLS SLS
(M1.2)
Pressure test port, X2 pressure. Pilot pressure (45 bar), bracke control, pump regulation.
(8.1)
Gear pump for pilot pressure, pump regulation and pump bearing lubrication
(14.1/.2 + 15.1/.2)
Remote control valve blocks
(33)
Pressure filter
(35)
Valve cartridge block
(41)
Main hydraulic oil tank
(85)
Bladder accumulator – 10 liters, 10 bar (located underneath the catwalk in front of the PTO)
(252.1)
Pressure relief valve for pilot pressure X2 (45 bar)
(252.2)
Pressure relief valve for pump support pressure X4 (60 bar)
General The control circuit is fed by one gear pump, and splitted in two pressure lines X4 and X2. The controlling includes the pilot pressure system and the pump regulation system. The pump (Fig. 5-1, Pos. 8.1) forces the oil through the filter (Fig. 5-1, Pos. 33) to all involved valves. The pressure accumulator ensures that under any circumstances enough pilot pressure oil is available. The accumulator (Fig. 5-1, Pos. 85) also serves as a hydraulic back-up system for a certain time when the engine was shut down, or to relieve the system pressure for repair works. The remote control valves are constantly supplied with the pilot pressure X2 (45 bar). When the operator is using the control elements, an electric signal is sent to electric system which energises and controls the relevant proportional valve(s) of the remote control valves (Fig. 5-1, Pos. 14.1/.2+15.1/.2). As a consequence of this, hydraulic oil runs to the corresponding component.
Version 2010/1
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Valve cartridge block
5.2
VALVE CARTRIDGE BLOCK
Fig. 5-2
Valve cartridge block, location of components
5-26
CONTROLLING
Version 2010/1
CONTROLLING
Valve cartridge block
Legend for Fig. 5-2: Solenoid valves (57Q505)
Slew parking brake operating pressure
(57K506a-1)
Cooler fan RPM control, minimum speed
(57K506b-1)
Cooler fan RPM control, medium speed
(57Q516)
Travel parking brake operating pressure
(57K517)
Qmin control (pump control system)
(57K517a)
½ Qmax (reduced oil flow at cold oil [below T2])
(57K553-1)
”Reduction pre-load pressure PTO gear lubrication - oil cooler”
(57K561-1)
X1 pressure, pumps 1 – 4
(57K620)
Hydraulic swing brake, operating pressure
(57Q623a)
Ladder, raise
(57Q623b)
Ladder, lower
(57Q624a)
Refilling arm, raise
(57Q624b)
Refilling arm, lower
(57Q624c)
Refilling arm stop, hold position
(57Q625)
Ladder, fast movement
(57K626)
Flow reduction swing (pump 1)
(57Q627)
Proportional swing brake pressure
(57K630)
Fixed pump No. 1 (max. flow, X1 = 45 bar)
(57K631)
Fixed pump No. 3 (max. flow, X1 = 45 bar)
(57K636)
Engine radiator fan speed (proportional valve)
(57K646)
Energy Efficiency (pump No. 2 + No. 4)
(57K647)
Energy Efficiency (pump No. 3)
(57K648)
Energy Efficiency (pump No. 1) Filter
(33)
Pilot pressure
(34.1)
Hydraulic oil cooler fan drive
(34.2)
Engine radiator fan drive
(36)
PTO gear lubrication
Version 2010/1
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Valve cartridge block
Fig. 5-3
5-28
CONTROLLING
Valve cartridge block, location of components
Version 2010/1
CONTROLLING
Valve cartridge block
Miscellaneous (29)
Pressure relief valve – PTO gear lubrication
(31.1)
Pressure relief valve – hydraulic oil cooler fan drive, with solenoid valve 57K506a/b-1 for fan RPM control
(31.2)
Pressure relief valve - engine radiator fan drive, with proportional solenoid valve 57K636-1 for fan RPM control
(47)
Pressure reducing valve – track tensioning system (35 bar)
(124)
Pressure relief valve medium speed cooler fan
(152)
Pressure reducing valve – Energy Efficiency (X3 ~ 18 bar, pre-adjustment)
(252.1)
Pressure reducing valve for pilot pressure X2 (45 bar)
(252.2)
Pressure relief valve for pump support pressure X4 (60 bar)
(253.1)
Change-over valve – electronic pump regulation or hydraulic constant regulation
(253.2)
Pressure reducing valve – hydraulic constant regulation
(255.4)
Pressure reducing valve – ½ Qmax
(257.1)
Pressure relief valve – safety valve for travel brake / track tensioning system (55 bar)
(258.3)
Pressure relief valve – safety valve for hydraulic access ladder (70 bar)
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Valve cartridge block
Fig. 5-4
5-30
CONTROLLING
Valve cartridge block, location of components
Version 2010/1
CONTROLLING
Valve cartridge block
Legend for Fig. 5-4: Pressure switches (57B017-1)
PTO gear lubrication pressure
(57B027-1)
PTO gear lubrication - filter element monitoring
(57B085-1)
Pressure transducer – X1 pressure
(57B086)
Pressure transducer – X2 pressure Pressure test ports
(M1.1)
X4, pump support pressure, pump bearing lubrication (60 bar)
(M1.2)
X2 pressure, pilot pressure (45 bar)
(M2)
Bladder accumulator, pilot pressure (45 bar)
(M3)
PTO gear lubrication pressure
(M4)
Travel parking brake operating pressure (35 bar)
(M5)
Slew parking brake operating pressure (45 bar)
(M6)
Hydraulic oil cooler fan drive operating pressure
(M7)
Engine radiator fan drive operating pressure
(M15)
X1 pressure, hydraulic constant regulation only
(M18)
X1 pressure – general (electronic or hydraulic constant regulation general)
(M19)
X3 pressure – Energy Efficiency (~18 bar pre-adjustment)
(M23)
Travel parking brake safety pressure (55 bar)
(M30)
X4 pressure (60 bar)
(M31)
Option operating pressure: “fast motion for travel” not used
(M32)
X3 pressure – pumps No. 2 to No. 4
(M33)
Reduced X3 pressure – to pump No. 1 – ½ Qmax (~15 bar)
(M35.1)
Hydraulic cylinder access ladder “piston side”
(M35.2)
Hydraulic cylinder access ladder “rod side”
(M38.1)
Hydraulic cylinder refilling arm “piston side”
(M38.2)
Hydraulic cylinder refilling arm “rod side”
(M39)
Proportional pressure to hydraulic swing brake
(M41)
X1 pressure – fixed pump No. 3 (max. flow, X1 = 45 bar)
(M42)
X1 pressure – fixed pump No. 1 (max. flow, X1 = 45 bar)
Version 2010/1
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Pilot pressure supply and adjustments
CONTROLLING
5.3
PILOT PRESSURE SUPPLY AND ADJUSTMENTS
Fig. 5-5
Pilot pressure supply and adjustments
5-32
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CONTROLLING
Pilot pressure supply and adjustments
Legend for Fig. 5-5: (20S019)
Electro proportional joystick control
(20S020)
Electro proportional joystick control
(20S021a)
Electro proportional pedal control, travelling of left crawler
(20S021b)
Electro proportional pedal control, travelling of right crawler
(20S022)
Electro proportional pedal control, swing brake
(20S023)
Electro proportional pedal control, closing of the clam
(20S024)
Electro proportional pedal control, opening of the clam
(M1.1)
Pressure test port, X4 pressure. (Pump bearing lubrication, pump support pressure (60 bar)) CLS SLS
(M1.2)
Pressure test port, X2 pressure. Pilot pressure (45 bar), bracke control, pump regulation.
(8.1)
Gear pump for pilot pressure, pump regulation and pump bearing lubrication
(14.1/2+15.1/.2)
Remote control valve blocks
(33)
Pressure filter
(35)
Valve cartridge block
(41)
Main hydraulic oil tank
(85)
Bladder accumulator – 10 liters, 10 bar (located underneath the catwalk in front of the PTO)
(252.1)
Pressure relief valve for pilot pressure X2 (45 bar)
(252.2)
Pressure relief valve for pump support pressure X4 (60 bar)
5.3.1
PILOT PRESSURE CONTROL (PPC) CIRCUIT
The pilot pressure oil is used for the following functions: To operate 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 grease pumps and to supply the hydraulic track tensioning system. Function NOTE: For further details refer to the hydraulic circuit diagram! The pump (Fig. 5-5, Pos. .8.1) delivers the oil through the pressure filter (Fig. 5-5, Pos. 33) to port "A" of the pressure relief valve (Fig. 5-5, Pos. 252.2) to limit the pump support pressure X4 (60 bar). The pressure reducing valve (Fig. 5-5, Pos. 252.1) maintains the adjusted pressure of 45 bar (X2) for the pilot pressure system, the pump regulation system and the supply for some auxiliary systems. The pressure accumulator (Fig. 5-5, Pos. 85) holds a certain amount of oil under pressure to provide sufficient pilot pressure during normal operation, and to ensure a limited number of lowering operations with the main drive motor at standstill.
Version 2010/1
5-33
Pilot pressure supply and adjustments
Fig. 5-6
5-34
CONTROLLING
Pilot pressure supply and adjustments
Version 2010/1
CONTROLLING
Pilot pressure supply and adjustments
Legend for Fig. 5-6: (41)
Main hydraulic oil tank
(85)
Bladder accumulator – 10 liters, 10 bar (located underneath the catwalk in front of the PTO)
(PX2)
Pilot pressure line
(LX2)
Leak / return oil line from the remote control valve blocks
Function The pilot pressure oil (X2 pressure) flows via a line (Fig. 5-6, Pos. PX2) to the pressure port of each remote control valve block. These solenoid valves are energized when operating the electro proportional controls (joysticks or pedals). The soleniod valves direct the pilot pressure oil to the respective spools of the main control blocks. The pressure correlates to the deflection of the controls corresponding to the adjustments of the amplifiers and the ramp time module. NOTE: For the location and designation of the proportional and directional solenoid valves of the remote control blocks refer to section 5.3.3 on page 5-38.
Version 2010/1
5-35
Pilot pressure supply and adjustments
5.3.2
CHECKS AND ADJUSTMENT OF PILOT PRESSURE
Fig. 5-7
Checks and adjustment of pilot pressure
5-36
CONTROLLING
Version 2010/1
CONTROLLING
Pilot pressure supply and adjustments
Legend for Fig. 5-7: (1), (3)
Lock nut
(2), (4)
Set screw, pressure relief valve
(85)
Bladder accumulator – 10 liters, 10 bar pre-charge pressure
(252.1)
Pressure reducing valve for pilot pressure X2 (45 bar)
(252.2)
Pressure relief valve for pump support pressure X4 (60 bar)
(M1.1)
Pressure test port X4, pump support pressure (60 bar)
(M1.2)
Pressure test port X2 pressure, pilot pressure (45 bar)
(M2, M40)
Pressure test ports for accumulator
NOTE: Carry out oil pressure testing and adjustment only at hydraulic oil temperature T3. X4 pressure (60 bar), valve 252.2: 1. Connect a pressure gauge to the appropriate test port (Fig. 5-7, Pos. M1.1). 2. Start the engine, run at high idle. 3. Read pressure, required = 60 bar (±1.0 bar). If readjustment is required, proceed as follows: z
Loosen the lock nut (Fig. 5-7, Pos. 1).
z
Set pressure with the set screw (Fig. 5-7, Pos. 2).
z
Tighten the lock nut (Fig. 5-7, Pos. 1).
X2 pressure (45 bar), valve 252.1: 1. Connect a pressure gauge to the appropriate test port (Fig. 5-7, Pos. M1.2). 2. Start the engine, run at high idle. 3. Read pressure, required = 45 bar (±1.0 bar). If readjustment is required proceed as follow: z
Loosen lock nut (Fig. 5-7, Pos. 3).
z
Set pressure with the set screw (Fig. 5-7, Pos. 4).
z
Tighten the lock nut (Fig. 5-7, Pos. 3).
Checking the accumulator function: 1. Connect a pressure gauge to the appropriate test port (Fig. 5-7, Pos. M2). 2. Start the engine, run at high idle. 3. After build-up of pressure stop the drive engine, but do not turn the key switch to zero position. 4. Watch the pressure gauge. Pressure should remain constant for at least 5 minutes. NOTE: If the pressure drops, the system must be checked for leakages. To check the accumulator charging pressure, refer to PARTS & SERVICE NEWS “AH01531”, latest edition.
Version 2010/1
5-37
Pilot pressure supply and adjustments
5.3.3
REMOTE CONTROL VALVES ARRANGEMENT
Fig. 5-8
Remote control valves arrangement
5-38
CONTROLLING
Version 2010/1
CONTROLLING
Pilot pressure supply and adjustments
Legend for Fig. 5-8: Remote control unit schematic code
Directional solenoid
Proportional solenoid
61K540
Function BHA
FSA Boom raising
61K573 61K541
Boom lowering
61K538
Stick extending
Clam closing
Stick retracting
Clam opening
Bucket filling
Bucket filling
Bucket dump
Stick extending
61K572 61K539 (15.1) 61K536 61K571 61K537 61K534
L.H. crawler reverse 61K570
61K535
L.H. crawler forward
61K524
L.H. swing 61K565
61K525
R.H. swing
61K522 (14.1)
Bucket filling (curl) 61K564
61K523
Bucket emptying
61K520
Boom raising 61K563
61K521
Boom lowering
61K526
R.H. swing 61K566
61K527
L.H. swing
61K532 (14.2)
Boom lowering
Bucket filling
Boom raising
Boom raising
61K569 61K533 61K530
Stick extending 61K568
61K531
Stick retracting
61K546
Boom raising 61K576
61K547
Boom lowering
61K544
Bucket filling (curl) 61K575
61K545
Bucket emptying
(15.2) 61K542
Stick extending 61K574
61K543
Stick retracting
61K528
R.H. crawler forward 61K567
61K529
Version 2010/1
R.H. crawler reverse
5-39
Function of the electro hydraulic control system
5.4
FUNCTION OF THE ELECTRO HYDRAULIC CONTROL SYSTEM
Fig. 5-9
Electro hydraulic control system
5-40
CONTROLLING
Version 2010/1
CONTROLLING
Function of the electro hydraulic control system
Legend for Fig. 5-9: (1)
Control lever (joystick)
(2)
MTC controller (zero position and direction recognition)
(3)
Node
(4)
Proportional solenoid valve
(5)
Directional solenoid valve, a side
(6)
Directional solenoid valve, b side
(7)
Main control valve block
(8)
Pump
(9)
Filter
(10)
Pressure relief valve
(11)
Check valve
(12)
Pressure accumulator
Function The electric-hydraulic control system is used to control the direction and volume of the oil flow to the operating cylinders and motors via the main control valve blocks. Hydraulically The oil volume of the pump (Fig. 5-9, Pos. 8) flows through the filter (Fig. 5-9, Pos. 9) into the pilot pressure system. The pressure is limited by the pressure relief valve (Fig. 5-9, Pos. 10). With the pressurized oil stored in accumulator (Fig. 5-9, Pos. 12), a limited number of control valve spool movements can be carried out with the main drive motor at standstill. When a lever (or pedal) is actuated, the proportional solenoid valve (Fig. 5-9, Pos. 4) and one of the directional solenoid valves (Fig. 5-9, either Pos. 5 or 6) are energized, the pilot pressure moves the spools of the main control valve blocks. Electrical Whenever a lever or a pedal is moved out of its neutral position, an amplifier will create a current between 0 and 1000 mA. (For detailed information see next page.) Depending on the lever direction, one of the directional solenoid valves (Fig. 5-9, either Pos. 6 or 7) is energized to select the main valve direction. The proportional solenoid valve alters the pilot pressure according to the lever deflection, effecting a spool movement between neutral and full stroke position.
Version 2010/1
5-41
Function of the electro hydraulic control system
CONTROLLING
Fig. 5-10 Electro hydraulic proportional control
5-42
Version 2010/1
CONTROLLING
Function of the electro hydraulic control system
Legend for Fig. 5-10 (exemplary illustration of the function of two axis with one amplifier only): (1)
Control lever (joystick)
(2)
Capacitor module
(3)
Ramp time module
(4)
Proportional amplifier module
(5)
Relay (supply voltage)
(6)
Proportional solenoid valve
(7)
Directional solenoid valve
(8)
Control block spool
General Function The control lever (Fig. 5-10, Pos. 1) is supplied with 24 VDC battery voltage for the switch contacts and with capacitor supported 24 VDC to create a stable signal voltage. When moving the the lever (Fig. 5-10, Pos. 1) out of his neutral position, 24 VDC battery voltage is applied to the relay (Fig. 5-10, Pos. 5) and energizes the proportional amplifier (Fig. 5-10, Pos. 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 „X-axis“ (left/right direction). The polarity of the output signal from the joystick (Fig. 5-10, Pos. 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 (Fig. 5-10, Pos. 3) at terminal 5 which will arrive after the adjusted ramp time delay via terminal 7 at the proportional amplifier (Fig. 5-10, Pos. 4), terminal 5. This input signal (between 0 and 10 VDC) is amplified to an output signal between 0 to 1000 mA and is simultaneously sent via terminal 7 (negative) or terminal 8 (positive) to the proportional solenoid valve (Fig. 5-10, Pos. 6) and the directional solenoid valve (Fig. 5-10, Pos. 7) via terminal 3 (negative) or terminal 9 (positive) to the “a” or “b”-side. The proportional solenoid valve (Fig. 5-10, Pos. 6) alters the pilot pressure (“X2”) of max. 45 bar to a value proportional to the current signal. This pressure controls the movement of the control block spool (Fig. 5-10, Pos. 8) between neutral and full stroke position.
Version 2010/1
5-43
Hand lever (joystick) control
5.5
CONTROLLING
HAND LEVER (JOYSTICK) CONTROL
Fig. 5-11 Potentiometer control
5-44
Version 2010/1
CONTROLLING
Hand lever (joystick) control
Legend for Fig. 5-11: (1)
Control lever (joystick)
(2)
Control unit
(3)
Deutsch connector
(4)
Inductive linear transmitter
(5)
Push pin
(6)
Coil
(7)
Direction monitoring
(8)
Zero position monitoring
(9)
Electronics of the control unit
(10)
Direction contacts
(11)
Zero position contacts
* Alternative application The non-contacting lever control (inductive linear transmitter) contains both the electronic and mechanical components which convert the lever movement into a proportional electrical voltage. The lever can be operated in two axes: z
Axis "Y", splitted into the half axis Y- and Y + (backward and forward)
z
Axis "X", splitted into the half axis X- and X + (left and right)
Of course the lever can be moved in any combined direction (joystick function). In order to be able to monitor the direction of the lever movement and the neutral position, the electronics (Fig. 5-11, Pos. 9) sends a 24 V signal as soon as the lever gets moved out of its neutral position. For one axis two inductive linear transmitter (Fig. 5-11, Pos. 4) are used. The motion of the coil core connected to the push pin (Fig. 5-11, Pos. 5) causes a variation of the induction in the coil (Fig. 5-11, Pos. 6). The electronics converts this inductive signal into a proportional output signal of -10...0...+10 V for the amplifiers. In order to be able to monitor the direction of the lever movement and its neutral position, two switches (Fig. 5-12, Pos. 7 and 8) are fitted, which are actuated by the switch actuator attached to the push pin (Fig. 5-12, Pos. 5) as soon as the lever gets moved out of its neutral position. The monitoring of the neutral position and the direction of the lever is carried out by the MTC controller.
Version 2010/1
5-45
Foot pedal control
5.6
CONTROLLING
FOOT PEDAL CONTROL
Fig. 5-12 Foot pedal control
5-46
Version 2010/1
CONTROLLING
Foot pedal control
Legend for Fig. 5-12: (1)
Pedal control unit
(2)
Foot pedal
(3)
Connection cable
(4)
Deutsch connector
(5)
Push pin
(6)
Coil
(7)
Direction monitoring
(8)
Direction contacts
(9)
Electronics
(10)
Switch actuator
(11)
Neutral (zero) position contacts
(12)
Neutral (zero) position monitoring
Application for: (A)
Clam opening/closing
(B)
Travelling
(C)
Swing foot brake
The foot pedal control (inductive, linear travel transmitter) contains both the electronic and mechanical components which convert the pedal movement into a proportional electrical voltage. In order to be able to electrically monitor the pedals (Fig. 5-12, Pos. A-C) action, neutral position switches are fitted. These switches close when the pedal is moved out of the neutral position. In order to be able to monitor the direction of the pedal movement and the neutral position of travel unit (Fig. 5-12, Pos. B), two switches (Fig. 5-12, Pos. 7 and 12) are fitted, which are actuated by the switch actuator (Fig. 5-12, Pos. 10) as soon as the pedal gets moved out of its neutral position.
Version 2010/1
5-47
Proportional amplifier module, type A
5.7
CONTROLLING
PROPORTIONAL AMPLIFIER MODULE, TYPE A
Fig. 5-13 Proportional amplifier module, type A
5-48
Version 2010/1
CONTROLLING
Proportional amplifier module, type A
Legend for Fig. 5-13: Type A
Usage: Swing brake :
11T016
(1)
LED for solenoid A or B
(2)
Set potentiometer R1 and R2 R1 for the lowest current value R2 for the highest current value
The amplifier module contains the necessary electronics for the control of two proportional solenoids. Depending on the input polarity, either channel A or channel B is operated. Both channels outputs are combined. 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. Input signals up to 1 V generate no output signal (ouput current = 0). From 1 V to 9 V, the output current rises linearly from 40 mA to 350 mA. For input signals above 9 V, the ouptut current is fixed to the maximum of 1000 mA. The module also generates a direction-dependent voltage signal (solenoid A - solenoid B) as soon as the solenoid current reaches the lowest set value. Both endpoints for the linear increase (proportinal area) are set externally via the potentiometer R1 and R2. NOTE: For adjustment of the type A amplifier refer to section 5.10.2 on page 5-56.
Version 2010/1
5-49
Proportional amplifier module, type B
5.8
CONTROLLING
PROPORTIONAL AMPLIFIER MODULE, TYPE B
Fig. 5-14 Proportional amplifier module, type B
5-50
Version 2010/1
CONTROLLING
Proportional amplifier module, type B
Legend for Fig. 5-14: Type B
Usage: Boom Stick Bucket Clam Swing Travel, left Travel, right
: : : : : : :
11T010… (4 Pcs.) 11T008… (2 Pcs.) 11T009… (3 Pcs.) 11T011 11T007… (2 Pcs.) 11T012 11T013
(LED) Ax: AS: Bx: BS: Power: Fault:
Proportional output Ax active Switched output AS active Proportional output Bx active Switched output BS active Internal supply voltage Fault indication (P)
(P)
Set potentiometer: z 10% for the lowest current value z J2 for the highest current value
The amplifier module contains the necessary electronics for the control of two proportional solenoids and two directional solenoids. The amplifier outputs for proportional solenoids Ax and Bx and the switched outputs As and Bs are activated by connecting a minimum of approx. 10% signal voltage at the amplifier input. A positive signal voltage controls outputs A, a negative signal voltage controls output B. A signal voltage of approx. 10% with respect to ±10 V input voltage at the amplifier, produces a stepped output voltage. The height of this 10% jumps may be set separately for the proportional outputs Ax and Bx via external potentiometers. As the signal voltage rises, the solenoid current for the proportional outputs increases linearly. A further step in the 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 potentiometers. Hence the gradient of the output curve may be influenced. LED`s indicate the current output to each proportional and switched output, whereby the brightness is approx. proportional to the solenoid current in Ax and Bx. A fault is indicated by the LED „Fault“.
Version 2010/1
5-51
Ramp time module
5.9
CONTROLLING
RAMP TIME MODULE
Fig. 5-15 Ramp time module
5-52
Version 2010/1
CONTROLLING
Ramp time module
Legend for Fig. 5-15: Ramp time module
Usage: Boom Stick Travel
: : :
Swing : Swing brake : Bucket :
11T049 11T048 11T051 (left) 11T052 (right) 11T050/50a 11T050b 11T059
Potentiometer "t1" to "t5"
Ramp time adjustment (t5 not used)
"w1" to "w4"
Command value call-ups (not used)
"G"
Zero point matching
"Z"
Amplitude attenuation for the differential input
LED Displays (1)
green => operational power
(2)
"4-Q" => quadrant recognition (not used)
(3)
"INV" => inversion active (not used)
(4)
yellow => display for potentiometer t1 to t4
(5)
yellow => display for potentiometer w1 to w4
(6)
Measurement sockets: z z z
"t" - Actual ramp time (tension signal) "w" - Internal adjustment variable (not used) "⊥" - 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 be changed from 0% to approx. 110% via potentiometer "G". 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 illuminated. Version 2010/1
5-53
Adjustments of amplifier modules
CONTROLLING
5.10 ADJUSTMENTS OF AMPLIFIER MODULES
Fig. 5-16 Adjustments of amplifier modules
5-54
Version 2010/1
CONTROLLING
Adjustments of amplifier modules
Legend for Fig. 5-16: (1)
Control lever (joystick)
(2)
Terminal with a separating possibility
(3)
Ramp time module
(4)
Amplifier
(5)
Solenoid valve (Proportional valve)
(6)
Service module
5.10.1 GENERAL Introduction Fig. 5-16 is a simplified illustration of the signal voltage route from the joystick control (Fig. 5-16, Pos. 1) to the solenoid valve (Fig. 5-16, Pos. 5): (A)
With ramp time module FSA & BHA – Boom, stick, bucket, travel, swing brake and swing function NOTE: For adjustment data, please also refer to the Parts & Service News "AH09525" (latest edition).
(B)
Without ramp time module FSA only – Clam function
The ramp time modules (Fig. 5-16, Pos. 3) and the amplifiers (Fig. 5-16, Pos. 4) are adjustable. Adjustments are required: Ramp Time Modules z z
When commissioning the machine. When replacing a module.
Amplifiers z z
When replacing a proportional solenoid valve. When replacing an amplifier.
For checking and setting the signal current at the proportional-amplifier (Fig. 5-16, Pos. 4), both separating terminal (Fig. 5-16, Pos. 2) before and behind the amplifier (Fig. 5-16, Pos. 4) must be opened. For the setting procedure the signal voltage from the potentiometer control (Fig. 5-16, Pos. 1) can be simulated with the potentiometer of the service module (Fig. 5-16, Pos. 6) installed on the X2 board.
Version 2010/1
5-55
Adjustments of amplifier modules
CONTROLLING
5.10.2 ADJUSTING THE AMPLIFIERS TYPE A
Fig. 5-17 Adjusting the amplifiers type A
5-56
Version 2010/1
CONTROLLING
Adjustments of amplifier modules
NOTE: The adjustment of the amplifier for the swing brake is slightly different from the adjustment procedures for the amplifiers of the other foot pedals and the joysticks, also refer to section 5.10.3 on page 5-58. Adjustment procedure for the amplifier of the swing brake (foot pedal): 1. Open* the respective separating terminal (Fig. 5-17, Pos. T1) between the pedal unit and the amplifier module to be set. 2. Open* the respective separating terminal (Fig. 5-17, Pos. T2) between the amplifier module to be set and the proportional solenoid valve. 3. Disconnect the wire from the amplifier, terminal 5. 4. Connect the positive output of the service module with terminal 5 of the amplifier module using a test lead (Fig. 5-17, Pos. 2). 5. Attach a multimeter for voltage reading to the service module using test leads (Fig. 5-17, Pos. 3). 6. Attach a multimeter (in series) for ampere reading to the terminals between the amplifier module and the solenoid valve using test leads (Fig. 5-17, Pos. 3). 7. Press the swing brake pedal fully down, or manually override the relay supplying the amplifier module with 24 VDC operating voltage. (Thus, the amplifier gets 24 V operating voltage.) 8. Turn the potentiometer (Fig. 5-17, Pos. P) of the service module until the multimeter for voltage reading shows 1 VDC; the multimeter for the current reading will show a value that should correspond to the value given in the circuit diagram, e.g. 40 mA (10% value). If necessary correct the value with the potentiometer (Fig. 5-17, Pos. R1). 9. Turn the potentiometer (Fig. 5-17, Pos. P) of the service module until the multimeter for voltage reading shows 10 VDC; the multimeter for the current reading will show a value that should correspond to the value given in the circuit diagram, e.g. 350 mA (100% value). If necessary correct the value with the potentiometer (Fig. 5-17, Pos. R2). NOTE: It is important that the pilot pressure for the pressure increasing valve is 24 ±1 bar. For more information refer to section 8.3 on page 8-102. * How to open and close the terminal: Push the yellow stud (Fig. 5-17, Pos. 1) down with a screw driver and turn it 90° to the left to open or to the right to close the terminal. Then a spring pushes the stud outwards and the contacts are either open or closed.
Version 2010/1
5-57
Adjustments of amplifier modules
CONTROLLING
5.10.3 ADJUSTING THE AMPLIFIERS TYPE B
Fig. 5-18 Adjusting the amplifiers type B
5-58
Version 2010/1
CONTROLLING
Adjustments of amplifier modules
Procedure applicable for all amplifiers except the one for the swing brake: NOTE: Used respective electric circuit diagram to identify the required terminals, components and valves. NOTE: Do not start the engine, only turn the key switch into ON-position. 1. Open* the respective separating terminal (Fig. 5-18, Pos. T1) between the lever unit and the amplifier module. 2. Open* the respective separating terminal (Fig. 5-18, Pos. T2) between the amplifier module and the proportional solenoid valve. 3. Disconnect the wire from terminal 5. 4. Connect the positive output of the service module with terminal 5 of the amplifier module using a test lead (Fig. 5-18, Pos. 2). 5. Attach a multimeter for voltage reading to the service module using test leads (Fig. 5-18, Pos. 3). 6. Attach a multimeter (in series) for ampere reading to the terminal between the amplifier module and the solenoid valve using test leads (Fig. 5-18, Pos. 3). 7. Move the lever 20S105 into operating position, or manually override the relay supplying the amplifier module with 24 VDC operating voltage. Thus the amplifier gets 24 V operating voltage. Simultaneously the power LED and either LED A(+) or B(-) light up, depending on the polarity. 8. Turn the potentiometer (Fig. 5-18, Pos. P) of the service module until the multimeter shows 1 VDC (it may be either positive or negative); the multimeter for the current reading should show a value corresponding to the value given in the circuit diagram, e.g. 300 mA (first step / 10% value [R1]). The LED’s show which channel (positiv A or negativ B) is activated. For adjustment use always potentiomenter in horizontal line to the activated LED’s. If necessary correct the value with the potentiometer (Fig. 5-18, Pos. R1). 9. Turn the potentiometer (Fig. 5-18, Pos. P) of the service module further until the multimeter shows 9 VDC; the multimeter for the current reading should show a value corresponding to the value given in the circuit diagram, e.g. 550 mA (second step / 90% value [R2]). The LED’s show which channel (positiv A or negativ B) is activated. For adjustment use always potentiomenter in horizontal line to the activated LED’s. If necessary correct the value with potentiometer (Fig. 5-18, Pos. R2). 10. Repeat settings of item 8 and 9 until both mA values are stabilized, because R1 and R2 influence each other. 11. If the setting with either positive or negative potential was successful, turn the potentiometer (Fig. 5-18, Pos. P) of the service module into the opposite direction and check the settings with the other polarity. 12. Repeat the setting as described in steps 7 to 10. 13. Remove the multimeter, test leads, 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 (Fig. 5-18, Pos. 1) down with a screw driver and turn it 90° to the left to open or to the right to close the terminal. Then a spring pushes the stud outwards and the contacts are either open or closed.
Version 2010/1
5-59
Adjusting the ramp time modul
CONTROLLING
5.11 ADJUSTING THE RAMP TIME MODUL
Fig. 5-19 Adjusting the ramp time module
5-60
Version 2010/1
CONTROLLING
Adjusting the ramp time modul
Legend for Fig. 5-19: (1)
Capacitor module
(2)
Service module
(3)
Ramp time module
(P)
Potentiometer
NOTE: The following adjustments have to be done when commissioning the machine and whenever the ramp time module has been replaced. Do not start the motor, turn only the key switch in ON – position. The following step numbers corespond to the boldface numbers in Fig. 5-19. Basic adjustment: 1. Connect a multimeter for voltage reading to the service module (Fig. 5-19, Pos. 6) and, if required, set voltage to 0 V by turning the potentiometer "P". Connect another multimeter for voltage reading to terminal 7 (+) and terminal 8 (-) of the ramp time module (Fig. 5-19, Pos. 3). Connect the red (positive) terminal of the service module with terminal 5 of the ramp time module using a test lead. If the multimeter at the ramp time module does not show "0 V", adjust the value by turning potentiometer "Z" at the ramp time module. 2. Now set the output voltage of the service module to 10 V. Check the voltage reading of the multimeter connected to the ramp time module; if neccessary, adjust to "10 V" by turning the potentiometer "G". NOTE: Repeat settings of item 1 and 2 until both values are stabilized, because "Pot Z" and "Pot G" influence each other. Disconnect the test lead after the setting is done. NOTE: The factory setting of potentiometer "w1" to "w4" must not be adjusted!
Version 2010/1
5-61
Adjusting the ramp time modul
CONTROLLING
Fig. 5-20 Adjusting the ramp time module
5-62
Version 2010/1
CONTROLLING
Adjusting the ramp time modul
Legend for Fig. 5-20: (1)
Capacitor module
(2)
Control lever (joystick)
(3)
Ramp time module
(4)
Proportional amplifier module
(5)
Relay (supply voltage)
(6)
Extract from the circuit diagram
(7)
Designation of the amplifier connected to the ramp time module to be set
Ramp time adjustment in relation to the operating movements: 3. Disconnect the cables at terminal 3 and terminal 5 of the respective module. Connect a multimeter for voltage reading to the ramp time module terminals marked "t" (+) and "⊥" (-). 4. For setting the ramp times "t1" to "t4" one after another: Apply +24 VDC to the corresponding terminal (9 to 12, see Fig. 5-20) of the ramp time module using a test lead. (+24 VDC can be taken from terminal 1 of the ramp time module itself.) Take the set value for the ramp time(s) from the corresponding table in the circuit diagram and set the voltage by adjusting the appropriate potentiometer marked "t1" to "t4" at the ramp time module. NOTE: The ramp time "t" corresponds to the voltage "Ut"set as desribed above, see following table and examples. Voltage Ut measured at socket "t" [V]
Ramp time (±20%) [ms]
t = 100 Vms / Ut
5
20
Quick reaction
3
33
2
50
1
100
0.5
200
0.3
333
0.2
500
0.1
1000
0.05
2000
0.03
3333
0.02
5000
Example: Measured value Ut = 5 V
⇒ Resulting ramp time t = 100 V ms / 5 V = 20 ms
Example: Requested ramp time = 50 ms ⇒ Voltage to be set Ut = 100 V ms / 50 ms = 2 V
Slow reaction
NOTE: Through the new release of the PM Clinic procedure (and adjustment of the Energy Efficiency), the ramp time modules (except swing and travel circuit) are basically adjusted to 20 ms / 5 V. For more details refer to your electric circuit diagram. The amplifiers and ramp time modules will soon be replaced with a closed control module for controlling.
Version 2010/1
5-63
Adjusting the ramp time modul
CONTROLLING
5-64
Version 2010/1
COMPONENTS
6. COMPONENTS
Version 2010/1
6-1
Main control blocks and high pressure filter (FSA)
COMPONENTS
6.1
MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER (FSA)
Fig. 6-1
Main control blocks and high pressure filter (FSA)
6-2
Version 2010/1
COMPONENTS
Main control blocks and high pressure filter (FSA)
NOTE: Legend for Fig. 6-1: Pump Circuit No. I (10 / I)
Main control block (swing [fast] L.H. & R.H., bucket fill / boom raise, stick retract / extend)
(13.2)
High pressure filter
(68.1)
Anti cavitation valve – stick cylinder piston side
(66.4)
Service-line relief valve – stick cylinder rod side Pump Circuit No. II
(11 / II)
Main control block (boom, clam, bucket fill / stick extend, L.H. travel)
(13.3)
High pressure filter
(45)
SRV clam cylinder piston side
(66.5)
SRV boom cylinder piston side
(68.2)
ACV clam cylinder rod side
(68.3 + 68.4)
ACV travel motors Pump Circuit No. III
(9 / III)
Main control block (swing [slow], clam, bucket, boom [lower])
(13.1)
High pressure filter (with differential pressure switch B7)
(66.1)
SRV bucket cylinder piston side
(66.2)
SRV bucket cylinder rod side Pump Circuit No. IV
(12 / IV)
Main control block (R.H. travel, boom / bucket, stick)
(12.3)
High pressure filter
(66.7)
SRV boom cylinder piston side
(66.8)
SRV boom cylinder rod side
(66.9)
SRV bucket cylinder piston side
(66.10)
SRV bucket cylinder rod side
(66.11)
SRV stick cylinder piston side
(66.12)
SRV stick cylinder rod side
(68.5)
ACV stick cylinder piston side
(68.6 + 68.7)
ACV travel motors
NOTE: There is one main relief valve in each control block.
Version 2010/1
6-3
Main control blocks and high pressure filter (BHA)
COMPONENTS
6.2
MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER (BHA)
Fig. 6-2
Main control blocks and high pressure filter (BHA)
6-4
Version 2010/1
COMPONENTS
Main control blocks and high pressure filter (BHA)
Legend for Fig. 6-2: Pump Circuit No. I (10 / I)
Main control block (swing [fast], boom, stick)
(13.2)
High pressure filter
(66.4)
Service-line relief valve – Stick cylinder rod side Pump Circuit No. II
(11 / II)
Main control block (boom, bucket, stick, L.H. travel)
(13.3)
High pressure filter
(66.5)
SRV boom cylinder piston side
(66.6)
SRV clam cylinder rod side
(68.3 + 68.4)
ACV travel motors Pump Circuit No. III
(9 / III)
Main control block (swing [slow], bucket, boom)
(13.1)
High pressure filter
(66.3)
SRV bucket cylinder rod side Pump Circuit No. IV
(100 / IV)
Main control block (boom, bucket, stick, R.H. travel)
(13.4)
High pressure filter
(66.7)
SRV boom cylinder piston side
(66.8)
SRV boom cylinder rod side
(66.12)
SRV stick cylinder rod side
(68.6 + 68.7)
ACV travel motors
NOTE: There is one main relief valve in each control block.
Version 2010/1
6-5
Distributor manifold - location of restrictor blocks and anti cavitation valves (FSA)
COMPONENTS
6.3
DISTRIBUTOR MANIFOLD - LOCATION OF RESTRICTOR BLOCKS AND ANTI CAVITATION VALVES (FSA)
Fig. 6-3
Distributor manifold - location of restrictor blocks and anti cavitation valves (FSA)
6-6
Version 2010/1
COMPONENTS
Distributor manifold - location of restrictor blocks and anti cavitation valves (FSA)
Legend for Fig. 6-3: (SB)
Synchronization (equalization) block
(SL)
Synchronization (equalization) lines
(SRV)
Secondary relief valve
(M)
Pressure check point
(42)
Distributor manifold
(64.1)
ACV block section A, boom cylinder rod side
(70.1 + 70.2)
Restrictor blocks section B, boom cylinder piston side with SRVs and pressure check points M16.1 + M16.2
(65.1)
SRV section C, bucket cylinder piston side with SRV and pressure check point M17.1
(70.4)
Restrictor block section C, bucket cylinder piston side with pressure check point M17.2
(64.2)
ACV block section C, bucket cylinder piston side
(64.3)
ACV block section D, bucket cylinder rod side
(70.6)
Restrictor block section E, clam cylinder rod side with SRV and pressure check point M19
(64.4)
ACV block section F, stick cylinder rod side
(65.2)
SRV section G, stick cylinder piston side with pressure check point M20
(64.5)
ACV block section H, stick cylinder rod side
(70.8 + 70.9)
Restrictor blocks section J, stick cylinder piston side with SRVs and pressure check points M21.1 + M21.2
(18)
SRV section K, clam cylinder piston side with pressure check points M22
(64.6)
ACV block section K, clam cylinder piston side
(64.7)
ACV block section L, bucket cylinder rod side
(64.8)
ACV block section M, bucket cylinder piston side
(70.12)
Restrictor block section M, bucket cylinder piston side with SRV and pressure check point M24
(65.3)
SRV section N, bucket cylinder piston side with pressure check point M25
(65.4)
SRV section O, boom cylinder piston side with pressure check point M26.2
(70.13)
Restrictor blocks section O, boom cylinder piston side with SRV and pressure check point M26.1
(64.9)
ACV block section P, boom cylinder rod side
Version 2010/1
6-7
Distributor manifold - location of restrictor blocks and anti cavitation valves (BHA)
COMPONENTS
6.4
DISTRIBUTOR MANIFOLD - LOCATION OF RESTRICTOR BLOCKS AND ANTI CAVITATION VALVES (BHA)
Fig. 6-4
Distributor Manifold - Location of restrictor blocks and anti cavitation valves (BHA)
6-8
Version 2010/1
COMPONENTS
Distributor manifold - location of restrictor blocks and anti cavitation valves (BHA)
Legend for Fig. 6-4: (SL)
Synchronization (equalization) lines
(SRV)
Secondary relief valve
(M)
Pressure check point
(42)
Distributor manifold
(64.1)
ACV block section A, boom cylinder rod side
(70.1 + 70.2)
Restrictor blocks section B, boom cylinder piston side with SRVs and pressure check points M16.1 + M16.2
(70.3)
Restrictor block section C, bucket cylinder piston side with SRV and pressure check point M17.1
(70.4)
Restrictor block section C, bucket cylinder piston side with SRV and pressure check point M17.2
(64.2)
ACV block section C, bucket cylinder piston side
(64.3)
ACV block section D, bucket cylinder rod side
(70.5)
Restrictor block section D, bucket cylinder rod side with SRV and pressure check point M18
(64.4)
ACV block section F, stick cylinder piston side
(70.7)
Restrictor block section G, bucket cylinder rod side with SRV and pressure check point M20
(64.5)
ACV block section H, stick cylinder piston side
(70.8 + 70.9)
Restrictor blocks section J, stick cylinder rod side with SRVs and pressure check points M21.1 + M21.2
(70.10)
Restrictor blocks section K, stick cylinder rod side with SRVs and pressure check points M22
(64.6)
ACV block section K, stick cylinder rod side
(70.11)
Restrictor blocks section L, stick cylinder rod side with SRVs and pressure check points M23
(64.7)
ACV block section L, bucket cylinder rod side
(70.12)
Restrictor block section M, bucket cylinder piston side with SRV and pressure check point M24
(64.8)
ACV block section M, bucket cylinder piston side
(70.13)
Restrictor blocks section O, boom cylinder piston side with SRV and pressure check point M26.1
(70.14)
Restrictor blocks section O, boom cylinder piston side with SRV and pressure check point M26.2
(64.9)
ACV block section P, boom cylinder rod side
Version 2010/1
6-9
Single control blocks (floating) for stick and boom (FSA)
COMPONENTS
6.5
SINGLE CONTROL BLOCKS (FLOATING) FOR STICK AND BOOM (FSA)
Fig. 6-5
Single control blocks (floating) for stick and boom (FSA)
6-10
Version 2010/1
COMPONENTS
Single control blocks (floating) for stick and boom (FSA)
Legend for Fig. 6-5: (60Q632)
Single control block - Stick lowering function Floating position
(60Q633)
Single control block - Stick lowering function Floating position
(60Q634)
Single control block - Stick lowering function Floating position
(61Q635)
Single control block - Boom lowering function Floating position
Function (only Front Shovel Attachment) The additionally installed single control blocks connect the piston side of the cylinders with the rod side and also with the hydraulic oil tank: z
60Q632, 60Q633 and 60Q634 for the stick cylinders
z
61Q635 for the boom cylinders
In normal operation mode (floating position) the pilot pressure oil holds the spool in the single control blocks (via de-energized solenoid valves) open when lowering the boom or stick. If a pressurized lowering of the cylinders is required, the pilot pressure oil is switched via energized solenoid valves to the main control blocks. The solenoid valves (4/2-directional control valves) are controlled by push buttons located in the control levers (joysticks).
Version 2010/1
6-11
Restrictor block with pressure relief valve
COMPONENTS
6.6
RESTRICTOR BLOCK WITH PRESSURE RELIEF VALVE
Fig. 6-6
Restrictor block with secondary relief valve
6-12
Version 2010/1
COMPONENTS
Restrictor block with pressure relief valve
Legend for Fig. 6-6: (1)
Adjustment pin
(2 + 3)
O-ring with back-up ring
(4)
Retainer
(5 + 6)
O-ring with back-up ring
(7)
Spring
(8)
Spring cup
(9)
Valve poppet
(10)
O-ring
(11)
Housing
(12)
Return line port, T
(13)
Secondary relief valve
(14)
Allen bolt
(15)
Clip ring
(16)
Lock nut
(A + B)
Line ports
M
Pressure check point
Y
Control oil drain port
NOTICE A restrictor block is used for limiting cylinder lowering speeds.
z z
A secondary relief valve is installed to limit the maximum system pressure due to external forces.
Function Setting of the maximum permissible cylinder speed (flow B to A) is carried out by the adjustment pin (Fig. 6-6, Pos. 1). Depending on the setting, the radial holes (Fig. 6-6 Pos. 9.1) in the valve poppet (Fig. 6-6, Pos. 9) will be partially opened to achieve the required throttling of the oil flow. The extra holes (fixed throttle 9.2) prevent the valve from becoming completely closed. For the lifting operation (flow A to B), the valve poppet (Fig. 6-6 Pos. 9), which is guided by the pin (Fig. 6-6, Pos. 1), is pressed against the spring (Fig. 6-6, Pos. 7) so that the valve will be completely open. NOTE: Ex factory the throttle valves are pre-adjusted, refer to PM-Clinic.
Version 2010/1
6-13
Anti cavitation valve block
6.7
ANTI CAVITATION VALVE BLOCK
Fig. 6-7
Anti cavitation valve block
6-14
COMPONENTS
Version 2010/1
COMPONENTS
Anti cavitation valve block
Legend for Fig. 6-7 (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
(A + B)
Line connections
NOTE: ACVs are installed to avoid cavitation damages on hydraulic cylinders by compensating a possible lack of oil when the SRV at the opposite side of the cylinder opens (see circuit diagram). Function The circuit pressure in lines A and B hold the valve cone (Fig. 6-7, Pos. 2) closed. Pressure of the supply line S is put on the valve cone. The valve cone opens, whenever the pressure at the A and B side is lower than the back pressure at the return oil port S, to allow necessary oil supply into the circuit.
Version 2010/1
6-15
Remote control valves
6.8
REMOTE CONTROL VALVES
Fig. 6-8
Remote control valves
6-16
COMPONENTS
Version 2010/1
COMPONENTS
Remote control valves
Legend for Fig. 6-8: (1)
Pilot pressure supply port (marked with P)
(2)
Pilot pressure return port to tank (marked with L)
(3)
Pilot pressure output lines to the control block
(4)
Proportional solenoid valve
(5)
4/3 Directional solenoid valve
NOTE: Remote control valves are part of the electric-hydraulic control system. 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 (Fig. 6-8, Pos. 4) and one of the directional solenoid valves (Fig. 6-8, Pos. 5 / either Ax or Bx) are energized, allowing 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, resulting in a spool movement in the main control block between neutral and full stroke position.
Version 2010/1
6-17
4/3 Directional solenoid valves
6.9
4/3 DIRECTIONAL SOLENOID VALVES
Fig. 6-9
Directional solenoid valve
6-18
COMPONENTS
Version 2010/1
COMPONENTS
4/3 Directional solenoid valves
Legend for Fig. 6-9: (1)
Control spool
(2)
Plunger
(3)
Solenoids
(4)
Reset springs
(5)
Housing
NOTE: This solenoid operated directional spool valves are installed to control the start, stop and direction of an oil flow. Function In un-operated condition the control spool (Fig. 6-9, Pos. 1) is held in the neutral position by the reset springs (Fig. 6-9, Pos. 4). Operation of the control spool takes place by means of oil immersed solenoids (Fig. 6-9, Pos. 3). The force of the solenoid (Fig. 6-9, Pos. 3) acts via the plunger (Fig. 6-9, Pos. 2) on the control spool (Fig. 6-9, Pos. 1) and pushes it from its neutral position into the required end position. This results in the required flow from P to A and B to T, or from P to B and A to T. When the solenoid (Fig. 6-9, Pos. 3) is de-energised, the control spool (Fig. 6-9, Pos. 1) is returned to its original position by the reset springs (Fig. 6-9, Pos. 4).
Version 2010/1
6-19
Proportional solenoid valves
6.10
PROPORTIONAL SOLENOID VALVES
Fig. 6-10
Proportional solenoid valve
6-20
COMPONENTS
Version 2010/1
COMPONENTS
Proportional solenoid valves
Legend for Fig. 6-10: (1)
Connector socket
(2)
Bleed screw
(3)
Proportional solenoid
(4)
Valve housing
(5)
Piston stop
(6)
Pressure spool
(7)
Control piston
(8)
Pressure spool
NOTE: These valves are responsible for the creation of a variable control pressure proportional to the electrical signal output of an amplifier. Function In neutral condition the control piston (Fig. 6-10, Pos. 7) is held in the neutral or starting position by reset springs. The control piston (Fig. 6-10, Pos. 7) is directly operated by the proportional solenoid (Fig. 6-10, Pos. 3). If the solenoid is energised, it produces a force to operate the control piston (Fig. 6-10, Pos. 7) via the pressure spool (Fig. 6-10, Pos. 8) 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 piston (Fig. 6-10, Pos. 7) to the inner end of the pressure spool (Fig. 6-10, Pos. 4). The force generated by the pressure now works against the solenoid force and pushes the control piston (Fig. 6-10, Pos. 7) to the right (closing direction) until a balance is achieved between the two forces. In order to achieve this, the pressure spool (Fig. 6-10, Pos. 4) moves to the left in the direction of the piston stop (Fig. 6-10, Pos. 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 piston (Fig. 6-10, Pos. 7). The control spool is then moved to the right causing a connection from A to T, allowing the pressure to fall until a balance is re-established at a lower level. At rest, when the solenoid is de-energized, ports A and B are open to tank, while port P is blocked from both ports A and B.
Version 2010/1
6-21
High pressure filter
6.11
HIGH PRESSURE FILTER
Fig. 6-11
High pressure filter
6-22
COMPONENTS
Version 2010/1
COMPONENTS
High pressure filter
Legend for Fig. 6-11: (1)
Hexagon
(2)
Drain plug
(3)
Packing ring
(4)
Spring
(5)
Filter element
(6)
Filter case
(7)
Filter head
(8)
Back-up ring
(9)
O-ring
(10)
Spring
NOTE: High pressure filters are installed in each pump line. Function High-pressure in-line filters prevent contamination from entering the hydraulic circuits. The spin-on filters are installed between the main hydraulic pumps and multi-valve control blocks. All hydraulic components behind the pumps are effectively protected from damage and undue wear.
Version 2010/1
6-23
Control blocks and valves
6.12
CONTROL BLOCKS AND VALVES
Fig. 6-12
Control blocks and valves
6-24
COMPONENTS
Version 2010/1
COMPONENTS
Control blocks and valves
Legend for Fig. 6-12: (1)
Control block housing
(2)
Main relief valve (MRV)
(3)
Boom lifting / lowering spool (special)
(4)
Long cap ("B" side)
(5)
"B" side service line ports
(6)
Centering springs
(7)
Solid spool
(8)
Short cap ("A" side)
(9)
"A" side service line ports
(10)
Load check valves
(11)
Pilot oil warm up and flushing grooves
(12)
Fine controlling grooves
(13)
Type plate
NOTE: Principle drawing, showing valve block II and IV. The control blocks are "Open Center Blocks". Control blocks I and III are 3 spool blocks, control blocks II and IV are 4 spool blocks. See hydraulic circuit diagram for spool details. Each spool is provided with "Fine Controlling Grooves", ring grooves for hydraulically centering of the spool and “Pilot oil warm up and flushing“ grooves. Pilot pressure between 8 and 19 bar moves the spools in their fine control range. The spool (Fig. 6-12, Pos. 3) is especially designed to keep the pressure channel connected to the center channel during the function “Boom lowering“ is selected, so that pump flow is available for other functions. The Load Holding Valves are installed beneath a plug from the service port side of the control block. The MRV is a pilot operated pressure relief valve.
Version 2010/1
6-25
Control blocks and valves
Fig. 6-13
6-26
COMPONENTS
Control blocks and valves
Version 2010/1
COMPONENTS
Control blocks and valves
Legend for Fig. 6-13: (1)
Main relief valve (MRV) control block housing
(2)
Load check valve
(3)
Anti cavitation valve (ACV)
(4)
Secondary relief valve (SRV)
Explanation of the schematic drawing of the control block: The hydraulic oil flows (Qmin = 190 liters/min) through the control block from port P to T, if all spools are in neutral position ("open center“). z
Fig. 6-13 ,Pos. A: E.g. the spools pilot pressure is built up in the control pipe line a1. (Imagine the upper symbol box moves to the center position.) Now pump oil flows through check valve (Fig. 6-13, Pos. 2) to the user port A1 because the free flow circulation to the hydraulic reservoir is closed. The main relief valve (Fig. 6-13, Pos. 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 (Fig. 6-13, Pos. 3) prevent 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.
z
Fig. 6-13, Pos. B: E.g. spool #3 moves up when pilot pressure is built up in the control pipe b3. Now the user port B3 is supplied with pump pressure. Via port A3 the return oil from the user is flowing back to the hydraulic reservoir. The secondary relief valve (Fig. 6-13, Pos. 4) is additional installed in this circuit to protect the circuit against extreme pressure. The short-time extreme pressure also closes the check valve (Fig. 6-13 Pos. 2) which protects the hydraulic pump against extreme pressure peaks. The check valves (Fig. 6-13, Pos. 2) also have the function of load holding valves, because during the fine controlling period all lines are interconnected (negative over-lapping). For a moment, the load pressure is higher than the pump pressure.
Version 2010/1
6-27
Control blocks and valves
COMPONENTS
Spool in "neutral position"
Pilot pressure connected to spool cab "a"
Fig. 6-14
6-28
Control blocks and valves
Version 2010/1
COMPONENTS
Control blocks and valves
Legend for Fig. 6-14: (1)
Main relief valve (MRV)
(2)
Reset springs
(3)
Fine control grooves
(4)
Spool
Function Reset springs (Fig. 6-14, Pos. 2) move the spool (Fig. 6-14, Pos. 4) into neutral position. Fine control grooves (Fig. 6-14, Pos. 3) provide for sensitive controlling, because a motion is always started while the pressure oil and the return oil first pass these fine control grooves before the spool (Fig. 6-14, Pos. 4) is interconnecting the entire groove to the user channel. In neutral position of spool (Fig. 6-14, Pos. 4) the pump oil is flowing back via port PU to the tank. Lower Picture Example: The spool is moved to left position: Port PU is closed and the connection through the check valve RP1 to the user (port A) is open. In addition, the connection from the other user side (port B return) is connected to the port T (return line to tank). The return line of the pressure relief valve MRV (Fig. 6-14, Pos. 1) is also connected to the port T.
Version 2010/1
6-29
Control blocks and valves
Fig. 6-15 6-30
COMPONENTS
Control blocks and valves Version 2010/1
COMPONENTS
Control blocks and valves
Legend for Fig. 6-15: (1)
Secondary relief valve (SRV)
(2)
Anti cavitation valve
(3)
Main relief valve (MRV)
(4)
Closing plate
(5)
Plug screw
(6)
Spring
(7)
Valve cone
(8)
Dust cap
(9)
Set screw
(10)
Lock nut
(11)
Spring, pilot part
(12)
Poppet
(13 + 16)
Jet bore
(14)
Spring, main cone
(15)
Main valve cone
(17)
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. z
Function: The circuit pressure P pushes the piston surface A of the main valve cone (Fig. 6-15, Pos. 15) with the force F1. Because there is the same pressure on the back side of the main cone via the jet bore (Fig. 6-15, Pos. 16), this, together with the spring (Fig. 6-15 Pos. 14) force, results in a force F2 that keeps the main cone closed. Via the jet bore (Fig. 6-15, Pos. 13) the circuit pressure is in front of the poppet (Fig. 6-15, Pos. 12). When the circuit pressure exceeds the setting value of the spring (Fig. 6-15, Pos. 11), the poppet opens against the force of the spring (Fig. 6-15, Pos. 11). As a result, force F2 decreases and there is no more balance condition between F1 and F2. The valve cone (Fig. 6-15, Pos. 15) is moved upwards by the greater force F1. That means now there is a direct connection from port P to T (tank).
ACVs serve for compensating a possible lack of oil when the SRV at the opposite port is actuated (see circuit diagram) and for avoiding cavitation damages. In addition, they serve to supply a user in case it is continuously moved by acceleration forces at zero position of the control spool. z
Function: The circuit pressure inside the spring chamber closes the valve cone (Fig. 6-15, Pos. 7). The back pressure of the return line acts on the surface of the valve cone (Fig. 6-15, Pos. 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 additionally supplied.
Version 2010/1
6-31
Control blocks and valves
Fig. 6-16
6-32
COMPONENTS
Control blocks and valves
Version 2010/1
COMPONENTS
Control blocks and valves
Legend for Fig. 6-16 (load holding valve): (1)
Valve cone guide
(2)
Valve spring
(3)
Valve cone
(4)
Valve block housing
(5)
Passage from pump (P)
(6)
Passage to control block spool A/B
Control blocks II and IV (4 spool blocks) The load holding valves are fitted into separate spaces of the control block housing, one valve for each spool. The load holding valves have three tasks: 1. When the circuit pressure is higher than pump pressure due to the attachment weight, these valves prevent dropping of the attachment, within their sensitive (fine controlling) range. 2. Due to sudden pressure peaks in the service-lines the valves also protect the pump. 3. When two pump flows are used for one user, the valves ensure that at least the flow of one pump reaches the user in case one MRV is defect or no longer properly 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 pushes onto the front area of the valve cone (Fig. 6-16 Pos. 1). This force moves the valve cone against the spring (Fig. 6-16 Pos. 2) and allows the oil to flow from the pump to the spool. In neutral position of the spool no further flow is possible (see circuit diagram). If the spool is no longer in neutral position, 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).
Version 2010/1
6-33
Control blocks and valves
Fig. 6-17 6-34
COMPONENTS
Control blocks and valves Version 2010/1
COMPONENTS
Control blocks and valves
Legend for Fig. 6-17 (load holding valve): (1)
Spool
(2)
Valve cone
(3)
Valve spring
(4)
Passage from P to A
(5)
Passage from B to T
NOTE: This is a principle drawing only, showing the location of load holding valves in valve block I and III. Control blocks I and III (3 Spool Blocks) The load holding valves are directly fitted into the spools (one on each side). The load holding valves have three tasks: When circuit pressure is higher than pump pressure due to attachment weight, these valves prevent dropping of the attachment, within their sensitive (fine controlling) range. Due to sudden pressure peaks in the service lines, the valves also protect the pump. When two pumps flows are used for one user, the load holding valves ensure that at least the flow of one pump reaches the user in case one MRV is defect or no longer properly 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 In neutral position (upper picture) of the spool (Fig 6-17, Pos. 1) both valve cones (Fig. 6-17, Pos. 2) are closed by the springs (Fig. 6-17, Pos. 3). In a switched position (lower picture), the circuit pressure pushes onto the front area of the valve piston (Fig. 6-17, Pos. 2). This force moves the piston against the spring (Fig. 6-17, Pos. 3) and allows the oil to flow from the pump supply (Fig. 6-17, Pos. 4) to the user port (A) and from port B via boring (Fig. 6-17, Pos. 5) to the return oil passage. If, due to an external force, the pressure directed to the pump overcomes the pressure in the pump line, this pressure/force closes the valve (direction P to A).
Version 2010/1
6-35
Travel brake valve
6.13
TRAVEL BRAKE VALVE
Fig. 6-18
Travel brake valve
6-36
COMPONENTS
Version 2010/1
COMPONENTS
Travel brake valve
Task Travel brake valves control the oil flow from the hydraulic motor to the tank depending on the operating pressure. This braking action prevents the motors from overspeeding.
Function Spring force keeps the spool in the lowest flow position. With increasing operating pressure the opening for the return oil flow becomes larger. On its way to the hydraulic motor the oil flows from A to A1 or B to B1, depending on the selected travel motion.
Example The operating pressure at port A moves spool (Fig. 6-18, Pos. 1) against the force of the spring (Fig. 6-18, Pos. 2) and opens the way for the return oil (Fig. 6-18, Pos. B1 to B). The check valve (Fig. 6-18, Pos. 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.
Version 2010/1
6-37
Pressure reducing valve
6.14
PRESSURE REDUCING VALVE
Fig. 6-19
Pressure reducing valve
6-38
COMPONENTS
Version 2010/1
COMPONENTS
Pressure reducing valve
Legend for Fig. 6-19: (1)
Set screw
(2)
Threaded sleeve
(3)
Compression spring
(4)
Spring chamber
(5)
Spool
(6)
Non-return valve
(7)
Cone
(8)
Control line
NOTE: Pressure reducing valves are installed to reduce the common 45 bar pilot pressure to a lower pressure for other systems, e.g. the track tensioning system or the travel parking brake. 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 oil can flow from port P to A. Pressure in port A is also present on the end of the spool (Fig. 6-19, Pos. 5) via control line (Fig. 6-19, Pos. 8), opposing the compression spring (Fig. 6-19, Pos. 3). When the pressure in port A reaches the pressure level set at spring (Fig. 6-19, Pos. 3), the spool (Fig. 6-19, Pos. 5) moves to the control position and holds the pressure in port A constant. Oil to control the valve is taken from port A via the control line (Fig. 6-19, Pos. 8). If the pressure in port A still rises further due to external forces, the spool (Fig. 6-19, Pos. 5) is moved further towards the compression spring (Fig. 6-19, Pos. 3). This causes a flow path to be opened over the cone (Fig. 6-19, Pos. 7) of the control spool (Fig. 6-19, Pos. 5) to tank. Sufficient fluid then flows to tank to prevent any further rise in pressure. An optional non-return valve (Fig. 6-19, Pos. 6) is available to allow free flow from A to P.
Version 2010/1
6-39
4/2 Directional solenoid valves
6.15
4/2 DIRECTIONAL SOLENOID VALVES
Fig. 6-20
Directional solenoid valves
6-40
COMPONENTS
Version 2010/1
COMPONENTS
4/2 Directional solenoid valves
Legend for Fig. 6-20: (1)
Housing
(2)
Control spool
(3)
Plunger
(4)
Solenoid
(5)
Dust cap with stem for manual operation
(6)
Return spring
NOTE: These solenoid operated directional spool valves are installed to control the start, stop, and direction of an oil flow. Function When there is no flow through the valve, the control spool (Fig. 6-20, Pos. 2) is held in neutral or output position by means of the return springs (Fig. 6-20, Pos. 6). The control spool (Fig. 6-20, Pos. 2) is operated by means of oil immersed solenoid (Fig. 6-20, Pos. 4). The force of the solenoid (Fig. 6-20, Pos. 4) effects the control spool (Fig. 6-20, Pos. 2) by means of the plunger (Fig. 6-20, Pos. 3) and pushes it from its resting position to the required end position. This results in free flow from or P to B and A to T. When the solenoid (Fig. 6-20, Pos. 4) is de-energized, the control spool (Fig. 6-20, Pos. 2) is moved back to its resting position by means of return springs (Fig. 6-20, Pos. 6). An optional emergency operating device for manual operation (Fig. 6-20, Pos. 5) allows movement of the control spool (Fig. 6-20, Pos. 2) without energizing the solenoid.
Version 2010/1
6-41
Pressure double stage valve
6.16
PRESSURE DOUBLE STAGE VALVE
Fig. 6-21
Pressure double stage valve
6-42
COMPONENTS
Version 2010/1
COMPONENTS
Pressure double stage valve
Legend for Fig. 6-21: (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
NOTE: The pressure double stage valve is a remote controlled pressure relief valve, actuated by hydraulic pressure. The individual relieve pressure is determined by the pilot pressure. Function The valve poppet (Fig. 6-21, Pos. 2) is connected via the jet bores (Fig. 6-21, Pos. 11 and Pos. 12) with port P. If static pressure increases above the set pressure value, the valve poppet (Fig. 6-21 Pos. 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 (Fig. 6-21, Pos. 6) is cancelled, and the main piston (Fig. 6-21, Pos. 5) opens to allow the pump flow to tank (T2). Damped opening and closing is obtained by the throttled volumetric change. By applying external pressure of Pst max = 45 bar to the main spool (Fig. 6-21, Pos. 9) via port X, the pre-tensioning of the pressure spring (Fig. 6-21, Pos. 3) is increased by the amount of the piston stroke "S", and system pressure is increased correspondingly. The possible pressure increase p is 440 bar max. or 440 bar minus the basic setting. The setting is fixed by means of the setting screw (Fig. 6-21, Pos. 7) and lock nut (Fig. 6-21, Pos. 13); 1 turn of the screw = 150 bar.
Version 2010/1
6-43
Hydraulic cylinder
6.17
HYDRAULIC CYLINDER
Fig. 6-22
Hydraulic cylinder, layout
6-44
COMPONENTS
Version 2010/1
COMPONENTS
Hydraulic cylinder
Legend for Fig. 6-22: (1)
Bushing
(2)
Grease fitting
(3)
Cylinder head with rod guide and rod seal
(4)
Snap ring
(5)
Piston rod
(6)
Piston seal
(7)
Cylinder barrel
(8)
Main piston seal
(9)
Back up ring
(10)
Piston
(11)
Piston nut
(12)
Bushing
(13)
Hydraulic port to piston side
(14)
Set screw connection of piston nut and piston
(15)
Set screw secured with a prick-punch (acc. to works standard)
(16)
Rod seal to piston
(17)
Back up ring
(18)
O-ring
(19)
Hydraulic port to rod side
(20)
Cylinder head seal to barrel
(21)
O-ring
(22)
Back up ring
(23)
Buffer ring
(24)
Rod seal
(25)
Back up ring for rod buffer ring
(26)
Rod packing
(27)
Rod seal
(28)
Back up ring
(29)
Dust seal
(30)
Dust seal
(31)
Snap ring
Version 2010/1
6-45
Hydraulic cylinder
COMPONENTS
Function Hydraulic cylinders (also called linear hydraulic motors) are actuators which convert fluid power into mechnical power. The cylinders get their power from pressurized hydraulic fluid, typically oil. Hydraulic cylinders are used at high pressures to produce large forces and presice movements. Therefore they are constructed of strong materials and designed to withstand large forces. The hydraulic cylinder is the the actuator or "motor" side of the system. The "generator"side of the system is the hydraulic pump which brings in a regulated flow of oil to the bottom side of the cylinder to move the piston rod outwards. The oil in the chamber on the rod side is pushed back to the oil tank. The force of the cylinder depends on the hydraulic oil pressure and the piston face. The force F is given by the formula F = p A, where p is the pressure (in N/m²) and A is the face (in m²) of the piston the pressure acts on. That means, that the force of the hydraulic oil can be multiplied as needed, the maxium force is only limited by the dimension of the piston face. Structure The layout of the hydraulic cylinder is shown in Fig. 6-22. The piston (Fig. 6-22, Pos. 10) separates the two sides of the cylinder barrel internally. To prevent leakage from one side to the other, the piston is fitted with the piston seal (Fig. 6-22, Pos. 6) and the rod seal (Fig. 6-22, Pos. 16). At the other side of the cylinder, there are 4 different seal packages: – a dust seal (Fig. 6-22, Pos. 29) the prevent dirt beeing drawn into the cylinder – a rod packing (Fig. 6-22, Pos. 26) as the main seal to the outside – a buffer ring (Fig. 6-22, Pos. 23) to prevent leakage between the cylinder head and the piston rod – a cylinder head seal (Fig. 6-22, Pos. 20) to prevent the leakage from the fit between cylinder head and barrel. The cylinder head (Fig. 6-22, Pos. 10) is bolted to the cylinder barrel (Fig. 6-22, Pos. 7).
WARNING During commissioning and when new hydraulic cylinders are installed, first of all, the air has to be bled from the cylinders, refer to the ’air bleeding’ procedure described in the TROUBLESHOOTING MANUAL.
NOTE: In case abnormal movements of the hydraulic cylinder are noticed, carry out a cylinder bypass test, refer to the TROUBLESHOOTING MANUAL.
6-46
Version 2010/1
COMPONENTS
Hydraulic cylinder
Cylinder data markings, with the following information, are located at the piston rod side (sealing area) of the cylinder tube.
Fig. 6-23
Hydraulic cylinder, data markings
Legend for Fig. 6-23 (example for cylinder data markings): (1)
Piston diameter in [mm]
(2)
Piston rod diameter in [mm]
(3)
Piston stroke in [mm]
(4)
Symbol of producer
(5)
Consecutive number (serial number) for each year of production
(6)
Month of production (06 = June)
(7)
Last two digits of the year of production (10 = 2010)
(8)
Part-no.
Version 2010/1
6-47
Slew ring
COMPONENTS
6.18
SLEW RING
Fig. 6-24
Slew ring
6-48
Version 2010/1
COMPONENTS
Slew ring
Legend for Fig. 6-24: (1)
Seal ring
(2)
Outer ring gear
(3)
Thread for mounting to car body
(4)
Axial roller bearing, bottom
(5)
Lower internal bearing ring
(6)
Radial roller bearing
(7)
Axial roller bearing, top
(8)
Upper internal bearing ring
(9)
Bore for mounting to superstructure
Function The slew ring is the movable connection between the superstructure and the undercarriage. The bearing is from a cylindrical roller design with three roller paths, two for axial guiding (Fig. 6-24, Pos. 4 and 7) and one for radial guiding (Fig. 6-24, Pos. 6). The outer gear is directly machined to the outer bearing ring (Fig. 6-24, Pos. 2). The slew ring bearing is connected to the central lubrication system. The outer ring gear is lubricated by a separate lubrication system SLS for which a special open gear lubricant is used. NOTE: For assembly and additional checks refer to Parts & Service News AH00511, AH01532, and AH02513 (latest edition).
Version 2010/1
6-49
Slew ring
6-50
COMPONENTS
Version 2010/1
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
7. MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Version 2010/1
7-1
General
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
7.1
GENERAL
Fig. 7-1
Circuit diagram of the main hydraulic pumps and pump regulation
7-2
Version 2010/1
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
General
General layout (hydraulic only) Legend for Fig. 7-1: (1-4)
Main hydraulic pumps
(8.1)
Pilot pressure pump
(33)
Pilot pressure filter unit
(152)
Pressure relief valve – energy efficiency (X3: ~18 bar)
(252.1)
45 bar pressure relief valve
(252.2)
60 bar pressure relief valve
(253.1)
Cchange-over valve: "Electronic or hydraulic pump regulation"
(253.2)
Pressure relief valve: " Pump regulation pressure X1 at hydraulic pump regulation" (hydraulic constant regulation mode)
(255.4)
Pressure relief valve: "Remote control pressure" ½ Qmax flow reduction for the warming-up period and flow reduction for pump #1
(57K517)
Solenoid valve:Qmin flow for all main pumps
(57K517a)
Solenoid valve: "Remote control pressure" ½ Qmax flow reduction for all main pumps
(57K561-1)
Proportional solenoid valve: "Pump regulation pressure X1 at electronic pump regulation" (Standard operation mode)
(57K626)
Solenoid valve: "Remote control pressure" ½ Qmax flow reduction for pump #1 only
(57K630)
Solenoid valve: " Pump regulation pressure X1 = 45 bar for pump #1" (fixed pump for swing)
(57K631)
Solenoid valve: " Pump regulation pressure X1 = 45 bar for pump #3" (fixed pump for swing)
(57K646)
Flow reduction (pump No. 2 + No. 4)
(57K647)
Flow reduction (pump No. 3)
(57K648)
Flow reduction (pump No. 1)
Version 2010/1
7-3
General
Fig. 7-2
7-4
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Circuit diagram of the main hydraulic pumps and pump regulation
Version 2010/1
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
General
Pump regulation system ("open sensing system") General z
The system controls the output flow of the main pumps, dependent on engine power, most efficiently.
z
It limits the power request of the hydraulic pumps according to the maximum engine power (Electronic pump regulation with micro-controller RC4-4).
z
For additional functions, such as rotating dependent or temperature-dependent flow reduction.
Function X1 – Pump Regulation Pressure (0–34 bar): The power controller of the main pumps can be remotely controlled by applying an external pilot pressure (X1) at port XLR to the spring chamber of the power control valve. The start of destroking can be varied in proportion to the applied pressure X1. X2 – Pilot Pressure (45 bar): Constant pilot pressure to regulate the main pumps at special circumstances, e.g. to fix pump #1 and # 3 in Qmax position when swinging. X3 – Remote Control Pressure (0 / 15 / 45 bar): Basic setting Qmin (0 bar), the flow rate increases with the pilot pressure X3 at port Pst, up to Qmax (45 bar). The hyperbolic power control is superimposed on the pilot pressure signal and keeps the specified drive power constant. (p x Vg = constant). The flow rates are: Qmin:
X3 = 0 bar
½ Qmax:
X3 = 15 bar
Qmax:
X3 = 45 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.
Version 2010/1
7-5
General
Fig. 7-3
7-6
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Circuit diagram of the main hydraulic pumps and pump regulation
Version 2010/1
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
General
Pump regulation system general Function Solenoid Valve 57K517: If de-energized pumps #1-4 are in Qmin position. It gets energized as soon as one of the control levers/pedals has been operated, and stays energized as long as the temperature state is above T3. It gets de-energized whenever all controls are in neutral position for more than 20 seconds and a temperature state between T1 and T3. Solenoid Valve 57K517a: The solenoid is de-energized as long as the temperature state is below „T2“ (depending on the filled in hydraulic oil) shown in the table ( pumps #1-4 are in ½ Qmax. position for warm up). It gets energized at a temperature state between T2 and T4 as soon as one of the control levers/pedals has been operated, and gets de-energized with 2 seconds delay whenever all controls are in neutral position.
Pump flow control (i.e. pause = not moving the joysticks and pedals OFF
ON
ON
OFF
OFF
ON
Oil temperature
Flow reduction 2 seconds after pause
Flow reduction 20 seconds after pause
Flow reduction 20 seconds after pause
Oil flow
Fig. 7-4
Version 2010/1
7-7
General
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Solenoid Valve 57K626: If energized, pump #1 is in the same regulation mode like pumps #2, #3 and #4. If de-energized, the flow of pump#1 is limited to ½ Qmax by the function of pressure relief valve (255.4). It gets de-energized when the swing function in main control block 1 is activated, or when the hydraulic oil temperature is below „T2“. Normal operating conditions without swinging
Normal operating conditions with swinging (fast speed)
57K517
1
1
57K517a
1
1
57K626
1
0
(1) = Energized (0) = De-energized Proportional solenoid valve 57K561-1: This valve, connected to the RC4-4 micro-controller (electronic pump regulation), creates a X1-pressure depending on the load of the engine. This X1-pressure is the information for the pumps to destroke from Qmax into Qmin position, to keep the engine at rated speed of approx. 1800 rpm. Solenoid valve 57K630: If energized, pump regulation pressure X1 = 45 bar for pump #1 (fixed pump for swinging) Solenoid valve 57K631: If energized, pump regulation pressure X1 = 45 bar for pump #3 (fixed pump for swinging with fast speed) Pressure relief valve 255.4: "Remote control pressure" (X3) z
½ Qmax flow reduction during the warming-up period for all pumps by the function of solenoid valve 57K517a.
z
½ Qmax flow reduction only for pump #1 while swinging with max. speed by the function of solenoid valve 57K626.
Pressure relief valve 253.2: Pump regulation pressure X1 at "Hydraulic pump regulation" (hydraulic constant regulation mode) by the function of change-over valve (22). Change-over valve 253.1: Change-over three way cock valve to select "Electronic or constant regulation mode".
7-8
Version 2010/1
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
General
Pressure relief valve 152: "Remote control pressure" (Energy efficiency ~ 18 bar) Pressure relief valve 152 in connection with the MTC controlled solenoid valves 57K646, 57K647 and 57K648 increases the energy efficiency by optimizing the oil flow of all main pumps under definite combinations of working movements. Solenoid valve 57K646: If energized, main pumps #2 and #4 with optimized oil flow. Solenoid valve 57K647: If energized, main pump #3 with optimized oil flow. Solenoid valve 57K648: If energized, main pump #1 with optimized oil flow.
Version 2010/1
7-9
Main pumps
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
7.2
MAIN PUMPS
Fig. 7-5
Main pumps
7-10
Version 2010/1
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
7.2.1
Main pumps
LOCATION OF PUMPS
Legend for Fig. 7-5: (1-4)
(5.1)
(5.2)
(8.1)
(8.2)
Axial piston pump (swash plate type) theoretical for all working motions Flow rate, each Drive speed*
1034 Liters/min n = 1378 rpm
Axial piston pumpfor oil cooler fan drive Theoretical flow rate Drive speed*
214 Liters/min n = 2000 rpm
Axial piston pump for radiator fan drive Theoretical flow rate Drive speed*
214 Liters/min n = 2000 rpm
Gear pumpfor pilot pressure supply Theoretical flow rate Drive speed*
138 Liters/min n = 1378 rpm
Gear pump PTO gear lubrication Theoretical flow rate Drive speed*
138 Liters/min n = 1378 rpm
NOTE: * at 1800 rpm input drive speed
Version 2010/1
7-11
Main pumps
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
7.2.2
PUMP BEARING FLUSHING / LUBRICATION
Fig. 7-6
Pump bearing flushing / lubrication
7-12
Version 2010/1
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Main pumps
Legend for Fig. 7-6: (1 – 4)
Main pumps
(20.1 – 20.4)
Orifice (one for each main pump)
(33)
Filter for pilot pressure
(B-E)
Ports for X4-pressure (pump support pressure)
(U)
Port for the pump bearing lubrication
The installed main pumps are provided with an external lubrication system for flushing the drive shaft bearing and shaft seal. Oil supply is provided from the X4-pressure circuit. To reach the restricted guidance of the external bearing lubrication, the throttle screw (located behind the union at port U) must be screwed in all the way. An information sign is fixed at the pump.
Fig. 7-7
Circuit diagram
Version 2010/1
7-13
Main pumps
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
7.2.3
OPERATING PRINCIPLE
Fig. 7-8
Main hydraulic pump A4VSLO 750 LR3DN / 30L
7-14
Version 2010/1
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Main pumps
Legend for Fig. 7-8: (1)
Drive shaft
(11)
Drive through (auxiliary pump drive)
(2)
Cylindrical roller bearing
(12)
Swash plate
(3)
Slide shoes
(13)
Qmin stop bolt
(4)
Angle indicator
(14)
Power control valve
(5)
Servo piston
(15)
Pressure balance valve
(6)
Rocker cam
(16)
Power curve correction
(7)
Barrel with pistons
(17)
Pressure cut-off valve
(8)
Case (rear)
(18)
Qmax stop bolt
(9)
Cylindrical roller bearing
(19)
Remote control valve
(10)
Impeller pump
Main hydraulic pump A4VSO750i Type code explanation: A4VSO
750
i
L Rotation
Series Displacement in cm3 at one (1) revolution Axial piston pump series 4, variable displacement ,swash plate design for open circuits with charge pump Function and Characteristics: z
The A4VSO750i variable displacement axial piston pump in swash plate design is intended for drives in open circuit operation.
z
The flow volume is proportional to the drive speed and the displacement. By adjusting the swash plate an infinitely variable flow adjustment is possible.
z
Pumps of the same nominal size can be built onto the trough drive. Combinations with gear pumps are also possible.
Version 2010/1
7-15
Main pumps
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Symbol of main hydraulic pump A4VSO750i
Fig. 7-9
7-16
Symbol of main hydraulic pump A4VSO750i
Version 2010/1
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Main pumps
Legend for Fig. 7-9: (1)
Main pump (swash plate pump, variable displacement)
(2)
Impeller pump
(3)
Pump bearing
(4)
Drive shaft
(5)
Non-return valves
(6)
Remote control valve
(6.1)
Mechanical stroke limitation*
(6.2)
Remote pressure (PST) operated piston for item 6
(6.3)
Mechanical stroke limitation*
(7)
Spool valve (pressure balance valve)
(8)
Throttle valve
(9)
Power control valve
(10)
Throttle valve
(11)
Pressure cut-off valve
(12)
Auxiliary pump (gear pump)
(13)
Servo piston
(14)
Slipper pad piston
(15)
Lever
(16)
Cam
(17)
Through drive shaft
NOTE: * Factory side adjusted, no field adjustment required (B/B1)
Pressure port
(S)
Suction line
(MB)
Operating pressure test port
(ML)
Charging pressure test port
(MST)
Control pressure test port
(R)
Filler and bleeder port
(P)
Pump support pressure (”X4”-pressure)
(PST)
Remote control pressure port (”X3”-pressure)
(U)
Bearing lubrication port
(XLR)
Regulating pressure port (”X1”-pressure)
Version 2010/1
7-17
Main pumps
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Sectional drawing of regulating valves
Fig. 7-10
7-18
Sectional drawing of regulating valves
Version 2010/1
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Main pumps
Legend for Fig. 7-10: (6)
Remote control valve
(6.1)
Mechanical stroke limitation
(6.2)
Remote pressure (PST) operated piston for item 6
(6.3)
Mechanical stroke limitation
(7)
Spool valve (pressure balance valve)
(9)
Power control valve
(11)
Pressure cut-off valve
(13)
Positioning piston
(14)
Slipper pad piston
(15)
Lever
NOTE: Also refer to Fig. 7-9.
Version 2010/1
7-19
Main pumps
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Main pump at Qmin (190 l/min, no lever or pedal activated)
Fig. 7-11
7-20
Operating principle
Version 2010/1
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Main pumps
Qmin position: When are the pumps in Qmin position? A
Engine at standstill
B
Engine running and the controls are not used for 20 sec. or longer at temperature state between T1 and T3.
C
Engine running and via (VHMS Service Menu) 57K517 activated (Qmin position)
Example C with the following conditions: z
Engine running (high idle)
z
Pump circuit pressure less than X4 = 60 bar (pump support pressure).
z
X1 = 34 bar (pump regulation pressure), this pressure will not influence the Qmin position under these conditions.
z
X3 = 0 bar (remote control pressure); 57K517 de-energized (Qmin activated) for pumps #2, #3 and #4. For pump #1, 57K517 de-energized and 57K626 energized.
z
X4 = 60 bar (pump support pressure). Pump support pressure is present at valve #7, the slipper pad of piston #14 and the small area side of the positioning piston #13.
Response of pump control mechanism: Valve #7 moves to position "b" because the X4 pressure exceeds the spring force, since the oil behind nozzle (Fig. 7-11, Pos. 8) flows through valve #6 (which is in position "a", due to the missing remote control pressure X3) back to tank. Pump support pressure X4 passes valve #7 position "b" and flows via power control valve #9 position "a" to the large area side of positioning piston #13 Because the large area side of positioning piston #13 is approximately three times larger than 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 Qmin position. NOTE: The pump remains in Qmin position.
Version 2010/1
7-21
Main pumps
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Main pump at Qmax
Fig. 7-12
7-22
Operating principle
Version 2010/1
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Main pumps
Qmax position: (remember Q means volume) When does the pump move into Qmax position? z
Engine running
z
and hydraulic oil at normal operating temperature (>T2) (57K517a is energized)
z
and the controls individually used for individual movements (or 57K517 activated via VHMS – Qmax position)
z
and a pump pressure below start of de-stroking.
Example with the following conditions: z
Engine running (>1800 rpm)
z
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
z
X1 = 34 bar (pump regulation pressure via 57K561-1 or constant pressure XLR in hydraulic mode)
z
X3 = 45 bar (remote control pressure); 57K517 + 57K517a energized and 57K646 + 57K647 de-energized for pumps #2, #3 and #4. For pump #1, 57K517 + 57K517a energized and 57K648 de-energized
z
X4 = 60 bar (pump support pressure), present at valve #7.
Response of pump control mechanism: Valve #7 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 #6 (which is in position "b", due to the 45 bar remote control pressure X3). The large area side of positioning piston #13 is connected, via power control valve (Fig. 7-12, Pos. 9) position "a" and pressure balance valve (Fig. 7-12, Pos. 7) position "a", to the return oil line. The pump moves into Qmax position, because the pump pressure acts only at the small area side of positioning piston #13. NOTE: The pump moves into Qmax position
Version 2010/1
7-23
Main pumps
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Main pump at ½Qmax
Fig. 7-13
7-24
Operating principle
Version 2010/1
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Main pumps
½Qmax position: When does the pumps move into ½Qmax position? z
Engine running
z
and hydraulic oil below normal operating temperature (< T2)
z
and the controls frequently used within 20 sec.
z
or the controls not used at a temperature state between T3 and T4
z
and a pump pressure below start of de-stroking.
Example with the following conditions: z
Engine running (> 1800 rpm)
z
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
z
X1 = 34 bar (pump regulation pressure via 57K561-1)
z
X3 = 15 bar (remote control pressure); 57K517 energized and 57K517a de-energized for pumps #2, #3 and #4. For pump #1, 57K517 energized and 57K626 de-energized or energized.
z
X4 = 60 bar (pump support pressure), present at valve #7.
Response of pump control mechanism: Valve #7 moves to an intermediate position (in-between "a" and "b"), since a certain amount of oil behind nozzle (Fig. 7-13, Pos. 8) flows through valve #6 (which is also in an intermediate position, due to the 15 bar remote control pressure X3) back to tank. The large area side of positioning piston #13 is connected, via power control valve (Fig. 7-13, Pos. 9) position "a" and pressure balance valve (Fig. 7-13, Pos. 7), to the return oil line. The pump moves into ½Qmax position, because the return oil flow through pressure balance valve (Fig. 7-13, Pos. 7) is restricted (due to its intermediate position), resulting in a pressure at the large area side of the positioning piston (Fig. 7-13, Pos. 13). NOTE: The pump moves into ½Q-max position.
Version 2010/1
7-25
Main pumps
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Main pump destroking
Fig. 7-14
7-26
Operating principle
Version 2010/1
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Main pumps
Destroking: (pump moves from Qmax into of Qmin direction) When does the pumps start to destroke? z
Engine running
z
and hydraulic at normal operating temperature (> T2)
z
and VHMS Service Menu "Qmax" deactivated
z
and the load stalls the engine RPM below 1800 rpm. (The electronic pump regulation system will reduce the X1-pressure.)
z
or with pump pressure above ≈180 bar (hydraulic constant regulation) (constant X1-pressure of approximately 13 bar).
Example with the following conditions: z
Engine running (> 1800 rpm)
z
Pump pressure 180 bar at the main relief valve, present at the slipper pad of piston #14 and the small area side of the positioning piston #13.
z
X1 = 13 bar (constant regulation pressure adjustable at pressure relief valve 253.2) Change-over valve (253.1) switched to hydraulic mode.
z
X3 = 45 bar (remote control pressure); 57K517 energized and 57K517a energized for pumps #2, #3 and #4. For pump #1, 57K517 energized and 57K626 energized.
z
X4 = 60 bar (pump support pressure), present at valve #7.
Response of pump control mechanism: Valve #7 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 #6 (which is in position "b", due to the 45 bar remote control pressure X3). The operating pressure (with the value for start of de-stroking) at the slipper pad of piston #14 moves the power control valve (Fig. 7-14, Pos. 9) 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 #13. Because the large area side of positioning piston #13 is approximately three times larger than 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 direction. NOTE: The pump de-strokes until the forces at positioning piston #13 are balanced.
Version 2010/1
7-27
Main pumps
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Main pump – pressure cut-off
Fig. 7-15
7-28
Operating principle
Version 2010/1
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Main pumps
Pressure cut-off valve: (DR control valve, Pump moves into Qmin position) When is the pressure cut-off valve active? z
Engine running
z
and with pump pressure above ≈300 bar
Example with the following conditions: Engine running (> 1800 rpm) Pump pressure 300 bar X1 = 34 bar (pump regulation pressure via 57K561-1) X3 = 45 bar (remote control pressure via 57K517 / 57K517a) X4 = 60 bar (pump support pressure)
Response of pump control mechanism: Independent of the position of power control valve #9, the pressure cut-off valve #11 causes the pump to de-stroke to the pre-adjusted Qmin position. The operating pressure moves the pressure cut-off valve #11 (at set pressure) into position "b" and flows to the large area side of positioning piston #13. Because the large area side of positioning piston #13 is approximately three times larger than 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. NOTE: The pump moves into Qmin position.
Version 2010/1
7-29
Main pumps
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
7.2.4
CHECKS / ADJUSTMENTS
Fig. 7-16
Checks / adjustments
7-30
Version 2010/1
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Main pumps
Legend for Fig. 7-16: (1)
Remote control valve
(2)
Torque adjustment bolt
(3)
Pressure balance valve
(4)
Start of destroking
(5)
Power curve correction
(6)
Pressure cut-off valve
(7)
Qmax stop bolt
(8)
Angle indicator
Average length "L" of the adjustment bolts: Location:
1
2
3
4
5
6
7
Length (mm)
13.8
26.9
8.0
8.1
---
6.0
34.4
NOTE: The length "L" is an orientation only if the adjustment is totally out of requirements. They must not be used for final adjustments.
CAUTION The detail for (Fig. 7-16, Pos. 5) shows the position of the housing edge and the edge of the excentric set bolt. The example shows them in parallel position which is mostly not the case. The adjustment should never be altered.
Pressure balance valve (Fig. 7-16, Pos. 3)
CAUTION The pressure balance valve is bench adjusted. There is no field setting with a sufficient result possible.
Version 2010/1
7-31
Main pumps
Fig. 7-17
7-32
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Checks / adjustments
Version 2010/1
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Main pumps
Start of destroking (LR valve), (Fig. 7-17) The purpose of this check is to make sure the pump starts destroking at an operating pressure of 180 bar with a pump regulation pressure X1 of 13 bar. 1. Connect a 400 bar pressure gauge to the pressure test port at the respective high pressure filter for the pumps being checked. 2. Connect a 60 bar pressure gauge to pressure test port M18 at the control and filter panel (X1-pressure). 3. Move the change-over valve into position “Hydraulic” (constant regulation mode). 4. Insert an Allen key into the angle indicator bolt (see illustration) for better visibility of the start of destroking. 5. Start the engine, let it run in high idle and adjust the X1-pressure to 13 bar at pressure relief valve (253.2). 6. Stall the hydraulic for the pump to be checked and alter the operating pressure with the MRV between 160 and 200 bar. Start of destroking should be at an operating pressure of 180 bar, shown at the gauge connected to the high pressure filter. If readjustment is required, proceed as follows: z
With the MRV, adjust the operating pressure to 180 bar.
z
Loosen lock nut #6 (power control valve).
z
Turn set bolt #7 so that the pump is still in Qmax position, but just at the beginning of destroking.
z
Tighten lock nut #6.
7. Readjust the operating pressure at the MRV to 310+5 bar and the X1-pressure at the pressure relief valve (253.2) to approx. 15 bar. (For exact values refer to the final test report.) 8. Remove Allen key and gauges. 9. Move the change-over valve back to eletronic pump regulation.
Version 2010/1
7-33
Main pumps
Fig. 7-18
7-34
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Checks / adjustments
Version 2010/1
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Main pumps
Pressure cut-off valve (DR control valve), (Fig. 7-18) The purpose of this check is to make sure that the pump is in Qmin position at an operating pressure 300±10 bar. 1. Connect a 400 bar pressure gauge to the pressure test port at the respective high pressure filter for the pumps being checked. 2. Insert an Allen key into the angle indicator bolt (see illustration) for better visibility of the start of destroking. 3. Start the engine and run in high idle, stall the hydraulic for the pump that is to be checked and alter the operating pressure ± 20 bar from the starting pressure of 310+5 bar. 4. The angle indicator must indicate Qmin position at a pressure of 300±10 bar shown at the gauge connected to the high pressure filter. If readjustment is required proceed as follow: z
Loosen lock nut (Fig. 7-18, Pos. 8).
z
Turn set bolt (Fig. 7-18, Pos. 9), so that the pump is in Qmin position at the required value.
z
Tighten lock nut (Fig. 7-18, Pos. 8).
5. Re-adjust the operating pressure at the MRV to 310+5 bar 6. Remove Allen key and gauges.
Version 2010/1
7-35
Main pumps
Fig. 7-19
7-36
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Checks / adjustments
Version 2010/1
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Main pumps
Qmax and torque adjustment bolt (Fig. 7-19) 1. Unscrew cap nut (Fig. 7-19, Pos. 10 or 14). 2. Loosen the lock nut (Fig. 7-19, Pos. 11 or 13). 3. Turn the stop bolt (Fig. 7-19, Pos. 12 or 15) in or out until required length "X" or "Y" is obtained. 4. Tighten the lock nut and screw on cap nut (Fig. 7-19, Pos. 10 or 14).
NOTE: If, in exceptional cases the necessary high pressure, required for the secondary valve adjustment, can not be obtained, the cause could be insufficient pump delivery. To enable the adjustment, screw in the torque adjustment bolt (Fig. 7-19, Pos. 15) two turns. After the adjustments are finished the torque adjustment bolt (Fig. 7-19, Pos. 15) must be reset to the initial setting.
WARNING Do not turn the torque adjustment bolt (Fig. 7-19, Pos. 15) too far out, because this 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.
NOTE: If the machine works at an altitude above 3600 meters, the maximum displacement of the pumps must be reduced by changing the Qmax stop bolt setting according to PARTS & SERVICE NEWS AH05515 (latest edition).
Version 2010/1
7-37
Electronic Pump Regulation System
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
7.3
ELECTRONIC PUMP REGULATION SYSTEM
Fig. 7-20
Electronic pump regulation system
7-38
Version 2010/1
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
7.3.1
Electronic Pump Regulation System
ELECTRONIC LOAD LIMITING CONTROL - GENERAL
The drive train of the excavator consists of a 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. Fig. 7-20 shows the principle of the electronic load limiting control. The RC4-4 (10K032) processes the following input signals: z
Diesel engine speed (Pin 33) from magnetic pick-up (52B064).
z
Switch signal (Pin 37) from engine control (25K014-1), 24 V if n > 300 rpm.
The RC4-4 (10K032) processes the following output signals: z
Signal value to control the proportional solenoid valve 57K561-1 (Pin 31).
z
Switch signals (Pin 15 and 29), diagnostic of the RC4-4 (10K032).
The Diesel engine drives four 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 destroking). The command value (X1-pressure) is present via proportional solenoid valve 57K561-1 at the hydraulic power controllers of each pump. The actual speed of the engine is measured with a speed sensor at the flywheel. NOTE: 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 rpm, i.e. the torque of the main pumps will be lowered (by reducing the X1-pressure) until the rated speed of 1800 rpm is attained again.
Version 2010/1
7-39
Electronic Pump Regulation System
Fig. 7-21
7-40
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Electronic pump regulation system
Version 2010/1
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
7.3.2
Electronic Pump Regulation System
MICROCONTROLLER RC4-4
The RC4-4 microcontroller is used for the programmable control of a maximum of four proportional solenoids and four additional switching functions. As input signals, the microprocessor processes analog voltages in the 0 V to 5 V range and switching information. All inputs are protected against overvoltage and electrical interference. As output signals, the output stages of the RC4-4 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 z
Closed loop control of solenoid currents, i.e. independent of voltage and temperature.
z
Pulse width modulated (PWM) solenoid currents for minimal hysteresis.
z
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 a PC w ith the BODEM 24 software.
Fig. 7-22
RC4-4 - Unit dimensions
Fig. 7-23
RC4-4 - Block circuit diagram
Version 2010/1
7-41
Electronic Pump Regulation System
Fig. 7-24
7-42
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Checks and adjustments
Version 2010/1
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
7.3.3
Electronic Pump Regulation System
CHECKS AND ADJUSTMENTS
Microcontroller RC4-4 (Fig. 7-24) The adjustment of the X1-pressure can be done with two different methods: 1. "A" : with 24 V supply to separating terminals at the X2-board, 2. "B" : with a laptop and the BODEM 24 software connected to the serial interface 20X110 (located in the operators cab)
NOTE: Procedure 2 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 only the necessary setups are described. If additional information is required, please contact KMG-Service department.
Version 2010/1
7-43
Electronic Pump Regulation System
Fig. 7-25
7-44
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Checks and adjustments
Version 2010/1
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Electronic Pump Regulation System
Microcontroller RC4-4 (Fig. 7-25) Method "A" X1-pressure adjustment with 24 V supply to separating terminals at the X2-switch over the 11X_09 board. 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 test port (M18), using a long pressure gauge hose to be able reading the pressure in front of the 11X_09 board. 3. Selection of adjusting mode: Turn the main key switch in on position and activate the adjusting mode as follows: Connect 24 V, simultaneously to terminals 11X_09-4 and -5 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, the output terminal of proportional solenoid valve 57K561-1 is directly selected. Since there is only one engine with one proportional solenoid valve installed, a 24 V connection is not required. 5. Adjusting the X1-pressure: Start the engine, let it run with maximum speed. Read the pressure, required = 34±0,5 bar. If necessary, increase the X1-pressure as follows: Connect 24 V to terminal 4. NOTE: 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 X1-pressure. NOTE: Example: Keeping voltage supply for two seconds will increase the X1-pressure of approximately 1 bar. 6. To decrease the X1-pressure connect 24 V to terminal 5 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 the pressure gauge, and turn the main key switch in OFF position to deactivate the adjusting mode.
Version 2010/1
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Electronic Pump Regulation System
Fig. 7-26
7-46
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Checks and adjustments
Version 2010/1
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Electronic Pump Regulation System
Method "B"
With a laptop and BODEM/24 software connected to the serial interface 20X110 (located in the operators cab). Pre-conditions: Normal operating temperature, correct pilot pressure setting and the system must be free of air.
Fig. 7-27 BODEM/24 software CD 1. Make sure the change-over valve is in position “Electronic Pump Regulation”. 2. Connect a pressure gauge to test port (M18). 3. Connect the laptop computer to the data link adapter 20X110, with key switch (20S001) in OFF position. 4. Make sure that the USB dongle is connected to the laptop computer.
Fig. 7-28 USB dongle BODEM/24 software 5. Turn key switch (20S001) in ON position. 6. Switch on the laptop computer. 7. Click on the BODEM/24 icon to start the program (see Fig. 7-29). NOTE: For information about the BODEM/24 software, please refer to the software user’s guide.
Fig. 7-29
Version 2010/1
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Electronic Pump Regulation System
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
8. Open menu "Display/Edit parameters" and, from the Device list, select the required excavator type. Confirm saving the parameters with "OK". 9. Open menu "Display/Edit parameters" and select "Max current" from the shortlist. 10. Adjust the required pressure with the engine running at high idle, and move the slide control to the required pressure. Confirm with OK.
Fig. 7-30 11. After adjusting the pressure, confirm saving the parameters with OK.
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MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Electronic Pump Regulation System
This page was left blank intentionally.
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Hydraulic Constant Regulation System
7.4
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
HYDRAULIC CONSTANT REGULATION SYSTEM
Pilot pressure (X2) Pump support pressure (X4) Pump regulation pressure (X1) Pump regulation pressure (X1) or pilot pressure (X2), depending on the position of 57K6350 and 57K631 respectively Fig. 7-31
7-50
Hydraulic constant regulation system
Version 2010/1
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
7.4.1
Hydraulic Constant Regulation System
GENERAL
Legend for Fig. 7-31: (1 – 4)
Main hydraulic pumps
(8.1)
Pilot pressure pump
(33)
Pilot pressure filter unit
(252.2)
60 bar pressure relief valve
(252.1)
45 bar pressure relief valve
(253.1)
Change-over valve: "Electronic or hydraulic pump regulation"
(253.2)
Pressure relief valve: " Pump regulation pressure X1 at hydraulic pump regulation" (hydraulic constant regulation mode)
(57K561-1)
Proportional solenoid valve: "Pump regulation pressure X1 at electronic pump regulation" (standard operation mode)
(57K630)
Solenoid valve: " Pump regulation pressure X1 = 45 bar for pump #1" (fixed pump for swinging)
(57K631)
Solenoid valve: " Pump regulation pressure X1 = 45 bar for pump #3" (fixed pump for swinging)
The pilot pressure pump (Fig. 7-31, Pos. 8.1) delivers the oil via the pressure filter (Fig. 7-31, Pos. 33) to port A of the pressure relief valve (Fig. 7-31, Pos. 252.2) for limiting the pump support pressure X4 (60 bar). The pilot pressure oil X2 (45 bar) maintained at pressure relief valve (Fig. 7-31, Pos. 252.1) flows through the manifold to the pressure relief valve (Fig. 7-31, Pos. 253.2), which reduces the X2 pressure to the necessary constant X1 pressure to prevent the engine from overloading. NOTE: 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. NOTE: The standard operation mode of the pump regulation system is the Electronic Operation Mode.
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Hydraulic Constant Regulation System
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
7.4.2
X1 PRESSURE ADJUSTMENT (CONSTANT PRESSURE)
Fig. 7-32
X1 pressure adjustment
7-52
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MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Hydraulic Constant Regulation System
1. Connect gauges to test ports (M11, M12, M13; and M14) at the high pressure filters. 2. Connect pressure gauge to the X1 pressure test port M18. 3. Unplug solenoid valves 57K506a/b-1 and 57K636-1 to ensure that all fans are running with maximum speed. 4. Shift the three way cock valves (Fig. 7-32, Pos. 253.1) to position “Hydraulic (constant) regulation mode”. 5. Actuate the "Qmax" position via the VHMS Service Menu. 6. Start the engine and let it run at high idle. 7. Set the XLR pressure at pressure relief valve (Fig. 7-32, Pos. 253.2) to approx. 6 bar** 8. Apply max. load to all pumps z
(e.g. BHA: retract the bucket and stick cylinders to the stop position until the hydraulic system stalls. e.g. FSA: extend the bucket cylinders to the stop position until the hydraulic system stalls),
z
and adjust the pressure at all 4 MRV’s* equally to 260 bar.
z
Check the engine speed. Required = 1840 rpm.
z
If necessary, correct the XLR pressure at pressure relief valve (Fig. 7-32, Pos. 253.2), until the required engine speed is obtained. Record the XLR pressure.
9. Shift the cock valves (Fig. 7-32, Pos. 253.1) to position “Electronic regulation“. 10. Switch back "Qmax" via the VHMS Service Menu. 11. Adjust the MRV’s * to 310+5 bar and remove the gauges. *Altering the MRV-setting: z
Remove the dust cap (Fig. 7-32, Pos. a).
z
Loosen the lock nut (Fig. 7-32, Pos. b).
z
Turning the set screw (Fig. 7-32, Pos. c) - cw the pressure will increase.
z
Turning the set screw - ccw the pressure will decrease.
**Altering the XLR-setting: z
Loosen the lock nut (Fig. 7-32, Pos. e).
z
Turning the set screw (Fig. 7-32, Pos. f) - cw the pressure will increase.
z
Turning the set screw - ccw the pressure will decrease.
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Determination of the peak point (engine performance)
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
7.5
DETERMINATION OF THE PEAK POINT (ENGINE PERFORMANCE)
Fig. 7-33
Determination of the peak point
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Version 2010/1
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Determination of the peak point (engine performance)
1. Connect pressure gauges to test ports M11, M12, M13, M14 at the high pressure filter. 2. Connect a pressure gauge to the XLR pressure test port M18. 3. Unplug solenoid valves 57K506a-1 and 57K506b-1 to ensure that the hydraulic oil cooler fans are running at maximum speed. 4. Unplug the solenoid valve 57K636-1 to ensure that the engine radiator fan is running at maximum speed. 5. Start the engine and let it run at high idle. 6. Check high idle speed = 1900±10 rpm. 7. Set the MRV individually to approx. 120 bar* to prevent the engine from overloading during the test. 8. Shift the cock valve (Fig. 7-33, Pos. 253.1) to position "hydraulic regulation". 9. Actuate the "Qmax" position via the VHMS Service Menu. 10. Set the XLR pressure at pressure relief valve (Fig. 7-33, Pos. 253.2) > 34 bar** to ensure that the pumps remain in Qmax flow position during the test. 11. Apply max. load to all pumps z
(e.g. BHA: retract the bucket and stick cylinders to the stop position until the hydraulic system stalls. e.g. FSA: extend the bucket cylinders to the stop position until the hydraulic system stalls),
z
and adjust the pressure at all 4 MRV’s *equally until the engine speed is 1800±10 rpm.
z
Record this pressure for other tests. Required: 4 times 157±5 bar.
NOTE: If either the operating pressure or the engine speed is higher than required, there is probably not the full volume available. NOTE: If either the operating pressure or the engine speed is lower than required, there is probably not the full engine power available. 12. Re-set the XLR pressure at pressure relief valve (Fig. 7-33, Pos. 253.2) as recorded**. 13. Shift the cock valve (Fig. 7-33, Pos. 253.1) to position “Electronic regulation“ 14. Switch back "Qmax" via the VHMS Service Menu. 15. Adjust the MRV’s * to 310+5 bar and remove the gauges. * Altering the MRV-Setting: z
Remove the dust cap (Fig. 7-33, Pos. a).
z
Loosen the lock nut (Fig. 7-33, Pos. b).
z
Turning the set screw (Fig. 7-33, Pos. c) - cw the pressure will increase.
z
Turning the set screw - ccw the pressure will decrease.
** Altering the X1-Setting: z
Loosen the lock nut (Fig. 7-33, Pos. e).
z
Turning the set screw (Fig. 7-33, Pos. f) - cw the pressure will increase.
Turning the set screw - ccw the pressure will decrease.
Version 2010/1
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Engine speed sensor (pick-up)
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
7.6
ENGINE SPEED SENSOR (PICK-UP)
Fig. 7-34
Engine speed sensor
7-56
Version 2010/1
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Engine speed sensor (pick-up)
Legend for Fig. 7-34: (1)
Speed sensor (pick-up)
(2)
Flywheel housing
(3)
Flywheel
(4)
Look nut
(5)
RPM-module
7.6.1
GENERAL
The engine speed sensor 52B064-1 (pick-up), together with the RPM-module 51T018-1, use the flywheel teeth to count RPM. With running engine, each tooth induces a coltage in the pick-up coil. That causes an alternative voltage at the pick-up coil wire. With engine at stand still, there is no voltage at the pick-up wire. The frequency of this alternative voltage will increase or decrease proportional to the engine RPM. The RPM-module converts the frequency into a proportional milliampere signal. This signal is used for different components, e.g. pump regulation, display, VHMS.
7.6.2
ENGINE SPEED SENSOR (PICK-UP) ADJUSTMENT
1. Stop the engine. 2. Disconnect plug at the pick-up wire. 3. Loosen the 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 touches the flywheel (Fig. 7-34, Pos. A). 7. Turn the pick-up ¾ turn out (ccw) (Fig. 7-34, Pos. B). 8. Secure the pick-up with look nut (Fig. 7-34, Pos. C). 9. Connect the plug. Final Check 10. Start engine and let it run at high idle. 11. Check the voltage (AC) of the pick-up. Insert the T-box on the sensor connector and connect between pick-up and RPM-module 51T018-1. 12. The voltage should be 10±2.5 volts AC.
WARNING z
Avoid pick-up contact with the flywheel while engine is running!
z
The induced AC voltage must be measured with connected pick-up to the RPM-module.
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Energy Efficiency
7.7
ENERGY EFFICIENCY
Fig. 7-35
Energy efficiency
7-58
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Version 2010/1
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Energy Efficiency
Legend for Fig. 7-35: (1 – 4)
Main pumps
(11K301)
MTC (Master Turbo Controller)
M19
Test port, pressure control valve
M55
Test port, output 57K646
M56
Test port, output 57K647
M57
Test port, output 57K648
(57K517)
„Idle time“ control (pump control system)
(57K517a)
½ Qmax (reduced oil flow if oil is too cold)
(57K626)
Flow control (pump 1, when swinging with fast speed)
(57K646)
Flow control (pump No. 2 + No. 4)
(57K647)
Flow control (pump No. 3)
(57K648)
Flow control (pump No. 1)
(152)
Pressure control valve – controlled pump flow
(255.4)
Pressure relief valve – ½ Qmax (X3 = 15 bar)
7.7.1
GENERAL
Energy which is not used for active movements can be considered as a loss of energy. Although energy can not be destroyed, it can be converted into heat, which is useless for performing work by means of hydraulics. With the following measures the energy efficiency in your machines is optimized, the oil delivery takes place through specified pumps corresponding to the definite movements of the excavator. NOTE: If individual movements (single movements) are selected, the pumps will have maximum flow, but with one exception. Pump No. 1 will have half flow when high speed swinging is selected (important for PMclinic and other tests). z
Individual movements of the attachment are selected: => 57K646 OFF + 57K647 OFF + 57K648 OFF + 57K626 ON
z
Only travel is selected: => 57K646 OFF + 57K647 OFF + 57K648 OFF + 57K626 ON
z
Only swinging (low speed) is selected: => 57K646 ON + 57K647 OFF + 57K648 ON + 57K626 ON
z
Only swinging (high speed) is selected: => 57K646 ON + 57K647 OFF + 57K648 OFF + 57K626 OFF
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Energy Efficiency
7.7.2
CHECKS AND ADJUSTMENTS
Fig. 7-36
Checks and adjustments
7-60
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Version 2010/1
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Energy Efficiency
Legend for Fig. 7-36: (a)
Lock nuts
(b)
Set screws
(M19)
Test port, pressure control valve – X3-pressure
(57K646)
Flow control (pump No. 2 + No. 4)
(57K647)
Flow control (pump No. 3)
(57K648)
Flow control (pump No. 1)
(152)
Pressure relief valve – reduced pump flow (X3 ~ 18 to 19 bar)
To check the function of the Energy Efficiency System it is necessary to follow the instructions below. Adjusting the flow control: 1. Connect a pressure gauge (0-60 bar) to test port M19. 2. Turn the superstructure 90° to the travel direction. 3. Apply the slew parking brake. 4. Move the bucket close to the side frame and raise one track off the ground just enough to get the track free. 5. Activate the travel pedal of the lifted track fully in one direction. Make sure there is no other function activted. 6. Test of max. pump flow: 57K646, 57K647 and 57K648 must be de-energized, and 57K626 must be energized. Check the time of five (5) sprocket revolutions, see table Fig. 7-38. 7. Test of optimized pump flow: Activate the swing function (against the brake). 8. Let the sprocket turn with the swing function still applied (slew parking brake closed). 9. Measure the time for five (5) sprocket revolutions; see table Fig. 7-38 for the required value.
CAUTION Values are based for machine working from see level up to 3600 m. Machines working on higher altitude require a reduced Qmax setup which influences the test values.
NOTE: X3 or PST: both are the same pressure. It is the pressure to control the maximum permissible pump output flow. PST is the port name of the main pump.
Version 2010/1
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Energy Efficiency
Fig. 7-37
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MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Checks and adjustments
Version 2010/1
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Energy Efficiency
If adjustment is required: Change the setting at pressure control valve (152): 1. Loosen lock nut (Fig. 7-36, Pos. a) of the pressure control valve. 2. Turn the set screw (b) of the pressure control valve (152) clockwise to reduce or counterclockwise to increase the sprocket speed. Adjust the sprocket speed according to the table below. 3. Lock set screw by tightening the lock nut.
Pump flow control test values No.
Function
57K646
57K647
57K648
57K626
Left sprocket Time/5 revs.
Right sprocket Time/5 revs.
1
Travel right only
0V
0V
0V
24 V
50±1 sec
50±1 sec
2
Travel right and swing (low speed)
24 V
24 V
24 V
24 V
65±1 sec
65±1 sec
3
Travel right and swing (high speed)
24 V
0V
0V
0V
65±1 sec
65±1 sec
4
Travel left only
0V
0V
0V
24 V
50±1 sec
50±1 sec
5
Travel left and swing (low speed)
24 V
24 V
24 V
24 V
65±1 sec
65±1 sec
6
Travel left and swing (high speed)
24 V
0V
0V
0V
65±1 sec
65±1 sec
Fig. 7-38
Pump flow control test values
NOTE: Switch swing speed between low and high with switch 20S154 at the left control lever. 5 revolutions of the sprocket within 65 seconds are mandatory to determine the optimized pump flow. The pressure control valve (152) is factory preset to 18 bar, a field test / adjustment after comissoning is necessary.
Version 2010/1
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Energy Efficiency
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MAIN HYDRAULIC PUMPS AND PUMP REGULATION
Version 2010/1
OPERATING HYDRAULICS
8. OPERATING HYDRAULICS
Version 2010/1
8-1
General
OPERATING HYDRAULICS
8.1
GENERAL
Fig. 8-1
Overall view of the hydraulic system
8-2
Version 2010/1
OPERATING HYDRAULICS
General
Legend for Fig. 8-1: (1 - 4)
Main pumps
(5)
High pressure filters
(6)
Main control blocks
(7)
Distributor maniflod
(8)
Attachment cylinders
(9)
Swing motors
(10)
Rotary joint
(11)
Travel motors
General Information The control blocks, the piping to the distributor manifold and the connecting hoses to the attachment are 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: NOTE: Also refer to the circuit diagram. NOTE: The following numbering refers to the hydraulic circuit diagram. Each main pump (Fig. 8-1, Pos. 1 to 4) delivers oil trough the high pressure filter (13.1 to 13.4) to port P of the main control blocks (I to IV). This results in four main circuits. If all spools of the control blocks (I to IV) are in neutral position, the oil flows through the blocks at port T and returns via return oil pipes, return oil collector manifold (107), return oil pipes (L6 and L7), return oil collector pipe (54), back pressure valve (55) and the return oil filters (49.1 - 49.4) into the tank. The function of back pressure valve (55) ensures: z
sufficient oil supply for all anticavitation valves
z
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 flows via the return oil circuit back into the tank. Each circuit is provided with one MRV (Main Relief Valve), at least one SRV (Secondary Relief Valve) and at least one flow restrictor.
Version 2010/1
8-3
General
OPERATING HYDRAULICS
8.1.1
FLOATING SYSTEM
Fig. 8-2
Floating function of boom and stick cylinders, FSA
8-4
Version 2010/1
OPERATING HYDRAULICS
General
The excavator operates automatically with the floating position for boom and stick activated. That means the lowering movement of boom and stick is always done in the floating position. For deactivation of the floating position, two push-buttons are installed: z
20S095 in the right joystick (20S019) for the boom function,
z
20S098 in the left joystick (20S020) for the stick function.
Press the respective button and keep it depressed as long as the floating position shall be deactivated. When releasing the button, the floating position is activated again. Function: The additionally installed single control blocks (Fig. 8-2, Pos. 60Q632, 60Q633, 60Q634 and 61Q635) connect the piston side of the cylinders with the rod side and also with the tank: z
60Q632, 60Q633 and 60Q634 for the stick cylinders,
z
61Q635 for the boom cylinders.
In normal operation mode (i.e. floating position) the pilot pressure oil is directed via 60Q632, 60Q633 and 61Q635 to the single control blocks when lowering the boom or stick. If a pressurised lowering of the cylinders is required, the pilot pressure oil is directed via 60Q632, 60Q633 and 61Q635 to the main control blocks. The solenoid valves 60Q632, 60Q633 and 61Q635 (4/2-directional control valves) are controlled by push-buttons 20S095 and 20S098. Boom:
20S095 ON => 61K635 ON => Floating position deactivated 20S095 OFF => 61K635 OFF => Floating position activated
Stick:
20S098 ON => 61K632 + 61K633 OFF => Floating position deactivated 20S098 OFF => 61K632 + 61K633 OFF => Floating position activated
NOTE: Due to the two different operation modes for lowering, the lowering speed of boom and stick cylinder must be adjusted twice: • floating position deactivated, • floating position activated.
Version 2010/1
8-5
Hydraulics for the attachment cylinder FSA and BHA
OPERATING HYDRAULICS
8.2
HYDRAULICS FOR THE ATTACHMENT CYLINDER FSA AND BHA
8.2.1
ELECTRIC / HYDRAULIC FLOWCHART "BOOM RAISE" FSA
Fig. 8-3
Electric / hydraulic flowchart "boom raise", FSA
8-6
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the attachment cylinder FSA and BHA
Legend for Fig. 8-3: (20S019)
Control lever (joystick)
(YD)
Direction (axis) of joystick
(-10V)
Signal voltage (maximum)
(11X_...)
Terminal rail with number
(11T049)
Ramp time module
(11T010)
Amplifier module - boom
(11T010a)
Amplifier module - boom
(11T010b)
Amplifier module - boom up or bucket fill when not raising the boom
(11T010c)
Amplifier module - boom
(11K058)
Relay - pilot control: Contacts 6/10 and 7/11 only closed while lifting the boom.
(11K076)
Relay - pilot control: Contacts 8/12 only closed while travelling, left crawler.
(11K078)
Relay - pilot control: Contacts 6/10 only closed while travelling, right crawler.
(14.1 + 14.2) (15.1 + 15.2)
Remote control valves
(61K563) (61K569) (61K573) (61K576)
Proportional solenoid valve
(61K533) (61K540) (61K546)
Directional solenoid valve
(I - IV)
Main control blocks I - IV
(42)
Distributor manifold
Electrical signal flow Signal voltage of joystick (Fig. 8-3, Pos. 20S019) goes via ramp time module (Fig. 8-3, Pos. 11T049) to terminal 5 of the amplifier modules (Fig. 8-3, Pos. 11T010 to 11T010c) and further to the proportional and directional solenoid valves of the remote control blocks (Fig. 8-3, Pos. 14.1, 14.2, 15.1 and 15.2). 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 main control blocks. Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I ; II ; IV) and, via distributor manifold (Fig. 8-3, Pos. 42), arrives at the hydraulic cylinders.
Version 2010/1
8-7
Hydraulics for the attachment cylinder FSA and BHA
OPERATING HYDRAULICS
8.2.2
ELECTRIC / HYDRAULIC FLOWCHART "BOOM RAISE" BHA
Fig. 8-4
Electric / hydraulic flowchart "boom raise", BHA
8-8
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the attachment cylinder FSA and BHA
Legend for Fig. 8-4: (20S019)
Control lever (joystick)
(YD)
Direction (axis) of joystick
(-10V)
Signal voltage (maximum)
(11X_…)
Terminal rail with number
(11T049 – 11T049c)
Ramp time module
(11T010 – 11T010c)
Amplifier module – boom
(11K076)
Relay – pilot control: Contacts 8/12 only closed while travelling, left crawler.
(11K078)
Relay – pilot control: Contacts 6/10 only closed while travelling, right crawler.
(14.1 + 14.2) (15.1 + 15.2)
Remote control valves
(61K563) (61K569) (61K573) (61K576)
Proportional solenoid valve
(61K533) (61K540) (61K546)
Directional solenoid valve
(I - IV)
Main control blocks I - IV
(42)
Distributor manifold
Electrical signal flow Signal voltage of joystick (Fig. 8-4, Pos. 20S019) goes via ramp time modules (Fig. 8-4, Pos. 11T049 to 11T049c) to terminal 5 of the amplifier modules (Fig. 8-4, Pos. 11T010 to 11T010c) and further to the proportional and directional solenoid valves of the remote control blocks (Fig. 8-4, Pos. 14.1, 14.2, 15.1 and 15.2). 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 main control blocks. Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I ; II ; IV) via distributor manifold (Fig. 8-4, Pos. 42) to the hydraulic cylinders.
Version 2010/1
8-9
Hydraulics for the attachment cylinder FSA and BHA
OPERATING HYDRAULICS
8.2.3
ELECTRIC / HYDRAULIC FLOWCHART "BOOM LOWERING" FSA
Fig. 8-5
Electric / hydraulic flowchart "boom lowering", FSA
8-10
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the attachment cylinder FSA and BHA
Legend for Fig. 8-5: (20S019)
Control lever (joystick)
(YC)
Direction (axis) of joystick
(+10V)
Signal voltage (maximum)
(11X_…)
Terminal rail with number
(11T049)
Ramp time module
(11T010)
Amplifier module - boom
(11T010a)
Amplifier module - boom
(11T010b)
Amplifier module - boom or bucket
(11T010c)
Amplifier module - boom
(11K058)
Relay – pilot control: Contacts 6/10 only closed while lifting the boom.
(11K076)
Relay – pilot control: Contacts 8/12 only closed while travelling, left crawler.
(11K078)
Relay – pilot control: Contacts 6/10 only closed while travelling, right crawler.
(14.1 + 14.2) (15.1 + 15.2)
Remote control valves
(61K563) (61K573) (61K576)
Proportional solenoid valve
(61K521) (61K541) (61K547) (61K635)
Directional solenoid valve
(61Q635)
Single control block
(I - IV)
Main control blocks I - IV
(42)
Distributor manifold
Electrical signal flow Signal voltage of joystick (Fig. 8-5, Pos. 20S019) goes via ramp time module (Fig. 8-5, Pos. 11T049) to terminal 5 of the amplifier modules (11T010, 11T010a and 11T010c) and further to the proportional and directional solenoid valves of the remote control blocks (Fig. 8-5, Pos. 14.1, 15.1 and 15.2). 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 main control blocks and single control block (Fig. 8-5, Pos. 61Q635). Hydraulic oil flow Now piston and piston rod side of the boom cylinders are connected, so that the boom lowers only by gravity. The excess oil flows via distributor manifold (Fig. 8-5, Pos. 42) through the main control blocks (II and III) and single control block (Fig. 8-5, Pos. 61Q635) back to tank.
Version 2010/1
8-11
Hydraulics for the attachment cylinder FSA and BHA
OPERATING HYDRAULICS
8.2.4
ELECTRIC / HYDRAULIC FLOWCHART "BOOM LOWERING" BHA
Fig. 8-6
Electric / hydraulic flowchart "boom lowering", BHA
8-12
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the attachment cylinder FSA and BHA
Legend for Fig. 8-6: (20S019)
Control lever (joystick)
(YC)
Direction (axis) of joystick
(+10V)
Signal voltage (maximum)
(11X_…)
Terminal rail with number
(11T049 11T049c)
Ramp time module
(A10)
Amplifier module – boom
(A10a)
Amplifier module – boom
(A10b)
Amplifier module – boom or bucket
(A10c)
Amplifier module – boom
(K76)
Relay – pilot control: Contacts 8/12 only closed while travelling, left crawler.
(K78)
Relay – pilot control: Contacts 6/10 only closed while travelling, right crawler.
(14.1 + 14.2) (15.1 + 15.2)
Remote control valves
(61K563) (61K569) (61K573) (61K576)
Proportional solenoid valve
(61K521) (61K532) (61K541) (61K547)
Directional solenoid valve
(I - IV)
Main control blocks I - IV
(42)
Distributor manifold
Electrical signal flow Signal voltage of joystick (Fig. 8-6, Pos. 20S019) goes via ramp time modules (Fig. 8-6, Pos. 1T049 to 11T049c) to terminal 5 of the amplifier modules (Fig. 8-6, Pos. 11T010 to 11T010c) and further to the proportional and directional solenoid valves of the remote control blocks (Fig. 8-6, Pos. 14.1, 14.2, 15.1 and 15.2). 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 main control blocks. Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I to IV) and via distributor manifold (Fig. 8-6, Pos. 42) to the hydraulic cylinders.
Version 2010/1
8-13
Hydraulics for the attachment cylinder FSA and BHA
OPERATING HYDRAULICS
8.2.5
ELECTRIC / HYDRAULIC FLOWCHART "STICK EXTEND" FSA
Fig. 8-7
Electric / hydraulic flowchart "stick extend", FSA
8-14
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the attachment cylinder FSA and BHA
Legend for Fig. 8-7: (20S020)
Control lever (joystick)
(YC)
Direction (axis) of joystick
(+10V)
Signal voltage (maximum)
(11X_61…)
Terminal rail with number
(11T048)
Ramp time module
(11T008)
Amplifier module – stick
(11T008a)
Amplifier module – stick
(11T009)
Amplifier module – stick extend or bucket fill
(11K074)
Relay – pilot control: Contacts 5/9 only closed while extending the stick.
(11K076)
Relay – pilot control: Contacts 6/10 only closed while travelling, left crawler.
(11K078)
Relay – pilot control: Contacts 8/12 only closed while travelling, right crawler.
(14.2) (15.1 + 15.2)
Remote control valves
(61K568) (61K571) (61K574)
Proportional solenoid valve
(61K530) (61K537) (61K542)
Directional solenoid valve
(60Q632) – (60Q634)
Single control blocks (closed ports while extending the stick)
(I, II + IV)
Main control blocks
(42)
Distributor manifold
Electrical signal flow Signal voltage of joystick (Fig. 8-7, Pos. 20S020) goes via ramp time module (Fig. 8-7, Pos. 11T048) to terminal 5 of the amplifier modules (Fig. 8-7, Pos. 11T008, 11T008a and 11T009) and further to the proportional and directional solenoid valves of the remote control blocks (Fig. 8-7, Pos. 14.2, 15.1 and 15.2). 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 main control blocks . Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I, II, IV) and via distributor manifold (Fig. 8-7, Pos. 42) to the hydraulic cylinders.
Version 2010/1
8-15
Hydraulics for the attachment cylinder FSA and BHA
OPERATING HYDRAULICS
8.2.6
ELECTRIC / HYDRAULIC FLOWCHART "STICK EXTEND" BHA
Fig. 8-8
Electric / hydraulic flowchart "stick extend", BHA
8-16
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the attachment cylinder FSA and BHA
Legend for Fig. 8-8: (20S020)
Control lever (joystick)
(YC)
Direction (axis) of joystick
(+10V)
Signal voltage (maximum)
(11X_00…)
Terminal rail with number
(11T048)
Ramp time module
(11T008)
Amplifier module – stick
(11T008a)
Amplifier module – stick
(11T011)
Amplifier module – stick
(11K076)
Relay – pilot control: Contacts 7/11 only closed while travelling, left crawler.
(11K078)
Relay – pilot control: Contacts 8/12 only closed while travelling, right crawler.
(14.2) (15.1 + 15.2)
Remote control valves
(61K568) (61K572) (51K574)
Proportional solenoid valve
(61K530) (61K538) (61K542)
Directional solenoid valve
(61K632) – (61K634)
Single control blocks (closed ports while extending the stick)
(I, II + IV)
Main control blocks
(42)
Distributor manifold
Electrical signal flow Signal voltage of joystick (Fig. 8-8, Pos. 20S020) goes via ramp time module (Fig. 8-8, Pos. 11T048) to terminal 5 of the amplifier modules (Fig. 8-8, Pos. 11T008, 11T008a and 11T011) and further to the proportional and directional solenoid valves of the remote control blocks (Fig. 8-8, Pos. 14.2, 15.1 and 15.2). 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 main control blocks. Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I, II, IV) and via distributor manifold (Fig. 8-8, Pos. 42) to the hydraulic cylinders.
Version 2010/1
8-17
Hydraulics for the attachment cylinder FSA and BHA
OPERATING HYDRAULICS
8.2.7
ELECTRIC / HYDRAULIC FLOWCHART "STICK RETRACT" FSA
Fig. 8-9
Electric / hydraulic flowchart "stick retract", FSA
8-18
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the attachment cylinder FSA and BHA
Legend for Fig. 8-9: (20S020)
Control lever (joystick)
(YD)
Direction (axis) of joystick
(-10V)
Signal voltage (maximum)
(11X_00…)
Terminal rail with number
(11T048)
Ramp time module
(11T008)
Amplifier module – stick
(11T008a)
Amplifier module – stick
(11T009)
Amplifier module – stick extend or bucket fill
(11K074)
Relay – pilot control: Contacts 5/9 only closed while extending the stick.
(11K076)
Relay – pilot control: Contacts 6/10 only closed while travelling, left crawler.
(11K078)
Relay – pilot control: Contacts 8/12 only closed while travelling, right crawler.
(14.1 + 15.2)
Remote control valves
(99.5)
Check valve (necessary for combined operation of travel right crawler and retracting the stick)
(61K568) (61K574)
Proportional solenoid valve
(61K531) (61K632) (61K633) (61K542) (61K543)
Directional solenoid valve
(60Q632) – (60Q634)
Single control blocks (ports A-B-T connected while retracting the stick)
(I + IV)
Main control blocks I + IV
(42)
Distributor manifold
Electrical signal flow Signal voltage of joystick (Fig. 8-9, Pos. 20S020) goes via ramp time module (Fig. 8-9, Pos. 11T048) to terminal 5 of the amplifier modules (Fig. 8-9, Pos. 11T008, 11T008a) and further to the proportional and directional solenoid valves of the remote control blocks (Fig. 8-9, Pos. 14.2 and 15.2). 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 single control blocks (Fig. 8-9, Pos. 60Q632, 60Q633 and 60Q634). Hydraulic oil flow Now piston and piston rod side of the stick cylinders are connected, so that the stick lowers only by gravity. The excess oil flows via distributor manifold (Fig. 8-9, Pos. 42) through the single control blocks (Fig. 8-9, Pos. 60Q632, 60Q633 and 60Q634) back to tank.
Version 2010/1
8-19
Hydraulics for the attachment cylinder FSA and BHA
OPERATING HYDRAULICS
8.2.8
ELECTRIC / HYDRAULIC FLOWCHART "STICK RETRACT" BHA
Fig. 8-10
Electric / hydraulic flowchart "stick retract", BHA
8-20
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the attachment cylinder FSA and BHA
Legend for Fig. 8-10: (20S020)
Control lever (joystick)
(YD)
Direction (axis) of joystick
(-10V)
Signal voltage (maximum)
(11X_00…)
Terminal rail with number
(11T048)
Ramp time module
(11T008)
Amplifier module – stick
(11T008a)
Amplifier module – stick
(11T011)
Amplifier module – stick
(11K076)
Relay – pilot control: Contacts 7/11 only closed while traveling the left crawler.
(11K078)
Relay – pilot control: Contacts 8/12 only closed while traveling the right crawler.
(14.2) (15.1 + 15.2)
Remote control valves
(61K568) (61K572) (61K574)
Proportional solenoid valve
(61K531) (61K539) (61K543)
Directional solenoid valve
(I, II + IV)
Main control blocks I, II + IV
(42)
Distributor manifold
Electrical signal flow Signal voltage of joystick (Fig. 8-10, Pos. 20S020) goes via ramp time module (Fig. 8-10, Pos. E48) to terminal 5 of the amplifier modules (Fig. 8-10, Pos. 11T008, 11T008a and 11T011) and further to the proportional and directional solenoid valves of the remote control blocks (Fig. 8-10, Pos. 14.2, 15.1 and 15.2). 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 main control blocks . Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I, II, IV) and via distributor manifold (Fig. 8-10, Pos. 42) to the hydraulic cylinders.
Version 2010/1
8-21
Hydraulics for the attachment cylinder FSA and BHA
OPERATING HYDRAULICS
8.2.9
ELECTRIC / HYDRAULIC FLOWCHART "BUCKET CURL" FSA
Fig. 8-11
Electric / hydraulic flowchart "bucket curl", FSA
8-22
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the attachment cylinder FSA and BHA
Legend for Fig. 8-11: (20S019)
Control lever (joystick)
(XB)
Direction (axis) of joystick
(-10V)
Signal voltage (maximum)
(11X_00…)
Terminal rail with number
(11T009) (11T009a) (11T009b)
Amplifier module – bucket
(11T010b)
Amplifier module – boom up or bucket fill when not raising the boom.
(11K050)
Relay – pilot control: bucket cut-off. Contacts 11/12 only closed if the hydraulic oil is overheated.
(11K058)
Relay – pilot control: Contacts 6/10 and 5/9 only closed while lifting the boom.
(11K071)
Relay – pilot control: Contacts 6/10 and 5/9 only closed while filling the bucket.
(11K074)
Relay – pilot control: Contacts 5/9 only closed while extending the stick.
(11K076)
Relay – pilot control: Contacts 6/10 only closed while traveling the left crawler.
(11K078)
Relay – pilot control: Contacts 7/11 only closed while traveling the right crawler.
(14.1 + 14.2) (15.1 + 15.2)
Remote control valves
(61K569) (61K564) (61K571) (61K575)
Proportional solenoid valve
(61K522) (61K532) (61K536) (61K544)
Directional solenoid valve
(I - IV)
Main control blocks I - IV
(42)
Distributor manifold
Electrical signal flow Signal voltage of joystick (Fig. 8-11, Pos. 20S019) goes via relay contacts at terminal 5 of the amplifier modules (Fig. 8-11, Pos. 11T009, 11T009a, 11T009b and 11T010b) and further to the proportional and directional solenoid valves of the remote control blocks (Fig. 8-11, Pos. 14.1, 14.2, 15.1 and 15.2). 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 main control blocks. Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I to IV) and via distributor manifold (Fig. 8-11, Pos. 42) to the hydraulic cylinders.
Version 2010/1
8-23
Hydraulics for the attachment cylinder FSA and BHA
OPERATING HYDRAULICS
8.2.10
ELECTRIC / HYDRAULIC FLOWCHART "BUCKET CURL" BHA
Fig. 8-12
Electric / hydraulic flowchart "bucket curl", BHA
8-24
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the attachment cylinder FSA and BHA
Legend for Fig. 8-12: (20S019)
Control lever (joystick)
(XB)
Direction (axis) of joystick
(-10V)
Signal voltage (maximum)
(11X_00…)
Terminal rail with number
(11T009) (11T009a) (11T009b)
Amplifier module – bucket
(11K050)
Relay – pilot control: Bucket cut-off. Contacts 11/12 only closed if the hydraulic oil is overheated.
(11K076)
Relay – pilot control: Contacts 6/10 only closed while traveling the left crawler.
(11K078)
Relay – pilot control: Contacts 7/11 only closed while traveling the right crawler.
(14.1) (15.1 + 15.2)
Remote control valves
(61K564) (61K571) (61K575)
Proportional solenoid valve
(61K522) (61K536) (61K544)
Directional solenoid valve
(II, III + IV)
Main control blocks II, III + IV
(42)
Distributor manifold
Electrical signal flow Signal voltage of joystick (Fig. 8-12, Pos. 20S019) goes via relay contacts to terminal 5 to the amplifier modules (Fig. 8-12, Pos. 11T009, 11T009a, 11T009b) and further to the proportional and directional solenoid valves of the remote control blocks (Fig. 8-12, Pos. 14.1, 15.1 and 15.2). 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 main control blocks . Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (II, III, IV) and via distributor manifold (Fig. 8-12, Pos. 42) to the hydraulic cylinders.
Version 2010/1
8-25
Hydraulics for the attachment cylinder FSA and BHA
OPERATING HYDRAULICS
8.2.11
ELECTRIC / HYDRAULIC FLOWCHART "BUCKET DUMP" FSA
Fig. 8-13
Electric / hydraulic flowchart "bucket dump", FSA
8-26
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the attachment cylinder FSA and BHA
Legend for Fig. 8-13: (20S019)
Control lever (joystick)
(XA)
Direction (axis) of joystick
(+10V)
Signal voltage (maximum)
(11X_00…)
Terminal rail with number
(11T009a) (11T009b)
Amplifier module – bucket
(11K050)
Relay – pilot control: Bucket cut-off. Contacts 11/12 only closed if the hydraulic oil is overheated.
(11K058)
Relay – pilot control: Contacts 5/9 only closed while lifting the boom.
(11K071)
Relay – pilot control: Contacts 5/9 only closed while filling the bucket.
(11K078)
Relay – pilot control: Contacts 7/11 only closed while travelling, right crawler.
(14.1 + 15.2)
Remote control valves
(61K564) (61K575)
Proportional solenoid valve
(61K523) (61K545)
Directional solenoid valve
(III + IV)
Main control blocks III + IV
(42)
Distributor manifold
Electrical signal flow Signal voltage of joystick (Fig. 8-13, Pos. 20S019) goes via relay contacts to terminal 5 of the amplifier modules (Fig. 8-13, Pos. 11T009a and 11T009b) and further to the proportional and directional solenoid valves of the remote control blocks (Fig. 8-13, Pos. 4.1 and 15.2). 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 main control blocks. Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (III + IV) and via distributor manifold (Fig. 8-13, Pos. 42) to the hydraulic cylinders.
Version 2010/1
8-27
Hydraulics for the attachment cylinder FSA and BHA
OPERATING HYDRAULICS
8.2.12
ELECTRIC / HYDRAULIC FLOWCHART "BUCKET DUMP" BHA
Fig. 8-14
Electric / hydraulic flowchart "bucket dump", BHA
8-28
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the attachment cylinder FSA and BHA
Legend for Fig. 8-14: (20S019)
Control lever (joystick)
(XA)
Direction (axis) of joystick
(+10V)
Signal voltage (maximum)
(11X_00…)
Terminal rail with number
(11T009a) (11T009b)
Amplifier module – bucket
(11K050)
Relay – pilot control: Bucket cut-off. Contacts 11/12 only closed if the hydraulic oil is overheated.
(11K076)
Relay – pilot control: Contacts 6/10 only closed while travelling, left crawler.
(11K078)
Relay – pilot control: Contacts 7/11 only closed while travelling, right crawler.
(14.1) (15.1 + 15.2)
Remote control valves
(61K564) (61K571) (61K575)
Proportional solenoid valve
(61K523) (61K537) (61K545)
Directional solenoid valve
(II, III + IV)
Main control blocks II, III + IV
(42)
Distributor manifold
Electrical signal flow Signal voltage of joystick (Fig. 8-14, Pos. 20S019) goes via relay contacts to terminal 5 of the amplifier modules (Fig. 8-14, Pos. 11T009, 11T009a, 11T009b) and further to the proportional and directional solenoid valves of the remote control blocks (Fig. 8-14, Pos. 14.1, 15.1 and 15.2). 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 main control blocks. Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (II, III, IV) and via distributor manifold (Fig. 8-14, Pos. 42) to the hydraulic cylinders.
Version 2010/1
8-29
Hydraulics for the attachment cylinder FSA and BHA
OPERATING HYDRAULICS
8.2.13
ELECTRIC / HYDRAULIC FLOWCHART "CLAM OPEN" FSA
Fig. 8-15
Electric / hydraulic flowchart "clam open", FSA
8-30
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the attachment cylinder FSA and BHA
Legend for Fig. 8-15: (20S024)
Control pedal
(-10V)
Signal voltage (maximum)
(11X_00…)
Terminal rail with number
(11T011)
Amplifier module – clam
(11K076)
Relay – pilot control: Contacts 7/11 only closed while travelling the left crawler.
(15.1)
Remote control valves
(61K572)
Proportional solenoid valve
(61K539)
Directional solenoid valve
(II)
Main control block II
(42)
Distributor manifold
Electrical signal flow Signal voltage of control pedal (Fig. 8-15, Pos. 20S024) goes via relay contact to terminal 5 of the amplifier module (Fig. 8-15, Pos. 11T011) and further to the proportional and directional solenoid valves of the remote control block (Fig. 8-15, Pos. 15.1). 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 via distributor manifold (Fig. 8-15, Pos. 42) to the hydraulic cylinders.
Version 2010/1
8-31
Hydraulics for the attachment cylinder FSA and BHA
OPERATING HYDRAULICS
8.2.14
ELECTRIC / HYDRAULIC FLOWCHART "CLAM CLOSE" FSA
Fig. 8-16
Electric / hydraulic flowchart "clam close", FSA
8-32
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the attachment cylinder FSA and BHA
Legend for Fig. 8-16: (20S023)
Control pedal
(+10V)
Signal voltage (maximum)
(11X_00…)
Terminal rail with number
(11T011)
Amplifier module – clam
(11K076)
Relay – pilot control: Contacts 7/11 only closed while traveling the left crawler.
(15.1)
Remote control valves
(61K572)
Proportional solenoid valve
(61K538)
Directional solenoid valve
(II)
Main control block II
(42)
Distributor manifold
Electrical signal slow Signal voltage of control pedal (Fig. 8-16, Pos. 20S023) goes via relay contact to terminal 5 of the amplifier module (Fig. 8-16, Pos. 11T011) and further to the proportional and directional solenoid valves of the remote control block (Fig. 8-16, Pos. 15.1). 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 via distributor manifold (Fig. 8-16, Pos. 42) to the hydraulic cylinders.
Version 2010/1
8-33
Hydraulics for the attachment cylinder FSA and BHA
OPERATING HYDRAULICS
8.2.15
CHECKS AND ADJUSTMENTS OF THE MAIN RELIEF VALVES (FSA)
Fig. 8-17
Checks and adjustments of the main relief valves (FSA)
8-34
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the attachment cylinder FSA and BHA
There are four main relief valves (MRV) installed, one in each main control block, to limit the maximum pump supply pressure (operating pressure). MRV in control block
Test port
Pump circuit I
I
M14
Pump circuit II
II
M12
Pump circuit III
III
M11
Pump circuit IV
IV
M13
Functions FSA Swing Boom
Clam Swing
Boom
Bucket
Bucket filling Boom raise
Stick
Bucket filling Stick extend
Travel
Bucket
Boom
Stick
Travel
Each pump circuit can be checked or adjusted individually by selecting one function of the required pump circuit. Checking: 1. Connect the gauge to the required test port M11 - M14. 2. Start engine and let it run at high idle. 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 another function, in order to avoid wrong measuring results caused by wrongly adjusted SRV or other defects in the system. Adjusting: 1. Remove protective cap (Fig. 8-17, Pos. a). 2. Loosen lock nut (Fig. 8-17, Pos. b). 3. Turn set-screw (Fig. 8-17, Pos. c) clockwise to increase pressure, or counter-clockwise to decrease pressure. 4. Tighten lock nut (Fig. 8-17, Pos. b) and install cap (Fig. 8-17, Pos. a).
NOTE: It is important that the valve bodies of the MRVs and the SRVs are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly, which results in loud flow noises and wrong adjustments.
Version 2010/1
8-35
Hydraulics for the attachment cylinder FSA and BHA
OPERATING HYDRAULICS
8.2.16
CHECKS AND ADJUSTMENTS OF THE MAIN RELIEF VALVES (BHA)
Fig. 8-18
Checks and adjustments of the main relief valves (BHA)
8-36
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the attachment cylinder FSA and BHA
There are four main relief valves (MRV) installed, one in each main control block, to limit the maximum pump supply pressure (operating pressure). MRV in control block
Test port
Pump circuit I
I
M14
Pump circuit II
II
M12
Pump circuit III
III
M11
Pump circuit IV
IV
M13
Functions BHA Swing Boom
Stick Swing
Boom
Bucket
Boom
Stick
Bucket
Travel
Bucket
Boom
Stick
Travel
Each pump circuit can be checked or adjusted individually by selecting one function of the required pump circuit. Checking: 1. Connect the gauge to the required test port M11 - M14. 2. Start engine and let it run at high idle. 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. Adjusting: 1. Remove protective cap (Fig. 8-18, Pos. a). 2. Loosen lock nut (Fig. 8-18, Pos. b). 3. Turn set-screw (Fig. 8-18, Pos. c) clockwise to increase pressure, counter-clockwise to decrease pressure. 4. Tighten lock nut (Fig. 8-18, Pos. b) and install cap (Fig. 8-18, Pos. a).
NOTE: It is important that the valve bodies of the MRVs and the SRVs are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly, which results in loud flow noises and wrong adjustments.
Version 2010/1
8-37
Hydraulics for the attachment cylinder FSA and BHA
OPERATING HYDRAULICS
8.2.17
CHECKS AND ADJUSTMENTS OF THE SECONDARY RELIEF VALVES (SRV)
Fig. 8-19
Checks and adjustments of the secondary relief valves (SRV)
8-38
Version 2010/1
OPERATING HYDRAULICS
8.2.17.1
Hydraulics for the attachment cylinder FSA and BHA
BOOM CYLINDER "PISTON SIDE" FSA + BHA
There are 6 secondary relief valves (SRV) installed, 4 at the distributor manifold (Fig. 8-19, Pos. 42), 1 in main control block II and 1 in block IV, to limit the maximum possible pressure peaks in the lines. 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
Pressure Test Port
Location
SRV 66.5
M12 (High pressure filter)
Control block II, section A1
SRV 66.7
M13 (High pressure filter)
Control block IV, section A1
SRV 65.7
M26.2
Manifold (Fig. 8-19, Pos. 42), section O
SRV 70.13
M26.1
Manifold (Fig. 8-19, Pos. 42), section O
SRV 70.2
M16.2
Manifold (Fig. 8-19, Pos. 42), section B
SRV 70.1
M16.1
Manifold (Fig. 8-19, Pos. 42), section B
MRV circuit II
M12 (High pressure filter)
Control block II
MRV circuit IV
M13 (High pressure filter)
Control block IV
1. Connect gauges to all above listed test ports. 2. Start engine and let it run at high idle. 3. Extend the boom cylinder to the stop position until the hydraulic system stalls. 4. Slowly increase the pump circuit pressure by turning in set-screws (Fig. 8-19, Pos. 3) of both MRVs in control block II and IV while observing the pressure gauges. Stop as soon as the pressure does not rise any further. The gauge pointers should remain at 350±5 bar. NOTE: Since the piston side of the boom cylinders are protected by several SRVs, the pressure gauges show the pressure of the valve with the lowest setting. Even if 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. 5. Remove protective cap (Fig. 8-19, Pos. 1) of the MRV. 6. Loosen lock nut (Fig. 8-19, Pos. 2). 7. Turn set-screw (Fig. 8-19, Pos. 3) of both MRVs ½ a turn further in, the gauge pointers will remain at the value shown in step 4 (350±5 bar). 8. Tighten lock nut (Fig. 8-19, Pos. 2) and install cap (Fig. 8-19, Pos. 1).
Version 2010/1
8-39
Hydraulics for the attachment cylinder FSA and BHA
Fig. 8-20
8-40
OPERATING HYDRAULICS
Checks and adjustments of the secondary relief valves (SRV)
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the attachment cylinder FSA and BHA
9. Adjust all 6 SRVs equally, until all gauges show a pressure of 350 bar. Adjust in steps of ¼ turn of set-screw (Fig. 8-20, Pos. 3) in the following sequence: z
70.1Ö 70.2 Ö 70.13 Ö 65.4 Ö 66.5 Ö 66.7
z
Remove protective cap (Fig. 8-20, Pos. 1) of the SRVs.
z
Loosen lock nut (Fig. 8-20, Pos. 2).
z
Turn set-screw (Fig. 8-20, Pos. 3) clockwise to increase pressure, or counter-clockwise to decrease pressure.
z
Tighten lock nut (Fig. 8-20, Pos. 2) and install cap (Fig. 8-20, Pos. 1).
NOTE: Now all gauges will show the same value of 350±5 bar. 10. Proceed with the other valves in the same manner.
WARNING 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 secondary relief valves.
11. Reset the MRVs to 310+5 bar after the check / adjustment is finished, as follows: z
Remove protective cap (Fig. 8-20, Pos. 1).
z
Loosen lock nut (Fig. 8-20, Pos. 2).
z
Turn set-screw (Fig. 8-20, Pos. 3) clockwise to increase pressure, or counter-clockwise to decrease pressure.
z
Tighten lock nut (Fig. 8-20, Pos. 2) and install cap (Fig. 8-20, Pos. 1).
NOTE: It is important that the valve bodies of the MRVs and the SRVs are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly, which results in loud flow noises and wrong adjustments.
Version 2010/1
8-41
Hydraulics for the attachment cylinder FSA and BHA
Fig. 8-21
8-42
OPERATING HYDRAULICS
Checks and adjustments of the secondary relief valves (SRV)
Version 2010/1
OPERATING HYDRAULICS
8.2.17.2
Hydraulics for the attachment cylinder FSA and BHA
BOOM CYLINDER "PISTON ROD SIDE" FSA +BHA
There is 1 secondary relief valve (SRV) installed in the main control blocks, to limit the maximum possible pressure peaks in the lines. 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
Pressure Test Port
Location
SRV 66.3
M11 (High pressure filter)
Control block III, section B3
SRV 66.8
M13 (High pressure filter)
Control block IV, section B1
MRV circuit III
M11 (High pressure filter)
Control block III
MRV circuit IV
M13 (High pressure filter)
Control block IV
1. Connect gauges to all above listed test ports. 2. Start engine and let it run at high idle. 3. Retract the boom cylinder to the stop position until the hydraulic system stalls. 4. Slowly increase the pump circuit pressure by turning in set-screws (Fig. 8-21, Pos. 3) of the MRVs in the control blocks, while observing the pressure gauges. Stop as soon as the pressure does not rise any further. The gauge pointers should remain at 350±5 bar. NOTE: If the piston rod side of the boom cylinders are protected by several SRVs, the pressure gauges show the pressure of the valve with the lowest setting. Even if 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. 5. Remove protective cap (Fig. 8-21, Pos. 1) of MRV. 6. Loosen lock nut (Fig. 8-21, Pos. 2). 7. Turn set-screw (Fig. 8-21, Pos. 3) of both MRV's ½ a turn further in. 8. Tighten lock nut (Fig. 8-21, Pos. 2) and install cap (Fig. 8-21, Pos. 1).
Version 2010/1
8-43
Hydraulics for the attachment cylinder FSA and BHA
Fig. 8-22
8-44
OPERATING HYDRAULICS
Checks and adjustments of the secondary relief valves (SRV)
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the attachment cylinder FSA and BHA
9. Adjust all SRVs equally, until all gauges show a pressure of 350 bar. z
Adjust in steps of ¼ turn of set-screw (Fig. 8-22, Pos. 3).
z
Remove protective cap (Fig. 8-22, Pos. 1) of SRVs.
z
Loosen lock nut (Fig. 8-22, Pos. 2).
z
Turn set-screw (Fig. 8-22, Pos. 3) clockwise to increase pressure, or counter-clockwise to decrease pressure.
z
Tighten lock nut (Fig. 8-22, Pos. 2) and install cap (Fig. 8-22, Pos. 1).
NOTE: All gauges will show the same value of 350 bar. 10. Proceed with the other valves in the same manner.
WARNING Strong pulsation of the return line hoses indicates deviation in opening pressure of SRVs and must be avoided. Otherwise, the internal sealing is not properly, which results in loud flow noises and wrong adjustments.
11. Reset the MRV's to 310+5 bar after the check / adjustment is finished, as follows: z
Remove protective cap (Fig. 8-22, Pos. 1).
z
Loosen lock nut (Fig. 8-22, Pos. 2).
z
Turn set-screw (Fig. 8-22, Pos. 3) clockwise to increase pressure, or counter-clockwise to decrease pressure.
z
Tighten lock nut (Fig. 8-22, Pos. 2) and install cap (Fig. 8-22, Pos. 1).
NOTE: It is important that the valve bodies of the MRVs and the SRVs are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly, which results in loud flow noises and wrong adjustments.
Version 2010/1
8-45
Hydraulics for the attachment cylinder FSA and BHA
Fig. 8-23
8-46
OPERATING HYDRAULICS
Checks and adjustments of the secondary relief valves (SRV)
Version 2010/1
OPERATING HYDRAULICS
8.2.17.3
Hydraulics for the attachment cylinder FSA and BHA
STICK CYLINDER "PISTON SIDE" FSA
There are 4 secondary relief valves (SRV) installed, 3 at the distributor manifold (Fig. 8-23, Pos. 42) and 1 in main control block IV, to limit the maximum possible pressure peaks in the lines. Since the opening pressure of the SRVs is higher than the setting of the main relief valves (MRV), it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve
Press. test port
Location
SRV 66.11
M13 (High pressure filter)
Control block IV, section A3
SRV 65.2
M20
Manifold (Fig. 8-23, Pos. 42), section G
SRV 70.8
M21.1
Manifold (Fig. 8-23, Pos. 42), section J
SRV 70.9
M13 (High pressure filter)
Control block IV
1. Connect gauges to all test ports listed above. 2. Start engine and let it run at high idle. 3. Extend the stick cylinder to the stop position until the hydraulic system stalls. 4. Slowly increase the pump circuit pressure by turning in set-screws (Fig. 8-23, Pos. 3) of the MRV in control block IV, while observing the pressure gauges. Stop as soon as the pressure does not rise any further. The gauge pointers should remain at 350±5 bar. NOTE: Since the piston side of the stick cylinders are protected by several SRVs, the pressure gauges show the pressure of the valve with the lowest setting. Even if 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. 5. Remove protective cap (Fig. 8-23, Pos. 1) of MRV. 6. Loosen lock nut (Fig. 8-23, Pos. 2). 7. Turn set-screw (Fig. 8-23, Pos. 3) of the MRV ½ a turn further in; the gauge pointers will remain at the value shown in step 4 (350±5 bar). 8. Tighten lock nut (Fig. 8-23, Pos. 2) and install cap (Fig. 8-23, Pos. 1).
Version 2010/1
8-47
Hydraulics for the attachment cylinder FSA and BHA
Fig. 8-24
8-48
OPERATING HYDRAULICS
Checks and adjustments of the secondary relief valves (SRV)
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the attachment cylinder FSA and BHA
9. Adjust all 4 SRVs equally, until all gauges show a pressure of 350 bar. Adjust in steps of ¼ turn of set-screw (Fig. 8-24, Pos. 3) in the following sequence: z
65.2 Ö 70.8 Ö 70.9 Ö 66.11
z
Remove protective cap (Fig. 8-24, Pos. 1) of SRVs.
z
Loosen lock nut (Fig. 8-24, Pos. 2).
z
Turn set-screw (Fig. 8-24, Pos. 3) clockwise to increase pressure, or counter-clockwise to decrease pressure.
z
Tighten lock nut (Fig. 8-24, Pos. 2) and install cap (Fig. 8-24, Pos. 1).
NOTE: Now all gauges will show the same value of 350±5 bar. 10. Proceed with the other valves in the same manner in the following sequence: z
70.8 Ö 70.9 Ö 66.11
WARNING 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 four secondary relief valves.
11. Reset the MRV to 310+5 bar after the check / adjustment is finished, as follows: z
Remove protective cap (Fig. 8-24, Pos. 1).
z
Loosen lock nut (Fig. 8-24, Pos. 2).
z
Turn set-screw (Fig. 8-24, Pos. 3) clockwise to increase pressure, or counter-clockwise to decrease pressure.
z
Tighten lock nut (Fig. 8-24, Pos. 2) and install cap (Fig. 8-24, Pos. 1).
NOTE: It is important that the valve bodies of the MRVs and the SRVs are firmly tightened (with 300 Nm). Otherwise the internal sealing is not properly, which results in loud flow noises and wrong adjustments.
Version 2010/1
8-49
Hydraulics for the attachment cylinder FSA and BHA
Fig. 8-25
8-50
OPERATING HYDRAULICS
Checks and adjustments of the secondary relief valves (SRV)
Version 2010/1
OPERATING HYDRAULICS
8.2.17.4
Hydraulics for the attachment cylinder FSA and BHA
STICK CYLINDER "PISTON SIDE" BHA
There are 3 secondary relief valves (SRVs) installed in main control blocks I, II and IV to limit the maximum possible pressure peaks in the lines. 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. test port
Location
SRV 66.4
M14 (High pressure filter)
Control block I, section B3
SRV 66.6
M13 (High pressure filter)
Control block II, section B2
SRV 66.12
M12 (High pressure filter)
Control block IV, section B3
MRV circuit I
M14 (High pressure filter)
Control block I
MRV circuit II
M13 (High pressure filter)
Control block II
MRV circuit IV
M12 (High pressure filter)
Control block IV
1. Connect gauges to all test ports listed above. 2. Start engine and let it run at high idle. 3. Retract the stick cylinder to the stop position until the hydraulic system stalls. 4. Slowly increase the pump circuit pressure by turning in set-screws (Fig. 8-25, Pos. 3) of the MRVs in the control blocks, while observing the pressure gauges. Stop as soon as the pressure does not rise any further. The gauge pointers should remain at 350±5 bar. NOTE: Since the piston side of the stick cylinders are protected by several SRVs, the pressure gauges show the pressure of the valve with the lowest setting. Even if 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. 5. Remove protective cap (Fig. 8-25, Pos. 1) of MRV. 6. Loosen lock nut (Fig. 8-25, Pos. 2). 7. Turn set-screw (Fig. 8-25, Pos. 3) of the MRV's ½ a turn further in, the gauge pointers will remain at the value shown at step 4 (350±5 bar). 8. Tighten lock nut (Fig. 8-25, Pos. 2) and install cap (Fig. 8-25, Pos. 1).
Version 2010/1
8-51
Hydraulics for the attachment cylinder FSA and BHA
Fig. 8-26
8-52
OPERATING HYDRAULICS
Checks and adjustments of the secondary relief valves (SRV)
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the attachment cylinder FSA and BHA
9. Adjust all 3 SRVs equally, until all gauges show a pressure of 350 bar. z
Adjust in steps of ¼ turn of set-screw (Fig. 8-26, Pos. 3) in the following sequence:
z
66.4 Ö 66.6 Ö 66.12
z
Remove protective cap (Fig. 8-26, Pos. ) of SRVs.
z
Loosen lock nut (Fig. 8-26, Pos. 2).
z
Turn set-screw (Fig. 8-26, Pos. ) clockwise to increase pressure, or counter-clockwise to decrease pressure.
z
Tighten lock nut (Fig. 8-26, Pos. 2) and install cap (Fig. 8-26, Pos. 1).
NOTE: Now all gauges will show the same value of 350±5 bar. 10. Proceed with the other valves in the same manner in the following sequence: z
66.6 Ö 66.12
WARNING Strong pulsation of the return line hoses, indicates deviation in opening pressure of SRV's and must be avoided. Repeat the adjusting procedure until the oil returns well-balanced via all 3 secondary relief valves.
11. Reset the MRV to 310+5 bar after the check/adjustment is finished, as follows: z
Remove protective cap (Fig. 8-26, Pos. 1).
z
Loosen lock nut (Fig. 8-26, Pos. 2).
z
Turn set-screw (Fig. 8-26, Pos. 3) clockwise to increase pressure, or counter-clockwise to decrease pressure.
z
Tighten lock nut (Fig. 8-26, Pos. 2) and install cap (Fig. 8-26, Pos. 1).
NOTE: It is important that the valve bodies of MRV and SRV are firmly tightened (with 300 Nm). Otherwise the internal sealing is not properly, which results in loud flow noises and wrong adjustments.
Version 2010/1
8-53
Hydraulics for the attachment cylinder FSA and BHA
Fig. 8-27
8-54
OPERATING HYDRAULICS
Checks and adjustments of the secondary relief valves (SRV)
Version 2010/1
OPERATING HYDRAULICS
8.2.18
Hydraulics for the attachment cylinder FSA and BHA
STICK CYLINDER "PISTON ROD SIDE" FSA
There are 2 secondary relief valves (SRVs) installed in main control blocks I and IV to limit the maximum possible pressure peaks in the lines. 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
Pressure Test Port
Location
SRV 66.4
M14 (High pressure filter)
Control block I, section B3
SRV 66.12
M13 (High pressure filter)
Control block IV, section B3
MRV circuit I
M14 (High pressure filter)
Control block I
MRV circuit IV
M13 (High pressure filter)
Control block IV
1. Connect gauges to all test ports listed above. 2. Start engine and let it run at high idle. 3. Retract the stick cylinder to the stop position until the hydraulic system stalls. (Switch 20S098) 4. Slowly increase the pump circuit pressure by turning in set-screws (Fig. 8-27, Pos. 3) of MRVs in the control blocks, while observing the pressure gauges. Stop as soon as the pressure does not rise any further. The gauge pointers should remain at 350±5 bar. NOTE: Since the piston rod side of the stick cylinders are protected by several SRVs, the pressure gauges show the pressure of the valve with the lowest setting. Even if 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. 5. Remove protective cap (Fig. 8-27, Pos. 1) of MRV. 6. Loosen lock nut (Fig. 8-27, Pos. 2). 7. Turn set-screw (Fig. 8-27, Pos. 3) of both MRV's ½ a turn further in. 8. Tighten lock nut (Fig. 8-27, Pos. 2) and install cap (Fig. 8-27, Pos. 1).
Version 2010/1
8-55
Hydraulics for the attachment cylinder FSA and BHA
Fig. 8-28
8-56
OPERATING HYDRAULICS
Checks and adjustments of the secondary relief valves (SRV)
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the attachment cylinder FSA and BHA
9. Adjust both SRVs equally, until all gauges show a pressure of 350 bar. Adjust in steps of ¼ turn of set-screw (Fig. 8-28, Pos. 3) in the following sequence: z
66.4 Ö 66.12
z
Remove protective cap (Fig. 8-28, Pos. ) of SRVs.
z
Loosen lock nut (Fig. 8-28, Pos. 2).
z
Turn set-screw (Fig. 8-28, Pos. 3) clockwise to increase pressure, or counter-clockwise to decrease pressure.
z
Tighten lock nut (Fig. 8-28, Pos. 2) and install cap (Fig. 8-28, Pos. 1).
NOTE: Now all gauges will show the same value of 350±5 bar. 10. Proceed with the other valves in the same manner.
WARNING 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 secondary relief valves.
11. Reset the MRVs to 310+5 bar after the check / adjustment is finished, as follows: z
Remove protective cap (Fig. 8-28, Pos. 1).
z
Loosen lock nut (Fig. 8-28, Pos. 2).
z
Turn set-screw (Fig. 8-28, Pos. 3) clockwise to increase pressure, or counter-clockwise to decrease pressure.
z
Tighten lock nut (Fig. 8-28, Pos. 2) and install cap (Fig. 8-28, Pos. 1).
NOTE: It is important that the valve bodies of MRV and SRV are firmly tightened (with 300 Nm). Otherwise the internal sealing is not properly, which results in loud flow noises and wrong adjustments.
Version 2010/1
8-57
Hydraulics for the attachment cylinder FSA and BHA
Fig. 8-29
8-58
OPERATING HYDRAULICS
Checks and adjustments of the secondary relief valves (SRV)
Version 2010/1
OPERATING HYDRAULICS
8.2.18.1
Hydraulics for the attachment cylinder FSA and BHA
STICK CYLINDER "PISTON ROD SIDE" BHA
There are 3 secondary relief valves (SRVs) installed at the distributor manifold (Fig. 8-29, Pos. 42) to limit the maximum possible pressure peaks in the lines. 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
Pressure Test Port
Location
SRV 70.8
M21.1
Manifold (Fig. 8-29, Pos. 42), section J
SRV 70.9
M21.2
Manifold (Fig. 8-29, Pos. 42), section J
SRV 70.10
M22
Manifold (Fig. 8-29, Pos. 42), section K
MRV circuit I
M14 (High pressure filter)
Control block I
1. Connect gauges to all test ports listed above. 2. Start engine and let it run at high idle. 3. Retract the stick cylinder to the stop position until the hydraulic system stalls. 4. Slowly increase the pump circuit pressure by turning in set-screws (Fig. 8-29, Pos. 3) of MRVs in the control blocks while observing the pressure gauges. Stop as soon as the pressure does not rise any further. The gauge pointers should remain at 350±5 bar. NOTE: Since the piston rod side of the stick cylinders are protected by several SRVs, the pressure gauges show the pressure of the valve with the lowest setting. Even if 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. 5. Remove protective cap (Fig. 8-29, Pos. 1) of the MRV. 6. Loosen lock nut (Fig. 8-29, Pos. 2). 7. Turn set-screw (Fig. 8-29, Pos. 3) of both MRVs ½ a turn further in. 8. Tighten lock nut (Fig. 8-29, Pos. 2) and install cap (Fig. 8-29, Pos. 1).
Version 2010/1
8-59
Hydraulics for the attachment cylinder FSA and BHA
Fig. 8-30
8-60
OPERATING HYDRAULICS
Checks and adjustments of the secondary relief valves (SRV)
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the attachment cylinder FSA and BHA
9. Adjust all SRVs equally, until all gauges show a pressure of 350±5 bar. Adjust in steps of ¼ turn of set-screw (Fig. 8-30, Pos. 3) in the following sequence: z
70.8 Ö 70.9 Ö 70.10
z
Remove protective cap (Fig. 8-30, Pos. 1) of SRVs.
z
Loosen lock nut (Fig. 8-30, Pos. 2).
z
Turn set-screw (Fig. 8-30, Pos. 3) clockwise to increase pressure, or counter-clockwise to decrease pressure.
z
Tighten lock nut (Fig. 8-30, Pos. 2) and install cap (Fig. 8-30, Pos. 1).
NOTE: Now all gauges will show the same value of 350±5 bar. 10. Proceed with the other valves in the same manner in the following sequence: z
70.9 Ö 70.10
WARNING 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 secondary relief valves.
11. Reset the MRVs to 310+5 bar after the check / adjustment is finished, as follows: z
Remove protective cap (Fig. 8-30, Pos. 1).
z
Loosen lock nut (Fig. 8-30, Pos. 2).
z
Turn set-screw (Fig. 8-30, Pos. 3) clockwise to increase pressure, or counter-clockwise to decrease pressure.
z
Tighten lock nut (Fig. 8-30, Pos.2) and install cap (Fig. 8-30, Pos. 1).
NOTE: It is important that the valve bodies of MRV and SRVs are firmly tightened (with 300 Nm). Otherwise the internal sealing is not properly, which results in loud flow noises and wrong adjustments.
Version 2010/1
8-61
Hydraulics for the attachment cylinder FSA and BHA
Fig. 8-31
8-62
OPERATING HYDRAULICS
Checks and adjustments of the secondary relief valves (SRV)
Version 2010/1
OPERATING HYDRAULICS
8.2.18.2
Hydraulics for the attachment cylinder FSA and BHA
BUCKET CYLINDER "PISTON SIDE" FSA
There are 6 secondary relief valves (SRVs) installed, 4 at the distributor manifold (Fig. 8-31, Pos. 42), 1 in main control block III, and 1 in block IV, to limit the maximum possible pressure peaks in the lines. 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
Pressure Test Port
Location
SRV 66.1
M11 (High pressure filter)
Control block III, section A2
SRV 66.9
M13 (High pressure filter)
Control block IV, section A2
SRV 65.1
M17.1
Manifold (Fig. 8-31, Pos. 42), section C
SRV 70.4
M17.2
Manifold (Fig. 8-31, Pos. 42), section C
SRV 70.12
M24
Manifold (Fig. 8-31, Pos. 42), section M
SRV 65.3
M25
Manifold (Fig. 8-31, Pos. 42), section N
MRV circuit III
M11 (High pressure filter)
Control block III
MRV circuit IV
M13 (High pressure filter)
Control block IV
1. Connect gauges to all test ports listed above. 2. Start engine and let it run at high idle. 3. Extend the bucket cylinder to the stop position until the hydraulic system stalls. 4. Slowly increase the MRV pressure by turning in set-screws (Fig. 8-31, Pos. 3) of both MRVs in control blocks III and IV, while observing the pressure gauges. Stop as soon as the pressure does not rise any further. The gauge pointers should remain at 360–370 bar. NOTE: Since the piston side of the bucket cylinders are protected by several SRVs, the pressure gauges show the pressure of the valve with the lowest setting. Even if 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. 5. Remove protective cap (Fig. 8-31, Pos. 1) of MRV. 6. Loosen lock nut (Fig. 8-31, Pos. 2). 7. Turn set-screw (Fig. 8-31, Pos. 3) of both MRVs ½ a turn further in; the gauge pointers will remain at the value shown in step 4 (360–370 bar). 8. Tighten lock nut (Fig. 8-31, Pos. 2) and install cap (Fig. 8-31, Pos. 1).
Version 2010/1
8-63
Hydraulics for the attachment cylinder FSA and BHA
Fig. 8-32
8-64
OPERATING HYDRAULICS
Checks and adjustments of the secondary relief valves (SRV)
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the attachment cylinder FSA and BHA
9. Adjust all 6 SRVs equally until all gauges show a pressure of 350±5 bar. Adjust in steps of ¼ turn of set-screw (Fig. 8-32, Pos. 3) in the following sequence: z
65.1 Ö 70.4 Ö 70.12 Ö 65.3 Ö 66.1 Ö 66.9
z
Remove protective cap (Fig. 8-32, Pos. 1) of SRVs.
z
Loosen lock nut (Fig. 8-32, Pos. 2).
z
Turn set-screw (Fig. 8-32, Pos. 3) clockwise to increase pressure, or counter-clockwise to decrease pressure.
z
Tighten lock nut (Fig. 8-32, Pos. 2) and install cap (Fig. 8-32, Pos. 1).
10. Reduce the pressure, at SRV 65.1 to a value below the required value, and then increase up to the required pressure (350±5 bar), while observing all gauges. NOTE: Now all gauges will show the same value of 350±5 bar, but only SRV 65.1 has the correct setting. 11. Proceed with the other valves in the same manner in the following sequence: z
70.4 Ö 70.12 Ö 65.3 Ö 66.1 Ö 66.9
WARNING 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 6 secondary relief valves.
12. Reset the MRVs to 310+5 bar after the check / adjustment is finished, as follows: z
Remove protective cap (Fig. 8-32, Pos. 1).
z
Loosen lock nut (Fig. 8-32, Pos. 2).
z
Turn set-screw (Fig. 8-32, Pos. 3) clockwise to increase pressure, or counter-clockwise to decrease pressure.
z
Tighten lock nut (Fig. 8-32, Pos. 2) and install cap (Fig. 8-32, Pos. 1).
NOTE: It is important that the valve bodies of MRV and SRVs are firmly tightened (with 300 Nm). Otherwise the internal sealing is not properly, which results in loud flow noises and wrong adjustments.
Version 2010/1
8-65
Hydraulics for the attachment cylinder FSA and BHA
Fig. 8-33
8-66
OPERATING HYDRAULICS
Checks and adjustments of the secondary relief valves (SRV)
Version 2010/1
OPERATING HYDRAULICS
8.2.18.3
Hydraulics for the attachment cylinder FSA and BHA
BUCKET CYLINDER "PISTON SIDE" BHA
There are 3 secondary relief valves (SRVs) installed at the distributor manifold (Fig. 8-33, Pos. 42) to limit the maximum possible pressure peaks in the lines. 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
Pressure Test Port
Location
SRV 70.3
M17.1
Manifold (Fig. 8-33, Pos. 42), section C
SRV 70.4
M17.2
Manifold (Fig. 8-33, Pos. 42), section C
SRV 70.12
M24
Manifold (Fig. 8-33, Pos. 42), section M
MRV circuit III
M11 (High pressure filter)
Control block III
1. Connect gauges to all test ports listed above. 2. Start engine and let it run at high idle. 3. Extend the bucket cylinder to the final stop position until the hydraulic system stalls. 4. Slowly increase the pump circuit pressure by turning in set-screws (Fig. 8-33, Pos. 3) of MRV in control block III, while observing the pressure gauges. Stop as soon as the pressure does not rise any further. The gauge pointers should remain at 350±5 bar. NOTE: Since the piston side of the bucket cylinders are protected by several SRVs, the pressure gauges show the pressure of the valve with the lowest setting. Even if 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. 5. Remove protective cap (Fig. 8-33, Pos. 1) of MRV. 6. Loosen lock nut (Fig. 8-33, Pos. 2). 7. Turn set-screw (Fig. 8-33, Pos. 3) of both MRVs ½ a turn further in; the gauge pointers will remain at the value shown in step 4 (350±5 bar ). 8. Tighten lock nut (Fig. 8-33, Pos. 2) and install cap (Fig. 8-33, Pos. 1).
Version 2010/1
8-67
Hydraulics for the attachment cylinder FSA and BHA
Fig. 8-34
8-68
OPERATING HYDRAULICS
Checks and adjustments of the secondary relief valves (SRV)
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the attachment cylinder FSA and BHA
9. Adjust all 3 SRVs equally until all gauges show a pressure of 350±5 bar. Adjust in steps of ¼ turn of set-screw (Fig. 8-34, Pos. 3) in the following sequence: z
70.3 Ö 70.4 Ö 70.12
z
Remove protective cap (Fig. 8-34, Pos. 1) of SRVs.
z
Loosen lock nut (Fig. 8-34, Pos. 2).
z
Turn set-screw (Fig. 8-34, Pos. 3) clockwise to increase pressure, or counter-clockwise to decrease pressure.
z
Tighten lock nut (Fig. 8-34, Pos. 2) and install cap (Fig. 8-34, Pos. 1).
10. Reduce the pressure at SRV 70.3 to a value below the required value, and then increase up to the required pressure (350±5 bar), while observing all gauges. NOTE: Now all gauges will show the same value of 350±5 bar, but only SRV 70.3 has the correct setting. 11. Proceed with the other valves in the same manner in the following sequence: z
70.4 Ö 70.12
WARNING 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 3 secondary relief valves.
12. Reset the MRVs to 310+5 bar after the check / adjustment is finished, as follows: z
Remove protective cap (Fig. 8-34, Pos. 1).
z
Loosen lock nut (Fig. 8-34, Pos. 2).
z
Turn set-screw (Fig. 8-34, Pos. 3) clockwise to increase pressure, or counter-clockwise to decrease pressure.
z
Tighten lock nut (Fig. 8-34, Pos. 2) and install cap (Fig. 8-34, Pos. 1).
NOTE: It is important that the valve bodies of MRV and the SRVs are firmly tightened (with 300 Nm). Otherwise the internal sealing is not properly, which results in loud flow noises and wrong adjustments.
Version 2010/1
8-69
Hydraulics for the attachment cylinder FSA and BHA
Fig. 8-35
8-70
OPERATING HYDRAULICS
Checks and adjustments of the secondary relief valves (SRV)
Version 2010/1
OPERATING HYDRAULICS
8.2.18.4
Hydraulics for the attachment cylinder FSA and BHA
BUCKET CYLINDER "PISTON ROD SIDE" FSA
There are 2 secondary relief valves (SRVs) installed, 1 in main control block III, and 1 in block IV, to limit the maximum possible pressure peaks in the lines. 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
Pressure Test Port
Location
SRV 66.2
M11 (High pressure filter)
Control block III, section B2
SRV 66.10
M13 (High pressure filter)
Control block IV, section B2
MRV circuit III
M11 (High pressure filter)
Control block III
MRV circuit IV
M13 (High pressure filter)
Control block IV
1. Connect gauges to all test ports listed above. 2. Start engine and let it run at high idle. 3. Retract the bucket cylinder to the stop position until the hydraulic system stalls. 4. Slowly increase the pump circuit pressure by turning in set-screws (Fig. 8-35, Pos. 3) of MRVs in the control blocks, while observing the pressure gauges. Stop as soon as the pressure does not rise any further. The gauge pointers should remain at 350±5 bar. NOTE: Since the piston rod side of the bucket cylinders are protected by several SRVs, the pressure gauges show the pressure of the valve with the lowest setting. Even if 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. 5. Remove protective cap (Fig. 8-35, Pos. 1) of MRV. 6. Loosen lock nut (Fig. 8-35, Pos. 2). 7. Turn set-screw (Fig. 8-35, Pos. 3) of both MRVs ½ a turn further in. 8. Tighten lock nut (Fig. 8-35, Pos. 2) and install cap (Fig. 8-35, Pos. 1).
Version 2010/1
8-71
Hydraulics for the attachment cylinder FSA and BHA
Fig. 8-36
8-72
OPERATING HYDRAULICS
Checks and adjustments of the secondary relief valves (SRV)
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the attachment cylinder FSA and BHA
9. Adjust both SRVs equally until all gauges show a pressure of 350±5 bar. Adjust in steps of ¼ turn of set-screw (Fig. 8-36, Pos. 3) in the following sequence: z
66.2 Ö 66.10
z
Remove protective cap (Fig. 8-36, Pos. 1) of SRVs.
z
Loosen lock nut (Fig. 8-36, Pos. 2).
z
Turn set-screw (Fig. 8-36, Pos. 3) clockwise to increase pressure, or counter-clockwise to decrease pressure.
z
Tighten lock nut (Fig. 8-36, Pos. 2) and install cap (Fig. 8-36, Pos. 1).
10. Reduce the pressure at SRV 66.2 to a value below the required value, and then increase up to the required pressure (350±5 bar), while observing all gauges. NOTE: Now all gauges will show the same value of 350±5 bar, but only SRV 66.2 has the correct setting. 11. Proceed with the other valve in the same manner.
WARNING 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 secondary relief valves.
12. Reset the MRVs to 310+5 bar after the check / adjustment is finished, as follows: z
Remove protective cap (Fig. 8-36, Pos. 1).
z
Loosen lock nut (Fig. 8-36, Pos. 2).
z
Turn set-screw (Fig. 8-36, Pos. 3) clockwise to increase pressure, or counter-clockwise to decrease pressure.
z
Tighten lock nut (Fig. 8-36, Pos. 2) and install cap (Fig. 8-36, Pos. 1).
NOTE: It is important that the valve bodies of MRV and SRVs are firmly tightened (with 300 Nm). Otherwise the internal sealing is not properly, which results in loud flow noises and wrong adjustments.
Version 2010/1
8-73
Hydraulics for the attachment cylinder FSA and BHA
Fig. 8-37
8-74
OPERATING HYDRAULICS
Checks and adjustments of the secondary relief valves (SRV)
Version 2010/1
OPERATING HYDRAULICS
8.2.18.5
Hydraulics for the attachment cylinder FSA and BHA
BUCKET CYLINDER "PISTON ROD SIDE" BHA
There are 3 secondary relief valves (SRVs) installed at the distributor manifold (Fig. 8-37, Pos. 42) to limit the maximum possible pressure peaks in the lines. 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
Pressure Test Port
Location
SRV 70.5
M18
Manifold (Fig. 8-37, Pos. 42), section D
SRV 70.7
M20
Manifold (Fig. 8-37, Pos. 42), section G
SRV 70.11
M23
Manifold (Fig. 8-37, Pos. 42), section L
MRV circuit IV
M11 (High pressure filter)
Control block III
1. Connect gauges to all above listed test ports. 2. Start engine and let it run at high idle. 3. Extend the bucket cylinder to the stop position until the hydraulic system stalls. 4. Slowly increase the pump circuit pressure by turning in set-screws (Fig. 8-37, Pos. 3) of MRV in control block III, while observing the pressure gauges. Stop as soon as the pressure does not rise any further. The gauge pointers should remain at 350±5 bar. NOTE: Since the piston rod side of the bucket cylinders are protected by several SRVs, the pressure gauges show the pressure of the valve with the lowest setting. Even if 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. 5. Remove protective cap (Fig. 8-37, Pos. 1) of MRV. 6. Loosen lock nut (Fig. 8-37, Pos. 2). 7. Turn set-screw (Fig. 8-37, Pos. 3) of both MRVs ½ a turn further in; the gauge pointers will remain at the value shown in step 4 (350±5 bar). 8. Tighten lock nut (Fig. 8-37, Pos. 2) and install cap (Fig. 8-37, Pos. 1).
Version 2010/1
8-75
Hydraulics for the attachment cylinder FSA and BHA
Fig. 8-38
8-76
OPERATING HYDRAULICS
Checks and adjustments of the secondary relief valves (SRV)
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the attachment cylinder FSA and BHA
9. Adjust all 3 SRVs equally until all gauges show a pressure of 350±5 bar. Adjust in steps of ¼ turn of set-screw (Fig. 8-38, Pos. 3) in the following sequence: z
70.5 Ö 70.7 Ö 70.11
z
Remove protective cap (Fig. 8-38, Pos. 1) of SRVs.
z
Loosen lock nut (Fig. 8-38, Pos. 2).
z
Turn set-screw (Fig. 8-38, Pos. 3) clockwise to increase pressure, or counter-clockwise to decrease pressure.
z
Tighten lock nut (Fig. 8-38, Pos. 2) and install cap (Fig. 8-38, Pos. 1).
10. Reduce the pressure at SRV 70.5 to a value below the required value, and then increase up to the required pressure (350±5 bar), while observing all gauges. NOTE: Now all gauges will show the same value of 350±5 bar, but only SRV 70.5 has the correct setting. 11. Proceed with the other valves in the same manner in the following sequence: z
70.7 Ö 70.11
WARNING 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 3 secondary relief valves.
12. Reset the MRVs to 310+5 bar after the check/adjustment is finished, as follows: z
Remove protective cap (Fig. 8-38, Pos. 1).
z
Loosen lock nut (Fig. 8-38, Pos. 2).
z
Turn set-screw (Fig. 8-38, Pos. 3) clockwise to increase pressure, or counter-clockwise to decrease pressure.
z
Tighten lock nut (Fig. 8-38, Pos. 2) and install cap (Fig. 8-38, Pos. 1).
NOTE: It is important that the valve bodies of MRVs and SRVs are firmly tightened (with 300 Nm). Otherwise the internal sealing is not properly, which results in loud flow noises and wrong adjustments.
Version 2010/1
8-77
Hydraulics for the attachment cylinder FSA and BHA
Fig. 8-39
8-78
OPERATING HYDRAULICS
Checks and adjustments of the secondary relief valves (SRV)
Version 2010/1
OPERATING HYDRAULICS
8.2.18.6
Hydraulics for the attachment cylinder FSA and BHA
CLAM CYLINDER "PISTON ROD SIDE" FSA
There is one secondary relief valve (SRV) installed at the distributor manifold (Fig. 8-39, Pos. 42) to limit the maximum possible pressure peaks in the lines. 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
Pressure Test Port
Location
SRV 70.6
M19
Manifold (Fig. 8-39, Pos. 42), section E
MRV cicuit II
M12 (High pressure filter)
Control block II
1. Connect gauges to the test ports listed above. 2. Start engine and let it run at high idle. 3. Retract the clam cylinder (open the bucket) to the stop position until the hydraulic system stalls. 4. Slowly increase the pump circuit pressure by turning in set-screws (Fig. 8-39, Pos. 3) of MRV in control block II, while observing the pressure gauges. Stop as soon as the pressure does not rise any further. The gauge pointers should remain at 350±5 bar. If necessary, correct the adjustment as follows: 1. Remove protective cap (Fig. 8-39, Pos. 1) of MRV. 2. Loosen lock nut (Fig. 8-39, Pos. 2). 3. Turn set-screw (Fig. 8-39, Pos. 3) of the MRV ½ a turn further in; the gauge pointers will remain at the value shown in step 4 (350±5 bar). 4. Tighten lock nut (Fig. 8-39, Pos. 2) and install cap (Fig. 8-39, Pos. 1). 5. Reduce the pressure at SRV 70.6 to a value below the required value, and then increase up to the required pressure (350±5 bar), while observing all gauges. 6. Reset the MRV to 310+5 bar after adjustment is finished, as follows: z
Remove protective cap (Fig. 8-39, Pos. 1).
z
Loosen lock nut (Fig. 8-39, Pos. 2).
z
Turn set-screw (Fig. 8-39, Pos. 3) clockwise to increase pressure, or counter-clockwise to decrease pressure.
z
Tighten lock nut (Fig. 8-39, Pos. 2) and install cap (Fig. 8-39, Pos. 1).
NOTE: It is important that the valve bodies of MRV and SRV are firmly tightened (with 300 Nm). Otherwise the internal sealing is not properly, which results in loud flow noises and wrong adjustments.
Version 2010/1
8-79
Hydraulics for the attachment cylinder FSA and BHA
Fig. 8-40
8-80
OPERATING HYDRAULICS
Checks and adjustments of the secondary relief valves (SRV)
Version 2010/1
OPERATING HYDRAULICS
8.2.18.7
Hydraulics for the attachment cylinder FSA and BHA
CLAM CYLINDER "PISTON SIDE" FSA
There are 2 secondary relief valves (SRVs) installed, 1 at distributor manifold (Fig. 8-40, Pos. 42), and 1 in main control block II, to limit the maximum possible pressure in the lines when closing the bucket. To avoid damages at the clam shell due to improper operation, the SRVs should be adjusted in a way that the pressure is just sufficient to keep the bucket closed. Valve
Pressure Test Port
Location
SRV 18
M18
Manifold (Fig. 8-40, Pos. 42), section K
SRV 45
M12 (High pressure filter)
Control block II
1. Connect gauges to all test ports listed above. 2. Start engine and let it run at high idle. 3. Raise the attachment and bring the back wall of the bucket into horizontal position. 4. Press the pedal "bucket closing" until the hydraulic system stalls. Release the pedal back to neutral position. The bucket must stay closed. That means the clam-cylinders must not be retracted by the force (weight) of the clam shell. Adjust the SRVs as follows: z
Remove protective cap (Fig. 8-40, Pos. 1) of SRVs.
z
Loosen lock nut (Fig. 8-40, Pos. 2).
z
Turn set-screw (Fig. 8-40, Pos. 3) clockwise to increase pressure, or counter-clockwise to decrease pressure.
z
Tighten lock nut (Fig. 8-40, Pos. 2) and install cap (Fig. 8-40, Pos. 1).
5. Adjust both SRVs equally until the gauges show a pressure of 150±30 bar. NOTE: Since the piston side of the clam cylinders are protected by several SRVs, the pressure gauges show the pressure of the valve with the lowest setting. For standard buckets the pressure is 150 bar, reinforced or with heavy wear package attached, the pressure may be raised up to 180 bar. ###
Version 2010/1
8-81
Hydraulics for the attachment cylinder FSA and BHA
Fig. 8-41
8-82
OPERATING HYDRAULICS
Checks and adjustments of the lowering speed
Version 2010/1
OPERATING HYDRAULICS
8.2.18.8
Hydraulics for the attachment cylinder FSA and BHA
CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED
General On excavators equipped with face shovel attachment (FSA), there are two different operation modes for lowering the boom and stick: 1. Floating position activated, the lowering speed is restricted by the stroke limiters (Fig. 8-41, Pos. 1) of the single control blocks (Fig. 8-41, Pos. 2). (Standard adjustment: ’fully open’) 2. Floating position deactivated, the lowering speed has to be adjusted at the the flow restrictors (throttle valves) at the distributor manifold (Fig. 8-41, Pos. 42). On excavators equipped with backhoe attachment (BHA), the lowering speed has to be adjusted at the flow restrictors only (no floating system installed). Purpose of the flow restrictors: z
To avoid an interruption (stops during movements) of the pump delivery.
z
To provide smooth cylinder movement.
z
To limit the return oil flow through the control block to the maximum permissible volume.
Checks and adjustments: z
Standard test method is measuring the total cylinder running time (from start to final stop) by using a stop watch.
z
Basic adjustment of all restrictors as follows: z
For easy turning of set-screw (Fig. 8-41, Pos. 3), lower the attachment to ground, stop motor and allow pressure equalising by moving the joysticks several times.
z
Loosen the lock nut (Fig. 8-41, Pos. 4) and turn the bolt (Fig. 8-41, Pos. 3) cw. for more restriction and ccw. for less restricton. If more than one restrictor is used for one movement make sure all set-screws are equally adjusted.
NOTE: For the values to be set, refer to column "Nominal" in the PM-CLINIC data sheet for the respective attachment (FSA / BHA), see following illustrations (extracts – sample only). FSA:
BHA:
Version 2010/1
8-83
Hydraulics for the attachment cylinder FSA and BHA
OPERATING HYDRAULICS
NOTE: During commissioning, a standard throttle valve adjustment has to be carried out. For safety reasons, the throttle valves are basically adjusted before the machine is leaving the factory. For more information, refer to PM CLINIC.
Fig. 8-42
8-84
Checks and adjustments of the lowering speed (boom cylinder FSA)
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the attachment cylinder FSA and BHA
Boom cylinder FSA Due to the 2 different operation modes for lowering the boom, the lowering speed must be adjusted twice: 1. Floating position activated 2. Floating position deactivated Maximum permissible lowering speed Refer to the PM-CLINIC sheet for your machine. Adjustments / checks (floating position activated): 1. Use a stop watch to measure the time for the cylinder movement (from start to final stop). NOTE: Pay attention to measure the time of the cylinder movement only. 2. Raise the fully extended attachment with empty bucket to the maximum height position (Fig. 8-42, Pos. A). 3. Run the engine at high idle. 4. Lower the attachment; do not press button 20S095 (floating position switch). Rapidly move the control lever 20S019 to the front end position (start stop watch when the boom starts moving) and hold the control lever in this position until the final position (Fig. 8-42, Pos. B) is reached (stop the stop watch). NOTE: Lower the boom so that the bucket stops just above the ground. 5. If the lowering speed is too high (measured time is less than the permissible time), the speed must be reduced by adjusting the stroke limiter of the single control block (Fig. 8-42, Pos. 61Q635). Adjust as follows: z
To decrease the lowering speed, loosen the lock nut (Fig. 8-42, Pos. 2) and turn the bolt (Fig. 8-42, Pos. 1) clockwise.
z
To increase the lowering speed, loosen the lock nut (Fig. 8-42, Pos. 2) and turn the bolt (Fig. 8-42, Pos. 1) counter-clockwise.
6. Check the lowering speed again and repeat the adjustment, if necessary. 7. If the adjustment is finished, tighten lock nut (Fig. 8-42, Pos. 2).
Version 2010/1
8-85
Hydraulics for the attachment cylinder FSA and BHA
Fig. 8-43
8-86
OPERATING HYDRAULICS
Checks and adjustments of the lowering speed (boom cylinder FSA)
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the attachment cylinder FSA and BHA
Maximum permissible lowering speed: Refer to the PM-CLINIC sheet for your machine. Adjustments / checks (floating position deactivated). 1. Use a stop watch to measure the time for the cylinder movement. 2. Raise the fully extended attachment with empty bucket to the maximum height position (Fig. 8-43, Pos. A). 3. Run the engine at high idle. 4. Press push-button 20S095 and keep it depressed while lowering the attachment. Rapidly move the control lever (Fig. 8-43, Pos. 20S019) to the front end position (start the stop watch) and hold it in this position until the final position (Fig. 8-43, Pos. B) is reached (stop the stop watch). NOTE: Lower the boom so that the bucket stops just above the ground. 5. If the lowering speed is too high (measured time is less than the permissible time), the speed must be reduced by adjusting the throttle valves 70.1, 70.2 and 70.13 at the distributor manifold (Fig. 8-43, Pos. 42). Adjust as follows: z
To decrease the lowering speed, loosen the lock nut (Fig. 8-43, Pos. 2) and turn the bolt (Fig. 8-43, Pos. 1) clockwise.
z
To increase the lowering speed, loosen the lock nut (Fig. 8-43, Pos. 2) and turn the bolt (Fig. 8-43, Pos. 1) counter-clockwise.
NOTE: There are several throttle valves mounted in the return line. The return oil flow oil flow of the boom cylinder through the throttle valves must be set synchronously. All valves have to be adjusted in a way the bolts are turned in by the same amount of revolutions.
6. Check lowering speed again and repeat the adjustment, if necessary. 7. If the adjustment is finished, tighten lock nut (Fig. 8-43, Pos. 2).
Version 2010/1
8-87
Hydraulics for the attachment cylinder FSA and BHA
Fig. 8-44
8-88
OPERATING HYDRAULICS
Checks and adjustments of the lowering speed (boom cylinder BHA)
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the attachment cylinder FSA and BHA
Boom cylinder BHA Maximum permissible lowering speed: Refer to the PM-CLINIC sheet for your machine. Adjustments / checks: 1. Use a stop watch to measure the time for the cylinder movement. 2. Raise the fully extended attachment with empty bucket to the maximum height position (Fig. 8-44, Pos. A). 3. Run the engine at high idle. 4. Rapidly move the control lever (Fig. 8-44, Pos. 20S019) to the front end position (start the stop watch) and hold it in this position until the final position of the boom (Fig. 8-44, Pos. B) is reached.(stop the stop watch). NOTE: Lower the boom so that the bucket stops just above the ground. 5. If the lowering speed is too high (measured time is less than the permissible time), the speed must be reduced by adjusting the throttle valves 70.1, 70.2 , 70.13 and 70.14 at the distributor manifold (Fig. 8-44, Pos. 42). Adjust as follows: z
To decrease the lowering speed, loosen the lock nut (Fig. 8-44, Pos. 2) and turn the bolt (Fig. 8-44, Pos. 1) clockwise.
z
To increase the lowering speed, loosen the lock nut (Fig. 8-44, Pos. 2) and turn the bolt (Fig. 8-44, Pos. 1) counter-clockwise.
NOTE: There are several throttle valves mounted in the return line. The return oil flow oil flow of the boom cylinder through the throttle valves must be set synchronously. All valves have to be adjusted in a way the bolts are turned in by the same amount of revolutions. 6. Check lowering speed again and repeat the adjustment, if necessary. 7. If the adjustment is finished, tighten lock nut (Fig. 8-44, Pos. 2).
Version 2010/1
8-89
Hydraulics for the attachment cylinder FSA and BHA
Fig. 8-45
8-90
OPERATING HYDRAULICS
Checks and adjustments of the lowering speed (stick cylinder FSA)
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the attachment cylinder FSA and BHA
Stick cylinder FSA Due to the two different operation modes for lowering the stick, the lowering speed must be adjusted twice: 1. Floating position activated 2. Floating position deactivated Maximum permissible lowering speed: Refer to the PM-CLINIC sheet for your machine. Adjustments / checks (floating position activated): 1. Use a stop watch to measure the time for the cylinder movement. 2. Raise the fully extended attachment with empty bucket to the maximum height position (Fig. 8-45, Pos. A). 3. Run the engine at high idle. 4. Rapidly move the control lever (Fig. 8-45, Pos. 20S020) to the rear end position (start the stop watch) and hold it in this position until the final position (Fig. 8-45, Pos. B) is reached (stop the stop watch). 5. If the lowering speed is too high (measured time is less than the permissible time), the speed must be reduced by adjusting the stroke limiter of the single control block (Fig. 8-45, Pos. 60Q632, 60Q633 and 60Q634). Adjust as follows: z
To decrease the lowering speed, loosen the lock nut (Fig. 8-45, Pos. 2) and turn the bolt (Fig. 8-42, Pos. 1) clockwise.
z
To increase the lowering speed, loosen the lock nut (Fig. 8-45, Pos. 2) and turn the bolt (Fig. 8-42, Pos. 1) counter-clockwise.
NOTE: Since there are several single control blocks used for the stick movement, make sure that all stroke limiters are equally adjusted. 6. Check lowering speed again and repeat the adjustment, if necessary. 7. If the adjustment is finished, tighten lock nut (Fig. 8-45, Pos. 2).
Version 2010/1
8-91
Hydraulics for the attachment cylinder FSA and BHA
Fig. 8-46
8-92
OPERATING HYDRAULICS
Checks and adjustments of the lowering speed (stick cylinder FSA)
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the attachment cylinder FSA and BHA
Maximum permissible lowering speed: Refer to the PM-CLINIC sheet for your machine. Adjustments / checks (floating position deactivated with push-button 20S098): 1. Use a stop watch to measure the time for the cylinder movement. 2. Raise the fully extended attachment with empty bucket to the maximum height position (Fig. 8-46, Pos. A). 3. Run the engine at high idle. 4. Press push-button 20S098 and keep it depressed while lowering the stick. Rapidly move the control lever (Fig. 8-46, Pos. 20S020) to the rear end position (start the stop watch) and hold it until the final position (Fig. 8-46, Pos. B) is reached (stop the stop watch). 5. If the lowering speed is too high (measured time is less than the permissible time), the speed must be reduced by adjusting the throttle valves 70.8 and 70.9 at the distributor manifold (Fig. 8-46, Pos. 42). Adjust as follows: z
To decrease the lowering speed, loosen the lock nut (Fig. 8-46, Pos. 2) and turn the bolt (Fig. 8-46, Pos. 2) clockwise.
z
To increase the lowering speed, loosen the lock nut (Fig. 8-46, Pos. 2) and turn the bolt (Fig. 8-46, Pos. 2) counter-clockwise.
NOTE: There are several throttle valves mounted in the return line. The return oil flow oil flow of the boom cylinder through the throttle valves must be set synchronously. All valves have to be adjusted in a way the bolts are turned in by the same amount of revolutions. 6. Check lowering speed again and repeat the adjustment, if necessary. 7. If the adjustment is finished, tighten lock nut (Fig. 8-46, Pos. 2).
Version 2010/1
8-93
Hydraulics for the attachment cylinder FSA and BHA
Fig. 8-47
8-94
OPERATING HYDRAULICS
Checks and adjustments of the lowering speed (stick cylinder BHA)
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the attachment cylinder FSA and BHA
Stick cylinder BHA Maximum permissible lowering speed: Refer to the PM-CLINIC sheet for your machine. Adjustments / checks: 1. Use a stop watch to measure the time for the cylinder movement. 2. Raise the fully extended attachment with empty bucket to the maximum height position (Fig. 8-47, Pos. A). 3. Run the engine at high idle. 4. Rapidly move the control lever (Fig. 8-47, Pos. 20S020) to the rear end position (start the stop watch) and hold it until the final position (Fig. 8-47, Pos. B) is reached (stop the stop watch). 5. If the lowering speed is too high (measured time is less than the permissible time), the speed must be reduced by adjusting the throttle valves 70.8, 70.9 and 70.10 at the distributor manifold (Fig. 8-47, Pos. 42). Adjust as follows: z
To decrease the lowering speed, loosen the lock nut (Fig. 8-47, Pos. 2) and turn the bolt (Fig. 8-47, Pos. 1) clockwise.
z
To increase the lowering speed, loosen the lock nut (Fig. 8-47, Pos. 2) and turn the bolt (Fig. 8-47, Pos. 1) counter-clockwise.
NOTE: There are several throttle valves mounted in the return line. The return oil flow oil flow of the boom cylinder through the throttle valves must be set synchronously. All valves have to be adjusted in a way the bolts are turned in by the same amount of revolutions. 6. Check lowering speed again and repeat the adjustment, if necessary. 7. If the adjustment is finished, tighten lock nut (Fig. 8-47, Pos. 2).
Version 2010/1
8-95
Hydraulics for the attachment cylinder FSA and BHA
Fig. 8-48
8-96
OPERATING HYDRAULICS
Checks and adjustments of the lowering speed (bucket cylinder FSA)
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the attachment cylinder FSA and BHA
Bucket cylinder FSA Maximum permissible lowering speed: Refer to the PM-CLINIC sheet for your machine. Adjustments / checks: 1. Use a stop watch to measure the time for the cylinder movement. 2. Raise the fully extended attachment with empty bucket to the maximum height position (Fig. 8-48, Pos. A). 3. Run the engine at high idle. 4. Rapidly move the control lever (Fig. 8-48, Pos. 20S019) to the r.h. end position (start the stop watch) and hold it until the final position (Fig. 8-48, Pos. B) is reached (stop the stop watch). 5. If the lowering speed is too high (measured time is less than the permissible time), the speed must be reduced by adjusting the throttle valves 70.4 and 70.12 at the distributor manifold (Fig. 8-48, Pos. 42). Adjust as follows: z
To decrease the lowering speed, loosen the lock nut (Fig. 8-48, Pos. 2) and turn the bolt (Fig. 8-48, Pos. 1) clockwise.
z
To increase the lowering speed, loosen the lock nut (Fig. 8-48, Pos. 2) and turn the bolt (Fig. 8-48, Pos. 1) counter-clockwise.
NOTE: There are several throttle valves mounted in the return line. The return oil flow oil flow of the boom cylinder through the throttle valves must be set synchronously. All valves have to be adjusted in a way the bolts are turned in by the same amount of revolutions. 6. Check lowering speed again and repeat the adjustment, if necessary. 7. If the adjustment is finished tighten lock nut (Fig. 8-48, Pos. 2).
Version 2010/1
8-97
Hydraulics for the attachment cylinder FSA and BHA
Fig. 8-49
8-98
OPERATING HYDRAULICS
Checks and adjustments of the lowering speed (bucket cylinder BHA)
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the attachment cylinder FSA and BHA
Bucket cylinder BHA Maximum permissible lowering speed: Refer to the PM-CLINIC sheet for your machine. Adjustments / checks: 1. Use a stop watch to measure the time for the cylinder movement. 2. Raise the fully extended attachment with empty bucket to the maximum height position (Fig. 8-49, Pos. A). 3. Run the engine at high idle. 4. Rapidly move the control lever (Fig. 8-49, Pos. 20S019) to the r.h. end position (start the stop watch) and hold it until the final position (Fig. 8-49, Pos. B) is reached (stop the stop watch). 5. If the lowering speed is too high (measured time is less than the permissible time), the speed must be reduced by adjusting the throttle valves 70.3, 70.4 and 70.12 at the distributor manifold (Fig. 8-49, Pos. 42). Adjust as follows: z
To decrease the lowering speed, loosen the lock nut (Fig. 8-49, Pos. 2) and turn the bolt (Fig. 8-49, Pos. 1) clockwise.
z
To increase the lowering speed, loosen the lock nut (Fig. 8-49, Pos. 2) and turn the bolt (Fig. 8-49, Pos. 1) counter-clockwise.
NOTE: There are several throttle valves mounted in the return line. The return oil flow oil flow of the boom cylinder through the throttle valves must be set synchronously. All valves have to be adjusted in a way the bolts are turned in by the same amount of revolutions. 6. Check lowering speed again and repeat the adjustment, if necessary. 7. If the adjustment is finished, tighten lock nut (Fig. 8-49, Pos. 2).
Version 2010/1
8-99
Hydraulics for the attachment cylinder FSA and BHA
Fig. 8-50
8-100
OPERATING HYDRAULICS
Checks and adjustments of the lowering speed (clam cylinder FSA)
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the attachment cylinder FSA and BHA
Clam cylinder BHA Maximum permissible lowering speed: Refer to the PM-CLINIC sheet for your machine. Adjustments / checks: 1. Use a stop watch to measure the time for the cylinder movement. 2. Open the clam of the empty bucket to the maximum height position (Fig. 8-50, Pos. A). 3. Run the engine at high idle. 4. Rapidly push the control pedal (Fig. 8-50, Pos. 20S023) to the end position (start the stop watch) and hold it until the final position (Fig. 8-50, Pos. B) is reached (stop the stop watch). 5. If the lowering speed is too high (measured time is less than the permissible time), the speed must be reduced by adjusting the throttle valve 70.6 at the distributor manifold (Fig. 8-50, Pos. 42). Adjust as follows: z
To decrease the lowering speed, loosen the lock nut (Fig. 8-50, Pos. 2) and turn the bolt (Fig. 8-50, Pos. 1) clockwise.
z
To increase the lowering speed, loosen the lock nut (Fig. 8-50, Pos. 2) and turn the bolt (Fig. 8-50, Pos. 1) counter-clockwise.
NOTE: There are several throttle valves mounted in the return line. The return oil flow oil flow of the boom cylinder through the throttle valves must be set synchronously. All valves have to be adjusted in a way the bolts are turned in by the same amount of revolutions. 6. Check lowering speed again and repeat the adjustment, if necessary. 7. If the adjustment is finished, tighten lock nut (Fig. 8-50, Pos. 2).
Version 2010/1
8-101
Hydraulics for the swing circuit
OPERATING HYDRAULICS
8.3
HYDRAULICS FOR THE SWING CIRCUIT
8.3.1
SWING CIRCUIT
Fig. 8-51
Swing circuit
8-102
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the swing circuit
Legend for Fig. 8-51: (1 + 3)
Main pumps
(9/III)
Control block
(10/I)
Control block
(16.1 + 16.2)
Manifold
(60.1 + 60.2)
Swing motors
Brief description (service circuits) The machine is equipped with a two speed swing system (also refer to the hydraulic and electric circuit diagram). The swing motors (Fig. 8-51, Pos. 60.1 + 60.2) are driven by the pumps (Fig. 8-51, Pos. 1 + 3). The oil flows from the pumps through high pressure filters to the control block (Fig. 8-51, Pos. 9/III) and (Fig. 8-51, Pos. 10/I). With the spools in neutral position, oil flows via the return oil line into the collector pipe (107) and further via the return oil lines (L6 + L7) back to the tank. On the way back to the tank the oil must flow through the back pressure valve (55) and the return oil filters (59.1 59.4). (For the back pressure valve function, refer to section 4.2 on page 4-4). When operating the control lever for "swinging", the pump line is connected in the control blocks (Fig. 8-51, Pos. 9/III and 10/I) with the corresponding service line (A1 or B1) to the swing motors (Fig. 8-51, Pos. 60.1 + 60.2). The oil flows from the control block through each of the swing brake valves (61.1 + 61.2; for description refer to section 8.3.7 on page 8-116) and the swing motors (Fig. 8-51, Pos. 60.1 + 60.2). Each swing gear includes one spring loaded multi-disk brake for locking the superstructure. The leak oil (case drain) flows through the lines (L18 + L19) and the leak oil filter (53) back to the tank.
Version 2010/1
8-103
Hydraulics for the swing circuit
Fig. 8-52
8-104
OPERATING HYDRAULICS
Swing circuit
Version 2010/1
OPERATING HYDRAULICS
Legend for Fig. 8-52: (1 + 3)
Main pumps
(9/III)
Control block
(10/I)
Control block
(14.1 + 14.2)
Remote control valve block
(16.1 + 16.2)
Manifold
(60.1 + 60.2)
Swing motors
(61K524) (61K525) (61K526) (61K527)
Directional solenoid valves
(61K565) (61K566)
Proportional solenoid valves
(57K620) (57K626)
Directional solenoid valves
(57Q627)
Proportional solenoid valves
(57K630) (57K631)
Directional solenoid valves
Hydraulics for the swing circuit
If swing speed switch 20S154 is activated, also proportional solenoid valve 61K566 and, depending on the swinging direction, directional solenoid valves 61K526 (swing right) or 61K527 (swing left) are energized. Simultaneously solenoid valves 57K630 and 57K626 (pump #1 fixed in ½ Qmax position) are energized, so that only a reduced oil flow from pump #1 will be added to increase the swing speed. I.e.: Swing speed fast = oil flow of pump #3 + reduced oil flow of pump #1
Description When the lever (Fig. 8-53, Pos. 20S020) is moved out of its neutral position, proportional solenoid valve 61K565 and solenoid valve 57K631 (pump #3 fixed in Qmax position) are energized. Simultaneously the directional solenoid valves 61K524 (swing right) or 61K525 (swing left) are energized. At the same time, by the function of proportional solenoid valve 57Q627, pilot pressure is present at port "X" of each brake valve block.
Fig. 8-53
I.e.: Swing speed low = only oil flow of pump #3
Version 2010/1
8-105
Hydraulics for the swing circuit
8.3.2
SWING MOTOR
Fig. 8-54
Axial piston motor A2FLM (with SL-bearing)
8-106
OPERATING HYDRAULICS
Version 2010/1
OPERATING HYDRAULICS
Legend for Fig. 8-54:
Hydraulics for the swing circuit
Description of the SL-bearing (SL = Slipper Bearing)
(1)
Drive shaft
(2)
Housing
(3)
Case drain port
(4)
Retaining plate
(5)
Piston
(5a)
Pivot (center) pin
(6a)
Upper dead point
(6b)
Lower dead point
The slipper pads support themselves on the thrust washer (Fig. 8-54, Pos. 14) and discharge axially the tapered roller bearing (Fig. 8-54, Pos. 11). Without pressure, the slipper pads are kept on the thrust washer by means of spring (Fig. 8-54, Pos. 12).
(7)
Cylinder
Function
(8)
Control lens
(9)
End plate
(10)
Centering spring
The pressure oil inlet (Fig. 8-54, Pos. A or B) and consequent oil outlet (Fig. 8-54, Pos. B or A) determine the output drive direction of the drive shaft (Fig. 8-54, Pos. 1).
(11)
Taper roller bearing
Direction of rotation:
(12)
Spring
(13)
Slipper pads
(14)
Thrust washer
(15)
Roller bearing
(16)
Circlip
(17)
Sealing flange
(18)
Radial seal ring
Axial piston motor A2FLM The axial piston units of product group A2FM with fixed displacement can operate as a hydraulic motor only. The drive speed is proportional to the consumption capacity. The output torque increases with the pressure drop between high and low pressure side. The motor converts hydrostatic energy into mechanical energy.
Version 2010/1
The main part of the axial forces is supported by the slipper pads (Fig. 8-54, Pos. 13) which are installed on the driving circular side of the drive shaft. Each piston is allocated to one slipper pad. These slipper pads are located in the cylinder chamber and get pressurized via piston borings (Fig. 8-54, Pos. 5).
"Clockwise" = Direction of flow A to B "Counter-clockwise" = Direction of flow B to A with view onto drive shaft! Via the control lens (Fig. 8-54, Pos. 8), the oil is directed to the cylinder bores. The piston (Fig. 8-54, Pos. 5) is moved from the lower (Fig. 8-54, Pos. 6b) to the upper dead point (Fig. 8-54, Pos. 6a) by means of the force acting on it and causes the drive shaft to rotate. On further rotation of the drive shaft (additional pistons are pressurized), this piston is moved towards the lower dead point again, and oil of the cylinder chamber is forced out through the kidney formed openings of the control lens. This oil is fed back to the tank via the return line. If the supply and return line is changed, it changes the output drive direction of the drive shaft. By means of the angled arrangement of the cylinder (Fig. 8-54, Pos. 7) (bent axis design), a certain piston stroke is produced which results in a fixed displacement per revolution of the drive shaft. According to the size of the applied flow, this produces a specific output speed.The output torque at the drive shaft is dependent on the size of the motor and the required operating pressure.
8-107
Hydraulics for the swing circuit
8.3.3
SWING GEARBOX (L&S)
Fig. 8-55
Swing gearbox (L&S)
8-108
OPERATING HYDRAULICS
Version 2010/1
OPERATING HYDRAULICS
Legend for Fig. 8-55: (1)
Drive housing
(2)
Drive shaft
(3)
Sun gear shaft
(4)
Multi-disk brake
(5)
Breather filter Drive shaft housing
(6)
Oil level gauge (dipstick) Drive shaft housing
(7)
Disk brake housing
(8)
Cylindrical roller bearing
(9)
Internal ring gear
(10)
Cylindrical roller bearing
(11)
Bearing ring
(12)
Cartridge
(13)
Spherical roller bearing
(14)
Oil drain plug, gearbox
(15)
Cylindrical roller bearing
(16)
Oil level gauge (dipstick) Gearbox
(17)
First planetary stage
(18)
Drive shaft to second stage
(19)
Second planetary stage
(20)
Radial seal ring
(21)
Drive pinion
(22)
Grease line port
Version 2010/1
Hydraulics for the swing circuit
The swing gear is of compact design with a two stage planetary gear including a multi-disk brake. The gear is bolted to the superstructure and fits firmly due to the machined diameter (Fig. 8-55, Pos. A) and the bolt torque. The torque loaded on the hydraulic motor is transmitted by drive shafts (Fig. 8-55, Pos. 2) and sun gear shaft (Fig. 8-55, Pos. 3) to the first planetary stage (Fig. 8-55, Pos. 17). The sun shaft of the first planetary stage (Fig. 8-55, Pos. 17) transmits the torque into the second planetary stage (Fig. 8-55, Pos. 19). By the planetary gears, the output drive shaft is rotated and transmits the torque to the pinion (Fig. 8-55, Pos. 21). The drive housing and the gearbox are filled with gear oil. Aeration is done by breather filters. To lubricate the pinion, the grease line port (Fig. 8-55, Pos. 22) is connected to the central lubrication system.
8-109
Hydraulics for the swing circuit
8.3.4
SWING GEARBOX (SIEBENHAAR)
Fig. 8-56
Swing gearbox (Siebenhaar)
8-110
OPERATING HYDRAULICS
Version 2010/1
OPERATING HYDRAULICS
Legend for Fig. 8-56: (1)
Drive housing
(2)
Drive shaft
(3)
Sun gear shaft
(4)
Multi-disk brake
(5)
Equalizing reservoir
(6)
Oil level gauge (dipstick), gearbox
(7)
Oil level gauge (diptick), parking brake
(8)
Adapter (gearbox / brake housing)
(9)
First planetary stage
(10)
Sun wheel (drive shaft to second stage)
(11)
Annulus gear
(12)
Spherical roller bearing
(13)
Oil drain plug, gearbox
(14)
Bearing center
(15)
Grease line port
(16)
Cylindrical roller bearing
(17)
Drive pinion
(18)
Shaft sealing rings
(19)
Fixed bearing bushing
(20)
Second planetary stage
(21)
Cylindrical roller bearings
(22)
Cylindrical roller bearings
(23)
Oil drain plug, parking brake
(24)
Pressure oil port, parking brake
(25)
Oil drain plug, motor
(26)
Oil filler pipe, gearbox
(27)
Oil level gauge (dipstick), motor
Version 2010/1
Hydraulics for the swing circuit
The swing gear is of compact design with a two stage planetary gear including a multi-disk brake. The gear is bolted to the superstructure and fits firmly due to the machined diameter (Fig. 8-56, Pos. A) and the bolt torque. The torque loaded on the hydraulic motor is transmitted by drive shaft (Fig. 8-56, Pos. 2) and sun gear shaft (Fig. 8-56, Pos. 3) to the first planetary stage (Fig. 8-56, Pos. 9). Through the pivot carrier of the planetary wheels, the torque is transmitted to sun wheel (Fig. 8-56, Pos. 10) of the second planetary stage (Fig. 8-56, Pos. 20). By the planetary gears of the second stage, the output drive shaft is rotated and transmits the torque to the pinion (Fig. 8-56, Pos. 17). Drive housing, gearbox and brake housing are filled with oil. Aeration is done by breather filters. NOTE: In opposition to the parking brake installed to the L&S swing gear, the SIEBENHAAR slew parking brake is not splash lubricated through gearbox oil. To lubricate the pinion, the grease line port (Fig. 8-56, Pos. 15) is connected to the central lubrication system.
8-111
Hydraulics for the swing circuit
8.3.5
SLEW PARKING BRAKE (L&S)
Fig. 8-57
Sew parking brake (L&S)
8-112
OPERATING HYDRAULICS
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the swing circuit
Legend for Fig. 8-57: (1)
Disk housing
(2)
Thrust washer
(3)
Inner disks (lamellas)
(4)
Outer disks (lamellas)
(5)
Sinus (spacing) ring
(6)
Piston
(7)
Quad-rings with back-up rings
(8)
Quad-ring with back-up rings
(9)
Springs
(10)
Thrust washer
(11)
Circlip
(12)
Drive shaft
(13)
Oil pressure port
The spring loaded multi-disk brake is a safety brake; applied by spring force and released by oil pressure. The slew parking brake is a "wet brake", because the brake housing is splash lubricated by the gearbox oil. Function Brake applied: The outer disks (Fig. 8-57, Pos. 4) engaged to the housing by serration and the inner disks (Fig. 8-57, Pos. 3) in serrated connection with drive shaft (Fig. 8-57, Pos. 12) are pressed together by the springs (Fig. 8-57, Pos. 9). This results in a fixed connection between housing and drive shaft. Brake released: Oil pressure via port (Fig. 8-57, Pos. 13) reaches the bottom of the piston (Fig. 8-57, Pos. 6) and forces the piston upwards against the thrust washer (Fig. 8-57, Pos. 10). This function eliminates the spring force onto the disks so that the sinus (spacing) rings can keep the outer disks (Fig. 8-57, Pos. 4) apart, thus the brake is released. The releasing pressure is 19-20 bar, the maximum permissible pressure 60 bar.
Version 2010/1
8-113
Hydraulics for the swing circuit
8.3.6
SLEW PARKING BRAKE (SIEBENHAAR)
Fig. 8-58
Slew parking brake (Siebenhaar)
8-114
OPERATING HYDRAULICS
Version 2010/1
OPERATING HYDRAULICS
Legend for Fig. 8-58: (1)
Outer disk (lamella)
(2)
Inner disk (lamella)
(3)
Oil drain plug
(4)
Pressure oil port
(5)
Piston
(6)
Springs
(7)
Ball bearing seal
(8)
Inner piston seal
(9)
Outer piston seal
(10)
Disk housing
(11)
Through-hole for attaching gearbox
(12)
Rotary shaft seal
(13)
Drive shaft
Hydraulics for the swing circuit
Function Brake applied: The outer disks (Fig. 8-58, Pos. 1) engaged to the housing by serration and the inner disks (Fig. 8-58, Pos. 2) in serrated connection with drive shaft (Fig. 8-58, Pos. 13) are pressed together by the springs (Fig. 8-58, Pos. 6). This results in a fixed connection between housing (Fig. 8-58, Pos. 11) and drive shaft. Brake released: Pressure oil runs through port (Fig. 8-58, Pos. 4) to the chamber between the piston (Fig. 8-58, Pos. 5) and the brake housing ring. The oil moves the piston upwards away from the brake disks (Fig. 8-58, Pos. 1 and 2) when the resulting force exceeds the force of the springs (Fig. 8-58, Pos. 6). When the piston is lifted, the spring force onto the disks is eliminated. The required releasing pressure is 19-20 bar, the maximum permissible pressure 60 bar.
The spring loaded multi-disk brake is a safety brake; applied by spring force and released by oil pressure. The slew parking brake is a "wet brake", because the brake disks are lubricated by the oil filling in the brake housing.
Version 2010/1
8-115
Hydraulics for the swing circuit
8.3.7
SWING BRAKE VALVE
Fig. 8-59
Swing brake valve
8-116
OPERATING HYDRAULICS
Version 2010/1
OPERATING HYDRAULICS
Legend for Fig. 8-59:
Hydraulics for the swing circuit
(Fig. 8-59, Pos. 1 or 2) and opens the check valves (Fig. 8-59, Pos. 3 or 4). That means by the check valves (Fig. 8-59, Pos. 3 or 4) the service lines are connected to the pressure increasing valve.
(1)
Anti-carvitation valve circuit A
(2)
Anti-cavitation valve circuit B
(3)
Check valve circuit B
(4)
Check valve circuit A
(5)
Pressure increasing valve (item 6 - 13)
(6)
Pilot pressure piston
(7)
Intermediate piston
(8)
Spring
(9)
Valve poppet
(10)
Jet bore
(11)
Spring of main piston
(12)
Jet bore of main piston plug
(13)
Main piston
Function of the double stage valve
(Y)
Leak oil
When ever a swing motion is carried out or the foot brake is used, pilot pressure arrives the pressure increasing valve (Fig. 8-59, Pos. 5) at port "X". The pilot pressure pre-loads these valves.
(T)
Return oil
(A)
Service line from control block
(A’)
Service line to the motor
(B)
Service line from control block
(B’)
Service line to the motor
Ports:
Pressure test ports: (MA)
Circuit A
(MB)
Circuit B
Function When ever a swing motion is carried out or the foot brake is used, pilot pressure arrives at the pressure increasing valve (Fig. 8-59, Pos. 5) at port "X". The pilot pressure pre-loads these low stages. The oil for the hydraulic motor from the control block arrives at the service line port A or B, depending if a R.H. or a L.H. swing motion is carried out with max. MRV pressure.
Whenever the pressure is higher than the setting of the pressure increasing valve, this valve opens and dumps the oil into the return line (Fig. 8-59, Pos. T) to tank. The pressure can be checked at the test ports MA or MB. If after a swing motion the joystick is put into neutral position without using the foot brake, the superstructure is turned by inertial force and the hydraulic motor acts as a pump because it is driven by the swing gear. In this period the pressure in the service line is lower than the pressure in the return line, because there is a back pressure valve at the tank line, and oil is forced through the anti-cavitation valves into the service line.
By applying pilot pressure via the external port X to piston (Fig. 8-59, Pos. 6), the pre-tensioning of the pressure spring (Fig. 8-59, Pos. 8) 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 (Fig. 8-59, Pos. 13) and via the jet bore (Fig. 8-59, Pos. 12) also in the chamber of the spring (Fig. 8-59, Pos. 11) and via the jet bore (Fig. 8-59, Pos. 10) at the pressure relief valve poppet (Fig. 8-59, Pos. 9). Due to the force balance, the piston (Fig. 8-59, Pos. 13) is kept in its position supported by the spring (Fig. 8-59, Pos. 11). Does the system pressure exceed the setting of the valve (Fig. 8-59, Pos. 9), this valve opens a channel to the dump line port (Fig. 8-59, Pos. Y). Due to the drop of force, the piston (Fig. 8-59, Pos. 13) is moved to the right. The pressure line gets connected with the return line (Fig. 8-59, Pos. T). The shuttle valves 270.1 and 270.2 stabilize the pilot pressure for the double stage valve (lower stage) to avoid pressure sequences when starting swinging.
The ports A and B are internally connected to the ports A’ and B’, and these ports in turn with the hydraulic motor. The operating pressure, either at port A or B closes the anti-cavitation valves Version 2010/1
8-117
Hydraulics for the swing circuit
OPERATING HYDRAULICS
8.3.8
ELECTRIC / HYDRAULIC FLOWCHART "SWING LEFT"
Fig. 8-60
Electric / hydraulic flowchart "swing left"
8-118
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the swing circuit
Legend for Fig. 8-60: (20S020)
Control lever (joystick)
(20S022)
Control pedal swing brake
(-X)
Direction (axis) of joystick
(-10V)
Signal voltage (maximum)
(11X_…)
Terminal rail with number
(11T050 / 50a / 50b)
Ramp time modules
(11T007)
Amplifier module – swing (61K565 + 61K524 / 61K525 - Block III)
(11T007a)
Amplifier module – swing (61K566 + 61K526 / 61K527 - Block I)
(11T016)
Amplifier module – swing brake
(11K080)
Relay - Contacts 7/11 only closed while rotating with swing speed switch 20S154 activated and not lifting the boom.
(11Q190)
Relay - Swing brake without ramp time - Contacts 5/9 and 6/10 only closed while using the brake pedal
(14.1 + 14.2)
Remote control valve block
(61K565 + 61K566)
Proportional solenoid valve
(61K524 + 61K526)
Directional solenoid valve
(61QK627)
Proportional solenoid valve
(I + III)
Main control blocks I + III
(16.2)
Distributor manifold
(61.1 + 61.2)
Swing brake valve block
(DSV)
Double stage valve
(60.1 + 60.2)
Swing motor
(270.1 + 270.2)
Shuttle valve
The electrical signal Signal voltage of joystick (Fig. 8-60, Pos. 20S020) arrives via ramp time modules (Fig. 8-60, Pos. 11T050/a) at terminal 5 of the amplifier modules (Fig. 8-60, Pos. 11T007 + 11T007a) and further to the proportional and directional solenoid valves of the remote control blocks (Fig. 8-60, Pos. 14.1 + 14.2). Simultaneously, signal voltage arrives via ramp time modules (Fig. 8-60, Pos. 11T050b) at terminal 5 of the amplifier modules (Fig. 8-60, Pos. 11T016) and further to the proportional valve (Fig. 8-60, Pos. 57Q627). Pilot pressure When the proportional and directional solenoid valves are energized, pilot pressure oil flows to the pressure ports of the main control blocks and to the double stage valves (Fig. 8-60, Pos. DSV). Main hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (Fig. 8-60, Pos. I + III) and arrives via swing brake valves (Fig. 8-60, Pos. 61.1 + 61.2) at the swing motors (Fig. 8-60, Pos. 60.1 + 60.2).
Version 2010/1
8-119
Hydraulics for the swing circuit
OPERATING HYDRAULICS
8.3.9
ELECTRIC / HYDRAULIC FLOWCHART "SWING RIGHT"
Fig. 8-61
Electric / hydraulic flowchart "swing right"
8-120
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the swing circuit
Legend for Fig. 8-61: (20S020)
Control lever (joystick)
(20S022)
Control pedal swing brake
(+X)
Direction (axis) of joystick
(+10V)
Signal voltage (maximum)
(11X_…)
Terminal rail with number
(11T050 / 50a / 50b)
Ramp time modules
(11T007)
Amplifier module – swing (61K565 + 61K524/61K525 - Block III)
(11T007a)
Amplifier module – swing (61K566 + 61K526/61K527 - Block I)
(11T016)
Amplifier module – swing brake
(11K080)
Relay – Contacts 7/11 only closed while rotating with swing speed switch 20S154 activated and not lifting the boom.
(11Q190)
Relay – Swing brake without ramp time – Contacts 5/9 and 6/10 only closed while using the brake pedal
(14.1 + 14.2)
Remote control valve block
(61K565 + 61K566)
Proportional solenoid valve
(61K524 + 61K526)
Directional solenoid valve
(57Q627)
Proportional solenoid valve
(I + III)
Main control blocks I + III
(16.1)
Distributor manifold
(61.1 + 61.2)
Swing brake valve block
(DSV)
Double stage valve
(60.1 + 60.2)
Swing motor
(270.1 + 270.2)
Shuttle valve
The electrical signal Signal voltage of joystick (Fig. 8-61, Pos. 20S020) arrives via ramp time modules (Fig. 8-61, Pos. 11T0E50,-a) at terminal 5 of the amplifier modules (Fig. 8-61, Pos. 11T007 + 11T007a) and further to the proportional and directional solenoid valves of the remote control blocks (Fig. 8-61, Pos. 14.1 + 14.2). Simultaneously, signal voltage arrives via ramp time modules (Fig. 8-61, Pos. 11T050b) at terminal 5 of the amplifier modules (Fig. 8-61, Pos. 11T016) and further to the proportional valve (Fig. 8-61, Pos. 57Q627). Pilot pressure When the proportional and directional solenoid valves are energized, pilot pressure oil flows to the pressure ports of the main control blocks and to the double stage valves (Fig. 8-61, Pos. DSV). Main hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (Fig. 8-61, Pos. I + III) and arrives via swing brake valves (Fig. 8-61, Pos. 61.1 + 61.2) at the swing motors (Fig. 8-61, Pos. 60.1 + 60.2).
Version 2010/1
8-121
Hydraulics for the swing circuit
OPERATING HYDRAULICS
8.3.10
CHECKS AND ADJUSTMENTS FOR THE SWING CIRCUIT
Fig. 8-62
Checks and adjustments for the swing circuit
8-122
Version 2010/1
OPERATING HYDRAULICS
Legend for Fig. 8-62: (M33)
Test port – pressure increasing valve
(M41)
"X1" pressure – fixed pump No. 3 (X1 = 45 bar)
(M42)
"X1" pressure – fixed pump No. 1 (X1 = 45 bar)
(M32)
Reduced "X3" pressure – to pump No. 1
(255.4)
Pressure reducing valve – reduced "X3" pressure (½ Qmax)
(57K626)
Solenoid valve – flow reduction (pump No. 1)
(57K630)
Solenoid valve – fixed pump (pump No. 1)
(57K631)
Solenoid valve – fixed pump (pump No. 3)
Hydraulics for the swing circuit
4. Read pressure while swinging. Required values at 5 turns: 20S154 = ON (fast)
20S154 = OFF (slow)
M33 = 15 bar
M33 = 45 bar
M41 = 45 bar
M41 = 45 bar
M42 = 45 bar
M42 = 34 bar
time = 75–80 sec
time = 150–160 sec
WARNING WARNING Do not exceed the maximum permissible swing speed of 5 turns within 75 sec.
NOTE: Note down the pressures and speeds in sec. as reference values. If adjustment is necessary:
1. Connect pressure gauges to test ports M33, M41 and M42. 2. Start the engine and let it run at high idle. 3. Move the control lever (Fig. 8-63, Pos. 20S020) to the end position (L.H. or R.H.) with activated and deactivated swing speed switch (Fig. 8-63, Pos. 20S154). Swing 5 turns and start counting the time in seconds .
5. Loosen lock nut (Fig. 8-62, Pos. 2). 6. Adjust the pressure with set-screw (Fig. 8-62, Pos. 1). 7. Tighten lock nut and remove the gauges.
Fig. 8-63 Version 2010/1
8-123
Hydraulics for the swing circuit
Fig. 8-64
8-124
OPERATING HYDRAULICS
Checks and adjustments for the swing circuit
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the swing circuit
NOTE: It is important that the complete MRV and the double stage valve is firmly tightened (with 300 Nm). Otherwise, internal leaks could occur which result in: problems of incorrect adjustment, loud flow noises, abnormal swing movements and high temperatures. NOTE: Whenever pressure checks are carried out, they must be carried out for both, R.H. and L.H. swinging to make sure the shuttle valves in the control lines and the check valves in the brake valve blocks are in good condition. NOTE: Because the swing motors are working hydraulically in combined operation, the pressure gauge shows the pressure of the double stage valve with the lowest setting. Even if 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 gauges to test ports M11 and M14 at the high pressure filters. 2. Disconnect the pilot pressure lines from the double stage valve and close the lines with a suitable plug (Fig 8-64, Pos. 6). 3. Loosen lock nut (Fig. 8-64, Pos. 3) of both double stage valves (DSV) and screw in set-screw (Fig. 8-64, Pos. 4) until piston (Fig. 8-64, Pos. 5) comes to stop. 4. Start the engine and let it run at high idle. 5. Lower attachment to ground and apply the slew parking brake with switch 20S029. 6. Adjust the MRVs to ~350 bar. 7. Actuate either L.H. or R.H. rotation (20S154 ON) until the hydraulic system stalls. Read the pressure, required = 330±5 bar. 8. If the gauge shows a lower or higher value, the valves must be adjusted: z
Loosen lock nut (Fig. 8-64, Pos. 1) of the second stage (330 bar) of the DSV.
z
Adjust pressure with set-screw (Fig. 8-64, Pos. 2) to ~340 bar. If the pressure can not be raised, turn set-screw (Fig. 8-64, Pos. 2) of the second DSV a ¼ turn (cw.) further in.
z
Secure by tightening lock nut (Fig. 8-64, Pos. 1).
z
Reduce the pressure with set-screw (Fig. 8-64, Pos. 2) to a value of ~320 bar, and then raise the pressure up to the required value of 330 bar.
z
Secure adjusted set-screw (Fig. 8-64, Pos. 2) by tightening lock nut (Fig. 8-64, Pos. 1).
z
Reduce the pressure with set-screw (Fig. 8-64, Pos. 2) of the first DSV to a value of ~320 bar, and then raise the pressure up to the required value of 330 bar.
z
Secure adjusted set-screw (Fig. 8-64, Pos. 2) by tightening lock nut (Fig. 8-64, Pos. 1).
Version 2010/1
8-125
Hydraulics for the swing circuit
OPERATING HYDRAULICS
Ho
Fig. 8-65
8-126
Checks and adjustments for the swing circuit
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the swing circuit
Low pressure check / adjustment (swing brake pedal with pilot pressure line still disconnected) 9. Actuate either L.H. or R.H. rotation (20S154 ON) until the hydraulic system stalls. z
Loosen lock nut (Fig. 8-65, Pos. 3) of both DSVs and reduce the pressure equally with set-screws (Fig. 8-65, Pos. 4) to a value of 130±5 bar, secure setting with lock nut (Fig. 8-65, Pos. 3).
z
Loosen lock nut (Fig. 8-65, Pos. 3) of the first DSV.
z
Reduce the pressure with set-screw (Fig. 8-65, Pos. 4) of the first DSV to a value of about 110 bar, and then raise up to the required pressure of 130±5 bar.
z
Secure adjusted set-screw (Fig. 8-65, Pos. 4) by tightening lock nut (Fig. 8-65, Pos. 3).
z
Loosen lock nut (Fig. 8-65, Pos. 3) of the second DSV.
z
Reduce the pressure with set-screw (Fig. 8-65, Pos. 4) of the second DSV to a value of about 110 bar, and then raise up to the required pressure of 130±5 bar.
z
Secure adjusted set-screw (Fig. 8-65, Pos. 4) by tightening lock nut (Fig. 8-65, Pos. 3).
10. Re-plug and connect the pilot pressure lines. 11. Re-set MRVs to 310+5 bar and remove the gauges after the check / adjustment is finished.
WARNING Strong pulsation of the return line hoses indicates deviation in opening pressure of DSVs and must be avoided. Repeat the adjusting procedure until the oil returns well-balanced via both double stage valves.
Brake pilot pressure – check / adjustment 1. Connect the gauge to test port M27. 2. Start the engine and let it run at high idle. 3. Press down the swing brake pedal (20S022) fully and read the pressure. The pressure must be 24±1 bar. If adjustment is required: 4. Adjust the output (mA) of the amplifier (11T016) with potentiometer R2 until the pressure of 24±1 bar is reached. NOTE: For basic values for the amplifiers, refer to the electric circuit diagram of your shovel.
Version 2010/1
8-127
Hydraulics for the swing circuit
OPERATING HYDRAULICS
8.3.11
FUNCTION CHECK FOR THE HYDRAULIC SWING BRAKE
Fig. 8-66
Function check for hydraulic swing brake
8-128
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the swing circuit
Legend for Fig. 8-66: (M39)
Test port
(20S022)
Switch – position of acces ladder
(20S105)
Switch – lock lever
(57K620)
Solenoid valve – hydraulic swing brake ON - OFF
(57Q627)
Proportional solenoid valve – hydraulic swing brake
Safety circuit (automatic actuation) The hydraulic swing brake will be applied automatically when the access ladder and/or the service arm of the central refilling system is not in its completely upper position and/or if the lock lever is not in the lower end position. Brake apply pressure 1. Connect a gauge to test port M39 (Fig. 8-66). 2. Start the engine and let it run at high idle. 3. Lift the access ladder to the upper end position. 4. Check the pressure at test port M39 under the following conditons: z
Lock lever in lower end position and ladder completely up. No message should appear on the monitor.
0 bar => released.
z
Lock lever in lower end position and ladder completely down. Message G00091 "Pilot control cut out" should appear.
45 bar => applied.
z
Lock lever in upper end position and ladder completely up. Message G00091 "Pilot control cut out" should appear.
45 bar => applied.
Operation circuit (manual actuation through joystick or brake pedal) To shorten the braking angle of the superstructure, either the brake pedal must be actuated or a counter action of the joystick is required. As a result, proportional valve 57Q627 will vary the pilot pressure at the double stage valves (DSV) in relation to the lever deflection. 5. Apply the slew parking brake. Therefore, move switch (Fig. 8-68, Pos. 20S029) into position "1". 6. Actuate either the joystick (L.H. or R.H.) or the swing brake pedal and read the pressure. Required: 0 24 bar (variable, i.e. proportional to the lever deflection) 7. Disconnect the pressure gauge. NOTE: In case of malfunction, check the electrical control system and the function of solenoid valve 57K6120 and/or 57Q627.
Version 2010/1
8-129
Hydraulics for the swing circuit
OPERATING HYDRAULICS
8.3.12
FUNCTION CHECK FOR THE SLEW PARKING BRAKE
Fig. 8-67
Function check for the slew parking brake
8-130
Version 2010/1
OPERATING HYDRAULICS
Legend for Fig. 8-67: (20P047)
Monitor MH 801
(M1.2)
Pressure test port (X2 – pilot pressure)
(57Q505)
Solenoid valve – slew parking brake ON - OFF
(252.1)
Pressure reducing valve
Parking brake release pressure 1. Connect gauge to test port (Fig. 8-67, Pos. M1.2). 2. Start engine, let it run at high idle and read the pressure. Required = 45±1 bar. If not, the pilot pressure adjustment must be corrected (refer to section 5.3.2 on page 5-36). 3. Apply the slew parking brake. Therefore, move switch (Fig. 8-68, Pos. 20S029) into position "1", now the following message G00247 should appear:
Hydraulics for the swing circuit
4. Actuate either L.H. or R.H. swinging, the machine should not turn.
WARNING WARNING If the machine turns, the parking brakes must be repaired.
5. Release the slew parking brake. Therefore, move switch (Fig. 8-68, Pos. 20S029) into position "0"; now the swing function must be executable again, and message G00247 should disappear from the monitor. NOTE: In case of malfunction, check the electrical control system and the function of solenoid valve 57Q505. Function check of relays 56K250a & b 1. Connect a pressure gauge to test port (Fig. 8-67, Pos. M5).
z
Slew ring gear house brake
2. Start the engine and let it run at high idle. Pilot pressure X2 = 45±1 bar.
z
Instruction message 26: Slew ring gear house brake ON
3. Move switch position "0".
(Fig. 8-68,
Pos. 20S029)
into
4. Unplug / reconnect solenoid valve 57Q505 to allow pressure relief / increase from pilot pressure line to slew parking brake. 5. Select the "Real Time Monitor Menu" at the monitor and check whether the signal of 57Q505 has changed from "1" to "0". NOTE: 20S029 in position "0" Ö 57Q505= 1 = 45 bar Ö at Real Time Monitor 56K250a = 1 and 56K250b = 1 Ö Slew parking brake OFF 20S029 in position "1" Ö 57Q505= 0 = 0 bar Ö at Real Time Monitor 56K250a = 0 and 56K250b = 0 Ö Slew parking brake ON
Fig. 8-68
Version 2010/1
8-131
Hydraulics for the travel circuit
OPERATING HYDRAULICS
8.4
HYDRAULICS FOR THE TRAVEL CIRCUIT
8.4.1
TRAVEL CIRCUIT
Fig. 8-69
Travel circuit
8-132
Version 2010/1
OPERATING HYDRAULICS
Legend for Fig. 8-69: (2 + 4)
Main pumps
(II + IV)
Control blocks
(15.1 + 15.2)
Remote control valve blocks
(19)
Rotary distributor
(21.1 + 21.2)
Travel motors
(41)
Main oil reservoir
(55)
Back pressure valve
(56.1 + 56.2)
Travel brake valves
(57.1 + 57.2)
Travel parking (house) brakes
(M4)
Pressure test port for parking brake release pressure
(57Q516)
Solenoid valve for travel parking brake
(L9)
Case drain (leak oil) line
(St)
Pilot pressure line to the travel parking brake
Hydraulics for the travel circuit
Description (control circuits) (Also use the hydraulic and electric circuit diagram). When the pedals 20S021a and 20S021b are moved out of their neutral position, the proportional solenoid valves 61K567 & 61K570 and the directional solenoid valves 61K528 or 61K529 (R.H. crawler) and 61K534 or 61K535 (L.H. crawler) are energized simultaneously.
Fig. 8-70
Version 2010/1
(20S021a) Control pedal – left track
A – forward => 61K570 + 61K535
(20S021b) Control pedal – right track
A – forward => 61K567 +61K528
B – reverse => 61K570 + 61K534
B – reverse => 61K567 +61K529
8-133
Hydraulics for the travel circuit
Fig. 8-71
8-134
OPERATING HYDRAULICS
Travel circuit
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the travel circuit
Description (Also use the hydraulic and electric circuit diagram.) The travel motors (Fig. 8-71, Po. 21.1 and 21.2) are driven by the pumps (Fig. 8-71, Pos. 2 and 4). The oil flows from the pumps through the high pressure filters to the control blocks (Fig. 8-71, Pos. II and IV). In neutral position of the spools the oil flows via the return oil lines into the return manifold (107) and further via the return oil lines (L6 and L7) into the collector pipe (54), and further through the filter back to the tank. On its way to the tank the oil must flow through the back pressure valve (Fig. 8-71, Pos. 55) and the return oil filter (59.1 - 59.4). (For back pressure valve function refer to section 4.2 on page 4-4.) 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 (Fig. 8-71, Pos. 19) and travel brake valves (Fig. 8-71, Pos. 56.1 and 56.2) to the travel motors (Fig. 8-71, Pos. 21.1 and 21.2). The travel brake valve acts as a flow control valve in order to avoid the travel motors picking up speed when travelling downhill. Each travel gear includes a spring loaded multi-disk brake (house brakes 57.1 and 57.2). They are used as parking brakes, automatically applied by the function of 57Q516 whenever the engine is switched OFF, or the ladder or the refilling arm is in bottom position. The leak oil (case drain) flows through the line (Fig. 8-71, Pos. L9) and the leak oil filter (53) back to the tank.
Version 2010/1
8-135
Hydraulics for the travel circuit
8.4.2
TRAVEL MOTOR
Fig. 8-72
Travel motor
8-136
OPERATING HYDRAULICS
Version 2010/1
OPERATING HYDRAULICS
Legend for Fig. 8-72:
Hydraulics for the travel circuit
Function The pressure oil inlet (Fig. 8-72, Pos. A or B) and consequent oil outlet (Fig. 8-72, Pos. B or A) determine the output drive direction of the drive shaft (Fig. 8-72, Pos. 1).
(1)
Drive shaft
(2)
Housing
(3)
Case drain port
(4)
Retaining plate
(5)
Piston
"Clockwise"
= Direction of flow A to B
(5a)
Pivot (center) pin
"Counter-clockwise"
= Direction of flow B to A
(6a)
Upper dead point
(6b)
Lower dead point
(7)
Cylinder
(8)
Control lens
(9)
End plate
(10)
Taper roller bearing
(11)
Roller bearing
(12)
Thrust washer
(13)
Circlip
(14)
Circlip
(15)
Sealing flange
(16)
Radial seal ring
Direction of rotation:
with view onto drive shaft! Via the control lens (Fig. 8-72, Pos. 8), the oil is directed to the cylinder bores. The piston (Fig. 8-72, Pos. 5) is moved from the lower (Fig. 8-72, Pos. 6b) to the upper point (Fig. 8-72, Pos. 6a) by means of the force acting on it and causes the drive shaft to rotate. On further rotation of the drive shaft (additional pistons are pressurized), this piston is moved towards the lower point again and oil of the cylinder chamber is forced out through the kidney formed openings of the control lens. This oil is fed back to the tank via the return line. If the supply and return line are interchanged, the output drive direction of the drive shaft is changed. By means of the angled arrangement of the cylinder (Fig. 8-72, Pos. 7) (bent axis design), a certain piston stroke is produced which results in a fixed displacement per revolution of the drive shaft.
Axial Piston Motor A2FLM The axial piston units of product group A2FM with fixed displacement can operate as a hydraulic motor only. The drive speed is proportional to the consumption capacity.
According to the size of the applied flow, this produces a specific output speed. The output torque at the drive shaft is dependent on the size of the motor and the required operating pressure.
The output torque increases with the pressure drop between high and low pressure side. The motor converts hydrostatic energy into mechanical energy.
Version 2010/1
8-137
Hydraulics for the travel circuit
8.4.3
ROTARY JOINT
Fig. 8-73
Rotary joint
8-138
OPERATING HYDRAULICS
Version 2010/1
OPERATING HYDRAULICS
Legend for Fig. 8-73: (1)
Rotor
(2)
Rotary distributor housing
(3)
Cover
(4)
Bearing ring (splitted)
(5)
Sealing element
(6)
Seal
(7)
Rotor guide rings
(8)
O-ring
(9)
Plug screws
(10)
Mover
Ports: (A - D)
Service lines
(K1 / K2)
Control oil track tensioning
(L)
Leak oil
(ST)
Control oil
(T)
Return oil to tank
Hydraulics for the travel circuit
Function During operation superstructure and under carriage constantly rotate towards each other. Nevertheless, the travel oil motors must be supplied with hydraulic oil in every position in which the superstructure is moved in regard to the undercarriage. Oil is directed by the control blocks to the ports (Fig. 8-73, Pos. A - D) of the housing (Fig. 8-73, Pos. 2). The oil flows to the outlet ports (Fig. 8-73, Pos. A - D), of the rotor (Fig. 8-73, Pos. 1), via ring grooves as well as longitudinal and cross holes. The rotor is bolted to the under carriage. The sealing of the ring grooves among one another is done by sealing elements (Fig. 8-73, Pos. 5). The hydraulic connection for case drain, house brake and the track tensioning cylinders is done via the ports (Fig. 8-73, Pos. L, St, K1 and K2). Entering of dirt is prevented by the seal ring (Fig. 8-73, Pos. 6) and the collar of the cover (Fig. 8-73, Pos. 3). The rotor (Fig. 8-73, Pos. 1) is at the top and bottom section guided in the housing by the guide rings (Fig. 8-73, Pos. 7).
The letters punch marked, beside the ports are marked as they are used in the hydraulic diagram. Task The rotary distributor (joint) permits a hydraulic connection between the superstructure and the undercarriage, that means between the rotating and the stationary part.
Version 2010/1
8-139
Hydraulics for the travel circuit
8.4.4
TRAVEL GEARBOX (L&S)
Fig. 8-74
Travel gearbox (L&S)
8-140
OPERATING HYDRAULICS
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the travel circuit
Legend for Fig. 8-74: (1)
Input drive shaft
(2)
Spur gear
(3)
Sun gear first stage
(4)
Planetary ring gear first stage
(5)
Planetary carrier first stage
(6)
Planetary ring gear second stage
(7)
Sun gear second stage
(8)
Planetary carrier second stage
(9)
Side frame mounting flange
(10)
Motor adapter and brake housing
(11)
Multi-disk house brake
The travel gear consists of one spur gear set and two planetary stages. The travel gearbox is fitted to the side frame with bolts. Function The spur gear (Fig. 8-74, Pos. 2) is driven by a hydraulic motor and the input drive shaft (Fig. 8-74, Pos. 1). The planetary carrier (Fig. 8-74, Pos. 5) of the fist stage is driven by the sun gear (Fig. 8-74, Pos. 3) which is connected to the spur gear (Fig. 8-74, Pos. 2). The planetary gears are revolving in the planetary ring gear of the housing. As a result of the fixed housing, the planetary carrier will be turned. The planetary carrier (Fig. 8-74, Pos. 8) of the second stage is turned by the sun gear (Fig. 8-74, Pos. 7) which is connected to the sprocket drive shaft.
Version 2010/1
8-141
Hydraulics for the travel circuit
8.4.5
TRAVEL GEARBOX (ZOLLERN)
Fig. 8-75
Travel gearbox (Zollern)
8-142
OPERATING HYDRAULICS
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the travel circuit
Legend for Fig. 8-75: (1)
Input drive shaft
(2)
Parking brake housing
(3)
Motor adapter
(4)
Spur gear
(5)
Sun gear, first stage
(6)
Planetary ring gear, first stage
(7)
Planetary carrier, first stage
(8)
Planetary ring gear, second stage
(9)
Sun gear, second stage
(10)
Planetary carrier, second stage
(11)
Side frame mounting flange
The travel gear consists of one spur gear set and two planetary stages. The travel gearbox is fitted to the side frame with bolts. Function The spur gear (Fig. 8-75, Pos. 4) is driven by a hydraulic motor connected to the input drive shaft (Fig. 8-75, Pos. 1) by means of the hollow shaft ot the parking brake (Fig. 8-75, Pos. 2) . The planetary carrier (Fig. 8-75, Pos. 7) of the first stage is driven by the sun gear (Fig. 8-75, Pos. 5) which is connected to the spur gear (Fig. 8-75, Pos. 4). The planetary gears are revolving in the planetary ring gear (Fig. 8-75, Pos. 6) of the housing. As a result of the fixed housing, the planetary carrier (Fig. 8-75, Pos. 7) will be turned. The planetary carrier of the first stage propels the sun gear (Fig. 8-75, Pos. 9) of the second stage. Like in the first stage, the planetary gears are revolving in a planetary ring gear (Fig. 8-75, Pos. 8) of the housing. The planetary carrier of the second stage (Fig. 8-75, Pos. 10) simultaneously acts as the sprocket drive hub.
Version 2010/1
8-143
Hydraulics for the travel circuit
OPERATING HYDRAULICS
8.4.6
TRAVEL PARKING BRAKE (GEAR HOUSE BRAKE)
Fig. 8-76
Travel parking brake (gear house brake) ZOLLERN (exemplarily)
8-144
Version 2010/1
OPERATING HYDRAULICS
Legend for Fig. 8-76: (1)
Outer disk carrier (brake housing)
(2)
Intermediate ring (hydraulic unit with piston)
(3)
Seals
(4)
Piston
(5)
Pressure oil port
(6)
Motor flange
(7)
Compression spring
(8)
Travel gear housing
(9)
Inner disk carrier / drive sleeve
(10)
Inner brake disk
(11)
Outer brake disk
The spring loaded multi-disk brake is a safety brake; applied by spring force and released by oil pressure.
Hydraulics for the travel circuit
Function Brake applied: By means of toothings, the outer disks (Fig. 8-76, Pos. 11) are engaged to the housing (Fig. 8-76, Pos. 1), the inner disks (Fig. 8-76, Pos. 10) to the disk carrier / drive sleeve (Fig. 8-76, Pos. 9). Inner and outer disks are pressed together by the piston (Fig. 8-76, Pos. 4) with the force of the springs (Fig. 8-76, Pos. 7). This results in a fixed connection between housing and inner disk carrier / drive sleeve (Fig. 8-76, Pos. 11). Brake released: Pressure oil runs through port (Fig. 8-76, Pos. 5) to the chamber between intermediate ring (Fig. 8-76, Pos. 2) and piston (Fig. 8-76, Pos. 4). When the resulting force of the oil pressure exceeds the force of the compression springs, the piston is moved away form the brake disks to the motor flange. Now the disk are not longer pressed against each other, the brake is released. The minimum releasing pressure is 19-20 bar, the maximum permissible pressure 60 bar. The ZOLLERN parking brake is a "dry brake", no oil is permissible in the housing / on the brake disks.
WARNING WARNING The parking brake in the L&S gearbox has a similar design, but is a so called "wet brake" with an oil filling in the brake housing.
NOTE: For more information refer to the OPERATION AND MAINTENANCE MANUAL of the corresponding machine.
Version 2010/1
8-145
Hydraulics for the travel circuit
8.4.7
TRAVEL BRAKE VALVE
Fig. 8-77
Travel brake valve
8-146
OPERATING HYDRAULICS
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the travel circuit
Task Travel brake valves control the oil flow from the hydraulic motor to the tank depending on the operating pressure. This braking action prevents the motors from overspeeding and cavitation. 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 and from B to B1 respectively, depending on the selected travel motion. Example Operating pressure at port A moves the spool (Fig. 8-77, Pos. 1) against the force of the spring (Fig. 8-77, Pos. 2) and opens the way for the return oil (Fig. 8-77, Pos. B1 to B). The check valve (Fig. 8-77, Pos. 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 the travel motion of the machine.
Version 2010/1
8-147
Hydraulics for the travel circuit
OPERATING HYDRAULICS
8.4.8
ELECTRIC / HYDRAULIC FLOWCHART “TRAVEL FORWARD”
Fig. 8-78
Electric / hydraulic flowchart “travel forward”
8-148
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the travel circuit
Legend for Fig. 8-78: (20S021a)
Foot pedal left crawler
(20S021b)
Foot pedal right crawler
(+10V)
Signal voltage (maximum)
(11X_…)
Terminal rail with number
(11T051) (11T052)
Ramp time module
(11T012)
Amplifier module – left crawler
(11T013)
Amplifier module – right crawler
(15.1 + 15.2)
Remote control valves
(61K567) (61K570)
Proportional solenoid valve
(61K528) (61K535)
Directional solenoid valve
(II + IV)
Main control blocks
(19)
Rotary joint
(21.1 + 21.2)
Hydraulic motors
(56.1 + 56.2)
Travel brake valves
Electrical signal flow The signal voltage of the foot pedals (Fig. 8-78, Pos. 20S021a + 20S021b) arrives via ramp time module (Fig. 8-78, Pos. 11T051 + 11T052) at terminal 5 of the amplifier modules (Fig. 8-78, Pos. 11T012 and 11T013) and runs further to the proportional and directional solenoid valves of the remote control blocks (Fig. 8-78, Pos. 15.1 and 15.2). 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 main control blocks according to the amplifier output signal [mA]. Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (Fig. 8-78, Pos. II and IV) and arrives via rotary joint (Fig. 8-78, Pos. 19) and travel brake valves (Fig. 8-78, Pos. 56.1 and 56.2) at the hydraulic travel motors.
Version 2010/1
8-149
Hydraulics for the travel circuit
OPERATING HYDRAULICS
8.4.9
ELECTRIC / HYDRAULIC FLOWCHART “TRAVEL BACKWARDS”
Fig. 8-79
Electric / hydraulic flowchart “travel backwards”
8-150
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the travel circuit
Legend for Fig. 8-79: (20S021a)
Foot pedal left crawler
(20S021b)
Foot pedal right crawler
(-10V)
Signal voltage (maximum)
(11X_…)
Terminal rail with number
(11T051) (11T052)
Ramp time module
(11T012)
Amplifier module – left crawler
(11T013)
Amplifier module – right crawler
(15.1 + 15.2)
Remote control valves
(61K567) (61K570)
Proportional solenoid valve
(61K529) (61K534)
Directional solenoid valve
(II + IV)
Main control blocks
(19)
Rotary joint
(21.1 + 21.2)
Hydraulic motors
(56.1 + 56.2)
Travel brake valves
Electrical signal flow The signal voltage of the foot pedals (Fig. 8-79, Pos. 20S021a + 20S021b) arrives via ramp time module (Fig. 8-79, Pos. 11T051 + 11T052) at terminal 5 of the amplifier modules (Fig. 8-79, Pos. 11T012 and 11T013) and runs further to the proportional and directional solenoid valves of the remote control blocks (Fig. 8-79, Pos. 15.1 and 15.2). 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 main control blocks. Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (Fig. 8-79, Pos. II and IV) and arrives via rotary joint (Fig. 8-79, Pos. 19) and travel brake valves (Fig. 8-79, Pos. 56.1 and 56.2) at the hydraulic travel motors.
Version 2010/1
8-151
Hydraulics for the travel circuit
OPERATING HYDRAULICS
8.4.10
CHECKS AND ADJUSTMENTS FOR THE TRAVEL CIRCUIT
Fig. 8-80
Checks and adjustments for the travel circuit
8-152
Version 2010/1
OPERATING HYDRAULICS
Legend for Fig. 8-80:
Hydraulics for the travel circuit
Adjusting the SRVs: 1. Set the MRVs to 310+5 bar.
(1)
Protective cap
(2)
Lock nut
(3)
Set-screw
(19)
Rotary joint
(56.1 + 56.2)
Travel brake valves
(68.3 + 68.4)
Anti-cavitation valves L.H.
3. Lower the pressure at the required SRV to 290 bar, and then increase it up to the required pressure of 310 bar. Proceed with next valves in the same manner.
(68.3 + 68.4)
Anti-cavitation valves R.H.
4. Replug solenoid valve 57Q516.
(M12 – M28.4)
Pressure test ports
2. Carefully engage the desired travel motion and keep the pedal in final position to built up max. pressure.
How to adjust MRVs and SRVs:
Pressure check of the secondary relief valves (SRV)
1. Remove protective cap (Fig. 8-80, Pos. 1) and loosen lock nut (Fig. 8-80, Pos. 2).
1. Connect pressure gauge to the required test ports:
2. Adjust pressure with set-screw (Fig. 8-80, Pos. 3).
z
z
L.H. track M12 = Operating pressure for the L.H. motor M28.1 = SRV pressure L.H., travel forward M28.2 = SRV pressure L.H., travel backward R.H. track M13 = Operating pressure for the R.H.-motor M28.3 = SRV pressure R.H., travel forward M28.4 = SRV pressure R.H., travel backward
2. Unplug solenoid valve 57Q516 (located at the valve cartridge block) to keep the parking brake applied.
3. Secure the adjustment by tightening lock nut (Fig. 8-80, Pos. 2) and replace cap (Fig. 8-80, Pos. 1). 4. Re-check pressure setting. NOTE: It is important that the complete MRV valve and the SRV valve is firmly tightened (with 300 Nm). Otherwise internal leaks could occur, which result in: problems of correct adjustment, loud flow noises and hydraulic temperatures higher than normal.
3. Start the engine and let it run at high idle. 4. Carefully engage the desired travel motion and keep the pedal in final position to built up max. pressure. 5. Slowly increase the MRV pressure while observing the pressure gauge. The displayed value must remain at 310+5 bar. If the gauge shows a smaller or greater value, the SRV must be adjusted. NOTE: A faulty anti-cavitation valve (Fig. 8-80, Pos. 68.3 + 68.4, 68.6 + 68.7) or a leaking seal of the rotary joint (Fig. 8-80, Pos. 19) can influence the SRV pressure reading / setting. Repair or replace faulty parts, if necessary.
Version 2010/1
8-153
Hydraulics for the travel circuit
OPERATING HYDRAULICS
8.4.11
FUNCTION CHECK FOR THE TRAVEL PARKING BRAKE
Fig. 8-81
Function check for the travel parking brake
8-154
Version 2010/1
OPERATING HYDRAULICS
Hydraulics for the travel circuit
Legend for Fig. 8-81: (252.1)
Pressure reducing valve
(20P047)
Monitor MH 801
(M1.2 – M4)
Pressure test ports
(57Q516)
Solenoid valve
Travel parking brake release pressure 1. Connect a pressure gauge to test port (M1.2). 2. Start the engine and let it run at high idle. 3. Read the pressure (required = 45±1 bar). If differing from the nominal value, the pilot pressure adjustment must be corrected (refer to section 5.3 on page 5-32). 4. Disconnect solenoid valve 57Q516. Now the following message should appear over 56K251a/b: z
G00175 "Trouble travel gear house brake"
5. Operate the travel pedals; the machine should not travel.
WARNING If the machine moves, the travel parking brake is defective and must be repaired.
6. Replug solenoid valve 57Q516. Now the trouble message should disappear and travelling should be possible again. NOTE: In case of malfunction check the electrical control system and the function of the solenoid valve 57Q516. NOTE: If the signals for 56K251a/b on the Real Time Monitor screen show "1", the travel parking brake should be released by the pressurized oil: Real Time Monitor "0" Ù Travel parking brake applied (ON) Real Time Monitor "1" Ù Travel parking brake released (OFF)
Version 2010/1
8-155
Hydraulics for the travel circuit
8-156
OPERATING HYDRAULICS
Version 2010/1
HYDRAULIC TRACK TENSIONING SYSTEM
9. HYDRAULIC TRACK TENSIONING SYSTEM
Version 2010/1
9-1
General
HYDRAULIC TRACK TENSIONING SYSTEM
9.1
GENERAL
Fig. 9-1
Overall view of the hydraulic track tensioning system
9-2
Version 2010/1
HYDRAULIC TRACK TENSIONING SYSTEM
General
Legend for Fig. 9-1: (19)
Rotary joint
(62.1)
Shut-off cock at the track tensioning valve block (130)
(62.2)
Service / transport shut-off cock for L.H. side
*("O" = open / "C" = closed)
(62.3)
Service / transport shut-off cock for R.H. side
*("O" = open / "C" = closed)
(82.1 + 82.2)
Bladder accumulator, 5 liters (pre-charge gas pressure: 150 bar)
(83.1 – 83.4)
Track tensioning cylinders
(89.1 + 89.2)
Membrane accumulator, 0,7 liter (pre-charge gas pressure: 31 bar)
(130)
Track tensioning valve block
(L11)
Supply line (travel parking brake circuit)
(M29.1 + M29.5)
Bleeder and hydraulic pressure test ports at the tensioning cylinders, L.H. side
(M29.2 + M29.6)
Bleeder and hydraulic pressure test ports at the tensioning cylinders, R.H. side
(M29.3)
Bleeder and hydraulic pressure test port at the bladder accumulator (82.1), L.H.-side.
(M29.4)
Bleeder and hydraulic pressure test port at the bladder accumulator (82.2), R.H.-side.
General information The hydraulic track tensioning system automatically ensures the correct tension of the tracks. The track tensioning pressure (35 bar) provides the force to move the guide wheels to the front until the correct track tension is obained. The track safety function is controlled by valve block 130 with a double stage valve (35/310 bar). Pressure peaks due to external forces acting on the idlers will be absorbed by means of the pressure accumulators of the first (31 bar / 89.1 + 89.2) and second stage (150 bar / 82.1 + 82.2). Heavy shocks and high pressure peaks will be eliminated by the double stage valve of the 310 bar section in the valve block (130).
CAUTION After the assembly and during comissioning, before the shovel moves for the first time, each track tensioning cylinder has to be bled via the test ports (29.1 / 29.2 / 29.5 / 29.6) until air-free oil is draining off.
CAUTION Under normal operating conditions, the shut-off cocks (62.2 & 62.3) inside the side frames must always be open. Only for service or repair reasons, the cocks may be shut.
CAUTION The accumulators (89.1, 89.2, 82.1, 82.2) are to be maintained frequently (every 3000 hours) because of the gas pressure charge. See KMG tool catalogue for the charging tool box. After 30,000 hours, the accumulators are to be replaced by new ones.
Version 2010/1
9-3
Functional description
9.2
FUNCTIONAL DESCRIPTION
Fig. 9-2
Circuit diagram of the hydraulic track tensioning system
9-4
HYDRAULIC TRACK TENSIONING SYSTEM
Version 2010/1
HYDRAULIC TRACK TENSIONING SYSTEM
Functional description
X2 pressure (45 bar) is supplied by the travel parking brake circuit via valve 57Q516 in case the access ladder and the refilling arm are in upper end position. The pressure for the track tensioning system is limited to 35 bar by the pressure reducing valve (47) with a built-in non-return valve to prevent high pressure peaks in the pilot pressure circuit. When the tensioning cylinders (83.1 – 83.4) are moved in by external forces, the non-return valves (137.1 & 137.2) will be closed. A certain amount of the displaced oil from the tensioning cylinders is taken up by the pressure accumulators First stage: At a pressure higher than 31 bar, oil is taken up by the membrane accumulators (89.1 & 89.2) mounted at the side frames. Second stage: At a pressure higher than 150 bar, oil is taken up by the bladder accumulators (82.1 & 82.2) in the middle of the car body. The system pressure can rise up to 310 bar according to the setting of the double stage valve (140) inside the valve block (130). When the external forces fall below the forces of the track tensioning cylinders, the oil taken up by the accumulators is pushed back into the track tensioning cylinders (83.1 – 83.4). If not the whole amount of oil could be taken up the accumulators beforehand, oil is added from the pilot pressure circuit (35 bar) when the tensioning cylinders move in their initial position.
Version 2010/1
9-5
Pressure double stage valve
HYDRAULIC TRACK TENSIONING SYSTEM
9.3
PRESSURE DOUBLE STAGE VALVE
Fig. 9-3
Pressure double stage valve
9-6
Version 2010/1
HYDRAULIC TRACK TENSIONING SYSTEM
Pressure double stage valve
Legend for Fig. 9-3: (1)
Pilot valve with valve seat
(2)
Valve poppet
(3)
Compression spring
(4)
Main valve with sleeve
(5)
Main piston
(6)
Closing spring
(7)
Set screw – low pressure (35 bar)
(8)
Set screw – high pressure (310 bar)
(9)
Piston
(10)
Pin
(11 + 12)
Jet bore
(13 +14)
Lock nut
Description The pressure double stage valve is a remote controlled secondary relief valve at 310 bar. Function The valve poppet (Fig. 9-3, Pos. 2) is connected to port "P" via jet bores (Fig. 9-3, Pos. 11 and 12). If static pressure increases above the set pressure value, the valve poppet (Fig. 9-3, Pos. 2) opens and allows the oil to flow freely to the tank (Fig. 9-3, Pos. T1). This oil generates a pressure drop in the spring chamber of the main spool, the closing force of the spring (Fig. 9-3, Pos. 6) is cancelled, and the main piston (Fig. 9-3, Pos. 5) opens to allow the oil flow to the tank (Fig. 9-3, Pos. T2).
Version 2010/1
9-7
Tensioning cylinder
9.4
TENSIONING CYLINDER
Fig. 9-4
Tensioning cylinder
9-8
HYDRAULIC TRACK TENSIONING SYSTEM
Version 2010/1
HYDRAULIC TRACK TENSIONING SYSTEM
Tensioning cylinder
Legend for Fig. 9-4: (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)
Oil supply
Version 2010/1
9-9
Adjustments / checks
9.5
ADJUSTMENTS / CHECKS
Fig. 9-5
Adjustments / checks on hydraulic track tensioning system
9-10
HYDRAULIC TRACK TENSIONING SYSTEM
Version 2010/1
HYDRAULIC TRACK TENSIONING SYSTEM
Adjustments / checks
Legend for Fig. 9-4: (47)
Pressure reducing valve – track tensioning system (35 bar)
(57Q516)
Solenoid valve – travel parking brake
(257.1)
Safety relief valve (SRV) – safety valve for travel parking brake / track tensioning system (55 bar)
(M4)
Test port – travel parking brake operating pressure (35 bar)
Basic check 1. Connect a pressure gauge to test port M4. 2. Start the engine and let it run at high idle. 3. Ensure that the access ladder and the refilling arm are in the upper end position (as the pre-condition for releasing the travel parking brake). 4. Read the pressure (nominal value: 55 bar). 5. Stop the engine. 6. The pressure should now drop to 0 bar because solenoid valve is de-energized, allowing the oil to flow back to the tank. 7. Disconnect the pressure gauge. NOTE: If the pressure reading differs substantially from the nominal value, the pre-set pressure reducing valve is presumably defective and should be replaced.
Version 2010/1
9-11
Adjustments / checks
9-12
HYDRAULIC TRACK TENSIONING SYSTEM
Version 2010/1
ACCESS LADDER, HYDRAULICALLY OPERATED
10. ACCESS LADDER, HYDRAULICALLY OPERATED
Version 2010/1
10-1
General
ACCESS LADDER, HYDRAULICALLY OPERATED
10.1
GENERAL
Fig. 10-1
Overall view of the hydraulic access ladder
10-2
Version 2010/1
ACCESS LADDER, HYDRAULICALLY OPERATED
General
Legend for Fig. 10-1: (A)
Access ladder in upper position (working position)
(B)
Access ladder in lowered position
(1)
Stop bar
(2)
Pull chain for emergency lowering of the access ladder
(3)
Hydraulic cylinder
(70B091)
Monitor and control sensor This sensor monitors the ladder position and controls the moving speed of the ladder. In case the sensor (70B122) fails to function properly, the sensor (70B091) prevents unintended movement of the ladder.
(70B122)
Safety sensor, located on ladder pivot bracket Cut out of the pilot control system and actuation of the hydraulic swing brake with the ladder in lowered position.
(70S084)
Ladder control switch for lowering and lifting the ladder
(70S084a)
Safety switch for emergency lowering of the access ladder. When the chain (Fig. 10-12. Pos. 2) is being pulled down with the engine running, the pilot control system is made inoperative preventing further movement of the shovel.
The access ladder is hydraulically operated by the hydraulic cylinder (Fig. 10-1, Pos. 3) with the pilot pressure X2 of 45 bar. The movement of the ladder is controlled by the function of switch (70S084). Lifting the ladder is only possible with the engine running. The lowering movement is possible by hydraulic force with the engine running or by force of gravity with the engine at standstill. NOTE: If the ladder is not in the upper end position (70S122 not activated), the pilot control is switched off via relais 11K111a and 11K111b. Solenoid valve 57K620 activates the hydraulic slew parking brake and a message appears on the display in the operators cab.
Version 2010/1
10-3
Function of Hydraulically Operated Access Ladder
ACCESS LADDER, HYDRAULICALLY OPERATED
10.2
FUNCTION OF HYDRAULICALLY OPERATED ACCESS LADDER
Fig. 10-2
Function of hydraulically operated access ladder
Legend for Fig. 10-2: (2)
Main pump
(258.3)
Pressure relief valve (safety valve 70 bar)
(8.1)
Pilot pump
(258.4)
Shuttle valve
(33)
Pilot pressure filter
(258.5+.6)
Check valve
(101)
Hydraulic cylinder
(258.7)
Orifice
(157)
Solenoid valve 57Q623a/b
(57Q625)
Solenoid valve (lowering speed control) (OFF => reduced speed)
(252.1)
Pressure relief valve (45+3 bar), X2 pressure
(57Q623a)
Solenoid valve (ON => ladder up)
(252.2)
Pressure relief valve (60+3 bar), X4 pressure
(57Q623b)
Solenoid valve (ON => ladder down)
(258.1)
Solenoid valve 57Q625
10-4
Version 2010/1
ACCESS LADDER, HYDRAULICALLY OPERATED
Function of Hydraulically Operated Access Ladder
Prime drive is running The pump (Fig. 10-2, Pos. 8.1) delivers the oil through the filter (Fig. 10-2, Pos. 33) to port A of the pressure relief valve (Fig. 10-2, Pos. 252.2). The pressure relief valve (Fig. 10-2, Pos. 252.2) maintains the adjusted pressure of 60+3 bar, called "X4“-pressure. By the function of pressure relief valve (Fig. 10-2, Pos. 252.1), the “X4“-pressure will be reduced to 45+3 bar (called "X2“-pressure) and is present at port P of solenoid valve 57Q623a/b. If solenoid valve 57Q623a or b is energized, the oil flows to the cylinder, and the ladder will move up or down. By the function of shuttle valve (Fig. 10-2, Pos. 258.4) both service lines are connected to safety valve (Fig. 10-2, Pos. 258.3), which limits the pressure to 70 bar. Return oil from cylinder (Fig. 10-2, Pos. 101) flows back via solenoid valve 57Q623a/b to solenoid valve 57Q625. 57Q625 = ON => Maximum cylinder speed, return oil flow is not restricted when both proximity switches 70B122 and 70B091 are not activated (ladder between top and bottom end position) 57Q625 = OFF => Reduced cylinder speed, return oil flow is restricted by orifice (Fig. 10-2, Pos. 258.7) when one of the proximity switches 70B122 (ladder up) or 70B091 (ladder down) is activated (i.e. cushioning function just before the final upper or lower end position is reached). If the ladder is in the “top position”, the activated sensor 70B122 de-energizes 57Q625 and energizes 57Q623a, with the result that the cylinder of the ladder is always charged (held) with pressure in this position. If switch 70S084 is in neutral position and the ladder is in “bottom position”, sensor 70B091 de-energises all solenoids (Fig. 10-2, Pos. 57Q625 and 57Q6123 a+b) and the ladder is “blocked”.
Version 2010/1
10-5
Function of Hydraulically Operated Access Ladder
Fig. 10-3
10-6
ACCESS LADDER, HYDRAULICALLY OPERATED
Electric circuit diagram of the hydraulically operated access ladder
Version 2010/1
ACCESS LADDER, HYDRAULICALLY OPERATED
Function of Hydraulically Operated Access Ladder
Engine is not running and the ladder is in the “final upper position” With switch (70S084) activated in position "ladder down", the solenoid valves 57Q623b and 57Q625 are energized. 57Q6123b connects the piston side of the cylinder to the return line, so that the oil can return to the tank without resistance. Now the ladder can move down on its own (due to the force of gravity). The operator has to push the ladder slightly until it starts moving down on its own. In case the operator switches off the key switch (20S001), the "ladder down" function will be available via the MTC for approx. 30 min. After this time, the self-holding circuit (11Q100) switches off the MTC, and the travel alarm sounds twice. After that, the key switch (20S001) has to be switched on again for lowering the ladder. In case the operator switches off the key switch (20S001), and acitvates switch (70S084) in position "ladder down" until the ladder reaches the bottom end position (70B091 active), the self-holding circuit (11Q100) switches off the MTC after 2 minutes, the travel alarm will then sound twice.
WARNING z
Make sure that there are no obstacles in the moving range of the ladder! Stop raising the ladder by releasing the control switch (70S084) if there are any obstacles in the moving range!
z
Mount the ladder only in completely lowered position!
z
Do not lift persons or objects (tools) with the hydraulic access ladder! Serious injury or death could occur!
Version 2010/1
10-7
Adjustments / Checks
10.3
ADJUSTMENTS / CHECKS
Fig. 10-4
Adjustments / checks
10-8
ACCESS LADDER, HYDRAULICALLY OPERATED
Version 2010/1
ACCESS LADDER, HYDRAULICALLY OPERATED
Adjustments / Checks
Legend for Fig. 10-4: (1)
Stop bar
(2)
Inner pivot bracket of the access ladder
(3)
Pull chain for emergency lowering of the access ladder
(4) + (6)
Lock nut
(5) + (7)
Set screw
(A)
Access ladder in upper position (working position)
(B)
Access ladder in lowered position
(M1.1)
Test port – X4 pressure (60+3 bar)
(M1.2)
Test port – X2 pressure, pilot pressure (45+3 bar)
(M35.1)
Test port – hydraulic cylinder pressure, access ladder “piston side”
(252.1)
Pressure relief valve (45+3 bar) – X2 pressure (pilot pressure)
(252.2)
Pressure relief valve (60+3 bar) – X4 pressure (pump support pressure)
(258.3)
Pressure relief valve (safety valve 70 bar)
(70S084)
Ladder control switch for lowering and lifting the ladder
(70SS84a)
Pull switch for emergency lowering of the access ladder. When the chain (3) is being pulled down with the engine running, the pilot control system is made inoperative preventing further movement of the shovel. (Operator warning system)
(70B091)
Monitor and control sensor, located on ladder pivot bracket. This sensor monitors the ladder position and controls the moving speed of the ladder. In case the sensor (70B122) fails to function properly, the sensor (70B091) prevents unintended movement of the ladder.
(70B122)
Safety sensor, located on ladder pivot bracket. Cut out of the pilot control system and actuation of the hydraulic swing brake with the ladder in lowered position.
1. Connect pressure gauges to test ports (M1.1), (M1.2) and (M35.1). 2. Start the engine and let it run at high idle. 3. Lift the access ladder to the upper end position using switch (70S084). 4. Increase the X4 pressure to 80 bar at pressure relief valve (252.2) by loosening the lock nut (Fig. 10-4, Pos. 4) and then turning in set screw (Fig. 10-4, Pos. 5). 5. Increase the X2 pressure to 75 bar at pressure relief valve (252.1) by loosening the lock nut (Fig. 10-4, Pos. 6) and then turning in set screw (Fig. 10-4, Pos. 7). 6. Check the setting of pressure relief valve (258.3) at test port (M35.1); required: 70 bar. If the gauge does not show the proper pressure, the entire valve has to be replaced by a new, bench tested safety valve! 7. Reset valve (252.2) to 60+3 bar and reset valve (252.1) to 45+3 bar. 8. At last, tighten the lock nuts (Fig. 10-4, Pos. 4 and 6).
Version 2010/1
10-9
Adjustments / Checks
10-10
ACCESS LADDER, HYDRAULICALLY OPERATED
Version 2010/1
CENTRAL REFILLING SYSTEM (SERVICE ARM)
11. CENTRAL REFILLING SYSTEM (SERVICE ARM)
Version 2010/1
11-1
General
CENTRAL REFILLING SYSTEM (SERVICE ARM)
11.1
GENERAL
Fig. 11-1
Overall view of the central refilling system
11-2
Version 2010/1
CENTRAL REFILLING SYSTEM (SERVICE ARM)
General
Legend for Fig. 11-1: (1)
Hydraulic cylinder
(2)
Pull switch 55S087
(3)
Service arm
(4)
Proximity switch 55B023
(5)
Enabling switch 20S094 for the hydraulic service arm operation
Basics The hydraulically operated service arm for diesel driven machines is primarily important to refuel the machine easily. Therefore, it is important to have a basic central refilling system directly connected to the service truck. In order to move the service arm, first of all it is necessary to move the service arm enabling switch 20S094 at the cabin dashboard into position "1". After that, the service arm can be lowered/raised by pulling switch 55S087. NOTE: As long as the pull switch 55S087 is activated, the service arm continues to move up/down. If the pull switch is released, the service arm stops. NOTE: When the service arm enabling switch 20S094 at the cabin dashboard is switched to ON position ("1"), pilot control for shovel movements is switched to OFF.
WARNING Before initiating a service arm movement, make sure nobody is in range of the moving arm.
Version 2010/1
11-3
Function
CENTRAL REFILLING SYSTEM (SERVICE ARM)
11.2
FUNCTION
Fig. 11-2
Electric circuit diagram of the central refilling system
Legend for Fig. 11-2: (2)
Main pump
(8.1)
Pilot pump
(33)
Pilot oil filter
(115)
Hydraulic cylinder
(252.1)
Pressure relief valve – X2 pressure (45+3 bar)
(252.2)
Pressure relief valve – X4 pressure (60+3 bar)
(259.3+.4)
Check valves
(259.5)
Orifice
(57Q624a)
Solenoid valve: refilling arm UP
(57Q624b)
Solenoid valve: refilling arm DOWN
(57Q624c)
Solenoid valve: position with nonreturn valve => service arm locked
11-4
Version 2010/1
CENTRAL REFILLING SYSTEM (SERVICE ARM)
Function
Pre-condtion: the engine is running. NOTE: In addition to the hydraulic diagram in Fig. 11-2, also see the respective electric circuit diagram. The pump (Fig. 11-2, Pos. 8.1) delivers oil through filter (Fig. 11-2, Pos. 33) to port A of pressure relief valve (Fig. 11-2, Pos. 252.2). The pressure relief valve (Fig. 11-2, Pos. 252.2) maintains the adjusted pressure of 60+3 bar, called X4 pressure. By means of the pressure relief valve (Fig. 11-2, Pos. 252.1), the X4 pressure will be reduced to 45+3 bar (called X2 pressure), that is present at port P of solenoid valve 57Q624a/b. If the solenoid valves 57Q624a and 57Q624c are energized, pressurized oil flows to the piston side of the service arm cylinder, and the service arm will move up. If the solenoid valves 57Q624b and 57Q624c are energized, pressurised oil flows to the rod side of the service arm cylinder, and the service arm will move down. Under working conditions, solenoid valve 57Q624c is permanently energized to hold the service arm in the upper position under pressure. When the solenoid valve is de-energized by key switch 20S001 in OFF position, the service arm position is held by the non-return valve in solenoid valve 57Q624c. All solenoid valves 57Q624a/b and c are MTC controlled. The pull switch 55S087 is also connected to the MTC and acts as a remote control. The service arm can only be moved down or up with activated key switch 20S001 and activated "service arm enabling switch" 20S094 in the operators cab. The proximity switch 55B023 signalizes the MTC that the service arm is in the upper position. If the service arm enabling switch 20S094 is activated, the pilot pressure is cut off. Pilot pressure is also cut off when the service arm is out of range of the proximity switch 55B023 in order to prevent damage to the lowered service arm.
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11-5
Function
11-6
CENTRAL REFILLING SYSTEM (SERVICE ARM)
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HINTS FOR READING THE HYDRAULIC DIAGRAM
12. HINTS FOR READING THE HYDRAULIC DIAGRAM
Version 2010/1
12-1
General
HINTS FOR READING THE HYDRAULIC DIAGRAM
12.1
GENERAL
Fig. 12-1
Example of a hydraulic circuit diagram
12-2
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HINTS FOR READING THE HYDRAULIC DIAGRAM
General
NOTE: The illustration is only used exemplarily. Use the circuit diagram corresponding to your machine for details. Legend for Fig. 12-1:
Item
Number/Code [Example]
Description
Explanation
A
Diagram no. and type of the specified machine
948 552 40 b PC4000-D
Diagram no. is only valid for the specified machine.
B
Defined serial no.
08199
—
C
Sheet no. / total number of sheets
01 / 02
1st of two sheets
D
Diagram title
Hydraulikplan KS
"Hydraulikplan KS" (KS: Klappschaufel) = "Hydraulic Diagram FSA" (FSA: Front Shovel Attachment) / "Hydraulikplan TL" (TL: Tieflöffel) = "Hydraulic Diagram BHA" (BHA: Backhoe Attachment)
E
Coordinates to specify the location of a component
1 C 10
Page 1, coordinate C vertically and coordinate 10 horizontally
F
Component no.
9
No. for main control block III
G
Line no. with cross reference
L20/ 2D4
Line no. 20; coming from / going to sheet 2 coordinates D4
H
Assignment of main control block spools to machine functions, function priorities
—
The rectangles respresent the main control block spools (numbered from bottom up); when devided in two parts, spool "a…" (left) and spool "b…" (right) are used for different components. Rectangles appearing on the lower right stand for additional components for special functions.
J
Block diagram for assignment of pumps to main control blocks
—
Position of main pumps (with no.) on the PTO and the associated main control block (with control spool designations)
K
See Fig. 12-2 on next page: Switching points for functions acc. to PTO and hydraulic oil temperatures and type of oil
—
The machine control determines the switching points according to the applied oil type/viscosity; therefore, the correct type has to be entered via VHMS.
Further remarks: z
All components are shown in neutral and pressureless position.
z
A wide continuous black line shows a main component or assembly (e.g.: valve and filter panel, main pump, hydraulic tank, …).
z
A continuous black line shows a main hydraulic line. This line is temporarily or permanently loaded with high or pilot pressure.
z
A broken line represents a return, drain or control oil line.
z
A black dot shows a connection point. The position of this connection is not explicitly defined.
z
A white dot shows a connection or port of a component with a well-defined position at the component (e.g.: via port marking/number).
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12-3
Hydraulic symbols
12.2
HYDRAULIC SYMBOLS
Fig. 12-2
Example of a hydraulic circuit diagram
12-4
HINTS FOR READING THE HYDRAULIC DIAGRAM
Version 2010/1
HINTS FOR READING THE HYDRAULIC DIAGRAM
Hydraulic symbols
NOTICE The illustration is only used exemplarily. Use the original circuit diagram for better readability.
z z
There are symbols described on the following pages not marked in Fig. 12-2.
z
The list of hydraulic symbols is not intended to be exhaustive. For more information, refer to standard ISO 1219.
12.2.1 Lines, unions Item
Symbol
Description
1.
Used as / at / on
Oil supply line, hose or pipe
Suction line or pressurized line of main hydraulic circuit, pilot pressure circuit or auxiliary circuits
Return oil line, hose or pipe
Return lines connected to the return oil filter chamber of the main oil tank
Case drain line (leak oil), hose or pipe
Return line connected to the case drain oil filter chamber of the main oil tank
Control oil line, hose or pipe
Pilot control, pump regulation line, parking brake control line
Crossed line
Pipes or hoses not connected with each other
Connection point
Connection of hydraulic lines without a well-defined position
Component connection point
Connection to components like valve blocks, tanks, pumps. Connection with a well-defined position at a component.
2.
3.
4.
5.
6.
7.
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Hydraulic symbols
HINTS FOR READING THE HYDRAULIC DIAGRAM
12.2.1 Lines, unions Item
Symbol
Description
Used as / at / on
8. Plugged connection point, plugged with any kind of plug
Shut (currently not used) connection point
Plugged connection point, plugged with any kind of plug
Shut (currently not used) connection point
Compensator, compensates line differences in length due to vibration and change in temperature
Oil reservoir outlet to the suction tank
Quick coupling, special union with integrated check valve
Tank drain couplings and lines to be removed frequently, e.g. at lubrication systems with removable barrels.
Orifice restriction, not adjustable, with stated orifice diameter [mm]
E.g.: oil cooler inlet
Pressure test port, with a special quick coupling
HP filter, fan valve block.... at all important circuits
Distributor block
Connection of lines with the same destination, e.g. return lines to tank
9.
10.
11.
12.
13.
14.
12-6
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Hydraulic symbols
12.2.2 Components, valves Item
Symbol
15.
Description
Used as / at / on
Accumulator, filled with nitrogen with the specified pressure for the accumulator
Input line to the remote control valves, return oil collecting tube, track tensioning system
Screen filter (min screening size: 1.0 mm)
Installed in suction lines to the pumps, oil tank outlet and return oil collecting tube.
Oil cooler
Hydraulic oil cooler, PTO oil cooler
Breather filter
On top of PTO or hydraulic oil tank
Spray nozzles, inside a case for cooling and lubrication
Gearbox (PTO) cooling and lubrication system
16.
17.
18.
19.
12.2.3 Sensors Item 20.
Symbol
Description
Used as / at / on
Pressure switch / sensor Input = pressure Output = electrical signal (analogue or digital)
E.g.: return/leak oil tank (digital), high pressure filter (analogue)
Pressure switch Input = pressure Output = digital
E.g.: Filter monitoring PTO lubrication
21.
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Hydraulic symbols
HINTS FOR READING THE HYDRAULIC DIAGRAM
12.2.3 Sensors Item
Symbol
22.
23.
Description
Used as / at / on
Temperature sensor Input = temperature Output = electrical signal, proportional to the temperature
E.g.: hydraulic tank
Level sensor Input = fluid level Output = electrical signal, analogue or digital
Hydraulic tank
12.2.4 Valves, valve components Item
Symbol
Description
Used as / at / on
24. Manually operated lever
Valve in track tensioning system to hold the cylinders’ position
Electric / magnetic operated unit Solenoid
Solenoid valves
Pilot pressure controlled unit
Pressure relief valves, disc brakes
Spring (fixed force)
Solenoid valves
Spring (adjustable spring force)
Pressure relief valves
25.
26.
27.
28.
12-8
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Hydraulic symbols
12.2.4 Valves, valve components Item 29.
30.
31.
Symbol
Description
Used as / at / on
Check valve In drawn position: free flow from right to left, blocked flow from left to right
E.g.: main pump outlet, swing brake valve block, anti cavitation valves at main control blocks
Check valve, spring loaded Opens in flow direction only against spring force (if pressure exceeds spring force)
Double check valve In shown position: valve only allows flow from left to bottom or from right to bottom
Slew brake control
Shut-off valve with monitoring switc, The adjustable switch monitors the valve position
Main shut-off valve between oil tank and suction tank
2/2 control valve, manually operated (with lever); check valve
Track tensioning system
3/2 control valve, manually operated; change-over valve
Change-over valve of pump regulation
4/2 directional control valve, electrically controlled (4/2 solenoid valve) Neutral position: P-A and B-T connected
Slew parking brake, travel parking brake, ladder control
Variable throttle valve, hydraulically controlled, pilot control port pressureless = maximum restriction
Travel brake valve located at the car body
32.
33.
34.
35.
36.
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Hydraulic symbols
HINTS FOR READING THE HYDRAULIC DIAGRAM
12.2.4 Valves, valve components Item 37.
38.
Symbol
Description
Used as / at / on
3/2 directional control solenoid valve, seat design = leak oil free; 3/2 way solenoid valve, neutral = ports P–A connected
4/3 direction control solenoid valve, 4/3 solenoid valve; in neutral position all ports closed
Ladder control, service arm control
External pilot controlled proportional floating valve
PC3000 and PC4000 FSA: at stick and boom
39.
40. Main control valve with standard function Neutral position: open pump flow (P–T), control port flushing (T–a, T–b), closed pressure ports A and B. Position b: closed circulation port (P–T), ports P–B and A–T connected. Position a: closed circulation port (P–T), ports P–A and B–T connected.
41.
Main control valve with pressureless lowering function (lowering function marked with additional symbol " ") Neutral position: open pump flow (P–T), control port flushing (T–a, T–b), closed pressure ports A and B. Position b: closed circulation port (P–T), ports P–B and A–T connected. Position a: open pump flow P–T, closed pressure port A, ports B–T connected.
12-10
Standard control valve for bi-directional motors and double-acting cylinders
Control valve for pressureless lowering. Used to assist the floating function of boom and/or stick.
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HINTS FOR READING THE HYDRAULIC DIAGRAM
Hydraulic symbols
12.2.4 Valves, valve components Item 42.
Symbol
Description
Used as / at / on
Main control valve with floating function (floating function marked with additional symbol " ") Neutral position: open pump flow (P–T), control port flushing (T–a, T–b), closed pressure ports A and B. Position b: closed circulation port (P–T), ports P–B and A–T connected, check valve prevents flow BÖP. Position a: open pump flow P–T and P–A, ports B–A connected with check valve to prevent flow TÖB.
43.
Floating valve for boom and/or stick
Pressure reducing valve assembly Variable inlet pressure at port P and constant lower output pressure at port A, adjustable output pressure (set to 35 bar)
Pressure reducing valve to provide reduced operating pressure for travel parking brakes and slew parking brakes
Pressure relief valve, directly controlled and adjustable
Safety valve in ladder control circuit
Pressure relief valve with anti-cavitation valve (check valve) assembly, external drain at port Y
Secondary relief valve at main control blocks
Throttle check valve with secondary relief valve, throttle and secondary valve mechanically adjustable, external drain at port Y
Distribution manifold normally in the line to the cylinder, piston side
Pressure increasing valve, pressure relief valve with variable setting, pilot pressure controlled via port X, low pilot pressure = low relief pressure
Slew brake valve block, track tensioning system
44.
45.
46.
47.
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Hydraulic symbols
HINTS FOR READING THE HYDRAULIC DIAGRAM
12.2.4 Valves, valve components Item
Symbol
Description
Used as / at / on
48. Proportional pressure valve, to reduce the supply pressure P at port A proportional to the solenoid current
Remote control valves, pump regulation
4-port proportional valve, directly operated by a solenoid
Pump regulation
Pressure relief valve, mechanically and hydraulically adjustable via pilot port X, pilot valve drain port Y
Radiator and oil cooler fan drive
49.
50.
12.2.5 Pump, motor, cylinder Item 51.
Symbol
Description
Used as / at / on
Single-acting cylinder, only moving in one direction when pressurized, returning by external forces
Track tensioning system
Double-acting cylinder, operated in both directions by pressurized oil
Attachment
Drive shaft of a motor or pump with one direction
Main pumps
Hydraulic pump, fixed volume per REV, suction port S, pressure outlet P
Pilot pump, engine coolant fan, oil cooler fan, PTO lubrication pump
52.
53.
54.
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Hydraulic symbols
12.2.5 Pump, motor, cylinder Item
Symbol
Description
Used as / at / on
55. Hydraulic pump, variable output volume per REV with external case drain
Main pump
Hydraulic pump assembly with pump bearing lubrication, one direction and external case drain
Main pump
Variable hydraulic pump with charge pump and external drive shaft bearing lubrication
Main pump
Hydraulic motor can be used in both directions, with external case drain L
Oil cooler fan motors
Motor with disc brake, disc brake spring loaded: pressureless pilot line = maximum brake torque
Travel motor, slew motor
56.
57.
58.
59.
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Hydraulic symbols
HINTS FOR READING THE HYDRAULIC DIAGRAM
12.2.5 Pump, motor, cylinder Item
Symbol
Description
Used as / at / on
60.
Lubrication pump drive, differential cylinder with integrated control valves
Lubrication pump station for central lubrication system and slew ring lubrication system
61. Slew brake valve assembly Acts as a hydraulically back pressure system parallel to a slew motor with variable pressure setting and independent pressure side. Input port A or B and outlet on the opposite side, relieve port T
Slew service brake system on top of the slew motor
62.
63.
64.
12-14
Rotary joint, upper part with connections to the superstructure hydraulic, and lower part with connections to the car body
Hydraulically connection between superstructure and car body
Travel brake valve block with secondary pressure relief valve 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
Hydraulic oil tank with leak and return oil filter, back pressure valve and sensors
Main hydraulic oil tank
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Hydraulic symbols
12.2.5 Pump, motor, cylinder Item
Symbol
Description
Used as / at / on
65.
Main pump with charge pump, variable displacement individual for each pump, controlled via proportional solenoid valve
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Main pumps
12-15
Hydraulic symbols
12-16
HINTS FOR READING THE HYDRAULIC DIAGRAM
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HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
13. HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
Version 2010/1
13-1
General
13.1
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
GENERAL
In this chapter you’ll find information about: z
the (new) designation of electrical components (reference code)
z
the graphical symbols used
z
the layout of the electric wiring diagram
z
hints for a fast look-up of electrical components in the electric wiring diagram.
NOTE: The electric wiring diagram is solely intended for wiring purposes. For information on operating sequences or the process logic, refer to the CoDeSys visualisation software.
13-2
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HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
13.2
Reference designation of the electrical components
REFERENCE DESIGNATION OF THE ELECTRICAL COMPONENTS
Each electrical component is well-defined by a code containing two single reference designations, see following table. Code "aabcdd–x"
Meaning
Remarks
aabcdd–x
aa : Area code (location reference designation)
See chap. 13.2.1 for details
aabcdd–x
b : Product reference designation, component identifying letter acc. to IEC 61346-2
See chap. 13.2.2 for details
aabcdd–x
c : 2 = Pre-heating / 3 = CAN bus / 5 and 6 = valves
aabcdd–x
dd : Further product reference designation
aabcdd–x
–x : Powertrain (–1 and –2)
Because this reference designation was just introduced at KMG, and differs from the previously used designation, this chapter also contains a table with the new and old component designation are listed side by side, refer to section 13.6 on page 13-21.
13.2.1
AREA CODE
The first two letters of the product code of the electrical components indicate its location, see following table: Area code
CAN*
10
Location Cab base
11
X
ELV board (DC / 0…60 V)
12
X
Low voltage board (AC / 60…400 V)
13
Cab base bottom compartment
14
—
15
Customer board in the cab base
16
Switch board, pre-heating hydraulic oil
17
Air condition at cab base
18
Air condition switch board, HV cabinet
19
Air condition switch board, LV cabinet
20
X
Cab
21
Customer board in the cab
30
Drive
31
Fuel tank
32
High voltage cabinet (400 V and up)
33
Low voltage in the high voltage cabinet
34
Air condition at the high voltage cabinet
40
Version 2010/1
X
Hydraulic oil tank
13-3
Reference designation of the electrical components
Area code
CAN*
Location
41
Oil cooler (hydraulic)
50
Machinery house
51
X
Engine / motor room
52
Engine / motor
54
Counterweight
55
Service arm
56
X
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
Pump compartment
57
Control panel, PTO
59
Suction tank
60
Superstructure
61
Control blocks, remote control valves
62
Lubrication system
63
Reserve oil tank, engine
65
Engine coolant pre-heating
67
Crane
68
Compressor
70
Stairs, access ladder
71
Battery box
80
Loader attachment
90
Undercarriage
91
X
Cable drum
92
Rotary joint
93
Slip ring
94
Junction box, cable drum
* : "X" = Location with CAN node
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13.2.2
Reference designation of the electrical components
COMPONENT IDENTIFYING LETTER
According to IEC 61346-2, it is now the function / purpose of the electrical component within the circuit that determines its identifying letter in the reference designation (refer to section 13.2 on page 13-3). Letter
Component fuction / purpose
Examples
A
Double function (basic functions are equivalent)
VHMS display, multimonitor
B
Converting physical values into processable signals
End switch, binary or analog sensor, transducer, camera
C
Saving/storing of energy, information, or material
Battery, data memory
E
Supplying rays, heat, or coldness
Heater, lamp
F
Protective devices
Fuse, circuit breaker, power circuit breaker, emergency shut-off switch, safety lock switch, insulation monitor, motor overload switch, ground fault circuit interruptor
G
Initiate energy signals, material flow signals, referBattery, generator ence signals
K
Information processing (without F)
Relay, time relay, controller, phase protective relay
M
Supply mechanical energy (linear or rotating)
E-motor, actuation coil
P
Exposition of information
Display, signal transducer, gauge, clock, counter or operating hours, LED, printer, counter, sevensegment display
Q
Switching or modifying material flow or energy flow Contactor, power relay, battery main switch, dis(without F) connecting switch, starter, power switch
R
Limiting, damping, stabilizing, blocking of energy, information, or material
"Z-diode, diode, throttle, resistance, series resistance, capacitor module, cut-in unit
S
Converting manual mechanical signals into processable signals
Switch, buttton, selector switch, setpoint sensor/ transmitter
T
Converting energy or information without modifica- Current transformer, voltage transformer, amplifier, tion of the kind of energy and the information con- aerial, measurement transformer, transformator, tent rectifier, charger, inverter
U
Supporting, retaining, carrying, holding up of objects
Isolator, cable duct, switchboard, wiring rack, cable drum
V
Processing material, energy, information signals
Mains filter, frequency filter
W
Guiding, channeling, transferring energy, material, Conductor, wiring, rail, bus, fiber optic cable, slipinformation ring
X
Connecting objects
Version 2010/1
Terminal, terminal block, terminal strip, connector, socket, cable connector
13-5
Graphical symbols
13.3
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
GRAPHICAL SYMBOLS
The circuit symbols used in the wiring diagram are based upon IEC (International Electrical Commission) standard IEC 60617, which differ from the symbols in accordance with the standards NEMA ICS 19-2002 (R2007), ANSI Y32.2/IEEE 315/315A, CSA Z99 for the North American market. The symbols shown in the table below only present an excerpt of the standards, not an exhaustive list of all symbols relating to the standards.
Description
Junction of conductors
Symbol acc. to IEC
or
Symbol acc. to NEMA ICS/ANSI/IEEE
or
Connection of conductors (node) Terminal Line of effect, general symbol Line of effect, denoting small interval Line of separation between functional units Shielding Earth, general symbol ’Ground’, general symbol Protective earth / Protective ground Connector with plug and socket
or
Isolating point, lug, closed Passive components Resistor, general symbol
or
or
Variable resistor, general Resistor with sliding contact, potentiometer Winding, inductance, general Capacitor, general symbol
or or
or
Variable capacitor Visual indicator, general symbol
13-6
(* with color indication)
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HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
Description Indicator light, general symbol
Symbol acc. to IEC
Graphical symbols
Symbol acc. to NEMA ICS/ANSI/IEEE
or
or
Buzzers Horn, claxon Drives Manual operation, general use Operated by pushing Operated by pulling Operated by turning Operated by key Operated by rollers, sensors Stored energy mechanism, general symbol Operated by motor Emergency switch Operated by electromagnetic overcurrent protection Operated by thermal overcurrent protection Electromagnetic operation Control by fluid level Electromechanical, electromagnetic operating devices Electromechanical operating device, general symbol, relay coil, general symbol Electromechanical operating device with ONdelay Electromechanical device with OFF-delay
or or (× : device code letter)
Electromechanical device with ON- and OFFdelay Electromechanical device of a thermal relay
Version 2010/1
or
13-7
Graphical symbols
Description
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
Symbol acc. to IEC
Symbol acc. to NEMA ICS/ANSI/IEEE
Contacts N/O contact
or
N/C contact
or
Changeover contact with interruption
or TC or TDC
Early-make N/O contact of a contact assembly
TO or TDO
Late-break N/C contact of a contact assembly N/O contact, delayed when closing N/C contact, delayed when reclosing
or
or or
Control devices Push-button (not stay-put) Spring-return switches with N/C contact, manually operated by pushing, e.g. push-button Spring-return switches with N/O and N/C contact, manually operated by pushing Spring-return switches with latching position and one N/O contact, manually operated by pushing Spring-return switches with latching position and one N/C contact, manually operated by striking (e.g. mushroom button) Position switches (N/O contacts), limit switches (N/O contacts) Position switches (N/C contacts), limit switches (N/C contacts) Proximity switches (N/C contacts), actuated by the proximity of iron Proximity switches, inductive, N/O contacts Proximity switches, block diagram Under-pressure relays, N/O contacts Pressure switches, N/C contact
or or
Float switches, N/O contact Float switches, N/C contact
13-8
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HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
Description
Symbol acc. to IEC
Graphical symbols
Symbol acc. to NEMA ICS/ANSI/IEEE
Switchgear Contactors (N/O contacts)
(× : code letter)
Three-pole switch-disconnector Three-pole circuit-breaker Fuse, general symbol Transformers, current transformers Transformers with two windings
Current transformer
or
or
or
Machines Generator Motor, general symbol
or or
DC motor, general symbol AC motor, general symbol Three-phase asynchronous motor with squirrel-cage rotor
or
Three-phase asynchronous motor with slipring rotor Semiconductor components Semiconductor diode, general symbol Limiting diode Zener diode Light-emitting diode (LED), general symbol Bi-directional diode, diac Thyristor, general symbol
Version 2010/1
13-9
Drawing concept
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
13.4
DRAWING CONCEPT
Fig. 13-1
Cover page of the KMG electric circuit diagram
13-10
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HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
Drawing concept
Komatsu circuit diagrams Each page of the circuit diagram has the following information in the bottom right hand corner: z
Diagram number (Fig. 13-1, Pos. 5); – example: 942 123 40 d
z
Machine type (Fig. 13-1, Pos. 6) – example: PC4000-6D
z
Machine number(s), the diagrams are valid for (Fig. 13-1, Pos. 7) – example: 08210 and following
z
Diagram title (Fig. 13-1, Pos. 8) and contents – example: "Elektroplan" [German for "electric circuit diagram"] and "Table of contents"
z
Current page number and total number of pages (Fig. 13-1, Pos. 4) – example: 01/175
Each page 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 (see Fig. 13-1, Pos. 3). This coordinate system allows to indicate the location of components, as well as to locate a component on a given page more easily.
Table of contents In the table of contents on the first pages, the pages (Fig. 13-1, Pos. 1) are listed in ascending order, for each page the title (Fig. 13-1, Pos. 2, with area code relating to the units presented on the page, where applicable) is listed. The english version of the table of contents is to be found following the german version. Example: "103 51 bus connector node 17, 18, 19" => On page 103, the bus connectors for nodes 17, 18, and 19, to be found in the engine room (area code 51), are shown.
Version 2010/1
13-11
Drawing concept
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
Cross reference list The pages following the table of contents contain the cross reference list.
Fig. 13-2
Cross reference list
In the cross reference list, all electrical parts/components are listed in alphabetical order (Fig. 13-2, Pos. 2 and 3). In front of the components’ designation, the relevant page number (Fig. 13-2, Pos. 1) on which the component is drawn, is given. NOTE: Following the cross reference list, but still in front of the circuit diagram pages, you’ll find: – the FAQ (about how information is represented in the diagrams) – information about the structure of the reference designations. NOTE: The underscore in cross references like "40X_41.5" stands for a connection to a terminal block.
13-12
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Drawing concept
This page was left blank intentionally.
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13-13
Drawing concept
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
Eletrical wiring diagrams – explanations The following illustrations shall show up some basics about the wiring diagrams and how information is presented.
Fig. 13-3
13-14
Wiring diagram (example)
Version 2010/1
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
Drawing concept
Legend for Fig. 13-3: (1)
Phase / wire designation
(2)
Cross reference to further connection (e.g. "158.1" : continuation on page 158, column 1)
(3)
Notation of temperature switch (63B204: pre-heating reserve oil tank)
(4)
Notation of circuit breaker (12F206a: heater in cab support)
(5)
Required wire cross-section area in mm² (e.g.: 2.5 mm² = AWG 14)
(6)
Separation line for an electrical module / assembly group
(7)
Cable connector designation and pin number
(8)
Connection to a terminal block (e.g. pin 19 of terminal block 11X_51)
(9)
Contacts of relay 12K201 (Fig. 13-3, Pos. 10). The switching contacts are always drawn at the bottom below the associated relay. For switching contacts in usage, a cross reference is given alongside; for contacts not used, only ":" is shown. In the example, only the switching contacts 43 an 44 are used, the contacts are shown in detail on page 69, section/column 1.
(10)
Relay coil
(11)
Notation of heating resistor (e.g.: 63E212)
(12)
Functional unit’s name for the wiring diagram sector shown above
(13)
Protective earthing (PE)
(14)
Ground wire / machine ground (e.g.: 12GND)
(15)
Designation for optional design (e.g.: TT = low-temperature design)
Version 2010/1
13-15
Drawing concept
Fig. 13-4
13-16
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
Wiring diagram (example)
Version 2010/1
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
Drawing concept
Legend for Fig. 13-4: (1)
Designation of CAN-bus node
(2)
Separating line for functional unit (40K311, ICN-D, CAN-bus node 11)
(3)
Notation of input resistance of CAN-bus node ICN-D (at socket 3, pin 8)
(4)
Identification for logic input signal also used in the flowchart (first line), first letter in second line identifying type of port (SB_… : input / OB_… : output)
(5)
Notation of pressure switch (40B024: filter monitoring of air filter at the hydraulic tank)
(6)
Functional unit’s name for the wiring diagram sector shown above
(7)
Color code of connecting line (e.g.: "BN" = brown), refer to cable color identification table below.
(8)
Connector identification
(9)
Cross reference/location of the complete assembly group, if only a part of the group is shown here. In the example, onyl the relevant resistor between pins 9 and 10 of the resistor array 40R008 is shown in th drawing for the functional unit (hydraulic oil tank monitoring); the complete resitor array is shown on page 143, section/column 2.
(10)
Cross reference/location of the complete assembly group, if only a part of the group is shown here. In the example, onyl the relevant diode between pins 1 and 2 of the diode array 40R014 is shown in th drawing for the functional unit (hydraulic oil tank monitoring); the complete diode array is shown on page 143, section/column 1.
NOTE: All circuits are shown without current, and all relays and switches in neutral position.
Cable color identification Refer to the following table if the identification of cable colors in wiring diagrams may be unclear due to different existing systems of color codes. Color English
Color code Standard IEC 60757*
German (current)
German (previous)
BK
SW
sw
BN
BR
br
Black
German Schwarz
Brown
Braun
Red
Rot
RD
RT
rt
Orange
Orange
OG
OR
or
Yellow
Gelb
YE
GE
ge
Green
Grün
GN
GN
gn
Blue
Blau
BU
BL
bl
Violet
Violett
VT
VI
vi
Grey
Grau
GY
GR
gr
White
Weiß
WH
WS
ws
Pink
Rosa
PK
RS
rs
Turquoise
Türkis
TQ
TK
tk
* IEC: International Electrotechnical Commission
Version 2010/1
13-17
Drawing concept
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
Wiring diagram sequence The layout of the wiring diagram, especially the order of the contents, is shown in the following chart. Location (in ascending order) Emergency equipment Power supply / ground Circuit breaker Circuit breaker, controller Sensors Bus connectors (CAN-bus) Node / controller Power supply / ground Bus connections (CAN) Diode and resistor arrays (built-in) Input digital and analog Output digital and analog Node / controller Power supply / ground Bus connections (CAN) Diode and resistor arrays (built-in) Input digital and analog Output digital and analog ... Other elements Location Emergency equipment Power supply / ground Circuit breaker Circuit breaker, controller Sensors Bus connectors (CAN-bus) Node / controller Power supply / ground Bus connections (CAN) Diode and resistor arrays (built-in) Input digital and analog Output digital and analog Node / controller ... ... Other elements ... (Location) Accessories Settings Additional information Correlation hand-lever deflection – movements Pump and control block layout Coding of connectors DIP switch setting ...
13-18
Version 2010/1
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
Drawing concept
Search hints In order to find the required information fast and easily, the following hints may be useful. 1. A component at a certain location is to be looked-up in the wiring diagram, the component designation is missing / unrecognizable: => if needed, look-up the location reference designation (area code) for the relevant place of the machine in the "List of location reference designations" following the FAQ. => Look-up the page number the wiring diagram starts for the desired location in the table of contents. => If the functional unit the component belongs to is identified, look-up the page number for the functional unit in the table of contents for the entries for the relevant location reference code. => Identify the electrical component on the specified page(s). 2. The component’s product reference code is known / identifiable: => Go to the cross reference list following the table of contents. => Look-up the component’s product reference designation and the corresponding page number in the alphabetically sorted list. => Identify the electrical component on the specified page.
Version 2010/1
13-19
Cable marking
13.5
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
CABLE MARKING
On all blue wires there is a printed code approx. every 10 cm.
Fig. 13-5
Example for cable marking
The code next to the cable end shows where the cable end has to be connected, the code further away from the end gives information about what is connected at the other end of the wire.
13-20
Version 2010/1
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
13.6
Table of new and old component designations
TABLE OF NEW AND OLD COMPONENT DESIGNATIONS
The following table lists components of all KMG excavator models. Therefore, it possibly contains components not existing at the particular machine. New code
Previous code
10a000
Component Cab support
10B001
6B1
Temperature cab support
10B002
3B2
Temperature switch for heater in LV switch cabinet
10B005
2S5
Door switch in LV switch cabinetLV switch cabinet
10B006a
2B6a
Temperature switch for air condition in LV switch cabinet
10B007a
2B7a
Dampness switch for air condition in LV switch cabinet
10B351
Fire suppression system pressure switch
10B451
9B1
Temperature transmitter for fire suppression system LV switch cabinet
10B452
9B2
Temperature transmitter for fire suppression system LV switch cabinet
10B463
E63
Camera cab support
10E008
7H8
Emergency light cab support (Electric)
10E009
7H9
Emergency light cab support (Electric)
10E025
3R25
Heater in LV switch cabinet
10E026
3R26
Heater in LV switch cabinet
10E046
H46
Lighting cab support (Diesel)
10E055
H55
Lighting at stage for cab
10E144e
H144e
Additional light cab support left
10E144f
H144f
Additional light cab support left
10E144g
H144g
Additional light cab support right
10E144h
H144h
Additional light cab support right
10E231
1H1
Heater for cab support
10G007
M3
Compressor for warning horn
10G010
M10
Excess pressure blower (old cab)
10K032
E32/X14
Load limit regulation
10K300
E46
VHMS controller
10P001
1P1
Battery charging device emergency-lighting, charging-current-display
10P003-1
0P3-1
Cos-Phi-display motor 1
10P003-2
0P3-2
Cos-Phi-display motor 2
12P004-1
0P4-1
KWh_counter_motor_1
12P004-2
0P4-2
KWh_counter_motor_2
10P008
1P8
Battery charging device emergency-lighting, charging-voltage-display
10Q104
*K4M
Power switch for air condition compressor in HV switch cabinet at cab support wall
Version 2010/1
13-21
Table of new and old component designations
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
New code
Previous code
Component
10Q204
+K4M-1
Power switch for air condition compressor in LV switch cabinet at cab support wall
10R100
R100
Terminal resistor at hydraulic tank (in need)
10R101
R101
Terminal resistor at VHMS controller
10S017
S17
Switch for cab support lighting
10T055
E55
Charging device
10T058
E58
Satellite communication ORBCOMM controller (option)
10W322
WLAN-Interface cable between MTC and cab floor (MTCPC)
10X037
Socket connector for satellite communication (option)
10X300
X35d
CAN-Bus-T-Splitter at VHHV controller too QUANTUM for terminal resistor
10X300a
X35d
CAN-Bus-T-Splitter at VHHV controller too MH801 display for terminal resistor
10X300b
X35d
CAN-Bus-Connector in cab support
10X306
CAN-Bus-Connector
10X307
CAN-Bus-Connector
10X309
X35d
CAN-Bus-Connector in cab support
10X322
WLAN-Interface connector in cab floor (MTCPC)
10X335b
CAN-Bus-T-Splitter prepared for Modular-Mining-System-Interface (MMS) hub (Diesel)
10X335c
CAN-Bus-Connector between cab support and cab
11a000
Extra low voltage switch panel (DC)
11B142
E42
Direction of rotation
11B143
E43
Speed of rotation
11B144
Speed of rotation from gyroscop (in preparation!)
11F001
F1
Circuit breaker 15 (+24V DC) (50A)
11F001a
F1a
Circuit breaker 30 (+24V DC) (50A)
11F001b
F1b
Main circuit breaker for pilot control (50 A)
11F001c
F1c
Circuit breaker for working light, lighting superstructure and ladder (50A)
11F001d
F1d
Main circuit breaker cab (50A)
11F001e
F1e
Main circuit breaker TT (50A)
11F001f
F1f
Circuit breaker motor controller QUANTUM (16A)
11F002
F2
Circuit breaker warning light, compressor signal horn (16A)
11F003
F3
Circuit breaker für pilot control (32A)
11F005
F5
Circuit breaker windscreen wiper (16A)
11F005a
F5a
Circuit breaker windscreen wiper wash system (6A)
11F006
F6
Circuit breaker for emergency line and key switch
11F006a
F6a
Circuit breaker service light pump room and engine room (25A) and sockets
11F006b
F6b
Circuit breaker cab indoor light, socket cab support (25A), washbasin pump, cigarette lighter
11F006c
F6c
Circuit breaker sockets in motor- and pump room (16A)
13-22
Version 2010/1
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
New code
Previous code
11F006d
Table of new and old component designations
Component Circuit breaker cab indoor light (16A)
11F007
F7
Circuit breaker light cab roof right (10A)
11F007a
F7a
Circuit breaker light cab roof left (10A)
11F008
F8
Circuit breaker light oil cooler (10A)
11F008a
F8a
Circuit breaker light counterweight (10A)
11F008c
F8c
Circuit breaker light oil cooler (16A)
11F008d
F8d
Circuit breaker light oil cooler (16A)
11F008e
F8e
Circuit breaker light oil cooler (16A)
11F009
F9
Circuit breaker air-condition (50A)
11F009c
F9c
Circuit breaker air-condition control panel
11F011
F11
Circuit breaker motor controller QUANTUM (16A)
11F012
F12
Circuit breaker key switch (6A)
11F013
F13
Circuit breaker for power supply of binary sensors (6A)
11F013a
F13a
Circuit breaker for power supply of analog sensors (6A)
11F014
F14
Circuit breaker for power supply of CAN-node-outputs (20A)
11F015a
F15a
Circuit breaker VHMS controller and VHMS monitor MH801 (10A)
11F016
F17
Circuit breaker PWM-amplifier for cooler fan speed (6A)
11F017
F17
Circuit breaker self-holding (16A)
11F018
F18
Circuit breaker slew park brake (6A)
11F019
F19
Circuit breaker light oil cooler (16A)
11F026
F26
Circuit breaker cab over pressure blower (16A)
11F028
F28
Circuit breaker pilot control supply (10A)
11F028a
F28a
Circuit breaker pilot control supply (10A)
11F029
F29
Circuit breaker pilot control supply (10A)
11F029a
f29a
Circuit breaker pilot control supply (10A)
11F032
F32
Circuit breaker camera system (10A)
11F034
F34
Circuit breaker transfer pump (32A)
11F043
F43
Circuit breaker motor start relay, travel brake, hydr. slew brake, service arm (16A)
11F046
F46
Circuit breaker fan air condition (TT)
11F047
F47
Circuit breaker mixing-valve and fan for cab heater (TT)
11F048
F48
Circuit breaker radio, reading lamp (6A)
11F049
F49
Circuit breaker customer enhancements (16A)
11F059
F59
Main circuit breaker for stabilized battery voltage (50A)
11F061
F61
Circuit breaker load limit regulation (10A)
11F062
F62
Circuit breaker refrigerator, mirror (16A)
11F063
F63
Circuit breaker operator seat heater blower (10A)
11F065
F65
Circuit breaker light superstructure and ladder (16A)
11F066
F66
Circuit breaker engine oil refilling system (16A)
Version 2010/1
13-23
Table of new and old component designations
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
New code
Previous code
Component
11F067
F67
Circuit breaker socket in cab (25A)
11F068
F68
Circuit breaker socket in cab (25A)
11F070
F70
Circuit breaker VHMS supply (10A)
11F071
F71
Circuit breaker independent cab heater Hydronic M (25A)
11F075
F75
Circuit breaker sensor wire for control battery voltage (6A)
11F084
F84
Circuit breaker hydraulic oil level (6A)
11F100
Supply control outputs node 3 (10A)
11F101
Supply control outputs node 4 (10A)
11F102
Supply control outputs node 5 (10A)
11F103
Supply control outputs node 9 (10A)
11F104
Supply control outputs node 10 (10A)
11F105
Supply control outputs node 11 (10A)
11F106
Supply control outputs node 12 (10A)
11F107
Supply control outputs node 13 (10A)
11F108
Supply control outputs node 14 (10A)
11F109
Supply control outputs node 15 (10A)
11F110
Supply control outputs node 16 (10A)
11F111
Supply control outputs node 17 (10A)
11F112
Supply control outputs node 18 (10A)
11F113
Supply control outputs node 19 und 20 (10A)
11F114
Supply control outputs node 21 (10A)
11F115
Supply control outputs node 6 (10A)
11F116
Supply control outputs node 7 (10A)
11F117
Supply control outputs node 8 (10A)
11F121
Bus node supply, switched (10A)
11F122
Bus node supply (10A)
11F123
Bus node supply (10A)
11F306
3F6
Supply for cab heater monitoring
11F310c
3F10c
Circuit breaker for blower under operator seat for blower after-running
11G003
A3
Test modul (-10V bis +10V)
11K003-1
K3-1
Engine 1 running (> 300 1/min), generator field current switch on
11K003-2
K3-2
Engine 2 running (> 300 1/min), generator field current switch on
11K032
D32
Safety relay with cut-off delay for zero position signal
11K044a
Safety line (before safety contactors)
11K050
K50
Bucket switch off
11K058
K58
Pilot control boom up (PC4000)
11K064-1
K64-1
Engine enable
11K064-2
K64-2
Engine enable
13-24
Version 2010/1
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
Table of new and old component designations
New code
Previous code
Component
11K065-1
K65
Enable engine-controller 1
11K065-2
K65
Enable engine-controller 2
11K071
K71
Pilot control bucket fill
11K074
K74
Pilot control stick out
11K075
K75
Boom down (PC5500)
11K076
K76
Pilot control left crawler (PC4000)
11K076a
K76a
Stick out (PC5500)
11K077
K77
Pilot control crawler: left crawler (PC5500)
11K077a
Pilot control crawler: right crawler (PC5500)
11K078
K78
Pilot control right crawler (PC4000)
11K079
K79
Boom up (PC5500)
11K080
K80
Control block 1 switch on
11K111a
K111a
Supply pilot control
11K111b
K111b
Supply pilot control redundant
11K126
K126
Supply relay monitoring for pilot control
11K160
K160
Boom floating position OFF
11K170
K170
Stick floating position OFF
11K176
K76
Stick in (PC5500)
11K177
K177
Travel cut off forward
11K177a
Travel cut off forward (Parallel to 11K177)
11K178
K78
Bucket dump (PC5500)
11K178
K178
Travel cut-off backward
11K178a
Travel cut-off backward (Parallel too 11K178)
11K179
K179
Travel cut-off backward left crawler
11K180
K180
Travel cut-off backward right crawler
11K301
MTC (Master Turbo Controller) (central controller in cab support)
11K302
CAN-Node 2 (ICND)
11K303
CAN-Node 3 (ICNV)
11K304
CAN-Node 4 (ICNV)
11K305
CAN-Node 5 (ICNV)
11P001
H1-1
Operating hour meter motors
11P029
H29
Operating hour meter crawler
11P063
H63
LED load limit regulation activ
11P094-1
H94-1
Quantum fluid signal lamp motor 1 (white)
11P094-2
H94-2
Quantum fluid signal lamp motor 2 (white)
11P095-1
H95-1
Quantum warning signal lamp motor 1 (yellow)
11P095-2
H95-2
Quantum warning signal lamp motor 2 (yellow)
11P096-1
H96-1
Quantum stop signal lamp motor 1 (rot)
Version 2010/1
13-25
Table of new and old component designations
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
New code
Previous code
Component
11P096-2
H96-2
Quantum stop signal lamp motor 2 (red)
11P138
H138
LED error load limit regulation
11P143-1
H143-1
Signal lamp motor oil pump 1
11P143-2
H143-2
Signal lamp motor oil pump 2
11Q010
Self holding of MTC; MTC output for travel alarm control by relay and diode
11Q020
K20
Horn
11Q023
K23 / 4K23
Superstructure lighting contactor
11Q023a
K23a / 4K23a
Additional superstructure lighting contactor (option)
11Q044
K44
Control voltage on by key switch-contactor for diesel shovels
11Q044a
K44a
Control voltage on by key switch-contactor for diesel shovels (parallel to 11Q044)
11Q044c
Q44c
Emergency stop circuit
11Q044d
Q44d
Emergency stop circuit
11Q045a
Main supply for pilot control
11Q045b
Main supply for pilot control
11Q045c
Main supply for pilot control
11Q045d
Main supply for pilot control
11Q045e
Main supply for pilot control
11Q090
K90
Emergency lighting ladder
11Q100
K100
Self holding control contactor
11Q111
K111c
Supply pilot control power contactor (10A)
11Q122
K122
Connect control voltage battery with battery for starter
11Q190
K190
Select slew brake signal source beetween lever and pedal
11R005
A5a
Pull-up/-down resistors
11R013
Diode array (3A)
11R016
Diode array (3A)
11R017
Diode array (3A)
11S041-1
S41-1
Test speed engine 1 : 1800 1/min
11S041-2
S41-2
Test speed engine 2 : 1800 1/min
11S097
S97
Programming mode switch VHMS
11S145
Windscreen wiper arm (QUIT-button)
11C004
A4
Pilot control capacitor modul bucket
11C004a
A4a
Pilot control capacitor modul boom
11C005
A5a
Pilot control capacitor modul slew gear / stick
11C006
A6
Pilot control capacitor modul crawler / clam
11T007
A7
Pilot control amplifier slew gear
11T007a
A7a
Pilot control amplifier slew gear
11T008
A8
Pilot control amplifier stick
11T008a
A8a
Pilot control amplifier stick
13-26
Version 2010/1
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
Table of new and old component designations
New code
Previous code
Component
11T008b
A8b
Pilot control amplifier stick
11T009
A9
Pilot control amplifier bucket
11T009a
A9a
Pilot control amplifier bucket
11T009b
A9b
Pilot control amplifier bucket
11T010
A10
Pilot control amplifier boom
11T010a
A10a
Pilot control amplifier boom
11T010b
A10b
Pilot control amplifier boom
11T010c
A10c
Pilot control amplifier boom
11T011
A11
Pilot control amplifier clam
11T012
A12
Pilot control amplifier crawler left
11T013
A13
Pilot control amplifier crawler right
11T016
A16
Pilot control amplifier slew brake
11T017
E17
Electronic bucket limitation (EBL)
11T048
E48
Ramp modul stick
11T049
E49
Ramp modul boom
11T049a
E49a
Ramp modul boom
11T049b
E49b
Ramp modul boom
11T049c
E49c
Ramp modul boom
11T050
E50
Ramp modul slew gear
11T050a
E50a
Ramp modul slew gear
11T050b
E50b
Ramp modul slew brake
11T051
E51
Ramp modul crawlers
11T052
E52
Ramp modul clam
11T059
E59
Ramp modul bucket
11T080
R80
Measuring transducer for battery voltage
11X027a
VHMS: Download- and programming connector in cab
11X027b
X27b
VHMS: Download- and programming connector in cab support
11X030
X30
Socket cab support
11X093
Terminal strip in cab support too slip ring
11X193
Connector at cab support too slip ring
11X301
CAN-Bus-T-Splitter MTC
11X302
CAN-Bus-T-Splitter Node 2
11X303
CAN-Bus-T-Splitter Node 3
11X304
CAN-Bus-T-Splitter Node 4
11X305
CAN-Bus-T-Splitter Node 5
12a000
Low voltage switch panel (Also low voltage for pre-heating for Diesel TT)
12B403a-1
Winding temperature measuring transducer Pt100 motor 1
12B403b-1
Winding temperature measuring transducer Pt100 motor 1
Version 2010/1
13-27
Table of new and old component designations
New code
Previous code
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
Component
12B403c-1
Winding temperature measuring transducer Pt100 motor 1
12B403d-1
Bearing temperature measuring transducer Pt100 motor 1
12B403e-1
Bearing temperature measuring transducer Pt100 motor 1
12B404a-2
Winding temperature measuring transducer Pt100 motor 2
12B404b-2
Winding temperature measuring transducer Pt100 motor 2
12B404c-2
Winding temperature measuring transducer Pt100 motor 2
12B404d-2
Bearing temperature measuring transducer Pt100 motor 2
12B404e-2
Bearing temperature measuring transducer Pt100 motor 2
12F076
1F76
Circuit breaker charging current (125A)
12F201
1F1
Circuit breaker charging device (16A)
12F202
1F2
Circuit breaker pre-heating motor oil (6A)
12F203
1F3
Circuit breaker pre-heating power take off (PTO) (6A)
12F204
1F4
Circuit breaker pre-heating battery (6A)
12F205
1F5
Circuit breaker pre-heating suction oil tank (6A)
12F206
1F6a
Circuit breaker heater RESERVE - oil tank (6A)
12F206a
1F6a
Circuit breaker heater in cab support (20A)
12F209-1
1F9-1
Circuit breaker pre-heating coolant (25A)
12F209-2
1F9-2
Circuit breaker pre-heating coolant (25A)
12F267
1F8
Circuit breaker pre-heating hydraulic oil (25A)
12F401
2F1
Circuit breaker air condition control for HV and LV switch cabinet
12F401a
1Q1a
Power protection switch for secondary protection for transformer 1
12F401b
1Q1b
Power protection switch for secondary protection for transformer 2
12F402
2F2
Circuit breaker air condition HV switch cabinet
12F403
2F3
Circuit breaker air condition LV switch cabinet
12F404-1
0F4-1
Motor protection relay motor 1
12F404-2
0F4-2
Motor protection relay motor 2
12F405
1F5
Triphasic lightning- and over voltage protection for system voltage
12F405a
1F5a
Triphasic lightning- and over voltage protection for system voltage
12F406a
Power supply vacuum contactor motor 1
12F406b
Power supply vacuum contactor motor 2
12F407
5Q7
Motor protection switch drive cable drum
12F409
0F9
Protection switch for voltage signal too KWh-counter
12F410
1F10
Threefold circuit breaker for lightning protection and over voltage protection 1
12F410a
1F10a
Threefold circuit breaker for lightning protection and over voltage protection 2
12F411
4F11
Circuit breaker socket cab
12F412
4F12
Circuit breaker socket in machinery room
12F412a
4F12a
Circuit breaker socket in machinery room
12F412b
4F12b
Circuit breaker socket in machinery room
13-28
Version 2010/1
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
Table of new and old component designations
New code
Previous code
Component
12F412c
4F12c
Circuit breaker socket in machinery room
12F414
4F10
Circuit breaker socket cab
12F416
4F16
Circuit breaker welding socket machinery room
12F417
F17
Circuit breaker radio, ladder, fire suppressin system (25A)
12F420-1
3F20-1
Circuit breaker motor standstill heater 0.47 KW
12F420-2
3F20-2
Circuit breaker motor standstill heater 0.47 KW
12F421
3F21
Circuit breaker heater and lighting for slip-ring-box
12F422
3F22
Circuit breaker terminal box heater
12F424
3F24
Circuit breaker for heater at HV switch cabinet
12F424a
3F24a
Circuit breaker for heater at HV switch cabinet
12F425
3F25
Circuit breaker for heater in LV switch cabinet
12F426
3F26
Circuit breaker for heater air condition motors
12F427
3F27
Circuit breaker heaters control
12F431
1F2
Isolation monitoring
12F432
7F1
Battery charging device emergency lighting secondary double circuit breaker
12F433
7F2
Circuit breaker emergency lighting HV switch cabinet
12F434
2Q2
Power protection switch for air condition compressor LV switch cabinet
12F435
1Q2
Motor protection relay
12F436
2Q1
Power protection switch for air condition compressor HV switch cabinet
12F437
2Q3a
Power protection switch for air condition compressor cab
12F438
0F6
Threefold circuit breaker between voltage converters
12F439
4F17
Circuit breaker welding socket ladder
12F440-1
Circuit breaker blower control cab heater
12F440-2
Circuit breaker blower control cab heater
12F441
1F4
12F442
Phase sequence relay Power supply cab heater
12F451
4Q1
(RCD) Residual current device for cab sockets, machinery room and options
12F452
4Q2
(RCD) Residual current device for welding sockets machinery room and ladder (Option)
12F453
5Q3
Motor protection switch crane on machinery room
12F454
5Q4
Motor protection switch air compressor
12F456
1F6
Circuit breaker phase sequence relay
12F462
1F12
Circuit breaker charging device supply
12F462a
1F10a
Circuit breaker charging device supply
12F462b
1F10b
Circuit breaker charging device supply
12F463
4Q2
Power protection switch for working lighting with sodium discharge lamp
12F464
4Q3
Power protection switch for working lighting with sodium discharge lamp
12F465
4Q4
Power protection switch for working lighting with sodium discharge lamp
12F466
4Q5
Power protection switch for working lighting with sodium discharge lamp
Version 2010/1
13-29
Table of new and old component designations
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
New code
Previous code
Component
12F467
4Q6
Power protection switch for working lighting with sodium discharge lamp
12F468
4Q7
Power protection switch for working lighting with sodium discharge lamp
12F469
4Q8
Power protection switch for working lighting with sodium discharge lamp
12F470
4Q9
Power protection switch for working lighting with sodium discharge lamp
12F476a
1F76a
Secondary double circuit breaker charging device 1
12F476b
1F76b
Secondary double circuit breaker charging device 2
12F476c
Secondary circuit breaker charging device 1
12F476d
Secondary circuit breaker charging device 2
12F476e
Secondary circuit breaker charging device emergency lighting
12F515
5F15
Circuit breaker heater at cable drum switch cabinet
12K010
1K10
SF6-monitoring
12K201
1K1
Independent heater on
12K209
1K9
Hydraulic oil level
12K306
CAN-Node 6 (ICND)
12K307
CAN-Node 7 (ICND)
12K308
CAN-Node 8 (ICNV)
12K403a
9K3
Fire warning system maschinery room, suppression system switch cabinets ANSUL
12K403b
9K3
Fire warning system maschinery room, suppression system switch cabinets ANSUL
12K408-1
1K8-1a
Auxiliary contactor vacuum contactor motor 1
12K408-2
1K8-2a
Auxiliary contactor vacuum contactor motor 2
12K408a-1
1K8a-1
Auxiliary relay 1 for vacuum contactor 1
12K408a-2
1K8a-2
Auxiliary relay 1 for vacuum contactor 2
12K408b-1
1K8b-1
Auxiliary relay 2 for vacuum contactor 1 redundant
12K408b-2
1K8b-2
Auxiliary relay 2 for vacuum contactor 2 redundant
12K452
K152
Safety relay for switch off heating cartridge under refrigerator for TT 60°
12K453
K152a
Safety relay for switch off heating cartridge under refrigerator for TT 100°
12K481a
K181
Safety relay for switch off heating cartridge under operator seat for TT 60°
12K481b
Safety relay for switch off heating cartridge under operator seat for TT 60°
12K481c
Safety relay for switch off heating cartridge under operator seat for TT 60°
12K481d
Safety relay for switch off heating cartridge under operator seat for TT 60°
12K482a
K182
Safety relay for switch off heating cartridge under operator seat for TT 100°
12K482b
Safety relay for switch off heating cartridge under operator seat for TT 100°
12K482c
Safety relay for switch off heating cartridge under operator seat for TT 100°
12K482d
Safety relay for switch off heating cartridge under operator seat for TT 100°
12K482-re
Reset electric cab heater
12Q201
Pre-heating, manual power switch for power supply
12Q209-1
Pre-heating, level motor oil
13-30
Version 2010/1
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
Table of new and old component designations
New code
Previous code
Component
12Q401
3K1
Relay heater HV switch cabinet
12Q402
3K2
Relay heater LV switch cabinet
12Q403
5K3
Motor contactor air compressor
12Q404
2K4
Powers switch for air condition compressor cab
12Q405
3K5
Contactor for heating cartridge b under operator seat (4 KW)
12Q406
3K6
Contactor for heating cartridge c under operator seat (6 KW)
12Q407
3K7
Contactor for heating cartridge a under operator seat (2 KW)
12Q411
2K1
Relay air condition HV switch cabinet
12Q411a
2K1a
Relay air condition LV switch cabinet
12Q421-1
1K21-1
Standstill heater motor 1
12Q421-2
1K21-2
Standstill heater motor 2
12Q444
1K44
Key switch on for electric shovels
12Q452e
Blower after-running for heater under operator seat
12Q481e
Blower after-running for heater under refrigerator
12Q490a
4K1a
Contactor working lighting sodium discharge lamp
12Q490b
4K1b
Contactor working lighting sodium discharge lamp
12Q490c
4K1c
Contactor working lighting sodium discharge lamp
12Q490d
4K1d
Contactor working lighting sodium discharge lamp
12R402
1R2
Battery charging device emergency lighting shunt
12R403
4L1
Power supply unit working lighting sodium discharge lamp
12R404
4L2
Power supply unit working lighting sodium discharge lamp
12R405
4L3
Power supply unit working lighting sodium discharge lamp
12R406
4L4
Power supply unit working lighting sodium discharge lamp
12R407
4L5
Power supply unit working lighting sodium discharge lamp
12R408
4L6
Power supply unit working lighting sodium discharge lamp
12R409
4L7
Power supply unit working lighting sodium discharge lamp
12R410
4L8
Power supply unit working lighting sodium discharge lamp
12R420
Resistor array
12R421
Diode array
12S561
1S161
Test key for isolation monitoring
12T082
R82
Measuring transducer for battery voltage (emergency voltage supply)
12T401
1A1
Measuring transducer temperature transformator 1
12T402
1A2
Measuring transducer temperature transformator 1
12T407
0T7
Voltage transformer for load limit regulation and X2-box-controller
12T408-1
0T8-1
Current- / Voltage converter for load limit regulation motor 1 5A AC / 10V AC
12T408-2
0T8-2
Current- / Voltage converter for load limit regulation motor 2 5A AC / 10V AC
12T410-1
0T10-1
Current transformer KWh-counter L1 motor 1
12T410-2
0T10-2
Current transformer KWh-counter L1 motor 2
Version 2010/1
13-31
Table of new and old component designations
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
New code
Previous code
Component
12T411-1
0T11-1
Current transformer KWh-counter L2 motor 1
12T411-2
0T11-2
Current transformer KWh-counter L2 motor 2
12T412-1
0T12-1
Current transformer KWh-counter L3 motor 1
12T412-2
0T12-2
Current transformer KWh-counter L3 motor 2
12T431
Signal rectifier for voltage, current 1 and current 2
12T431-1
Signal rectifier point of connection for current 1
12T431-2
Signal rectifier point of connection for current 2
12T431-3
Signal rectifier point of connection for voltage
12X001
1X1
Terminal strip on LV-switch panel
12X306
CAN-Bus-T-Splitter Node 6
12X307
CAN-Bus-T-Splitter Node 7
12X308
CAN-Bus-T-Splitter Node 8
13a000
Under-floor from cab support
13B090
B90
Ambient air temperature
13E003
2M3a
Air condition compressor cab
13E101
2R1
Heater air condition compressor HV switch cabinet
13E208
1R8
Pre-heating for battery control voltage
13E209
1R9
Pre-heating for battery control voltage
13G008
G8
Battery control voltage
13G009
G9
Battery control voltage
13M001
**M1V
Air condition compressor motor cab
13Q003
Battery main switch control voltage
13T002
1U2
Battery charging device 75A
13T003
1U3
Battery charging device 75A
13T004
1U4
Battery charging device 75A
14a000 15a000
Board for customer extensions in cab support
16a000
Switch box pre-heating hydraulic oil
16F260
Circuit breaker pre-heating hydraulic oil heating element 4E60 (3x10A)
16F261
Circuit breaker pre-heating hydraulic oil heating element 4E61 (3x10A)
16F262
Circuit breaker pre-heating hydraulic oil heating element 4E62 (3x10A)
16F263
Circuit breaker pre-heating hydraulic oil heating element 4E63 (3x10A)
16F264
Circuit breaker pre-heating hydraulic oil heating element 4E64 (3x10A)
16F265
Circuit breaker pre-heating hydraulic oil on
16K267
Switch off pre-heating hydraulic oil for low hydraulic oil level
16P267
Hydraulic oil pre-heating ready
16P268
Hydraulic oil pre-heating on
16Q260
Pre-heating hydraulic oil heating element 4E60 on
13-32
Version 2010/1
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
New code
Previous code
Table of new and old component designations
Component
16Q261
Pre-heating hydraulic oil heating element 4E61 on
16Q262
Pre-heating hydraulic oil heating element 4E62 on
16Q263
Pre-heating hydraulic oil heating element 4E63 on
16Q264
Pre-heating hydraulic oil heating element 4E64 on
16Q265
Pre-heating hydraulic oil on
16S267
Pre-heating hydraulic oil on
17a000
Air condition at cab support
17B001a
*B1Ta
Thermostat evaporator LV switch cabinet
17B001b
*B1Tb
Thermostat evaporator LV switch cabinet
17B001f
*B1F
Pressure switch condenser LV switch cabinet (Lower pressure limit)
17B011f
*B11F
Pressure switch condenser LV switch cabinet (Upper pressure limit)
17E001
2M2
Air condition compressor LV switch cabinet
17E101
*2R1
Heater air condition compressor LV switch cabinet
17F001
*A1P
Motor protection relay for compressor motor for LV switch cabinet
17G001
*M1G
Blower evaporator LV switch cabinet
17G021
*M21M
Blower liquefier LV switch cabinet
17G022
*M22M
Blower liquefier LV switch cabinet
17K004
2E4
Air condition LV switch cabinet
17M001
*M1V
Compressor motor LV switch cabinet
18a000
Board for air condition HV switch cabinet
18F001
*F1M
Circuit breaker blower evaporator HV switch cabinet
18F002
*F2M
Circuit breaker blower liquefier HV switch cabinet
18F003
*F3M
Circuit breaker blower liquefier HV switch cabinet
18F004
*F1A
Circuit breaker for blower HV switch cabinet
18K401
2E1-1
Board air condition HV switch cabinet at wall in cab support
18Q001
*K1M
Power relay blower evaporator HV switch cabinet
18Q002
*K2M
Power relay blower liquefier HV switch cabinet
18Q003
*K3M
Power relay blower liquefier HV switch cabinet
19a000
Control panel for air condition LV switch cabinet
19F001
*F1M
Circuit breaker blower evaporator LV switch cabinet
19F002
*F2M
Circuit breaker blower liquefier LV switch cabinet
19F003
*F3M
Circuit breaker blower liquefier LV switch cabinet
19F004
*F1A
Circuit breaker for blower LV switch cabinet
19K404
2E4-1
Board air condition LV switch cabinet at wall in cab support
19Q001
*K1M
Power relay blower evaporator LV switch cabinet
19Q002
*K2M
Power relay blower liquefier LV switch cabinet
19Q003
*K3M
Power relay blower liquefier LV switch cabinet
20a000
Version 2010/1
Cab
13-33
Table of new and old component designations
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
New code
Previous code
Component
20B001
B1N
Thermostat air condition
20B003
3B3
Temperature switch overheat control for heating element under operator seat 60°
20B003a
3B3a
Temperature switch overheat control for heating element under operator seat 100°
20B004
3B4
Temperature switch overheat control for heating element under refrigerator 60° for TT
20B004a
3B4a
Temperature switch overheat control for heating element under refrigerator 100° for TT
20E001
Heater under operator seat
20E001a
3H1a
Heating element a under operator seat (2 KW)
20E001b
3H1b
Heating element b under operator seat (2 KW)
20E001c
3H1c
Heating element c under operator seat (2 KW)
20E002
Heating device under refrigerator
20E002a
3H2a
Heating element a under refrigerator for TT (2 KW)
20E002b
3H2b
Heating element b under refrigerator for TT (2 KW)
20E002c
3H2c
Heating element c under refrigerator for TT (2 KW)
20E013
E13
Cigarette lighter
20E026
E26
Air condition cab
20E034
9R4
Igniter fire suppression system
20E035
9R5
Resistor fire suppression system
20E036
9R6
Resistor fire suppression system
20E044
E44
Refrigerator
20E044a
E44a
Cab indoor lighting
20E044b
E44b
Cab indoor lighting
20E044c
E44c
Cab indoor lighting
20E044d
E44d
Cab indoor lighting
20E045
H45
Lighting pantry
20E047a
H47a
Lighting ladder at cab
20E048
H48
Working light cab roof left
20E048a
E48a
Working light cab roof left
20E048b
H48b
Working light cab roof right
20E048c
H48c
Working light cab roof right
20E090
R90
Operator seat heater
20E160
H160
Reading lamp
20G009
M9
Blower air condition
20G010
M10
Excess pressure blower (new cab)
20G027
M27
Water pump washbasin
20G501
Y3a
Pump windscreen wash system
13-34
Version 2010/1
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
New code
Previous code
Table of new and old component designations
Component For activ independent heater mixing-valve-control switch over from air condition too pre-heating
20K048 20K056
E56
Control panel independent heater Hydronic M
20K057
E57
Timer independent heater Hydronic M
20K166
K166
Switch over blower control between air condition and pre-heating
20K167
K167
Pre-heating on (TT)
20K309
CAN-Node 9 (ICND)
20K310
CAN-Node 10 (ICNV)
20K351
9E1
Fire warning system ANSUL for electric machinery room or fire suppression system ANSUL for diesel machinery room
20K352
9E2
Fire suppression system ANSUL for LV- and HV switch cabinetHV switch cabinet
20K464
E64
Control unit camera cab support
20K467
E67
Control unit camera counterweight left
20K470
E70
Control unit camera counterweight right
20K473
Control unit camera cable delivery
20M004
M4
Windscreen wiper motor upper
20M004a
3M4a
Blower motor under operator seat for TT
20M004b
3M4b
Blower motor under refrigerator for TT
20M007
M7
Windscreen wiper motor lower
20M025
M25
Operator seat adjust
20P022
H22
Acoustic signal for messages
20P025
E25
Radio
20P026
M26
Mirror right
20P026a
M26a
Mirror left
20P047
E47
VHMS monitor MH801
20P056
H56
Acoustic shutdown pre-warning
20P072
H72
Speaker
20P073
H73
Speaker
20P093a
H93a
Rotaflare light left
20P093b
H93b
Rotaflare light right
20P145-1
H145-1
VHMS-diagnostic lamp red 1
20P145-2
H145-2
VHMS-diagnostic lamp red 2
20P146-1
H146-1
VHMS-diagnostic lamp yellow 1
20P146-2
H146-2
VHMS-diagnostic lamp yellow 2
20P465
E65
Monitor camera cab support
20P468
E68
Monitor camera counterweight left
20P471
E71
Monitor camera counterweight rechts
20P474
E74
Monitor camera cable delivery
Version 2010/1
13-35
Table of new and old component designations
New code
Previous code
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
Component
20Q048a
Mixing valve control by pre-heating
20Q048b
Mixing valve control by air condition
20Q067
K67
Excess pressure blower cab
20Q097
Y97
Mixing valve for heater
20Q166
K166
Blower on by independent heater (TT)
20Q166a
Use constant blower speed signal from independent heater (10 V)
20Q166b
Use analog blower speed signal from air condition
20Q166c
Use blower supply from independent heater
20Q166d
Use blower supply from air condition
20Q167a
Swtich on independent heater if pre-heating system is switched on
20Q167b
Switch on independent heater by timer signal of independent heater
20Q193
K193
Windscreen wiper lower stop
20Q194
K194
Windscreen wiper upper stop
20Q195
K195
Windscreen wiper lower slow
20Q196
K196
Windscreen wiper lower fast
20Q197
K197
Windscreen wiper upper slow
20Q198
K198
Windscreen wiper upper fast
20R009
Resistor array
20R019
Diode array
20R101
Terminal resistor CAN-Bus
20R353
9R3
Terminal resistor fire sensor 10 V constant voltage generation for heater-blower-motor speed-signal in case of activ independent heater
20R560 20S001
S1
Key switch
20S004-1
S4-1
Motor / Engine start button 1
20S004-2
S4-2
Motor / Engine start button 2
20S005-1
S5-1
Motor / Engine stop button 1
20S005-2
S5-2
Motor / Engine stop button 2
20S006
S6
Horn contact
20S010
S10
Windscreen wiper wash system switch
20S011
S11
Windscreen wiper mode switch
20S016
S16
Switch cab indoor light
20S018a
S18a
Switch lighting ladder
20S019
E19
Lever right
20S020
E20
Lever left
20S021a
E21a
Pedal move, left crawler
20S021b
E21b
Pedal move, right crawler
20S022
E22
Pedal slew brake
20S023
E23
Pedal left (BC), clam close
13-36
Version 2010/1
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
Table of new and old component designations
New code
Previous code
Component
20S024
E24
Pedal right (BC), clam open
20S026a
E26a
Control panel air condition
20S029
S29
Switch slew parking brake
20S030
S30
Engine speed switch
20S034
S34
EBL-bypass
20S036
S36/0S36
Emergency shutdown cab
20S038
S38
Switch cab light
20S040
S40
Switch excess pressure blower cab
20S042
S42
Truck counter 2
20S053
S53
Service enable motor control QUANTUM for both engines
20S055
S55
Rotaflare light on
20S082
S82
Truck counter 1
20S086
S86
Operator seat adjust
20S088
S88
Mirror adjustment
20S089
S89
Operator seat heater on
20S094
S94
Enable service arm
20S095
S95
Floating position switch
20S096
S96
Mirror heater on
20S098
S98
Floating position switch
20S099
S99
CLS 2, central lubrication system attachment, manual lubrication
20S105
S105
Lock lever at operator seat
20S120
4S20/S20
Switch superstructure lighting
20S120a
S20a
Switch superstructure lighting (option)
20S124
S24
CLS 1, central lubrication system 1, button for manual lubrication cycles
20S126
S26
SLS, slew lubrication system, manual lubrication
20S154
S154
Slew speed mode
20W323
WLAN-Interface cable between cab floor and dashboard (MTCPC)
20X015-1
QUANTUM 1, RS232-Interface in cab
20X015-2
QUANTUM 2, RS232-Interface in cab
20X027a
X27a
VHMS: Download or programming in cab
20X031
X31
Socket cab outside
20X032
X32
Socket cab inside
20X033
X33
Socket cab inside
20X034
X34
Socket cab inside
20X035
X35
Socket cab inside
20X052-1
Diagnose connector in cab, QUANTUM 1, J1587
20X052-2
Diagnose connector in cab, QUANTUM 2, J1587
20X093a
Version 2010/1
X11a
Connector rotaflare light left
13-37
Table of new and old component designations
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
New code
Previous code
Component
20X093b
X11b
Connector rotaflare light right
20X110
X13
Service connector in der cab, load limit regulation
20X309
CAN-Bus-T-Splitter Node 9
20X323
WLAN-Interface connector in cab (MTCPC)
20X335b
CAN-Bus-T-Splitter to dispatch monitor HUB in cab support
20X335d
CAN-Bus-T-Splitter to dispatch monitor display in cab
20X335e
CAN-Bus-T-Splitter to service connector MH801
20X336
Service connector MH801 in cab
20X399
CAN-Bus-T-Splitter Node 10
20X401
4X1
Socket cab
20X402
4X2
Socket cab
30a000
Drive
30B701
6B1
Temperature sensor in HV switch cabinet
30B703A
0B3-1
Temperature sensor transformer A
30B703B
0B3-2
Temperature sensor transformer B
30B704A
0B3-1
Temperature sensor transformer A
30B704B
0B3-2
Temperature sensor transformer B
30B705A
0B3-1
Temperature sensor transformer A
30B705B
0B3-2
Temperature sensor transformer B
30B706
2B6
Temperature switch air condition in HV switch cabinet
30B707
2B7
Dampness switch air condition in HV switch cabinet
30B753
9B3
Temperature sensor HV switch cabinet fire suppression system
30B754
9B4
Temperature sensor HV switch cabinet fire suppression system
30B755
9B5
Temperature sensor HV switch cabinet fire suppression system
30B810
0S10
Limit switch at HV switch cabinet
30B811
0S11
Limit switch at transformer room
30E721
3R21
Heater for HV switch cabinet
30E722
3R22
Heater for HV switch cabinet
30E722a
3R22a
Heater am HV switch cabinet
30E723
Heater transformer room
30E802
7H2
Lighting in HV switch cabinet
30T706A
0T6-1
Transformer system voltage A
30T706B
0T6-2
Transformer system voltage B
31a000
Diesel tank
31B063
B63
Level fuel tank
31G140
Y140
Fuel pump Hydronic M
31Q599-1
Y99-1
Fuel valve motor 1
31Q599-2
Y99-2
Fuel valve motor 2
13-38
Version 2010/1
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
New code
Previous code
32a000
Table of new and old component designations
Component HV - switch cabinet
32B802
6B2
Temperature switch at HV switch cabinet
32F701-1
0F1-1
Circuit breaker for motor 1
32F701-2
0F1-2
Circuit breaker for motor 2
32F702
0F2
HV primary circuit breaker for system transformer 1 and 2
32F703-1
0F3-1
Over voltage protection at motor 1 (discharger)
32F703-2
0F3-2
Over voltage protection at motor 2 (discharger)
32F707
0F7
Over voltage protection in high voltage (VDR-resistor)
32Q700
0Q1
Main switch
32Q701-1
0K1-1
Vacuum contactor motor 1
32Q701-2
0K1-2
Vacuum contactor motor 2
32T701-1
0T1-1
Current transformer phase 1 motor 1
32T701-2
0T1-2
Current transformer phase 1 motor 2
32T702-1
0T2-1
Current transformer phase 2 motor 1
32T702-2
0T2-2
Current transformer phase 2 motor 2
32T703-1
0T3-1
Current transformer phase 3 motor 1
32T703-2
0T3-2
Current transformer phase 3 motor 2
32T704
0T4
Voltage transformer between high voltage and low voltage
32T705
0T5
Voltage transformer between high voltage and low voltage
33a000 33X003
Low voltage in HV switch cabinet 0X3
34a000
Terminal strip in HV switch cabinet Air condition at HV switch cabinet
34B001
3B1
Temperature switch heater at HV switch cabinet
34B001a
*B1Ta
Thermostat evaporator HV switch cabinet
34B001b
*B1Tb
Thermostat evaporator HV switch cabinet
34B001f
*B1F
Pressure switch capacitor HV switch cabinet (lower pressure limit)
34B006
2B6
Temperature switch air condition at HV switch cabinet
34B007
2B7
Dampness switch air condition at HV switch cabinet
34B011f
*B11F
Pressure switch capacitor HV switch cabinet (upper pressure limit)
34E801
2M1
Air condition compressor HV switch cabinet
34E802
*2R1
Heater air condition compressor HV switch cabinet
34F001
*A1P
Motor protection relay compressor drive HV switch cabinet
34G001
*M1G
Blower evaporator HV switch cabinet
34G021
*M21M
Blower liquefier HV switch cabinet
34G022
*M22M
Blower liquefier HV switch cabinet
34K801
2E1
Air condition HV switch cabinet
34M801
*M1V
Compressor motor HV switch cabinet
40a000
Version 2010/1
hydraulic oil tank
13-39
Table of new and old component designations
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
New code
Previous code
Component
40B004
B4
Very low hydraulic oil level
40B024
B24
Hydraulic oil tank air filter monitoring
40B031
S31
Shut-off valve oil tank open
40B050
B50
Oil level too low (Refill indicator)
40B068
B68
Level return oil chamber (Nur PC8000)
40B105
B105
Level hydraulic oil
40B111
B111
Temperature sensor transfer pump
40B163
B163
Pressure return oil chamber
40B164
B164
Pressure leak oil chamber
40B165
B165
Pressure oil cooler
40B166
B166
Pressure preload valve return oil
40B260
1B60
Pre-heating temperature switch heating element 4E60
40B261
1B61
Pre-heating temperature switch heating element 4E61
40B262
1B62
Pre-heating temperature switch heating element 4E62
40B263
1B63
Pre-heating temperature switch heating element 4E63
40B264
1B64
Pre-heating temperature switch heating element 4E64
40B265
1B65
Pre-heating temperature switch heating element 4E65
40B267
1B67
Pre-heating temperature switch hydraulic oiltank
40E260
Pre-heating hydraulic oil heating element
40E261
Pre-heating hydraulic oil heating element
40E262
Pre-heating hydraulic oil heating element
40E263
Pre-heating hydraulic oil heating element
40E264
Pre-heating hydraulic oil heating element
40E265
Pre-heating hydraulic oil heating element
40G018
M8
Transfer pump hydraulic oil
40K311
CAN-Node 11 (ICND)
40K312
CAN-Node 12 (ICND)
40K313
CAN-Node 13 (ICNV)
40K601
Y101
Reducing preload pressure oil cooler
40Q062
K62 / 5K62
Electronic relay 35 A for transfer pump 30 A
40R008
Pull-up/-down-resistors (resistor array)
40R014
Diode array
40R101
Terminal resistor CAN-Bus
40S035
S35
Transfer pump on
40X310
CAN-Bus-Connector
40X311
CAN-Bus-T-Splitter Node 11
40X312
CAN-Bus-T-Splitter Node 12
40X313
CAN-Bus-T-Splitter Node 13
13-40
Version 2010/1
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
New code
Previous code
Component
40X314
CAN-Bus-Connector
41a000
Oil cooler
41E050
H50
Light oil cooler
41E050a
H50a
Light oil cooler
41E050b
H50b
Light oil cooler
41E050c
H50c
Light oil cooler
41E050d
H50d
Light oil cooler
50a000 50B353
Table of new and old component designations
Machinery room 9S3
50Q352
Fire sensor Set free extinguishing medium (igniter)
50R352
9R2
Terminal resistor fire sensor
50S058
S58/1S58
Service safty switch
50X020
X20
External start socket
50X201
Main supply connector for pre-heating
51a000
Motor room
51B110
B110
Intake air temperature
51E041
H43
Lighting pump room
51E041a
H43a
Lighting pump room
51E041e
H43c
Lighting motor room
51E041f
H43d
Lighting motor room
51E219-1
Pre-heating coolant
51E219-2
Pre-heating coolant
51K001a-1
K1a-1
Engine start relay motor 1
51K001a-2
K1a-2
Engine start relay motor 2
51K001b-1
K1b-1
Engine start relay motor 1 redundant
51K001b-2
K1b-2
Engine start relay motor 2 redundant
51K003b-1
K3b-1
Engine running 1
51K003b-2
K3b-2
Engine running 2
51K003c-1
K3c-1
Engine running 1
51K003c-2
K3c-2
Engine running 2
51K045-1
K45-1
Engine speed control 1
51K045-2
K45-2
Engine speed control 2
51K164-1
K164-1
Relay for RESERVE - system motor oil tank not empty for motor 1
51K164-2
K164-2
Relay for RESERVE - system motor oil tank not empty for motor 2
51K317
CAN-Node 17 (ICND)
51K318
CAN-Node 18 (ICNV)
51K319
CAN-Node 19 (ICNV)
51R008
Pull-up/-down-resistors (resistor array)
Version 2010/1
13-41
Table of new and old component designations
New code
Previous code
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
Component
51R009
Pull-up/-down-resistors (resistor array)
51R013
Diode array (3 A)
51R017
Diode array (3 A)
51S015a
S15a
Lighting pump room / motor room
51S033d
S33d
Emergency stop button engine room (only PC5500 and PC8000)
51T017
E7
Measuring transducer charging-/discharging current
51T018-1
E8-1
Measuring transducer engine speed engine 1
51T018-2
E8-2
Measuring transducer engine speed engine 2
51X008
X8
Socket engine room
51X316
CAN-Bus-Connector
51X317
CAN-Bus-T-Splitter Node 17
51X318
CAN-Bus-T-Splitter Node 18
51X319
CAN-Bus-T-Splitter Node 19
51X320
CAN-Bus-Connector
51X403
4X3
Socket machinery room
51X404
4X4
Socket machinery room
51X405
4X5
Socket machinery room optional
51X405a
4X5a
Socket machinery room optional
51X406
4X6
Welding socket machinery room
52a000
Motor
52B002-1
0B2-1
Motor winding temperature sensor motor 1
52B002-2
0B2-2
Motor winding temperature sensor motor 2
52B002a-1
0B2a-1
Motor winding temperature sensor motor 1
52B002a-2
0B2a-2
Motor winding temperature sensor motor 2
52B002b-1
0B2b-1
Motor winding temperature sensor motor 1
52B002b-2
0B2b-2
Motor winding temperature sensor motor 2
52B006-1
0B6-1
Motor bearing temperature sensor motor 1 power take-off side
52B006-2
0B6-2
Motor bearing temperature sensor motor 2 power take-off side
52B007-1
0B7-1
Motor bearing temperature sensor motor 1 not power take-off side
52B007-2
0B7-2
Motor bearing temperature sensor motor 2 not power take-off side
52B018-1
B18-1
Monitoring engine intake air filter engine 1
52B018-2
B18-2
Monitoring engine intake air filter engine 2
52B019-1
B19-1
Monitoring engine intake air filter engine 1
52B019-2
B19-2
Monitoring engine intake air filter engine 2
52B064-1
3B64-1
Speed sensor, magnetic pickup 1
52B064-2
3B64-2
Speed sensor, magnetic pickup 2
52B093-1
3B93-1
Engine pre lub pressure reached
52B093-2
3B93-2
Engine pre lub pressure reached
13-42
Version 2010/1
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
Table of new and old component designations
New code
Previous code
Component
52B101-1
0S1-1
Capacitor pressure switch at motor 1
52B101-2
0S1-2
Capacitor pressure switch at motor 2
52B102-1
0S2-1
Capacitor pressure switch at motor 1
52B102-2
0S2-2
Capacitor pressure switch at motor 2
52B201-1
1B1
Pre-heating temperature switch motor oil
52B201-2
1B1
Pre-heating temperature switch motor oil
52C001-1
0C1-1
Capacitor pressure switch at motor 1
52C001-2
0C1-2
Capacitor pressure switch at motor 2
52E017-1
3R17-1
Motor standstill heater 0.,47 KW
52E017-2
3R17-2
Motor standstill heater 0.47 KW
52E201-1
1R1
Pre-heating motor oil 1
52E201-2
1R1
Pre-heating motor oil 2
52F0039-1
Circuit breaker pre lub pump 1 (300 A)
52F0039-2
Circuit breaker pre lub pump 2 (300 A)
52G005-1
3G5-1
Generator
52G005-2
3G5-2
Generator
52G006-1
3M6-1
Pre lub pump
52G006-2
3M6-2
Pre lub pump
52G045-1
3E45-1
Motor oil refilling system
52G045-2
3E45-2
Motor oil refilling system
52K014-1
3E14-1
Engine controller QUANTUM 1
52K014-2
3E14-2
Engine controller QUANTUM 2
52K030-1
3D30-1
Timer engine pre lub 1
52K030-2
3D30-2
Timer engine pre lub 2
52M001-1
3M1-1
Starter 1 (engine 1)
52M001-2
3M1-2
Starter 1 (engine 2)
52M002-1
3M2-1
Starter 2 (engine 1)
52M002-2
3M2-2
Starter 2 (engine 2)
52M101-1
0M1-1
E-Motor 1
52M101-2
0M1-2
E-Motor 2
52Q002a-1
3K2a-1
Starter 1 for engine 1 on
52Q002a-2
3K2a-2
Starter 1 for engine 2 on
52Q002b-1
3K2b-1
Starter 2 for engine 1 on redundant
52Q002b-2
3K2b-2
Starter 2 for engine 2 on redundant
52Q004-1
Y4
Magnetic clutch air condition
52Q030a-1
3K30a-1
Pre lub pump 1 on
52Q030a-2
3K30a-2
Pre lub pump 2 on
52Q502a-1
Y2-1
Cold start engine 1 valve a
Version 2010/1
13-43
Table of new and old component designations
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
New code
Previous code
Component
52Q502a-2
Y2-2
Cold start engine 2 valve a
52Q502b-1
Y2a-1
Cold start engine 1 valve b
52Q502b-2
Y2a-2
Cold start engine 2 valve b
54a000
Counterweight
54B466
E66
Camera counterweight left
54B469
E69
Camera counterweight right
54E144
H144
Light counterweight
54E144a
H144a
Light counterweight
54E144b
H144b
Light counterweight to cable drum
54S007
S7
Operator warning system, pull key
54S008
S8
Operator warning system, pull key
54S051
S54
Ground shutdown, pull switch
54S052
S54a
Ground shutdown, pull switch
54X008b
X8c
Socket counterweight
55a000
Service arm
55B023
S23
Service arm near upper position
55P052
H52
Hydraulic tank full
55P076
H76
CLS 1 Central lubrication system full
55P078
H78
SLS Slew lubrication system full
55P080
H80
CLS 2 Central lubrication system attachment full
55P139
H139
Signal lamp fuel tank full
55P142-1
H142-1
Signal lamp motor oil tank 1 full
55P142-2
H142-1
Signal lamp motor oil tank 2 full
55S043
S43
Lamp test service arm
55S087
S87
Pull switch service arm
56a000
Pump room
56E041b
H41
Lighting pump room
56E041c
H41a
Lighting pump room
56E041d
H41b
Lighting pump room
56K053-1
E53-1
Blower speed PWM-Converter for coolant 1
56K053-2
E53-2
Blower speed PWM-Converter for coolant 2
56K250a
K250a
Slew gear parking brake
56K250b
K250b
Slew gear parking brake
56K251a
K251a
Travel parking brake
56K251b
k251b
Travel parking brake
56K252a
K252a
Hydraulic slew gear parking brake
56K252b
k252b
Hydraulic slew gear parking brake
56K253a
13-44
Ladder up
Version 2010/1
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
New code
Previous code
Table of new and old component designations
Component
56K253b
Ladder up redundant
56K254a
Ladder down
56K254b
Ladder down redundant
56K255a
Service arm up
56K255b
Service arm up redundant
56K256a
Service arm down
56K256b
Service arm down redundant
56K314
CAN-Node 14 (ICND)
56K315
CAN-Node 15 (ICNV)
56K316
CAN-Node 16 (ICNV)
56R008
Resistor array
56R013
Diode array
56R014
Diode array
56S015
S15
Lighting pump room / motor room
56X008a
X8a
Socket pump room
56X313
CAN-Bus-Connector at switch cabinet pump room
56X314
CAN-Bus-T-Splitter Node 14
56X315
CAN-Bus-T-Splitter Node 15
56X316
CAN-Bus-T-Splitter Node 16
56X317
CAN-Bus-Connector at switch cabinet pump room
57a000
Control plate, pump
57B016
B16
Pressure brake slew gear
57B017-1
B17-1
Pressure gear lubrication
57B017-2
B17-2
Pressure gear lubrication
57B021-1
B21-1
Filter fan drive cooler
57B021-2
B21-2
Filter fan drive cooler
57B022-1
B22-1
Filter pump regulation
57B022-2
B22-2
Filter pump regulation
57B027-1
B27-1
Filter gear oil
57B027-2
B27-2
Filter gear oil
57B028-1
B28-1
Filter fan drive oil cooler
57B028-2
B28-2
Filter fan drive oil cooler
57B048
B48
Pressure travel parking brake
57B049-1
B49-1
Gear oil temperature
57B049-2
B49-2
Gear oil temperature
57B085-1
B85-1
X1-Pressure, motor / engine 1
57B085-2
B85-2
X1-Pressure, motor / engine 2
57B086
B86
X2-Pressure
Version 2010/1
13-45
Table of new and old component designations
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
New code
Previous code
Component
57B097-1
B97-1
Pump support pressure X4-1
57B097-2
B97-2
Pump support pressure X4-2
57B175-1
B175-1
Total loss gear oil
57B175-2
B175-2
Total loss gear oil
57B202-1
1B2
Pre-heating temperature switch PTO 1
57B202-2
1B2
Pre-heating temperature switch PTO 1
57E202-1
1R2, 3R23-1
Pre-heating heater PTO 1
57E202-2
1R2, 3R23-2
Pre-heating heater PTO 2
57E203-1
1R3, 3R24-1
Pre-heating heater PTO 1
57E203-2
1R3, 3R24-2
Pre-heating heater PTO 2
57K506a-1
Y6a-1
Fan drive oil cooler minimum
57K506a-2
Y6a-2
Fan drive oil cooler minimum
57K506b-1
Y6b-1
Fan drive oil cooler medium
57K506b-2
Y6b-2
Fan drive oil cooler medium
57K517
Y17
Pump control, Qmin-off
57K517a
Y17a
Pump control, Half-Qmax-off
57K548
Y48
Slew motor pivoting angle (only PC5500)
57K553-1
Y53-1
Gear oil cooler preload pressure
57K553-2
Y53-2
Gear oil cooler preload pressure
57K561-1
Y61-1
Load limit regulation valve
57K561-2
Y61-2
Load limit regulation valve
57K602-1
Y102-1
Switch off pump support pressure
57K602-2
Y102-2
Switch off pump support pressure
57K620
Y120
Hydraulic brake
57K626
Y126
Pump control, 57K517 at pump 1
57K630
Y130
Pump control, fixed pump 1 for slew gear
57K631
Y131
Pump control, fixed pump 3 for slew gear
57K636-1
Y136-1
Proportional valve fan coolant
57K636-2
Y136-2
Proportional valve fan coolant
57K646
Y146
Loss reduction pump 2+4
57K647
Y147
Loss reduction pump 3
57K648
Y148
Loss reduction pump 1
57K658f
Control pump 1 F
57K658r
Control pump 1 R
57K659f
Control pump 2 F
57K659r
Control pump 2 R
57K660f
Control pump 3 F
57K660r
Control pump 3 R
13-46
Version 2010/1
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
New code
Previous code
Table of new and old component designations
Component
57K661f
Control pump 4 F
57K661r
Control pump 4 R
57K662f
Control pump 5 F
57K662r
Control pump 5 R
57K663f
Control pump 6 F
57K663r
Control pump 6 R
57K664f
Control pump 7 F
57K664r
Control pump 7 R
57K665f
Control pump 8 F
57K665r
Control pump 8 R
57Q505
Y5
Slew gear parking brake
57Q516
Y16
Travel parking brake
57Q623a
Y123a
Valve ladder up
57Q623b
Y123b
Valve ladder down
57Q624a
Y124a
Valve service arm up
57Q624b
Y124b
Valve service arm down
57Q624c
Y124c
Valve service arm enable
57Q625
Y125
Valve ladder fast
57Q627
Y127
Proportional valve brake
57S033c
S33c
Emergency stop button control- and filter panel
59a000
Suction oil tank
59B015
B15
Temperature hydraulic oil
59B162
B162
Pressure suction oil tank
59B203
1B3
Pre-heating temperature switch suction oil tank
59E210
1R10
Pre-heating suction oil tank
59E211
1R11
Pre-heating suction oil tank
60a000
Superstructure
60B059
S59
Angle limit beetween supertructure and undercarriage
60B098
B98
Inductive proximity at sprocket
60B099
B99
Inductive proximity at sprocket
60B472
E72
Camera counterweight cable delivery
60E030
3R30
Pipe heater for fire suppression system
60E049
H49
Outside lighting superstructure atrium center
60E049a
H49a
Outside lighting superstructure atrium center
60E049b
H49b
Outside lighting superstructure atrium center
60E049c
H49c
Outside lighting superstructure atrium center
60E144c
H144c
Light superstructure left
60E144d
H144d
Light superstructure right
Version 2010/1
13-47
Table of new and old component designations
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
New code
Previous code
Component
60E148
4H48
Working lighting sodium discharge lamp 400W
60E149
4H49
Working lighting sodium discharge lamp 400W
60E150
4H50
Working lighting sodium discharge lamp 400W
60E150a
4H50a
Working lighting sodium discharge lamp 400W
60E244
4H144
Working lighting sodium discharge lamp 400W
60E244a
4H144a
Working lighting sodium discharge lamp 400W
60E244b
4H144b
Working lighting sodium discharge lamp 400W
60E244c
4H144c
Working lighting sodium discharge lamp 400W
60P140
H140
Travel alarm
60P351
9H1
Horn for fire ralarm
60S152
S152
Switch lighting superstructure
61a000
Control blocks, Remote control panels
61B087a
B87a
Input pressure control block 1
61B087b
B87b
Input pressure control block 2
61B087c
B87c
Input pressure control block 3
61B087d
B87d
Input pressure control block 4
61B158a
pressure pump 1
61B158b
pressure pump 2
61B158c
pressure pump 3
61B158d
pressure pump 4
61B158e
pressure pump 5
61B158f
pressure pump 6
61B158g
pressure pump 7
61B158h
pressure pump 8
61K071
Y71
Speed bucket BH
61K520
Y20
Directional spool valve boom up (PC4000-6)
61K521
Y21
Directional spool valve boom down (PC4000-6)
61K522
Y22
Directional spool valve bucket fill BC (PC4000-6)
61K523
Y23
Directional spool valve bucket dump BC (PC4000-6)
61K524
Y24
Directional spool valve slew gear left (PC4000-6)
61K525
Y25
Directional spool valve slew gear right (PC4000-6)
61K526
Y26
Directional spool valve slew gear left (PC4000-6)
61K527
Y27
Directional spool valve slew gear right (PC4000-6)
61K528
Y28
Proportional valve crawler right forward (PC4000-6)
61K529
Y29
Proportional valve crawler right backward (PC4000-6)
61K530
Y30
Directional spool valve stick in BH (PC4000-6)
61K531
Y31
Directional spool valve stick out BH (PC4000-6)
61K532
Y32
Directional spool valve boom up (PC4000-6)
13-48
Version 2010/1
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
Table of new and old component designations
New code
Previous code
Component
61K533
Y33
Directional spool valve boom down (PC4000-6)
61K534
Y34
Directional spool valve crawler left forward (PC4000-6)
61K535
Y35
Directional spool valve crawler left backward (PC4000-6)
61K536
Y36
Directional spool valve bucket fill BH (PC4000-6)
61K537
Y37
Directional spool valve bucket dump BH (PC4000-6)
61K538
Y38
Directional spool valve stick in BH (PC4000-6)
61K539
Y39
Directional spool valve stick out BH (PC4000-6)
61K540
Y40
Directional spool valve boom up (PC4000-6)
61K541
Y41
Directional spool valve boom down (PC4000-6)
61K542
Y42
Stick in (PC4000-6)
61K543
Y43
Stick out (PC4000-6)
61K544
Y44
Bucket fill (PC4000-6)
61K545
Y45
Bucket dump (PC4000-6)
61K546
Y46
Boom up (PC4000-6)
61K547
Y47
Boom down (PC4000-6)
61K563
Y63
Speed boom (PC4000-6)
61K564
Y64
Speed bucket BC (PC4000-6)
61K565
Y65
Speed slew gear (PC4000-6)
61K566
Y66
Proportional valve speed slew gear (PC4000-6)
61K567
Y67
Proportional valve speed crawler right (PC4000-6)
61K568
Y68
Proportional valve speed stick BH (PC4000-6)
61K569
Y69
Proportional valve speed boom (PC4000-6)
61K570
Y70
Proportional valve speed crawler left (PC4000-6)
61K572
Y72
Proportional valve speed stick BH (PC4000-6)
61K573
Y73
Proportional valve speed boom (PC4000-6)
61K574
Y74
Proportional valve speed stick (PC4000-6)
61K575
Y75
Proportional valve speed bucket (PC4000-6)
61K576
Y76
Proportional valve speed boom (PC4000-6)
61K620
Y20
Proportional valve speed crawler left (PC5500-6)
61K620a
Y20a
Directional spool valve crawler left forward (PC5500-6)
61K620b
Y20b
Directional spool valve crawler left backward (PC5500-6)
61K621
Y21
Proportional valve speed stick (PC5500-6)
61K621a
Y21a
Directional spool valve stick out (PC5500-6)
61K621b
Y21b
Directional spool valve stick in (PC5500-6)
61K622
Y22
Proportional valve speed bucket (PC5500-6)
61K622a
Y22a
Directional spool valve bucket fill (PC5500-6)
61K622b
Y22b
Directional spool valve bucket dump (PC5500-6)
61K623
Y23
Proportional valve speed boom (PC5500-6)
Version 2010/1
13-49
Table of new and old component designations
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
New code
Previous code
Component
61K623a
Y23a
Directional spool valve boom up (PC5500-6)
61K623b
Y23b
Directional spool valve boom down (PC5500-6)
61K624
Y24
Proportional valve speed clam BC (PC5500-6)
61K624
Y24
Proportional valve speed bucket BH (PC5500-6)
61K624a
Y24a
Directional spool valve bucket fill BH (PC5500-6)
61K624a
Y24a
Directional spool valve clam close BC (PC5500-6)
61K624b
Y24b
Directional spool valve bucket dump BH (PC5500-6)
61K624b
Y24b
Directional spool valve clam open BC (PC5500-6)
61K625
Y25
Proportional valve speed stick BH (PC5500-6)
61K625
Y25
Proportional valve speed bucket BC (PC5500-6)
61K625a
Y25a
Directional spool valve bucket fill BC (PC5500-6)
61K625a
Y25a
Directional spool valve boom up BH (PC5500-6)
61K625b
Y25b
Directional spool valve bucket dump BC (PC5500-6)
61K625b
Y25b
Directional spool valve boom down BH (PC5500-6)
61K626
Y26
Proportional valve speed boom BC (PC5500-6)
61K626a
Y26a
Directional spool valve boom up BC (PC5500-6)
61K626b
Y26b
Directional spool valve boom down BC (PC5500-6)
61K627
Y27
Directional spool valve speed stick (PC5500-6)
61K627a
Y27a
Directional spool valve stick in (PC5500-6)
61K627b
Y27b
Directional spool valve stick out (PC5500-6)
61K628
Y28
Proportional valve speed crawler right (PC5500-6)
61K628a
Y28a
Directional spool valve crawler right backward (PC5500-6)
61K628b
Y28b
Directional spool valve crawler right forward (PC5500-6)
61K629
Y29
Proportional valve speed boom (PC5500-6)
61K629a
Y29a
Directional spool valve boom up (PC5500-6)
61K629b
Y29b
Directional spool valve boom down (PC5500-6)
61K630
Y30
Proportional valve speed bucket (PC5500-6)
61K630a
Y30a
Directional spool valve bucket fill (PC5500-6)
61K630b
Y30b
Directional spool valve bucket dump (PC5500-6)
61K631
Y31
Proportional valve speed stick (PC5500-6)
61K631a
Y31a
Directional spool valve stick in BH (PC5500-6)
61K631a
Y31a
Directional spool valve stick out BC (PC5500-6)
61K631b
Y31b
Directional spool valve stick out BH (PC5500-6)
61K631b
Y31b
Directional spool valve stick in BC (PC5500-6)
61K632
Y32
Proportional valve speed slew gear (PC5500-6)
61K632a
Y32a
Directional spool valve slew gear right (PC5500-6)
61K632b
Y32b
Directional spool valve slew gear left (PC5500-6)
61Q632a
Y132a
Floating position stick (PC4000)
13-50
Version 2010/1
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
New code
Previous code
Component
61Q633a
Y133a
Floating position stick (PC4000)
61Q635a
Y135a
Floating position boom (PC4000)
61S033b
S33b
Emergency stop button valve block
62a000
Table of new and old component designations
Lubrication systems
80B043
B43
CLS 1 Central lubrcation system 1 end line pressure switch for lubrication line (for CLS 1 if CLS 2 installed !)
62B046
B46
SLS Slew lubrication system end line pressure switch for lubrication line
62B108-H
B108
CLS 1 Central lubrcation system container level monitoring
62B108-M
B108
CLS 1 Central lubrcation system container level monitoring
62B108b-H
B108b
CLS 1 Central lubrcation system changing barrel pre-warning
62B108b-M
B108b
CLS 1 Central lubrcation system changing barrel pre-warning
62B108c-H
B108c
CLS 1 Central lubrcation system changing barrel empty
62B108c-M
B108c
CLS 1 Central lubrcation system changing barrel empty
62B109-H
B109
SLS Slew lubrcation system container level monitoring
62B109-K
B109
SLS Slew lubrcation system container level monitoring
62B109-M
B109
SLS Slew lubrcation system container level monitoring
62B109b-H
B109b
SLS Slew lubrcation system changing barrel pre-warning
62B109b-K
B109b
SLS Slew lubrcation system changing barrel pre-warning
62B109b-M
B109b
SLS Slew lubrcation system changing barrel pre-warning
62B109c-H
B109c
SLS Slew lubrcation system changing barrel empty
62B109c-K
B109c
SLS Slew lubrcation system changing barrel empty
62B109c-M
B109c
SLS Slew lubrcation system changing barrel empty
62B112b
B112b
CLS 2 lubrication system attachment changing barrel pre-warning
62B112c
B112c
CLS 2 lubrication system attachment changing barrel empty
62B173
B173
CLS 2 lubrication system attachment container level monitoring
62B208
B108
CLS 1 Central lubrcation system container level monitoring binary
62B209
B109
SLS Slew lubrcation system container level monitoring binary
62B273
B173
CLS 2 lubrication system attachment container level monitoring binary
62Q507-H
Y7
CLS 1 Central lubrcation system lubrication pump on
62Q507-M
Y7
CLS 1 Central lubrcation system lubrication pump on
62Q507a-H
Y7a
CLS 1 Central lubrcation system release lubrication line
62Q507a-M
Y7a
CLS 1 Central lubrcation system release lubrication line
62Q509-H
Y9
SLS Slew lubrcation system lubrication pump on
62Q509-K
Y9
SLS Slew lubrcation system lubrication pump on
62Q509-M
Y9
SLS Slew lubrcation system lubrication pump on
62Q509a-H
Y9a
SLS Slew lubrcation system release lubrication line
62Q509a-K
Y9a
SLS Slew lubrcation system release lubrication line
62Q509a-M
Y9a
SLS Slew lubrcation system release lubrication line
62Q642-M
Y142
CLS 2 lubrication system attachment lubrication pump on
Version 2010/1
13-51
Table of new and old component designations
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
New code
Previous code
Component
62Q642a-M
Y142a
CLS 2 lubrication system attachment release lubrication line
63a000
Reserve motor oil tank
63B103-1
B103-1
Engine oil tank empty 1
63B103-2
B103-2
Engine oil tank empty 2
63B106-1
B106-1
Level motor oil tank
63B106-2
B106-2
Level motor oil tank
63B204-1
1B4
Pre-heating temperature switch reserve oil tank
63B204-2
1B4
Pre-heating temperature switch reserve oil tank
63E212-1
1R12
Pre-heating reserve oil tank
63E212-2
1R12
Pre-heating reserve oil tank
65a000
Coolant pre-heater
65B210-1
Temperature switch coolant
65B210-2
Temperature switch coolant
65F210
Circuit breaker coolant pre-heating transformer secondary side (10A)
65F211
Circuit breaker coolant pre-heating transformer secondary side (10A)
65F212
Circuit breaker coolant pre-heating pump motor (3A)
65F213
Circuit breaker coolant pre-heating control transformer primary side (3A)
65G211-1
Pump coolant pre-heating
65G211-2
Pump coolant pre-heating
65K202-1
Pre-heating control coolant
65K202-2
Pre-heating control coolant
65Q210-1
Coolant pre-heating heater on
65Q210-2
Coolant pre-heating heater on
65Q211-1
Pump coolant pre-heating on
65Q211-2
Pump coolant pre-heating on
65T202-1
Control voltage transformer coolant pre-heating
65T202-2
Control voltage transformer coolant pre-heating
67a000
Crane
67M012
5M12
68a000
Motor crane machinery room (option) Compressor
68M013
5M13
Motor air compressor (option)
68S010a
5S10a/5S16
Switch air compressor
70a000
Ladder
70B091
S91
Ladder down
70B122
S22
Ladder up
70E047
H47
Lighting ladder
70E047a
H47a
Lighting ladder
70S018
S18
Switch lighting ladder
13-52
Version 2010/1
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
New code
Previous code
Component
70S033a
S33a/0S33a
Emergency stop button ladder
70S084
S84
Ladder turn switch up / down
70S084a
S84a
Pull switch ladder down
70X406a
4X6a
Welding socket ladder
71a000
Table of new and old component designations
Battery box
71B050
1B50
Temperature transmitter batteries
71B051
1B51
Temperature transmitter batteries
71B052
1B52
Temperature transmitter Batteries emergency lighting
71B250
1B50
Battery temperature transmitter
71E204
Pre-heating start battery
71E205
Pre-heating start battery
71E206
Pre-heating start battery
71E207
Pre-heating start battery
71G001
G1
Battery 1
71G002
G2
Battery 2
71G003
7G1
Battery 3 (E: Emergency lighting)
71G004
7G2
Battery 4 (E: Emergency lighting)
71Q002
S2
Battery main switch control battery
71Q003
S3
Battery main switch for starter 2 and functional earth
71Q004
S2
Battery main switch for starter 1
71Q007
7S1
Battery main switch battery emergency light
71T003
R3
Shunt for measurement of charging- and discharging current
80a000
Attachment
80B020
B20
Pendulum bucket
80B043
B43
CLS 1 Central lubrcation system 1 end line pressure switch lubrication line for CLS 1 without CLS 2
80B174
B174
CLS 2 Central lubrcation system 2 (attachment lubrication system) end line pressure switch lubrication line
90a000
Undercarriage
91a000
Cable drum
91B006a
8S6a
Tight cable
91B006b
8S6b
Slacking cable
91B904a
8S4a
Full cable drum
91B904b
8S4b
Empty cable drum
91B908a
8S8a
Diagonally pulling
91B908b
8S8b
Diagonally pulling
91B909a
8S9a
Diagonally pulling
91B909b
8S9b
Diagonally pulling
91B911
8S11
Antenna style switch
Version 2010/1
13-53
Table of new and old component designations
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
New code
Previous code
Component
91B912
8S12
Ground collision detection
91B913
8S13
Ground collision detection
91B914
8S14
Antenna style switch
91B915
8S15
Antenna style switch
91B917
0S17
Limit switch at cable drum (body)
91B918
0S18
Limit switch at cable drum (body)
91B919
8S10
Antenna style switch
91B979
8F79
Temperature monitoring cable drum motor
91B980
8B79
Transducer for Pt100 at cable drum motor
91E929
3R20
Heating cable drum
91E927
Heater in switch cabinet cable drum
91E929
3R27
Heater in cable drum switch cabinet
91F911
8F13
Circuit breaker rotor circuit
91K320
CAN-Node 20 (ICND)
91K321
CAN-Node 21 (ICNV)
91M906
8M6
Drive motor cable drum
91Q907
8K8
Contactor for cable drum wound up
91Q908
8K11
Contactor for cable drum unwound
91Q911
8K7
Contactor for cable drum high torque
91R901
8R1
3 phasic series resistor for torque reduction
91R973
CAN-BUS-Terminal-Resistor at cable drum
91R974
Resistor array
91R975
Diode array (3A)
91R976
Resistor array
91S901
8S1
Mode selection switch cable drum
91S933e
S33e/0S33e
Emergency stop button cable drum
91U007
Terminal box for controller at cable drum
91U008
X8
Switch cabinet at cable drum
91W901
0E1
Slip-ring-box in cable drum
91X007 91X008
Terminal strip in switch cabinet at cable drum (controller switch cabinet) X8
Terminal strip in switch cabinet at cable drum
91X191
Connector for internal wiring at cable drum
91X194
Connector from controller 91U007 terminal box to HV terminal box
91X291
Connector for internal wiring at cable drum
91X319
CAN-Bus-Connector
91X320
CAN-Bus-T-Splitter Node 20
91X321
CAN-Bus-T-Splitter Node 21
91X391
Connector for internal wiring at cable drum (from terminal box controller to terminal box contactors, low voltage)
13-54
Version 2010/1
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
New code
Previous code
Table of new and old component designations
Component
92a000
Rotary transmission (hydr.)
93a000
Slip-ring-box (elec.)
93B004
0S4
Limit switch at slip-ring-box
93B004a
0S4a
Limit switch at slip-ring-box
93E918
3R18
Heater slip-ring-box HV room
93E918b
3R18b
Heater slip-ring-box LV room
93E993
3H3
Lighting slip-ring-box
93T909
0T9
Transformer slip-ring-box for lighting
93W901
0E2
Slip-ring-box in cable drum
93W902
0E2
Slip-ring-box between undercarriage and superstructure
93X011
3X2
Terminal strip in Slip-ring-box to cab support
94a000
Terminal box cable drum
94B919
0S19
Limit switch flap-terminal box
94E919
3R19
Heater terminal box cable drum
94F901
0F01
Over voltage protection phase 1
94F902
0F02
Over voltage protection phase 2
94F903
0F03
Over voltage protection phase 3
94F904
0F04
Over voltage protection pilot wire
94F905
Over voltage protection pilot wire
94X091
0X4
Terminal strip in terminal box
94X902
0X2
HV socket
Version 2010/1
13-55
Table of new and old component designations
13-56
HINTS FOR READING THE ELECTRIC WIRING DIAGRAM
Version 2010/1
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
14. VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Version 2010/1
14-1
General
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
14.1
GENERAL
Fig. 14-1
Data flow and control of the Vehicle Health Monitoring System
14-2
Version 2010/1
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
General
The Vehicle Health Monitoring System (VHMS) is an electronic on-board monitoring system which includes the functions REAL TIME MONITOR, basic adjustments, and history reporting. Details are as follows: z
System and component monitoring based on fault code detection and storage of faults and other events, incl. trend snapshot data etc.
z
Selected subsystems and components, generation of trending, histogram, and cumulative data to be used as a predictive maintenance aid.
z
PC-based downloads via VHMS Technical Analysis Tool Box.
z
Single serial data connection to the MTC controller, and CAN bus transfer between VHMS controller and VHMS monitor MH801.
z
MTC evaluation ON/OFF function for testing and troubleshooting.
Operating Principle The VHMS system with a keyboard below the monitor allows comfortable operation and quick access to all information about the machine status and maintenance calls. The Diesel engine, a Komatsu SDA16V160 (QSK 60), is equipped with ECMs (Electronic Control Modules). This control system is called QUANTUM. For communication with the shovel control system the Quantum system is connected to the CAN bus #1. Condition monitoring on the shovel systems is established by the MTC (Master Turbo Controller), also called X2Controller, in serial connection with the VHMS controller. The MTC is equipped with a read & write memory and a real time monitoring system. The access to the VHMS controller is established via laptop and a serial interface, using the respective software. The control system components VHMS & monitor, MTC-Controller & nodes, and Quantum are connected as follows: VHMS Quantum
CAN bus #1
MTC-Controller Nodes
internal CAN bus
MTC-Controller VHMS-Controller
RS232 (serial connection)
VHMS-Controller => VHMS monitor MH801
CAN bus #2
As optional equipment the ORBCOMM and the MODULAR MINING SYSTEM are available. View onto the VHMS monitor with key pad in the dashboard
Version 2010/1
14-3
Specifications for Operators
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
14.2
SPECIFICATIONS FOR OPERATORS
Fig. 14-2
Sequence of displays and opening screen
14-4
Version 2010/1
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Specifications for Operators
Legend for Fig. 14-2: (1)
The monitor displays the condition of the machine, the maintenance status, and messages for the operator & the maintenance staff
(2)
Buttons for changing the screens and for settings on the operator level
(3)
Key pad for entering data and the Personal Identification Number (PIN)
(4)
Main key switch on the dashboard
(5)
Opening message
(6)
Acknowledgement button for the opening message
14.2.1
SEQUENCE OF DISPLAYS
Fig. 14-3
Initialization screen
When the main key switch (Fig. 14-2, Pos. 4) is turned ON, the initialization screen (KOMATSU logo) (Fig. 14-3) is displayed for approx. 3 seconds. NOTE: The standard system offers three languages, ENGLISH - GERMAN - SPANISH, or according to customer’s request. Changing of the present language can be carried out in the main menu settings, refer to section 14.2.8 on page 14-18, Fig. 14-11.
14.2.2
OPENING SCREEN
The second display (Fig. 14-2, Pos. 5) is a general information for the operator. NOTE: Press button F6 (Fig. 14-2, Pos. 6) to acknowledge this message. The monitor will display the Main Gauge Screen 1, refer to Fig. 14-4.
Version 2010/1
14-5
Specifications for Operators
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
14.2.3
MAIN GAUGE SCREENS 1 TO 3
Fig. 14-4
Main gauge screens 1 to 3
14-6
Version 2010/1
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Specifications for Operators
Symbol explanation for Fig. 14-4: Main Gauge Screen 1 of 3 °C 1/min
Celsius, ambient temperature Engine speed
Time
Truck counter 1
Truck counter 2
Engine oil pressure
Engine coolant temperature
Hydraulic oil temperature
Fuel level
Version 2010/1
14-7
Specifications for Operators
Fig. 14-5 14-8
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Main gauge screens 1 to 3 Version 2010/1
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Specifications for Operators
Symbol explanation for Fig. 14-5: Main Gauge Screen 2 of 3
Battery, board power supply
Voltage
Gear oil temperature
Engine oil temperature
Main Gauge Screen 3 of 3
Central Lubrication System (CLS)
Slew Lubrication System (SLS)
Engine oil level
Hydraulic oil level
Definition of the gauge range colours Green Red
Normal operating range Serious trouble, act immediately. Engine derate or shutdown may happen.
NOTE: If the pointer of any gauge moves into a red range (upper or lower) the corresponding symbol will also have a red background. If this happens, in most cases an automatic message display will inform the operator in plain text about the failure and the necessary action to be taken. For a typical display refer to section 14.2.9 on page 14-26.
Version 2010/1
14-9
Specifications for Operators
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Symbols and functions of the buttons F1 - F6
14-10
F1
This button is used to scroll through the Main Gauge Screens 1, 2, and 3. If other screens are selected, the function of this button changes accordingly.
F2
This button switches to the Fuel Consumption Screen, for details refer to section 14.2.4 on page 14-11.
F3
This button switches to the Failure Message Screen for the operator. The colour of the icon above this button changes to yellow if a current message is pending in the Failure History. The icon remains yellow as long as the cause for the message exists, even if the message was cancelled.
F4
This button switches to the Main Gauge Screen for changing the display from Time to Service Meter Reading (SMR) or to Date and vice versa, refer to section 14.2.6 on page 14-15.
F5
This button switches to the Maintenance Monitor. The colour of the icon above this button changes to yellow or red if maintenance is due, for details refer to section 14.2.7 on page 14-16.
F6
This button switches to the main screen Settings for Operator, for details refer to section 14.2.8 on page 14-18.
Version 2010/1
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
14.2.4
FUEL CONSUMPTION SCREEN
Fig. 14-6
Fuel consumption screen
Version 2010/1
Specifications for Operators
14-11
Specifications for Operators
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Measuring the Fuel Consumption Starting from one of the three Main Gauge Screens press button F2, the screen changes to Fuel Consumption Screen (Fig. 14-6, Pos. 1). The fields in the screen (Fig. 14-6, Pos. 1) can be either blank or filled with the data of the last measurement. If you want to start a new fuel consumption measurement, push the START button F1. The date and the local time will be inserted into the Start Time frame and the START command above button F1 changes to STOP, refer to screen (Fig. 14-6, Pos. 2). Push the RETURN button F5 to go back to the Main Gauge Screen 1. When the time period for fuel consumption measurement is over, for example after 10 hours, select the Fuel Consumption Screen from any of the three Main Gauge Screens by pushing button F2. The displayed Fuel Consumption Screen shows the starting date and time of the fuel consumption measurement. Push the STOP button F1. The current date and time is inserted into the Stop Time field and the split fuel consumption calculated during the previous time period is inserted into the Fuel Consumption Frame. The STOP button F1 changes to START again, refer to screen (Fig. 14-6, Pos. 3). Push the return button F5 to return to the Main Gauge Screen 1.
14-12
Version 2010/1
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Specifications for Operators
14.2.5
FAILURE MESSAGE SCREEN FOR THE OPERATOR
Fig. 14-7
Main Gauge Screen 1/3 and Failure Message History
Version 2010/1
14-13
Specifications for Operators
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Failure Messages for the Operator The Failure Message Screen (Fig. 14-7) can be selected from the Main Gauge Screens 1, 2, or 3 by pressing button F3. The colour of the icon above the button F3 changes to yellow if a current message is pending in the Failure Message History for the operator.
Fig. 14-8
Failure Message
Legend for Fig. 14-8: F3
Scroll down - shifts down to the next message, if several messages are present
F4
Scroll up - shifts up to the previous message, if several messages are present
F5
Return - switches back to the Main Gauge Screen
If the cause for any failure message, which is shown on the Failure Message Screen for operators does not exist any longer, the message will be removed from the operator’s failure history. The time and the date of the removed failure message are added to the already stored failure information in the failure memory for the service level.
14-14
Version 2010/1
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Specifications for Operators
14.2.6
MAIN GAUGE SCREENS - CHANGING OF TIME / SMR / DATE
Fig. 14-9
Changing Time, SMR, Date
If button F4 of the Main Gauge Screen is pressed, the center information in the headline changes in the sequence: Time => Service Meter Reading (SMR) => Date => Time ... The selected information (Time, SMR, or Date) will be shown in the headline of all three Main Gauge Screens. Version 2010/1
14-15
Specifications for Operators
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
14.2.7
MAINTENANCE MONITOR
Fig. 14-10
Maintenance Monitor
14-16
Version 2010/1
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Specifications for Operators
The Maintenance Monitor can be selected from the Main Gauge Screens 1, 2, or 3 by pressing the maintenance button F5. The colour of the icon background above the button changes to yellow if maintenance is due. The colour will change to red if maintenance is overdue. Fig. 14-10 shows a Maintenance Monitor of a new machine which has been operated for 10 hours. There are 240 hours left before the 250 hour maintenance is due and 2990 hours before the 3000 hours maintenance is due. For returning to the Main Gauge Screen press button F5. Specifics to be observed Higher maintenance also includes lower maintenance. (Lower maintenance must also be carried out!) Maintenance Interval Overview Maintenance interval
Remark
250 h
Includes maintenance: 50 h • 10 h
500 h
Includes maintenance: 250 h • 50 h • 10 h
(750 h)
Is a follow-up maintenance of 250 h
1000 h
Includes maintenance: (750 h) • 500 h • 250 h • 50 h • 10 h
... 2000 h
Includes: PM-CLINIC
... 3000 h
Includes maintenance: 1000 h • 750 h • 500 h • 250 h • 50 h • 10 h
Exception: For the 3000 h maintenance it is not necessary to carry out the 2000 h maintenance also. The maintenance cycles are rigidly linked to the running time meter. Only running time hours are taken into consideration (no minutes or seconds). The routine visual checks and inspections after every 10 and 50 operating hours are not called up on the Maintenance Monitor. Carry out these checks and inspections according to the OPERATION & MAINTENANCE MANUEL section 4. The engine maintenance has to be carried out according to the separate ENGINE OPERATION & MAINTENANCE MANUEL filed in the volume 2 binder. REMARK For detailed maintenance cycle information refer to the OPERATION & MAINTENANCE MANUAL, section MAINTENANCE. NOTE: On new machines an INITIAL SERVICING after the first 250 and 1000 operating hours is required in addition to the periodic maintenance intervals displayed on the monitor. Carry out all maintenance items according to the OPERATION AND MAINTENANCE MANUEL, section 4. Maintenance Confirmation by Service Personnel Maintenance indicated with yellow or red background behind the icon above the maintenance button F5 should be confirmed by service personnel in the Service Menu subsequent to the execution of the maintenance. With each confirmation the actual maintenance number is increased by 1. The message in the Service Menu for Maintenance Confirmation then turns to white instead of yellow. For more information about the Maintenance Confirmation screen refer to section 14.4.8 on page 14-84.
Version 2010/1
14-17
Specifications for Operators
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
14.2.8
SETTINGS FOR OPERATORS
Fig. 14-11
Maintenance Monitor
14-18
Version 2010/1
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Specifications for Operators
The user menu Settings for Operators can be selected from the Main Gauge Screens 1, 2, or 3 by pressing the button F6. Selection of the Setting Screens The settings selection menu offers seven different setting screens, starting with USER ID and ending with the Language selection. Use the buttons F3 and F4 to scroll through all the seven selection items. Select the designated setting item and push button F6 in order to open the selected setting screen. Button F5 switches back to the Main Gauge Screen 1. The setting screens on the following pages appear in the same sequence as shown in the Main Setting Screen. Settings for Operators USER ID Screen Entering the USER ID (Operator Identification Number)
Fig. 14-12
Entering User ID
In order to personalize different operators, it is possible to enter any up to 10-digits USER ID (Operator Identification Number) via the key pad, refer to (Fig. 14-12). In order to acknowledge the USER ID press button F6. The display then changes to the Main Setting Screen for operators. NOTE: - If 10 digits are entered, each further entry will be ignored. - If any USER ID has been entered, the ID is saved together with the continuous machine operation records in the VHMS memory.
Version 2010/1
14-19
Specifications for Operators
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Reset Truck Counter 1 & 2
Fig. 14-13
Resetting Truck Counter 1
When the upper screen (Fig. 14-13, Pos. 1) is displayed, press button F6 to reset Truck Counter 1 to zero. The screen then changes to the Main Setting Screen. If you don’t want to reset the truck counter, press button F5 to return to the Main Setting Screen for operators again. The reset of Truck Counter 2 is performed analogously.
14-20
Version 2010/1
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Specifications for Operators
Screen Adjustment
Fig. 14-14
Screen Adjustment
Legend for Fig. 14-14: (1)
Day screen
(2)
Night screen
Version 2010/1
14-21
Specifications for Operators
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Screen Adjustment Day and Night The Day Screen (Fig. 14-14, Pos. 1) will be displayed during the day when the main working lights are switched off. The screen changes automatically to the Night mode when the main working lights are switched on, refer to Pos. 2 in the previous illustration (Fig. 14-14). The adjustment of both screens is done in the same way. The function of the buttons for Screen Adjustment (Fig. 14-14) is as follows: F2
Select the DEFAULT setting (factory setting) of Brightness, Contrast, and Back Light
F3
Decrease Brightness, Contrast, and Back Light
F4
Increase Brightness, Contrast, and Back Light
F5
Leave the adjustment screen and return to the Main Setting Screen for operators
F6
Save the current adjustment and jump to the next adjustment mode (Brightness >> Contrast >> Back Light)
Screen Adjustment z
Brightness adjustment In the first display of the screen the brightness field is highlighted yellow. For increasing the brightness press button F4 until the desired condition is obtained. For decreasing the brightness press button F3 until the desired condition is obtained. Press button F6 in order to save the selected brightness adjustment and to change over to the contrast adjustment.
z
Contrast adjustment The contrast field is now highlighted yellow. For increasing the contrast press button F4 until the desired condition is obtained. For decreasing the contrast press button F3 until the desired condition is obtained. Press button F6 in order to save the selected contrast adjustment and to change over to the back light adjustment.
z
Back Light adjustment The back light field is now highlighted yellow. For increasing the back light press button F4 until the desired condition is obtained. For decreasing the back light press button F3 until the desired condition is obtained. Press button F6 in order to save the selected back light adjustment and to return to the Main Setting Screen for operators.
If you want to leave the above adjustment screens without saving any adjustment, press button F5 and return to the Main Setting Screen for operators.
14-22
Version 2010/1
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Specifications for Operators
Date Adjustment Screen
Fig. 14-15 z
Date adjustment
Date adjustment In the first display of this adjustment screen ’Date’ is highlighted yellow and the year is highlighted orange, refer to Fig. 14-15. Press button F3 (down) or F4 (up) in order to adjust the correct year. If button F1 is pressed one time, the month is highlighted and can be adjusted, using the buttons F3 and F4 again. Press button F1 again in order to change to the adjustment mode of the day. Press button F6 in order to save the adjustment(s) of year, month, or day and to return to the Main Setting Screen for operators. Press button F5 if you want
Screen for Clock Adjustment and Daylight Saving Time ON/OFF
Fig. 14-16
Adjustment for Clock and Daylight Saving Time
NOTE: Via the screen for Clock Adjustment (Fig. 14-16) the clock time can be adjusted, and the Daylight Saving Time can be switched ON/OFF. REMARK If the Daylight Saving Time is switched ON, the Day Screen will be displayed during the day when the main working lights are switched off. The display changes automatically to the Night Screen when the main working lights are switched on.
Version 2010/1
14-23
Specifications for Operators
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
z
Clock adjustment In the first display of this adjustment screen ’Time’ is highlighted yellow and the hours are highlighted orange, refer to Fig. 14-16. Press button F3 (down) or F4 (up) in order to adjust the correct hours. If button F1 is pressed one time, the minutes are highlighted and can be adjusted, using the buttons F3 and F4 again. Press button F6 in order to save the adjustment(s) of the clock time and to return to the Main Setting Screen for operators.
z
Switching the Daylight Saving Time ON/OFF If you are in the clock adjustment mode for minutes (the minutes are highlighted) press button F1. ’Daylight Saving Time’ will be highlighted yellow. Press the button F3 or F4 in order to select the ON or OFF condition. The selected condition is highlighted green. Press button F6 if you want to save the adjustment(s) of the clock time and to return to the Main Setting Screen for operators.
If you want to leave the above adjustment screens without saving any adjustment, press button F5 and return to the Main Setting Screen for operators. Language Selection Screen
Fig. 14-17 z
Language selection
Language selection Select the desired language using button F3 or F4. Press button F6 in order to save the language selection and to return to the Main Setting Screen for operators. If you want to leave the above selection screen without saving any selection, press button F5 and return to the Main Setting Screen for operators.
14-24
Version 2010/1
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Specifications for Operators
This page was left blank intentionally.
Version 2010/1
14-25
Specifications for Operators
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
14.2.9
AUTOMATIC MESSAGES
Fig. 14-18
View onto the Main Gauge Screen indicating any pending message(s)
Fig. 14-19
Example of a message with red background
Fig. 14-20
Example of a message with yellow background
14-26
Version 2010/1
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Specifications for Operators
Legend for Fig. 14-19 and 14-20: (1)
Top Message: Short failure description
(2)
Instruction Message: Follow the displayed instruction(s)
(3)
Error Code: G = Shovel message C = Engine message (Cummins)
(4)
Number of the currently displayed message
(5)
Total number of existing messages
F1
CANCEL button When this button is pressed, the currently displayed message disappears and is listed in the failure history for operators. The message will be displayed again if any different USER ID (operator identification number) is entered.
F3
PAUSE button (green) When this button is pressed, automatic rolling up of messages is stopped and the displayed message will be frozen on the screen for two minutes. After that the button changes to RESET (red) and automatic roll up of current messages starts again. A new message will overwrite a frozen message.
F4
JUMP button This button switches to the previous displayed menu, normally to the Main Gauge Screen 1. After two minutes the display jumps automatically back to the last displayed Automatic Message, and rolling up of messages starts again. If any menu select button was pressed during the two minutes standard period, the display will also jump back to Automatic Message when the two minutes are over. A new message will overwrite any menu display and rolling up of messages starts again.
If any failure or information condition occurs during operation, the background of the exclamation mark (!) over button F3 is coloured yellow. Then the present display is automatically replaced by an Automatic Message. If there are several messages at the same time, the system displays these messages one after the other. Each message is displayed for a few seconds. The message text informs the operator about the type of failure and the action to be taken. Carry out the action which is recommended on the screen. NOTE: The Top Messages have background colours which indicate the trouble condition as follows: z
RED
Shut-down - act immediately Refer to Fig. 14-19 for a typical message with red background.
z
YELLOW
Caution - inform service Refer to Fig. 14-20 for a typical message with yellow background.
z
GREEN
Information Refer to Fig. 14-21 for a typical message with green background.
Version 2010/1
14-27
Specifications for Operators
Fig. 14-21
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Example of a message with green background
Legend for Fig. 14-21: (1)
Top message: Information description
(2)
Help text
(3)
Message (error) Code: G = Shovel message C = Engine message (Cummins)
(4)
Number of the currently displayed message
(5)
Total number of existing messages
NOTE: For all available Top Messages in the system refer to section 14.2.10 on page 14-29.
14-28
Version 2010/1
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Specifications for Operators
14.2.10 TABLES OF ALL MESSAGES PROVIDED BY THE SYSTEM The following charts of Top Messages (Error Codes) cover all shovels with X2-Controller. G-Codes
For the excavators PC3000 - PC4000 - PC5500 - PC8000 (Diesel & Electric), including optional equipment, refer to section 14.2.10.1
C-Codes TIER 2
for the Diesel engines QSK38 & QSK60 - Emission Standard TIER 2 refer to section 14.2.10.2 on page 14-39
C-Codes TIER 1
for the Diesel engines KTA38 & QSK60 - Emission Standard TIER 1 refer to section 14.2.10.3 on page 14-46
Instruction Messages
for the G-Codes & C-Codes, refer to section 14.2.10.4 on page 14-52
That means, that not all listed Error Codes and Instruction Messages may be applied to each shovel.
NOTE: Messages w/o color code are not displayed. These messages are stored in the history memory only.
Explanation of the columns in the following Error Code charts Error Code
Error Codes: G = Shovel message, C = Engine message (Cummins)
Colour Code of Top Message
0 = Red, 1 = Yellow, 2 = Green
Instruction Message No.
Number of the Instruction Message, which is displayed together with the Error Code (numbers 1 - 58)
Display
1 = displayed once, 2 = displayed at each occurrence, N = NOT displayed
Acoustic Signal
Y = an acoustic signal sounds if the relating error occurs
Memory
The error/message is saved in a History Memory: 1 = Service & Operator History, 2 = Service History, 3 = Operator History, 5 = VHMS History
G-Code/C-Code
Text of the Error Code or Message
Version 2010/1
14-29
Specifications for Operators
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
G = Shovel C = Engine
0 = RED 1 = YELLOW 2 = GREEN
Display
Colour Code of Top Message
Instruction Message No.
Error Code
Acoustic Signal
14.2.10.1 TABLE OF G-CODES
G00001
0
1
2
1
Trouble Shut-Off (gate) valve
G00002
2
37
2
3
Test speed 1800 1/min engine 1
G00003
1
38
1
1
Trouble pump controller
G00005
1
39
1
3
Low hydraulic oil level
G00007
0
2
2
1
Trouble hydraulic oil level
G00012
1
17
1
3
Central lubrication system grease level too low
G00013
1
17
1
3
Slew ring gear lubr. system grease level too low
G00020
0
4
2
1
Trouble Shut-Off (gate) valve (Start blocked)
G00031
2
-
2
3
Set engine to low idle
G00032
1
2
1
1
Trouble starter
G00033
1
2
1
1
Trouble VHMS-Controller
G00034
1
2
1
1
Trouble VHMS-Display
G00035
0
34
2
1
Trouble totally loss gear oil (PTO 1)
G00039
2
-
2
3
Actuate engine speed selector switch
G00040
0
10
2
1
Emergency shut-down pump compartment
G00042
1
2
1
1
Trouble monitoring screen at hydr. cooler entry
G00043
1
2
2
Y
1
Trouble output short-circuit
G00048
0
2
2
Y
1
Trouble emergency safety circuit
G00053
1
56
2
Y
1
Reset emergency safety circuit
G00060
0
6
2
1
Fire in the power house
G00061
0
2
2
1
Trouble monitoring, engine 1 speed too low
G00062
0
2
2
1
Trouble monitoring, engine 1 speed too high
G00063
0
2
1
1
Trouble monitoring hydraulic oil temp
14-30
Y
Y
G-Code Memory
(Message Code)
Version 2010/1
G = Shovel C = Engine
0 = RED 1 = YELLOW 2 = GREEN
Display
Colour Code of Top Message
Instruction Message No.
Error Code
Acoustic Signal
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
G00064
0
2
1
1
Trouble monitoring hydraulic oil level
G00065
1
2
1
1
Very low hydraulic oil level
G00066
0
2
2
1
Trouble hydraulic oil temperature
G00067
1
2
1
1
Trouble battery voltage too high
G00069
1
2
1
1
Trouble monitoring oil temperature gear (PTO 1)
G00070
1
2
2
Y
1
Trouble oil temperature gear (PTO 1)
G00071
1
2
2
Y
1
Trouble gear lubrication (PTO 1)
N
2
Trouble monitoring hydraulic oil level
G00073
N
2
Trouble monitoring remote engine oil level 1
G00074
N
2
Trouble monitoring grease pressure (central)
G00075
N
2
Trouble monitoring grease pressure (slew ring gear)
G00076
N
2
Trouble monitoring pressure suction tank
G00077
N
2
Trouble monitoring grease level (central)
G00078
N
2
Trouble monitoring grease level (slew ring gear)
G00079
N
2
Trouble monitoring pressure oil cooler 1
G00080
N
2
Trouble monitoring pressure preload valve
1
Trouble lubrication system
G00072
G-Code Memory
(Message Code)
G00081
0
2
2
G00086
2
12
2
Y
3
SHUTDOWN
G00087
2
2
Y
3
Stop all movements for low idle
G00089
1
2
2
3
EBL bypassed
G00090
0
8
2
1
Trouble power supply
G00091
0
9
2
3
Pilot control cut out
Version 2010/1
Y
Specifications for Operators
14-31
G = Shovel C = Engine
0 = RED 1 = YELLOW 2 = GREEN
Display
Colour Code of Top Message
Instruction Message No.
Error Code
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Acoustic Signal
Specifications for Operators
G00092
0
10
2
3
Emergency shut-down at access ladder
G00093
0
10
2
3
Emergency shut-down at valve block
G00094
0
10
2
3
Emergency shut-down at hydraulic control panel
G00095
0
10
2
3
Emergency shut-down in cabin
G00096
0
14
2
3
Pilot control cut out
G00099
0
48
2
1
Trouble power supply
G00100
0
11
2
3
Maintenance safety switch
G00102
1
2
2
Y
3
Switch off wiper
G00103
1
47
2
Y
1
Faulty switch 20M004
G00104
1
15
2
Y
1
Trouble battery current
G00105
1
16
2
Y
1
Trouble battery charging current too low
G00106
1
49
2
Y
1
Faulty switch 20M007
G00107
1
2
1
Y
1
Trouble slew parking brake control 56K250a
G00108
1
2
1
Y
1
Trouble slew parking brake control Output to 56K250a
G00109
1
2
1
Y
1
Trouble slew parking brake control 56K250b
G00110
1
2
1
Y
1
Trouble slew parking brake control Output to 56K250b
G00111
1
2
1
Y
1
Trouble travel parking brake control 56K251a
G00112
1
2
1
Y
1
Trouble travel parking brake control Output to 56K251a
G00113
1
2
1
Y
1
Trouble travel parking brake control 56K251b
G00114
1
2
1
Y
1
Trouble travel parking brake control Output to 56K251b
G00115
1
2
1
Y
1
Trouble slew hydraulic brake control 56K252a
G00116
1
2
1
Y
1
Trouble slew hydraulic brake control Output to 56K252a
14-32
Y
G-Code Memory
(Message Code)
Version 2010/1
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
G = Shovel C = Engine
0 = RED 1 = YELLOW 2 = GREEN
Display
Acoustic Signal
Memory
Colour Code of Top Message
Instruction Message No.
Error Code
G00117
1
2
1
Y
1
Trouble slew hydraulic brake control 56K252b
G00118
1
2
1
Y
1
Trouble slew hydraulic brake control Output to 56K252b
G00140
1
17
1
1
Trouble monitoring X1-1 Pressure
G00141
1
17
1
1
Trouble monitoring X2-Pressure
G00143
1
2
N
2
Trouble monitoring 61B087a
G00144
1
2
N
2
Trouble monitoring 61B087b
G00145
1
2
N
2
Trouble monitoring 61B087c
G00146
1
2
N
2
Trouble monitoring 61B087d
G00147
1
17
1
1
Trouble monitoring gear lubrication (PTO 1)
G00148
1
17
1
1
Trouble monitoring fuel level
G00149
0
2
N
2
Trouble monitoring ambient temperature
G00151
1
17
1
1
Trouble monitoring gear (PTO) oil filter 1
G00152
1
17
1
1
Trouble monitoring oil filter pump lubrication
G00154
1
17
1
1
Trouble monitoring return oil filter
G00155
1
17
1
1
Trouble monitoring leak oil filter
G00159
1
17
1
1
Trouble monitoring breather filter
G00160
1
17
1
1
Trouble monitoring engine air cleaner 1
G00161
1
17
1
1
Trouble monitoring battery voltage
G00162
1
17
1
1
Trouble monitoring charging-/discharging current
G00163
1
17
1
1
Trouble monitoring pilot control
G00164
1
17
1
1
Trouble air cleaner 1
(Message Code)
Version 2010/1
Specifications for Operators
G-Code
14-33
G = Shovel C = Engine
0 = RED 1 = YELLOW 2 = GREEN
Display
Colour Code of Top Message
Instruction Message No.
Error Code
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Acoustic Signal
Specifications for Operators
G00165
1
17
1
1
Trouble breather filter hydraulic oil tank
G00166
1
17
1
1
Trouble oil filter gear (PTO 1)
G00169
1
17
1
1
Trouble return oil filter hydraulic oil tank
G00170
1
17
1
1
Trouble leak oil filter hydraulic oil tank
G00176
1
17
1
1
Trouble battery voltage too low
G00177
1
17
1
1
Trouble battery charging circuit
G00178
1
17
1
1
Trouble battery charging current too high
G00179
1
17
1
1
Trouble control pressure X1-1
G00180
1
17
1
1
Trouble pilot pressure X2 too low
G00181
1
17
1
1
Trouble pilot pressure X2 too high
G00184
1
20
1
Y
1
Central lubrication system empty
G00185
1
20
1
Y
1
Trouble central lubrication system
G00186
1
20
1
Y
1
Trouble central lubrication system
G00187
1
20
1
Y
1
Slew ring gear lubrication system empty
G00188
1
20
1
Y
1
Trouble slew ring gear lubrication system
G00189
1
20
1
Y
1
Trouble slew ring gear lubrication system
G00207
1
2
1
Y
1
Engine remote oil tank 1 empty
G00216
1
2
2
Y
1
Trouble software not compatible
G00220
1
2
2
Y
1
Trouble transfer pump motor overheated
14-34
G-Code Memory
(Message Code)
Version 2010/1
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
G = Shovel C = Engine
0 = RED 1 = YELLOW 2 = GREEN
Display
Acoustic Signal
Memory
Colour Code of Top Message
Instruction Message No.
Error Code
G00222
1
2
2
Y
1
Load limiting clam defective
G00223
1
2
2
Y
1
Trouble starter control 51K001a-1
G00224
1
2
2
Y
1
Trouble starter control Output to 51K001a-1
G00225
1
2
2
Y
1
Trouble starter control 51K001b-1
G00226
1
2
2
Y
1
Trouble starter control Output to 51K001b-1
G00231
1
2
2
Y
1
Trouble pilot control lever 20S019
G00232
1
2
2
Y
1
Trouble pilot control lever 20S020
G00233
1
2
2
Y
1
Trouble pilot control 11Q045
G00234
1
2
2
Y
1
Trouble pilot control 11K111a
G00235
1
2
2
Y
1
Trouble pilot control Output to 11K111a
G00236
1
2
2
Y
1
Trouble pilot control 11K111b
G00237
1
2
2
Y
1
Trouble pilot control Output to 11K111b
G00238
1
2
2
Y
1
Trouble supply by key switch 11Q044
G00239
1
2
2
Y
1
Trouble electrical matter
G00240
2
21
1
1
Trouble hydraulic oil temperature
G00242
2
22
2
3
Engine 1 already running
G00243
2
23
1
3
Fill up fuel tank
G00245
0
24
2
1
Engine shutdown from ground
G00246
2
25
2
3
Hydraulic oil temperature
G00247
2
26
2
3
Slew ring gear house brake
G00249
1
27
2
3
Hydraulic oil temperature
(Message Code)
Version 2010/1
Y
Specifications for Operators
G-Code
14-35
G = Shovel C = Engine
0 = RED 1 = YELLOW 2 = GREEN
Display
Colour Code of Top Message
Instruction Message No.
Error Code
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Acoustic Signal
Specifications for Operators
G00252
0
10
2
1
Emergency shut-down at access ladder
G00253
0
10
2
1
Emergency shut-down at valve block
G00254
0
10
2
1
Emergency shut-down at hydraulic control panel
G00255
0
10
2
1
Emergency shut-down in cabin
G00257
2
30
2
3
Hydraulic oil temperature
G00261
1
11
2
1
Maintenance Safety Switch
G00262
1
20
1
Y
1
Trouble screen at hydr. cooler entry clogged
G00308
0
3
2
Y
1
Trouble CAN-Bus or CAN-Hardware
G00309
1
2
1
Y
1
Trouble ladder up 56K253a
G00310
1
2
1
Y
1
Trouble ladder up Output to 56K253a
G00311
1
2
1
Y
1
Trouble ladder up redundant 56K253b
G00312
1
2
1
Y
1
Trouble ladder up redundant Output to 56K253b
G00313
1
2
1
Y
1
Trouble ladder down 56K254a
G00314
1
2
1
Y
1
Trouble ladder down Output to 56K254a
G00315
1
2
1
Y
1
Trouble ladder down redundant 56K254b
G00316
1
2
1
Y
1
Trouble ladder down redundant Output to 56K254b
G00317
1
2
1
Y
1
Trouble service arm up 56K255a
G00318
1
2
1
Y
1
Trouble service arm up Output to 56K255a
G00319
1
2
1
Y
1
Trouble service arm up redundant 56K255b
G00320
1
2
1
Y
1
Trouble service arm up redundant Output to 56K255b
14-36
G-Code Memory
(Message Code)
Version 2010/1
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
G = Shovel C = Engine
0 = RED 1 = YELLOW 2 = GREEN
Display
Acoustic Signal
Memory
Colour Code of Top Message
Instruction Message No.
Error Code
G00321
1
2
1
Y
1
Trouble service arm down 56K256a
G00322
1
2
1
Y
1
Trouble service arm down Output to 56K256a
G00323
1
2
1
Y
1
Trouble service arm down redundant 56K256b
G00324
1
2
1
Y
1
Trouble service arm down redundant Output to 56K256b
G00325
1
2
1
Y
1
Trouble service arm input
G00326
1
2
1
Y
1
Trouble ladder input
G00327
1
2
1
Y
1
Trouble parking brake input
G00328
1
2
1
Y
1
Trouble start input
G00329
1
38
2
Y
1
Protection switch tripped
G00330
1
2
2
Y
1
Trouble pilot control 11Q111
(Message Code)
Specifications for Operators
G-Code
G00401
N
5
Shutdown: Engine / Motor shutdown at bottom - off
G00402
N
5
Shutdown: Engine / Motor shutdown at bottom - on
1
Communication failure PLC VHMS-Controller
2
Manual Trigger
G00417
1
2
MFA0
2
Y
N
G00419
1
2
2
Y
1
Source voltage error
G00420
1
2
2
Y
1
Connector sel error
G00421
1
2
2
Y
G00422
1
2
2
Y
1
Can-net sys (J1939)
G00423
1
2
2
Y
1
Application sys error
G00425
1
2
2
1
Settings impossible to take over into the PLC
G00426
N
5
250 h Maintenance performed
G00427
N
5
500 h Maintenance performed
G00428
N
5
1000 h Maintenance performed
G00429
N
5
2000 h Maintenance performed
Version 2010/1
Farm sys error
14-37
0 = RED 1 = YELLOW 2 = GREEN
G-Code Memory
G = Shovel C = Engine
Acoustic Signal
(Message Code)
Colour Code of Top Message
Display
Error Code
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Instruction Message No.
Specifications for Operators
G00430
N
5
3000 h Maintenance performed
G00431
N
5
Messages switched off
G00432
N
5
Messages switched on
G00433
N
5
PLC-Evaluation switched off
G00434
N
5
PLC-Evaluation switched on
G00451
N
5
Shutdown: Shut-Off (gate) valve (Start bl.) - off
G00452
N
5
Shutdown: Shut-Off (gate) valve (Start bl.) - on
G00453
N
5
Shutdown: Shut-Off (gate) valve - off
G00454
N
5
Shutdown: Shut-Off (gate) valve - on
G00455
N
5
Shutdown: Hydraulic oil level - off
G00456
N
5
Shutdown: Hydraulic oil level - on
G00457
N
5
Shutdown: Hydr. oil temp. too high - off
G00458
N
5
Shutdown: Hydr. oil temp. too high - on
G00459
N
5
Shutdown: Trouble Lubrication system - off
G00460
N
5
Shutdown: Trouble Lubrication system - on
G00461
N
5
Shutdown: Monitoring engine speed too low - off
G00462
N
5
Shutdown: Monitoring engine speed too low - on
G00463
N
5
Shutdown: Monitoring engine speed too high - off
G00464
N
5
Shutdown: Monitoring engine speed too high - on
G00465
N
5
Shutdown: Fire suppression system - off
G00466
N
5
Shutdown: Fire suppression system - on
1
Communication failure MH800 VHMS-Controller
G00491
1
2
2
Y
G00501
N
5
Shutdown: Total loss gear oil 1 - off
G00502
N
5
Shutdown: Total loss gear oil 1 - on
G00533
14-38
2
13
2
Engine state is "Warm-up".
Version 2010/1
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Specifications for Operators
0 = RED 1 = YELLOW 2 = GREEN
C115
0
34
1
(Message Code)
Menory
G = Shovel C = Engine
Display
Colour Code of Top Message
Instruction Message No.
Error Code
Acoustic Signal
14.2.10.2 TABLE OF C-CODES - DIESEL ENGINES WITH EMISSION STANDARD TIER 2
Y
1
Engine Speed Signal Lost
C-Code TIER 2
C135
N
2
Oil Press Ckt Failed High
C141
N
2
Oil Press Ckt Failed Low
C143
0
33
1
Y
1
Low Oil Press
C144
1
20
2
Y
1
Coolant Temp Ckt Failed High
C145
1
20
2
Y
1
Coolant Temp Ckt Failed Low
C146
1
40
1
Y
1
Coolant Temp Above Normal
C151
0
33
2
Y
1
High Coolant Temp
C153
N
2
Int Man Temp 1 Ckt Failed High
C154
N
2
Int Man Temp 1 Ckt Failed Low
1
High Int Man Temp 1
C155
0
32
2
Y
C156
N
2
Int Man Temp 2 Ckt Failed High
C157
N
2
Int Man Temp 2 Ckt Failed Low
1
High Int Man Temp 2
C158
0
32
2
Y
C159
N
2
Int Man Temp 3 Ckt Failed High
C161
N
2
Int Man Temp 3 Ckt Failed Low
1
High Int Man Temp 3
C162
0
32
2
Y
C163
N
2
Int Man Temp 4 Ckt Failed High
C164
N
2
Int Man Temp 4 Ckt Failed Low
1
High Int Man Temp 4
C165
0
32
2
Y
C187
N
2
Sensor Supply 2 Ckt Failed Low
C195
N
2
Coolant Level Ckt Failed High
C196
N
2
Coolant Level Ckt Failed Low
C197
N
2
Coolant Level Below Normal
C212
N
2
Oil Temp Ckt Failed High
C213
N
2
Oil Temp Ckt Failed Low
1
Engine Oil Temp to High
C214
0
32
2
Y
C221
N
2
Ambient Air Press Failed High
C222
N
2
Ambient Air Press Failed Low
C223
N
2
Centinel Burn Valve Below Normal
Version 2010/1
14-39
0 = RED 1 = YELLOW 2 = GREEN
C-Code TIER 2 Menory
G = Shovel C = Engine
Acoustic Signal
(Message Code)
Colour Code of Top Message
Display
Error Code
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Instruction Message No.
Specifications for Operators
C224
N
2
Centinel Burn Valve Above Normal
C227
N
2
Sensor Supply 2 Ckt Failed High
1
Very Low Coolant Pressure
C228
0
32
2
Y
C231
N
2
Coolant Press Ckt Failed High
C232
N
2
Coolant Press Ckt Failed Low
C234
0
32
2
Y
1
Engine overspeed
C235
0
31
2
Y
1
Low Coolant Level
C238
N
2
Sensor Supply 3 Ckt Failed Low
C245
N
2
Fan Control Circuit Failed Low
1
High Fuel Temp
C261
0
31
1
Y
C263
N
2
Fuel Temp Ckt Failed High
C265
N
2
Fuel Temp Ckt Failed Low
1
Very High Fuel Temp
C266
0
33
2
C271
1
40
1
1
Fuel Pump Press 1 Ckt Failed Low
C272
1
40
1
11
Fuel Pump Press 1 Ckt Failed High
C322
1
40
1
1
Injector Sol Driver Cyl 1 Below Normal
C323
1
40
1
1
Injector Sol Driver Cyl 5 Below Normal
C324
1
40
1
1
Injector Sol Driver Cyl 3 Below Normal
C325
1
40
1
1
Injector Sol Driver Cyl 6 Below Normal
C331
1
40
1
1
Injector Sol Driver Cyl 2 Below Normal
C332
1
40
1
1
Injector Sol Driver Cyl 4 Below Normal
N
2
ECM Hardware Issue Non Mission\n\ Disabling
1
1
Injector Power Supply Failed
C352
N
2
Sensor Supply 1 Ckt Failed Low
C386
N
2
Sensor Supply 1 Ckt Failed High
1
Very Low Oil Pressure
1
WIF Indicator Warning
1
Engine Oil Temp Above Normal
2
J1939 Datalink Can Not Transmit
C343 C351
0
34
C415
0
32
2
C418
1
31
1
C421
1
40
1
C426
Y
Y
Y
N
C441
1
31
1
Y
1
Low Battery Voltage
C442
1
31
1
Y
1
High Battery Voltage
14-40
Version 2010/1
0 = RED 1 = YELLOW 2 = GREEN
C449
0
31
2
(Message Code)
Menory
G = Shovel C = Engine
Display
Colour Code of Top Message
Instruction Message No.
Error Code
Acoustic Signal
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Y
2
High Rail Pressure
C-Code TIER 2
C451
N
2
Rail Press Ckt Failed High
C452
N
2
Rail Press Ckt Failed Low
1
1
High Intake Manifold Temp
C527
N
2
Dual Output A Failed High
C529
N
2
Dual Output B Failed High
C546
N
2
Fuel Del Pressure Ckt Failed High
C547
N
2
Fuel Del Pressure Ckt Failed Low
1
High Crankcase Pressure
C488
1
31
C556
0
32
2
C559
1
40
1
1
Rail Pressure 1 Below Normal
C621
N
2
Low Power Cylinder 1
C622
N
2
Low Power Cylinder 3
C623
N
2
Low Power Cylinder 5
C624
N
2
Low Power Cylinder 7
C625
N
2
Low Power Cylinder 9
C626
N
2
Low Power Cylinder 11
C627
N
2
Low Power Cylinder 13
C628
N
2
Low Power Cylinder 15
C631
N
2
Low Power Cylinder 2
C632
N
2
Low Power Cylinder 4
C633
N
2
Low Power Cylinder 6
C634
N
2
Low Power Cylinder 8
C635
N
2
Low Power Cylinder 10
C636
N
2
Low Power Cylinder 12
C637
N
2
Low Power Cylinder 14
C638
N
2
Low Power Cylinder 16
C671
N
2
Exh Temp Ckt Failed Low Cylinder 1
C672
N
2
Exh Temp Ckt Failed Low Cylinder 3
C673
N
2
Exh Temp Ckt Failed Low Cylinder 5
C674
N
2
Exh Temp Ckt Failed Low Cylinder 7
C675
N
2
Exh Temp Ckt Failed Low Cylinder 9
Version 2010/1
Y
Specifications for Operators
14-41
0 = RED 1 = YELLOW 2 = GREEN
C-Code TIER 2 Menory
G = Shovel C = Engine
Acoustic Signal
(Message Code)
Colour Code of Top Message
Display
Error Code
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Instruction Message No.
Specifications for Operators
C676
N
2
Exh Temp Ckt Failed Low Cylinder 11
C677
N
2
Exh Temp Ckt Failed Low Cylinder 13
C678
N
2
Exh Temp Ckt Failed Low Cylinder 15
1
1
Engine Crankshaft Speed Erratic
C721
N
2
Exh Temp Ckt Failed Low Cylinder 2
C722
N
2
Exh Temp Ckt Failed Low Cylinder 4
C723
N
2
Exh Temp Ckt Failed Low Cylinder 6
C724
N
2
Exh Temp Ckt Failed Low Cylinder 8
C725
N
2
Exh Temp Ckt Failed Low Cylinder 10
C726
N
2
Exh Temp Ckt Failed Low Cylinder 12
C727
N
2
Exh Temp Ckt Failed Low Cylinder 14
C728
N
2
Exh Temp Ckt Failed Low Cylinder 16
C731
N
1
Engine Speed Cam/Crank Misalignment
1
Rapid rise int man temp 1
N
2
Power Lost with Ignition On
C689
C783
1
0
40
32
C1117
2
Y
C1357
1
31
1
1
Remote Oil Level Below Normal
C1362
1
31
1
1
High Lube Oil Filter Restriction
C1363
1
40
1
1
Int Man Press 1 Below Normal
C1367
N
2
Pre Filter Oil Press Ckt Failed High
C1368
N
2
Pre Filter Oil Press Ckt Failed Low
C1373
N
2
Ether Injection Ckt Failed
C1377
N
2
Post Filter Oil Press Ckt Failed High
C1378
N
2
Post Filter Oil Press Ckt Failed Low
C1383
N
2
Int Man Press 1 Failed High
C1384
N
2
Int Man Press 1 Failed Low
C1385
N
2
Int Man Press 2 Failed High
C1386
N
2
Int Man Press 2 Failed Low
1
J1939 Engine Commanded Shutdown
C1387
0
34
2
Y
C1411
N
2
Gen Output Freq Ckt Failed High
C1412
N
2
Droop Adj Ckt Failed High
C1418
N
2
Gain Adj Ckt Failed High
14-42
Version 2010/1
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Display
Acoustic Signal
Menory
Colour Code of Top Message
Instruction Message No.
Error Code
Specifications for Operators
C1427
2
2
Y
2
Overspeed Shutdown Relay Driver Error
C1428
2
2
Y
2
Low Oil Press Shutdown Relay Driver Err
C1429
2
2
Y
2
High Eng Temp Shutdown Relay Driver Err
(Message Code) G = Shovel C = Engine
0 = RED 1 = YELLOW 2 = GREEN
C-Code TIER 2
C1431
N
2
Oil Pressure Relay Driver Error
C1432
N
2
High Engine Temp Relay Driver Error
C1517
1
31
1
1
ECM Detects Most Severe Fault
C1518
1
31
1
1
ECM Detects Moderately Severe Fault
C1519
1
31
1
1
ECM Detects Least Severe Fault
C1521
N
2
Exh Temp Ckt Failed High Cylinder 3
C1522
N
2
Exh Temp Ckt Failed High Cylinder 5
C1523
N
2
Exh Temp Ckt Failed High Cylinder 7
C1524
N
2
Exh Temp Ckt Failed High Cylinder 9
C1525
N
2
Exh Temp Ckt Failed High Cylinder 11
C1526
N
2
Exh Temp Ckt Failed High Cylinder 13
C1527
N
2
Exh Temp Ckt Failed High Cylinder 15
C1529
N
2
Exh Temp Ckt Failed High Cylinder 2
C1531
N
2
Exh Temp Ckt Failed High Cylinder 6
C1532
N
2
Exh Temp Ckt Failed High Cylinder 8
C1533
N
2
Exh Temp Ckt Failed High Cylinder 10
C1534
N
2
Exh Temp Ckt Failed High Cylinder 12
C1535
N
2
Exh Temp Ckt Failed High Cylinder 14
C1536
N
2
Exh Temp Ckt Failed High Cylinder 16
C1542
N
2
Engine oil level sensor Ckt Failed High
C1543
N
2
Engine oil level sensor Ckt Failed Low
C1548
40
N
2
Injector Sol Driver 7 Below Normal
C1549
40
N
2
Injector Sol Driver 8 Below Normal
C1551
40
N
2
Injector Sol Driver 10 Below Normal
C1552
40
N
2
Injector Sol Driver 11 Below Normal
C1553
40
N
2
Injector Sol Driver 12 Below Normal
C1554
40
N
2
Injector Sol Driver 13 Below Normal
C1555
40
N
2
Injector Sol Driver 14 Below Normal
Version 2010/1
14-43
Display
Colour Code of Top Message
Instruction Message No.
Error Code
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Acoustic Signal
Specifications for Operators
C1556
40
N
2
Injector Sol Driver 15 Below Normal
C1557
40
N
2
Injector Sol Driver 16 Below Normal
31
1
1
ECM Critical Internal Failure
C1618
N
2
Exh Temp Ckt Failed High Cylinder 1
C1619
N
2
Exh Temp Ckt Failed High Cylinder 4
C1622
N
2
Injector Sol Driver 9 Below Normal
1
1
Int Man Press 2 Below Normal
C1843
N
2
Crankcase Press Ckt Failed High
C1844
N
2
Crankcase Press Ckt Failed Low
C1845
N
2
WIF Indicator Ckt Failed High
C1846
N
2
WIF Indicator Ckt Failed Low
C1847
N
2
Engine Coolant Temp Exception
1
1
WIF Indicator Above Normal
N
2
Engine Oil Change Interval Exceeded
G = Shovel C = Engine
C1597
C1638
C1852
0 = RED 1 = YELLOW 2 = GREEN
1
1
1
40
31
C1891
C-Code TIER 2 Menory
(Message Code)
C1911
1
31
1
1
Inj Rail Pressure Above Normal
C1984
1
31
1
1
Int Man Temp 2 Above Normal
C1985
1
31
1
1
Int Man Temp 3 Above Normal
C1986
1
31
1
1
Int Man Temp 4 Above Normal
N
2
Engine Speed Above Normal
C1992 C2121
0
32
2
Y
1
High Exhaust Temp Cyl 1
C2122
0
32
2
Y
1
High Exhaust Temp Cyl 3
C2123
0
32
2
Y
1
High Exhaust Temp Cyl 5
C2124
0
32
2
Y
1
High Exhaust Temp Cyl 7
C2125
0
32
2
Y
1
High Exhaust Temp Cyl 9
C2126
0
32
2
Y
1
High Exhaust Temp Cyl 11
C2127
0
32
2
Y
1
High Exhaust Temp Cyl 13
C2128
0
32
2
Y
1
High Exhaust Temp Cyl 15
C2131
0
32
2
Y
1
High Exhaust Temp Cyl 2
C2132
0
32
2
Y
1
High Exhaust Temp Cyl 4
C2133
0
32
2
Y
1
High Exhaust Temp Cyl 6
14-44
Version 2010/1
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
G = Shovel C = Engine
0 = RED 1 = YELLOW 2 = GREEN
Display
Acoustic Signal
Menory
Colour Code of Top Message
Instruction Message No.
Error Code
C2134
0
32
2
Y
1
High Exhaust Temp Cyl 8
C2135
0
32
2
Y
1
High Exhaust Temp Cyl 10
C2136
0
32
2
Y
1
High Exhaust Temp Cyl 12
C2137
0
32
2
Y
1
High Exhaust Temp Cyl 14
C2157
0
32
2
Y
1
Rapid Rise Int Man Temp 2
C2158
0
32
2
Y
1
Rapid Rise Int Man Temp 3
C2159
0
32
2
Y
1
Rapid Rise Int Man Temp 4
(Message Code)
Specifications for Operators
C-Code TIER 2
C2185
N
2
Sensor Supply 4 Ckt Above Normal
C2186
N
2
Sensor Supply 4 Ckt Below Normal
C2215
1
40
1
1
Fuel Pump Pressure Below Normal
C2261
1
31
1
1
Fuel Pump Del Pressure Above Normal
C2262
1
40
1
1
Fuel Pump Del Pressure Below Normal
C2265
N
2
Lift Pump Supply Ckt Failed High
C2266
N
2
Lift Pump Supply Ckt Failed Low
C2311
N
2
Fuel Injection Valve Ckt Error
C2321
N
2
Engine Crankshaft Speed - Data Erratic
C2322
N
2
Engine Camshaft Speed - Data Erratic
C2377
N
2
Fan Control Ckt Failed High
C2474
N
2
Turbocharger 1 Speed - Data Erratic
Version 2010/1
14-45
Specifications for Operators
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
G = Shovel C = Engine
0 = RED 1 = YELLOW 2 = GREEN
C112
1
35
C113
Acoustic Signal
(Message Code)
Colour Code of Top Message
Display
Error Code
Instruction Message No.
14.2.10.3 TABLE OF C-CODES - DIESEL ENGINES WITH EMISSION STANDARD TIER 1
Y N
C-Code TIER 1
Timing Fueling Mismatch Timing Act Shorted High
C115
0
34
Y
Speed Signal Lost
C116
1
35
Timing Rail Press Ckt Failed High
C117
1
35
Timing Rail Press Ckt Failed Low
C118
N
Timing Rail Press Ckt Failed Low
C119
N
Fuel Pump Press Ckt Failed Low
C121
N
1 Eng Speed Signal Lost
C122
N
LB Boost Ckt Failed High
C123
N
LB Boost Ckt Failed Low
C124
1
31
1
High Boost LB
C125
N
Low Boost LB
C126
N
High Boost RB
C127
N
Low Boost RB
C128
N
RB Boost Ckt Failed High
C129
N
RB Boost Ckt Failed Low
C131
N
Throttle Ckt Failed High
C132
N
Throttle Ckt Failed Low
C133
N
PTO Circuit Shorted High
C134
N
PTO Circuit Shorted Low
C135
N
Oil Press Ckt Failed High
C136
N
Pre Filter Oil Press Ckt Failed High
C137
N
Pre Filter Oil Press Ckt Failed Low
C141
N
Oil Press Ckt Failed Low
C143
0
33
Low Oil Press
C144
N
Coolant Temp Ckt Failed High
C145
N
Coolant Temp Ckt Failed Low
C147
N
Freq Throttle OOR High
C151
14-46
0
33
Y
High Coolant Temp
Version 2010/1
G = Shovel C = Engine
0 = RED 1 = YELLOW 2 = GREEN
Acoustic Signal
(Message Code)
Colour Code of Top Message
Display
Error Code
Instruction Message No.
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
C-Code TIER 1
C153
N
LBF IMT Ckt Failed High
C154
N
LBF IMT Ckt Failed Low
C155
0
33
Y
High IMT LBF
C156
N
LBR IMT Ckt Failed High
C157
N
LBR IMT Ckt Failed Low
C158
0
32
Y
High IMT LBR
C159
N
RBF IMT Ckt Failed High
C161
N
RBF IMT Ckt Failed High
C162
0
32
Y
High IMT RBF
C163
N
RBR IMT Ckt Failed High
C164
N
RBR IMT Ckt Failed Low
C165
0
32
Y
High IMT RBR
C212
N
Oil Temp Ckt Failed High
C213
N
Oil Temp Ckt Failed Low
C214
1
31
Y
High Oil Temp
C219
N
Remote Oil Level Low
C221
N
Ambient Air Press Failed High
C222
N
Ambient Air Press Failed Low
C223
N
CORS Burn Valve Open Circuit
C225
N
CORS Makeup Valve Open Circuit
C231
N
Coolant Press Ckt Failed High
C232
N
Coolant Press Ckt Failed Low
C233
0
33
Y
Low Coolant Press
C234
0
32
Y
Engine Overspeed
C235
1
31
Y
Low Coolant Level
C237
N
Multi Unit Sync Error
C252
N
Oil Level Signal Invalid
C253
0
33
C254
0
34
FSOV Open Cicuit
C259
1
31
FSOV Mech Stuck Open
Version 2010/1
Y
Specifications for Operators
Oil Level Low
14-47
G = Shovel C = Engine
0 = RED 1 = YELLOW 2 = GREEN
C261
0
33
Acoustic Signal
(Message Code)
Colour Code of Top Message
Display
Error Code
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Instruction Message No.
Specifications for Operators
Y
C-Code TIER 1
High Fuel Temp
C263
N
Fuel Temp Ckt Failed High
C265
N
Fuel Temp Ckt Failed Low
C299
N
Hot Shutdown
C316
N
Fuel Pump Open Circuit
C318
N
Fuel Pump Mech Stuck
C343
N
ECM Hardware Issue Non Mission Disabling
C346
N
ECM Software / Hardware Failure
C349
N
Output Shaft Speed above normal
C384
N
Ether Solenoid Ckt Failed
C422
N
Coolant Level Signal Invalid
C423
1
35
Timing Press Incorrect
C426
N
J1939 Datalink Can Not Transmit
C427
N
J1939 Datalink Can Not Transmit
C431
N
Idle Validation Invalid
C432
N
Idle Validation Invalid
C441
1
31
Y
Low Battery Voltage
C442
1
31
Y
High Battery Voltage
C451
N
Rail Press Ckt Failed High
C452
N
Rail Press Ckt Failed Low
C455
1
31
Rail Actuator Open Ckt
C467
1
35
Desired Timing Not Achieved
C468
1
40
Desired Rail Press not Achieved
C473
N
Remote Oil Level Signal Invalid
C487
N
Ether Bottle Empty
C489
N
AXG Speed Low Error
C514
1
40
Rail Actuator Mech Stuck
C524
N
Alt Droop SW Val Fault
C527
N
Dual Output A Shorted High or Open Ckt
C528
N
Alt Torque SW Val Fault
14-48
Version 2010/1
G = Shovel C = Engine
0 = RED 1 = YELLOW 2 = GREEN
C529
Acoustic Signal
(Message Code)
Colour Code of Top Message
Display
Error Code
Instruction Message No.
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
N
C-Code TIER 1
Dual Output B Shorted High or Open Ckt
C551
0
32
Throttle Validation Switch High Error
C553
1
31
Rail Press OOR High
C554
1
40
Rail Press Incorrect
C555
0
33
C611 C612
Y N
1
31
High Blowby Press Engine Hot Shutdown High Oil Filter Rest
C616
N
High Turbo Comp Inlet Temp LBR
C621
N
Low Power #1 LB
C622
N
Low Power #2 LB
C623
N
Low Power #3 LB
C624
N
Low Power #4 LB
C625
N
Low Power #5 LB
C626
N
Low Power #6 LB
C627
N
Low Power #7 LB
C628
N
Low Power #8 LB
C631
N
Low Power #1 RB
C632
N
Low Power #2 RB
C633
N
Low Power #3 RB
C634
N
Low Power #4 RB
C635
N
Low Power #5 RB
C636
N
Low Power #6 RB
C637
N
Low Power #7 RB
C638
N
Low Power #8 RB
C641
0
32
High Exh Temp #1 LB
C642
0
32
High Exh Temp #2 LB
C643
0
32
High Exh Temp #3 LB
C644
0
32
High Exh Temp #4 LB
C645
0
32
High Exh Temp #5 LB
C646
0
32
High Exh Temp #6 LB
Version 2010/1
Specifications for Operators
14-49
Acoustic Signal
(Message Code)
Colour Code of Top Message
Display
Error Code
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Instruction Message No.
Specifications for Operators
C-Code TIER 1
G = Shovel C = Engine
0 = RED 1 = YELLOW 2 = GREEN
C647
0
32
High Exh Temp #7 LB
C648
0
32
High Exh Temp #8 LB
C649
N
Change Lubricating Oil and Filter
C651
0
32
High Exh Temp #1 RB
C652
0
32
High Exh Temp #2 RB
C653
0
32
High Exh Temp #3 RB
C654
0
32
High Exh Temp #4 RB
C655
0
32
High Exh Temp #5 RB
C656
0
32
High Exh Temp #6 RB
C657
0
32
High Exh Temp #7 RB
C658
0
32
High Exh Temp #8 RB
C661
N
High Power #1 LB
C662
N
High Power #2 LB
C663
N
High Power #3 LB
C664
N
High Power #4 LB
C665
N
High Power #5 LB
C666
N
High Power #6 LB
C667
N
High Power #7 LB
C668
N
High Power #8 LB
C671
N
Exh Temp Ckt Failed Low #1 LB
C672
N
Exh Temp Ckt Failed Low #2 LB
C673
N
Exh Temp Ckt Failed Low #3 LB
C674
N
Exh Temp Ckt Failed Low #4 LB
C675
N
Exh Temp Ckt Failed Low #5 LB
C676
N
Exh Temp Ckt Failed Low #6 LB
C677
N
Exh Temp Ckt Failed Low #7 LB
C678
N
Exh Temp Ckt Failed Low #8 LB
C694
N
LBR Turbo Comp Inlet Temp Sesnor Ckt Failed High
C695
N
LBR Turbo Comp Inlet Temp Sesnor Ckt Failed Low
C711
N
High Power #1 RB
14-50
Version 2010/1
G = Shovel C = Engine
0 = RED 1 = YELLOW 2 = GREEN
Acoustic Signal
(Message Code)
Colour Code of Top Message
Display
Error Code
Instruction Message No.
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
C-Code TIER 1
C712
N
High Power #2 RB
C713
N
High Power #3 RB
C714
N
High Power #4 RB
C715
N
High Power #5 RB
C716
N
High Power #6 RB
C717
N
High Power #7 RB
C718
N
High Power #8 RB
C719
N
Blowby Press Ckt Failed High
C721
N
Exh Temp Ckt Failed Low #1 RB
C722
N
Exh Temp Ckt Failed Low #1 RB
C723
N
Exh Temp Ckt Failed Low #1 RB
C724
N
Exh Temp Ckt Failed Low #1 RB
C725
N
Exh Temp Ckt Failed Low #1 RB
C726
N
Exh Temp Ckt Failed Low #1 RB
C727
N
Exh Temp Ckt Failed Low #1 RB
C728
N
Exh Temp Ckt Failed Low #1 RB
C729
N
Blowby Press Ckt Failed Low
C753
N
Cam Sync Error
C777
N
Ambient Derate Error
C783
0
32
C2154
Y N
Specifications for Operators
Rapid rise in left bank front intake temp. Post Oil Filter Press Ckt Failed High
C2155
Post Oil Filter Press Ckt Failed Low
C2157
0
32
Y
Rapid rise in left bank rear intake temp.
C2158
0
32
Y
Rapid rise in right bank front intake temp.
C2159
0
32
Y
Rapid rise in right bank rear intake temp.
Version 2010/1
14-51
Specifications for Operators
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
14.2.10.4 TABLE OF AVAILABLE INSTRUCTION MESSAGES Message No.
14-52
Instruction Message
1
Engine stopped because of main Shut-Off (gate) valve. - Open the Shut-Off (gate) valve. - If failure exist further, inform service.
2
Inform service.
3
Stop the engine. - Inform service.
4
Start blocked because of main Shut-Off (gate) valve. - Open the Shut-Off (gate) valve. - If failure exist further, inform service.
5
Start blocked - Inform service.
6
The fire suppression system has been actuated. - Inform the fire brigade. - Evacuate endangered persons. - Fight the fire. - Inform service.
7
Bucket motion switched off. - Inform service.
8
No 24V at circuit breaker 11F013 - If failure exist further, inform service.
9
Ladder end switch or lock lever contact open or service arm down or unlock. - If failure exist further, inform service.
10
Emergency shut-down switch was actuated. - Unlock before restarting. - If failure exist further, inform service.
11
Engine switched off by Maintenance Safety Switch in the engine room.
12
Operate the machine into the parking position.
13
Please wait! No high idle !
14
Enable switch for refilling arm active - If failure exist further, inform service.
15
Load of the batteries too high. - Inform service.
16
Batteries are not being charged. - Inform service.
17
Inform service till end of shift and then press cancel button.
Version 2010/1
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Message No.
Instruction Message
18
Slew ring gear house brake OFF - Inform service till end of shift and then press cancel button.
19
Travel gear house brake OFF - Inform service till end of shift and then press cancel button.
20
Inform service and then press cancel button.
21
Hydraulic oil far below operating temperature ! - Pre-heat hydraulic oil or warm up at low idle speed and reduced power.
22
Engine runs (starter motor inactive).
23
A fuel reserve only is still in the tank - Order tanker.
24
Engine shutdown has been actuated from ground man.
25
Hydraulic oil below operating temperature. - Operate with reduced power !
26
Slew ring gear house brake ON
27
Hydraulic oil overheat - engine power derated
28
The VHMS is by-passed. - Reset by-pass switch.
29
Engine shutdown by keyswitch before proper engine cool down. - Before you switch off the engine, cool down the engine in the low idle for 2-3 minutes.
30
Hydraulic oil far below operating temperature ! - Pre-heat hydraulic oil or warm up at low idle speed and reduced power.
31
Continue shift but advise service.
32
Stop engine call service.
33
Derate active, continue to work. Later shutdown possible. Inform service.
34
Call service because of shutdown.
35
Interrupt work and inform service about Speed Derate .
36
Continue work until next PM (Schedule work for next PM)
37
Switch Testspeed in cab base forces the engine to run constantly 1800 1/min.
Version 2010/1
Specifications for Operators
14-53
Specifications for Operators
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Message No.
14-54
Instruction Message
38
If failure exist further, inform service.
39
Inform service if attachment in defined position.
40
Continue to work and inform service about Power Derate.
41
Cable Drum at limit. - Move the shovel in an other direction.
42
Motor overheated. Wait until cooldown. - If failure exists further, inform service.
43
Switch off and restart motor - If failure exists further, inform service.
44
Switch off and restart motor (It may be necessary to wait for cool down) - If failure exists further, inform service.
46
Switch off windscreen wiper and call service.
47
Only upper windscreen wiper! Inform service.
48
No 24V at circuit breaker 11F013a - If failure exist further, inform service.
49
Only lower windscreen wiper! Inform service.
50
Reverse travel cut out by cable drum.
51
Cable drum-motor temperature too high. Allow motor to cool down.
52
Permanently switch off by device overheating. Inform service.
53
Temporary switch off by heating-air overheating. Inform service.
54
Wait during one minute after last start of motor.
55
Risk of collision with the cable drum!
56
Key switch off and back on !
57
Cool down period !
58
Travel gear house brake ON
Version 2010/1
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Flow Charts (1-4) VHMS Main Screens
14.3
FLOW CHARTS (1-4) VHMS MAIN SCREENS
Fig. 14-22
Main screen flow chart for the Operater Level (1 of 1)
Version 2010/1
14-55
Flow Charts (1-4) VHMS Main Screens
Fig. 14-23 14-56
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Main screen flow chart for the Service Level (1 of 3) Version 2010/1
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Fig. 14-24
Flow Charts (1-4) VHMS Main Screens
Main screen flow chart for the Service Level (2 of 3)
Version 2010/1
14-57
Flow Charts (1-4) VHMS Main Screens
Fig. 14-25 14-58
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Main screen flow chart for the Service Level (3 of 3) Version 2010/1
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
14.4
VHMS SERVICE LEVEL
Fig. 14-26
Entering the Service Level
VHMS Service Level
Legend for Fig. 14-26: (1)
Keep key 4 pressed
(2)
Enter digits 123 and release key 4
Version 2010/1
14-59
VHMS Service Level
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
The Service Level can be activated from all of the three Main Gauge Screens in the operator mode only. If one of the Main Gauge Screens is open, keep key 4 of the key pad pressed and simultaneously enter the digits 1, 2, 3. Then release key 4. Refer to illustration (Fig. 14-26). The following screen will appear:
Fig. 14-27
Input Service ID -1-
Enter the Service ID number and press F6 to confirm.
Fig. 14-29
Input Service ID -3-
14.4.1
EXPLANATION OF THE BUTTON SYMBOLS (SERVICE LEVEL)
NOTE: The function of the buttons depends on the menu context.
NOTE: The Service ID number 0400008152 is programmed ex factory.
Functions of the buttons F1 to F6 Go to the next screen. F1 Go to the previous screen. F2
Fig. 14-28
Move the cursor down or left in a menu.
F4
Move the cursor up or right in a menu.
Input Service ID -2-
If the entered Service ID was not correct, the display changes to the following screen. Enter the correct Service ID and press F6 to confirm. The number of attempts to enter the Service ID is not limited. NOTE: If you are unsure about the correct Service ID number, please contact your supervisor or your dealer if necessary.
14-60
F3
F5
F6
Leave the sub-menu and go back to the previous main menu. Confirm any setting, or switch any function ON or OFF (1 or 0).
Version 2010/1
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
14.4.2
SERVICE MENU SELECT SCREEN
After the log-in with the Service ID, the following 8 options of the SERVICE MENU SELECT screen are available:
Fig. 14-30
Fig. 14-31
Legend for Fig. 14-30 and 14-31:
01
z Real Time Monitor Shifts to the menu which allows to display real-time controller data, refer to section 14.4.3 on page 14-62.
02
z PM-Clinic Shifts to the menu which displays PM-Clinic data, refer to section 14.4.4 on page 14-78.
03
z Serial/GCC No. Setting Registers the serial numbers of the excavator model, the engine, and the VHMS monitor, refer to section 14.4.5 on page 14-80.
04
z Memory Clear Shifts to the menu which allows to clear the records in the VHMS memory, refer to section 14.4.6 on page 14-81.
05
z Failure History Shifts to the screen which displays the event and error history for service, refer to section 14.4.7 on page 14-83.
06
z Maintenance Shifts to the menu which allows to manage the data of the Maintenance Monitor, refer to section 14.4.8 on page 14-84.
07
z Snapshot Shifts to the menu which allows to manage the saving options of machine data in manual snapshots, refer to section 14.4.9 on page 14-85.
08
z Setting Shifts to the menu which allows to manage specific settings of machine data, refer to section 14.4.10 on page 14-86.
Service Menu - items 01 - 06
Service Menu - items 03 - 08
Version 2010/1
VHMS Service Level
14-61
VHMS Service Level
14.4.3
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
REAL TIME MENU SELECT SCREEN
NOTE: For entering the Service Menu refer to section 14.4 on page 14-59.
14.4.3.1
REAL TIME MENU, OPTION: 01 ENGINE 1
Press F3 or F4 to move up or down in the menu.
Use the three REAL TIME MENU SELECT screens to open sub-screens for all 15 options. The sub-screens are called REAL TIME MONITOR. i
Fig. 14-33
Real Time Menu, selection 01
Select menu option 01 Engine 1 and press button F6.i
Fig. 14-34
Real Time Monitor - Engine 1, 1 of 6
Press F1 or F2 to toggle the screens.i
Fig. 14-32
REAL TIME MENU - options 1 -15
The following REAL TIME MONITOR screens display all relevant controller data in real-time. Use the realtime data for testing & adjustment work and for troubleshooting.
14-62
Fig. 14-35
Real Time Monitor - Engine 1, 2 of 6
Version 2010/1
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Fig. 14-36
Real Time Monitor - Engine 1, 3 of 6
VHMS Service Level
Fig. 14-39
Real Time Monitor - Engine 1, 6 of 6
14.4.3.2
REAL TIME MENU, OPTION: 02 PTO 1
Press F3 or F4 to move up or down in the menu.
Fig. 14-37
Real Time Monitor - Engine 1, 4 of 6
Fig. 14-40
Real Time Menu, selection 02
Select menu option 02 PTO 1 and press button F6.
Fig. 14-38
Real Time Monitor - Engine 1, 5 of 6
Fig. 14-41
Version 2010/1
Real Time Monitor - PTO 1, 1 of 1
14-63
VHMS Service Level
14.4.3.3
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
REAL TIME MENU, OPTION: 03 HYDRAULIC
Press F3 or F4 to move up or down in the menu.
Fig. 14-42
Fig. 14-45
Real Time Monitor - Hydr. Press. 3 of 4
Fig. 14-46
Real Time Monitor - Hydr. Press. 4 of 4
Real Time Menu, selection 03
Select menu option 03 Hydraulic and press F6.
Fig. 14-43
Real Time Monitor - Hydr. Press. 1 of 4
Press F1 or F2 to toggle the screens.
Fig. 14-44
14-64
Real Time Monitor - Hydr. Press. 2 of 4
Version 2010/1
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
VHMS Service Level
14.4.3.4
REAL TIME MENU, OPTION: 04 SLEW
Select option 05 Electrical Equipm. and press F6
Fig. 14-47
Real Time Menu, selection 04
Fig. 14-50
Real Time Monitor - Electr. Equipm. 1 of 2
Select menu option 04 Slew and press F6.
Press F1 or F2 to toggle the screens.
Fig. 14-48
Fig. 14-51
Real Time Monitor - Electr. Equipm. 2 of 2
14.4.3.6
REAL TIME MENU, OPTION: 06 EMERGENCY STOP
Real Time Monitor - Slew 1 of 1
REMARK The entries SLEW SPEED ANALOG 11B144 and SLEW POSITION 60B059 only apply to PC5500 (automatic slew speed system).
Press F3 or F4 to move up or down in the menu.
14.4.3.5
REAL TIME MENU, OPTION: 05 ELECTRICAL EQUIPMENT
Press F3 or F4 to move up or down in the menu.
Fig. 14-52
Fig. 14-49
Real Time Menu, selection 06
Real Time Menu, selection 05
Version 2010/1
14-65
VHMS Service Level
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Select option 06 Emergency Stop and press F6.
Select option 07 Manual Switch and press F6.
Fig. 14-53
Fig. 14-56
Real Time Monitor - Emerg. Stop 1 of 2
Real Time Monitor - Manual Switch 1 of 4
Press F1 or F2 to toggle the screens.
Press F1 or F2 to toggle the screens.
Fig. 14-54
Real Time Monitor - Emerg. Stop 2 of 2
Fig. 14-57
Real Time Monitor - Manual Switch 2 of 4
14.4.3.7
REAL TIME MENU, OPTION: 07 MANUAL SWITCH
Fig. 14-58
Real Time Monitor - Manual Switch 3 of 4
Press F3 or F4 to move up or down in the menu.
Fig. 14-55
14-66
Real Time Menu, selection 07
Version 2010/1
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
VHMS Service Level
Press F1 or F2 to toggle the screens.
Fig. 14-59
Real Time Monitor - Manual Switch 4 of 4
Fig. 14-62
Real Time Monitor - Centr. Lube 2 of 2
14.4.3.8
REAL TIME MENU, OPTION: 08 CENTRAL LUBE SYSTEM 1
14.4.3.9
REAL TIME MENU, OPTION: 09 SLEW RING GEAR LUBE SYSTEM
Press F3 or F4 to move up or down in the menu.
Press F3 or F4 to move up or down in the menu.
Fig. 14-60
Real Time Menu, selection 08
Select option 08 Central Lube System 1 and press F6.
Fig. 14-63
Real Time Menu, selection 09
Select 09 Slew ring gear Lube System and press F6.
Fig. 14-61
Real Time Monitor - Centr. Lube 1 of 2 Fig. 14-64
Version 2010/1
Real Time Monitor - Slew ring lube 1 of 2
14-67
VHMS Service Level
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Press F1 or F2 to toggle the screens.
Press F1 or F2 to toggle the screens.
Fig. 14-65
Fig. 14-68
Real Time Monitor - Slew ring lube 2 of 2
Real Time Monitor - Windscr. Wiper 2 of 2
14.4.3.10 REAL TIME MENU, OPTION: 10 WINDSCREEN WIPER
14.4.3.11 REAL TIME MENU, OPTION: 11 LADDER
Press F3 or F4 to move up or down in the menu.
Press F3 or F4 to move up or down in the menu.
Fig. 14-66
Fig. 14-69
Real Time Menu, selection 10
Real Time Menu, selection 11
Select option 10 Windscreen Wiper and press F6.
Select option 11 Ladder and press F6.
Fig. 14-67
Fig. 14-70
14-68
Real Time Monitor - Windscr. Wiper 1 of 2
Real Time Monitor - Ladder 1 of 5
Version 2010/1
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
VHMS Service Level
Press F1 or F2 to toggle the screens.
Fig. 14-71
Real Time Monitor - Ladder 2 of 5
Fig. 14-74
Real Time Monitor - Ladder 5 of 5
14.4.3.12 REAL TIME MENU, OPTION: 12 SERVICE ARM Press F3 or F4 to move up or down in the menu.
Fig. 14-72
Real Time Monitor - Ladder 3 of 5
Fig. 14-75
Real Time Menu, selection 12
Select option 12 Service arm and press F6.
Fig. 14-73
Real Time Monitor - Ladder 4 of 5
Fig. 14-76
Version 2010/1
Real Time Monitor - Service arm 1 of 5
14-69
VHMS Service Level
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Press F1 or F2 to toggle the screens.
Fig. 14-77
Real Time Monitor - Service arm 2 of 5
Fig. 14-80
Real Time Monitor - Service arm 5 of 5
14.4.3.13 REAL TIME MENU, OPTION: 13 PILOT CONTROL Press F3 or F4 to move up or down in the menu.
Fig. 14-78
Real Time Monitor - Service arm 3 of 5
Fig. 14-81
Real Time Menu, selection 13
Select option 13 Pilot control and press F6.
Fig. 14-79
Real Time Monitor - Service arm 4 of 5
Fig. 14-82
14-70
Real Time Monitor - Pilot control 1 of 6
Version 2010/1
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
VHMS Service Level
Press F1 or F2 to toggle the screens.
Fig. 14-83
Real Time Monitor - Pilot control 2 of 6
Fig. 14-86
Real Time Monitor - Pilot control 5 of 6
Fig. 14-84
Real Time Monitor - Pilot control 3 of 6
Fig. 14-87
Real Time Monitor - Pilot control 6 of 6
14.4.3.14 REAL TIME MENU, OPTION: 14 OTHER ITEMS Press F3 or F4 to move up or down in the menu.
Fig. 14-85
Real Time Monitor - Pilot control 4 of 6
Fig. 14-88
Real Time Menu, selection 14
Select option 14 Other items and press F6
Version 2010/1
14-71
VHMS Service Level
Fig. 14-89
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Real Time Monitor - Other items 1 of 4
Fig. 14-92
Real Time Monitor - Other items 4 of 4
Press F1 or F2 to toggle the screens.
14.4.3.15 REAL TIME MENU, OPTION: 15 OUTPUT SIGNALS Press F3 or F4 to move up or down in the menu.
Fig. 14-90
Real Time Monitor - Other items 2 of 4
Fig. 14-93
Real Time Menu, selection 15
For testing and troubleshooting the Output Signals can be switched on (1) and off (0). For the appropriate procedure refer to Output Signals with deactivated MTC-Evaluation on page 77. Select option 15 Output Signals and press F6.
Fig. 14-91
Real Time Monitor - Other items 3 of 4
Fig. 14-94
Real Time Monitor - Output Signals 1/24
Press F1 or F2 to toggle the screens. 14-72
Version 2010/1
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
VHMS Service Level
Fig. 14-95
Real Time Monitor - Output Signals 2/24
Fig. 14-98
Real Time Monitor - Output Signals 5/24
Fig. 14-96
Real Time Monitor - Output Signals 3/24
Fig. 14-99
Real Time Monitor - Output Signals 6/24
Fig. 14-97
Real Time Monitor - Output Signals 4/24
Fig. 14-100 Real Time Monitor - Output Signals 7/24
Version 2010/1
14-73
VHMS Service Level
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Fig. 14-101 Real Time Monitor - Output Signals 8/24
Fig. 14-104 Real Time Monitor - Output Signals 11/24
Fig. 14-102 Real Time Monitor - Output Signals 9/24
Fig. 14-105 Real Time Monitor - Output Signals 12/24
Fig. 14-103 Real Time Monitor - Output Signals 10/24
Fig. 14-106 Real Time Monitor - Output Signals 13/24
14-74
Version 2010/1
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
VHMS Service Level
Fig. 14-107 Real Time Monitor - Output Signals 14/24
Fig. 14-110 Real Time Monitor - Output Signals 17/24
Fig. 14-108 Real Time Monitor - Output Signals 15/24
Fig. 14-111 Real Time Monitor - Output Signals 18/24
Fig. 14-109 Real Time Monitor - Output Signals 16/24
Fig. 14-112 Real Time Monitor - Output Signals 19/24
Version 2010/1
14-75
VHMS Service Level
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
Fig. 14-113 Real Time Monitor - Output Signals 20/24
Fig. 14-114 Real Time Monitor - Output Signals 21/24
Fig. 14-116 Real Time Monitor - Output Signals 23/24
Fig. 14-117 Real Time Monitor - Output Signals 24/24
Fig. 14-115 Real Time Monitor - Output Signals 22/24
14-76
Version 2010/1
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
14.4.3.16 OUTPUT SIGNALS WITH DEACTIVATED MTCEVALUATION
z
VHMS Service Level
Press button F6 (ON /OFF) to switch the solenoid valve 57K506b-1 ON (= 1) manually.f
As an on-board assistance for troubleshooting, the output signals of the REAL TIME MONITOR selection "15 Output Signals" can manually be switched on (1) and off (0), if the MTC-evaluation is deactivated. NOTE: For the procedure how to activate and deactivate the MTC-evaluation, refer to section 14.4.10.5 on page 14-90, PLC-evaluation ON/ OFF. Terminology (MTC & PLC) MTC is a synonym for PLC. Both acronyms indicate the same main control module. MTC is the acronym of Master Turbo Controller PLC is the acronym of Programmable Logic Controller WARNING If you need to deactivate the MTC-evaluation for testing, strictly observe the operating instructions for deactivation & activation of the MTC-evaluation. Refer to section "PLC-evaluation ON/OFF on page 91".
SAMPLE: Assumption It is necessary to check if voltage is present in the wiring of 57K506b-1 and at the solenoid valve itself.
Fig. 14-118 Output signal manually switched ON z
Now check the voltage in the circuit of solenoid valve 57K506b-1 and repair if necessary.
z
After check and repair are finished:
1. Switch the solenoid valve OFF (= 0) again in this case. 2. Activate the MTC-evaluation again, refer to "PLC-evaluation ON/OFF on page 91". 3. Switch off the main key switch (20S001) for more than 5 seconds, in order to cause a reset. After such a reset the MTC-evaluation is activated again and the electrical component is switched to its primary condition again by the system.
Procedure z
Stop the engine.
z
Turn the main key switch 20S001 to ON position.
z
Enter the service level on the VHMS monitor.
z
Deactivate the MTC-evaluation, refer to "PLCevaluation ON/OFF on page 91".
z
On the SERVICE MENU SELECT screen, select and open the entry 01 Real Time Monitor. Refer to Fig. no. 14-30.
z
Select and open the last option 15 Output signals. Refer to Fig. no. 14-93.
z
Move to the screen 16/ 24 REAL TIME MONITOR (Output Signals Control panel).
z
Use buttons F3 or F4 and select the second entry VALVE FAN DRIVE 1 MED.
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14.4.4
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
PM-CLINIC
NOTE: For entering the Service Menu refer to section 14.4 on page 14-59. The PM-Clinic Menu provides the following features: 1. General data of the machine and operating conditions are displayed, refer to Fig. 14-120 & 14-121. 2. Power Check relevant data can be frozen and also displayed by actuating: z
Button F4 in Fig. 14-123.
z
Push button 20S082 (R.H. control lever), which is normally used as truck counter.
3. The frozen data can be stored 3 times.
14.4.4.1
GENERAL
Press F3 or F4 to move up or down in the menu.
Fig. 14-121 PM-CLINIC - screen GENERAL 2 of 2 Press F6 to get into the second PM-CLINIC menu POWER CHECK Menu. In case data are already stored in the Menu POWER CHECK (Fig. 14-123) the following screen (Fig. 14122) appears before screen POWER CHECK (Fig. 14123) opens.
Fig. 14-119 Service Menu - 02 PM-CLINIC selected Select 02 PM-CLINIC and press F6.
Fig. 14-122 Delete PM-Clinic data - Yes/No If you want to save the current PM-Clinic data, delete the previously saved data by pressing button F6. If you don’t want to delete all PM-Clinic data, press button F5 in order to open the following screens of PM-Clinic POWER CHECK.
Fig. 14-120 PM-CLINIC - screen GENERAL 1 of 2 Press F1 or F2 to toggle the screen.
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14.4.4.2
POWER CHECK
VHMS Service Level
After pressing button F6 in screen POWER CHECK 3/3 (Fig. 14-124) the following screen appears:
The POWER CHECK screens should assist you if you want to check or identify: (a) engine performance/engine output power (b) pressure adjustment/hydraulic system problems There are 3 screens POWER CHECK for freezing data under different conditions. NOTE: In order to obtain a complete POWER CHECK, the F6 button should only be pressed after the 3rd screen (Fig. 14-124) "POWER CHECK 3/3" has been frozen. Fig. 14-125 Record PM-Clinic data - Yes/No Press button F6 if you want to record the data. Press button F5 for exit if you don’t want to record the data. The system returns to the POWER CHECK screen
Fig. 14-123 PM-CLINIC - POWER CHECK 1/3 It is possible to store the values of 3 different POWER CHECKS in the screens 1/3, 2/3, and 3/3. Press button F1 or F2 to monitor the POWER CHECK data of all 3 screens. If you want to freeze the data, press button F4 to move the yellow mark to Hold at the bottom of the display (Fig. 14-124). If Hold is highlighted yellow, press button F4 to freeze the current PM-CLINIC data. To show the current data again, press button F3. The yellow mark moves to Monitoring again (Fig. 14-123).
Fig. 14-124 PM-CLINIC - POWER CHECK 3/3
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VHMS Service Level
14.4.5
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
SERIAL/GCC NO. SETTING
NOTE: For entering the Service Menu refer to section 14.4 on page 14-59. Use this option to display the serial number of: (a) the excavator (b) the Diesel engine (c) the VHMS monitor MH801 Press F3 or F4 to move up or down in the menu.
Fig. 14-126 Service Menu - item 03 selected Select 03 Serial/GCC No. Setting and press F6.
Fig. 14-127 Screen SERIAL NO SETTING
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14.4.6
VHMS Service Level
MEMORY CLEAR
NOTE: For entering the Service Menu refer to section 14.4 on page 14-59.
14.4.6.1
INPUT MEMORY CLEAR ID
Use this option to enter the Memory Clear ID, which enables the user to delete memory data. With this function it is made sure that only authorized service personnel may delete saved data. Press F3 or F4 to move up or down in the menu. Fig. 14-129 Input Memory Clear ID Enter the Identification Number (ID) for clearing the memory and press F6 to confirm.
Fig. 14-128 Service Menu - item 04 selected Select 04 Memory Clear and press F6. Entry of the Identification Number Fig. 14-130 Memory Clear ID is typed in If 04 Memory Clear is selected in the Service Menu Selection screen, the display changes to the Input Memory Clear ID screen.
If the entered ID is not correct, the display changes to the following screen. Enter the ID number again.
The ID number entry is done via the key pad. The ID number is a number with up to 10 digits (same as the Service ID number). The enterd number is compared with the number which is registered in the VHMS controller. If the check result is correct, the display changes to the MEMORY CLEAR screen (Fig. 14-132), refer to section 14.4.6.2 on page 14-82.
Fig. 14-131 Enter Memory Clear ID again
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14.4.6.2
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
MEMORY CLEAR SCREEN
NOTE: For entering the Memory Clear ID refer to section 14.4.6.1 on page 14-81. After the correct Memory Clear ID is entered, the following MEMORY CLEAR menu will open. Press button F3 or F4 to move up or down in the menu and select the requested data set (01 - 06) which should be cleared in the memory.
Fig. 14-132 Memory Clear Menu - item 01 selected Confirm your selection by pressing button F6.
Fig. 14-133 Memory Clear - confirmation for deletion Press button F6 to confirm the deletion of the selected data or press F5 to exit. The deletion procedure is the same for all 6 entries in the above MEMORY CLEAR menu (Fig. 14-132).
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14.4.7
VHMS Service Level
FAILURE HISTORY
NOTE: For entering the Service Menu refer to section 14.4 on page 14-59. Press F3 or F4 to move up or down in the menu.
The chart FAILURE HISTORY(for Service) is displayed in the reverse order of the failure occurrence. The failure message which was saved lastly, is shown at the top of the displayed chart. As long as any listed failure is not rectified, the failure detection end time is not displayed. If you want to delete any failure record from the displayed chart: (a) Press button F3 or F4 to select any failure record. (b) Press F6 to delete the selected failure record. If you want to delete more failure records from the chart, proceed analogously.
Fig. 14-134 Service Menu - item 05 selected Select 05 Failure History and press button F6.
Fig. 14-135 Screen FAILURE HISTORY Legend for Fig. 14-135: (1)
Frame which indicates the selected failure message (using buttons F3 or F4)
(2)
Failure detection start time
(3)
- Number in the failure history chart (2) - failure code (G00253) - failure text message (Emergency ...)
(4)
Failure detection end time
(5)
Total number of saved failure messages in this failure history
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14.4.8
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
MAINTENANCE MONITOR
Press F6 to reset the selected service meter.
NOTE: For entering the Service Menu refer to section 14.4 on page 14-59. Press F3 or F4 to move up or down in the menu.
Fig. 14-138 Maintenance Monitor - reset function
Fig. 14-136 Service Menu - item 06 selected
NOTE: In this section only the selection of the 250h Maintenance is described as a sample. The procedure is the same for all remaining Maintenance entries on the MAINTENANCE MONITOR (Fig. 14-137).
Select 06 Maintenance and press F6.
Fig. 14-137 Maintenance Monitor - overview Maintenance Confirmation by the Service Personnel Maintenance indicated with yellow or red background colour should be confirmed by service personnel in the Service Menu subsequent to the execution of the respective maintenance. After that the selection in the Service Menu, used for maintenance confirmation, is without any function. The confirmation of the maintenance is stored in the VHMS controller. Example: 250h maintenance is required (red marked), service meter reading is -2 hours.
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14.4.9
VHMS Service Level
SNAPSHOT
NOTE: For entering the Service Menu refer to section 14.4 on page 14-59. Press F3 or F4 to move up or down in the menu.
Fig. 14-142 Snapshot running 5:34 minutes When data capturing is completed, the following screen appears for 2 seconds. Fig. 14-139 Service Menu - item 07 selected Select 07 Snapshot and press F6.
Fig. 14-143 Snapshot finished
Fig. 14-140 Snapshot - Start Monitor Press the START button F1 in the upper screen (Fig. 14-140) in order to save the (manual) SNAPSHOT data in the VHMS controller.
After that the screen changes back to the SNAPSHOT start monitor (Fig. 14-140). For any analysis of the manual SNAPSHOT data it is necessary to download these data onto a laptop. REMARK For download and analysis the VHMS-Setting Tool and the VHMS-Analizing Tool are required.
NOTE: If certain troubles occur, machine data at the time of the failure occurrence are saved automatically (automatic Snapshot). For details refer to the respective TROUBLESHOOTING MANUAL.
Fig. 14-141 Snapshot started and running 1 minute
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VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
14.4.10 SETTINGS NOTE: For entering the Service Menu refer to section 14.4 on page 14-59.
Enter the requested number of minutes via the key pad, for example 30.
This option allows you to determine the basic operating and system conditions (settings) via the VHMS system. Press F3 or F4 to move up or down in the menu.
Fig. 14-146 Enter CLS 1 PAUSE TIME Press button F6 to confirm the entered value.
Fig. 14-144 Service Menu - item 08 selected Select 08 Setting and press button F6.
14.4.10.1 CENTRAL LUBRICATION SYSTEM (CLS 1), SCREEN 1/8
Lubrication Cycle Counter Setting Use buttons F3 or F4 to select the Lubrication Cycle Counter (Fig. 14-145) and then press F6 to enter the Lubrication Cycle Counter setting screen. REMARK It is recommended to keep the counter reading over the live time of the machine. If necessary enter the number of the last download.
Fig. 14-145 SETTINGS 1/8 - CLS 1 SETTINGS Options on screen CLS 1 SETTINGS (Fig. 14-145): Pause Time Setting Use buttons F3 or F4 to select the CLS 1 Pause time and then press button F6 to open the Pause time setting screen (Fig. 14-146). Only values between 10 and 60 minutes can be selected.
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14.4.10.2 SWING LUBRICATION SYSTEM (SLS), SCREEN 2/8
VHMS Service Level
Lubrication Cycle Counter Setting Use buttons F3 or F4 to select the Lubrication Cycle Counter and then press button F6 to enter Lubrication Cycle Counter Setting screen. REMARK It is recommendable to keep the counter reading over the live time of the machine. If necessary enter the number of the last download.
Fig. 14-147 SETTINGS 2/8 - SLS SETTINGS Press F1 or F2 to move up or down in the menu. Options on screen SLS SETTINGS 2/8 (Fig. 14-147): Pause Time Setting Use buttons F3 or F4 to select the Pause time and then press button F6 to enter the Pause time setting screen (Fig. 14-148). Only values between 10 and 20 minutes can be selected. Enter the requested number of minutes via the key pad, for example 13.
Fig. 14-148 Enter SLS SETTINGS Press button F6 to confirm the entered value.
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VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
14.4.10.3 QMIN - QMAX - SETTING, SCREEN 3/8
14.4.10.4 OTHER SETTINGS 1/2, SCREEN 4/8
The settings Qmin and Qmax are provided for testing and adjustment procedures on the pump regulation system. Refer to the relevant descriptions in section 7 of this Service Manual.
Fig. 14-150 SETTINGS 4/8-OTHER SETTINGS (1/2) Press F3 or F4 to move up or down in the menu.
Fig. 14-149 SETTINGS 3/8 - Qmin-Qmax-SETTING Press button F1 or F2 to move up or down in the menu and then press button F6 to confirm your selection. Qmin This setting is e.g. used for the adjustment of the secondary relief valves.
NOTE: This screen only displays current information without any option for settings. REMARK For changing the settings of e.g. Language, Date, Time, and Daylight saving time refer to section 14.2.8 on page 14-18 "Settings for Operators". Hydraulic Oil & PTO Gear Oil Definition Table
Qmax This setting is e.g. used for the adjustment of the backpressure valve. AUTOMATIC This is the standard setting for machine operation (pump regulation). NOTE: If the setting Qmax is activated engine start is not possible. Always remember to activate the setting AUTOMATIC (pump regulation) again for normal machine operation, after any testing or adjustment under the condition of Qmin or Qmax is finished.
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VHMS Service Level
Fig. 14-151 Hydraulic Oil & PTO Gear Oil Definition Table
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VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
14.4.10.5 OTHER SETTINGS 2/2, SCREEN 5/8
PTO Gear Oil Viscosity Use this option to save the specification of the used PTO gear oil in the system. This saved information takes effect on the monitoring and controlling characteristics during machine operation. Select Oil viscosity gear and press button F6.
Fig. 14-152 SETTINGS 5/8-OTHER SETTINGS (2/2) Press button F3 or F4 to move up or down in the menu, and press button F6 to open the selected submenu. Fig. 14-154 PTO gear oil selection chart Hydraulic Oil Viscosity Use this option to save the specification of the used hydraulic oil in the system. This saved information takes effect on the monitoring and controlling characteristics during machine operation. Select Oil viscosity hydraulic and press button F6.
Fig. 14-155 PTO gear oil selection chart Refer to the Hydraulic Oil & PTO Gear Oil Definition Table (Fig. 14-151) and choose the required PTO gear oil specification according to the specific temperature conditions.
Fig. 14-153 Hydraulic oil selection chart
Press button F3 or F4 to select the required PTO gear oil specification on the above screen (Fig. 14-155) and press button F6 for confirmation.
Press button F1 or F2 to toggle the 5 screens. Refer to the Hydraulic Oil & PTO Gear Oil Definition Table (Fig. 14-151) and choose the required hydraulic oil specification according to the specific temperature conditions. Press button F3 or F4 to select the required hydraulic oil specification on the above screen (Fig. 14-153) and press button F6 for confirmation.
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Messages ON/OFF Use this option to avoid and eliminate unnecessary failure messages during certain service activities. In the OFF-state, setting works are not interrupted by accidentally generated messages and the memory will not be filled with messages caused by testing operations. Control and monitoring functions remain active. Every setting modification of the function Messages ON/OFF is saved in the service memory. Press button F3 or F4 to move up or down in the menu.
VHMS Service Level
If the MTC-evaluation is switched OFF, it is possible to manipulate the switch status (0/1) of the electrical components which are displayed on the Real Time Monitor, option 15 Output Signals, refer to section 14.4.3.15 on page 14-72. But always remember that all monitoring and control functions of the MTC controller are deactivated in this OFF-state. The MTC does no longer evaluate input signals and it does not transmit any control output signals. Every setting modification of the option PLC-evaluation ON/OFF is saved in the service memory. CAUTION As long as the PLC-evaluation is switched OFF, all monitoring and control functions of the MTC controller are inoperative.
Pre-conditions for the deactivation of the PLCevaluation z The engine must stand still. z
Fig. 14-156 Message OFF selected
The main key switch (20S001) must be in ON position.
If the option Messages ON/OFF is selected, press button F6 to deactivate messages (= OFF). After testing or service work is finished, activate the messages again by switching Messages ON/OFF to ON again. Optionally switch off the main key switch (20S001) for more than 5 seconds, in order to cause a reset. After such a reset the function Messages ON/OFF is set to ON again by the system. Fig. 14-157 PLC-evaluation OFF selected PLC-evaluation ON/OFF Use this option to deactivate the MTC-evaluation, if testing or troubleshooting procedures must be performed without any intervention of the MTC controller. Terminology (MTC & PLC) MTC is a synonym for PLC. Both acronyms indicate the same main control module. MTC is the acronym of Master Turbo Controller PLC is the acronym of Programmable Logic Controller
Version 2010/1
Use buttons F3 or F4 to select PLC-evaluation ON/ OFF. Then press button F6 to deactivate the PLC (= OFF). After testing or service work is finished, activate the MTC again by switching PLC-evaluation ON/OFF to ON again. Optionally switch off the main key switch (20S001) for more than 5 seconds, in order to cause a reset. After such a reset the function PLC-evaluation ON/OFF is set to ON again by the system.
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VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
14.4.10.6 SHUTDOWN BYPASS ON/OFF For purposes of initial start-up and during troubleshooting it is possible to bypass trouble conditions which may cause a shutdown. Refer to the following 3 screenshots.
Even if the automatic shutdown is deactivated, a corresponding message is generated at the moment when the trouble condition for a shutdown is met. Every setting modification of the function SHUTDOWN BYPASS ON/OFF is saved in the service memory.
WARNING Only activate the Shutdown Bypass in case of emergency. Fatal injury and serious damage of the machine may occur.
Press button F1 or F2 to toggle the 3 screens.
CAUTION If you consciously deactivate the automatic Shutdown for troubleshooting, always make sure that there is no risk for personal injury and damage of the machine.
REMARK If you feel unsure about the function SHUTDOWN BYPASS ON/OFF contact your supervisor.
Fig. 14-158 Shutdown Bypass ON/OFF (1/3)
Explanation of the Function Logic (1) SHUTDOWN BYPASS OFF - Standard setting The BYPASS of any trouble condition is switched OFF (Bypass = deactivated). In this case the trouble condition is not bypassed and it does trigger a shutdown, if the trouble condition is met (Shutdown = activated)
Fig. 14-159 Shutdown Bypass ON/OFF (2/3)
(2) SHUTDOWN BYPASS ON - Exceptional setting The BYPASS of any trouble condition is switched ON (Bypass = activated). In this case the trouble condition is bypassed and it does not trigger a shutdown, even if the trouble condition is met (Shutdown = deactivated) An activated SHUTDOWN BYPASS remains active until the setting of of the SHUTDOWN BYPASS is switched to OFF again. z
If the SHUTDOWN BYPASS is not switched to OFF again, this condition is only stored in the Failure History (Service Level) after next start, invisible for the operator.
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Fig. 14-160 Shutdown Bypass ON/OFF (3/3) Use buttons F3 and F4 to select the desired shutdown option. Then press button F6 (ON/OFF) to confirm your selection.
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VHMS Service Level
Automatic Shutdown Functions (Standard Setting = OFF) There are 3 different kinds of system intervention which are combined in the term SHUTDOWN. Refer to the below samples:
Fig. 14-161 Different kinds of SHUTDOWN Legend for Fig. 14-161
(1)
z Engine shutdown In case the hydraulic oil level is definitely too low, the engine is shutdown
(2)
z Bucket cut off In case the lubrication is disturbed, the bucket movement is cut off after a specified time period
(3)
z Start blocked In case the main gate valve is not open, engine start is blocked
(4)
Spare option
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Interface-Connection VHMS-Controller
14.5
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
INTERFACE-CONNECTION VHMS-CONTROLLER
Fig. 14-162 Interface-connection VHMS-controller
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Legend for Fig. 14-162 (1)
VHMS monitor (MH801)
(2)
MTC-controller (11K301)
(3)
Interface panel on the rear of the operator’s console
(4)
(5)
(6)
(7)
11X027a - VHMS Setting Tool - VHMS Analysis Tool 20X323 (LAN connector) - CoDeSys Software - Visualization 20X336 - Service Connector for the VHMS Monitor (MH801) 20X052-1 QUANTUM Service Connector
14.5.1
Interface-Connection VHMS-Controller
VHMS-CONTROLLER
The VHMS-Controller (10K300) provides interfaces and options for the user as follows: - Data link to the VHMS monitor - Data link to the MTC-controller - Data link to Quantum (engine control) - VHMS programming - Input of operator settings - Input of machine settings - Reading out machine troble codes - Download of snapshot data - Download of VHMS memory data - Trouble shooting features & assistance - Service link to Quantum (engine control)
REMARK Data cables, hardware devices, and software tools for data exchange via the VHMS interface connections are optional equipment. For detailed information about the VHMS software refer to the Troubleshooting Manual of your machine.
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Wiring of the VHMS-Controller
14.6
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
WIRING OF THE VHMS-CONTROLLER
Fig. 14-163 VHMS-Controller connectors 14-96
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Wiring of the VHMS-Controller
Legend for Fig. 14-163 (1)
z VHMS-Controller (10K300) Mounted in the cab base
(2)
LED indicator During standard operation the controller is continuously counting up a loop of digits. In case of any malfunction the counting loop is stopped.
(3)
Type label
(4)
Connector panel
(5)
Supply voltage indicator
(6)
z LED green ON = supply voltage (24V) OK
(7)
LED yellow ON = supply voltage error
z
z
CN2-B (green) Remark: not used
CN3-A (white) Remark: Pin 1 = tacho check (to Quantum unit 52K014) Pin 9 = connection check Pin 4, 12, 13 = RS232 interface to MTC Pin
Function
1
D_IN8
4
RS232 TX2
9
GND
12
RS232 RX2
13
RS232 GND
Pin layout of the sockets at the VHMS-Controller:
CN1 (white) Remark: Supply voltage & ground Pin
Function
6
VBB_IN
7
VBB_IN
Pin
Function
8
VB_IN
12
GND
9
VB_IN
11
GND
12
GND
18
Flash_write
19
GND
20
GND
CN3-B (white)
CN2-A (green) Remark: for optional equipment ORBComm Pin
Function
17
(low active input)
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VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
CN4-A (white) Remark: Pin 4, 12, 13 = CAN bus to Quantum Pin 5, 6, 14 = CAN bus to VHMS monitor and service connector 20X336 PIN 9, 10, 11 = RS232 interface to 20X027a and 11X027b CAN 0 = interface to VHMS monitor CAN 1 = interface to Quantum 20X027a = download or programming in cab 20X027b = download or programming in cab base Pin
Function
4
CAN 1 +
5
CAN 0 Shield
6
CAN 0 +
9
RS232 GND
10
RS232 RX0
11
RS232 TX0
12
CAN 1 -
13
CAN 1 Shield
14
CAN 0 -
CN4-B (white) Remark: for optional equipment ORBComm RS232 interface to ORBComm controller Pin
Function
3
RS232 GND
4
RS232 TX1
9
GND (shield)
10
RS232 RX1
CN5 (black) Remark: not used
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Wiring of the VHMS-Controller
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Global Layout of the MTC Control System VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
14.7
GLOBAL LAYOUT OF THE MTC CONTROL SYSTEM
Fig. 14-164 Global layout of the MTC control system 14-100
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Legend for Fig. 14-164: (1)
VHMS monitor (MH801) including key pad - located in the operator’s cab
(2)
VHMS controller - located in the cab support
(3)
Engine control modules (3 pcs) "Quantum system" - fitted at the engine
(4)
CAN bus - between VHMS controller and VHMS monitor
(5)
CAN bus - between VHMS controller and Quantum
(6)
Serial interface (RS 323) - between MTC and VHMS controller
(7)
MTC [MTC = Master Turbo Controller]
(8)
CAN bus - internal CAN bus between MTC and nodes
(9)
Node, type ICN-V and type ICN-D, [ICN = Intelligent CAN Node] - interface between internal CAN bus and electr. machine components
(10)
CAN node type ICN-V (9 pcs)
(11)
CAN node type ICN-D (6 pcs)
(12)
INPUT (status signal from component) - binary and analog inputs, e.g. signal from any switch
(13)
OUTPUT (control signal to component) - digital outputs, e.g. signal to any solenoid valve
NOTE: Optional equipment as ORBCOMM or MODULAR MINING SYSTEM can be connected to the system. Refer to the specific documents and Wiring Diagrams.
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Global Layout of the MTC Control System VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
14.7.1
MTC (MASTER TURBO CONTROLLER)
14.7.1.1
MTC-FLOWCHART
Fig. 14-165 MTC-Flowchart
14.7.1.2
MTC FEATURES
The MTC is a shock & vibration resistant (4G) controller for mobile configuration. It is dust & water resistant and works within a temperature range of -40°C to +85°C without any separate heating or cooling equipment. It is equipped with a motherboard with 32-Bit / 396 MHz and Floating Point Unit (parallel working process). The task time is < 1 µs.
The second part of the Microcontroller is the “Watch Dog” function. It includes system check, LED´s, and Input / Output sensing. Data storing features are: Compact Flash Card for data storing, real-time watching, and FRAM for safe data storing. There are also 2 DIGITAL main inputs & 2 DIGITAL main outputs (max. 400mA short cut resistant) including detection of wiring connection.
It runs with the software system CoDeSys V2.3.9.10 It is equipped with the following connections: 4x Main CAN open – connections, 2x RS 232 Serial ports, Ethernet port 10/100Mbit – Download / Upload / TCP/IP / UDP / USB connection for Firmware Upload.
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14.7.1.3
MTC-FIRMWARE AND SOFTWARE
The MTC is programmed with Firmware and Software. FIRMWARE The Firmware internally operates and manages the MTC unit, independent of the kind of the machine. SOFTWARE The Software is a machine-specific application which manages the excavator’s control system. Therefore it is essential that the Software version and the machine model properly fit together. It is possible to replace the programs (Firmware and Software) of the MTC. For such a procedure a specific version of the CoDeSys software must be installed on the used laptop. Via LAN connection such a software upload can be done comfortably. The CoDeSys software can also be used as a Visualization, which is an important tool for troubleshooting. For more details of the CoDeSys Visualization refer to the Visualization User Manual and to the Troubleshooting Manual of your machine.
For the details of the: z
MTC Firmware & Software
z
CoDeSys software
z
Visualization
z
Appropriate equipment
z
Communication procedures with the MTC
refer to the Troubleshooting Manual of your machine. CAUTION Before trying to change any software of the MTC, always make sure that: - the complete required equipment is present - the correct software packages are present - a qualified service technican will perform the procedure Otherwise a complete shutdown of the machine may result.
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Global Layout of the MTC Control System VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
14.7.1.4
VIEW ONTO THE MTC UNIT AND ITS CONNECTORS
Fig. 14-166 View onto the MTC unit and its connectors
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VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM Global Layout of the MTC Control System
Legend for Fig. 14-166: (1)
MTC unit [Master Turbo Controller]
(2)
Left hand side MTC connectors
(3)
LED panel1 of the MTC unit
(4)
Right hand side MTC connectors
(5)
MTC ground connection (housing)
(6)
LAN connection to cab / laptop
(7)
Digital output
(8)
Supply voltage (24V) connection
(9)
CAN bus connection
(10)
Serial port COM 2 (RS 232) to VHMS controller
1The
LEDs are showing operation conditions and they also blink out those trouble codes which cause a shutdown.
For the description of the LED panel and the operating mode of the LEDs refer to the OPERATION & MAINTENANCE MANUAL or to the TROUBLESHOOTING MANUAL of your machine.
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Global Layout of the Internal CAN bus
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
14.8
GLOBAL LAYOUT OF THE INTERNAL CAN BUS
14.8.1
GENERAL INFORMATION ABOUT A CAN BUS SYSTEM
Fig. 14-167 Control system - conventional layout [A] and CAN bus layout [B] The acronym CAN means: Controller Area Network Legend for Fig. 14-167: [A]
Wiring in a conventional control circuit
[B]
Wiring in control circuit with CAN bus
(1)
Low voltage switch board (11a000) and controller (A = PLC / B = MTC) in the cab base
(2)
Long wiring between low voltage switch board and each electrical component (including intermediate connectors for cable sections)
(3)
Electrical component (e.g. switch or solenoid valve)
(4)
Short wiring between nodes and electrical component
(5)
Internal CAN bus, leading from the MTC to each node
(6)
Node, type ICN-V and type ICN-D, [ICN = Intelligent CAN Node] - interface between internal CAN bus and electrical machine components
(7)
End resistor (120 Ω) of the CAN bus
(8)
INPUT - Status signals from the machine components
(9)
OUTPUT - Control signals from the MTC-controller
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14.8.1.1
GENERAL CAN BUS DESCRIPTION
The comparison of the wiring in a conventional control circuit and in a control circuit with CAN bus shows that the total length of the wiring between the controller and the electrical components in the CAN bus system is visibly shorter. Also the number of connectors is reduced, as several cable sections in the wiring between the controller and the machine components are no longer needed. In a CAN bus system all system components (input & output) are connected to a common data line via short branch lines. Therefore the system wiring is reduced and additional components may be connected easily.
14.8.1.2
Global Layout of the Internal CAN bus
CAN BUS TROUBLESHOOTING
The CAN bus system is equipped with effective selfdiagnosis tools. CAN troubles are displayed via the VHMS monitor and/or blinked out at the MTC-controller. With the help of a visualization software the location of any trouble can easily be determined. For troubleshooting in the CAN bus system a special CAN-Test Box is available. For details refer to the Tools and Accessories Catalogue. For the appropriate and qualified troubleshooting procedures refer to the TROUBLESHOOTING MANUAL of your machine.
The interfaces between the CAN bus and the electrical machine components are called Nodes. It is a fundamental idea of the CAN bus layout that the nodes are as close to the machine components as possible. However, the data flow must be controlled by an access method (protocol) in order to manage the well organized data transfer in one common data line. The MTC unit (refer to section 14.7 on page 14-100) and the Nodes (refer to section 14.9 on page 14-112) are essential components for the control and mangement of the CAN bus system. The status information from the electrical components as well as the control signals from the MTC are not continuously present in the CAN bus cable. Status information and control signals of each component are packed in data packages which are called Data Frames. These Data Frames are sent through the CAN bus periodically in small fractions of a second. The control components MTC & Nodes send and receive the Data Frames. Also they organize and manage a safety system, to make sure that defined and complete information packages are received by the designated components. Each Data Frame contains a protocol for its identification. A CAN bus cable consists of only 3 wires, which are: z
CAN high (H)
z
CAN low (L)
z
Shield
In a CAN bus system 2 voltages are present. Depending on the kind of system the CAN high voltage is in a range of up to approx. 6V. The CAN low voltage is up to approx. 3.5V.
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Global Layout of the Internal CAN bus
14.8.1.3
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
CAN BUS WIRING
Fig. 14-168 Detail of the CAN bus wiring1 1
For the entire overview refer to the complete Wiring Diagrams of the respective machine.
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Global Layout of the Internal CAN bus
Legend for Fig. 14-168: (1)
CAN bus wire CAN high (H)
(2)
CAN bus wire CAN low (L)
(3)
CAN bus wire shield
(4)
CAN bus branch connector
(5)
Node, type ICN-D, [ICN = Intelligent CAN Node] interface between internal CAN bus and electrical machine components
(6)
Node pin - connection CAN high to node
(7)
Node pin - connection CAN low to node
(8)
Node pin - connection shield to node
(9)
CAN bus End Resistor
(10)
Annotation in the Wiring Diagram: Length of branch cable max. 1m
(11)
View onto a standard CAN bus connector (male & female)
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Global Layout of the Internal CAN bus
14.8.1.4
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
CAN BUS END RESISTOR
A CAN bus does not build a closed wiring circuit as a conventional electrical circuit system in general does. As a result there is an "open" end. At this end the wires CAN high and CAN low must be connected by an End Resistor. The resistance of these End Resistors is 120 Ω each. A CAN bus can be split, and in this case an End Resistor needs to be connected to each end of the CAN bus. The following chart gives an overview over the fitted End Resistors on your machine. End Resistors - Overview Component Code2
No.
Location Code1
CAN bus
1
10
1
Cab base, CAN bus VHMS-controller to Quantum
10R100
2
10
2
Cab base, CAN bus VHMS-controller to VHMS monitor
10R101
3
20
internal
Operator’s cab, node 9
20R101
4
40
internal
Hydraulic oil tank, node 13
40R101
Description
1, 2
For a detailed explanation of the Location Code & Component Code definition refer to section 13. HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM in this Service Manual. View onto End Resistors
Fig. 14-169 View onto 2 different types of End Resistor
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Global Layout of the Internal CAN bus
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The Nodes in the CAN bus System
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
14.9
THE NODES IN THE CAN BUS SYSTEM
14.9.1
GLOBAL LAYOUT
Fig. 14-170 Exemplary Drawing of a CAN bus and its Nodes
14-112
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The Nodes in the CAN bus System
Legend for Fig. 14-170: (1)
Internal CAN bus, leading from the MTC to each node
(2)
MTC-controller and low voltage switch board (11a000) in the cab base
(3)
Node (type ICN-V or type ICN-D)
(4)
Wiring between node and electrical machine component
(5)
Electrical machine component (e.g. switch or solenoid valve)
(6)
INPUT - Status signals from the machine components
(7)
OUTPUT - Control signals from the MTC-controller
(8)
End resistor (120 Ω) of the CAN bus
14.9.2
INTRODUCTION
The Nodes are the interfaces between the CAN bus and the electrical machine components. They are located as close as possible to the machine components to permit a short wiring of the machine components. The Nodes organize: (a) the INPUTS from the machine components into the CAN bus (b) the CONTROL OUTPUTS from the MTC-controller to the actuating elements via CAN bus There are 2 different types of Nodes in the CAN bus system, ICN-V and ICN-D.
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The Nodes in the CAN bus System
14.9.2.1
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
ICN-V FEATURES
The acronym ICN-V means: Intelligent Can Node-Variable (application sample: Valves) The features of the ICN-V node are: - Designed for mobile use - Compact design - Solid housing - Equipped with one 55-pin central plug - Optional dual node design (in that case the housing is equipped with two 55-pin central plugs) - DIP-switches for individual adaption - Especially for the control of hydraulic components - 4 digital inputs, each to be configured as 0...10V or 0...20mA analog inputs - 8 digital Inputs & Outputs max. 4A, variable programmable - 2 separate power outputs (operating voltage) max. 0.1A - The outputs are short cut safe - CAN bus interface with CAN open protocol - Load dump safety 8...32V - Temperature range -40°C...+ 85°C
View onto ICN-V Nodes (dual & single)
Fig. 14-171 View onto ICN-V Nodes (dual & single) Legend for Fig. 14-171: (1)
Dual ICN-V Node
(2)
Single ICN-V Node
(3)
55-pin central plug for dual node function LH (shown sample: 11K303)
(4)
55-pin central plug for dual node design RH (shown sample: 11K304)
(5)
55-pin central plug for single node function (shown sample: 40K313)
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14.9.2.2
The Nodes in the CAN bus System
ICN-D FEATURES
The acronym ICN-D means: Intelligent Can Node-Digital (application sample: Dashboard) The features of the ICN-D node are: - Designed for mobile use - e.g. for installation in the dashboard - max. 64 configurable inputs / outputs - 28 digital inputs - 6 analog inputs 0...10V - 2 analog inputs 0...20mA - 4 separate input slots - 16 digital outputs - 4 digital inputs / outputs - 2 separate power sources 5, 7.5 / 8.2, 10V - 2 separate power output sources 10mA / 300Ω - Load dump safety 8...32V - Temperature range -40°C...+85°C - CAN bus interface with CAN open protocol - DIP-switches for individual adaption
View onto a ICN-D Node
Fig. 14-172 View onto a ICN-D Node
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The Nodes in the CAN bus System
14.9.3
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
NODE DIP-SWITCHES
All nodes of both node types are equipped with DIP-switches at the circuit board. These DIP-switches must be adjusted according to the requirement of each mounting location in the system. Ex factory the design of all used ICN-V nodes is identical and the design of all used ICN-D nodes is identical as well. If any node needs replacement its DIP-switches must be adjusted as defined in the Wiring Diagram of the respective machine. In the Wiring Diagram the adjustment of the DIP-switches is shown as in the below sample. Exemplary iew onto the DIP-switch setting specification
Fig. 14-173 Exemplary View onto the DIP switch setting specification
NOTE: When replacing any Node unit always check and adjust the DIP-switch setting according to the relevant Wiring Diagram to avoid malfunction or shutdown of the machine.
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14.9.4
NODE BOX
The Nodes in the CAN bus System
.
The node units which need to be installed at the outside of the machine are mounted in Node Boxes on the roof of the machine. Inside these boxes the electrical components are installed on 3 levels. 1st level: Wiring connections, resistors, and diodes 2nd level: CAN bus connections 3rd level: Nodes (ICN-V and ICN-D) Refer to the following figure which shows a typical node box and the arrangement of the 3 levels inside.
Fig. 14-174 View onto the 3 levels inside a Node Box
Fig. 14-175 View onto an open Node Box
To reach the 3 levels inside the Node Box open the door of the Node Box. Now there is access to the 1st level switch board (3).
Legend for Fig. 14-175
Fold the 1st level switch board forward and down. Now there is access to the 2nd level switch board (4) on the backside of the folded frame. The 3rd level switch board (5) is mounted at the inside of the Node Box backwall. Refer to the following photographs (Fig. 14-175).
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(1)
Node Box
(2)
1st level switch board - Wiring connections, resistors, and diodes
(3)
Door of the Node Box
(4)
2nd level switch board - CAN bus connections
(5)
3rd level switch board - ICN-V node(s) and ICN-D node(s) 14-117
The Nodes in the CAN bus System
14.9.5
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
NODE LOCATIONS ON THE MACHINE
Fig. 14-176 Node location overview Legend for Fig. 14-176: (11)
Location: Low voltage switch board in the cab base
(20)
Location: Operator’s cab
[40]
Location: Hydraulic oil tank (node box on top of the roof)
[51]
Location: Engine room (node box on top of the roof)
[56]
Location: Pump compartment (node box on top of the roof)
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14.9.5.1
The Nodes in the CAN bus System
NODE & LOCATION CHART
The following chart lists all Nodes and the relating Locations of the MTC control circuit on a PC4000-6D with MTCcontroller. For further details refer to the Wiring Diagrams of the respective machine. Node No.
Node Type
Component Code1
2
ICN-D
11K302
3
ICN-V
11K303
4
ICN-V
11K304
5
ICN-V
11K305
9
ICN-D
20K309
10
ICN-V
20K310
11
ICN-D
40K311
12
ICN-D
40K312
13
ICN-V
40K313
14
ICN-D
56K314
15
ICN-V
56K315
16
ICN-V
56K316
17
ICN-D
51K317
Location Code2
Description
11
Extra low voltage switch board in the cab base
20
Operator’s cab
40
Hydraulic oil tank (node box on top of the roof)
56
Pump compartment (node box on top of the roof)
51
Engine room (node box on top of the roof)
1, 2
For a detailed explanation of the Location Code & Component Code definition refer to section 13. HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM in this Service Manual.
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The Nodes in the CAN bus System
14.9.5.2
VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
EXEMPLARY VIEW ONTO LOCATION 11 (CAB BASE)
The following exemplary views show the arrangement of the CAN bus control components in a cab base.
Fig. 14-177 Exemplary view onto the CAN bus control components in the cab base Legend for Fig. 14-177: (1)
Low voltage switch board (11a000) in the cab base
(2)
ICN-D node (11K302)
(3)
Dual ICN-V node, LH side (11K303)
(4)
Dual ICN-V node, RH side (11K304)
(5)
MTC-controller (11K301)
(6)
CAN bus connector plate
(7)
Single ICN-V node (11K305) behind the CAN bus connector plate
For further troubleshooting information regarding the MTC control system refer to the Troubleshooting Manual of your machine.
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The Nodes in the CAN bus System
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The Nodes in the CAN bus System
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VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
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AUTOMATIC LUBRICATION SYSTEMS
15. AUTOMATIC LUBRICATION SYSTEMS
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15-1
General Overview CLS & SLS
AUTOMATIC LUBRICATION SYSTEMS
15.1
GENERAL OVERVIEW CLS & SLS
Fig. 15-1
General overview CLS & SLS
Legend for Fig. 15-1: CLS SLS
Central Lubrication System Pin & bearing lubrication
z
Swing ring Lubrication System z Open swing ring gear lubrication
(1)
Superstructure
(2)
Attachment (FSA & BHA)
(3)
Swing ring
(4)
Swing gearbox
(5)
Undercarriage
(6)
CLS station (barrel)
(7)
SLS station (barrel)
15-2
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AUTOMATIC LUBRICATION SYSTEMS
15.1.1
General Overview CLS & SLS
GENERAL DESCRIPTION
For maximum machine reliability and maximum lifetime the principal bearing points must be frequently lubricated with a sufficient amount of specified lubricant. For best lubricating reliability with minimum maintenance there are automatic lubrication systems which are controlled by the MTC. They lubricate all connected lubrication points within adjustable time intervals and with the required amount of lubricant. The automatic lubrication starts as soon as the machine runs at high idle. The excavator is equipped with 2 independent lubrication systems: CLS The CLS (Central Lubricating System) supplies the attachment bearings and the swing ring bearing with grease. SLS The SLS (Swing ring gear Lubrication System) supplies the open gear of the swing ring teeth and the lower bearings of the swing gearboxes with grease. These two independent lubrication systems are necessary because the attachment bearings and the open gear teeth require different types of lubricant.
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Basic Function of the Lubrication Systems
AUTOMATIC LUBRICATION SYSTEMS
15.2
BASIC FUNCTION OF THE LUBRICATION SYSTEMS
Fig. 15-2
Basic function of the lubrication systems
15-4
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AUTOMATIC LUBRICATION SYSTEMS
Basic Function of the Lubrication Systems
Legend for Fig. 15-2: (1)
Drive of lubrication pump (hydraulically)
(2)
Flow control valve (19-21 double strokes/min)
(3)
Pressure relief valve (max. 45 bar)
(4)
Grease pump control solenoid valve (62Q507 / 62Q509) - (pump on / off)
(5)
Hydraulic oil return line
(6)
Hydraulic oil supply line (60+3 bar X4-pressure)
(7)
Lubricant pressure gauge
(8)
Lubricant in-line filter
(9)
Lubricant pressure release solenoid valve (62Q507a / 62Q509a)
(10)
Lubricant supply line from pump to injector
(11)
Lubricant release line
(12)
End-line-pressure switch (80B043 / 62B046)
(13)
Lubricant injector
(14)
Lubricant feed line from injector to the lubrication point (bearings or open gear of the swing ring teeth)
(15)
Lubricant pump
(16a)
Bearing
(16b)
Dummy wheel
(17)
Lubricant
(18)
Lubricant container
(19)
Breather filter for lubricant container
(20)
Sonar sensor for lubricant level indication (62B108 / 62B109)
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Central Lubrication System (CLS)
AUTOMATIC LUBRICATION SYSTEMS
15.3
CENTRAL LUBRICATION SYSTEM (CLS)
Fig. 15-3
Lubrication pump station CLS
15-6
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AUTOMATIC LUBRICATION SYSTEMS
Central Lubrication System (CLS)
Legend for Fig. 15-3: (1)
Lubrication 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 the barrel)
(8)
Grease supply line to injectors
(9)
Grease level sensor (sonar sensor)
(10)
Grease barrel
(11)
Pump suction pipe
(12)
Lubricant filter
(13)
Hydraulic pressure test plug (operating pressure)
(14)
Lubricant pressure gauge (operating pressure)
(15)
Vent line to barrel
(16)
Breather
(17)
Electrical terminal box
(18)
Lubricant injector
(19)
Lubricant supply line to lubrication points (bearings or open gear of the swing ring teeth)
(20)
End-line switch
Description The lubrication pump station includes the grease barrel (Fig. 15-3, Pos. 10) and the barrel cover with the pump system. The barrel is fix-mounted. With the refilling arm the barrel is rechargeable via a filter. The main grease pump system is mounted onto the barrel cover. It includes the pump (Fig. 15-3, Pos. 1 & 11), valves (Fig. 15-3, Pos. 2, 3, 4, 7), a grease filter (Fig. 15-3, Pos. 12), a grease level sensor (Fig. 15-3, Pos. 9), and an end-line switch (Fig. 15-3, Pos. 20).
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Central Lubrication System (CLS)
15.3.1
AUTOMATIC LUBRICATION SYSTEMS
GENERAL INFORMATION ON CLS
A hydraulic driven lubricant pump (Fig. 15-3, Pos. 1 & 11) pumps grease from a barrel (Fig. 15-3, Pos. 10) through pipes (Fig. 15-3, Pos. 8) or hoses to the injectors (Fig. 15-3, Pos. 18). These injectors pump a defined quantity of grease to the lubrication points. After all injectors delivered their grease quantity to the lube points, the grease pump stops and the next lubrication cycle will start after an adjusted time period (pause time). The central lubrication system is only active if the engine is running at high idle. z
After the pilot pressure has been reduced it passes to the hydraulic cylinder (Fig. 15-3, Pos. 1) which operates the grease pump (Fig. 15-3, Pos. 11).
z
The hydraulic cylinder (Fig. 15-3, Pos. 1) operates the grease cylinder with 19 – 21 double strokes per minute. In that way 612 - 680 cm3 (approx. 550 - 612 g) of lubricant are delivered per minute.
z
With the vent valve (Fig. 15-3, Pos. 7) closed, the pump continues to cycle until the maximum pressure is achieved and the injectors (Fig. 15-3, Pos. 18) have metered grease to the lubrication points. The pressure in the lubrication system is 180 bar.
z
When the maximum system pressure is reached, the end-line switch (Fig. 15-3, Pos. 20) will open.
z
The open end-line switch (Fig. 15-3, Pos. 20) signals the controller that the pumping cycle has to be stopped.
z
The solenoid valve (Fig. 15-3, Pos. 2) is de-energized and the hydraulic oil stops flowing to the pump (Fig. 15-3, Pos. 1).
z
The MTC starts to count down a fixed time (pressure holding time) and an adjustable pause time (rest time between the automatic lubrication cycles).
z
The vent valve (Fig. 15-3, Pos. 7) is still closed (solenoid active) and the lubricant pressure will be kept on the pressure (a slow pressure decrease is normal).
z
If the countdown for the pressure holding time (5 min) is finished the controller terminates the signal to the solenoid valve (Fig. 15-3, Pos. 7).
z
If the vent valve (Fig. 15-3, Pos. 7) is de-energized, it opens and allows the grease pressure to drop to zero.
z
All injectors move into their initial position by spring force and recharge themselves for the next lubricant cycle.
z
The system is at rest now and ready for another lube cycle.
Manual lube activation A manual activation of the lubrication systems is possible by operating switch 20S124 (CLS) or 20S126 (SLS) at the dashboard. The MTC counts the number of switch activations and operates the lube system successively, as often as the switch was activated. The system rests between the lube cycles according to an adjustable pause time (pressure relief time). After the previous loop is completely finished and after the pause time is experied the next lubrication cycle can start if the engine is running at high idle (CLS/SLS) and if a slew movement was activated (SLS). Component Code Table (according to Wiring Diagram) System
Solenoid Valve (2)
Vent Valve (7)
End-Line Switch (20)
CLS
62Q507
62Q507a
80B043
SLS
62Q509
62Q509a
62B046
15-8
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AUTOMATIC LUBRICATION SYSTEMS
Central Lubrication System (CLS)
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15-9
Lubrication Pump Station (SLS)
AUTOMATIC LUBRICATION SYSTEMS
15.4
LUBRICATION PUMP STATION (SLS)
Fig. 15-4
Lubrication pump station SLS
15-10
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AUTOMATIC LUBRICATION SYSTEMS
Lubrication Pump Station (SLS)
Legend for Fig. 15-4: (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)
Grease level sensor (sonar sensor)
(10)
Grease barrel
(11)
Pump suction pipe
(12)
Lubricant filter
(13)
Hydraulic pressure test plug (operating pressure)
(14)
Lubricant pressure gauge (operating pressure)
(15)
Vent line to barrel
(16)
Breather
(17)
Electrical terminal box
(18)
Lubricant injector
(19)
Lubricant supply line to dummy wheel
(20)
End-line switch
(R)
Dummy wheel
(A)
Swing circle gear
(B)
Center bore
(C)
Stator radial bore
(D)
Grease outlet
Description The lubrication pump station includes the grease barrel (Fig. 15-4, Pos. 10) and the barrel cover with the pump system. The barrel is fix-mounted. With the refilling arm the barrel is rechargeable via a filter. The main grease pump system is mounted onto the barrel cover. It includes the pump (Fig. 15-4, Pos. 1, 11), valves (Fig. 15-4, Pos. 2, 3, 4, 7), a grease filter (Fig. 15-4, Pos. 12), a grease level sensor (Fig. 15-4, Pos. 9), and an end-line switch (Fig. 15-4, Pos. 20).
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15-11
Lubrication Pump Station (SLS)
15.4.1
AUTOMATIC LUBRICATION SYSTEMS
GENERAL INFORMATION ON SLS
The swing circle gear lubrication system (SLS) uses a special dummy wheel to apply the gear grease onto the swing circle gear. All other components between the grease barrel and the injectors are comparable to the central lubrication system (CLS). With each lube cycle the dummy wheel receives grease from two or more parallel connected injectors. After the injectors delivered their gear grease quantity through the dummy wheel to the swing ring gear, the grease pump stops and the next lubrication cycle will start after an adjusted time period (pause time). The swing circle gear lubrication system is only active if the engine is running at high idle and if the slew function is activated. z
After the pilot pressure has been reduced it passes to the hydraulic cylinder (Fig. 15-4, Pos. 11) which operates the grease pump.
z
The hydraulic cylinder (Fig. 15-4, Pos. 1) operates the grease cylinder with 19 - 21 double strokes per minute. In that way 612 - 680 cm3 (approx. 550 - 612 g) of lubricant are delivered per minute.
z
With the vent valve (Fig. 15-4, Pos. 7) closed, the pump continues to cycle until maximum pressure is achieved and the injectors (Fig. 15-4, Pos. 18) have metered grease to the dummy wheel. The pressure in the lubrication system is 180 bar.
z
When the maximum system pressure is reached, the end-line switch (Fig. 15-4, Pos. 20) will open.
z
The open end-line switch (Fig. 15-4, Pos. 20) signals the controller that the pumping cycle has to be stopped.
z
The solenoid valve (Fig. 15-4, Pos. 2) is de-energized and the hydraulic oil stops flowing to the pump (Fig. 15-4, Pos. 1).
z
The MTC starts to count down a fixed time (pressure holding time) and an adjustable pause time (rest time between the automatic lubrication cycles).
z
The vent valve (Fig. 15-4, Pos. 7) is still closed (solenoid active) and the lubricant pressure will be kept on the pressure (a slow pressure decrease is normal).
z
If the countdown for the pressure holding time (5 min) is finished the controller terminates the signal to the solenoid valve (Fig. 15-4, Pos. 7).
z
If the vent valve (Fig. 15-4, Pos. 7) is de-energized, it opens and allows the grease pressure to drop to zero.
z
All injectors move into their initial position by spring force and recharge themselves for the next lubricant cycle.
z
The system is at rest now and ready for another lube cycle.
Manual lube activation A manual activation of the lubrication systems is possible by operating switch 20S124 (CLS) or 20S126 (SLS) at the dashboard. The MTC counts the number of switch activations and operates the lube system successively during swing movement, as often as the switch was activated. The system rests between the lube cycles according to an adjustable pause time (pressure relief time). Component Code Table (according to Wiring Diagram) System
Solenoid Valve (2)
Vent Valve (7)
End-Line Switch (20)
CLS
62Q507
62Q507a
80B043
SLS
62Q509
62Q509a
62B046
CLS = Central Lubrication System SLS = Swing circle Lubrication System
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AUTOMATIC LUBRICATION SYSTEMS
15.5
LUBRICATION CYCLE
15.5.1
OPERATION AND CONTROL
Lubrication Cycle
General The lubrication systems (CLS & SLS) are completely controlled and monitored by the MTC. The MTC activates the outputs dependent on the inputs and dependent on the system timelines. For the electrical interrelations refer to the respective Wiring Diagram. NOTE: The exemplary explanations in this section are based on the Wiring Diagram 94856340 and on the Flow Chart 9485640. Beside the MTC the following electrical components are involved in lubrication control and operation: Inputs Description
CLS
SLS
End-line switch
80B043
62B046
Grease level sensor
62B108
62B109
Switch for manual lubrication cycle
20S124
20S126
Pre-condition: Swing circle (lever) moved
20S020
Pre-condition: Engine running at high idle
Engine ECM
Outputs Description
CLS
SLS
Lubrication pump solenoid valve
62Q507
62Q509
Vent valve (solenoid)
62Q507a
62Q509a
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Lubrication Cycle
15.5.2
LUBRICATION CYCLE - COMPONENTS
Fig. 15-5
Lubrication cycle components
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AUTOMATIC LUBRICATION SYSTEMS
Version 2010/1
AUTOMATIC LUBRICATION SYSTEMS
Lubrication Cycle
Legend for Fig. 15-5: (1)
Lubrication pump drive (hydraulic cylinder)
(2)
Flow control valve (19 - 21 double strokes / min)
(3)
Pressure relief valve
(4)
Main pump control solenoid valve (pump on / off)
(5)
Hydraulic oil return line
(6)
Hydraulic oil supply line (60 bar, X4 pressure)
(7)
Lubricant pressure gauge
(8)
Lubricant in-line filter
(9)
Lubricant pressure release solenoid valve
(10)
Lubricant supply line from pump to injector
(11)
Lubricant release line
(12)
End-line switch
(13)
Lubricant injector
(14)
Lubricant feed line to swing ring gear
(15)
Lubricant pump
(16)
Lubricant points (bearings) CLS only
(17)
Lubricant container
(18)
Breather filter for lubricant container
(19)
Grease level sensor (sonar sensor)
(20)
Test port lubricant pump drive pressure
(21)
Electrical terminal box
(22)
Dummy wheel, SLS only
(23)
Dipstick grease level
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Lubrication Cycle
AUTOMATIC LUBRICATION SYSTEMS
15.5.3
LUBRICATION CYCLE - PROCESSING
Fig. 15-6
Process of a lubrication cycle
Legend for Fig. 15-6 X axis
Task time
Y axis
Pressure timeline in the lubricant supply line
PINCREASE E-L SWOPENING PHOLD E-L SWCLOSING PRELEASE TPAUSE
15-16
Pressure increasing time End-line switch opening point Pressure holding time (5 minutes) End-line switch closing point Pressure release time Pause time
Version 2010/1
AUTOMATIC LUBRICATION SYSTEMS
15.5.4
Lubrication Cycle
TIME SEGMENTS & SWITCH POINTS OF A LUBRICATION CYCLE
Terms
PINCREASE
E-L SWOPENING
PHOLD
E-L SWCLOSING
PRELEASE
TPAUSE
Time segment
Explanation
a-b
If the engine is running at high idle a lubrication cycle starts after the pause time is expired or if the switch for manual lubrication 20S124 (CLS) or 20S126 (SLS) was activated. For SLS there is also the precondition that the control lever for "Swing" is moved out of its zero position. The MTC activates the solenoid valve and the pilot pressure (X4 pressure) starts to move the oscillating cylinder. At the same time the vent valve is closed and the lubrication pressure starts to increase. This time segment for building-up the pressure in the lubricant line is fix-programmed in the MTC and it is not adjustable.
b
After all lubrication points have been lubricated there is a pressure rise which opens the end-line switch when the max. pressure is reached. At this time the MTC de-energizes the solenoid valve and stops the oscillating cylinder of the lubrication pump. Now the pressure increasing phase is finished and the pressure holding time starts. The switch point of the end-line switch is 180 +5 bar.
b-c
At this time the MTC starts to count the pressure holding time (5 min) which is fix-programmed in the controller. This time segment is not adjustable. During the pressure holding time the vent valve is kept closed and the pressure is kept at its max. level of 180 bar.
c
After the pressure holding time (5 min) is expired, the end-line switch closes and the vent valve opens. Now the pressure holding phase is finished and the grease pressure is released back to the barrel.
c-d
The pressure release time is fix-programmed in the MTC. This time segment is not adjustable. It is necessary to drop the lubricant pressure completely to zero so the injectors can be recharged for the next lubrication cycle.
b - a’
The pause time prevents that the next lubrication cycle would start too early in case the switch for manual lubrication 20S124 (CLS) or 20S126 (SLS) was actived several times. The counting of the pause time starts at "b" when the end-line switch opens at max. line pressure. The next lubrication cycle starts after the pause time is expired. Preconditions: SLS/CLS: Engine running at high idle SLS only: Slew movement was activated Via the VHMS monitor the pause time is adjustable: CLS 10 - 60 minutes SLS 10 - 20 minutes
Lubrication pump solenoid valve
Vent valve (solenoid)
End-line switch
CLS
62Q507
62Q507a
80B043
SLS
62Q509
62Q509a
62B046
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Lubrication Cycle
AUTOMATIC LUBRICATION SYSTEMS
15.5.5
LUBRICATION MODES
15.5.5.2
15.5.5.1
AUTOMATIC LUBRICATION MODE
A manual lubrication cycle can be activated via the switches 20S124 (CLS) or 20S126 (SLS) at the dashboard.
The lubrication systems are controlled and monitored complete by the program of the MTC. The MTC activates the outputs dependent on inputs and time-lines according to the programmed software. The Pause Time can be adjust in a specified range via the VHMS Real Time Monitor. Monitoring time and pressure relief time are fix-programmed. After a restart of the engine the SLS / CLS system first continues the residual time of the current pause time period before a new start of the grease system is possible. The lube system only starts if the engine is running at high idle.
MANUAL LUBRICATION MODE
In the Operator Mode a manual lube cycle can be started after a waiting period of 10 minutes. This timeline is independent of the Pause Time setting for the automatic mode, which is input via the VHMS monitor.
15.5.5.3
VHMS SERVICE MODE
As long as the VHMS Service Mode is activated the Pause Time is automatically reduced to 30 seconds. Test and adjustment works can be performed more comfortable if the Pause Time is shortened in the VHMS Service Mode. After return to the Operator Mode the Pause Time will be reset to the automatic period which has been adjusted on the VHMS monitor before.
VHMS Pause Time Settings CLS Pause time range: 10 - 60 minutes Standard setting: 15 minutes SLS Pause time range: 10 - 20 minutes Standard setting: 20 minutes
NOTE: For more details of the Pause Time setting refer to the VHMS information in section 14.
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Lubrication Cycle
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Hydraulically Driven Lube Pump
AUTOMATIC LUBRICATION SYSTEMS
15.6
HYDRAULICALLY DRIVEN LUBE PUMP
Fig. 15-7
Hydraulically driven lubrication pump
15-20
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AUTOMATIC LUBRICATION SYSTEMS
Hydraulically Driven Lube Pump
Legend for Fig. 15-7 (1)
Pump drive hydraulic cylinder
(2)
Flow control valve
(3)
Pressure relief valve
(4)
Lubricant pump intake
(5)
Hydraulic oil supply port
(6)
Hydraulic oil return port
(7)
Pump drive control block
(8)
Breather port
(9)
Pump tube
(10)
Lubricant outlet port
(11)
Outlet check valve (ball type)
(12)
Piston rod
(13)
Pump rod shaft seal
(14)
Check valve (ball type)
(15)
Main piston and plunger
(16)
Piston rod set
(17)
Inlet valve
(18)
Scoop piston
(19)
Lubricant inlet
The lubrication pump is a hydraulically driven seal free differential piston pump. The pump pumps lubricant at the up and down stroke but sucks lubricant only during the up stroke. The scoop piston at the pump bottom supports the main pump especially with high viscosity lubricants. There are only one dynamic seal at the piston rod on top of the pump pipe therefor less on wear and long service time. The lubrication pump is divided in two main components, the pump drive hydraulic cylinder and the pump. The pump drive and only the pump outlet are outside on top of the lubricant container, the pump itself is inside and reaches into the lubricant. The maximum possible lubricant pressure depend on the adjusted supply pressure. The pressure multiplication factor between supply pressure and maximum lubricant pressure is 6.55. The pressure reduction valve has to be adjusted to 45 bar. Example: 45 bar supply pressure x 6.55 = 295 bar lubricant pressure. During normal operation the end-line switch stops the pump before reaching this high pressure. For a sufficient lube pump operation 19 - 21 double strokes / min for the pump drive cylinder are required. Therefore the flow reducing valve has to be adjusted, refer to section 15.6.1 on page 15-22. Technical pump data Pump stroke
Pump delivery per stroke
Pump speed
Total pump delivery
152 mm
30 cm3 / double stroke
19 - 21 double strokes / min
540 - 600 cm3 / min
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Hydraulically Driven Lube Pump
AUTOMATIC LUBRICATION SYSTEMS
15.6.1
ADJUSTMENT OF LUBE PUMP SPEED & WORKING PRESSURE
Fig. 15-8
Adjustment of pump speed and working pressure
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15.6.1.1
STROKE SPEED ADJUSTMENT
Hydraulically Driven Lube Pump
15.6.1.2
WORKING PRESSURE ADJUSTMENT
For a sufficient lubricating pump operation 19 - 21 double strokes / min of the pump drive cylinder are required. Therefore the flow reducing valve (Fig. 15-8, Pos. 3) has to be adjusted accordingly.
The pressure reducing valve (Fig. 15-8, Pos. 2) is mounted on the oscillation control block. It reduces the supply pressure to 45 ± bar.
Adjustment procedure
Adjustment procedure
1. Remove the connector from the vent valve (Fig. 15-8, Pos. 7), in order to avoid any pressure rise during the following test.
1. If not yet mounted install a test fitting in port M at the oscillation block, and connect a pressure gauge (0 - 60 bar)
2. Start the engine and run it at high idle.
2. Disconnect the quick-coupling (Fig. 15-8, Pos. 8) from the lubricant supply line in order to block the pump when it is started.
3. Manually switch ON the lube system by using switch 20S124 (CLS) or 20S26 (SLS) at the dasboard and count the double strokes per minute. Therefore remove the plug (Fig. 15-9, Pos. 1) from the pump cover (Fig. 15-9, Pos. 2) and watch the piston going up and down.
3. Start the engine and run it at high idle. 4. Manually switch ON the lube system. The gauge should indicate a max. pressure of 45 ± bar. If adjustment is required 5. Loosen the lock nut (Fig. 15-8, Pos. 2.1). 6. Turn the adjustment screw (Fig. 15-8, Pos. 2) until a pressure of 45 ± bar is achieved. 7. Tighten the lock nut (Fig. 15-8, Pos. 2.1). 8. Reconnect the quick-coupling (Fig. 15-8, Pos. 8). NOTE: If it is not possible to adjust the pressure to 45 ± bar, check the adjustment of the pilot pressure valve (X4 pressure) at the valve cartridge block in the machinery house. The pilot pressure should be 60 bar.
Fig. 15-9
Pump cover with plug
If adjustment is required 4. Loosen the lock nut (Fig. 15-8, Pos. 3.1). 5. Turn the adjustment screw (Fig. 15-8, Pos. 3) until the correct number of double strokes is achieved. 6. Tighten the lock nut (Fig. 15-8, Pos. 3.1). 7. Stop the engine. 8. Connect the connector to the vent valve (Fig. 15-8, Pos. 7).
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Lubricant Injectors
15.7
LUBRICANT INJECTORS
Fig. 15-10
Lubricant Injectors type SL-1 and type SL-11
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AUTOMATIC LUBRICATION SYSTEMS
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AUTOMATIC LUBRICATION SYSTEMS
Lubricant Injectors
15.7.2
Legend for Fig. 15-10 SL-1
Injector type SL-1
SL-11
Injector type SL-11
(1)
Adjustment screw
(2)
Indicator stem
(3)
Lock nut
(4)
Injector piston
(5)
Spring
(6)
Slide valve
(7)
Stud fitting (NPT)
(7a)
Cap nut
(8)
Discharge chamber
(9)
Passage
(10)
Lubricant supply inlet
(11)
Lubricant outlet
(12)
Mounting manifold
DESCRIPTION
Series SL-1 Injector The lubricant output volume is adjustable from 0.13 ... 1.3 cm3 per cycle. An hydraulic type fitting with a screw type cover cap is provided for initial filling of the feeder line. It may also be used for visual checks of the injector operation. Series SL-11 Injector The lubricant output volume is adjustable from 0.82 ... 8.2 cm3 per cycle. It is designed for systems where a large amount of lubricant is required. The operation principle is similar to the series SL-1.
15.7.3
ADJUSTMENT OF THE LUBRICANT OUTPUT
1. Loosen the lock nut (Fig. 15-10, Pos. 3).
15.7.1
TIGHTENING TORQUE FOR FITTINGS AT THE GREASE INCETORS
The exact tightening torque of 14 Nm has to be observed when installing a fitting to a grease injector. CAUTION
2. Turn the adjustment screw (Fig. 15-10, Pos. 1) counterclockwise (OUT) for more lubrication outlet. Turn the adjustment screw clockwise (IN) for less lubricant outlet. 3. Tighten the lock nut (Fig. 15-10, Pos. 3).
NOTE: The max. lubricant outlet is adjusted if the indicator stem (Fig. 15-10, Pos. 2) can no further be screwed out.
When installing a grease nipple fitting or a stud fitting (NPT) to an injector, always observe the maximum tightening torque of 14 Nm. Otherwise the fitting will be screwed too far into the injector and the injector piston movement will be blocked. As a result the grease supply will fail.
For the tightening procedure also refer to the PARTS & SERVICE NEWS AH10532 (latest edition). NOTE: In case of leakage use thread tape (Teflon®) or Loctite® when installing a fitting to any injector.
Version 2010/1
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Lubricant Injectors
AUTOMATIC LUBRICATION SYSTEMS
15.7.4
OPERATION PRINCIPLE OF LUBRICANT INJECTORS
Fig. 15-11
Operation principle of lubricant injectors
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Lubricant Injectors
Legend for Fig. 15-11 A
Normal position (rest position) pressure-free
B
Inlet pressure increasing and lubricant application
C
Maximum inlet pressure application completed
D
Inlet pressure relieved and internally reloading
(1)
Set screw
(2)
Indicator stem
(3)
Lock nut
(4)
Injector piston
(5)
Spring
(6)
Slide valve
(7)
Service port
(8)
Discharge chamber
(9)
Passage
(10)
Lubricant supply inlet
(11)
Lubricant outlet
(12)
Measuring chamber
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Lubricant Injectors
15.7.4.1
AUTOMATIC LUBRICATION SYSTEMS
FUNCTION DESCRIPTION
Stage A
Stage D
Inlet pressure 0 bar Outlet pressure 0 bar
Inlet pressure relieved
The injector piston is in its normal, or rest position. Visible by the extracted indicator stem (2) which is blocked in final position by the set screw (1). The discharge chamber (8) is filled with lubricant from the previous cycle.
Stage B
After lubricant supply pressure (10) is relieved, the compressed spring (5) moves the slide valve (6) to the closed position. This opens the port from the measuring chamber (12) and permits the lubricant to be transferred from the top of the piston to the discharge chamber (8). The indicator stem (2) extract to its initial final stop of the adjustment screw (1). Now the injector is prepared for the next lubricant application.
Inlet pressure increasing from 0 to 180 bar Outlet: lubricant injection 0 - 180 bar Output volume: adjusted amount of lubricant Under the pressure of incoming lubricant via port (10), slide valve (6) is about to open the passage (9) leading to the piston (4). When the slide valve (6) uncovers the passage (9), lubricant is admitted to the measuring chamber (12) at the top of the piston (4), forcing the piston down. The piston (4) forces lubricant from the discharge chamber (8) through the outlet port (11) to the bearing. The indicator stem (2) retracts.
Stage C Inlet pressure at maximum 180 bar Output injection is finished As the piston (4) completes its stroke, it pushes the slide valve (6) past the passage (9), cutting off further admission of lubricant to the passage (9). Piston (4) and slide valve (6) remain in this position until lubricant pressure in the supply line (10) is vented (relieved) at the pump station. The indicator stem (2) is fully retracted and the adjusted amount of lubricant is injected to the bearing.
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Lubricant Injectors
15.7.5
CONNECTION OF ONE OR MORE INJECTORS
Fig. 15-12
Connection of lubricant injectors
Description To increase the lubricant output volume, the injectors (1) are designed to be combined (2 or more injectors). A connector pipe (2) is used to connect two injectors (1). Lubricant from the first injector, outlet (b), is directed through the connector pipe (2) to the inlet (c) of the second injector. Both injectors are now connected, in order to lubricate one lubrication point via pipe (3). This connection is possible for both injector types (SL-1 and SL-11).
CAUTION When installing a fitting to an injector, always observe the maximum tightening torque of 14 Nm. Otherwise the fitting will be screwed too far into the injector and the injector piston movement will be blocked. As a result the grease supply will fail.
For the tightening procedure also refer to the PARTS & SERVICE NEWS AH10532 (latest edition). NOTE: In case of leakage use thread tape (Teflon®) or Loctite® when installing a fitting to any injector.
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Vent Valve
AUTOMATIC LUBRICATION SYSTEMS
15.8
VENT VALVE
Fig. 15-13
Vent valve
15-30
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AUTOMATIC LUBRICATION SYSTEMS
Vent Valve
Legend for Fig. 15-13: (1)
Solenoid
(2)
Valve assembly
(3)
Solenoid stem
(4)
Lever
(5)
Main valve piston
(6)
Auxiliary valve piston
(7)
Reset spring
15.8.1
DESCRIPTION
Task By the function of the vent valve the pressure in the lubricant supply line is relieved, after a lubrication cycle is finished. The injector pistons move back into their initial positions. The valve is open if the solenoid is de-energized. Then port A is connected with port B. Function The solenoid isenergized when a lubrication cycle starts. The connection from A to B gets closed, thus a pressure build-up in the grease supply line is possible. The solenoid gets de-energized, as soon as a lubrication cycle is finished. This causes an 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 piston (Fig. 15-13, Pos. 5).
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End-Line Switch
15.9
END-LINE SWITCH
Fig. 15-14
End-line switch
15-32
AUTOMATIC LUBRICATION SYSTEMS
Version 2010/1
AUTOMATIC LUBRICATION SYSTEMS
End-Line Switch
Legend for Fig. 15-14: (1)
Piston
(2)
Disk
(3)
Switch contact
(4)
Spring
(5)
Pressure switch
(6)
Adjustment sleeve
(7)
Connection to pressure circuit
(8)
Electrical connection
15.9.1
DESCRIPTION
Task The end-line pressure switch is the main part to monitor and to control the lubrication system. It stops the lubrication pump when the lubricant pressure reaches the max. adjusted pressure. Function One pressure control unit is installed in each lubrication system (CLS & SLS). The grease pressure, produced by the hydraulic barrel pump, acts also at the piston (Fig. 15-14, Pos. 1) If the force of the grease pressure exceeds the spring forces (Fig. 15-14, Pos. 4), the piston (Fig. 15-14, Pos. 1) is forced against the disk (Fig. 15-14, Pos. 2). Thus the contacts of the switch (Fig. 15-14, Pos. 5) are operated and an electric contact is given to the MTC. Any adjustment has to be done with the sleeve (Fig. 15-14, Pos. 6): Turning it clockwise - higher switch point Turning it counterclockwise - lower switch point
Version 2010/1
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End-Line Switch
15.9.2
CLS END-LINE SWITCH ADJUSTMENT
Fig. 15-15
End-line switch adjustment (CLS)
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AUTOMATIC LUBRICATION SYSTEMS
Version 2010/1
AUTOMATIC LUBRICATION SYSTEMS
End-Line Switch
Legend for Fig. 15-15: 80B043
End-line switch (CLS)
(1)
Pressure gauge
(2)
Grease container
(3)
Location of CLS pump station
(4)
Bolt
(5)
Cover
(6)
Allen key
(7)
Allen screw
Procedure 1. For adjustment use the pressure gauge (Fig. 15-15, Pos. 1) which is mounted on top of the grease container (Fig. 15-15, Pos. 2). NOTE: For the following adjustment procedure 2 service technicians are required. 2. Start the engine and run it at high idle. 3. Start a manual CLS lube cycle using the dashboard switch 20S124. 4. Watch the pressure gauge (Fig. 15-15, Pos. 1). At a pressure of 180 ± 5 bar the end-line switch (80B043) must open and the lubrication pump must be stopped. NOTE: 180 ± 5 bar is the standard setting. Under particular circumstances it may be necessary to increase the pressure slightly. If re-setting is required 5. Screw out the bolts (Fig. 15-15, Pos. 4) and remove the cover (Fig. 15-15, Pos. 5). 6. Using an allen key (Fig. 15-15, Pos. 6) turn the allen screw (Fig. 15-15, Pos. 7) and alter the spring tension until the switch operates at 180 ± 5 bar. 7. After adjustment is finished install the cover (Fig. 15-15, Pos. 5) and tighten the 4 bolts (Fig. 15-15, Pos. 4).
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End-Line Switch
15.9.3
SLS END-LINE SWITCH ADJUSTMENT
Fig. 15-16
End-line switch adjustment (SLS)
15-36
AUTOMATIC LUBRICATION SYSTEMS
Version 2010/1
AUTOMATIC LUBRICATION SYSTEMS
End-Line Switch
Legend for Fig. 15-16: 62B046
End-line switch (SLS)
(1)
Pressure gauge
(2)
Grease container
(3)
Location of SLS pump station
(4)
Bolt
(5)
Cover
(6)
Allen key
(7)
Allen screw
Procedure 1. For adjustment use the pressure gauge (Fig. 15-15, Pos. 1) which is mounted on top of the grease container (Fig. 15-15, Pos. 2). NOTE: For the following adjustment procedure 2 service technicians are required. 2. Block the swing function by applying the slew parking brake via switch 20S029. 3. Start the engine and run it at high idle. 4. Start a manual SLS lube cycle using the dashboard switch 20S126. 5. Watch the pressure gauge (Fig. 15-15, Pos. 1). At a pressure of 180 ± 5 bar the end-line switch (62B046) must open and the lubrication pump must be stopped. NOTE: 180 ± 5 bar is the standard setting. Under particular circumstances it may be necessary to increase the pressure slightly. If re-setting is required 6. Screw out the bolts (Fig. 15-15, Pos. 4) and remove the cover (Fig. 15-15, Pos. 5). 7. Using an allen key (Fig. 15-15, Pos. 6) turn the allen screw (Fig. 15-15, Pos. 7) and alter the spring tension until the switch operates at 180 ± 5 bar. 8. After adjustment is finished install the cover (Fig. 15-15, Pos. 5) and tighten the 4 bolts (Fig. 15-15, Pos. 4).
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In-Line Filter
AUTOMATIC LUBRICATION SYSTEMS
15.10 IN-LINE FILTER
Fig. 15-17
15-38
In-line filter
Version 2010/1
AUTOMATIC LUBRICATION SYSTEMS
Legend for Fig. 15-17: (1)
Plug screw
(2)
Plug screw gasket
(3)
Filter element
(4)
Filter housing
(5)
Spring guide
(6)
Spring
In-Line Filter
15.10.2 MAINTENANCE PROCEDURE CAUTION Before starting to work on the system, stop the engine and remove the key from the main key switch in order to prevent any engine start.
1. Remove the plug screw (Fig. 15-17, Pos. 1) using a 36 mm wrench. 2. Remove the plug screw gasket (Fig. 15-17, Pos. 2).
15.10.1 DESCRIPTION
3. Take out the spring (Fig. 15-17, Pos. 6), the spring guide (Fig. 15-17, Pos. 5), and the filter element (Fig. 15-17, Pos. 3).
Task 4. Clean all parts and inspect them for damage. The in line-filter between lubricant pump and injectors prevents a system contamination by rough particles. To prevent a too high intake pressure due to a blocked filter, the filter element is equipped with a by-pass function.
NOTE: A clogged filter element will be pressed against the spring force by the lubricant pressure and unfiltered lubricant reaches the system. 5. Replace damaged parts as necessary. 6. Insert the filter element, the spring guide, and the spring. 7. Install the plug screw with gasket and tighten it with a wrench. NOTE: For the service intervals refer to the MAINTENANCE MANUAL.
Version 2010/1
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Lubricant Level Sensor
AUTOMATIC LUBRICATION SYSTEMS
15.11 LUBRICANT LEVEL SENSOR
Fig. 15-18
15-40
Lubricant level sensor
Version 2010/1
AUTOMATIC LUBRICATION SYSTEMS
Legend for Fig. 15-18: (1)
Grease level sensor
(2)
Cover of grease container
(3)
Section of wiring diagram Sensor 62B108 (CLS)
(4)
Section of wiring diagram Sensor 62B109 (SLS)
(a)
Elbow plug
(b)
LED location at the sensor (red & yellow)
(c)
Upper lock nut
(d)
Retainer
(e)
Seal ring
(f)
Lower lock nut
(g)
Top view onto the sensor
Lubricant Level Sensor
Function The sonar sensor sends a proportional current signal according to the distance between the sonar sensor and the grease level to the MTC. The sensor operates in a range of 320 to 950 mm. The min. distance means the lubricant barrel is full. In this case the signal current to the MTC is ~ 20 mA. The max. distance means the lubricant barrel is empty. In this case the sensor signal current to the MTC is ~ 4 mA. NOTE: The sonar sensor gets out of range if it comes in contact with grease. Therefore an overfilling of the grease barrel should be avoided. In case of a sensor malfunction (red LED at the sensor ON), remove the sensor and wipe off any grease from its lower surface. For the LED function in case of a sensor error see the following section.
15.11.1 DESCRIPTION
15.11.1.1 LEDS AT THE SONAR SENSOR
Task
At the upper collar (Fig. 15-18, Pos. b) the sensor is equipped with LEDs (red & yellow). The function of these LEDs is as follows:
The lubricant level sensor is an analog sonar sensor type. Lubricant maximum filling level monitoring is necessary to prevent an overfilling of the grease barrel via the refilling arm. The minimum grease level monitoring allows timely refilling of grease and it prevents the grease pump from running dry. General The analog level signal comes from the sonar sensor which is mounted on the cover of the lubricant pump station. The sensor is connected to the MTC. The MTC activates the "full" light if the grease level reaches the maximum. This indication light is mounted at the refilling arm. If a grease level of 10 - 15 % is reached the MTC generates the message Central lubrication system grease level too low or Slew gear lubrication system grease level too low. This allows grease charging in time, which prevents an unexpected breakdown. If the lubricant level reaches 0 % the MTC deactivates the lubrication pump and generates the message Central lubrication system empty or Slew gear lubrication system empty. Version 2010/1
Sensor condition
LED red
LED yellow
Normal operation
OFF
ON
Error
ON
Previous state
Adjustment The sonar sensor doesn’t need adjustments, except the mounting depth in the lubricant container cover. This adjustment only has to be done if the sensor was removed for cleaning or if it is replaced by another one. Standard sensor length below the lubricant container cover: 20 mm If adjustment is required: 1. Unplug the sensor connector. 2. Loosen the upper lock nut (Fig. 15-18, Pos. c). 3. Loosen the lower lock nut (Fig. 15-18, Pos. f). 4. Adjust the sensor length below the lubricant container cover to 20 mm by turning the upper and lower nuts. 15-41
Lubricant Level Sensor
AUTOMATIC LUBRICATION SYSTEMS
5. If the correct measurement (20 mm) is achieved tighten the upper and lower lock nut (Fig. 15-18, Pos. c & f). 6. Plug-in the sensor connector. The MIN and MAX points of the grease level don’t need any sensor adaption. The sensors are preadjusted ex factory. NOTE: For the wiring connection of the sonar sensor also refer to the wiring diagram of the distribution box on top of the lubricant container.
15-42
Version 2010/1
AUTOMATIC LUBRICATION SYSTEMS
Lubricant Level Sensor
This page was left blank intentionally.
Version 2010/1
15-43
Lubrication Pinion (SLS)
AUTOMATIC LUBRICATION SYSTEMS
15.12 LUBRICATION PINION (SLS)
Fig. 15-19 15-44
Dummy wheel Version 2010/1
AUTOMATIC LUBRICATION SYSTEMS
Legend for Fig. 15-19: (A)
Swing circle gear
(B)
Center shaft
(C)
Stator radial bore
(D)
Grease outlet
(1)
Lubrication pump station
(2)
Lubrication container
(3)
Main pump control solenoid valve (pump on/off)
(4)
Lubricant pressure relief solenoid valve
(5)
Lubricant supply line from pump to injector
(6)
End-line pressure switch
(7)
Injectors
(8)
Lubricant feed line from injector to lubrication pinion
(9)
Lubrication pinion
Lubrication Pinion (SLS)
15.12.1 DESCRIPTION The SLS system lubricates the open gear of the swing ring with special open gear lubricant. The lubricant pump station (Fig. 15-19, Pos. 1) is the same as for the CLS system. To apply the lubricant equally to the swing ring gear teeth (Fig. 15-19, Pos. A) a special lubrication pinion (Fig. 15-19, Pos. 9) close to the swing drive pinion is mounted. The lubrication pinion (Fig. 15-19, Pos. 9) distributes the lubricant from the injectors evenly to the teeth. Normally two or more injectors are parallel connected to supply the required amount of lubricant to the lubrication pinion. The pinion center shaft (Fig. 15-19, Pos. B) acts as a rotary joint and distributes the lubricant through radial bores only to those teeth witch are in contact with the swing ring gear teeth. Outlet bores (Fig. 15-19, Pos. B) at different pinion gear levels distribute the lubricant equally to the swing ring gear teeth (Fig. 15-19, Pos. A). To prevent unnecessary lubrication with the swing ring in park position, the SLS pump only starts to operate after "swinging" was activated with the control lever. All other SLS control and monitoring functions are the same as they are used in the CLS system.
Version 2010/1
15-45
Commissioning
AUTOMATIC LUBRICATION SYSTEMS
15.13 COMMISSIONING 15.13.1 COMMISSIONING OF THE CLS LUBRICATION SYSTEM Commissioning procedures for the automatic Central Lubrication System. These procedures must be performed after the first assembly of the excavator, or after repair and exchange of components.
WARNING z
Some checks and adjustments can only be done with the engine running. For such jobs two persons are necessary.
z
Thereby, the controls must not be left unattended, while the other man carries out checks and adjustments.
z
The service technican on the operator’s seat must be skilled in the operation of the excavator.
z
He must keep constant visual contact with the other service technician and both must agree on suitable communication signals before they start their work.
1. Visual check of all hose and pipe connections from the lubrication pump station to the lubrication points via the injectors. 2. Check the correct mounting of the lubrication system. 3. Check the correct connection of the hydraulic oil supply line and the tank line. 4. Check the correct electrical connection. 5. Check the correct kind and quality of the respective grease according to the OPERATION AND MAINTENANCE MANUAL. In addition refer to the relevant PARTS & SERVICE NEWS. 6. Check the injector adjustment of each injector. It should be on max. volume, if not, adjust to max. volume, refer to section 15.7.3 on page 15-25. 7. Check if the grease supply line (from the pump station to the injectors) is pre-charged with grease. If not, open (unplug) the supply line close to the end-line switch. Start the engine and activate the lubrication station so often until grease comes out of the open end of the supply line. Stop the engine and close the open supply line. 8. Manually pre-lubricate all bearings with a grease gun of the lube track. To do this, unscrew the dust cap at the second port of each injector and connect the grease gun to the grease nipple. Apply sufficient grease into the bearing until a small amount of fresh grease appears at the bearing seals or open bearings. 9. Adjust the end-line switch if necessary, refer to section 15.9 on page 15-32. 10. Check the lubrication pump speed. If required adjust it, refer to section 15.6.1 on page 15-22. 11. Check the time settings of the pause time at the VHMS Real Time Monitor. Adjust the suggested settings which are given in the PM-CLINIC forms. This is the basic setting and also a guaranty for sufficient lubrication. NOTE: A fine adjustment is possible to adapt the lubricant apply to the working and environmental conditions by minimized lubricant consumption. 12. Start the engine and activate several cycles of the CLS lubrication. 13. Set the lubrication cycle counter to zero and note the actual working hours from the hour meter. 14. The excavator is now ready for operation. 15-46
Version 2010/1
AUTOMATIC LUBRICATION SYSTEMS
Commissioning
15. After ~20 working hours check the lubrication systems. Check the lubrication points for sufficient grease. Check the swing circle lubricating, a small amount of grease must appear at the inner swing circle seal. Watch the cycle counter and compare it with the respective working hours. z
Example: Pause time setting = 30 minutes Working hours since the last check = 10 hours 10 h / 0.5 h = 20 cycles Compare with the indication of the cycle counter. There should be 20 –1 cycles, provided no manual cycle was activated.
16. Check the lubrication systems every day. Compare all lubrication points. There should be a well balanced small amount of fresh grease at each bearing seal or open bearing.
15.13.2 FINE ADJUSTMENT General Under normal circumstances the lubrication system - with the basic adjustment - applies more lubricant as required. 1. Find out the lubrication point with the lowest quantity of fresh grease. This point is the indicator for the following pause time fine adjustment. 2. Reduce the applied quantity by extending the pause time as much until a small amount of wet grease appears at the bearing seal or open bearing of the indicator point. Extend the pause time only in small steps (~2 - 5min). Between each step wait for 40 working hours or more and watch the lubrication points. 3. If there are one or more bearing points with too much grease, adjust the respective injector to a lower volume, refer to section 15.7.3 on page 15-25. Change the setting only in small steps (max. 1 - 2 turns clockwise). Between each step wait for 40 working hours or more and watch the lubrication points. Be careful, don’t turn the set screw too much in, and block the injector against moving. NOTE: Check the CLS every day (Daily Check)! The lubrication points of a correct adjusted Central Lubrication System have a well balanced small amount of wet grease. Never let the excavator operate with a grease shortage. Find out the reason for this shortage and eliminate this problem immediately.
Version 2010/1
15-47
Commissioning
AUTOMATIC LUBRICATION SYSTEMS
15.13.3 COMMISSIONING OF THE SLS LUBRICATION SYSTEM Commissioning procedures for the automatic Swing circle Lubricating System. These procedures must be performed after the first assembly of the excavator, or after repair and exchange of components.
WARNING z
Some checks and adjustments can only be done with the engine running. For such jobs two persons are necessary.
z
Thereby, the controls must not be left unattended, while the other man carries out checks and adjustments.
z
The service technican on the operator’s seat must be skilled in the operation of the excavator.
z
He must keep constant visual contact with the other service technician and both must agree on suitable communication signals before they start their work.
1. Visual check of all hose and pipe connections from the lubrication pump station to the dummy wheel via the injectors. 2. Check the correct mounting of the lubrication system. 3. Check the correct connection of the hydraulic oil supply line and the tank line. 4. Check the correct electrical connection. 5. Check the correct kind and quality of the respective grease according to the OPERATION AND MAINTENANCE MANUAL. 6. Check the injector adjustment of each injector. It should be on max. volume, if not, adjust to max. volume, refer to section 15.7.3 on page 15-25. 7. Check if the grease supply line (from the pump station to the injectors) is pre-charged with grease. If not, open (unplug) the supply line close to the end-line switch. Start the engine and activate the lubrication station so often until grease comes out of the open end of the supply line. Stop the engine and close the open supply line. 8. Remove protection fluid, dust or old grease with adequate solvent from the swing circle toothing. 9. Important: First apply open ring gear compound manually at the clean slew ring, before the assembly of the swing circle protection. Use adhesive voler compound spray for the swing circle toothing (KMG ET-No.500 893 98). It is delivered together with the new excavator. 10. Apply the swing circle parking brake. Start the engine and activate the SLS manually (switch 20S126) and move the swing circle lever to one direction, only for a short time. The SLS starts to work due to the swing movement. 11. Adjust the end-line switch if necessary, refer to section 15.9 on page 15-32. 12. Check the lubrication pump speed. If required adjust it, refer to section 15.6.1 on page 15-22. 13. Check the time settings of the pause time at the VHMS Real Time Monitor. Adjust the suggested settings which are given in the PM-CLINIC forms. This is the basic setting and also a guaranty for sufficient lubrication. 14. Start two or three lubrication cycles. 15. Stop the engine and check the lubrication system. Check if a small amount of grease arrived at one or two dummy wheel teeth.
15-48
Version 2010/1
AUTOMATIC LUBRICATION SYSTEMS
Commissioning
16. Set the lubrication cycle counter to zero and note the actual working hours from the hour meter. The excavator is ready for digging. 17. After ~20 working hours check the SLS. Check the dummy wheel and the swing circle toothing. A small amount of fresh grease must be at the swing circle toothing. Check the SLS lubricant cycle counter. Its indication must be higher as the number of CLS cycles during the same time. NOTE: Check the SLS every day (Daily Check)! Never let the excavator work with a grease shortage. If the teeth get a clear metallic look it is immediately necessary to apply fresh open ring gear lubricant. Find out the reason of this shortage and eliminate this problem immediately. The swing circle toothing of a correct adjusted SLS have a thin layer of open ring gear lubricant. There should be a small amount of fresh open ring gear lubricant around the tooth contact area.
Version 2010/1
15-49
Commissioning
15-50
AUTOMATIC LUBRICATION SYSTEMS
Version 2010/1
LUBRICATION SYSTEMS
Central Lubrication System (CLS)
A manually activation of the lubrication systems is possible by switching a switch at the dashboard. The controller count the number of switch activated and operate the system this number one by on. The system rest between the cycles for a adjustable time (pressure relief time). Circuit Diagram Code Table Solenoid Valve 2
Vent Valve 7
End-Of-Line Switch
CLS (1)
Y7
Y7a
B43
SLS (2)
Y9
Y9a
B46
CLS = Central Lubrication System SLS = Swing circle Lubrication System
Version 2009/1
15-9
Lubrication Pump Station (SLS)
15.3
LUBRICATION PUMP STATION (SLS)
Fig. 15-4
Lubrication pump station SLS
15-10
LUBRICATION SYSTEMS
Version 2009/1
LUBRICATION SYSTEMS
Lubrication Pump Station (SLS)
Legend for Fig. 15-4: (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 (Sonar sending and receiver principal)
(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)
Breather
(17)
Electrical terminal box
(18)
Injector
(19)
Lubricant supply line to dummy wheel
(20)
Lubricant pressure sensor
(21)
Lubricant pressure test point
(22)
End of line switch
(R)
Dummy wheel
(A)
Swing circle gear
(B)
Center bore
(C)
Stator radial bore
(D)
Grease outlet
The lubrication pump station include the barrel (Fig. 15-4, Pos. 10) and the barrel cover with the pump system. The barrel is fix mounted. From the refilling arm is the barrel via a filter rechargeable. The main grease pump system is mounted on the barrel cover it consist the pump (Fig. 15-4, Pos. 1, 11), valves (Fig. 15-4, Pos. 2, 3, 4, 7), lubricant screen filter (Fig. 15-4, Pos. 12), lubricant level sensor (Fig. 15-4, Pos. 9) and a lubricant pressure sensor (Fig. 15-4, Pos. 20).
Version 2009/1
15-11
Lubrication Pump Station (SLS)
Fig. 15-5 15-12
LUBRICATION SYSTEMS
Lubrication Pump Station SLS Version 2009/1
LUBRICATION SYSTEMS
Lubrication Pump Station (SLS)
General The swing circle gear lubrication system use a special dummy wheel to apply the gear grease on to the swing circle gear. All other components between grease barrel and injectors are the same as the central lubrication system. The dummy wheel receives by each lub cycle grease from two or more parallel connected injectors. After the injectors have pump its gear grease quantity through the dummy wheel to the swing ring gear the grease pump stops and the next grease cycle starts after a adjusted time (pause time). The swing circle gear lubrication system start only by running engine in high idle and active slew function. z
After the pilot pressure has been reduced it passes to the hydraulic cylinder which operates the grease pump.
z
The oil cylinder shuttle’s the grease cylinder at 18 – 20 double strokes per minute and delivering 612 – 680 cm³ (37.3 – 41.5 in³) of lubricant per minute (approx. 550 – 612 g / 19.64 – 21.45 oz.)
z
With the vent valve (Fig. 15-5, Pos. 9) closed the pump continues to cycle until maximum pressure is achieved and the injectors have transmitted lubricant to the dummy wheel. In most lubrication systems this is 185 bar (2630 psi. ).
z
When the maximum system pressure is reached the end-of-line switch opens.
z
The open pressure switch signals the controller to stop the pump cycle.
z
Solenoid valve (Fig. 15-5, Pos.4) are de-energized and the hydraulic oil stops flowing to the pump.
z
The controller starts to count down a fixed time (load holding time) and a adjustable pause time (rest time between the automatic lubrication cycles).
z
The vent valve (Fig. 15-5, Pos. 9) is still closed (solenoid active) and the lubricant pressure will be rest on pressure (slow decrease is normal).
z
If the count down of the load holding time is finished the controller terminate the signal to solenoid valve (Fig.15-5, Pos. 9).
z
Vent valve (Fig. 15-5, Pos. 9) is de-energized, it opens and allows the grease pressure to drop to zero.
z
All injectors move in the initial position by spring force and recharge itself for the next lubricant cycle.
z
The system is now at rest and ready for another lube cycle.
It is possible to activate the slew gear lubrication system manually by using switch S26 on the dashboard. The controller count the number of switch activatings and operate the system this number one by on provided the slew function was activated. The system rest between each cycles for a adjustable time (pressure relief time).
Version 2009/1
15-13
Lubrication Pump Station (SLS)
15.3.0.1
SLS LUBRICATION SYSTEM ELECTRIC LAYOUT
Fig. 15-6
Circuit diagram lubrication system
15-14
LUBRICATION SYSTEMS
Version 2009/1
LUBRICATION SYSTEMS
Lubrication Pump Station (SLS)
. Circuit Diagram Code Table Solenoid Valve 2
Vent Valve 7
End-Of-Line Switch
CLS (1)
Y7
Y7a
B43
SLS (2)
Y9
Y9a
B46
CLS = Central Lubrication System SLS = Swing circle Lubrication System
CAUTION Grease qualities to be used: According to NLGI classes 000, 00, 0 and 1 according to the lowest ambient temperature in the operation area.
NOTE: The content of molybdenum must not exceed 5 %. Only synthetic graphite must be contained in graphite lubricants.
Version 2009/1
15-15
Lubrication Pump Station (SLS)
15.3.1
HYDRAULICALLY DRIVEN LUBE PUMP
Fig. 15-7
Hydraulically driven “Power Master III” lube pump
15-16
LUBRICATION SYSTEMS
Version 2009/1
LUBRICATION SYSTEMS
Lubrication Pump Station (SLS)
Legend for Fig. 15-7 (more detailed see parts list 991-0266a): (P)
Hydraulic oil supply
(T)
Hydraulic oil return
(Pr)
Pressure reducing valve
(Q)
Flow regulator valve
(M)
Measure point
(1)
Hydr. actuator piston
(2)
Oscillator control block
(3)
Pump tube
(4)
Breather port
(5)
Grease outlet port
(6)
Piston rod
(7)
Breather plug
(8)
Ball, outlet check valve
(9)
Ball and seat, check valve
(10)
Main piston and plunger
(11)
Piston rod set
(12)
Inlet valve
(13)
Scoop piston
(14)
Grease inlet
The pump assembly consist three main groups: z
Propulsion cylinder (Fig. 15-7, Pos. 1)
z
Cylinder controlling (Fig. 15-7, Pos. 2)
z
Grease pump (Fig. 15-7, Pos. 3)
The Propulsion cylinder (Fig. 15-7, Pos. 1) is connected to the pump piston (Fig. 15-7, Pos. 10). The lubricant pump pumps per stroke (up or down) lubricant through the pump tube (Fig. 15-7, Pos. 3) to the lubricant outlet port. The piston speed and force is adjustable via two valves mounted on the cylinder controlling block (Fig. 15-7, Pos. 2). The left hand valve is a adjustable flow regulation valve to limit the oil flow to the propulsion cylinder. This flow is responsible for the cylinder speed. The right hand valve is a pressure reducing valve to limit the maximum lubrication supply pressure. The stroke direction change automatically if the cylinder stops moving. Reach the cylinder its own stroke limit the moving direction change also if the cylinder stops by an external force. The maximum possible lubricant pressure depend on the adjusted supply pressure. The pressure multiplication factor between supply pressure and maximum lubricant pressure is 6,55. The pressure reduction valve has to be adjusted to 50 bar. Example: 50 bar supply pressure x 6,55 = 327,5 bar lubricant pressure. During normal operation the end line switch stop the pump before reaching this high pressure. For a sufficient lube pump operation 18 – 20 double strokes / min for the pump drive cylinder are required. Therefore the flow reducing valve has to be adjusted, refer to section 15.5 on page 15-38. Version 2009/1
15-17
Lubrication Pump Station (SLS)
15.3.2
VENT VALVE
Fig. 15-8
Vent valve
15-18
LUBRICATION SYSTEMS
Version 2009/1
LUBRICATION SYSTEMS
Lubrication Pump Station (SLS)
Legend for Fig. 15-8: (1)
Solenoid
(2)
Valve assembly
(3)
Solenoid stem
(4)
Lever
(5)
Main valve piston
(6)
Auxiliary valve piston
(7)
Reset spring
Task By the function of the vent valve the lubricant supply line gets pressure relieved, after the lubrication cycle is finished. The injector pistons move back into their initial position. The valve is open if the solenoid is de-energized. It means port A is connected with port B. Function The solenoid gets energized. When the lubrication cycle starts. The connection from A to B gets closed, thus a pressure build-up in the grease supply line 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 piston (Fig. 15-8, Pos. 5).
Version 2009/1
15-19
Lubrication Pump Station (SLS)
15.3.3
END OF LINE SWITCH
Fig. 15-9
End of line switch
15-20
LUBRICATION SYSTEMS
Version 2009/1
LUBRICATION SYSTEMS
Lubrication Pump Station (SLS)
Legend for Fig. 15-9: (1)
Piston
(2)
Disk
(3)
Switch contact
(4)
Spring
(5)
Pressure switch
(6)
Adjustment sleeve
(7)
Connection to pressure circuit
(8)
Electrical connection
Task The pressure control unit (end of line switch) is monitoring and controlling the lube system. Function One pressure control unit is installed in each lubrication system. The grease pressure, produced by the hydraulic barrel pump, acts also at the piston (Fig. 15-9, Pos. 1) If the grease pressure reaches the tension of the spring (Fig. 15-9, Pos. 4), the piston (Fig. 15-9, Pos. 1) is forced against the disk (Fig. 15-9, Pos. 2), thus that the contacts of the switch (Fig. 15-9, Pos. 5) are operated and a electric contact is given to the electronic control unit of the PLC. Adjusting has to be done with the sleeve (Fig. 15-9, Pos. 6). Clockwise - higher switch point, counterclockwise lower switch point. The adjusting have to be done, refer to section 15.5.3 on page 15-44 and on page 15-46.
Version 2009/1
15-21
Lubrication Pump Station (SLS)
15.3.4
IN-LINE FILTER
Fig. 15-10
In-line filter
15-22
LUBRICATION SYSTEMS
Version 2009/1
LUBRICATION SYSTEMS
Lubrication Pump Station (SLS)
Legend for Fig. 15-10: (1)
Plug screw
(2)
Plug screw gasket
(3)
Filter element
(4)
Filter housing
(5)
Spring guide
(6)
Spring
Task The in line filter prevent the lubrication injectors against contamination.
CAUTION Before servicing stop the motor and remove ignition key in order to prevent operation of the system!
NOTE: 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 (Fig. 15-10, Pos. 1) using 36 mm width wrench. 2. Remove plug screw gasket (Fig. 15-10, Pos. 2). 3. Take out spring (Fig. 15-10, Pos. 6), spring guide (Fig. 15-10, Pos. 5) and filter element (Fig. 15-10, Pos. 3). 4. Clean all parts and inspect for damage. Replace as necessary. 5. Insert filter element, spring guide (Fig. 15-10, Pos. 5) and spring. 6. Install plug screw (Fig. 15-10, Pos. 1) with gasket (Fig. 15-10, Pos. 2) and tighten with a wrench. NOTE: For service intervals refer to MAINTENANCE MANUAL
Version 2009/1
15-23
Lubrication Pump Station (SLS)
15.3.5
LUBRICANT LEVEL SENSOR
Fig. 15-11
Lubricant level sensor
LUBRICATION SYSTEMS
Capacitive analog level sensor for machines with PLC (PC 4000 .... PC8000) Legend for illustration Z 21190 1
Capacitive analog sensor housing
2
Capacitive level sensor pipe
3
Lubricant
4
Lubricant container
5
Electrical connection line
General: The capacitive analog level sensor measure the lubricant level with a capacitive measurement principle which is independend from the lubricant surface condition. The sensor create proportional to the lubricant level a analog output signal which use the PLC to monitor the lubricant level and to control the lubricant level messages. It is only one sensor for one container required. For power supply and signal output only two shield wires connected. The sensor is exact to the lubricant container adjusted there are no adjustments and maintenance required.
15-24
Version 2009/1
LUBRICATION SYSTEMS
15.3.6
LUBRICANT PRESSURE SENSOR
Fig. 15-12
Lubricant level sensor
Lubrication Pump Station (SLS)
Lubricant Pressure Sensor Function (electrical diagram Z 27402Page 26) The sensor is additional to the mechanical analogue pressure gauge mounted on the lubrication pump station. On display page REAL TIME MONITOR 4.1.21 is the grease pressure shown. The pressure sensor B160 (1) with a range from 0 bar to 500 bar is hydraulically connected parallel to the mechanical analog pressure gauge (2) in the lubricant supply line on top of the lubricant pump station. On electrical side there are three wire. +24 V electrical supply on plug A (br = brown) and ground on plug D (ws = white). The signal with a proportional voltage output to the lubricant pressure is connected on plug C (gn = green). Connecting between plug and main electrical box X2 is used a shielded wire, to protect the signal line against electrical magnetic interferences. this wire is in the X2 box connected with terminal 3-4, 5, 7-8 and ground (GND) on terminal group Z. The PLC is also connected from analog input port EW14.3 to the terminals. The PLC receive a voltage signal on port 6 of input plug 15 (EW14.3) between 0 – 10 Volt proportional to the lubricant pressure. Task The pressure sensor is used only for the VHMS. It check the lubricant pressure only for observe. NOTE: The grease pressure represent the lubrication pump pressure. The pressure on the end of the grease supply line is lower depend on line resistance and lubricant viscosity.
Version 2009/1
15-25
LUBRICATION SYSTEMS
15.3.7
LUBRICANT INJECTOR
Fig. 15-13
Lubricant injector (metering valve)
Lubrication Pump Station (SLS)
Legend for Fig. 15-13 (for model SL1 and SL11): (1)
Set screw
(2)
Control pin
(3)
Lock nut
(4)
Injector piston
(5)
Spring
(6)
Slide valve
(7)
Second outlet with greaser (injector couple poind)
(8)
Discharge chamber
(9)
Passage (Connecting bore)
(A)
Lubricant inlet
(B)
Lubricant outlet
Version 2009/1
15-26
LUBRICATION SYSTEMS
Lubrication Pump Station (SLS)
General: Each injector can be manually adjusted with set screw (1) to discharge the precise amount of lubricant each bearing needs. Injectors are mounted singly at each bearing, or grouped in a manifold with feed lines supplying lubricant to the bearings. In each case, injectors are supplied with lubricant under pump pressure through a single lubricant inlet port (A). Two injector size are used on KMG machines. Both size can be used in the same circuit, their selection is made on the basis of bearing lubricant requirements.The injectors are externally adjustable so each bearing can receive the correct amount of lubricant. Each injector incorporates an indicator pin that gives visual confirmation the injector is operating correctly. When necessary, troubleshooting is the simple process of checking indicator pins. Via service port (7) it is possible to lubricate the bearing with a manual operated grease gun. Open only cab nut (7a) of service port (7) to get access to the grease nipple. The cup nut (7a) must be replaced after manuel lubrication to plug and protect the nipple.
Injector type
Output volume range
SL1 (A)
0,131 to 1,31 cm³
SL11 (B)
0,82 to 8,2 cm³
Version 2009/1
15-27
Lubrication Pump Station (SLS)
15.3.7.1
FUNCTION STEPS:
Fig. 15-14
Function lubricant injectors
15-28
LUBRICATION SYSTEMS
Version 2009/1
LUBRICATION SYSTEMS
Lubrication Pump Station (SLS)
Function steps: Stage A: Inlet pressure 0 bar, Outlet pressure 0 bar The injector piston is in its normal, or rest position. Visible by the extracted indicator stem (2) which is blocked in final position by the set screw (1). The discharge chamber (8) is filled with lubricant from the previous cycle.
Stage B: Inlet pressure increasing from 0 to 180 bar, Outlet: lubricant injection 0 - 180 bar, Output volume: adjusted amount of lubricant Under the pressure of incoming lubricant via port (10), slide valve (6) is about to open the passage (9) leading to the piston (4). When the slide valve (6) uncovers the passage (9), lubricant is admitted to the measuring chamber (12) at the top of the piston (4), forcing the piston down. The piston (4) forces lubricant from the discharge chamber (8) through the outlet port (11) to the bearing. The indicator stem (2) retracts. Stage C: Inlet pressure at maximum 180 bar Output injection is finished As the piston (4) completes its stroke, it pushes the slide valve (6) past the passage (9), cutting off further admission of lubricant to the passage (9). Piston (4) and slide valve (6) remain in this position until lubricant pressure in the supply line (10) is vented (relieved) at the pump station. The indicator stem (2) is fully retracted and the adjusted amount of lubricant is injected to the bearing. Stage D: Inlet pressure relieved z
After lubricant supply pressure (10) is relieved, the compressed spring (5) moves the slide valve (6) to the closed position. This opens the port from the measuring chamber (12) and permits the lubricant to be transferred from the top of the piston to the discharge chamber (8). The indicator stem (2) extract to its initial final stop of the adjustment screw (1). Now the injector is prepared for the next lubricant application.
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Lubrication Pump Station (SLS)
15.3.7.2
INLINE CONNECTION OF INJECTORS
Fig. 15-15
Connection of lubricant injectors
LUBRICATION SYSTEMS
To increase the lubricant output volume the injectors are designed to combined two or more injectors together. The injector body (1) has two outlet ports (a) and (b), both connected to the discharge chamber. A connector pipe (2) is used to couple two injectors together. Lubricant from the first injector is directed through the connector pipe into the discharge chamber of the second injector. Both injectors now parallel connected to one bearing. Lubrication pinion
15-30
Version 2009/1
LUBRICATION SYSTEMS
15.3.8
LUBRICATION PINION
Fig. 15-16
Dummy wheel
Lubrication Pump Station (SLS)
Legend for Fig. 15-16: (R)
Lubrication pinion (Dummy whee)l
(A)
Swing circle gear
(B)
Center bore
(C)
Stator radial bore
(D)
Grease outlet
Principle of Operation By mean of a lubricant pump, the lubricant is supplied to the centered bore hole (B) of the lubricating pinion (R). Bore hole (B) must be perfectly aligned to the swing circle gear (A) to be greased, so that lubricant leaves the tooth flank always at matched condition. The grease outlet (D) of the lubricating 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. The pinion propulsion is by the slew gear. The pinion bearings are lubricated himself by the gear grease. The picture shows an example with one pinion only. There are also machines which will have two pinion (dummy wheel).
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Lubrication Pump Station (SLS)
LUBRICATION SYSTEMS
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15-32
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LUBRICATION SYSTEMS
15.4
Operating and Controlling
OPERATING AND CONTROLLING
General The Lubrication Systems are controlled and monitored complete through the PLC. The PLC activate the outputs dependent on inputs and time. The programmed flow is shown in the flowchart (898 688 40, page 31 to 34) and the electrical connection is shown in the electrical diagram 897 844 40 d. In- and Outputs of the PLC
Inputs
End of line switch Lubricant level Switch manual cycle Lubricant pressure
CLS
SLS
E2.6 / B43
E2.7 / B46
EW14.1 / B108
EW14.2 / B109
E4.4 / S24
E4.5 / S26
EW14.3 / B160
EW14.4 / B161
Swing circle condition
E 3.5 (18.4) Lever E 20
Engine operating condition
Engine controller
Outputs CLS
SLS
Lubrication pump
A3.1 / Y7
A3.2 / Y9
Vent line
A7.1/Y7a
A7.2 / Y9a
A5.2 / H76
A5.3 / H78
Light “full barrel”
Version 2009/1
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Operating and Controlling
15.4.1
OPERATING FLOW, ELECTRICAL FLOW
Fig. 15-17
Operating flow, Electrical flow
15-34
LUBRICATION SYSTEMS
Version 2009/1
LUBRICATION SYSTEMS
Operating and Controlling
Function of a lubrication cycle. (Illustration Z24042d). PT - phase With the pump and controller system in a rest sate a pre-set pause time interval occurs as determined by PLC: Diagram position (a): A 24Vdc signal from the PLC activate solenoid valve (2) that opens and activate the lubrication pump (*). As solenoid valve (2) opens, hydraulic oil flow 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 grase pump. The oil cylinder shuttle the grease cylinder at 18 - 20 double strokes per minute and delivering 212 680cm³ (37.3 - 41.5 in³) of lubricant per minute (approx. 550- 612 / 19....64 - 21.45 oz.) At the same time a 24V signal energize release valve (7), it close now the release line to the lubricantion container. PI - phase With energized release valve (7) (*) and solenoide valve (4) the pumpcontinues to cycle until mayimum pressure is achieved and the injectors have transmitted lubricant to the brearings. S + ponit, diagram position (b) Whenthe maximum system pressure is reached the end of the line switch (*) open it’s contact. In the normal application es the end of line switch adjusted to 180 bar (2610psi.). 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 valve (2). The pilot oil flow to the pump stops 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.) Once cycle With expired pressure holding time vent valve (7) de-energize. Itopens the release line to the lunbricant container. The lubricant line pressure drop to zero so the injectors can recharge for the next lubricant cycle. (PR-phase) PR-phase In the pressure relieve phase, the end of line switch (*) move back to neutral contact, given a singnal to PLC that the lube pressure relieve phase is now active. Pause time The systemis after pressure releasing at rest (pause time), ready for another lube cycle and the sequence repets itself when the adjusted pause time is elapsed.
Version 2009/1
15-35
Operating and Controlling
Fig. 15-18 15-36
LUBRICATION SYSTEMS
Operating flow, electrical flow Version 2009/1
LUBRICATION SYSTEMS
Operating and Controlling
:. Soleniod valve 2
Vent valve 7
End of line switch
Y7, CLS
Y7a, CLS (1)
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
X axis
Time
Y axis
Lubricant supply line pressure
PI
Pressure Increasing
S+
Swittch point ON of the end line pressure switch
PH
Pressure Holding
S-
Switch piont OFF of the end line pressure switch
PR
Pressure Relieve
Version 2009/1
15-37
Adjustments
LUBRICATION SYSTEMS
15.5
ADJUSTMENTS
Fig. 15-19
Adjust pump speed and working pressure
15-38
Version 2009/1
LUBRICATION SYSTEMS
15.5.1
PUMP SPEED AND WORKING PRESSURE
15.5.1.1
ADJUSTMENTS LUBRICATING PUMP SPEED
Adjustments
Stroke speed (Q) For a sufficient lubricating pump operation 18 – 20 double strokes/ min of the pump drive cylinder are required. Therefore the flow reducing valve (2) has to be adjusted accordingly. Procedure: 1. Disconnect electrical plug connection from the lubricant pressure release valve (9), so no pressure built up will take place during the following test. 2. Start engine and run at high idle. 3. Activate the required lube system manually with dash board switch S24 (CLS) or S26 (SLS) and count strokes per minute, visible via the oscillating pipe (24). If adjustment is required: 4. Loosen lock nut (2.1) 5. Turn setscrew (2) cadre to increase or cr. to decrease the stroke speed until the right number of strokes is achieved. 6. Tighten lock nut (3.1). 7. Reconnect electrical plug from lubricant pressure release valve (9).
Version 2009/1
15-39
Adjustments
Fig. 15-20
15-40
LUBRICATION SYSTEMS
Adjust pump speed and working pressure
Version 2009/1
LUBRICATION SYSTEMS
Adjustments
Adjustments lubricating pump pressure Maximum pump operating pressure (P) The pressure reducing valve (3) mounted in the oscillation control block reduce the pump drive cylinder pressure internally. The maximum allowed pressure is 45 bar but there is no direct pressure check required. The pressure ratio is 6,55 to 1, that means 45 bar supply pressure result in 295 bar maximum lubricant pressure. At the end line pressure switch the pressure should be 180 ±5bar. With the lubricant line resistance and different lubricant viscosity the pressure at the lubricant pump must be higher as 180 bar. 220 – 250 bar pump pressure (pressure gauge at lubrication station) is sufficient to achieve the 180 bar end line pressure after line resistance and different lubricant viscosity.
Procedure: 1. Disconnect quick coupling (10), so the pump supply line from the pump to the injectors is blocked. 2. Start engine and run at high idle. 3. Activate the required lube system manually, the gauge (14) should show 220-250 bar. 4. If adjustment is required: 5. Loosen lock nut (3.1) 6. Turn adjustment (3) until the right pressure is shown at the gauge (7) turn set screw ccw to lower pressure and cw to increase the pressure until the required pressure is achieved. 7. Tighten lock nut (3.1). 8. Change engine to low idle or stop engine which stop the lubricant pump and opened relieve valve (9) to relieve the lubricant pressure. 9. Reconnect quick coupling (8).
Version 2009/1
15-41
Adjustments
LUBRICATION SYSTEMS
15.5.2
INJECTORS
Fig. 15-21
Injectors
15-42
Version 2009/1
LUBRICATION SYSTEMS
Adjustments
Legend for illustration Z 21187a
General: Each injector can be manually adjusted with set screw (1) to discharge the precise amount of lubricant each bearing needs. Injectors are mounted singly at each bearing, or grouped in a manifold with feed lines supplying lubricant to the bearings. In each case, injectors are supplied with lubricant under pump pressure through a single supply line (10). Two injector size used. Both size can be used in the same circuit, their selection is made on the basis of bearing lubricant requirements.The injectors are externally adjustable so each bearing can receive the correct amount of lubricant. Each injector incorporates an indicator pin that gives visual confirmation the injector is operating correctly. When necessary, troubleshooting is the simple process of checking indicator pins. Via service port (7) it is possible to lubricate the bearing with a manual operated grease gun. Open only cab nut (7a) of service port (7) to get access to the grease nipple. The cup nut (7a) must be replaced after manuel lubrication to plug and protect the nipple.
Injector type
Output volume range
SL1 (A)
0,131 to 1,31 cm³
SL11 (B)
0,82 to 8,2 cm³
Version 2009/1
15-43
Adjustments
LUBRICATION SYSTEMS
15.5.3
END OF LINE SWITCH SETTING CLS
Fig. 15-22
End of line switch setting CLS
15-44
Version 2009/1
LUBRICATION SYSTEMS
Adjustments
1. Connect pressure gauge (0-400 bar) to check point near by the end line switch. There is only a T-union with one plugged port. Open this port and mount a adapter test union to connect the pressure gauge. NOTE: Use an other gauge as for checking hydraulic pressures because the gauge remains filled with grease after the test. 2. Start engine. 3. Start a lube cycle with the dashboard switch S24. 4. Watch pressure gauge. At a pressure of 180+10 bar the end-line switch must react and the lubricants pump must be stopped. *) NOTE: *) 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. NOTE: 180 bar is the normal setting. Under particular circumstances it may be necessary to increase the pressure slightly. If re-setting is required: 1. Screw out screw (Fig. 15-22, Pos. 1) and take off cover (Fig. 15-22, Pos. 2). 2. Alter the spring tension with adjustment screw (Fig. 15-22, Pos. 3) that the switch operates at 180 bar. 3. Install cover (Fig. 15-22, Pos. 2) and screw (Fig. 15-22, Pos. 1).
Version 2009/1
15-45
Adjustments
LUBRICATION SYSTEMS
15.5.4
END OF LINE SWITCH SETTING SLS
Fig. 15-23
End of line switch setting SLS
15-46
Version 2009/1
LUBRICATION SYSTEMS
Adjustments
1. Connect pressure gauge (0-400 bar) to check point near by the end line switch. There is only a T-union with one plugged port. Open this port and mount a adapter test union to connect the pressure gauge. NOTE: Use an other gauge as for checking hydraulic pressures, because the gauge remains filled with grease after the test. 2. Fix the swing functionby using the swing parking brake (Switch S29). 3. Start engine. 4. Start a lube cycle with the dashboard switch S26 and move the lever for the swing function for a short time. 5. Watch pressure gauge. At a pressure of 180+10 bar the end-line switch must react and the lubricant pump must be stopped. *) NOTE: *) 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. NOTE: 180 bar is the normal setting. Under particular circumstances it may be necessary to increase the pressure slightly. If re-setting is required: 1. Screw out screw (Fig. 15-23, Pos. 1) and take off cover (Fig. 15-23, Pos. 2). 2. Alter the spring tension with adjustment screw (Fig. 15-23, Pos. 3) that the switch operates at 180 bar. 3. Install cover (Fig. 15-23, Pos. 2) and screw (Fig. 15-23, Pos. 1).
Version 2009/1
15-47
Troubleshooting
15.6
TROUBLESHOOTING
Fig. 15-24
Troubleshooting
15-48
LUBRICATION SYSTEMS
Version 2009/1
LUBRICATION SYSTEMS
Troubleshooting
If the following procedures do not correct the problem, contact a factory authorized service center. Problems: Lubrication Pump Cylinder does not move 1. Check if the PLC start currently a lubrication cycle. z
Activate the lubrication system manually.
z
Be sure that the pressure holding time and relief time is over.
z
SLS only: move the slewing lever for a short time to switch the zero position contact.
2. Check if there a fault message on display CGC. z
If the level sensor indicate zero level, the PLC stop the lubrication system as long as the barrel is recharged.
3. Check for 24 VDC signal at solenoids (Fig. 15-22, Pos. 2). 4. Check the hydraulic oil supply and tank line coupling (Fig. 15-22, Pos. 5, 6). 5. Check system pressure to lubrication pump (X-4 Pressure). 6. Check pressure reducing valve (Fig. 15-22, Pos. 4) (lubrication pump) setting. 7. Check for faulty valves (Fig. 15-22, Pos. 3, 4) (check for foreign matters). Lubricant Pressure built up very slowly or not at all. 1. Check lubricant supply line to the injectors for leak or broken lines. 2. Check injectors for internal leaks. 3. Pressure reducing valve (Fig. 15-22, Pos. 4) may be set too low. 4. Grease viscosity may be too high for temperature at which pump is operating. 5. Check end line switch for correct setting. 6. Check lubrication pump (Fig. 15-22, Pos. 11). Piston and inlet checks may have foreign matter trapped causing leakage. Remove, inspect and clean if necessary. 7. Check solenoid valve (Fig. 15-22, Pos. 7) (vent line) for correct function and completely closed port. 8. Check lubricant pressure gauge (Fig. 15-22, Pos. 14) for correct function.
Version 2009/1
15-49
Troubleshooting
Fig. 15-25 15-50
LUBRICATION SYSTEMS
Troubleshooting Version 2009/1
LUBRICATION SYSTEMS
Troubleshooting
Insufficient Lubricant Supply to one or more Attachment Bearings 1. Check lubricant supply line to the respective bearing for leak or broken line. 2. Check injector function and adjustment z
Check if the indication pin move smooth during a lubrication cycle.
z
Check if the indication pin move completely back in the initial position.
z
Check the application volume by open line.
3. Check end line switch for correct setting. 4. Check lubricant supply bore for clogged up 5. Check pause time setting. 6. Check bearing condition (extensive wear) Insufficient Lubricant at the Swing Ring Gear 1. Check lubricant supply line to the dummy wheel 2. Check dummy wheel for clogged supply bore. 3. Check dummy wheel mounting position 4. Check electrical controlling system, especially the idle identify circuit. 5. Check kind of lubricant and quality.
Version 2009/1
15-51
Commissioning
LUBRICATION SYSTEMS
15.7
COMMISSIONING
15.7.1
COMMISSIONING OF THE CLS
Commissioning procedure for the automatic central lubricating systems. This procedure must be done after the first erection of the excavator or repair and exchange of components.
WARNING z
Some checks and adjustments can only be done with the engine running. For such jobs two person are necessary.
z
Thereby, the controls must not be left unattended, while the other man carries out checks and adjustments.
z
The Service technica in the operator’s seat must be skilled in the operating of the excavator.
z
He must keep constant visual contact with the other one and they must agree on suitable communication signals before they start their work.
1. Visual check of all hose and pipe connections from the lubrication pump station to the lubrication points via the injectors. 2. Check the correct mounting of the lubrication systems. 3. Check the correct connection of the hydraulic oil supply line and tank line. 4. Check the correct electrical connection. 5. Check the correct kind and quality of the respective grease according to the OPERATION AND MAINTENANCE MANUAL. 6. Check the injector adjustment of each injector, it should be on max. volume, if no adjust to max. volume refer to section 15.5.2 on page 15-42. 7. Check out if the grease supply line (from the pump station to the injectors) is precharged with grease. If no open (unplug) the supply line near by the end of line switch. Start engine and activate the lubrication station so often as grease comes out on the open end of the supply line. Stop engine and close the open supply line. 8. Pre lubricate all bearings manually with a grease gun. To do this, unscrew the dust cap at the second port of each injector and connect the grease gun to the grease nipple. Apply sufficient grease into the bearing until a small amount of fresh grease appears at the bearing seals or open bearings. 9. Adjust the end of line switch refer to section 15.5.3 on page 15-44. 10. Check the lubrication pump speed. If required adjust refer to section 15.5.1 on page 15-39. 11. Check the time settings of pause time, monitoring time and relief time. Set to our suggested settings written in the final test report . It is the base setting and guaranty a sufficient lubrication. NOTE: A fine adjustment is possible to adapt the lubricant apply to working and environmental conditions by minimized lubricant consumption. 12. Start engine and activate the CLS several cycles. 13. Set lubricant cycle counter to zero and note the actual working hours from hour meter. 14. The excavator is now ready for operation.
15-52
Version 2009/1
LUBRICATION SYSTEMS
Commissioning
15. After ~20 working hours check the lubrication systems. Check the lubrication points for sufficient grease. Check the swing circle lubricating, a small amount of grease must appear at the inner swing circle seal. Watch to the cycle counter and compare it with the respective working hours. z
Example: Pause time setting = 30 min Working hours since the last check = 10 hours 10 h / 0.5 h = 20 cycle Compare with the number of cycle counter it should be 20 –1 cycle, provided no manual cycle was activated.
16. Check the lubrication systems every day. Compare all lubrication points. There should be a well balanced small amount of fresh grease at each bearing seal or open bearing.
15.7.2
FINE ADJUSTMENT
General In normal circumstance the lubrication system apply with the basic adjustment more lubricant as required. 1. Find out the lubrication point with the lowest quantity of fresh grease. This point is the indicator for the following pause time fine adjustment. 2. Minimize the apply quantity by extending of the pause time as much as a small amount of wet grease appears at the bearing seal or open bearing from the indicator point. Extend the pause time only in small steps (~2-5min). Between each step wait 40 working hours or more and watch the lubrication points. 3. If there one or more bearing points with to much grease adjust this respective injector to a lower volume, refer to section 15.5.2 on page 15-42, change setting only in small steps (max. 1-2 turn clock wise) Between each step wait 40 working hours or more and watch the lubrication points. Be carefully, don’t turn the set screw to much in and block the injector moving. NOTE: Check the CLS every day. NOTE: The lubrication points of a correct adjusted central lubrication system have a well balanced small amount of wet grease. Never let the excavator operate with a grease shortage. Find out the reason of this shortage and eliminate this problem.
15.7.3
COMMISSIONING OF THE SLS
Commissioning procedure for the automatic swing circle lubricating systems. This pro-cedure must be done after erection of the excavator or repair and exchange of compo-nents.
WARNING z
Some checks and adjustments can only be done with the engine running. For such jobs two person are necessary.
z
Thereby, the controls must not be left unattended, while the other person carries out checks and adjustments.
z
The Service technica in the operator’s seat must be skilled in the operating of the excavator.
z
He must keep constant visual contact with the other one and they must agree on suitable communication signals before they start their work.
Version 2009/1
15-53
Commissioning
LUBRICATION SYSTEMS
1. Visual check of all hose and pipe connections from the lubrication pump station to the dummy wheel via the injectors. 2. Check the correct mounting of the lubrication systems. 3. Check the correct connection of the hydraulic oil supply line and tank line. 4. Check the correct electrical connection. 5. Check the correct kind and quality of the respective grease according to the OPERATION AND MAINTENANCE MANUAL. 6. Check the injector adjustment of each injector, it should be on max. volume, if no adjust to max. volume refer to section 15.5.1 on page 15-39. 7. Check out if the grease supply line (from the pump station to the injectors) is precharged with grease. If not open (unplug) the supply line near by the end of line switch. Start engine and activate the lubrication station so often as grease comes out on the open end of the supply line. Stop engine and close the open supply line. 8. Clean swing circle toothing from protection fluid with adequate solvent. 9. Apply the first open ring gear lubricant manually before assembly the swing circle protection. 10. Close swing circle parking brake. Start engine and activate the SLS manually (switch S26) and move the swing circle lever to one direction, only for a short time. The SLS start to work. Adjust the end of line switch refer to section 15.5.4 on page 15-46. 11. Check the lubrication pump speed. If required adjust refer to section 15.5.1 on page 15-39. 12. Check the time settings of pause time, monitoring time and relief time. Set to our suggested settings written in the final test report . It is the base setting and guaranty a sufficient lubrication. 13. Start two or three lubrication cycle. 14. Stop engine and check lubrication system. Check if a small amount of grease arrived at one or two dummy wheel tooth. 15. Set lubricant cycle counter to zero and note the actual working hours from hour meter. The excavator is ready for digging. 16. After ~20 working hours check the SLS. Check the dummy wheel and swing cir-cle toothing, a small amount of fresh grease must be at the swing circle toothing.. Check the SLS lubricant cycle counter. This cycle must be higher as the cycles at the CLS during the same time. NOTE: Check the SLS every day. NOTE: Never let the excavator work with a grease shortage. If the teeth get a clear metallic look it is immediately necessary to apply fresh open ring gear lubricant. Find out the reason of this shortage and eliminate this problem. The swing circle toothing of a correct adjusted SLS have a thin layer of open ring gear lubricant. It should be a small amount of fresh open ring gear lubricant around the tooth contact area.
15-54
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LUBRICATION SYSTEMS
Commissioning
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Version 2009/1
15-55
Commissioning
15-56
LUBRICATION SYSTEMS
Version 2009/1
TS 08199-upD-GB-0
HYDRAULIC MINING EXCAVATOR PC4000-6 DIESEL Machine model
Serial numbers
PC4000-6
08199 and up
40 Troubleshooting Troubleshooting procedures Release 0
10/2010
® Copyright 2010 KOMATSU MINING GERMANY GmbH
PC4000-6 S/N 08199 and up
1
2
PC4000-6 S/N 08199 and up
40 Troubleshooting
Contents of this Troubleshooting Manual Part I
Safety
Part II
Introduction & general information for troubleshooting
Part III Mounting locations, connector types and electrical standard values Part IV Troubleshooting by trouble code Part V
Troubleshooting by symptoms
PC4000-6 S/N 08199 and up
3
40 Troubleshooting
4
PC4000-6 S/N 08199 and up
40 Troubleshooting
Table of Contents SAFETY INFORMATION ............................................................................. 15 OVERVIEW .................................................................................................. 16 NORMAL OPERATIONS ....................................................................................................................... REGULAR MAINTENANCE .................................................................................................................. TROUBLESHOOTING, ADJUSTMENTS AND REPAIR ....................................................................... ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR ........................................................................................
16 16 16 16
SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB......................... 17 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR ....................................................................................... 18 UNDERSTANDING THE MACHINE...................................................................................................... PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR ...................................... PREPARATIONS FOR SAFE OPERATION ......................................................................................... FIRE PREVENTION .............................................................................................................................. PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE ......................................................... BURN PREVENTION ............................................................................................................................ PRECAUTIONS WHEN CLEANING CAB GLASS ................................................................................ PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES............................................................ PRECAUTIONS AT JOBSITE ............................................................................................................... STARTING ENGINE.............................................................................................................................. OPERATION..........................................................................................................................................
18 18 18 20 22 23 24 25 26 31 32
PRECAUTION FOR MAINTENANCE ......................................................... 38 GENERAL PRECAUTIONS................................................................................................................... 38 PRECAUTIONS FOR INSPECTION AND MAINTENANCE ................................................................. 46 PRECAUTIONS WITH HIGH PRESSURE Fluid ................................................................................... 47
ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS............................................ 52 INSPECTION OF THE HYDRAULIC SYSTEM ..................................................................................... 52 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS ................. 52 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR ....................................................... 52
SPECIAL SAFETY EQUIPMENT ................................................................ 54 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB .................................. OBJECT HANDLING ............................................................................................................................. LIGHTING.............................................................................................................................................. WARNING BEACON ............................................................................................................................. SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) .............................
PC4000-6D S/N 08199 and up
55 55 55 55 55
5
40 Troubleshooting
Introduction & general information for troubleshooting ........................ 63 Description of this troubleshooting manual ..................................................................................... 63 1. General precautions ................................................................................................................... 63 2. Preparations for work.................................................................................................................. 64 3. Precautions during work ............................................................................................................. 64 Precautions when carrying out any operation........................................................................................ 66 1. Precautions when carrying out removal work ............................................................................. 66 2. Precautions when carrying out installation work......................................................................... 66 3. Precautions when completing the operation............................................................................... 67 Fundamental requirements for troubleshooting............................................................................... 68 Technical documentation ................................................................................................................ 68 Tools ................................................................................................................................................ 68 Reference Guide for Deutsch removal tools ................................................................................... 70 Personnel ........................................................................................................................................ 71 Points to remember when troubleshooting ............................................................................................ 71 Sequence of events in troubleshooting.................................................................................................. 73 Checks before troubleshooting .............................................................................................................. 74 Handling of electric equipment and hydraulic components............................................................ 75 Points to remember when handling electric equipment ................................................................... 75 1. Handling wiring harnesses and connectors ................................................................................ 75 2. Main failures occurring in wiring harness.................................................................................... 75 3. Disconnecting connectors........................................................................................................... 76 Points to remember when handling hydraulic equipment ................................................................ 77 1. Be careful of the operating environment..................................................................................... 77 2. Disassembly and maintenance work in the field......................................................................... 77 3. Sealing openings ........................................................................................................................ 78 4. Do not let any dirt or dust get in during refilling operations......................................................... 78 5. Change hydraulic oil when the temperature is high.................................................................... 78 6. Flushing operations .................................................................................................................... 78 7. Cleaning operations.................................................................................................................... 78 General working procedures .............................................................................................................. 79 1. Air bleeding of various hydraulic parts........................................................................................ 79 2. Cylinder bypass test ................................................................................................................... 80 Information about MTC & Nodes ............................................................................................................ 81 Outline of the MTC and its connector locations ............................................................................... 81 General description of the MTC ...................................................................................................... 82 Information about the LED indications at the MTC .......................................................................... 82 Information about the ICN-D node .................................................................................................. 82 Information about the ICN-V node ................................................................................................... 85 DIP switches at the ICN-D and ICN-V nodes .................................................................................. 87 Sequence of the CAN nodes at the CAN bus ................................................................................. 88 Basics about „How to crimp” .................................................................................................................. 89 Cable colour identification...................................................................................................................... 92
6
PC4000-6D S/N 08199 and up
40 Troubleshooting
Mounting locations, connector types and electrical standard values .. 93 Component location ............................................................................................................................... 93 View onto the superstructure .......................................................................................................... 93 Location of engine electrical parts (1) ............................................................................................. 95 Location of engine electrical parts (2) ............................................................................................. 96 Location of hydraulic components (I) .............................................................................................. 97 Location of hydraulic components (II) ............................................................................................. 99 Location of the remote control valves ........................................................................................... 100 Location of the high pressure sensors .......................................................................................... 102 View onto the SLS and CLS grease barrel and the lubrication cycle components ....................... 103 View onto the cab base with electrical components ...................................................................... 105 Hydraulic oil tank - Location of electrical components .................................................................. 107 Hydraulically operated access ladder ........................................................................................... 109 Overview connector types and connector pin numbers ....................................................................... 111 Standard value table for electrical components ................................................................................... 114 PT100 temperature charts ................................................................................................................... 126
Troubleshooting by trouble code ........................................................... 129 G00001 - Trouble Shut-Off (gate) valve .............................................................................................. 129 View onto the gap of the proximity switch 40B031 ........................................................................ 131 View onto the VHMS settings for the proximity switch 40B031 ..................................................... 132 Wiring diagram related to trouble code G00001 ........................................................................... 133 Wiring diagram related to trouble code G00001 ........................................................................... 134 G00002 - Test speed 1800 1/min engine 1 ......................................................................................... 135 Wiring diagram related to trouble code G00002 ........................................................................... 137 G00003 - Trouble pump controller ....................................................................................................... 138 G00005 - Low hydraulic oil level.......................................................................................................... 142 Wiring diagram (G00005), oil level label, and defined position of the attachment ........................ 144 G00007 - Trouble hydraulic oil level .................................................................................................... 145 Wiring diagram (G00007) and the defined position of the attachment .......................................... 147 G00012 - Central lubrication system grease level too low................................................................... 148 G00013 - Slew ring gear lubr. system grease level too low................................................................. 148 Wiring diagram 1 related to trouble codes G00012 and G00013 .................................................. 152 Wiring diagram 2 related to trouble codes G00012 and G00013 .................................................. 153 G00020 - Trouble Shut-Off (gate) valve (Start blocked) ...................................................................... 154 Wiring diagram related to trouble code G00020 ........................................................................... 156 View onto the VHMS settings for proximity switch 40B031 ........................................................... 157 View onto the gap of the proximity switch 40B031 ........................................................................ 157 G00060 - Fire in the power house ....................................................................................................... 158 Wiring diagram related to trouble code G00060 ........................................................................... 160 G00061 - Trouble monitoring, engine 1 speed too low ........................................................................ 161 Wiring diagram related to trouble code G00061 ........................................................................... 162 G00062 - Trouble monitoring, engine 1 speed too high ...................................................................... 163 Wiring diagram related to trouble code G00062 ........................................................................... 166 G00063 - Trouble monitoring hydraulic oil temp .................................................................................. 167 Wiring diagram related to trouble code G00063 ........................................................................... 168 G00064 - Trouble monitoring hydraulic oil level .................................................................................. 169 Wiring diagram related to trouble code G00064 ........................................................................... 171
PC4000-6D S/N 08199 and up
7
40 Troubleshooting
G00065 - Very low hydraulic oil level................................................................................................... 172 Wiring diagram related to trouble code G00065 ............................................................................ 174 G00066 - Trouble hydraulic oil temperature ........................................................................................ 175 View onto the solenoid valves related to trouble code G00066 .................................................... 177 Hydraulic oil table .......................................................................................................................... 177 G00067 - Trouble battery voltage too high .......................................................................................... 178 Wiring diagram and component location related to trouble code G00067 .................................... 179 G00069 - Trouble monitoring oil temperature gear (PTO 1) ................................................................ 180 Wiring diagram and component location related to trouble code G00069 .................................... 181 G00070 - Trouble oil temperature gear (PTO 1).................................................................................. 182 Location of the PTO gear oil level dipstick and temperature sensor 57B049 ................................ 184 G00071 - Trouble gear lubrication (PTO 1) ......................................................................................... 185 Wiring diagram related to trouble code G00071 ............................................................................ 186 G00081 - Trouble lubrication system ................................................................................................... 187 Operation cycles of the lubrication systems .................................................................................. 188 Wiring diagram 1 related to trouble code G00081 ......................................................................... 189 Wiring diagram 2 related to trouble code G00081 ......................................................................... 190 G00090 - Trouble power supply........................................................................................................... 191 G00099 - Trouble power supply........................................................................................................... 191 Wiring diagram related to trouble codes G00090 and G00099 ..................................................... 192 G00091 - Pilot control cut out .............................................................................................................. 193 View onto the lock lever and the cover of switch 20S105 ............................................................. 194 G00092 - Emergency shut-down at access ladder .............................................................................. 195 G00093 - Emergency shut-down at valve block .................................................................................. 195 G00094 - Emergency shut-down at hydraulic control panel ................................................................ 195 G00095 - Emergency shut-down in cabin............................................................................................ 195 Wiring diagram related to trouble code G00092 - G00095 ............................................................ 196 G00096 - Pilot control cut out .............................................................................................................. 197 Wiring diagram related to trouble code G00096 ............................................................................ 198 G00100 - Maintenance safety switch................................................................................................... 199 Wiring diagram related to trouble code G00100 ............................................................................ 200 G00102 - Switch off wiper.................................................................................................................... 201 G00103 - Faulty switch 20M004 .......................................................................................................... 202 Wiring diagram 1 related to trouble code G00103 ......................................................................... 204 Wiring diagram 2 related to trouble code G00103 ......................................................................... 205 G00104 - Trouble battery current......................................................................................................... 206 Wiring diagram related to trouble code G00104 ............................................................................ 207 G00105 - Trouble battery charging current too low ............................................................................. 208 G00140 - Trouble monitoring X1-1 pressure ....................................................................................... 209 Wiring diagram for the X1-1 pressure sensor 57B085-1 ............................................................... 211 G00141 - Trouble monitoring X2 pressure........................................................................................... 212 Wiring diagram for the X2 pressure sensor 57B086 ..................................................................... 214 G00143 - Trouble monitoring 61B087a................................................................................................ 215 G00144 - Trouble monitoring 61B087b................................................................................................ 215 G00145 - Trouble monitoring 61B087c................................................................................................ 215 G00146 - Trouble monitoring 61B087d................................................................................................ 215 Wiring diagram related to trouble codes G00143 - G00146 .......................................................... 217
8
PC4000-6D S/N 08199 and up
40 Troubleshooting
G00147 - Trouble monitoring gear lubrication (PTO 1) ....................................................................... 218 Wiring diagram related to trouble code G00147 ........................................................................... 220 G00148 - Trouble monitoring fuel level................................................................................................ 221 Wiring diagram and component location (31B063) ....................................................................... 223 G00149 - Trouble monitoring ambient temperature............................................................................. 224 Wiring diagram related to trouble code G00149 ........................................................................... 225 G00151 - Trouble monitoring gear (PTO) oil filter 1 ............................................................................ 226 Wiring diagram related to trouble code G00151 ........................................................................... 228 G00154 - Trouble monitoring return oil filter ........................................................................................ 229 Wiring diagram related to trouble code G00154 ........................................................................... 231 G00155 - Trouble monitoring leak oil filter ........................................................................................... 232 Wiring diagram related to trouble code G00155 ........................................................................... 234 G00159 - Trouble monitoring breather filter......................................................................................... 235 Wiring diagram related to trouble code G00159 ........................................................................... 237 G00160 - Trouble monitoring engine air cleaner 1 .............................................................................. 238 Wiring diagram related to trouble code G00160 ........................................................................... 240 G00161 - Trouble monitoring battery voltage ...................................................................................... 241 Wiring diagram related to trouble code G00161 ........................................................................... 243 G00162 - Trouble monitoring charging-/discharging current ............................................................... 244 Wiring diagram related to trouble code G00162 ........................................................................... 246 G00163 - Trouble monitoring pilot control ........................................................................................... 247 Wiring diagram related to trouble code 00163 .............................................................................. 249 G00164 - Trouble air cleaner 1............................................................................................................ 250 View onto the engine air cleaner ................................................................................................... 251 G00165 - Trouble breather filter hydraulic oil tank............................................................................... 252 Label showing temperature information and defined positions ..................................................... 253 G00166 - Trouble oil filter gear (PTO 1) .............................................................................................. 254 View onto the PTO gear oil filter with pressure sensor 57B027-1 ................................................. 255 G00169 - Trouble return oil filter hydraulic oil tank .............................................................................. 256 G00170 - Trouble leak oil filter hydraulic oil tank ................................................................................. 257 G00176 - Trouble battery voltage too low............................................................................................ 258 Alternator 52G005-1, shunt resistor 11T003, and batteries 71G001-71G004 & 13G008-13G009 ........................................................................................................................... 259 G00177 - Trouble battery charging circuit ........................................................................................... 260 G00178 - Trouble battery charging current too high............................................................................ 261 G00179 - Trouble control pressure X1-1 ............................................................................................. 262 View onto the valve cartridge block 263 G00180 - Trouble pilot pressure X2 too low ........................................................................................ 264 View onto the valve cartridge block with X2 pressure sensor 57B086 & M1.2 ............................. 265 G00181 - Trouble pilot pressure X2 too high ....................................................................................... 266 View onto the valve cartridge block with X2 pressure sensor 57B086 & M1.2 ............................. 267 G00184 - Central lubrication system empty......................................................................................... 268 G00187 - Slew ring gear lubrication system empty ............................................................................. 268 G00185 - Trouble central lubrication system ....................................................................................... 269 G00188 - Trouble slew ring gear lubrication system ........................................................................... 269 Trouble codes G00185 and G00188 - view onto the vent valve ................................................... 271 Allocation of vent valves and end-of-line switches ........................................................................ 272 Wiring diagram related to trouble codes G00185 and G00188 ..................................................... 272 G00186 - Trouble central lubrication system ....................................................................................... 273
PC4000-6D S/N 08199 and up
9
40 Troubleshooting
G00189 - Trouble slew ring gear lubrication system............................................................................ 273 Allocation of the vent valves .......................................................................................................... 273 Time diagram for the operation cycles of the lubrication systems CLS and SLS .......................... 274 Trouble codes G00186 and G00189 - view onto the vent valve ................................................... 275 G00207 - Engine remote oil tank 1 empty ........................................................................................... 276 G00240 - Trouble hydraulic oil temperature ........................................................................................ 277 G00242 - Engine 1 already running ..................................................................................................... 278 G00243 - Fill up fuel tank..................................................................................................................... 279 G00245 - Engine shutdown from ground ............................................................................................. 280 Wiring diagrams related to trouble code G00245 .......................................................................... 281 G00246 - Hydraulic oil temperature ..................................................................................................... 282 G00247 - Slew ring gear house break ................................................................................................. 283 G00252 - Emergency shut-down at access ladder .............................................................................. 284 G00253 - Emergency shut-down at valve block .................................................................................. 284 G00254 - Emergency shut-down at hydraulic control panel ................................................................ 284 G00255 - Emergency shut-down in cabin............................................................................................ 284 Wiring diagram related to trouble codes G00252 - G00255 .......................................................... 285 G00257 - Hydraulic oil temperature ..................................................................................................... 286 G00261 - Maintenance safety switch................................................................................................... 287 Wiring diagram related to trouble code G00261 ............................................................................ 288 G00262 - Trouble screen at hydr. cooler entry clogged....................................................................... 289 Wiring diagram related to trouble code G00262 ............................................................................ 290 G00417 - Communication failure PLC VHMS controller............................................................. 291 Serial harness and ports between MTC and VHMS controller ...................................................... 291 G00420 - Connector sel error .............................................................................................................. 292 G00421 - Farm sys error...................................................................................................................... 293 G00422 - Can-net sys (J1939)............................................................................................................. 294 G00423 - Application sys error ............................................................................................................ 295 G00425 - Settings impossible to take over into the PLC ..................................................................... 296 Overview for G00425: Display (MH801) → VHMS controller → MTC .......................................... 297 G00491 - Communication failure MH800 VHMS-Controller ....................................................... 298 Overview for G00491: Display (MH801) → VHMS controller ........................................................ 299
Troubleshooting by symptoms ............................................................... 301 Symptoms of the engine and related electrical system ................................................................. 301 SEL001 - Engine does not start (engine does not rotate).................................................................... 301 Wiring diagram 1 related to trouble code SEL001 ......................................................................... 303 Wiring diagram 2 related to trouble code SEL001 ......................................................................... 305 SEL002 - Engine stops while in operation ........................................................................................... 306 View onto the fuel system water separator ................................................................................... 308 SEL003 - Engine speed is hunting during boom-up movement........................................................... 309 SEL004 - Engine does not stop ........................................................................................................... 310 SEL005 - Engine lacks output (no power) ........................................................................................... 311 SEL006 - Exhaust smoke is black ....................................................................................................... 313 SEL007 - Oil consumption is excessive............................................................................................... 315 SEL008 - Oil becomes contaminated quickly ...................................................................................... 317 SEL009 - Fuel consumption is excessive ............................................................................................ 319 SEL010 - Oil is in engine coolant......................................................................................................... 321 SEL011 - Oil level rises........................................................................................................................ 323 SEL012 - Coolant temperature becomes too high (overheating)......................................................... 325 10
PC4000-6D S/N 08199 and up
40 Troubleshooting
Symptoms of the hydraulic system ................................................................................................. 327 SHY001 - All the work equipment shows lack of power or slow movement (especially the "boom up" function) ..................................................................................................... 327 SHY002 - Engine speed sharply drops or engine stalls too much....................................................... 329 SHY003 - No work equipment, travel or swing movement .................................................................. 331 SHY004 - Work equipment has too much hydraulic drift ..................................................................... 332 SHY005 - Work equipment has big time lag ........................................................................................ 334 SHY006 - Machine deviates during travel movement.......................................................................... 335 SHY007 - Hydraulic system has lack of power (energy efficiency) ..................................................... 336 SHY008 - Machine does not swing...................................................................................................... 338 SHY009 - Swing acceleration is poor .................................................................................................. 339 SHY010 - Excessive overrun when stopping swing ............................................................................ 341 SHY011 - Floating system without function ......................................................................................... 343 SHY012 - Abnormal noise coming from SRV or MRV ......................................................................... 344 SHY013 - Track tensioning system without function ........................................................................... 345 SHY014 - Ladder does not move, or slow movement ......................................................................... 346 SHY015 - Refilling arm does not move, or slow movement ................................................................ 348 SHY016 - The hydraulic driven grease pump does not move ............................................................. 349 SHY017 - Trouble pump bearing lubrication........................................................................................ 350 SHY018 - Abnormal track chain movement during digging ................................................................. 351 SHY019 - Swing parking brake without function.................................................................................. 352 SHY020 - Travel parking brake without function ................................................................................. 353 Symptoms of the mechanical system.............................................................................................. 354 SME001 - Abnormal noise is made ..................................................................................................... 354 SME002 - Abnormal noise around the PTO / hydraulic pumps ........................................................... 356 SME003 - Vibration is excessive (engine mountings) ......................................................................... 358 SME004 - Vibration is excessive (engine torsion) ............................................................................... 360 SME005 - There is a big shock when stopping swing ......................................................................... 361 SME006 - There is a big abnormal noise when moving/stopping swing ............................................. 362 SME007 - Fan hub bearing noise is abnormal .................................................................................... 364 SME008 - Abnormal noise coming from a travel gearbox ................................................................... 365 SME009 - Abnormal noise coming from the work equipment (lack of grease) .................................... 367 SME010 - Abnormal idler movement ................................................................................................... 369 SME011 - Leak at the PTO shaft seal ................................................................................................. 370 Symptoms of additional systems..................................................................................................... 372 SAD001 - Air conditioner does not work .............................................................................................. 372 View onto the A/C unit ................................................................................................................... 373 SAD002 - Air conditioner compressor clutch is burnt .......................................................................... 374 View onto the A/C compressor and its mounting .......................................................................... 375 SAD003 - Air conditioning system defective (pipes and hoses full of moisture) .................................. 376 SAD004 - Travel alarm does not sound............................................................................................... 377 Wiring diagram related to trouble code SAD004 ........................................................................... 378
PC4000-6D S/N 08199 and up
11
40 Troubleshooting
12
PC4000-6D S/N 08199 and up
1 SAFETY
WARNING IGNORING THE INSTRUCTIONS IN THIS MANUAL COULD LEAD TO SERIOUS INJURY OR DEATH. Please read and make sure that you fully understand the precautions described in this section and the safety labels on the machine. When operating or servicing the machine, always follow these precaution strictly.
13
Safety
CONTENTS
14
1.1
SAFETY INFORMATION .................................................................................................................... 15
1.2
OVERVIEW.......................................................................................................................................... 1.2.1 NORMAL OPERATIONS ........................................................................................................ 1.2.2 REGULAR MAINTENANCE.................................................................................................... 1.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR ........................................................ 1.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR .................................................................
16 16 16 16 16
1.3
SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB. ............................................................... 17
1.4
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR............................ 1.4.1 UNDERSTANDING THE MACHINE ....................................................................................... 1.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR ....................... 1.4.3 PREPARATIONS FOR SAFE OPERATION........................................................................... 1.4.4 FIRE PREVENTION................................................................................................................ 1.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE .......................................... 1.4.6 BURN PREVENTION.............................................................................................................. 1.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS ................................................................. 1.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES ............................................. 1.4.9 PRECAUTIONS AT JOBSITE................................................................................................. 1.4.10 STARTING ENGINE ............................................................................................................... 1.4.11 OPERATION ...........................................................................................................................
18 18 18 18 20 22 23 24 25 26 31 32
1.5
PRECAUTION FOR MAINTENANCE ................................................................................................. 1.5.1 GENERAL PRECAUTIONS .................................................................................................... 1.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE................................................... 1.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID..................................................................
38 38 46 47
1.6
ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS .......... 1.6.1 INSPECTION OF THE HYDRAULIC SYSTEM ...................................................................... 1.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS... 1.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR.........................................
52 52 52 52
1.7
SPECIAL SAFETY EQUIPMENT........................................................................................................ 1.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB ................... 1.7.2 OBJECT HANDLING .............................................................................................................. 1.7.3 LIGHTING ............................................................................................................................... 1.7.4 WARNING BEACON............................................................................................................... 1.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) ..............
54 55 55 55 55 55
SPECIAL SAFETY EQUIPMENT
62
Safety
Part II
40 Troubleshooting
Part II
Introduction & general information for troubleshooting Description of this troubleshooting manual In this manual you find troubleshooting information which should assist you when troubleshooting. The content of this manual is divided in 5 parts, which are titled: Part I
Safety
Part II
Introduction and general information for troubleshooting
Part III Mounting locations, connector types, and electrical standard values Part IV Troubleshooting by trouble code Part V
Troubleshooting by symptoms
Part II contains Safety Notes and Precautions which should be followed during troubleshooting work. Furthermore fundamental requirements and points to remember when troubleshooting are given. Also you find recommendations concerning the sequence of working steps, checks which should be done before troubleshooting, how to handle electric and hydraulic equipment, and how to perform basic working procedures. Part III provides you with information about mounting locations of components, different connector types as they are used in your machine, and standard values for electrical components as a quick reference. In Part IV troubleshooting charts are listed in the numerical sequence of trouble codes as they are stored in the control system. The monitoring system follows the logic of defined flow charts. If predetermined conditions occur, the VHMS displays relevant trouble codes and messages. In Part V troubleshooting charts are listed for various engine electrical, mechanical, and hydraulic problems. These charts are showing symptoms of any malfunction which the monitoring system can not detect under the particular conditions. Therefore these malfunctions are not indicated by stored trouble codes or messages via VHMS. Nevertheless the troubleshooting charts in Part IV and Part V can not cover all eventual malfunctions which may possibly occur. In such cases a general inspection of the suspected system is necessary. Furthermore, it is not necessary that you strictly follow the given troubleshooting charts in every case. It is important to find the cause for any trouble in the easiest way and in the shortest time. In most times the relevant flow chart will help you to be successful.
1.
General precautions Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. 1)
Before carrying out any greasing or repairs, read all the safety plates stuck to the machine. For the locations of the safety plates and detailed explanation of precautions, see the Operation and Maintenance Manual.
2)
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, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
3)
When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
PC4000-6D S/N 08199 and up
63
40 Troubleshooting
Part II
• Always wear safety glasses when hitting parts with a hammer. • Always wear safety glasses when grinding parts with a grinder, etc. 4)
When carrying out any operation with 2 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 warning signs in the operator's compartment.
5)
Only qualified workers must carry out work and operation which require license or qualification.
6)
Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.
7)
If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work.
8)
Before starting work, warm up your body thoroughly to start work under good condition.
Safety points
2.
3.
1
Good arrangement
2
Correct work clothes
3
Following work standard
4
Making and checking signs
5
Prohibition of operation and handling by unlicensed workers
6
Safety check before starting work
7
Wearing protective goggles (for cleaning or grinding work)
8
Wearing shielding goggles and protectors (for welding work)
9
Good physical condition and preparation
10
Precautions against work which you are not used to or you are used to too much
Preparations for work 1)
Before adding oil or making any repairs, park the machine on hard and level ground. Isolate the machine according to local regulations.
2)
Before starting work, make sure that the work equipment is lowered to the ground. Also make sure that the maintenance safety switch (S58) is switched OFF and locked with a padlock. In addition hang up warning signs.
3)
When disassembling or assembling, support the respective unit with blocks, jacks, or stands as necessary before starting work.
4)
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 1) Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits.
64
PC4000-6D S/N 08199 and up
Part II
40 Troubleshooting
3) Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts. 4) Before starting work, remove the leads from the negative (–) terminal first. 5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 6) When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. 7) When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires. 8) When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires. 9) As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. 10) Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused 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 operated. 11) 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. In addition, check that connecting parts are correctly installed. 12) When assembling or installing parts, always tighten them to the specified 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. 13) When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 14) When measuring hydraulic pressure, check that the measuring tools are correctly assembled. 15) 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. 16) If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.
PC4000-6D S/N 08199 and up
65
40 Troubleshooting
Part II
Precautions when carrying out any operation When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation. 1.
Precautions when carrying out removal work
•
If the coolant contains antifreeze, dispose of it correctly.
•
After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
•
When draining oil, prepare a container of adequate size to catch the oil.
•
Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling.
•
To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires.
•
Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
•
Check the number and thickness of the shims, and keep in a safe place.
•
When raising components, be sure to use lifting equipment of ample strength.
•
When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
•
Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal.
•
After disconnecting any piping during disassembly operations make sure to use the correct plugs and seals when connecting the piping again.
2.
Precautions when carrying out installation work
•
Tighten all bolts and nuts (sleeve nuts) to the specified torque.
•
Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
•
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
•
Bend the cotter pins and lock plates securely.
•
When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 – 3 drops of adhesive.
•
When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant.
•
Clean all parts, and correct any damage, dents, burrs, or rust.
•
Coat rotating parts and sliding parts with engine oil.
•
When press fitting parts, coat the surface with anti-friction compound (LM-P).
•
After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
•
When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely.
•
When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook.
•
When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side. When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1) Start the engine and run at low idle. 2) Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times, stopping the cylinder 100 mm from the end of its stroke. 3) Next, operate the hydraulic cylinder 3 - 4 times to the end of its stroke. 4) After doing this, run the engine at normal speed. When using the machine for the first time after repair or long storage, follow the same procedure.
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3.
Precautions when completing the operation 1) Refilling with coolant, oil and grease • If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate the coolant through the system. Then check the coolant level again. • If any engine component has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. • If the piping or hydraulic equipment has been removed, always bleed the air from the system after reassembling the parts. For details, see “Bleeding air”. • Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
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Fundamental requirements for troubleshooting Technical documentation The personnel in charge of troubleshooting must have permanent and easy access to the following appropriate and up-to-date documents of the relevant hydraulic excavator: •
Electric Circuit Diagram
•
Hydraulic Circuit Diagram
•
Operation & Maintenance Manual
•
Service Manual
•
Cross-Reference Table (in process)
•
Cummins Troubleshooting and Repair Manual for the QSK60 Engine (SDA 12V 160 Komatsu Engine)
•
Inspection and Maintenance Manual of the equipped Fire Suppression System (optional equipment)
•
Inspection and Maintenance Manual of the equipped Air Conditioning System
Without the above documents troubleshooting is ineffective and unreliable! Tools For proper troubleshooting and subsequent repairs it is essential to have access to complete facilities which include appropriate measuring instruments as well as necessary tools for the repair of a hydraulic excavator. For troubleshooting, testing, and repair the following tools are obligatory. Multi Tester
Electrical Cable Set
The cable set includes: 732 702 40 732 703 40 732 704 40 732 705 40 732 706 40 732 707 40
P/N 232 756 40
68
Measuring cable Measuring cable Probe tip Probe tip Crocodile clip Crocodile clip
P/N 232 496 40
Clamp-On Ammeter
Deutsch T-Box
CAN T-Box
P/N 232 756 40
P/N 232 762 40
P/N 942 136 40
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Part II
40 Troubleshooting
Magnetic Stick
Insulation Pliers
Deutsch Crimp Pliers
P/N 232 712 40
P/N 232 663 40
P/N 793 729 73
Deutsch Test-Cable
Cable Stripping Knife (4 - 16 mm)
Digital Dial Gauge
In preparation
P/N 232 699 40
P/N 794 537 73
Infrared thermometer
RPM Tester
Digital hydr. test gauge
P/N 232 665 40
P/N 232 551 40
P/N 232 720 40
CoDeSys HMI software
Cables for CoDeSys & VHMS
VHMS techn. analysis tool box
Standard LAN cable
CoDeSys HMI
for CoDeSys (2 m), without P/N
Basis Software Tool (Visualization)
VHMS download cable (serial connection)
P/N 941 825 40
PC4000-6D S/N 08199 and up
P/N 894 580 40
P/N 792 504 73
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Deutsch Removal Tools
Standard Deutsch removal tools: 932 634 40 932 632 40 932 633 40 932 631 40
1.00 mm2 1.50 mm2 1.00 - 2.00 mm2 3 - 8 - 16 mm2
Also refer to the next chart
Reference Guide for Deutsch removal tools
70
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40 Troubleshooting
Personnel Only authorized and trained personnel s hould perform troubleshooting and the resulting repairs. Work on the electrical system and equipment of the machine must be carried out only by a skilled electrician or by instructed persons under the supervision and guidance of a skilled electrician and in accordance with electrical engineering rules and regulations. Work on the hydraulic system must be carried out only by personnel with special knowledge and experience of the hydraulic equipment. Work on the Fire Suppression System must be carried out only by certified persons.
Points to remember when troubleshooting Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted. When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near. If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause burns, so wait for the engine to cool down before starting troubleshooting. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. When disconnecting wiring, always disconnect the negative (–) terminal of the battery first. When removing the plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly. The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1.
When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any failure occurs: • Parts that have no connection with the failure or other unnecessary parts will be disassembled. • It will become impossible to find the cause of the failure.
It will also cause a waste of man hours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. 2.
Points to ask user or operator: 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before?
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3.
Check before troubleshooting 1) Check the oil level 2) Check for any external leakage of oil from the piping or hydraulic equipment 3) Other maintenance items can be checked externally, so check any item that is considered to be necessary.
4.
Confirming failure • Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation etc. When operating the machine to re-enact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse.
5.
Troubleshooting • Use the results of the investigation and inspection in items 2-4 to narrow down the causes of failure, then use the troubleshooting flowchart to locate the position of the failure exactly. The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information.
6.
Measures to remove the root cause of any failure Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.
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Sequence of events in troubleshooting
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Checks before troubleshooting Item
Lubricating oil, Coolant
Inspection
Hydraulic, mechanical equipment
Electrical compoments
74
Remedy
1.
Check of level and type of fuel
-
Add fuel
2.
Check of fuel for foreign matter
-
Clean and drain
3.
Check of fuel filter
-
Replace
4.
Check of hydraulic oil level
-
Add oil
5.
Check of hydraulic oil strainer
-
Clean and drain
6.
Check of swing machinery oil level
-
Add oil
7.
Check of level and type of engine oil (in oil pan)
-
Add oil
8.
Check of coolant level
-
Add coolant
9.
Check of dust indicator for clogging
-
Clean or replace
-
Replace
10. Check of hydraulic oil filter
Electrical equipment
Criterion
1.
Check of battery terminals and wiring for looseness and corrosion
-
Retighten or replace
2.
Check of alternator terminals and wiring for looseness and corrosion
-
Retighten or replace
3.
Check of starting motor terminals and wiring for looseness and corrosion
-
Retighten or replace
1.
Check for abnormal noise and smell
-
Repair
2.
Check for oil leakage
-
Repair
3.
Bleeding air
-
Bleed air
1.
Check of battery voltage (with engine stopped)
22 - 24V
Replace
2.
Check level of battery electrolyte
-
Add or replace
3.
Check of wires for discoloration, burn, and removal of the isolation cover
-
Replace
4.
Check for released wire clamp and dropping wire
-
Repair
5.
Check of wires for wetness (in particular check connectors and terminals for wetness)
-
Disconnect the connectors and dry
6.
Check for broken or corroded fuses
-
Repair
7.
Check alternator voltage (engine running at over half throttle)
8.
Check battery relay for operating sound (when starting switch is turned ON or OFF)
After operating for several minutes: 27.5 - 29.5V
Replace
-
Replace
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40 Troubleshooting
Handling of electric equipment and hydraulic components Points to remember when handling electric equipment 1.
Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses.
2.
Main failures occurring in wiring harness
1) Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces.
2) Defective criming or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.
3) Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.
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4) High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if highpressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. Accordingly, take care not to splash water over the connector. The connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be short-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it. 5) Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air. 3.
Disconnecting connectors 1)
When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. Never pull with one hand.
2) •
76
When removing from clips Both of the connector and clip have stoppers, which are engaged with each other when the connector is installed.
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40 Troubleshooting
•
When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers. If the connector is twisted up and down or to the left or right, the housing may break.
3)
Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful. 1.
Be careful of the operating environment Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust.
2.
Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to check the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be checked with special test equipment.
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Part II
Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out onto the ground, but collect it and ask the customer to dispose of it, or take it back with you for disposal.
4.
Do not let any dirt or dust get in during refilling operations Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.
5.
Change hydraulic oil when the temperature is high When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil.
6.
Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.
7.
Cleaning operations After repairing the hydraulic equipment (pump, control valve etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultra fine (about 3 µ) particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device.
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General working procedures 1.
Air bleeding of various hydraulic parts
A)
Air bleeding from the hydraulic pumps The air bleeding procedures for the hydraulic pumps are described in the following manuals. Refer to these manuals as necessary.
•
Operation & Maintenance Manual, section HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER
•
PARTS & SERVICE NEWS AH01513 (latest version) Precautions for air bleeding from the hydraulic pumps Before starting the air bleeding work explained above, run the engine at low idle for 10 minutes.
B)
Air bleeding from hydraulic cylinders 1)
Start the engine and keep it running at low idle for 5 minutes.
2)
Running the engine at high idle raise and lower the respective cylinders 12 to 15 times. Be careful not to apply the relief pressure, stopping the piston rod approx. 100 mm before its stroke end.
3)
Apply the relief pressure smoothly by extending the piston rod to its stroke end and with the engine running at high idle.
4)
For bleeding air from the arm cylinder and bucket cylinder, follow the same steps explained in items 2) and 3) above.
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2.
Part II
Cylinder bypass test The cylinder bypass test can be performed in order to check if a hydraulic cylinder has an internal leakage. A cylinder with an internal leakage generates a higher temperature (at operating temperature of the machine) than a hydraulic cylinder which has no internal leakage. For a bypass test at mining machines always use an infrared thermometer, refer to section Fundamental requirements for troubleshooting in this manual. Refer to chapter Safety and observe all safety notes for the following procedure.
Procedure 1. Before starting the bypass test, always make sure that the hydraulic circuit which is to be tested, has reached the operating temperature (T3). 2. Bring the concerning cylinders in their end position → rod end completely moved in or out. 3. Keep up the system pressure in the concerning hydraulic circuit for approx. 10 minutes. 4. During these 10 minutes, measure the cylinder temperature in the piston area of both cylinders, using an infrared thermometer. If any cylinder seal package is leaking, hydraulic oil is now pressed through this leakage, which causes the temperature to increase (90°C and higher) within a few minutes.
Case 1 Seal package is leaking in 1 cylinder only
Seal package is leaking in both cylinders
Defective cylinder: Temperature increase during the test, increased temperature approx. 90°C
Both defective clinders: Temperature increase during the test, increased temperature approx. 90°C
Proper clinder: No temperature increase during the test, normal temperature approx. 70°C
-
Remark: The hydraulic oil will heat up at the MRV, not in the proper cylinder.
80
Case 2
Remark: A strong drift occurs.
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40 Troubleshooting
Information about MTC & Nodes 1.
Outline of the MTC and its connector locations During troubleshooting always make sure to use your wiring diagrams which are assigned to your machine. Due to variable requirments in many aspects, the samples of wiring diagrams, MTC & nodes shown in this manual can not meet the actual state of each machine in every case. Inputs and outputs of MTC & nodes are not identical in construction. The shown connector locations in the below illustration are exemplarily. MTC connectorsRH
MTC connectors LH
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Part II
General description of the MTC For a general description of the MTC refer to your SERVICE MANUAL:
3.
Chapter
14. VEHICLE HEALTH MONITORUNG SYSTEM
Section
14.7 GLOBAL LAYOUT OF THE MTC CONTROL SYSTEM
Information about the LED indications at the MTC
*The LEDs are showing operation conditions and they also blink out those trouble codes which cause a shutdown. The LED function is described in the OPERATION & MAINTENANCE MANUAL:
4.
Chapter
3. OPERATION
Section
3.8.3 MASTER TURBO CONTROLLER MTC - LED INDICATIONS
Information about the ICN-D node Intelligent Can Node - Digital (Dashboard) with max. 64 free programmable in- and outputs.
For further information also refer to the SERVICE MANUAL, chapter 14. VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM
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View onto an ICN-D node without wiring
1.
ICN-D node
2.
DIP switches
3.
Status LEDs
4.
Allocation of the Status LEDs
5.
Connector X0 (power supply 24V, ground, CAN bus 3x)
6.
Connector X1 - X8 (in- & outputs)
7.
Ground receptacle
For details about the DIP switches refer to section 6. DIP switches at the ICN-D and ICN-V nodes in this manual.
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View onto the Status LEDs at the ICN-D node
1.
Allocation of the Status LEDs
2.
ICN-D node unit
3.
Status LED (4x)
General information on the LED control The node status (ICN-D) is indicated by the following 4 LEDs. •
PWR LED (red = RESET, green = normal operation)
•
CAN LED (CAN-Run and CAN-Error)
•
ERR LED (red and green)
•
DIAG LED (red and green)
Overview over all possible LED conditions (all LEDs red & green) LED
PWR
State
Meaning
OFF red green
Indication of Logic Power Supply and Operational State. Vcc not ON! System in RESET condition System RUNNING Indication of CAN Communication.
CAN
ECU ERR ECU DIAG
84
green blinking green single flash green ON red OFF red ON
Pre-operational Stopped Operational No error in the CAN bus CAN bus OFF
ERR + DIAG OFF ERR green ON ERR red ON ERR red ON + DIAG red ON ERR green + DIAG red blinking alternately DIAG green blinking
No errors or warnings present Internal warning present Internal error present An internal trouble code is set An internal trouble code is set Internal error or warning present (depending on the state of the ERR LED)
PC4000-6D S/N 08199 and up
Part II
5.
40 Troubleshooting
Information about the ICN-V node Intelligent Can Node - Variable (Valve) with max. 8 variable free programmable in- and outputs. The ICN-V node box may contain 1 or 2 node units. Each node unit is connected with a 55-pin central connector. View onto an ICN-V node
1.
ICN-V node box (dual unit)
2.
V-node connector, 55 pins (LH)
3.
V-node connector, 55 pins (RH)
4.
V-node socket, 55 pins
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View onto an open ICN-V node and its DIP-switches
86
1.
ICN-V node, taken out of the node box
2.
DIP-switches of an ICN-V node
PC4000-6D S/N 08199 and up
Part II
6.
40 Troubleshooting
DIP switches at the ICN-D and ICN-V nodes
General information 1.
The DIP switches 1 - 7 define the node number (binary), which is node #17 in the above illustration.
2.
The DIP switches 8 - 10 define the CAN bus transfer speed (kbaud).
3.
The adjustment principle and function of the DIP switches is the same for the ICN-V and ICN-D nodes.
Note •
The DIP switches of a new node unit are pre-adjusted ex factory.
•
If the DIP adjustment needs to be rechecked e.g. for troubleshooting, refer to he CoDeSysy Visualization or to the Wiring Diagram. The individual patterns of the DIP switches are shown there for each node unit.
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7.
Part II
Sequence of the CAN nodes at the CAN bus In case of a multiple trouble, the VHMS monitor displays only one faulty node. The faulty node which is closest to the MTC is displayed first. 1
The nodes in this direction are displayed first: MTC → Hydraulic tank
2
The nodes in this direction are displayed thereafter: MTC → operator‘s cab
Refer to the following chart, which lists the nodes in their sequence at the CAN bus. Component code
Component type
Location
20K309
ICN-D
Operator‘s cab
20K310
ICN-V
Operator‘s cab
11K301
MTC
Cab base
11K302
ICN-D
Cab base
11K303
ICN-V
Cab base
11K304
ICN-V
Cab base
11K305
ICN-V
Cab base
51K317
ICN-D
Machinery house - engine room
51K318
ICN-V
Machinery house - engine room
51K319
ICN-V
Machinery house - engine room
56K314
ICN-D
Machinery house - pump area
56K315
ICN-V
Machinery house - pump area
56K316
ICN-V
Machinery house - pump area
40K311
ICN-D
Hydraulic tank
40K312
ICN-D
Hydraulic tank
40K313
ICN-V
Hydraulic tank
2
1
Hint for troubleshooting The above system provides an advantage for effective troubleshooting. In case of an eventual CAN bus interruption use the CAN testbox and search for the interruption in the line from the displayed CAN node towards the MTC.
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Basics about „How to crimp” Stripping a wire for use with the HDT 48 crimp tool 1. Choose the correct wire cross section [mm2] respectively AWG for the contact being used. 2. Measure from the end of the wire the recommended strip length according to the contact size. 3. Place the wire into the stripping tool at the recommended strip length. Strip the wire according to stripping tool instructions. 4. After stripping, a small piece of the insulation shouldcome off.
5. Check for any broken strands or for a dent in the wire. If either exist, the wire is damaged and should be cut and stripped again. 6. Measure the exposed strands to be sure the crimp length is correct.
View onto the Deutsch crimp tool HDT 48
Crimp range: 0.35 - 3.0 mm2 / AWG 12 - 22
Basic adjustment of the wire size at the Deutsch crimp tool HDT 48
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Wire cross section units in mm2 and AWG The above scale of the crimping tool uses the units mm2 and AWG (American Wire Gauge). Free conversion charts and/or free calculators to convert between mm2 and AWG are open to the public. Refer to the following sample illustration of an AWG gauge.
Crimping instructions (for Deutsch crimp tool HDT 48) 1. Strip the insulation from the wire. Refer to Stripping a wire for use with the HDT 48 crimp tool 2. Raise the selector knob and rotate it until the arrow is aligned with the wire gauge to be crimped. Refer to illustration Z 28059-2a
3. Loosen the lock nut (1) and turn the adjusting screw (2) in until it stops.
4. Insert a contact into the insertion point (3), turn the adjusting screw clockwise out until the contact is flush or a bit above flush with the indentor cover. Tighten the lock nut.
5. Insert the wire into the contact (4). The contact must be centered between the indicators. Close the handles until the handles stop. 6. Release the handles and remove the crimped contact.
7. After completion, the correct assembly can be checked visually. When stripped, the insulation should expose a conductor length that will pass beyond the inspection hole in the contact. There should be about 0.63 to 2.54 mm of free conductor between the contact and the insulation on the wire.
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After crimping, check for: 1.
Damaged wire strands
2.
Missing wire strands
3.
Wire strands not entering the contact barrel or splayed wires
4.
Wire not inserted to the proper depth in the contact, not visible through the inspection hole
If any of the above conditions exists, please discard the contact, re-cut and strip the wire, and start the crimping process over.
Proper crimp
Crimp is OK if: 1.
Conductor strands must be visible through the inspection hole.
2.
Crimp centered between the inspection hole and the crimp barrel end.
3.
Insulation gap: 0.66 to 2.54 mm
For more detailed crimp specifications refer to the instructions which are delivered with the crimp tool.
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Cable colour identification Colour (English)
Colour (German)
Short Marks Standard IEC 60757*
German (current)
German (previous)
BK
SW
sw
Braun
BN
BR
br
Rot
RD
RT
rt
Orange
Orange
OG
OR
or
Yellow
Gelb
YE
GE
ge
Green
Grün
GN
GN
gn
Blue
Blau
BU
BL
bl
Black
Schwarz
Brown Red
Violet
Violett
VT
VI
vi
Grey
Grau
GY
GR
gr
White
Weiß
WH
WS
ws
Pink
Rosa
PK
RS
rs
Turquoise
Türkis
TQ
TK
tk
* IEC: International Electrotechnical Commission
Refer to the above table if the identification of cable colours in wiring diagrams may be unclear due to different existing systems of colour codes.
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Part III
Mounting locations, connector types and electrical standard values 1.
Component location
1.1 View onto the superstructure
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Part III
Legend for illustration Z 27752 - View onto the superstructure (1)
Hydraulically operated access ladder
(2)
Battery main switches (batteries G1-G4)
(2a)
Battery main switches (batteries G8-G9)
(3)
Lift cylinder for access ladder
(4)
Batteries, location below the catwalk (batteries G1-G4)
(5)
Control switch for access ladder
(6)
Emergency engine shut down switch
(7)
Fuel tank
(8)
Cab base, contains the electronic components of the VHMS system, the electrical switch boards, and the batteries G8 & G9
(9)
Side window of operator’s cab
(10)
Swing circle guard
(11)
Emergency escape ladder
(12)
Engine air cleaners
(13)
Exhaust mufflers
(14)
Air duct
(15)
Extinguishing agent tank assemblies, only on machines equipped with a fire detection, actuation and suppression system
94
(16)
Counterweight
(17)
Main control valves & remote control valves with high pressure in-line filters
(18)
Hydraulic oil reservoir
(19
Return oil filters and leak oil filter
(20)
Hydraulic oil cooler
(21)
Swing machinery
(22)
Distributor manifold
(23)
Swing circle pinion Lubrication System (SLS)
(24)
Central Lubrication System (CLS)
(25)
Node box, location 40
(26)
Node box, location 51
(27)
Node box, location 56
PC4000-6D S/N 08199 and up
Part III
40 Troubleshooting
1.2 Location of engine electrical parts (1)
PC4000-6D S/N 08199 and up
95
40 Troubleshooting
Part III
1.3 Location of engine electrical parts (2)
96
PC4000-6D S/N 08199 and up
Part III
40 Troubleshooting
1.4 Location of hydraulic components (I)
PC4000-6D S/N 08199 and up
97
40 Troubleshooting
Part III
Legend for illustration Z 21632f Solenoid valves (57Q505)
Slew parking brake operating pressure
(57K506a-1) Cooler fan RPM control, minimum speed (57K506b-1) Cooler fan RPM control, medium speed (57Q516)
Travel parking brake operating pressure
(57K517)
Qmin control (pump control system)
(57K517a)
½ Qmax (reduced oil flow at cold oil [below T2])
(57K553-1)
"Reduction pre-load pressure PTO gear lubrication - oil cooler”
(57K561-1)
X1 pressure, pumps 1 – 4
(57K620)
Hydraulic swing brake, operating pressure
(57Q623a)
Ladder, raise
(57Q623b)
Ladder, lower
(57Q624a)
Refilling arm, raise
(57Q624b)
Refilling arm, lower
(57Q624c)
Refilling arm stop, hold position
(57Q625)
Ladder, fast movement
(57K626)
Flow reduction swing (pump 1)
(57Q627)
Proportional swing brake pressure
(57K630)
Fixed pump No. 1 (max. flow, X1 = 45 bar)
(57K631)
Fixed pump No. 3 (max. flow, X1 = 45 bar)
(57K636)
Engine radiator fan speed (proportional valve)
(57K646)
Energy Efficiency (pump No. 2 + No. 4)
(57K647)
Energy Efficiency (pump No. 3)
(57K648)
Energy Efficiency (pump No. 1)
Filters (33)
Pilot pressure
(34.1)
Hydraulic oil cooler fan drive
(34.2)
Engine radiator fan drive
(36)
PTO gear lubrication
Miscellaneous (29)
Pressure relief valve – PTO gear lubrication
(31.1)
Pressure relief valve – hydraulic oil cooler fan drive, with solenoid valve 57K506a/b-1 for fan RPM control
(31.2)
Pressure relief valve - engine radiator fan drive, with proportional solenoid valve 57K636-1 for fan RPM control
98
(47)
Pressure reducing valve – track tensioning system (35 bar)
(124)
Pressure relief valve medium speed cooler fan
(152)
Pressure reducing valve – Energy Efficiency (X3 ~ 18 bar, pre-adjustment)
(252.1)
Pressure reducing valve for pilot pressure X2 (45 bar)
(252.2)
Pressure relief valve for pump support pressure X4 (60 bar)
(253.1)
Change-over valve – electronic pump regulation or hydraulic constant regulation
(253.2)
Pressure reducing valve – hydraulic constant regulation
(255.4)
Pressure reducing valve – ½ Qmax
(257.1)
Pressure relief valve – safety valve for travel brake / track tensioning system (55 bar)
(258.3)
Pressure relief valve – safety valve for hydraulic access ladder (70 bar)
PC4000-6D S/N 08199 and up
Part III
40 Troubleshooting
1.5 Location of hydraulic components (II)
Legend for illustration Z28188 (40B015)
Temperature sensor
(57B049-1)
Gear oil temperature sensor
(59B162)
Pressure sensor suction oil tank
PC4000-6D S/N 08199 and up
99
40 Troubleshooting
Part III
1.6 Location of the remote control valves
100
PC4000-6D S/N 08199 and up
Part III
40 Troubleshooting
Legend for illustration Z 21636e - Location of the remote control valves Remote control unit schematic code
Directional solenoid
Proportional solenoid
61K540
Function BHA
FSA Boom raising
61K573 61K541
Boom lowering
61K538
Stick extending
Clam closing
Stick retracting
Clam opening
Bucket filling
Bucket filling
Bucket dump
Stick extending
61K572 61K539 (15.1) 61K536 61K571 61K537 61K534
L.H. crawler reverse 61K570
61K535
L.H. crawler forward
61K524
L.H. swing 61K565
61K525
R.H. swing
61K522
Bucket filling (curl) 61K564
(14.1) 61K523
Bucket emptying
61K520
Boom raising 61K563
61K521
Boom lowering
61K526
R.H. swing 61K566
61K527
L.H. swing
61K532 (14.2)
Boom lowering
Bucket filling
Boom raising
Boom raising
61K569 61K533 61K530
Stick extending 61K568
61K531
Stick retracting
61K546
Boom raising 61K576
61K547
Boom lowering
61K544
Bucket filling (curl) 61K575
61K545
Bucket emptying
(15.2) 61K542
Stick extending 61K574
61K543
Stick retracting
61K528
R.H. crawler forward 61K567
61K529
PC4000-6D S/N 08199 and up
R.H. crawler reverse
101
40 Troubleshooting
Part III
1.7 Location of the high pressure sensors
Legend for illustration Z28189
102
(61B087a)
Pressure sensor – Input pressure control block I
(61B087b)
Pressure sensor – Input pressure control block II
(61B087c)
Pressure sensor – Input pressure control block III
(61B087d)
Pressure sensor – Input pressure control block IV
PC4000-6D S/N 08199 and up
Part III
40 Troubleshooting
1.8 View onto the SLS and CLS grease barrel and the lubrication cycle components
PC4000-6D S/N 08199 and up
103
40 Troubleshooting
Part III
Legend for illustration Z 28063-6 View onto the SLS and CLS grease barrel and the lubrication cycle components
(1)
Lubrication pump drive (hydraulic cylinder)
(2)
Flow control valve (19 - 21 double strokes / min)
(3)
Pressure relief valve
(4)
Main pump control solenoid valve (pump on / off)
(5)
Hydraulic oil return line
(6)
Hydraulic oil supply line (60 bar, X4 pressure)
(7)
Lubricant pressure gauge
(8)
Lubricant in-line filter
(9)
Lubricant pressure release solenoid valve
(10)
Lubricant supply line from pump to injector
(11)
Lubricant release line
(12)
End-line switch
(13)
Lubricant injector
(14)
Lubricant feed line to swing ring gear
(15)
Lubricant pump
(16)
Lubricant points (bearings) CLS only
(17)
Lubricant container
(18)
Breather filter for lubricant container
(19)
Grease level sensor (sonar sensor)
(20)
Test port lubricant pump drive pressure
(21)
Electrical terminal box
(22)
Dummy wheel, SLS only
104
PC4000-6D S/N 08199 and up
Part III
40 Troubleshooting
1.9 View onto the cab base with electrical components
PC4000-6D S/N 08199 and up
105
40 Troubleshooting
Part III
Legend for illustration Z 27364 - Cab base with electrical components
106
(1)
Resistor and diode array (11R005, 11R013, 11R016 and 11R017)
(2)
Node, type ICN-D (11K302)
(3)
MTC-controller (11K301)
(4)
Node, type ICN-V (11K305)
(5)
Dual node, type ICN-V (11K303/11K304)
(6)
Controller battery (13G008)
(7)
Controller battery (13G009)
(8)
VHMS controller (10K300)
(9)
Battery main switch (71Q002) for controller batteries
(10)
Electronic load limiting control (RC4-4)
PC4000-6D S/N 08199 and up
Part III
40 Troubleshooting
1.10 Hydraulic oil tank - Location of electrical components
PC4000-6D S/N 08199 and up
107
40 Troubleshooting
Part III
Legend for illustration Z26983 - Hydraulic oil tank
108
40B004
Hydraulic oil level sensor (minimum level indication)
59B015
Hydraulic oil temperature sensor
40B050
Hydraulic oil level sensor (refill level indication)
40B105
Hydraulic oil level - pressure transducer
59B162
Hydraulic oil level - pressure transducer
40B163
Pressure return-oil chamber - pressure transducer
40B164
Pressure leak-oil chamber - pressure transducer
40B165
Pressure oil cooler - pessure transducer
40B166
Pressure pre-load (back pressure) valve - pressure transducer
40G018
Hydraulic oil transfer pump
40B031
Proximity switch for shut-off gate valve
40B267
Thermostat (TT only, hydraulic oil pre-heating)
PC4000-6D S/N 08199 and up
Part III
40 Troubleshooting
1.11 Hydraulically operated access ladder
PC4000-6D S/N 08199 and up
109
40 Troubleshooting
Part III
Legend for illustration Z 27964 - Hydraulically operated access ladder
(A)
Access ladder in upper position (working position)
(B)
Access ladder in lowered position
(1)
Stop bar
(2)
Pull chain for emergency lowering of the access ladder
(3)
Hydraulic cylinder
(70B091)
Monitor and control sensor This sensor monitors the ladder position and controls the moving speed of the ladder. In case the sensor (70B122) fails to function properly, the sensor (70B091) prevents unintended movement of the ladder.
(70B122)
Safety sensor, located on ladder pivot bracket Cut out of the pilot control system and actuation of the hydraulic swing brake with the ladder in lowered position.
(70S084)
Ladder control switch for lowering and lifting the ladder
(70S084a)
Safety switch for emergency lowering of the access ladder. When the chain is being pulled down with the engine running, the pilot control system is made inoperative preventing further movement of the shovel.
110
PC4000-6D S/N 08199 and up
Part III
2.
40 Troubleshooting
Overview connector types and connector pin numbers The terms male and female refer to the connector pins, while the terms male housing and female housing refer to the mating portion of the connector housing parts. Male (female housing)
Female (male housing)
2 pins DT04-2P (Deutsch)
2 sockets DT06-2S (Deutsch)
3 pins DT04-3P (Deutsch)
3 sockets DT06-3S (Deutsch)
4 pins DT04-6P (Deutsch)
4 sockets DT06-6S (Deutsch)
PC4000-6D S/N 08199 and up
111
40 Troubleshooting
Part III
31-pole connector with aluminium housing
21-pole connector with plastic housing
Grease barrel connector
CAN bus connector
CAN feed-through into node box
Deutsch connectors HD 34/36-18-8-S…
Picture shows socket rear insert.
112
PC4000-6D S/N 08199 and up
Part III
40 Troubleshooting
Deutsch connectors HD 34/36-18-14-S… Picture shows socket rear insert.
Deutsch connectors HD 34/36-24-14-S… Picture shows socket rear insert.
Deutsch connectors HD 34/36-24-21-S… Picture shows socket rear insert.
Deutsch connectors HD 34/36-24-31-S… Picture shows socket rear insert.
PC4000-6D S/N 08199 and up
Deutsch connectors HD 34/36-24-9-S… Picture shows socket rear insert.
Deutsch connectors HD 34/36-24-16-S… Picture shows socket rear insert.
Deutsch connectors HD 34/36-24-23-S… Picture shows socket rear insert.
Deutsch connectors HD 34/36-24-91-S… Picture shows socket rear insert.
113
40 Troubleshooting
3.
Part III
Standard value table for electrical components Used abbreviations
Pre-lube oil pressure switch
Engine cold start aid solenoid valve
51B110
52B093-1
52Q502a-1 52Q502b-1
Inspection method Measure resistance Measure resistance Measure resistance
Air intake temperature sensor
52B064-1
If the condition is within the range shown in the table below, it is normal Between (1) - (2)
8.0 ± 2.0Ω
If the condition is within the range shown in the table below, it is normal.
Between (1) - (2)
850 ± 50Ω
If the condition is within the range shown in the table below, it is normal. Between (1) - (2)
Refer to: PT100 temperature charts
If the condition is within the range shown in the table below, it is normal.
If the condition is within the range shown in the table below, it is normal.
Measure voltage
52B018-1 52B019-1
Between (1) - (2)
Between (1) - (2)
min. 1MΩ
1) 2) 3) 1) 2) 3)
38 ± 3Ω
1) 2) 3) 1) 2)
Between (1) - (2)
20S001 OFF Disconnect connector Insert T-box Pick up adjustment: refer to S/M 20S001 OFF Disconnect connector Insert T-box 20S001 OFF Disconnect connector Insert T-box 20S001 OFF Disconnect connector Insert T-box
6)
7)
Filters: clogged
0V
22 - 24V
20S001 OFF Disconnect connector Insert T-box
20S001 OFF Disconnect connector Insert T-box 20S001 ON Open terminals 1 & 2 at the T-box Engine high idle
3) 4) 5)
Between (1) - (2)
114
1) 2) 3) 4)
If the condition is within the range shown in the table below, it is normal.
Engine air filter clogging sensor [N.O. type]
1) 2) 3)
Measure resistance
Engine related parts
Engine speed sensor
31Q599
Measurement conditions
Judgement table
Measure resistance
Fuel tank shut off solenoid valve
Component code
Engine Normally Closed Normally Open Main key switch 20S001 Service Manual Electrical test box for Deutsch connectors Electrical test box for the CAN bus
Component name
System
Eng N.C. N.O. 20S001 S/M Deutsch T-box CAN T-box
PC4000-6D S/N 08199 and up
Inspection method
Component code
40 Troubleshooting
Component name
System
Part III
57B021-1
Measure voltage
If the condition is within the range shown in the table below, it is normal.
Coolant cooler fan filter clogging sensor [N.O. type]
Between (1) - (2)
Between (1) - (2)
Measure voltage
63B103-1
22 - 24V
Between (1) - (3) Between (1) - (2)
22 - 24V 22 - 24V
→ without oil Between (1) - (3) Between (1) - (2)
22 - 24V 0V
If the condition is within the range shown in the table below, it is normal. Engine oil level sensor (pressure sensor)
63B106-1
Measure voltage
Engine related parts
0V
If the condition is within the range shown in the table below, it is normal.
Engine remote oil tank level sensor [N.C. type] → with oil
Between A (1) - C (4) Between B (2) - C (4)
22 - 24V 0.8 - 1.0V
Between B (2) - C (4)
1.0 - 6.0V
Measure voltage
If the condition is within the range shown in the table below, it is normal.
31B063
Measure current
Fuel level sensor (pressure sensor)
PC4000-6D S/N 08199 and up
Measurement conditions
Judgement table
Between B (2) - A (1) Between A (1) - C (3)
22 - 24V 0.8 - 1.0V
Between C (3) - C (3)
4 - 20mA
1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 4) 20S001 ON 5) Open terminals 1 & 2 at T-box 6) Eng OFF 7) Engine high idle 8) When filter clogged differential pressure >5bar 1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 4) 20S001 ON 5) Open terminals 1 & 2 at T-box 6) Engine OFF 1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 4) 20S001 ON 5) Open terminals 1 & 2 at T-box 6) Engine OFF 1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 4) 20S001 ON 5) Open terminals 1 & 2 at T-box 6) Engine OFF
6)
Engine high idle
1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 4) 20S001 ON 5) Open terminals 1 & 2 at T-box 6) Engine OFF
7)
Engine high idle
115
Inspection method
Part III
Component code
Component name
System
40 Troubleshooting
Measurement conditions
Judgement table
Abient temp sensor
Measure voltage Measure resistance
If the condition is within the range shown in the table below, it is normal. Between (C) - (B)
Refilling arm solenoid valve → enable
57K553-1
57Q624a
57Q624b
57Q624c
Measure resistance
0V
Start engine Engine high idle
1) 2)
20S001 OFF Disconnect connector Insert T-box
1) 2) 3) 1) 2) 3) 4) 5)
If the condition is within the range shown in the table below, it is normal. Between (C) - (B)
Refer to PT100 temperature charts
If the condition is within the range shown in the table below, it is normal.
If the condition is within the range shown in the table below, it is normal.
If the condition is within the range shown in the table below, it is normal.
If the condition is within the range shown in the table below, it is normal.
If the condition is within the range shown in the table below, it is normal.
Between (1) - (2)
Between (1) - (2)
Between (1) - (2)
Between (1) - (2)
Between (1) - (2)
min. 1MΩ
1) 2)
20S001 OFF Disconnect connector Insert T-box
1) 2)
1) 2)
1) 2) 3)
20 ± 1.0Ω
35 ± 1.0Ω
3)
3)
20 ± 1.0Ω
20S001 OFF Insert T-box 20S001 ON Open terminals 1 & 2 at T-box Engine OFF Engine high idle When filter clogged, switch point >0.5bar
3)
23 ± 1.0Ω
20S001 OFF Disconnect connector Insert T-box
6) 7) 22 - 24V
Measure resistance
Refilling arm solenoid valve → down
57B027-1
Refer to PT100 temperature charts
If the condition is within the range shown in the table below, it is normal. Between (1) - (2)
1) 2)
3)
Measure resistance
Refilling arm solenoid valve → up
57B049-1
4.5 ± 0.5Ω
Measure resistance
PTO lube oil temperature sensor
PTO preload pressure solenoid valve
Refilling arm
57B017-1
Between (R) - (L)
Between (1) - (2)
PTO lube oil filter clogging sensor
116
13B090
If the condition is within the range shown in the table below, it is normal.
Measure resistance
PTO & related parts
PTO lube oil pressure switch [N.C. type]
71T003
When the engine is running (high idle) 27.5 - 29.5 V Remark: If the battery is cold, or after starting in cold areas, the voltage may not increase for a time.
Measure resistance
Shunt resistor
52G005-1
Measure voltage
Alternator → between alternator terminal D+ and chassis
Measure resistance
Engine related parts
If the condition is within the range shown in the table below, it is normal.
1) 2) 3) 1) 2) 3)
20S001 OFF Disconnect connector Insert T-box 20S001 OFF Disconnect connector Insert T-box 20S001 OFF Disconnect connector Insert T-box 20S001 OFF Disconnect connector Insert T-box 20S001 OFF Disconnect connector Insert T-box
PC4000-6D S/N 08199 and up
Refilling arm limit switch [N.O. type] → arm in down position
Inspection method
Component code
Component name
40 Troubleshooting
55B023
→ arm in up position
Between (1) - (2) Between (1) - (3)
22 - 24V 0V
Between (1) - (3)
22 - 24V
Ladder
Down: 70B091
Ladder solenoid valve → lower Ladder solenoid valve → fast
Hydraulic system
Ladder solenoid valve → raise
57Q623b
57Q625
57Q623a
Swing parking brake solenoid valve
57Q505
Oil cooler fan drive solenoid valve
57K506a-1 57K506b-1
Travel parking brake solenoid valve
Qmin solenoid valve
57Q516
57K517
PC4000-6D S/N 08199 and up
Measure Measure Measure Measure Measure Measure Measure resistance resistance resistance resistance resistance resistance resistance
Ladder limit switch [N.O. type]
Measure voltage
If the condition is within the range shown in the table below, it is normal. Up: 70B122
Measurement conditions
Judgement table
If the condition is within the range shown in the table below, it is normal. Measure voltage
Refilling arm
System
Part III
Between (A) - (B) Between (A) - (C)
22 - 24V 0V
Between (A) - (C)
22 - 24V
If the condition is within the range shown in the table below, it is normal. Between (1) - (2)
20 ± 1.0Ω
If the condition is within the range shown in the table below, it is normal. Between (1) - (2)
35 ± 1.0Ω
If the condition is within the range shown in the table below, it is normal. Between (1) - (2)
20 ± 1.0Ω
If the condition is within the range shown in the table below, it is normal. Between (1) - (2)
20 ± 1.0Ω
If the condition is within the range shown in the table below, it is normal. Between (1) - (2)
22 ± 1.0Ω
If the condition is within the range shown in the table below, it is normal. Between (1) - (2)
30 ± 1.0Ω
If the condition is within the range shown in the table below, it is normal. Between (1) - (2)
35 ± 1.0Ω
1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 4) 20S001 ON 5) Open terminals 1, 2 & 3 at T-box 6) Engine OFF 7)
Engine high idle
1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 4) 20S001 ON 5) Open terminals 1, 2 & 3 at T-box 6) Engine OFF
7)
Engine high idle
1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 1) 20S001 OFF 2) Disconnect connector 3) Insert T-box
117
Inspection method Measure resistance
57K517a
Slew brake proportional solenoid valve
57K626
Between (1) - (2)
35 ± 1.0Ω
1) 2) Between (1) - (3)
22 - 24V
3) 4)
If the condition is within the range shown in the table below, it is normal. Between (1) - (2) at the solenoid
20 ± 1.0Ω
Between (1) - (2) or at the X2 board
670 ± 10mA 11X_56 pin 17
6)
If the condition is within the range shown in the table below, it is normal.
If the condition is within the range shown in the table below, it is normal.
Between (1) - (2)
20 ± 1.0Ω
Between (1) - (2)
Between (1) - (2)
20 ± 1.0Ω
1) 2) 3)
35 ± 1.0Ω
1) 2) 3)
35 ± 1.0Ω
1) 2) 3)
If the condition is within the range shown in the table below, it is normal. Between (1) - (2) 11X_56 pin 18
1) 2) 3)
If the condition is within the range shown in the table below, it is normal. Between (1) - (2)
1) 2) 3) 4) 5)
If the condition is within the range shown in the table below, it is normal.
57Q627
1) 2) 3)
Measure Measure resistance resistance
Slew flow reduction solenoid valve
57K620
If the condition is within the range shown in the table below, it is normal.
Measure resistance
Hydraulic system
Hydraulic brake (emergency)
40K601
Measurement conditions
Judgement table
Measure resistance
Oil cooler preload pressure solenoid valve
57K561-1
Measure current
Electronic pump control solenoid valve
Measure current/resistance
Measure voltage
Qmax ½ solenoid valve
Part III
Component code
Component name
System
40 Troubleshooting
Output 11T016 - R2 350 - 370mA
1) 2) 3) 4) 5)
Fixed pump flow solenoid valve (Pump 3) Coolant fan solenoid valve
118
57K630
57K631
57K636-1
Measure resistance
Fixed pump flow solenoid valve (Pump 1)
If the condition is within the range shown in the table below, it is normal.
Measure Measure resistance resistance
6) 7)
If the condition is within the range shown in the table below, it is normal.
Between (1) - (2)
Between (1) - (2)
35 ± 1.0Ω
35 ± 1.0Ω
1) 2) 3) 1) 2) 3) 1) 2)
Between (1) - (2)
10 ± 1.0Ω
3)
20S001 OFF Disconnect connector Insert T-box 20S001 OFF Disconnect connector Insert T-box 20S001 ON 20S001 OFF Disconnect connector Insert T-box 20S001 ON Open terminals 1 & 2 at T-box Engine high idle 20S001 OFF Disconnect connector Insert T-box 20S001 OFF Disconnect connector Insert T-box 20S001 OFF Disconnect connector Insert T-box 20S001 OFF Disconnect connector Insert T-box 20S001 OFF Disconnect connector Insert T-box 20S001 ON Open terminals 1 & 2 at T-box Engine high idle Press pedal 20S001 OFF Disconnect connector Insert T-box 20S001 OFF Disconnect connector Insert T-box 20S001 OFF Disconnect connector Insert T-box
PC4000-6D S/N 08199 and up
Remote control solenoid valve
Remote control solenoid valve
Remote control solenoid valve
61K527 61K528 61K529 61K530 61K531 61K532 61K533 61K534 61K535 61K536 61K537 61K538 61K539 61K540 61K541 61K542 61K543 61K544 61K545 61K546 61K547
PC4000-6D S/N 08199 and up
Inspection method Measure Measure resistance resistance
Remote control solenoid valve
61K520 61K521 61K522 61K523 61K524 61K525 61K526
Measure resistance
Remote control proportional solenoid valve
61K570 61K571 61K572 61K573 61K574 61K575 61K576
Measure resistance
Remote control proportional solenoid valve
61K563 61K564 61K565 61K566 61K567 61K568 61K569
Measure resistance
57K648
If the condition is within the range shown in the table below, it is normal.
Measure resistance
Energy efficiency solenoid valve (Pump 1)
Measure resistance
57K647
Measure resistance
Hydraulic system
Energy efficiency solenoid valve (Pump 3)
57K646
Judgement table
If the condition is within the range shown in the table below, it is normal.
Measure resistance
Energy efficiency solenoid valve (Pump 2 & 4)
Component code
40 Troubleshooting
Component name
System
Part III
Between (1) - (2)
20 ± 1.0Ω
If the condition is within the range shown in the table below, it is normal. Between (1) - (2)
Between (1) - (2)
20 ± 1.0Ω
20 ± 1.0Ω
If the condition is within the range shown in the table below, it is normal. Between (1) - (2)
24 ± 1.0Ω
If the condition is within the range shown in the table below, it is normal. Between (1) - (2)
24 ± 1.0Ω
If the condition is within the range shown in the table below, it is normal. Between (1) - (2)
20 ± 1.0Ω
If the condition is within the range shown in the table below, it is normal. Between (1) - (2)
20 ± 1.0Ω
If the condition is within the range shown in the table below, it is normal. Between (1) - (2)
20 ± 1.0Ω
If the condition is within the range shown in the table below, it is normal. Between (1) - (2)
20 ± 1.0Ω
Measurement conditions
1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 1) 20S001 OFF 2) Disconnect connector 3) Insert T-box
1) 20S001 OFF 2) Disconnect connector 3) Insert T-box
1) 20S001 OFF 2) Disconnect connector 3) Insert T-box
1) 20S001 OFF 2) Disconnect connector 3) Insert T-box
1) 20S001 OFF 2) Disconnect connector 3) Insert T-box
1) 20S001 OFF 2) Disconnect connector 3) Insert T-box
1) 20S001 OFF 2) Disconnect connector 3) Insert T-box
119
Inspection method
Part III
Component code
Measurement conditions
Judgement table
If the condition is within the range shown in the table below, it is normal.
Hydraulic oil level sensor (level: low) → with oil 40B004
Measure voltage
Component name
System
40 Troubleshooting
Between (A) - (C) Between (A) - (B)
3) 4) 5)
22 - 24V 22 - 24V
1) 2)
→ without oil
3) 4) 5)
22 - 24V 0V
If the condition is within the range shown in the table below, it is normal.
40B050
Measure voltage
Hydraulic system
Between (A) - (B) Between (A) - (C)
Hydraulic oil level sensor (level: refill) → with oil
Between (A) - (C) Between (A) - (B)
22 - 24V 22 - 24V
If the condition is within the range shown in the table below, it is normal.
Between (A) - (B) Between (A) - (C)
22 - 24V 0V
Measure voltage Measure current
120
59B015
Measure resistance
Hydr. oil temperature sensor (PT100 type)
Between (A) - (C)
22 - 24V
Between (C) - (B)
4 - 20mA
1) 2) 3) 4) 5)
20S001 OFF Disconnect connector Insert T-box 20S001 ON Open terminals 1, 2 & 3 at T-box 20S001 OFF Disconnect connector Insert T-box 20S001 ON Open terminals 1, 2 & 3 at T-box 20S001 OFF Disconnect connector Insert T-box 20S001 ON Open terminals 1, 2 & 3 at T-box 20S001 OFF Disconnect connector Insert T-box 20S001 ON Open terminals 1, 2 & 3 at T-box 20S001 OFF Disconnect connector Insert T-box 20S001 ON Open terminals 1, 2 & 3 at T-box
Depending on the hydraulic oil level
If the condition is within the range shown in the table below, it is normal. Between (B) - (C)
1) 2) 3) 4) 5)
If the condition is within the range shown in the table below, it is normal.
40B105
1) 2) 3) 4) 5)
→ without oil
Hydraulic oil level sensor (analog)
1) 2)
Refer to PT100 temperature charts
1) 2) 3)
20S001 OFF Disconnect connector Insert T-box
PC4000-6D S/N 08199 and up
Inspection method
Component code
40 Troubleshooting
Component name
System
Part III
Floating switch at 20X810
Hydraulic system
Stick: 20S098
High pressure switch (analog)
61B087-a 61B087-b 61B087-c 61B087-d
Measure voltage
Boom: 20S095
Measure voltage
40B031
Measure voltage
If the condition is within the range shown in the table below, it is normal. Hydr. oil tank shut off gate valve (proximity switch)
Between (A) - (B) Between (A) - (C)
22 - 24V 0V
Between (A) - (C)
22 - 24V
If the condition is within the range shown in the table below, it is normal. Between (B) - (L/K) Between (B) - (L/K)
22 - 24V 22 - 24V
Between (B) - (L/K) Between (B) - (L/K)
0V 0V
If the condition is within the range shown in the table below, it is normal.
Between (A) - (C)
22 - 24V
Between (B) - (C)
1.0 - 11.0V
57B022
Measure voltage
If the condition is within the range shown in the table below, it is normal.
Filter pump control clogging sensor [N.O. type]
Between (1) - (2)
57B016
PC4000-6D S/N 08199 and up
Measure voltage
Between (1) - (2)
Slew brake pressure sensor [N.C. type]
Measurement conditions
Judgement table
0V
22 - 24V
If the condition is within the range shown in the table below, it is normal.
Between (1) - (2)
0V
Between (1) - (2)
22 - 24V
1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 4) 20S001 ON 5) Open terminals 1, 2 & 3 at T-box 6) Main gate closed 7)
Main gate open
1) 20S001 OFF 2) Disconnect connector 3) Insert T-cable 4) 20S001 ON 5) Press switch 7)
Switch in neutral position
1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 4) 20S001 ON 5) Open terminals 1, 2 & 3 at T-box 6)
Engine high idle
1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 4) 20S001 ON 5) Open terminals 1 & 2 at T-box 6) Engine high idle 7) When filter clogged differential pressure >5bar 1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 4) 20S001 ON 5) Open terminals 1 & 2 at T-box 6) 7)
Engine high idle Switch point 24bar
121
57B048
Inspection method Measure voltage
Travel brake pressure sensor [N.C. type]
Part III
Component code
Component name
System
40 Troubleshooting
Measurement conditions
Judgement table
If the condition is within the range shown in the table below, it is normal.
Between (1) - (2)
0V
Between (1) - (2)
22 - 24V
3) 4) 5)
57B085-1
Measure voltage
If the condition is within the range shown in the table below, it is normal. X1 pressure sensor (analog)
Between (A) - (C)
22 - 24V
Between (B) - (C)
1.0 - 11.0V
Measure voltage
Hydraulic system
57B086
Between (A) - (C)
22 - 24V
Between (B) - (C)
1.0 - 11.0V
40B166
Measure voltage
Preload valve pressure sensor (analog)
Between (A) - (C)
22 - 24V
Between (B) - (C)
1.0 - 11.0V
Engine high idle Switch point 24bar
1) 2)
20S001 OFF Disconnect connector Insert T-box 20S001 ON Open terminals 1, 2 & 3 at T-box
6) 7)
Engine high idle max. 60bar
1) 2)
20S001 OFF Disconnect connector Insert T-box 20S001 ON Open terminals 1, 2 & 3 at T-box
3) 4) 5)
If the condition is within the range shown in the table below, it is normal.
6) 7)
Engine high idle max. 60bar
1) 2)
20S001 OFF Disconnect connector Insert T-box 20S001 ON Open terminals 1, 2 & 3 at T-box
3) 4) 5) 6) 7)
Leak oil chamber pressure sensor (analog)
40B164
Measure voltage
If the condition is within the range shown in the table below, it is normal.
Between (A) - (C)
22 - 24V
Between (B) - (C)
1.0 - 11.0V
1) 2) 3) 4) 5) 6) 7)
122
20S001 OFF Disconnect connector Insert T-box 20S001 ON Open terminals 1 & 2 at T-box
6) 7)
3) 4) 5)
If the condition is within the range shown in the table below, it is normal. X2 pressure sensor (analog)
1) 2)
Depending on the pressure max. 60bar 20S001 OFF Disconnect connector Insert T-box 20S001 ON Open terminals 1, 2 & 3 at T-box Depending on the pressure max. 6bar
PC4000-6D S/N 08199 and up
Inspection method
Component code
40 Troubleshooting
Component name
System
Part III
59B162
Measure voltage
Hydraulic system
Suction tank pressure sensor (analog)
40B163
Measure voltage
If the condition is within the range shown in the table below, it is normal. Return oil chamber pressure sensor (analog)
Between (A) - (C)
22 - 24V
Between (B) - (C)
1.0 - 11.0V
Measure voltage
40B165
If the condition is within the range shown in the table below, it is normal.
Between (A) - (C)
22 - 24V
Between (B) - (C)
1.0 - 10.0V
Between (A) - (C)
22 - 24V
Between (B) - (C)
1.0 - 11.0V
Measure voltage
Between (A) - (B)
Grease pump solenoid valve
Grease line solenoid valve (Vent valve)
62Q507 62Q509
62Q507a 62Q509a
PC4000-6D S/N 08199 and up
Measure resistance
Between (A) - (B)
Measure resistance
Grease system
80B043 62B046
Depending on the pressure 7) max. 6bar 1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 4) 20S001 ON 5) Open terminals 1, 2 & 3 at T-box 6) Engine high idle 7) max. +1bar 1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 4) 20S001 ON 5) Open terminals 1, 2 & 3 at T-box 6)
If the condition is within the range shown in the table below, it is normal.
End line switch grease pressure
1) 20S001 OFF 2) Disconnect connector 3) Insert T-box 4) 20S001 ON 5) Open terminals 1, 2 & 3 at T-box 6)
If the condition is within the range shown in the table below, it is normal. Oil cooler pressure sensor
Measurement conditions
Judgement table
22 - 24V
0V
If the condition is within the range shown in the table below, it is normal. Between (D) - (F/H)
22 ± 1.0Ω
If the condition is within the range shown in the table below, it is normal. Between (D) - (F/H)
22 ± 1.0Ω
Depending on the pressure 7) max. 60bar 1) 20S001 OFF 2) Disconnect connector 3) Insert T-cable 4) 20S001 ON 5) Engine high idle 6) Grease pump running 7) Grease pressure 180bar present 1) Engine high idle 2) Grease pump running 3) Grease pressure below 180bar 1) Engine high idle 2) Grease pump running 3) Grease pressure below 180bar
123
Electronic control levers
Actuator pedal → left crawler
Actuator pedal → right crawler
Actuator pedal → slew brake
124
20Q097
20S021a
20S021b
20S022
Inspection method Measure current Measure voltage Measure voltage
52Q004
If the condition is within the range shown in the table below, it is normal.
Measure voltage
Heater mixing valve
62B108 62B109
Measurement conditions
Judgement table
If the condition is within the range shown in the table below, it is normal.
Measure voltage
Air conditioning
Magnetic clutch compressor
Component code
Component name Grease barrel level sensor
Part III
Measure voltage
Grease system
System
40 Troubleshooting
Between (B) - (B)
Between (1) - (gnd)
1) 2) 3) 4) 5)
4 - 20mA
1) 2) 3) 4) 5)
22 - 24V
If the condition is within the range shown in the table below, it is normal.
1) 2) 3) 4) 5)
Between (1) - (2)
22 - 24V
6)
If the condition is within the range shown in the table below, it is normal.
Between 11X_20 - 87
0 up to +10V
Between 11X_20 - 87
0 up to -10V
3) 4) 5)
If the condition is within the range shown in the table below, it is normal.
Between 11X_20 - 86
0 up to +10V
Between 11X_20 - 86
0 up to -10V
0 up to +10V
20S001 OFF Disconnect connection Insert T-cable 20S001 ON Switch ON A/C 20S001 OFF Disconnect connector Insert T-box 20S001 ON Open terminals 1 & 2 at T-box Switch ON heater 20S001 OFF Disconnect connection Insert T-cable 20S001 ON Move pedal → forward
6)
Move pedal → backward
1) 2)
20S001 OFF Disconnect connection Insert T-cable 20S001 ON Depress pedal → forward
3) 4) 5)
If the condition is within the range shown in the table below, it is normal.
Between 11X_20 - 62
1) 2)
20S001 OFF Disconnect connection Insert T-cable 20S001 ON Depending on grease level
6)
Depress pedal → backward
1) 2)
20S001 OFF Disconnect connection Insert T-cable 20S001 ON Depress pedal
3) 4) 5)
PC4000-6D S/N 08199 and up
Inspection method
Component code
40 Troubleshooting
Component name
System
Part III
Judgement table
Betw. 11X_00 - 7 L
0 up to -10V
Betw. 11X_00 - 7 R
0 up to +10V
Betw. 11X_00 - 12 F
0 up to +10V
Betw. 11X_00- 12 B
0 up to -10V
Control lever → right hand X & Y axis
20S019
Measure voltage
If the condition is within the range shown in the table below, it is normal. Between 11X_00-9 L
0 up to -10V
Between 11X_00-9 R
0 up to +10V
Between 11X_00-14 F
0 up to +10V
Between 11X_00-14 B 0 up to -10V
Actuator pedal → clam open
Actuator pedal → clam close
CAN
20S020
CAN bus resistor
20S024
20S023
10R100 10R101 40R101
PC4000-6D S/N 08199 and up
Measure Measure voltage Measure voltage resistance
Electronic control levers
Control lever → left hand X & Y axis
Measure voltage
If the condition is within the range shown in the table below, it is normal.
If the condition is within the range shown in the table below, it is normal.
Between 11X_00 - 46
0 up to -10V
If the condition is within the range shown in the table below, it is normal.
Between 11X_00 - 46
0 up to +10V
If the condition is within the range shown in the table below, it is normal. Between (A) - (B)
120Ω
Measurement conditions
1) 20S001 OFF 2) Disconnect connection 3) Insert T-cable 4) 20S001 ON 5) Move lever to left & right side 6) Move lever to front & backward 1) 20S001 OFF 2) Disconnect connection 3) Insert T-cable 4) 20S001 ON 5) Move lever to left & right side 6) Move lever to front & backward 1) 20S001 OFF 2) Disconnect connection 3) Insert T-cable 4) 20S001 ON 5) Depress pedal 1) 20S001 OFF 2) Disconnect connection 3) Insert T-cable 4) 20S001 ON 5) Depress pedal 1) 20S001 OFF 2) Disconnect CAN connector
125
40 Troubleshooting
4.
Part III
PT100 temperature charts Basic resistance values (Ohm) for measuring the resistance of PT100 sensors in relation to the temperature (degree centigrade) Resistance values according to ISO 4376
126
PC4000-6D S/N 08199 and up
Part III
40 Troubleshooting
This page was left blank intentionally.
PC4000-6D S/N 08199 and up
127
40 Troubleshooting
128
Part III
PC4000-6D S/N 08199 and up
Part IV
40 Troubleshooting
Part IV
Troubleshooting by trouble code G00001 - Trouble Shut-Off (gate) valve [1/5] Trouble code G00001
Trouble
Trouble Shut-Off (gate) valve
Contents of trouble
• The system assumes that the main gate valve is not completely open while the engine is running.
Related information
• If the voltage at the proximity switch 40B031 is 0 V, the main gate valve should be closed.
Action of controller
• Background colour of the trouble code information: red • If the basic VHMS setting for "PLC-evaluation - ON/OFF" is ON and if the shutdown bypass setting for "Shut-Off (gate) valve - ON/OFF" is OFF, the engine will be shut down (for sample VHMS displays refer to illustration Z 28050-1 at the end of this troubleshooting chart, page 4/5). Remark: For detailed information on the VHMS settings refer to the SERVICE MANUAL, section VEHCLE HEALTH MONITORING SYSTEM.
Problem that appears on machine
• The engine start is blocked.
Instruction message
Possible cause
1
Step
• Engine stopped because of main Shut-Off (gate) valve. - Open the Shut-Off (gate) valve. - If failure exists further, inform service.
Test condition & Inspection
Procedure
Nominal value
► Keep the main key switch 20S001 in ON position.
The engine is stopped, because the main gate valve at the hydraulic oil tank is not fully open
1
Verify if the main gate valve is fully open or not. Is the main gate valve fully open?
Yes
Go to next step.
No
Open the main gate valve completely and verify that trouble code G00001 (or G00020) is not set again. If trouble code G00020 is set, refer to the troubleshooting chart of G00020.
► Keep the main key switch 20S001 in ON position.
The gap between the proximity switch 40B031 and the open main gate valve is too large
2
PC4000-6 S/N 08199 and up
Check for the proper gap between the proximity switch and the open main gate valve. Does the gap meet the specification?
Yes
Go to next step.
No
Adjust the gap. Make sure that the proximity switch does not touch the gate valve when the gate valve is completely open.
Gap: approx. 3–5mm
129
40 Troubleshooting
Part IV
G00001 - Trouble Shut-Off (gate) valve [2/5] Possible cause
Step
Test condition & Inspection
Procedure
Nominal value
► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch in ON position. 3
Disconnect the cable connector from the proximity switch and measure the supply voltage at the connector terminal A. Is supply voltage present?
Incorrect or no supply voltage at the proximity switch 40B031
Vmin 22V Yes
Go to step 6. Vmax 24V
No
Go to next step.
Yes
Go to next step.
Vmin 22V
4
Vmax 24V
Check if supply voltage is present at the power supply line 11F013. Is supply voltage present? No
Follow the troubleshooting chart for trouble code G00090 "Trouble power supply".
► Keep the main key switch 20S001 in OFF position. Malfunction in the power supply wiring between proximity switch 40B031 and circuit breaker 11F013 (disconnection or defective contact in any connector)
5
Refer to the wiring diagram. Disconnect the connector from the proximity switch. Check the wire segments between the proximity switch and the power supply line for continuity. Is continuity present?
Yes
Go to next step.
No
Disconnection or short circuit in any wire segment (including connectors) between proximity switch and circuit breaker. Locate the problem and repair as necessary.
Rmax 1Ω
► VHMS Service menu ON - Input check at node 11
6 Malfunction in the signal wiring between proximity switch 40B031 and node 11 (40K311) (disconnection or defective contact in any connector)
• Engine OFF • 20S001 ON • PLC-evaluation ON (VHMS) Check the input signal of 40B031 at the VHMS Real Time Monitor. Is the input displayed?
Yes
Go to step 8.
No
Go to next step.
► Keep the main key switch 20S001 in OFF position
7
Refer to the wiring diagram. a) Check resistor 40R008: Disconnect the wires from 40R008 and measure its resistance. b) Check the signal wiring: Check the signal wire segments for continuity. Do all measurement readings meet the specifications?
Yes
Got to next step.
No
Locate the problem and repair as necessary.
R40R008 820Ω Rwire max 1Ω
► Keep the main key switch 20S001 in OFF position Defective ground connection at the proximity switch 40B031 (disconnection or defective contact in any connector)
130
8
Disconnect the cable connector from the proximity switch and check for proper ground connection at connector terminal B. Is the ground connection ok?
Yes
Go to next step.
No
Malfunction in any wire segment (including connectors) between proximity switch and ground line (GND). Locate the problem and repair as necessary.
Rmax 1Ω
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00001 - Trouble Shut-Off (gate) valve [3/5] Possible cause
Step
Test condition & Inspection
Procedure
Nominal value
► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch in ON position. Defective proximity switch 40B031
Final check
9
10
If the switch function is not as specified replace the proximity Using the Deutsch T-box, check the proximity switch for switch and verify that continuity in both switch positions. the repair was successful. Got to final step 10.
Switch closed: Rmax 1Ω Switch open: R ∞Ω
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
View onto the gap of the proximity switch 40B031
Legend for figure Z 26985 (1)
Proximity switch (40B031)
(A) Gap: 3-5 mm
PC4000-6 S/N 08199 and up
131
40 Troubleshooting
Part IV
View onto the VHMS settings for the proximity switch 40B031 [4/5] Terminology (MTC & PLC) MTC is a synonym for PLC. Both acronyms indicate the same main control module. MTC is the acronym of Master Turbo Controller PLC is the acronym of Programmable Logic Controller
Legend for figure Z 28050-1
(1) Basic setting for the MTC PLC-evaluation ON/OFF ON = MTC evaluation activated OFF = MTC evaluation not activated
(2) Bypass setting for the Shut-Off (gate) valve SHUTDOWN BYPASS for the ShutOff (gate) valve ON/OFF ON = Bypass ON Shutdown function OFF OFF = Bypass Shutdown function ON
132
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
Wiring diagram related to trouble code G00001 [5/5]
PC4000-6 S/N 08199 and up
133
40 Troubleshooting
Part IV
Wiring diagram related to trouble code G00001 [5/5]
134
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00002 - Test speed 1800 1/min engine 1 [1/3] Trouble code G00002
Trouble
Test speed 1800 rpm
Contents of trouble
• Test speed 1800 rpm is activated by switch 11S041-1 in the cab base.
Related information
• If the Quantum engine control module is switched to ground, the engine speed is fixed at 1800 rpm.
Action of controller
• Background colour of the trouble code information: green
Problem that appears on machine
• In this condition the engine speed is not changeable.
Instruction message
Possible cause
37
Step
• Switch Testspeed (11S041-1) in cab base forces the engine to run constantly 1800 1/min.
Test condition & Inspection
Procedure
Nominal value
► Keep the main key switch 20S001 in ON position The function "test speed 1800 rpm" is activated (switch 11S041-1 is closed)
1
If it is necessary, toggle the switch in order to disable the test speed function. Is the test speed function disabled?
Yes
No further troubleshooting necessary.
No
Go to next step.
► Keep the main key switch 20S001 in OFF position
Defective switch 11S041-1 (switch does not open)
2
Check the switch for continuity between the terminals 1 and 1a. Toggle the switch and check for continuity again. Turn the main key switch in ON position. Toggle switch 11S041-1 and check if the message on the display disappears. Do the measurements correspond to the specification and does the trouble message disappear?
Yes
Go to next step.
No
Replace switch 11S041-1 and verify that the repair was successful.
Switch closed: Rmax 1Ω Switch open: R ∞Ω
► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch in ON position. Vmin 22V 3 Incorrect or no supply voltage in the electrical circuit of switch 11S041-1 4
PC4000-6 S/N 08199 and up
Check if supply voltage is present at the switch terminal 1a. Is supply voltage present?
Check if trouble code G00090 "Trouble power supply" is set. Is trouble code G00090 displayed?
Yes
Go to step 6. Vmax 24V
No
Go to next step.
Yes
No power in the supply line of 11F013. Follow the troubleshooting chart for trouble code G00090.
No
Go to next step.
135
40 Troubleshooting
Part IV
G00002 - Test speed 1800 1/min engine 1 [2/3] Possible cause
Step
Test condition & Inspection
Procedure
Nominal value
► Keep the main key switch 20S001 in OFF position.
Disconnection in the wiring between switch 11S041-1 and the power supply line of circuit breaker 11F013 (disconnection or defective contact in any connector)
5
Refer to the wiring diagram and check the wire segments between switch 11S041-1 and the power supply line 11F013 for continuity. Also check the resistance of resistor 11R005. Is continuity present and is the resistance as specified?
Yes
Go to next step.
No
Continuity problem Disconnection or short circuit in any wire segment (including connectors) between switch 11S041-1 and the line of the circuit breaker 11F13_2. Locate the problem and repair as necessary. Resistor problem Replace resistor 11R005 if necessary.
11R005 820Ω
► Keep the main key switch 20S001 in OFF position Disconnection in the wiring between switch 11S041-1 terminal 1a and the Quantum engine control module (disconnection or defective contact in any connector)
6
Disconnect connector 51X452, pin Q, from the Quantum engine control module. Refer to the wiring diagram and check the wire segments between switch 11S041-1 and the Quantum engine control module for continuity. Is continuity present?
Yes
Go to next step.
No
Disconnection or short circuit in any wire segment (including connectors) between switch 11S041-1 and the Quantum engine control module. Locate the problem and repair as necessary.
Rmax 1Ω
► Keep the main key switch 20S001 in OFF position. Defective ground connection at switch 11S041-1
7
Final check
8
136
Check the ground connection at the switch terminal 1.
Locate the problem and repair as necessary. Then verify that the repair was successful. Then go to final step 8.
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
Wiring diagram related to trouble code G00002 [3/3]
PC4000-6 S/N 08199 and up
137
40 Troubleshooting
Part IV
G00003 - Trouble pump controller [1/4] Trouble code G00003
Trouble
Trouble pump controller
Contents of trouble
• The microcontroller RC4-4 (10K032) of the Electronic Load Limiting Control signals a problem.
Related information
• If trouble code G00003 is displayed, the electronic pump regulation system is inoperative.
Action of controller
• Background colour of the trouble code information: yellow • The electronic pump control circuit is disturbed. • The hydraulic performance is too slow (or bad).
Problem that appears on the machine
Remark: If you need to keep the shovel busy and if it is not possible to perform the repair in an appropriate space of time, the pump regulation may be switched into the hydraulic mode temporarily. For more information refer to step 4 in the following troubleshooting chart.
Instruction message Possible cause
38
Step
• If failure exists further, inform service.
Test condition & Inspection
Procedure
Nominal value
► Keep the engine running at high idle and keep the control levers in neutral position. On normal regulation condition the green LED 10P063 at the X2 board is permanently switched ON (24V).
The pump controller RC4-4 (10K032) may be defective
Yes
The power supply for the pump controller RC4-4 and the electrical circuit inside the controller is faultless. Go to next step.
No
The system assumes that the power input to the pump controller at connector 11X_10, pins 33, 34, 35 is OK. The electrical circuit inside the pump controller is defective. Replace the pump controller and check the system for proper function.
1
Vmin 22V Vmax 24V
Check if the green LED 10P063 at the X2 board is permanently switched ON. Is the green LED switched ON (24V)?
138
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00003 - Trouble pump controller [2/4] Possible cause
Step
The pump controller RC4-4 (10K032) for electronic pump regulation signals any malfunction in the pump regulation system Blink code
Test condition & Inspection
2
Remark: If any trouble is detected in the pump regulation system the red LED 11P138 at the X2 board is flashing blink codes. For the meaning of the blink codes refer to the following chart:
Error message
1
57K561-1, proportional solenoid valve (1)
Output stored
Possible cause
Yes
- Electric circuit of 57K561-1 open or short to ground
Effect
- No signal from engine speed sensor 52B064-1 or circuit short or interrupted
Procedure
Main pumps running with max. power (Qmax)
Check solenoid valve or the electric circuit
Reduced hydraulic power
Check signal and connection to 52B064-1, or trouble code G00061
Check high idle limitation (Cummins Service) or trouble code G00062
- Engine is not running or engine rpm too low. 2
2
Low speed (1)
No
3
2
High speed (1)
Yes
- Engine defective or engine rpm too high.
Malfunction of the load limiting control
-
Low battery voltage
Yes
- Battery voltage below approx. 17 V
Check alternator Engine charging or trouble codes: voltage too low G00104, G00105 G00176, G00177
-
57K561-2, proportional solenoid valve (2)
Yes
4
5
Nominal value
► Keep the engine running at high idle and keep the control levers in neutral position.
Refer to Fig. no.
1
Procedure
For engine 2 (PC5500 & PC8000) only
6
-
Low speed (2)
No
7
-
High speed (2)
Yes
► Keep the engine running at high idle without hydraulic load. Checking the output signals of the pump controller - Open terminal 11 X_56-17. - Install a multi-tester at the terminals of 11X_56-17. Step 2 continued
- Measure the current [mA]. Standard: 670 ± 10 mA - Close the terminal of 11X_56-17 again. Otherwise check 57K561-1 and the wiring.
Blink code 1 Fig. no. 1 Check the resistance of 57K561-1 between pin 1 & 2. - Standard: 20 ± 1Ω
PC4000-6 S/N 08199 and up
139
40 Troubleshooting
Part IV
G00003 - Trouble pump controller [3/4] Possible cause
Step
Test condition & Inspection
Procedure
Nominal value
Step 2 continued
Blink code 2 & 3 Fig. no. 2
Checking the rpm sensor 52B064-1 ► Engine OFF - Main key switch 20S001 OFF - Lock out switch 50S058 locked -
Disconnect the engine speed sensor 52B064-1 and visually check for damage. Mount 52B064-1 and adjust the gap as follows: turn the sensor in clockwise until it touches the flywheel, then unscrew the sensor ¾ turns, and fasten the locknut securely.
Checking the input signal to the pump controller ► Keep the engine running at high idle. -
Check the voltage at 11X_51-38. Standard: approx. 2.5V Otherwise check the wiring to the rpm sensor 52B064-1.
Checking the function of the rpm sensor 52B064-1 ► Keep the engine running at high idle. Step 2 continued
-
140
Disconnect the connector of the engine speed sensor 52B064-1. Check the resistance between pin 1 & 2. Standard: 850 ± 50Ω Otherwise replace the sensor 52B064-1 and adjust as described above.
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00003 - Trouble pump controller [4/4] Possible cause
Continued
The proportional valve 57K561-1 has been replaced
Step
2
3
Test condition & Inspection If LED 11P138 (red) is flashing any blink code, follow the according procedure in the above chart. Could you locate and repair the problem?
Procedure Yes
Go to final step 5.
No
Go to next step.
Nominal value
Refer to the SERVICE MANUAL section ELECTRONIC PUMP REGULATION SYSTEM subsection CHECKS AND ADJUSTMENT. Go to final step 5. Check and adjust the system as described in this section. If you need to keep the shovel busy and if it is not possible to perform the repair in an appropriate space of time, the pump regulation may be switched into the hydraulic mode temporarily. Turn the lever (253.1) at the valve cartridge block (1) into the horizontal position (H) in order to work in the hydraulic mode only, and put the machine back into operation.
The electronic pump regulation is inoperative
(1)
Valve cartridge block
(253.1)
Emergency lever for pump control (electronic and hydraulic mode)
4
Information In the hydraulic mode (H) the rated output power is reduced to approx. 75%. Therefore it is necessary to perform the repair as soon as possible. Final check
5
PC4000-6 S/N 08199 and up
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
141
40 Troubleshooting
Part IV
G00005 - Low hydraulic oil level [1/3] Trouble code G00005
Trouble
Low hydraulic oil level
Contents of trouble
• Pressure transducer 40B105 detected that the hydraulic oil level is low (below the warning limit) • Conditions for the generation of trouble code G00005: Condition 1: The main key switch 20S001 is in ON position for more than 10 seconds. Condition 2: The engine is shut off for more than 15 seconds and the attachment is in its defined position (refer to illustration Z 26724 on page 3 of this troubleshooting chart, showing the hydraulic oil tank label with the defined positions at the bottom).
Related information
• The pressure transducer 40B105 (analog) sends the hydraulic oil level to the VHMS monitor.
Action of controller
• Background colour of the trouble code information: yellow
Problem that appears on the machine
• Risk, to run out of hydraulic oil.
Instruction message Possible cause
39
Step
• Inform service if attachment in defined position.
Test condition & Inspection
Procedure
Nominal value
► Check with stopped engine and the attachment in its defined position.
Hydraulic oil level low
1
In consideration of the kind of attachment (BHA or FSA) and the hydraulic oil temperature, check the hydraulic oil level sight gauge and verify if the hydraulic oil level corresponds to the displayed trouble message. Refer to illustration Z 26724 on page 3 of this troubleshooting chart, which shows the hydraulic oil tank label with the relevant oil levels on the left and right side of the label. Is the oil level too low?
Yes
Refill specified hydraulic oil and verify that trouble code G00005 is not displayed again.
No
Go to next step.
► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch in ON position. 2 Incorrect or no supply voltage in the circuit of pressure transducer 40B105 3
142
Disconnect the cable connector from the pressure transducer and measure the supply voltage at the connector terminal B. Is supply voltage present?
Check if trouble code G00090 "No power supply" is set. Is trouble code G00090 displayed?
Vmin 22V Yes
Go to step 5. Vmax 24V
No
Go to next step.
Yes
Follow the troubleshooting chart for trouble code G00090.
No
Go to next step.
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00005 - Low hydraulic oil level [2/3] Possible cause
Step
Test condition & Inspection
Procedure
Nominal value
► Keep the main key switch 20S001 in OFF position. Disconnection in the wiring between pressure transducer 40B105 and the power supply line of circuit breaker 11F013a (disconnection or defective contact in any connector)
4
Refer to the wiring diagram and check the wire segments between pressure transducer and the power supply line 11F013a for continuity. Is continuity present?
Yes
Go to next step.
No
Disconnection or short circuit in any wire segment (including connectors) between pressure transducer and the line of the circuit breaker 11F013a. Locate the problem and repair as necessary.
Rmax 1Ω
► Keep the main key switch 20S001 in OFF position.
Disconnection in the signal wiring between pressure transducer 40B105 terminal C and node 11 (disconnection or defective contact in any connector)
5
Disconnect connector 2 from node 11 and measure at the terminal of 40X340-3. Refer to the wiring diagram and check the signal wiring segments between the pressure transducer , terminal C, and the cable connector 40X340, terminal 3, and node 11 for continuity. Is continuity present?
Yes
Go to next step.
No
Disconnection or short circuit in any wire segment (including connectors) between pressure transducer and cable connector 40X340, terminal 3, and node 11. Locate the problem and repair as necessary.
Rmax 1Ω
► Keep the main key switch 20S001 in OFF position.
Defective shield wiring at the pressure transducer 40B105 (disconnection or defective contact in any connector)
6
Disconnect the cable connector from the pressure transducer. Refer to the wiring diagram and check the shield wiring segments for proper ground connection and continuity between connector terminal A and shield line 40X340-1. Are ground connection and continuity ok?
Yes
Go to next step.
No
Disconnection or short circuit in any wiring segment (including connectors) between cable connector terminal A and the shield line 40X340-1. Locate the problem and repair as necessary.
Rmax 1Ω
► Prepare with the main key switch S1 in OFF position, and then carry out troubleshooting with the main key switch in ON position. Defective pressure transducer 40B105 (missing or poor signal current)
Final check
7
8
PC4000-6 S/N 08199 and up
Using the Deutsch T-box measure the signal current at the connector terminal C of the pressure transducer. Does the measurement meet the specification?
Yes
Go to next step.
No
Replace the pressure transducer and verify that the repair was successful.
Imin 4mA Imax 20mA
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
143
40 Troubleshooting
Part IV
Wiring diagram (G00005), oil level label, and defined position of the attachment [3/3]
144
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00007 - Trouble hydraulic oil level [1/3] Trouble code G00007
Trouble
Trouble hydraulic oil level
Contents of trouble
• Sensor 40B004 indicates that the hydraulic oil level is below the minimum refill level.
Related information
• If the sensor 40B004 does not sense oil, its signal voltage turns to 0 V. • If the signal voltage of sensor 40B004 continues to be 0 V for 10 seconds, trouble code G00007 is set. • If the monitoring setting of the hydraulic oil level is set to OFF, the engine is stopped. • If the monitoring setting of the hydraulic oil level is set to ON, the engine is not stopped.
Action of controller
• Background colour of the trouble code information: red
Problem that appears on machine
• Risk, to run out of hydraulic oil.
Instruction message Possible cause
2
Step
• Inform service.
Test condition & Inspection
Procedure
Nominal value
► Check with stopped engine and the attachment in its defined position. The hydraulic oil level is below the minimum level
1
Verify if the hydraulic oil level in the main oil reservoir is above or below the oil level sensor 40B004. Is the oil level below the sensor?
Yes
Refill specified hydraulic oil and verify that trouble code G00007 is not displayed again.
No
Go to next step.
► Keep the main key switch 20S001 in ON position. The monitoring loop of the hydraulic oil level is inoperative
2
Check the input signal of 40B004 at the VHMS Real Time Monitor. Is the input signal at node 11 displayed?
Yes
Go to next step.
No
Check the condition of the monitoring loop at node 11, connector 3, pin 8.
► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch in ON position. 3 Incorrect or no supply voltage in the circuit of the oil level sensor 40B004 4
Disconnect the cable connector from the oil level sensor , insert the Deutsch T-box, and measure the supply voltage at the cable connector terminal A. Is supply voltage present?
Check if supply voltage is present at the power supply line 11F013. Is supply voltage present?
Yes
Go to step 6.
No
Go to next step.
Yes
Go to step 5.
No
Follow the troubleshooting chart for trouble code G00090 "Trouble power supply".
Vmin 22V Vmax 24V
Vmin 22V Vmax 24V
► Keep the main key switch 20S001 in OFF position. Disconnection in the wiring segments between the oil level sensor 40B004 and the power supply line of circuit breaker 11F013 (disconnection or defective contact in any connector)
5
PC4000-6 S/N 08199 and up
Refer to the wiring diagram and check the wiring segments between oil level sensor and the power supply line for continuity. Is continuity present?
Yes
Go to next step.
No
Disconnection or short circuit in any wiring segment (including connectors) between the oil level sensor and the line of circuit breaker 11F013. Locate the problem and repair as necessary.
Rmax 1Ω
145
40 Troubleshooting
Part IV
G00007 - Trouble hydraulic oil level [2/3] Possible cause
Step
Test condition & Inspection
Procedure
Nominal value
► Keep the main key switch 20S001 in OFF position.
Defective ground connection at the oil level sensor 40B004
6
Disconnect the cable connector from the oil level sensor and check for proper ground connection at the connector terminal B. Is the ground connection ok?
Yes
Go to next step.
No
Disconnection or short circuit in any wiring segment (including connectors) between oil level sensor and the ground line. Locate the problem and repair as necessary.
Rmax 1Ω
► Keep the main key switch 20S001 in OFF position. Disconnection in the signal wiring between the oil level sensor 40B004, terminal C, and node 11. (disconnection or defective contact in any connector)
7
Disconnect the signal line connector 3, terminal 8, from node 11 (40K311). Refer to the wiring diagram and check the signal wiring segments between the oil level sensor, terminal C, and the node connector 3, terminal 8, for continuity. Is continuity present?
Yes
Go to next step.
No
Disconnection or short circuit in any wiring segment (including connectors) between oil level sensor and node cable connector 3, terminal 8. Locate the problem and repair as necessary.
40R008max 820Ω
► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch in ON position.
Defective oil level sensor 40B004
Final check
146
8
9
Using the Deutsch T-box measure the signal voltage at the connector terminal C of the oil level sensor when the sensor is dipped into oil (sensor closed), and when it is not touching any oil (sensor open). Do the measurements meet the specifications?
Yes
VSignal open: 0V A sporadic malfunction may exist. Further VSignal inspection is required. closed: 22-24V
No
Replace the oil level sensor and verify that the repair was successful.
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
Wiring diagram (G00007) and the defined position of the attachment [3/3]
PC4000-6 S/N 08199 and up
147
40 Troubleshooting
Part IV
G00012 - Central lubrication system grease level too low G00013 - Slew ring gear lubr. system grease level too low [1/6] Trouble code G00012 G00013 Contents of trouble
Trouble
G00012 - Central lubrication system grease level too low G00013 - Slew ring gear lubr. system grease level too low
• Monitoring of CLS (Central Lubrication System) grease level - 62B108 • Monitoring of SLS (Slew ring gear Lubrication System) grease level - 62B109 • The reserve level in the CLS grease barrel respectively in the SLS grease barrel is reached. • The sensing range of the grease level sensors is pre-adjusted ex factory. Further adjustment is not possible. • The grease level sensors do not influence the engine control. They can not trigger an engine shut down, they have an indication function only. LED functions (A) Green
Power supply (24V) is present
(B) Orange or red Same function as (C) Related information
(C) Orange
Object detected (normal operational condition)
(C) Red
Inhibited area detected (error condition) (grease may be too close to the ultrasonic sensor)
Overview Lube Syst.
Sensor
Node
CLS
62B108
12
SLS
62B109
3
• Background colour of the trouble code information: yellow Problem that appears on machine
• Risk, to run out of grease.
Instruction message Possible cause
The concerned grease barrel (CLS or SLS) needs refilling
148
17
Step
1
• Inform service till end of shift and then press cancel button.
Test condition & Inspection
Using the dipstick, verify if the grease level in the concerned barrel corresponds to the displayed message. Is the grease level too low?
Procedure
Yes
Press the cancel button and refill the specified grease. Verify that trouble code G00012 or G00013 is not displayed again.
No
Go to next step.
Nominal value
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00012 - Central lubrication system grease level too low G00013 - Slew ring gear lubr. system grease level too low [2/6] Possible cause
Step
Test condition & Inspection
Procedure
Nominal value
► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch in ON position. The ultrasonic sensor may be covered with grease or the concerned grease barrel may be overfilled. (a) Is the lower surface of the ultrasonic sensor covered with grease? and/or (b) Is the grease barrel overfilled? LEDs (B) & (C) of the concerned grease level sensor (62B108 or 62B109) light up red
Yes
(a) Clean the lower sensor surface and/or (b) Reduce the grease level in the barrel. Then verify if the problem is solved [LEDs (B) & (C) = orange and G00012/ G00013 no longer displayed].
No
If LED (A) lights green under these trouble conditions, the sensor may be disturbed. Go to step 8.
Definition of the grease levels 2
► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch in ON position. Incorrect or no supply voltage in the circuit of the concerning grease level sensor (62B108 or 62B109) [Green sensor LED (A) does not light up]
3
4
PC4000-6 S/N 08199 and up
Remove the cover of the junction box on top of the concerned grease barrel. Measure the supply voltage at terminal 1 of the terminal block inside the junction box. Is supply voltage present?
Check if supply voltage is present at the power supply line 11F013a. Is supply voltage present?
Yes
Go to step 6.
No
Go to next step.
Yes
Go to step 6.
No
Follow the troubleshooting chart for trouble code G00090 "No power supply".
Vmin 22V Vmax 24V
Vmin 22V Vmax 24V
149
40 Troubleshooting
Part IV
G00012 - Central lubrication system grease level too low G00013 - Slew ring gear lubr. system grease level too low [3/6] Possible cause Disconnection in the wiring between the concerned grease level sensor (62B108 or 62B109) and the power supply line of circuit breaker 11F013a (disconnection or defective contact in any connector or in the junction box on top of the concerned grease barrel)
Step
Test condition & Inspection
Procedure
Nominal value
► Keep the main key switch 20S001 in OFF position.
5
Refer to the wiring diagrams and check the wiring segments between the concerned grease level sensor and the power supply line for continuity. Is continuity present?
Yes
Go to next step.
No
Disconnection or short circuit in any wiring segment (including connectors) between the concerned grease level sensor and the line of the circuit breaker 11F013a. Locate the problem and repair as necessary.
Rmax 1Ω
► Keep the main key switch 20S001 in OFF position. Disconnection in the signal wiring between the concerned grease level sensor (62B108 or 62B109) and node 12 or 3 (disconnection or defective contact in any connector or in the junction box on top of the concerned grease barrel)
6
Disconnect the signal line of the concerned grease level and the respective node. 62B108: Node 12, connector 2, terminal 3 62B109: Node 3, connector 1, terminal 7 Refer to the wiring diagrams and check the signal wiring segments between the concerned grease level sensor and the relating node connector/terminal for continuity. Is continuity present?
Yes
Go to next step.
No
Disconnection or short circuit in any wiring segment of the signal line (including connectors and junction box) between the concerned grease level sensor and the relating node/ connector/terminal. Locate the problem and repair as necessary.
Rmax 1Ω
► Keep the main key switch 20S001 in OFF position. Defective shield wiring at the cables of the concerned grease level sensor (62B108 or 62B109) (disconnection or defective contact in any connector)
150
7
Refer to the wiring diagrams and check the shield wiring segments for continuity and proper ground connection to the shield line. Are continuity and ground connection ok?
Yes
Go to next step.
No
Disconnection or short circuit in any wiring segment (including connectors) between the cable shield and the ground line. Locate the problem and repair as necessary.
Rmax 1Ω
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00012 - Central lubrication system grease level too low G00013 - Slew ring gear lubr. system grease level too low [4/6] Possible cause
Step
Test condition & Inspection
Procedure
Nominal value
► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch in ON position.
8 Wrong sensor reaction or defective grease level sensor (62B108 or 62B109) [missing or poor signal current]
Yes
Go to next step.
No
Replace the concerned grease level sensor and verify that the repair was successful.
► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch in ON position. 9
Final check
Move your hand closer than 7 cm towards the lower sensor surface. LEDs (B) and (C) should turn from orange (OK) to red (ERROR). Do the LEDs turm from orange to red?
Upper sensing range limit: 300)-1 / 1.04
Final check
2
3
PC4000-6 S/N 08199 and up
If battery voltage (VBatt 22 - 24V) is present at the terminal 51(rpm>300)-1 / 1.04 while the engine is standing still, refer to the wiring diagram and inspect the complete relating wiring loop. The voltage at terminal 51(rpm>300)-1 / 1.04 should be 0V. Is the voltage at terminal 51(rpm>300)-1 / 1.04 = 0V?
Yes
Check 52K014-1. Contact the Cummins service if necessary.
No
Inspect and repair the wiring connections as necessary. Also check the wires and connectors for their correct allocation. After any repair recheck the system for proper function.
VDefault 0V
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
161
40 Troubleshooting
Part IV
Wiring diagram related to trouble code G00061 [2/2]
162
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00062 - Trouble monitoring, engine 1 speed too high [1/4] Trouble code
Trouble
G00062
Trouble monitoring, engine speed too high
Contents of trouble
• A malfunction in the monitoring loop for too high engine speed is detected. • The system assumes that any cable, the sensor, or the RPM-module 51T018-1 is defective.
Related information
-
Action of controller
• Background colour of the trouble code information: red
Problem that appears on machine
• The monitoring for too high engine speed is disabled (overspeed).
Instruction message Possible cause
Wrong adjustment and/ or contamination of the engine speed sensor (pick up) 52B064-1
2
Step
1
• Inform service.
Test condition & Inspection Refer to the SERVICE MANUAL, section MAIN HYDRAULIC PUMPS AND PUMP REGULATION SYSTEM, and find the adjustment procedure for the engine speed sensor (pick up). In the first step remove the engine speed sensor and clean the sensor tip from magnetic chips and dirt as described. Then follow the adjustment procedure and perform the final check. If necessary replace the pick up (52B064-1) or the RPM-module (51T018-1). The terminal numbers of your shovel may differ from the terminal numbers mentioned in the SERVICE MANUAL. Refer to the wiring diagram for the individual terminal numbers. Could you rectify the problem?
Procedure
Yes
Go to final step 9.
No
Go to next step.
Nominal value
approx. 10VAC
► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch in ON position. Vmin 22V 2
Measure the supply voltage at terminal +24V of the RPM-module. Is supply voltage present?
Incorrect or no supply voltage at the RPMmodule (51T018-1).
Yes
Go to final step 9. Vmax 24V
No
Go to next step.
Yes
Go to next step.
Vmin 22V
3
Vmax 24V
Check if supply voltage is present at the power supply line 11F013a. Is supply voltage present? No
PC4000-6 S/N 08199 and up
Follow the troubleshooting chart for trouble code G00099 "Trouble power supply".
163
40 Troubleshooting
Part IV
G00062 - Trouble monitoring, engine 1 speed too high [2/4] Possible cause
Step
Test condition & Inspection
Procedure
Nominal value
► Keep the main key switch 20S001 in OFF position. Disconnection in the wiring between the RPM-module 51T018-1 and the line of the circuit breaker 11F013a (disconnection or defective contact in any connector)
4
Refer to the wiring diagram and check the wiring between terminal +24V of the RPMmodule and the power supply line 11F013a for continuity. Is continuity present?
Yes
Go to next step.
No
Disconnection or short circuit in the wiring (including connector) between terminal +24V of the RPM-module and the power supply line 11F013a. Locate the problem and repair as necessary.
Rmax 1Ω
► Keep the main key switch 20S001 in OFF position.
Defective or poor ground connection at terminal 0V of the RPM-module 51T018-1
5
Disconnect the cable connector from the RPMmodule. Check the ground cable for continuity between terminal 0V and the ground line. Is continuity present?
Yes
Go to next step.
No
Disconnection or short circuit in the wiring (including connector) between the RPMmodule, terminal 0V, and the ground line. Locate the problem and repair as necessary.
Rmax 1Ω
► Keep the main key switch 20S001 in OFF position. Disconnection in the wiring between the pick up 52B064-1 and the RPM-module 51T018-1 (disconnection or defective contact in any connector)
6
Refer to the wiring diagram. Disconnect the wiring from the RPM-module (terminals sign and 0VS) and disconnect the pick up connenctor. Also disconnect line 52B064-1 which leads to the pump control module 10K032 (RC4-4). Check the wiring segments between the RPMmodule and the pick up for continuity. Is continuity present?
Yes
Go to next step.
No
Disconnection or short circuit in any wiring segment between the RPM-module and the pick up (including connectors). Locate the problem and repair as necessary.
Rmax 1Ω
► Keep the main key switch 20S001 in OFF position. Disconnection in the signal wiring between the RPM-module 51T018-1 (terminals 1+ and 1-) to node 17 and to ground (disconnection or defective contact in any connector)
164
7
Refer to the wiring diagram. Disconnect the wiring from the RPM-module (terminals 1+ and 1-) and disconnect the node connector 2 , terminal 3. Check the wiring between the RPM-module and node 17 for continuity. Is continuity present?
Yes
Go to next step.
No
Disconnection or short circuit in the wiring between the RPMmodule (terminals 1+ and 1-) and the node connector 2, terminal 3 (including connectors). Locate the problem and repair as necessary.
Rmax 1Ω
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00062 - Trouble monitoring, engine 1 speed too high [3/4] Possible cause
Step
Test condition & Inspection
Procedure
Nominal value
► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch in ON position. Measure the signal current at terminals 1+ and 1- of the RPM-module. Do the measurements meet the specification? Defective RPM-module 51T018-1 (missing or poor signal current) or wrong setting
Final check
8
9
PC4000-6 S/N 08199 and up
Remark: The RPM-module is pre-programmed in the factory. Make sure that the presetting is not modified. If further details for the RPM-module are needed, contact the KMG Service department.
Yes
Go to next step.
No
Replace the RPMmodule if necessary and verify that the repair was successful.
Imin 0mA Imax 20mA
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
165
40 Troubleshooting
Part IV
Wiring diagram related to trouble code G00062 [4/4]
166
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00063 - Trouble monitoring hydraulic oil temp [1/2] Trouble code G00063
Trouble
Trouble monitoring hydraulic oil temp
Contents of trouble
• A malfunction in the monitoring loop for the hydraulic oil temperature is detected. • The system assumes that the hydraulic oil temperature sensor 59B015 (PT100 type) or the wiring circuit of the monitoring system is defective. • Pre-condition for the monitoring loop: The bucket function is enabled and not shut-off due to overheated hydraulic oil (optional setting)!
Related information
• Within the temperature range of -50°C up to +150°C the sensor 59B015 generates a voltage signal in the range of 0.5 - 9.5V.
Action of controller
• On condition that the engine is running: the fan speed is set to max. speed • Background colour of the trouble code information: red
Problem that appears on machine
• The monitoring of the hydraulic oil temperature is disabled.
Instruction message Possible cause
Wiring or connector problem
No input signal at node 17
Sensor defective
Final check
2
Step
1
2
3
4
PC4000-6 S/N 08199 and up
• Inform service.
Test condition & Inspection Check the wiring between sensor and connector 51X152: pin 23 to shield pin 24 to A pin 25 to C pin 26 to B Is continuty present? Check the input signal at node 17 (51K317). Measure the input signal of 59B015 at connector 2, pin 6 . Measure the signal voltage and compare the voltage to your Real Time temperature. Does the signal correspond to the Real Time temperature? Check the resistance of temperature sensor 59B015. Disconnect the sensor connector and measure the sensor resistance between pin B and C according to the PT100 temperature chart. Does the resistance correspond to the PT100 chart?
Procedure Yes
Go to next step 2.
No
Repair or replace according to the actual wiring diagram.
Yes
Go to final step.
No
Go to next step.
Yes
Go to next step 2.
No
Replace the PT100 sensor.
Nominal value Rmax 1Ω
VSignal 0.5-9.5V
Refer to the PT100 temp. chart
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
167
40 Troubleshooting
Part IV
Wiring diagram related to trouble code G00063 [2/2]
168
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00064 - Trouble monitoring hydraulic oil level [1/3] Trouble code G00064 Contents of trouble
Trouble
Trouble monitoring hydraulic oil level
• The signals of the hydraulic oil level sensors 40B050 (refilling level indication) and 40B004 (minimum level indication) are contradictory. • If trouble code G00064 is displayed, the hydraulic oil level sensor 40B004 has a malfunction.
Related information
Remark: If the sensor 40B004 does not sense oil, its signal voltage turns to 0 V.
Action of controller
• Background colour of the trouble code information: red
Problem that appears on machine
• Risk, to run out of hydraulic oil.
Instruction message Possible cause The signal of the hydraulic oil level sensor 40B004 (minimum level indication) is disturbed
2
Step
• Inform service.
Test condition & Inspection
Procedure
Nominal value
► Check with stopped engine and the attachment in its defined position. 1
If the actual hydraulic oil level in the main hydraulic oil reservoir is higher than the level of the hydraulic oil level sensor 40B050, then sensor 40B004 or its wiring can be assumed to be defective.
Go to next step.
► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. 2 Incorrect or no supply voltage in the circuit of the oil level sensor 40B004 3
Disconnect the cable connector from the oil level sensor 40B004, insert the Deutsch T-box, and measure the supply voltage at the cable connector terminal A. Is supply voltage present?
Check if supply voltage is present at the power supply line 11F013 (TT: 11F084). Is supply voltage present?
Yes
Go to step 5.
No
Go to next step.
Yes
Go to step 5.
No
Follow the troubleshooting chart for trouble code G00090 "Trouble power supply".
Vmin 22V Vmax 24V
Vmin 22V Vmax 24V
► Keep the main key switch 20S001 in OFF position. Disconnection in the wiring between the oil level sensor 40B004 and the power supply line of circuit breaker 11F013 (TT: 11F084) (disconnection or defective contact in any connector)
4
PC4000-6 S/N 08199 and up
Refer to the wiring diagram and check the wiring segments between oil level sensor 40B004 and the power supply line for continuity. Is continuity present?
Yes
Go to next step.
No
Disconnection or short circuit in any wiring segment (including connectors) between oil level sensor 40B004 and the line of the circuit breaker. Locate the problem and repair as necessary.
Rmax 1Ω
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40 Troubleshooting
Part IV
G00064 - Trouble monitoring hydraulic oil level [2/3] Possible cause
Step
Test condition & Inspection
Procedure
Nominal value
► Keep the main key switch 20S001 in OFF position.
Defective ground connection at the oil level sensor 40B004
5
Disconnect the cable connector from the oil level sensor 40B004 and check for proper ground connection at the connector terminal B. Is the ground connection ok?
Yes
Go to next step.
No
Disconnection or short circuit in any wiring segment (including connectors) between oil level sensor 40B004 and the ground line (B). Locate the problem and repair as necessary.
Rmax 1Ω
► Keep the main key switch 20S001 in OFF position. Disconnection in the signal wiring between the oil level sensor 40B004 terminal A and node 11 (disconnection or defective contact in any connector)
6
Refer to the relating wiring diagram and check the input signal at node 11 (40K311). Disconnect the signal line connector 3, terminal 8 from node 11. Refer to the wiring diagram and check the signal wiring segments between the oil level sensor 40B004, terminal C and node 11 cable connector 3, terminal 8 for continuity. Is continuity present?
Yes
Go to next step.
No
Disconnection or short circuit in any wiring segment (including connectors) between oil level sensor 40B004 and node 11 cable connector 3, terminal 8. Locate the problem and repair as necessary.
Rmax 1Ω
► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. VSignal
Defective oil level sensor 40B004
7
Using the Deutsch T-box, measure the signal voltage at the connector terminal C o f the oil level sensor 40B004 when the sensor is dipped into oil (sensor closed) and when it is not touching any oil (sensor open). Do the measurements meet the specifications?
Yes
approx. 24V No
Final check
170
8
open: A sporadic malfunction 0V may exist. Further VSignal inspection is required. closed:
Replace the oil level sensor 40B004 and verify that the repair was successful.
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
Wiring diagram related to trouble code G00064 [3/3]
PC4000-6 S/N 08199 and up
171
40 Troubleshooting
Part IV
G00065 - Very low hydraulic oil level [1/3] Trouble code G00065 Contents of trouble Related information
Trouble
Very low hydraulic oil level
• Message: Refill hydraulic oil! • The hydraulic oil level dropped below the refilling oil level (sensor 40B050). • The hydraulic oil level is still above the minimum oil level (sensor 40B004). Remark: If the sensor 40B050 does not sense oil, its signal voltage turns to 0 V.
Action of controller
• Background colour of the trouble code information: yellow
Problem that appears on machine
• Risk, to run out of hydraulic oil.
Instruction message Possible cause
2
Step
• Inform service.
Test condition & Inspection
Procedure
Nominal value
► Check with stopped engine and the attachment in its defined position.
The hydraulic oil fill level is reached
1
Verify if the hydraulic oil level in the main oil reservoir is below the oil level sensor 40B050. Is the oil level below the sensor 40B050?
Yes
Refill hydraulic oil and verify that trouble code G00065 is not displayed again.
No
If the oil level is above the sensor, go to next step.
► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. 2 Incorrect or no supply voltage in the circuit of the oil level sensor 40B050 3
Disconnect the cable connector from the oil level sensor 40B050, insert the Deutsch T-box, and measure the supply voltage at the cable connector terminal A. Is supply voltage present?
Check if supply voltage is present at the power supply line 11F013. Is supply voltage present?
Yes
Go to step 5.
No
Go to next step.
Yes
Go to step 5.
No
Follow the troubleshooting chart for trouble code G00090 "Trouble power supply".
Vmin 22V Vmax 24V
Vmin 22V Vmax 24V
► Keep the main key switch 20S001 in OFF position. Disconnection in the wiring between the oil level sensor 40B050 and the power supply line of circuit breaker 11F013 (disconnection or defective contact in any connector)
172
4
Refer to the wiring diagram and check the wiring segments between oil level sensor 40B050 and the power supply line 11F013 for continuity. Is continuity present?
Yes
Go to next step.
No
Disconnection or short circuit in any wiring segment (including connectors) between oil level sensor 40B050 and the line of the circuit breaker 11F013. Locate the problem and repair as necessary.
Rmax 1Ω
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00065 - Very low hydraulic oil level [2/3] Possible cause
Step
Test condition & Inspection
Procedure
Nominal value
► Keep the main key switch 20S001 in OFF position.
Defective ground connection at the oil level sensor 40B050
5
Disconnect the cable connector from the oil level sensor 40B050 and check for proper ground connection at the connector terminal B. Is the ground connection ok?
Yes
Go to next step.
No
Disconnection or short circuit in any wiring segment (including connectors) between oil level sensor 40B050 and the ground line (B). Locate the problem and repair as necessary.
Rmax 1Ω
► Keep the main key switch 20S001 in OFF position.
Disconnection in the signal wiring between the oil level sensor 40B050 terminal C and node 11 (disconnection or defective contact in any connector)
6
Refer to the relating wiring diagram and check the input signal at node 11. Disconnect the signal line connector 3, terminal 5 from node 11 (40K311). Refer to the wiring diagram and check the signal wiring segments between the oil level sensor 40B050, terminal C and the node cable connector 3, terminal 5 for continuity. Is continuity present?
Yes
Go to next step.
No
Disconnection or short circuit in any wiring segment (including connectors) between oil level sensor 40B050 and the node cable connector 3, terminal 5. Locate the problem and repair as necessary.
Rmax 1Ω
► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position.
Defective oil level sensor 40B050
Final check
7
8
PC4000-6 S/N 08199 and up
Using the Deutsch T-box, measure the signal voltage at the connector terminal C of the oil level sensor 40B050 when the sensor is dipped into oil (sensor closed) and when it is not touching any oil (sensor open). Do the measurements meet the specifications?
Yes
VSignal open: A sporadic malfunction 0V may exist. Further VSignal inspection is required. closed: approx. 24V
No
Replace the oil level sensor 40B050 and verify that the repair was successful.
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
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40 Troubleshooting
Part IV
Wiring diagram related to trouble code G00065 [3/3]
174
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00066 - Trouble hydraulic oil temperature [1/3] Trouble code G00066
Trouble
Trouble hydraulic oil temperature
Contents of trouble
• Overheated hydraulic oil is detected. (And the bucket function is disabled - option). • The system assumes that the hydraulic oil temperature sensor 59B015 (PT100 type) or the wiring circuit of the monitoring system is not defective.
Related information
• The hydraulic oil temperature sensor 59B015 detects an oil temperature >T4 for 20 seconds. • For the definition of the hydraulic oil temperatures T1, T2, T3, T4 refer to the oil temperature table on page 3/3 of this troubleshooting chart.
Action of controller
• On condition that the engine is running: the fan speed is set to max. speed. • Background colour of the trouble code information: red
Problem that appears on machine
• The hydraulic oil is overheated (option - bucket function is shut off).
Instruction message Possible cause
2
Step
• Inform service.
Test condition & Inspection
Procedure
Nominal value
► Keep the engine running at high idle, with max. fan speed.
The hydraulic oil is overheated
1
Using a laser temperature meter check the hydraulic oil temperature at the temperature sensor 59B015. For the defined hydraulic oil temperatures refer to the oil temperature table at the end of this flowchart. Does the measured hydraulic oil temperature indicate overheating as well?
Yes
Go to next step.
No
Check for other relating trouble codes and follow the relating troubleshooting chart as necessary.
► Keep the main key switch 20S001 in ON position. Wrong hydraulic oil settings may cause the problem
2
Check the hydraulic oil settings (oil type, viscosity) in the service mode of the VHMS system. Are the oil settings correct?
Yes
Go to next step.
No
Adjust the hydraulic oil settings in the service mode of the VHMS system and recheck for normal range.
Yes
Go to next step.
No
Refer to the Service Manual, section Hydraulic Oil Cooling, and perform the setting of the max. fan speed. If the setting is not as specified follow the adjustment and/or inspection procedures in the Service Manual as necessary.
Yes
Clean the hydraulic oil cooler with a water pressure cleaner as necessary. Continue to work and monitor the hydraulic oil temperature on the VHMS display.
No
Go to next step.
► Keep the engine running at high idle.
The fan is not driven at max. speed
3
Maximum fan speed is achieved if no voltage (0 V) is applied at both solenoid valves 57K506a-1 and 57K506b-1. Therefore disconnect the cable connectors from both solenoid valves 57506a-1 & 57K506b-1. If the fan speed does not increase, check the hydraulic settings for the fan speed (refer to the Service Manual). Connect both cable connectors to the solenoid valves 57K506a-1 and 57K506b-1 again. Is the setting for max. fan speed correct?
RPM max. 1250±50 RPM medium 1000±50
► Shut the engine OFF.
Any clogged hydraulic oil cooler caused the overheating of the hydraulic oil
4
PC4000-6 S/N 08199 and up
This test step must only be performed if the engine is standing still. Perform a visual inspection of the hydraulic oil cooler. Also open the swing out doors of the cooler frame and check for deposits between these door wings. Is intense pollution present?
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40 Troubleshooting
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G00066 - Trouble hydraulic oil temperature [2/3] Possible cause
Step
Test condition & Inspection
Procedure
Nominal value
► Keep the engine running at high idle, with max. fan speed. Overheating due to any malfunction in the hydraulic system
5
Final check
6
176
Check the hydraulic system by performing the PM-Clinic.
Continue to work and monitor the hydraulic oil temperature on the VHMS display.
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
View onto the solenoid valves related to trouble code G00066 [3/3]
Hydraulic oil table
PC4000-6 S/N 08199 and up
177
40 Troubleshooting
Part IV
G00067 - Trouble battery voltage too high [1/2] Trouble code G00067
Trouble
Trouble battery voltage too high
Contents of trouble
• Via the resistor 11T080 the system detects too high battery voltage.
Related information
• If the battery voltage at 11T080 is >=29 V for 5 V, the trouble code is set. • The system assumes that the resistor 11T080 and its wiring is not defective, otherwise trouble code G00161 should be displayed.
Action of controller
• Background colour of the trouble code information: yellow
Problem that appears on machine
-
Instruction message Possible cause
2
Step
• Inform service.
Test condition & Inspection
Procedure
Nominal value
► Keep the engine running at high idle. The voltage regulator in the alternator may be defective and causes the battery over voltage
1
Resistor 11T080 or its wiring may be the cause for the battery over voltage
2
Final check
3
178
Measure the charging voltage between alternator terminal "B+" and chassis (body ground). Also see the charging voltage value which is shown in the VHMS Real Time Monitor. Does the charging voltage exceed the specification? If trouble code G00161 "Trouble monitoring battery voltage" is displayed at the same time, follow the belonging procedures. Could you rectify the problem?
Vcharge Yes
Go to next step.
No
Replace the alternator.
Yes
Go to final step 3.
No
A sporadic malfunction may exist. Further inspection is required.
min. 27.5V max. 29V
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
Wiring diagram and component location related to trouble code G00067 [2/2]
PC4000-6 S/N 08199 and up
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40 Troubleshooting
Part IV
G00069 - Trouble monitoring oil temperature gear (PTO 1) [1/2] Trouble code G00069
Trouble
Trouble monitoring oil temperature gear (PTO 1)
Contents of trouble
• A malfunction in the monitoring loop for the gear oil temperature (PTO) is detected. • The system assumes that the gear oil temperature sensor 57B049 (PT100 type) or the wiring circuit of the monitoring system is defective.
Related information
• Within the temperature range of -50°C up to +150°C the sensor 57B049 generates a voltage of 0,5-9,5 V.
Action of controller
• Background colour of the trouble code information: yellow
Problem that appears on machine
• The monitoring of the gear oil temperature (PTO 1) is disabled.
Instruction message Possible cause
Wiring or connector problem
No input signal at node 18.
2
Step
1
2
• Inform service.
Test condition & Inspection
Procedure
Check wiring between sensor and connector 51X252 pin 26 to shield, pin 27 to A, pin 28 to C and pin 29 to B.
Yes
Go to step 2.
Is continuty present?
No
Repair or replace according the actual electrical circuit drawing.
Check the input signal at node 18 (51K318). Measure the input signal of the 59B049 between connector 0, pin 4. Measure the signal in Voltage and compare the voltage according your real time temperature.
Nominal value Rmax 1Ω
VSignal Yes
Go to final step.
No
Go to next step
Yes
Go to next step.
No
Change the PT100 sensor.
0.5-9.5V
Is the signal according the real temp?
Sensor defective
Final check
180
3
2
Check the temperature sensor 59B049 of resistance. Disconnect the sensor connenctor and measure the sensor of resistance between pin B and C according the PT100 temperature chart. Is the resistance according to the PT100 chart ok?
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
Wiring diagram and component location related to trouble code G00069 [2/2]
PC4000-6 S/N 08199 and up
181
40 Troubleshooting
Part IV
G00070 - Trouble oil temperature gear (PTO 1) [1/3] Trouble code G00070 Contents of trouble
Trouble
Trouble oil temperature gear (PTO 1)
• The PTO gear oil temperature sensor 57B049 (PT100 type) signals overheating. • The system assumes that the gear oil temperature sensor 57B049 (PT100 type) or the wiring circuit of the monitoring system is not defective. • PTO gear oil temperature for 5 seconds > TG2 • For the definition of the PTO gear oil temperatures refer to the following table (Z 26718) (taken from the flowchart).
Related information
Action of controller
• Background colour of the trouble code information: yellow
Problem that appears on machine
• The PTO gear oil is overheated.
Instruction message Possible cause
2
Step
• Inform service.
Test condition & Inspection
Procedure
Nominal value
► Keep the engine running at high idle, with max. fan speed.
PTO gear oil overheated
PTO gear oil level too low
1
2
Using a laser temperature meter, verify that the PTO gear oil temperature at the temperature sensor 57B049 is too high. For the location of 57B049 refer to "no. 2" in illustration Z 26958 at the end of this troubleshooting chart. For the definition of the PTO gear oil temperatures refer to the above table (Z 26718). Check the PTO gear oil level with the dipstick as described in the OPERATION & MAINTENANCE MANUAL, section "Every 50 Operating Hours or Weekly". Is the PTO gear oil level within the specified range?
Go to next step.
Yes
Go to next step.
No
Refill or drain PTO gear oil until the target level is reached. Then monitor the PTO gear oil temperature again.
OPERATION & MAINTENANCE MANUAL
► Keep the main key switch 20S001 in ON position. Wrong PTO gear oil settings may cause the problem
182
3
Check the PTO gear oil settings (oil type and viscosity) in the service mode of the VHMS system. Are the oil settings correct?
Yes
Go to next step.
No
Adjust the PTO gear oil settings in the service mode of the VHMS system and verify that the temperature is in normal range.
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00070 - Trouble oil temperature gear (PTO 1) [2/3] Possible cause
Step
Test condition & Inspection
Procedure
Nominal value
► Keep the engine running at high idle.
The fan is not driven at max. speed
4
Maximum fan speed is achieved if no voltage (0 V) is applied at both solenoid valves 57K506a-1 and 57K506b-1. Therefore disconnect the cable connectors from both solenoid valves 57K506a-1 & 57K506b-1. If the fan speed does not increase, check the hydraulic settings for the fan speed (refer to the Service Manual). Connect both cable connectors to the solenoid valves 57K506a-1 and 57K506b-1 again. Is the setting for max. fan speed correct?
Yes
Go to next step.
No
Refer to the Service Manual, section Hydraulic Oil Cooling, and perform the setting of the max. fan speed. If the setting is not as specified follow the adjustment and/or inspection procedures in the Service Manual as necessary.
Yes
Clean the gear oil/ hydraulic oil cooler with a steam cleaner as necessary. Continue to work and verify that the PTO gear oil temperature is in normal range.
No
Go to next step.
Yes
Go to next step.
No
Carry out adjustments as necessary. After that verify that the PTO gear oil temperature is in normal range. If any other relating trouble code is present, follow the troubleshooting procedures of the corresponding troubleshooting chart.
RPM max. 1250±50 RPM medium 1000±50
► Shut the engine OFF. Any clogged gear oil cooler segment in the hydraulic oil cooler frame caused the overheating of the PTO gear oil
5
This test step must only be performed if the engine is standing still. Perform a visual inspection of the gear oil cooler segments. Also open the swing out doors of the cooler frame and check for deposits between these door wings. Is intense pollution present? ► Keep the engine running at high idle.
Overheating due to any malfunction in the PTO lubrication system
6
Final check
7
PC4000-6 S/N 08199 and up
Refer to the Service Manual, chapter 2, section "PTO LUBRICATION AND COOLING" and follow the given adjustment procedures. Are the pump adjustments as specified?
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
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40 Troubleshooting
Part IV
Location of the PTO gear oil level dipstick and temperature sensor 57B049 [3/3]
Legend for illustration Z26958 (1)
Dipstick for PTO gear oil level
(2)
Location of the PTO gear oil temperature sensor 57B049
184
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00071 - Trouble gear lubrication (PTO 1) [1/2] Trouble code G00071 Contents of trouble
Trouble
Trouble gear lubrication (PTO 1)
• Pressure sensor 57B017-1 (NC*) signals, that there is no pressure in the PTO gear lubrication system, even the engine is running. *NC = Normally Closed • A problem with the pressure sensor 57B017-1 or its wiring (G00147) may also cause the trouble. Basic sensor data (57B017-1)
Related information
No pressure present
0V
Switch closed
Pressure present
24 V
Switch open
Switch point
0.5 bar
Action of controller
• Background colour of the trouble code information: yellow
Problem that appears on machine
• Risk, to operate the machine without PTO gear lubrication (PTO overheating).
Instruction message Possible cause
2
Step
1
• Inform service.
Test condition & Inspection
Refer to the Service Manual, chapter 2, section "PTO LUBRICATION AND COOLING" and follow the given adjustment procedures. Are the pump adjustments as specified?
Procedure Yes
Go to next step.
No
Carry out adjustments as necessary. After that recheck if the PTO gear lubrication pressure is in normal range.
Nominal value
► Keep the engine running at high idle. No PTO gear lubrication pressure present
2
Final check
3
PC4000-6 S/N 08199 and up
Check the PTO gear oil settings (oil type and viscosity) in the service mode of the VHMS system. Are the oil settings correct?
Continue to work and verify that trouble code G00071 "Trouble gear lubrication (PTO)" is not set again. If any other relating trouble code is present, in particular G00147 "Trouble monitoring gear lubrication (PTO)", follow the troubleshooting procedures of the corresponding troubleshooting chart.
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
185
40 Troubleshooting
Part IV
Wiring diagram related to trouble code G00071 [2/2]
186
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00081 - Trouble lubrication system [1/4] Trouble code G00081
Trouble
Trouble lubrication system
Contents of trouble
• The movement of the bucket will be disabled, if there was no successful lubrication cycle during the last approx. 4 working hours (option).
Related information
• The function Bucket Cut-Off is an option. Via the CoDeSys Visualization software this option can be activated or deactivated. • If this option is deactivated the trouble message G00081 is displayed, but the bucket movement is not cut-off.
Action of controller
• Background colour of the trouble code information: red
Problem that appears on machine
• If the optional function Bucket Cut-Off is activated: Bucket movement is disabled (lubrication cycle not complete).
Instruction message Possible cause
2
Step
•
Inform service.
Test condition & Inspection
Procedure
Nominal value
► Engine running at high idle & ladder up & safety lever down
Problem in the lubrication system(s). A problem with the lubrication cycles causes the bucket cutoff (option)
Yes
Follow the troubleshooting chart of the displayed trouble code(s) and rectify the lubrication problem. After the repair manually switch the lubrication system and recheck for proper function. Also verify that the bucket motion is no longer affected. (option)
No
Go to next step.
Check if any trouble code(s) concerning the lubrication systems is present. Is any trouble code present which indicates a problem in the lubrication systems?
1
Remark Remember the PauseTime setting is reduced to 30 s: - if you entered the VHMS Service Mode or - after the first manual lubrication cycle was started. If you leave the Service Mode, the preadjusted Pause Time is resumed.
► Keep the main key switch 20S001 in ON position.
A malfunction of relay 11K050 causes the bucket cut off
2
PC4000-6 S/N 08199 and up
Check the function of relay 11K050 in the X2 switch board. - 11K050 active (24 V): Bucket movement enabled - 11K050 inactive (0 V): Bucket movement disabled Does the function of relay 11K050 meet the above specification?
Yes
Go to next step.
No
Replace the relay and check for proper system function. If the problem is not yet rectified go to next step.
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40 Troubleshooting
Part IV
G00081 - Trouble lubrication system [2/4] Possible cause
Step
Test condition & Inspection
Procedure
Yes
Malfunction or damage in the wiring circuit of relay 11K050
Final check
3
4
Refer to the wiring diagram: - Check if B+ voltage is present - Check for proper ground connection - Check the wiring for continuity - Check the diode for proper condition Is any problem diagnosable in the wiring circuit of relay 11K050?
No
Nominal value
Repair the wiring or replace any defective electrical component as necessary. Check if any other trouble code is set which may be in crosscorrelation with the existing problem. If so, follow the according troubleshooting chart and after that recheck for proper system function.
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
Operation cycles of the lubrication systems
188
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
Wiring diagram 1 related to trouble code G00081 [3/4]
PC4000-6 S/N 08199 and up
189
40 Troubleshooting
Part IV
Wiring diagram 2 related to trouble code G00081 [4/4]
190
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00090 - Trouble power supply G00099 - Trouble power supply [1/2] Trouble code G00090 G00099 Contents of trouble
Trouble
Trouble power supply
• The power supply circuit (stabilized B+) for sensors and switches is interrupted. • The stabilized supply power is provided by the batteries 13G008 and 13G009 (located in the cab base).
Related information
Remark: If the supply voltage (B+) drops below 17 V, the monitoring function is shut dow (supply voltage below the self holding voltage).
Action of controller
• Background colour of the trouble code information: red
Problem that appears on machine
• The engine start is impossible. • The monitoring function is inoperative.
Instruction message Possible cause
8 / 48
Step
• No 24 V at circuit breaker 11F013 / 11F013a. - If failure exists further, inform service.
Test condition & Inspection
Procedure
Nominal value
► Keep the main key switch 20S001 in OFF position. V min The batteries 13G008 / 13G009 in the cab support are defective
1
Check the batteries. Are the batteries OK?
Yes
Go to next step.
V max 24V
No
Replace the batteries.
The circuit between the batteries 13G008/13G009 and the circuit breaker 11F013 (G00090) or 11F013a (G00099) is disturbed
2
Repair or replace components as Refer to the wiring diagram. necessary and verify Check the circuit (wires and electrical components) that the repair was between the batteries in the cab support and the circuit successful. breaker in the X2 switchboard. After that go to final step 3.
Final check
3
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
PC4000-6 S/N 08199 and up
17V
191
40 Troubleshooting
Part IV
Wiring diagram related to trouble codes G00090 and G00099 [2/2]
192
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00091 - Pilot control cut out [1/2] Trouble code G00091
Trouble
Pilot control cut out
Contents of trouble
• Pilot control is locked.
Related information
• Pilot control is also locked if the refilling arm and/or ladder are down, or if the lock lever is pulled up. • Verify the switch setting of the refilling arm enable switch 20S094.
Action of controller
• Background colour of the trouble code information: red
Problem that appears on machine
• Hydraulic operation is not possible.
Instruction message Possible cause
9
Step
• Ladder end switch or lock lever contact open or service arm down or unlocked. - If failure exists further, inform service. Test condition & Inspection
Procedure
Nominal value
► Keep the main key switch 20S001 in ON position. The lock lever is not pushed down or its switch 20S105 is not closed
Lock lever switch 20S105 or its wiring is defective
The refilling arm is not in the upper end position
1
2
3
PC4000-6 S/N 08199 and up
Check the position of the lock lever (down). Is the lock lever pushed down in its operating position?
Refer to the wiring diagram and check the switch function and the belonging wiring. Are the switch and its wiring ok?
Yes
Go to next step.
No
Push the lock lever down in its operating position and continue to work.
Yes
Go to next step.
No
Replace the switch if it is defective. If the wiring has a problem, locate the problem and repair as necessary. After the repair recheck the system for proper function.
Yes
If no refilling process takes place, move the refilling arm back into its upper end position. Verify that the trouble message is no longer displayed.
No
For detailed information concerning the adjustment of the proximity switch 55B023 at the refilling arm (end position), refer to the latest version of PARTS & SERVICE NEWS AH05539 and follow the instructions.
Check the refilling arm position. Is the refilling arm in the upper end position?
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40 Troubleshooting
Part IV
G00091 - Pilot control cut out [2/2] Possible cause
Step
Test condition & Inspection
Procedure
Yes The access ladder is down
4
Check if the access ladder is down. Is the access ladder down?
No
Final check
5
Nominal value
Move the access ladder up. After that verify the following: - The trouble message is no longer displayed. - The excavator can be operated normally (hydraulic operation is no longer blocked). For detailed information concerning the access ladder function refer to your SERVICE MANUAL, section ACCESS LADDER.
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
View onto the lock lever and the cover of switch 20S105 Legend for figure Z 27281 (1) Lock lever (2) Cover of lock lever switch 20S105 at the right side of operator's seat [F] UNLOCKED, lock lever down in operation position [L] LOCKED, lock lever up, pilot control is locked
194
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00092 - Emergency shut-down at access ladder G00093 - Emergency shut-down at valve block G00094 - Emergency shut-down at hydraulic control panel G00095 - Emergency shut-down in cabin [1/2] Trouble code G00092 ~ G00095
Trouble
G00092 - Emergency shut-down at access ladder G00093 - Emergency shut-down at valve block G00094 - Emergency shut-down at hydraulic control panel G00095 - Emergency shut-down in cabin
• Emergency shut-down switch was activated when the engine is standing still. Emergency shut-down switch Contents of trouble
Location
Trouble code
70S033a
Ladder
G00092
61S033b
Valve block
G00093
57S033c
Hydraulic control panel
G00094
20S036
Operator´s cab
G00095
Related information
• The engine start is blocked
Action of controller
• Background colour of the trouble code information: red
Problem that appears on machine
• It needs to be checked why the relating emergency shut-down switch was activated.
Instruction message
Possible cause
Any emergency shut-off button was activated
10
Step
1
• Emergency shut-down switch was actuated. - Unlock before restarting. - If failure exist further, inform service. Test condition & Inspection
Check the cause for the emergency activation. Is any cause present?
Procedure
Yes
Rectify the cause or problem. After that, release the concerned emergency shut-down switch(es).
No
Go to next step. Refer to the wiring diagram. Repair or replace the concerned switch or its wiring as necessary. After the repair go to final step 3.
The concerned emergency shut-off button or its wiring may be defective
2
Visually inspect the concerned switch, the switch contacts, and the respective wiring.
Final check
3
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
PC4000-6 S/N 08199 and up
Nominal value
195
40 Troubleshooting
Part IV
Wiring diagram related to trouble code G00092 - G00095 [2/2]
Only present if not equipped with switches 54S051 and 54S052 (option)
196
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00096 - Pilot control cut out [1/2] Trouble code G00096
Trouble
Pilot control cut out
Contents of trouble
• Pilot control is locked.
Related information
• Pilot control is also locked if the refilling arm is down or if the lock lever is pulled up. • Verify the switch setting of the refilling arm enable switch 20S094.
Action of controller
• Background colour of the trouble code information: red
Problem that appears on machine
• Hydraulic operation is not possible.
Instruction message Possible cause
14
Step
• Enable switch for refilling arm active. - If failure exist further, inform service. Test condition & Inspection
Procedure
Nominal value
► Keep the engine running at high idle.
The enable switch (20S094 - at the dashboard) for the refilling arm is in ON position [1]
1
Check the switch position of the refilling arm enable switch. Is enable switch in ON position [1]?
Yes
Toggle enable switch in OFF position [0].
No
For detailed information concerning the adjustment of the proximity switch 55B023 at the refilling arm (end position) refer to the latest version of PARTS & SERVICE NEWS AH05539 and follow the instructions.
► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position.
The enable switch (20S094 - at the dashboard) for the refilling arm or its wiring (safety monitoring of pilot control) is defective
2
Final check
3
PC4000-6 S/N 08199 and up
(a) Pre-check: Check the supply voltage at terminal A. If supply voltage is not present, locate the problem and repair as necessary. In switch position ON [1] there is continuity between A → C. (b) Verification: If the enable switch is in ON position [1] (switch closed), the message should light up on the VHMS display. Does the message light up when the enable switch is switched into ON position?
Yes
Go to final step 3.
No
Check the electric circuit below 20X_20 (terminal 30 at the X2 board). Locate the problem and repair as necessary. After that verify that the pilot control is no longer cut out.
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
197
40 Troubleshooting
Part IV
Wiring diagram related to trouble code G00096 [2/2]
198
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00100 - Maintenance safety switch [1/2] Trouble code G00100
Trouble
Maintenance safety switch
Contents of trouble
• The maintenance safety switch 50S058 is switched off, the engine is turned off / standing still.
Related information
• Engine start is blocked for safety reasons. • 50S058 is the maintenance safety switch which can be secured with padlocks.
Action of controller
• Background colour of the trouble code information: red
Problem that appears on machine
• For safety reasons the engine start is made impossible via the safety switch 50S058.
Instruction message Possible cause
11
Step
• Engine switched off by Maintenance Safety Switch in the engine room.
Test condition & Inspection
Procedure
Nominal value
► Main key switch 20S001 in OFF position The maintenance safety switch 50S058 is locked intentionally
1
Check the condition of the maintenance safety switch. Is the maintenance safety switch switched OFF and locked with a padlock?
Yes
Contact your supervisor and clarify the situation.
No
Go to next step.
Yes
Switch 50S058 Repair or replace as necessary. Wiring of 50S058 Refer to the wiring diagram. Locate the problem and repair as necessary.
No
Verify if other trouble codes are displayed, which may cause the problem. If any suspicious trouble code is displayed, follow the relating troubleshooting chart.
► Main key switch 20S001 in OFF position
Malfunction of the maintenance safety switch 50S058 or its wiring
Final check
2
3
PC4000-6 S/N 08199 and up
Check the function of the maintenance safety switch and its wiring. Could you identify any trouble?
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
199
40 Troubleshooting
Part IV
Wiring diagram related to trouble code G00100
Only present if not equipped with switches 54S051 and 54S052 (option)
[2/2]
200
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00102 - Switch off wiper [1/1] Trouble code G00102
Trouble
Switch off wiper
Contents of trouble
• A malfunction in the wiper system is detected.
Related information
• The monitoring system detected any problem with the mechanics or with the logical control of the wiper system.
Action of controller
• Background colour of the trouble code information: yellow
Problem that appears on machine
• The wiper system is inoperative.
Instruction message Possible cause
2
• Inform Service
Step
Test condition & Inspection
Procedure
Nominal value
► Keep the main key switch 20S001 in ON position.
Malfunction in the wiper system
1
a) Switch off the wiper switch (20S011) (switch position "0"). b) Pull off the wiper arms from the windscreen. Is the wiper system switched off and could you pull off the lower wiper arm from the windscreen?
Yes
Go to next step.
No
Repair or replace the defective wiper parts as necessary (wiper arms and/or wiper blade). Recheck the wiper system for proper function.
Yes
Go to step 4.
No
Go to next step.
► Main key switch 20S001 in ON position Wiper switched OFF (20S011 in position "0") a) The logical wiper control sequence is disturbed
2
Press the QUIT button (11S145) at the X2 board in the cab base in order to reset the wiper system. b) After that, the wiper arms should move into their end position. c) Switch ON the wiper. If the reset was successful, the wiper function should be proper now. Does the wiper operate without any problem?
► Keep the main key switch 20S001 in OFF position. The basic mechanical adjustment of the wiper linkage is wrong
3
Final check
4
PC4000-6 S/N 08199 and up
Refer to the latest version of PARTS & SERVICE NEWS AH06533 and follow the given adjustment instructions. After that, recheck the wiper system for proper function. Does the wiper operate without any problem?
Yes
Go to step 4.
No
If trouble code G00101 or G00103 is present follow the relating troubleshooting chart.
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
201
40 Troubleshooting
Part IV
G00103 - Faulty switch 20M004 [1/4] Trouble code G00103 Contents of trouble
Trouble
Faulty switch 20M004
• The monitoring system detected any problem with the limit switch in the wiper motor (20M004). • The limit switch in the wiper motor (20M004) may have an electrical problem.
Related information
Remark: If trouble code G00102 is present, first follow the relating troubleshooting chart.
Action of controller
• Background colour of the trouble code information: yellow
Problem that appears on machine
• The wiper doesn't move in its initial position (end position). Therefore the logical control sequence may be disturbed and the wiper system is inoperative. • The wiper motor (20M004) or its limit switch may be burnt.
Instruction message Possible cause
47
- Only upper windscreen wiper! - Inform Service.
Step
Test condition & Inspection
Procedure
Nominal value
► Main key switch 20S001 in ON position. Wiper switched OFF (20S011 in position "0") a) The logical wiper control sequence is disturbed
1
Press the QUIT button (11S145) at the X2 board in the cab base in order to reset the wiper system. b) After that, both wiper arms should move into their end position. c) Switch ON the wipers. If the reset was successful, the wiper function should be proper now. Do the wipers operate without any problem?
Yes
Go to step 6.
No
Go to next step.
Yes
The system assumes that the upper wiper reached its end position, but the wiper arms don't move. When the VHMS shows "1", the wiring between wiper motor 20M004, pin 2 and node 9, connector 3, pin 2 is ok. Go to step 4.
No
Go to next step.
► Main key switch 20S001 in ON position. Wiper switch 20S011 switched ON. Check the conditions via VHMS
The upper wiper motor (20M004), the limit switch, or its wiring is defective
2
Conditions: Upper wiper arm in end position Upper wiper arm not in end position
VHMS : 1 VHMS : 0
For wiper start, the wiper arm has to be in end position. Do the conditions on VHMS correspond to the upper wiper arm position?
Go to next step.
The limit switch system is disturbed
202
3
Refer to the wiring diagrams. Check the wiring between the wiper motor, pin 2, and node 9, connector 3, pin 2 for continuity. Is continuity present?
Locate the problem and repair as necessary. If any problem was found and repaired, verify that the wiper function is free of problems. If no problem was found, go to next step.
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00103 - Faulty switch 20M004 [2/4] Possible cause
Step
The wiper motor 20M004 is defective
4
Malfunction in the wiring circuit of the wiper system
5
Final check
6
PC4000-6 S/N 08199 and up
Test condition & Inspection
Procedure
Nominal value
► Main key switch 20S001 in OFF position. Wiper switched OFF (20S011 in position "0") Replace the wiper motor 20M004. Yes Go to step 6. During the installation of the wiper motor follow Refer to the wiring the adjustment procedures in the PARTS & diagrams. SERVICE NEWS AH06533 (latest version) and Check the relating and make sure, that the basic adjustment of circuits and the No electrical components. the wiper linkage is made properly. After that, recheck the wiper system for proper After that, verify that function. the wiper function is free of problems. Do the wipers operate without any problem? Refer to the wiring diagrams. Check the relating circuits and the electrical components, locate the problem, and repair or replace Go to next step. defective components as necessary. After that, verify that the wiper function is free of problems. Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
203
40 Troubleshooting
Part IV
Wiring diagram 1 related to trouble code G00103 [3/4]
204
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
Wiring diagram 2 related to trouble code G00103 [4/4]
PC4000-6 S/N 08199 and up
205
40 Troubleshooting
Part IV
G00104 - Trouble battery current [1/2] Trouble code G00104
Trouble
Trouble battery current
Contents of trouble
• The discharging current is too high. • At the shunt resistor 71T003 a discharging current of less than -200 A is present (the engine is standing still).
Related information
• For this test step a clamp-on ammeter is required (Ampere). • The discharge current is abnormally high.
Action of controller
• Background colour of the trouble code information: yellow
Problem that appears on machine
-
Instruction message Possible cause
15
• Load of the batteries too high. - Inform service.
Step
Test condition & Inspection
Procedure
Nominal value
► Main key switch 20S001 ON - engine OFF Remark: Before taking the following measurements check for the correct order of the cable connections at 71T003 "B" and 71T003 "L". In case the cable connections are mixed up, connect them in the correct order. B = battery side L = alternator side The alternator (5200G5-1) is defective (short circuit to ground)
1
Yes
Replace the alternator. After repair recheck the system for proper function.
No
Go to next step.
Using a clamp-on ammeter measure the current in front of and behind the shunt resistor 71T003. Ammeter Batteries
Ammeter Alternator
Did you measure a negative current flow < -200 A between 71T003 & 52G005-1 and between 71T003 & the batteries? ► Main key switch 20S001 ON - engine OFF
The starter motors (52M001-1 & 52M002-1) are defective
2
Final check
3
206
Refer to the wiring diagram and using a clamp-on ammeter: • Measure the current between the terminal block 71X_71-4 and starter motor 52M001-1. • Measure the current between the terminal block 71X_71-5 and starter motor 52M002-1. • Measure the current between the starter motors and ground.
If the current flow at one of both starter motors is too high, both starter motors have to be replaced. After repair recheck the system for proper function. Check if other trouble codes relating to the charging system are pending. Go to final step 3.
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
Wiring diagram related to trouble code G00104 [2/2]
PC4000-6 S/N 08199 and up
207
40 Troubleshooting
Part IV
G00105 - Trouble battery charging current too low [1/1] Trouble code G00105
Trouble
Trouble battery charging current too low
Contents of trouble
• The charging current from the alternator (52G005-1) is too low. • The monitoring system detected that the battery voltage dropped below 23 V.
Related information
• For this test step a clamp-on ammeter is required (Ampere). • Also see the charging current on the REAL TIME MONITOR (Electr. Equipment) in the service mode of the VHMS system (for detailed instructions refer to the SERVICE MANUAL, section VEHICLE HEALTH MONITORING SYSTEM).
Action of controller
• Background colour of the trouble code information: yellow
Problem that appears on machine
• Further engine starts may be impossible due to discharged batteries.
Instruction message Possible cause
16
Step
• Batteries are not being charged. - Inform service.
Test condition & Inspection
Procedure
Nominal value
► Keep the engine running at high idle.
1
Remark: Before taking the following measurements check for the correct order of the cable connections at 71T003 "B" and 71T003 "L". In case the cable connections are mixed up, connect them in the correct order. B = battery side L = alternator side Measure the charging voltage between alternator, terminal B+, and ground. Does the measurement reading meet the specification?
The alternator (52G005-1) or its wiring is defective
Yes
Go to next step.
No
Replace the alternator and check its wiring. After repair recheck the system for proper function.
2
Ammeter Batteries
208
Vmax 29.5V
► Keep the engine running at high idle. Using a clamp-on ammeter measure the charging current in front of and behind the shunt resistor 71T003.
Final check
Vmin 27.5V
3
Ammeter Alternator
If the charging current is too low, replace the alternator. After repair recheck the system for proper function. Check if other trouble codes relating to the charging system are pending. Go to final step 3.
Icharge 25-35A
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00140 - Trouble monitoring X1-1 pressure [1/3] Trouble code G00140
Trouble
Trouble monitoring X1-1 (XLR) pressure
Contents of trouble
• A malfunction in the monitoring loop for the pump regulation pressure X1 is detected. • Monitoring the X1 pressure is impossible because of: - Defective wiring or defective pressure sensor 57B085-1 - Poor terminal contact or disconnected connector in the wiring of pressure sensor 57B085-1
Related information
• Within a pressure range of 0 - 60 bar the sensor 57B085-1 generates a signal voltage of 1-11 V.
Action of controller
• Background colour of the trouble code information: yellow
Problem that appears on machine
• Monitoring of the pump regulation pressure X1 pressure is disabled.
Instruction message Possible cause
17
Step
• Inform service till end of shift and then press cancel button.
Test condition & Inspection
Procedure
Nominal value
► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. 1 Incorrect or no supply voltage at the pressure sensor 57B085-1
2
Disconnect the sensor connector and insert the Deutsch T-box. Measure the voltage between the sensor pins A and C. Is supply voltage present? Check if trouble code G00090 "No power supply" is set: Is trouble code G00090 set?
Yes
Go to step 3.
No
Go to next step.
Yes
Follow the troubleshooting chart for trouble code G00090.
No
Go to next step.
Vmin 22V Vmax 24V
► Keep the main key switch 20S001 in OFF position. Disconnection in the wiring between circuit breaker 11F013a and X1 pressure sensor 57B085-1 (disconnection or defective contact in any connector)
3
Refer to the wiring diagram and check the wiring segments between circuit breaker 11F013a and connector terminal A at the X1 pressure sensor for continuity. Is continuity present?
Yes
Go to next step.
No
Disconnection or short circuit in any wiring segment (including connectors) between circuit breaker and connector terminal A at the pressure sensor. Locate the problem and repair as necessary.
Rmax 1Ω
► Keep the main key switch 20S001 in OFF position.
Disconnection in the shield wiring between shield terminal 56X157-26 and GND
4
PC4000-6 S/N 08199 and up
Refer to the wiring diagram and check the wiring segments between shield terminal and GND for continuity. Is continuity present?
Yes
Go to next step.
No
Disconnection or short circuit in any wiring segment (including connectors) between shield terminal and GND. Locate the problem and repair as necessary.
Rmax 1Ω
209
40 Troubleshooting
Part IV
G00140 - Trouble monitoring X1-1 pressure [2/3] Possible cause
Step
Test condition & Inspection
Procedure
Nominal value
► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. Defective pressure sensor 57B085-1 (internal malfunction)
5
Disconnect the sensor connector and insert the Deutsch T-box. Measure the signal voltage at the connector terminal B of the X1 pressure sensor. Does the measurement meet the specification?
Yes
Go to next step.
No
Replace the pressure sensor and verify that the repair was successful.
Vsignal 1-11V
► Keep the main key switch 20S001 in OFF position.
Disconnection in the signal wiring between X1 pressure sensor 57B085-1 and node 14 (disconnection or defective contact in any connector)
6
Final check
7
210
Check the wiring between terminal B at the pressure sensor and terminal 6 at node connector 2 for continuity.
If the continuity is not Rmax 1Ω as specified any malfunction in the wiring (including connectors) between terminal B at the pressure sensor and terminal 6 at node connector 2 is the problem. Locate the problem and repair as necessary. After successful repair go to final step 7.
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
Wiring diagram for the X1-1 pressure sensor 57B085-1 [3/3]
PC4000-6 S/N 08199 and up
211
40 Troubleshooting
Part IV
G00141 - Trouble monitoring X2 pressure [1/3] Trouble code G00141
Trouble
Trouble monitoring X2 pressure
Contents of trouble
• A malfunction in the monitoring loop for the X2 pressure is detected. • Monitoring the X2 pressure is impossible because of: - Defective wiring or defective sensor 57B086 - Poor terminal contact or any disconnected connector in the wiring of sensor 57B086
Related information
• Within a pressure range of 0 - 60 bar the X2 pressure sensor 57B086 generates a signal voltage of 1-11 V. • If the output voltage to the MTC is out of range the trouble code is set.
Action of controller
• Background colour of the trouble code information: yellow
Problem that appears on machine
• The monitoring circuit for the X2 pressure is inoperative.
Instruction message Possible cause
17
Step
• Inform service till end of shift and then press cancel button.
Test condition & Inspection
Procedure
Nominal value
► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. 1 Incorrect or no supply voltage at the X2 pressure sensor 57B086 2
Disconnect the sensor connector and insert the Deutsch T-box. Measure the voltage between the sensor terminals A and C. Is supply voltage present? Check if trouble code G00090 "No power supply" is set. Is trouble code G00090 set?
Yes
Go to step 3.
No
Go to next step.
Yes
Follow the troubleshooting table for trouble code G00090.
No
Go to next step.
Vmin 22V Vmax 24V
► Keep the main key switch 20S001 in OFF position. Disconnection in the wiring between circuit breaker 11F013a and X2 pressure sensor 57B086 (disconnection or defective contact in any connector)
3
Refer to the wiring diagram and check the wiring between circuit breaker and connector terminal A at the X2 pressure sensor for continuity. Is continuity present?
Yes
Go to next step.
No
Disconnection or short circuit in the wiring (including connectors) between circuit breaker and cable connector terminal A at the X2 pressure sensor. Locate the problem and repair as necessary.
Rmax 1Ω
► Keep the main key switch 20S001 in OFF position.
Disconnection in the shield wiring between shield terminal 56X257-1 and GND
212
4
Refer to the wiring diagram and check for continuity between the shield terminal and GND. Is continuity present?
Yes
Go to next step.
No
Disconnection or short circuit in the wiring (including connectors) between shield terminal and GND. Locate the problem and repair as necessary.
Rmax 1Ω
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00141 - Trouble monitoring X2 pressure [2/3] Possible cause
Step
Test condition & Inspection
Procedure
Nominal value
► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. Defective X2 pressure sensor 57B086 (internal malfunction)
5
Disconnect the connector from the X2 pressure sensor and insert the Deutsch T-box. Measure the signal voltage at the sensor terminals B and C. Do the measurements meet the specification?
Yes
Go to next step.
No
Replace the X2 pressure sensor and verify that the repair was successful.
Vsignal 1-11V
► Keep the main key switch 20S001 in OFF position. Check for continuity in the signal wiring between sensor terminal B and node 14.
Disconnection in the signal wiring between X2 pressure sensor and node 14, connector 2, pin 4 (disconnection or defective contact in any connector).
6
Final check
7
PC4000-6 S/N 08199 and up
57B086 terminal
Node 14, connector/terminal
B
2/4
If the resistance is too high, refer to the wiring diagram and locate the problem in the signal wiring of the Rmax 1Ω X2 pressure sensor. Repair as necessary. After successful repair go to final step 7.
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
213
40 Troubleshooting
Part IV
Wiring diagram for the X2 pressure sensor 57B086 [3/3]
214
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00143 - Trouble monitoring 61B087a G00144 - Trouble monitoring 61B087b G00145 - Trouble monitoring 61B087c G00146 - Trouble monitoring 61B087d [1/3] Trouble code G00143 ~ G00146
Contents of trouble
Trouble
G00143 - Trouble monitoring 61B087a G00144 - Trouble monitoring 61B087b G00145 - Trouble monitoring 61B087c G00146 - Trouble monitoring 61B087d
• A malfunction in the monitoring loop of the relating pump pressure sensor is detected. • Monitoring the pump pressure (pump 1–4) is impossible because of: - Defective wiring or defective pressure sensor (61B087a, b, c, d) - Poor terminal contact or disconnected connector in the wiring of any pressure sensor (61B087a–d) • Within a pressure range of 0–500 bar, the pump pressure sensors generate a signal voltage of 1–11 V. • These high pressure sensors (61B087a–d) are used for pump monitoring only, not for pump control.
Related information
Action of controller Problem that appears on machine
Pump 1
Pump 2
Pump 3
Pump 4
Pump pressure sensor
61B087a
61B087b
61B087c
61B087d
Node 12 connector - terminal "Signal"
2-6
2-9
2-8
2-7
Node 12 connector - terminal "Ground"
40X161-4
40X161-8
40X161-12
40X161-16
• The pump pressure monitoring loop of the relating pump is inoperative.
Instruction message Possible cause
Pump #
2
Step
• Inform Service
Test condition & Inspection
Procedure
Nominal value
► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. 1 Incorrect or no supply voltage at the relating pump pressure sensor (61B087a–d) 2
Disconnect the relating sensor connector and insert the Deutsch T-box. Measure the voltage between the sensor pins A and C. Is supply voltage present? Check if trouble code G00090 "No power supply" is set: Is trouble code G00090 set?
Yes
Go to step 3.
No
Go to next step.
Yes
Follow the troubleshooting chart for trouble code G00090.
No
Go to next step.
Vmin 22V Vmax 24V
► Keep the main key switch 20S001 in OFF position. Disconnection in the wiring between circuit breaker 11F013a and the relating pump pressure sensor (61B087a–d) (disconnection or defective contact in any connector)
3
PC4000-6 S/N 08199 and up
Refer to the wiring diagram and check the wire segments between circuit breaker and connector terminal A of the relating pump pressure sensor for continuity. Is continuity present?
Yes
Go to next step.
No
Disconnection or short circuit in any wire segment (including connectors) between circuit breaker and connector terminal A of the relating pump pressure sensor. Locate the problem and repair as necessary.
Rmax 1Ω
215
40 Troubleshooting
Part IV
G00143 - Trouble monitoring 61B087a G00144 - Trouble monitoring 61B087b G00145 - Trouble monitoring 61B087c G00146 - Trouble monitoring 61B087d [2/3] Possible cause
Step
Test condition & Inspection
Procedure
Nominal value
► Keep the main key switch 20S001 in OFF position. Disconnection in the shield wiring between GND and the relating pump pressure sensor (61B087a–d) (disconnection or defective contact in any connector)
4
Refer to the wiring diagram and check the wire segments between GND and shield terminal 40X161 of the relating pump pressure sensor for continuity. Is continuity present?
Yes
Go to next step.
No
Disconnection or short circuit in any wire segment (including connectors) between shield terminal 41X161 and the relating pump pressure sensor. Locate the problem and repair as necessary.
Rmax 1Ω
► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. Defective pump pressure sensor (61B087a–d) (internal malfunction)
5
Disconnect the relating pump pressure sensor connector and insert the Deutsch T-box. Measure the signal voltage at the connector terminal B of the relating pump pressure sensor. Does the measurement meet the specification?
Yes
Go to next step.
No
Replace the relating pump pressure sensor and verify that the repair was successful.
Vsignal 1-11V
► Keep the main key switch 20S001 in OFF position.
Disconnection in the signal wiring between the relating pump pressure sensor (61B087a–d) and node 12 (disconnection or defective contact in any connector)
6
Final check
7
216
Check the wire segments between terminal B at the relating pump pressure sensor and the relating node connector & terminal for continuity.
If the continuity is not as Rmax 1Ω specified, any malfunction in the wiring (including connectors) between terminal B of the relating pump pressure sensor and node 12, connector & terminal is the problem. Locate the problem and repair as necessary. After successful repair go to final step 7.
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
Wiring diagram related to trouble codes G00143 - G00146 [3/3]
PC4000-6 S/N 08199 and up
217
40 Troubleshooting
Part IV
G00147 - Trouble monitoring gear lubrication (PTO 1) [1/3] Trouble code G00147 Contents of trouble
Related information
Trouble
Trouble monitoring gear lubrication (PTO 1)
• A malfunction in the monitoring loop for the PTO gear oil pressure is detected. • Pressure sensor 57B017-1 monitors the pressure in the PTO gear lubrication system. • Conditions: - The engine is standing still - 20S001 in ON position - Pressure switch 57B017-1 signals gear oil pressure (approx. 24 V), even the engine is standing still Basic sensor data (57B017-1) No pressure present
0V
Switch closed
Pressure present
24 V
Switch open
Switch point
0.5 bar
Action of controller
• Background colour of the trouble code information: yellow
Problem that appears on machine
• Monitoring of the PTO gear oil pressure is inoperative.
Instruction message Possible cause
17
Step
• Inform service till end of shift and then press cancel button.
Test condition & Inspection
Procedure
Nominal value
► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. 1 Incorrect or no supply voltage at the pressure switch 57B017-1 2
Using the Deutsch T-box, measure the supply voltage for 57B017-1 at the connector terminal 24. Is the correct supply voltage present? Check if trouble code G00090 "No power supply" is set. Is trouble code G00090 set?
Yes
Go to step 4.
No
Go to next step.
Yes
Follow the troubleshooting table for trouble code G00090.
No
Go to next step.
Vmin 22V Vmax 24V
► Keep the main key switch 20S001 in OFF position.
Disconnection in the voltage supply wiring between circuit breaker 11F013 and pressure switch 57B017-1 (disconnection or defective contact in any connector)
218
3
Refer to the wiring diagram. Using the Deutsch T-box, check the voltage supply wiring segments between the pressure switch and circuit breaker for continuity. Is continuity present?
Yes
Go to next step.
No
Disconnection, short circuit, or fault in the wiring (including connectors and resistor 56R008) between connector 56X157, terminal 24 and circuit breaker. If necessary, check the segments of the voltage supply wiring separately, locate the problem, and repair as necessary.
Rmax 820Ω
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00147 - Trouble monitoring gear lubrication (PTO 1) [2/3] Possible cause
Step
Test condition & Inspection
Procedure
Nominal value
► Keep the main key switch 20S001 in OFF position.
Disconnection in the signal wiring between pressure switch 57B017-1 and node 14 (disconnection or defective contact in any connector)
Defective ground connection at the pressure switch 57B017-1
4
Yes
The signal wiring between pressure switch and node 14 is ok. Go to next step.
No
Disconnection, short circuit, or fault in the wiring (including connectors and pins) between pressure switch and node connector 1, pin 8. If necessary, check the segments of the signal wiring separately, locate the problem, and repair as necessary.
Check the input signal at node connector 1, pin 8. Is the signal present?
► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. 5
Disconnect the cable connector 56X157 and check for proper ground connection at the connector terminal 25. Is the ground connection ok?
Yes
Go to next step.
No
Locate the problem and repair as necessary.
► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. Defective pressure switch 57B017-1 (switch does not close)
Final check
6
7
PC4000-6 S/N 08199 and up
Disconnect connector 56X157. Measure the continuity of the pressure switch between the connector pins 25 and 24. Is continuity present?
Yes
Go to next step.
No
Replace the pressure switch and verify that the repair was successful.
Rmax 1Ω
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
219
40 Troubleshooting
Part IV
Wiring diagram related to trouble code G00147 [3/3]
220
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00148 - Trouble monitoring fuel level [1/3] Trouble code G00148
Trouble
Trouble monitoring fuel level
Contents of trouble
• A malfunction in the monitoring loop of the fuel level sensor 31B063 is detected. • Monitoring of the fuel level is impossible because of: - Defective wiring or defective sensor 31B063 - Poor terminal contact or any disconnected connector in the wiring of sensor 31B063 • The signal current may be out of range because the shut-off cock is closed.
Related information
• Within a pressure range of 0-0.4 bar the sensor 31B063 generates a signal current of 4-20 mA.
Action of controller
• Background colour of the trouble code information: yellow
Problem that appears on machine
• Risk to run out of fuel.
Instruction message Possible cause
The shut-off cock is closed
17
Step
1
• Inform service till end of shift and then press cancel button.
Test condition & Inspection Open the shut-off cock between fuel tank and fuel level sensor 31B063 to allow pressure compensation. Is trouble code G00148 still present?
Procedure Yes
Go to next step.
No
End of troubleshooting.
Nominal value
► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. 2 Incorrect or no supply voltage at the fuel level sensor 31B063
3
Disconnect the cable connector from the fuel level sensor and insert the Deutsch T-box. Measure the supply voltage at the connector terminal B. Is supply voltage present? Check if trouble code G00090 "No power supply" is set. Is trouble code G00090 set?
Yes
Go to step 4.
No
Go to next step.
Yes
Follow the troubleshooting chart for trouble code G00090.
No
Go to next step.
Vmin 22V Vmax 24V
► Keep the main key switch 20S001 in OFF position.
Disconnection in the wiring between circuit breaker 11F013a and fuel level sensor 31B063 (disconnection or defective contact in any connector)
4
PC4000-6 S/N 08199 and up
Refer to the wiring diagram and check the wiring segments between circuit breaker and connector terminal B at the fuel level sensor for continuity. Is continuity present?
Yes
Go to next step.
No
Disconnection or short circuit in any wiring segment (including connectors) between circuit breaker and cable connector terminal B at the fuel level sensor. Locate the problem and repair as necessary.
Rmax 1Ω
221
40 Troubleshooting
Part IV
G00148 - Trouble monitoring fuel level [2/3] Possible cause
Step
Test condition & Inspection
Procedure
Nominal value
► Keep the main key switch 20S001 in OFF position. Disconnection in the shield wiring between connector 10X140, terminal H and fuel level sensor 31B063 (disconnection or defective contact in any connector)
5
Refer to the wiring diagram and check the wiring segments between connector 10X140, terminal H and fuel level sensor connector, terminal A for continuity. Is continuity present?
Yes
Go to next step.
No
Disconnection or short circuit in any wiring segment (including connectors) between shield terminal and cable connector, terminal A at the fuel level sensor. Locate the problem and repair as necessary.
Rmax 1Ω
► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. Defective fuel level sensor 31B063 (internal malfunction)
6
Disconnect the sensor connector and measure the signal current at the connector terminal C of the fuel level sensor. Does the measurement meet the specification?
Yes
Go to next step.
No
Replace the fuel level sensor and verify that the repair was successful.
Imin 4mA Imax 20mA
► Keep the main key switch 20S001 in OFF position. Disconnection in the signal wiring between fuel level sensor 31B063 and connector 10X140, terminal K (disconnection or defective contact in any connector)
7
Refer to the wiring diagram and check the wiring between terminal C at the fuel level sensor and connector 10X140, terminal K for continuity. Is continuity present?
Yes
Go to next step.
No
Disconnection or short circuit in the wiring (including connectors) between terminal C at the fuel level sensor and connector 10X140, terminal K. Locate the problem and repair as necessary.
Rmax 1Ω
► Keep the main key switch 20S001 in OFF position. Disconnection in the signal wiring of fuel level sensor 31B063 between connector 10X140, terminal K and node 2 (disconnection or defective contact in any connector)
8
Final check
9
222
Check the wiring between connector 10X140, terminal K and node 2, connector 2, terminal 3 for continuity. Is continuity present?
Yes
Go to next step.
No
Disconnection or short circuit in the wiring (including connectors) between connector 10X140, terminal K and node connector 2, terminal 3. Locate the problem and repair as necessary.
Rmax 1Ω
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
Wiring diagram and component location (31B063) [3/3]
Legend for figure Z 27352
PC4000-6 S/N 08199 and up
(1)
Fuel tank
(2)
Shut-off cock
(3)
Fuel level sensor (pressure transducer) 31B063
223
40 Troubleshooting
Part IV
G00149 - Trouble monitoring ambient temperature [1/2] Trouble code G00149
Trouble
Trouble monitoring ambient air temperature
Contents of trouble
• A malfunction in the monitoring loop of the ambient air temperature sensor 13B090 is detected. • Monitoring of the ambient air temperature may be impossible because of: - Defective wiring or defective sensor 13B090 - Poor terminal contact or disconnected connector in the wiring of sensor 13B090
Related information
• Within the temperature range of -50°C up to +150°C the sensor 13B090 generates a voltage signal of 0.5-9.5 V.
Action of controller Problem that appears on machine
• The monitoring of the ambient air temperature sensor 13B090 is disabled.
Instruction message Possible cause
Disconnection in the wiring of ambient air sensor 13B090
-
Step
1
-
Test condition & Inspection Check wiring between sensor and connector 11X_13 from pin 4 to shield, from connector pin 1 to sensor terminal A, from connector pin 2 to sensor terminal C, and from connector pin 3 to sensor terminal B.
Procedure
Yes
Go to next step.
No
Repair or replace as necessary according the actual wiring diagram.
Yes
Go to final step.
No
Go to next step
Yes
Go to next step.
No
Replace ambient air temperature sensor.
Is continuty present?
No input signal present at node 2
2
Check the input signal at node 2 (11K302). Measure the voltage of input signal from sensor 13B090 at node connector 2, pin 9. Compare the voltage reading (the related temperature value) with the real ambient air temperature.
Nominal value Rmax 1Ω
VSignal 0.5-9.5V
Does the signal voltage correspond to the real ambient air temperature?
Defective ambient air sensor 13B090
Final check
224
3
4
Check the resistance of the ambient air sensor. Disconnect the sensor connector and measure the resistance of the sensor between pins B and C according the PT100 temperature chart. Is the resistance according to the PT100 temperature chart ok?
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
Wiring diagram related to trouble code G00149 [2/2]
PC4000-6 S/N 08199 and up
225
40 Troubleshooting
Part IV
G00151 - Trouble monitoring gear (PTO) oil filter 1 [1/3] Trouble code G00151 Contents of trouble
Related information
Trouble
Trouble monitoring gear (PTO) oil filter 1
• A malfunction in the monitoring loop for the PTO gear oil filter pressure is detected. • Pressure sensor 57B027-1 monitors the differential pressure in the oil filter for the X4 pressure. • Conditions: - The engine is standing still - 20S001 in ON position - Pressure switch 57B027-1 signals pressure in the PTO gear oil filter (0 V), even the engine is standing still. Basic sensor data (NO switch 57B027-1) No pressure present
24 V
Switch open
Pressure present
0V
Switch closed
Switch point
5 bar
Action of controller
• Background colour of the trouble code information: yellow
Problem that appears on machine
• Monitoring of the PTO gear oil filter pressure is inoperative.
Instruction message Possible cause
17
Step
• Inform service till end of shift and then press cancel button.
Test condition & Inspection
Procedure
Nominal value
► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. 1 Incorrect or no supply voltage at the pressure switch 57B027-1 2
Measure the supply voltage for the pressure switch at connector 56X157, terminal 22. Is the correct supply voltage present?
Check if trouble code G00090 "No power supply" is set. Is trouble code G00090 set?
Yes
Go to step 4.
No
Go to next step.
Yes
Follow the troubleshooting table for trouble code G00090.
No
Go to next step.
Vmin 22V Vmax 24V
► Keep the main key switch 20S001 in OFF position.
Disconnection in the voltage supply wiring between circuit breaker 11F013 and pressure switch 57B027-1 (disconnection or defective contact in any connector)
226
3
Refer to the wiring diagram. Check the voltage supply wiring between the pressure switch and the line of circuit breaker for continuity. Is continuity present?
Yes
Go to next step.
No
Disconnection, short circuit, or fault in the wiring (including connectors and resistor 56R008) between connector 56X157, terminal 22 and the circuit breaker. If necessary, check the segments of the voltage supply wiring separately, locate the problem, and repair as necessary.
Rmax 820Ω
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00151 - Trouble monitoring gear (PTO) oil filter 1 [2/3] Possible cause
Step
Test condition & Inspection
Procedure
Nominal value
► Keep the main key switch 20S001 in OFF position.
Disconnection in the signal wiring between pressure switch 57B027-1 and node 14 (disconnection or defective contact in any connector)
4
Yes
The signal wiring between the pressure switch and node 14 is ok. Go to next step.
No
Disconnection, short circuit, or fault in the wiring (including connectors and pins) between pressure switch and node connector 1, pin 2. If necessary, check the segments of the signal wiring separately, locate the problem, and repair as necessary.
Check the input signal at node 14. Is the signal present?
► Keep the main key switch 20S001 in OFF position. Defective ground connection at the pressure switch 57B027-1
5
Disconnect the sensor connector and check for proper ground connection at connector terminal 2 (via 56X157, terminal 23). Is the ground connection ok?
Yes
Go to next step.
No
Locate the problem and repair as necessary.
► Keep the main key switch 20S001 in OFF position. Defective pressure switch 57B027-1 (switch does not open)
6
Final check
7
PC4000-6 S/N 08199 and up
Disconnect connector 56X157. Measure the continuity of the pressure switch between the connector pins 1 and 2. Is continuity present?
Yes
Go to next step.
No
Replace the pressure switch and verify that the repair was successful.
Rmax 1Ω
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
227
40 Troubleshooting
Part IV
Wiring diagram related to trouble code G00151 [3/3]
228
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00154 - Trouble monitoring return oil filter [1/3] Trouble code G00154
Trouble
Trouble monitoring return oil filter
Contents of trouble
• A malfunction in the monitoring loop for the return-oil chamber pressure is detected. • The system assumes that the pressure sensor 40B163 or its wiring is defective.
Related information
• If the system senses a signal of = 6.0 bar for 5 seconds when the engine is standing still, trouble code G00154 is set.
Action of controller
• Background colour of the trouble code information: yellow
Problem that appears on machine
• The pressure monitoring in the return-oil chamber is disturbed.
Instruction message Possible cause
17
Step
• Inform service till end of shift and then press cancel button.
Test condition & Inspection
Procedure
Nominal value
► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. 1 Incorrect or no supply voltage in the circuit of pressure sensor 40B163 (return-oil chamber pressure) 2
Disconnect the cable connector from the pressure sensor, insert the Deutsch T-box, and measure the supply voltage at the pressure sensor connector, terminal A. Is supply voltage present? Check if trouble code G00090 "No power supply" is set. Is trouble code G00090 displayed?
Yes
Go to step 4.
No
Go to next step.
Yes
Follow the troubleshooting table for trouble code G00090.
No
Go to next step.
Vmin 22V Vmax 24V
► Keep the main key switch 20S001 in OFF position. Disconnection in the wiring between pressure sensor 40B163 (return-oil chamber pressure) and the power supply line of circuit breaker 11F013a (disconnection or defective contact in any connector)
3
PC4000-6 S/N 08199 and up
Refer to the wiring diagram and check the wiring segments between pressure sensor, terminal A and the power supply line from the circuit breaker for continuity. Is continuity present?
Yes
Go to next step.
No
Disconnection or short circuit in any wiring segment (including connectors) between the line of the circuit breaker and connector terminal A at the pressure sensor. Locate the problem and repair as necessary.
Rmax 1Ω
229
40 Troubleshooting
Part IV
G00154 - Trouble monitoring return oil filter [2/3] Possible cause
Step
Test condition & Inspection
Procedure
Nominal value
► Keep the main key switch 20S001 in OFF position.
Disconnection in the signal wiring between pressure sensor 40B163 and node 11 connector 2, terminal 8 (disconnection or defective contact in any connector)
4
Disconnect the signal line of pressure sensor from node connector 2, terminal 8. Refer to the wiring diagram and check the signal wiring between pressure sensor, terminal B (via connector 40X340, terminal 13) and node 11 (connector 2, terminal 8) for continuity. Is continuity present?
Yes
Go to next step.
No
Disconnection or short circuit in any wiring segment of the signal line (including connectors) between pressure sensor (returnoil chamber pressure) and cable connector 2, terminal 2, at node 11. Locate the problem and repair as necessary.
Rmax 1Ω
► Keep the main key switch 20S001 in OFF position. Defective ground connection at connector terminal C of pressure sensor 40B163 (return-oil chamber pressure) (disconnection or defective contact in any connector)
5
Refer to the wiring diagram and check the ground wiring between pressure sensor and connector 40X340, terminal 14 for continuity and proper ground connection. Are continuity and ground connection ok?
Yes
Go to next step.
No
Disconnection or short circuit in any ground wiring segment (including connector 40X340) of the pressure sensor. Locate the problem and repair as necessary.
Rmax 1Ω
► Keep the main key switch 20S001 in OFF position. Defective shield wiring at the cables of pressure sensor 40B163 (return-oil chamber pressure) (disconnection or defective contact in any connector)
6
Refer to the wiring diagram and check the shield wiring for continuity and proper ground connection at connector 40X340, terminal 11. Are continuity and ground connection ok?
Yes
Go to next step.
No
Disconnection or short circuit in any wiring segment (including connector 40X340, terminal 11) of the shield line. Locate the problem and repair as necessary.
Rmax 1Ω
► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. Defective pressure sensor 40B163 (returnoil chamber pressure) (missing or poor signal current)
7
Final check
8
230
Insert the Deutsch T-box at the cable connector of the pressure sensor. Measure the signal voltage of the pressure sensor at the relating terminal of the Deutsch T-box. Does the measurement meet the specification?
Yes
A sporadic malfunction Vmin 1V may exist. Further inspection is required. Vmax 11V
No
Replace the pressure sensor (return-oil chamber pressure) and verify that the repair was successful.
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
Wiring diagram related to trouble code G00154 [3/3]
PC4000-6 S/N 08199 and up
231
40 Troubleshooting
Part IV
G00155 - Trouble monitoring leak oil filter [1/3] Trouble code G00155
Trouble
Trouble monitoring leak oil filter
Contents of trouble
• A malfunction in the monitoring loop for the leak-oil chamber pressure is detected. • The system assumes that the pressure sensor 40B164 or its wiring is defective.
Related information
• If the system senses a signal of = 6.0 bar for 5 seconds when the engine is standing still, trouble code G00155 is set.
Action of controller
• Background colour of the trouble code information: yellow
Problem that appears on machine
• The pressure monitoring in the leak-oil chamber is disturbed.
Instruction message Possible cause
17
Step
• Inform service till end of shift and then press cancel button.
Test condition & Inspection
Procedure
Nominal value
► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. Incorrect or no supply voltage in the circuit of pressure sensor 40B164 (leak-oil chamber pressure)
1
2
Disconnect the cable connector from the pressure sensor, insert the T-box, and measure the supply voltage at the connector, terminal A. Is supply voltage present? Check if trouble code G00099 "No power supply" is set. Is trouble code G00099 displayed?
Yes
Go to step 4.
No
Go to next step.
Yes
Follow the troubleshooting table for trouble code G00099.
Vmin 22V Vmax 24V
► Keep the main key switch 20S001 in OFF position. Disconnection in the wiring between pressure sensor 40B164 (leak-oil chamber pressure) and the power supply line of circuit breaker 11F013a (disconnection or defective contact in any connector)
232
3
Refer to the wiring diagram and check the wiring segments between the pressure sensor, terminal A) and the power supply line of the circuit breaker for continuity. Is continuity present?
Yes
Go to next step.
No
Disconnection or short circuit in any wiring segment (including connectors) between the line of the circuit breaker and connector terminal A at the pressure sensor. Locate the problem and repair as necessary.
Rmax 1Ω
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00155 - Trouble monitoring leak oil filter [2/3] Possible cause
Step
Test condition & Inspection
Procedure
Nominal value
► Keep the main key switch 20S001 in OFF position.
Disconnection in the signal wiring between pressure sensor 40B164 and node 11 connector 2, terminal 7 (disconnection or defective contact in any connector)
4
Disconnect the signal line of the pressure sensor from node 11 (connector 2, terminal 7). Refer to the wiring diagram and check the signal wiring between pressure sensor, terminal B (via connector 40X340, terminal 17) and node 11 (connector 2, terminal 7) for continuity. Is continuity present?
Yes
Go to next step.
No
Disconnection or short circuit in any wiring segment of the signal line (including connectors) between pressure sensor (leakoil chamber pressure) and cable connector 2, terminal 7 at node 11. Locate the problem and repair as necessary.
Rmax 1Ω
► Keep the main key switch 20S001 in OFF position. Defective ground connection at connector terminal C of pressure sensor 40B164 (leak-oil chamber pressure) (disconnection or defective contact in any connector)
5
Refer to the wiring diagram and check the ground wiring between the pressure sensor and connector 40X340, terminal 18 for continuity and proper ground connection. Are continuity and ground connection ok?
Yes
Go to next step.
No
Disconnection or short circuit in any ground wiring segment (including connector 40X340) of the pressure sensor. Locate the problem and repair as necessary.
Rmax 1Ω
► Keep the main key switch 20S001 in OFF position. Defective shield wiring at the cables of pressure sensor 40B164 (leak-oil chamber pressure) (disconnection or defective contact in any connector)
6
Refer to the wiring diagram and check the shield wiring for continuity and proper ground connection at 40X340, terminal 15. Are continuity and ground connection ok?
Yes
Go to next step.
No
Disconnection or short circuit in any wiring segment (including connectors and terminal block 40X340) of the shield line. Locate the problem and repair as necessary.
Rmax 1Ω
► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. Defective pressure sensor 40B164 (leakoil chamber pressure) (missing or poor signal current)
7
Final check
8
PC4000-6 S/N 08199 and up
Insert the Deutsch T-box at the cable connector of the pressure sensor. Measure the signal voltage of the pressure sensor at the relating terminal of the T-box. Does the measurement meet the specification?
Yes
A sporadic malfunction Vmin 1V may exist. Further inspection is required. Vmax 11V
No
Replace the pressure sensor (leak-oil chamber pressure) and verify that the repair was successful.
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
233
40 Troubleshooting
Part IV
Wiring diagram related to trouble code G00155 [3/3]
234
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00159 - Trouble monitoring breather filter [1/3] Trouble code G00159 Contents of trouble
Trouble
Trouble monitoring breather filter
• A malfunction in the monitoring loop for the hydraulic oil tank breather filter (2 pcs) is detected. • Pressure sensor 40B024 monitors the (vacuum) pressure at the breather filter (2 pcs) on top of the hydraulic oil tank. • Conditions: - The engine is standing still - 20S001 in ON position - Pressure switch 40B024 signals vacuum (0 V) at the breather filter, even the engine is standing still
Related information
Basic sensor data (40B024) NO* No pressure present
24 V
Switch open
Pressure present
0V
Switch closed
Switch point
0.08 bar (vacuum)
* NO= Normally Open
Action of controller
• Background colour of the trouble code information: yellow
Problem that appears on machine
• Monitoring of the breather filter pressure is inoperative.
Instruction message Possible cause
17
Step
• Inform service till end of shift and then press cancel button.
Test condition & Inspection
Procedure
Nominal value
► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. 1 Incorrect or no supply voltage at the pressure switch 40B024 2
Measure the supply voltage for the pressure switch at connector 40X240, terminal 10. Is the correct supply voltage present?
Check if trouble code G00090 "No power supply" is set. Is trouble code G00090 set?
Yes
Go to step 4.
No
Go to next step.
Yes
Follow the troubleshooting table for trouble code G00090.
No
Go to next step.
Vmin 22V Vmax 24V
► Keep the main key switch 20S001 in OFF position.
Disconnection in the voltage supply wiring between circuit breaker 11F013 and pressure switch 40B024 (disconnection or defective contact in any connector)
3
PC4000-6 S/N 08199 and up
Refer to the wiring diagram. Check the voltage supply wiring between the pressure switch and the line of the circuit breaker for continuity. Is continuity present?
Yes
Go to next step.
No
Disconnection, short circuit, or fault in the wiring (including connectors and resistor 40R008) between connector 40X240, terminal 10 and the circuit breaker. If necessary, check the segments of the voltage supply wiri,ng separately, locate the problem, and repair as necessary.
40R008 820Ω
235
40 Troubleshooting
Part IV
G00159 - Trouble monitoring breather filter [2/3] Possible cause
Step
Test condition & Inspection
Procedure
Nominal value
► Keep the main key switch 20S001 in OFF position.
Disconnection in the signal wiring between pressure switch 40B024 and node 11 (disconnection or defective contact in any connector)
4
Yes
The signal wiring between pressure switch and node 11 is ok. Go to next step.
No
Disconnection, short circuit, or fault in the wiring (including connectors and pins) between pressure switch and node 11, connector 3, pin 9. If necessary, check the segments of the signal wiring separately, locate the problem, and repair as necessary.
Check the input signal at node 11, connector 3, pin 9. Is the signal present?
► Keep the main key switch 20S001 in OFF position. Defective ground connection at the pressure switch 40B024
5
Disconnect connector 40X240 and check for proper ground connection at the connector terminal 11. Is the ground connection ok?
Yes
Go to next step.
No
Locate the problem and repair as necessary.
► Keep the main key switch 20S001 in OFF position. Defective pressure switch 40B024 (switch does not open)
6
Final check
7
236
Disconnect connector 40X240. Measure the continuity of the pressure switch between the connector pins 10 and 11. Is continuity present?
Yes
Go to next step.
No
Replace the pressure switch and verify that the repair was successful.
Rmax 1Ω
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
Wiring diagram related to trouble code G00159 [3/3]
PC4000-6 S/N 08199 and up
237
40 Troubleshooting
Part IV
G00160 - Trouble monitoring engine air cleaner 1 [1/3] Trouble code G00160 Contents of trouble
Trouble
Trouble monitoring engine air cleaner
• A malfunction in the monitoring loop for the engine air filter pressure sensors is detected. • Sensors 52B018-1 & 52B019-1 monitor the (vacuum) pressure in the inlet manifolds between air filters and engine. ► Conditions: - The engine is standing still - 20S001 in ON position - Pressure switch 52B018-1 and/or 52B019-1 signals vacuum (0 V) in the inlet manifold below the engine air cleaner, even the engine is standing still.
Related information
Basic sensor data (52B018-1/52B019-1) NO* No pressure present
24 V
Switch open
Pressure present
0V
Switch closed
Switch point
>60 mbar (vacuum) * NO= Normally Open
Action of controller
• Background colour of the trouble code information: yellow
Problem that appears on machine
• Monitoring of the engine air cleaners is inoperative.
Instruction message Possible cause
17
Step
• Inform service till end of shift and then press cancel button.
Test condition & Inspection
Procedure
Nominal value
► Prepare with the main key switch 20S001 in OFF position, and then carry out troubleshooting with the main key switch 20S001 in ON position. Incorrect or no supply voltage at the affected pressure switch (52B018-1 or 52B019-1)
1
2
Measure the supply voltage for 52B018-1 at connector 51X252, terminal 1. For 52B019-1 measure at terminal 3 in the same connector. Is the correct supply voltage present? Check if trouble code G00090 "No power supply" is set. Is trouble code G00090 set?
Yes
Go to step 4.
No
Go to next step.
Yes
Follow the troubleshooting table for trouble code G00090.
No
Go to next step.
Vmin 22V Vmax 24V
► Keep the main key switch 20S001 in OFF position.
Disconnection in the voltage supply wiring between circuit breaker 11F013 and pressure switch 52B018-1 or 52B019-1 (disconnection or defective contact in any connector)
238
3
Refer to the wiring diagram. Check the voltage supply wiring between pressure switch 52B018-1 or 52B019-1 and the line of the circuit breaker for continuity. Is continuity present?
Yes
Go to next step.
No
Disconnection, short circuit, or fault in the wiring (including connectors and resistor 51R008) between connector 51X252, terminal 1 (52B018-1) or terminal 3 (52B019-1) and the circuit breaker. If necessary, check the segments of the voltage supply wiring separately, locate the problem, and repair as necessary.
51R008 820Ω
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00160 - Trouble monitoring engine air cleaner 1 [2/3] Possible cause
Step
Test condition & Inspection
Procedure
Nominal value
► Keep the main key switch 20S001 in OFF position.
Disconnection in the signal wiring between pressure switch 52B018-1/52B019-1 and node 17. (disconnection or defective contact in any connector)
4
Yes
The signal wiring between pressure switch 52B018-1/ 52B019-1 and node 17 is ok. Go to next step.
No
Disconnection, short circuit, or fault in the wiring (including connectors and pins) between pressure switch 52B018-1/ 52B019-1 and node 17. If necessary, check the segments of the signal wiring separately, locate the problem, and repair as necessary.
Check the input signal at node 17, connector 3, pin 8 (for 52B018-1) or connector 3, pin 6 (for 52B019-1). Is the signal present?
► Keep the main key switch 20S001 in OFF position. Defective ground connection at the pressure switch 52B018-1 or 52B019-1
5
Disconnect connector 51X252 and check for proper ground connection at the connector terminal 2 (52B018-1) or terminal 4 (52B019-1). Is the ground connection ok?
Yes
Go to next step.
No
Locate the problem and repair as necessary.
► Keep the main key switch 20S001 in OFF position. Defective pressure switch 52B018-1 or 52B019-1 (switch does not open)
6
Final check
7
PC4000-6 S/N 08199 and up
Disconnect connector 51X252. Measure the continuity of the pressure switches between the connector pins 1 and 2 (52B018-1) or between the connector pins 3 and 4 (52B019-1). Is continuity present?
Yes
Go to next step.
No
Replace the defective pressure switch 52B018-1 or 52B019-1 and verify that the repair was successful.
Rmax 1Ω
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
239
40 Troubleshooting
Part IV
Wiring diagram related to trouble code G00160 [3/3]
240
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00161 - Trouble monitoring battery voltage [1/3] Trouble code G00161
Trouble
Trouble monitoring battery voltage
Contents of trouble
• A malfunction in the monitoring loop for the battery voltage is detected. • The system assumes that the resistor 11T080 or the wiring circuit of the battery charging system is defective.
Related information
• If the battery voltage signal at 11T080 indicates >=39 V for 5 seconds, the trouble code is set.
Action of controller
• Background colour of the trouble code information: yellow
Problem that appears on machine
• The monitoring of the battery voltage is disabled.
Instruction message Possible cause
17
Step
• Inform service till end of shift and then press cancel button.
Test condition & Inspection
Procedure
Nominal value
► Keep the engine running at high idle. 1
Measure the input voltage at the resistor. Is correct input voltage present?
Incorrect or no input voltage (24 V) at resistor 11T080 2
Check if supply voltage is present at the power supply line 11F013a. Is voltage present?
Yes
Go to step 4.
No
Go to next step.
Yes
Go to next step.
No
Follow the troubleshooting chart for trouble code G00099 "Trouble power supply".
Vmin 22V Vmax 24V
Vmin 22V Vmax 24V
► Keep the main key switch 20S001 in OFF position. Disconnection in the (+) wire between resistor 11T080 and the power supply line of circuit breaker 11F013a (disconnection or defective contact in any connector)
3
Refer to the wiring diagram and check the (+) wire between the resistor 11T080 and the power supply line of the circuit breaker for continuity. Is continuity present?
Yes
Go to next step.
No
Disconnection or short circuit in the (+) wire (including connections) between the resistor and the power supply line of the circuit breaker. Locate the problem and repair as necessary.
Rmax 1Ω
► Keep the main key switch 20S001 in OFF position.
Defective ground connection at resistor 11T080
4
PC4000-6 S/N 08199 and up
Check for proper ground connection at the (-) terminal of the resistor. Is the ground connection ok?
Yes
Go to next step.
No
Disconnection or short circuit in the (-) wire (including connections) between the resistor and ground (GND). Locate the problem and repair as necessary.
Rmax 1Ω
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40 Troubleshooting
Part IV
G00161 - Trouble monitoring battery voltage [2/3] Possible cause
Step
Test condition & Inspection
Procedure
Nominal value
► Keep the main key switch 20S001 in ON position. The signal voltage of resistor 11T080 to node 2, connector 2, terminal 8 is not correct or not present
VSignal 5
Disconnect the node connector 2 and measure the signal voltage at terminal 8. Does the signal voltage meet the specification?
Yes
Go to step 7.
max. 10V
VSignal min. 0V
No
Go to next step.
► Keep the main key switch 20S001 in OFF position.
Resistor 11T080 is defective
6
Measure the resistance of both internal resistors in 11T080. Does the resistance correspond to the nominal value
Yes
Go to next step.
No
Replace the defective resisitor(s) and recheck the system for proper function.
11T080 30.1kΩ+ 10.0kΩ
► Keep the main key switch 20S001 in OFF position.
Disconnection in the signal wire between resistor 11T080 and node 2, connector 2, terminal 8 (disconnection or defective contact)
7
Check the signal wire between resistor 11T080 and node 2, connector 2, terminal 8 for continuity. Is continuity present?
Yes
Go to next step.
No
Disconnection or short circuit in the signal wire (including connections) between resistor 11T080 and node 2, connector 2, terminal 8. Locate the problem and repair as necessary.
Rmax 1Ω
► Keep the main key switch 20S001 in OFF position.
Defective ground connection between 11T080 and ground (disconnection or defective contact)
8
Final check
9
242
Refer to the wiring diagram and check for proper ground connection from module 11T080 to ground. Is the ground connection ok?
Yes
Go to next step.
No
Disconnection or short circuit in the ground wire (including connections) between 11T080 and ground. Locate the problem and repair as necessary.
Rmax 1Ω
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
Wiring diagram related to trouble code G00161 [3/3]
PC4000-6 S/N 08199 and up
243
40 Troubleshooting
Part IV
G00162 - Trouble monitoring charging-/discharging current [1/3] Trouble code G00162 Contents of trouble
Trouble
Trouble monitoring charging-/discharging current
• The system detected that the shunt resistor 71T003, or the module 51T017, or the belonging wiring is defective. • The purpose of the module 51T017 is to monitor the charging and discharging current of the batteries. Battery information Battery
Location
Function
Cat walk
Battery charging
Cab base
Stabilized voltage for MTC
71G001
Related information
71G002 71G003 71G004 13G008 13G009
Action of controller
• Background colour of the trouble code information: yellow
Problem that appears on machine
• The monitoring circuit of the charging and discharging current for the batteries is inoperative. • The batteries will be discharged if the charging current is too low.
Instruction message Possible cause
17
Step
• Inform service till end of shift and then press cancel button.
Test condition & Inspection
Procedure
Nominal value
► Keep the main key switch 20S001 in OFF position. Switch OFF the battery main switches 71Q003 & 71Q004.
The shunt resistor 71T003 may be defective
1
Disconnect the main battery cables and the signal lines (terminals B & L) from the shunt resistor. Then measure the resistance of the shunt resistor. Does the measurement reading meet the specification?
Yes
Go to next step.
No
Replace the shunt resistor. Connect all cables and recheck the monitoring circuit for proper function. If the repair was successful, go to final step 5.
71T003 4.5±0.5Ω
► Keep the main key switch 20S001 in OFF position. Switch OFF the battery main switches 71Q003 & 71Q004.
The wiring of the shunt resistor 71T003 may cause the problem
244
2
Refer to the wiring diagrams. Check the following cables for continuity: - Between alternator 52G005 and the shunt resistor (input) - Between shunt resistor (output) and all batteries - Between shunt resistor (terrminals B & L) and module 51T017, including the wire shielding Is the continuity as specified?
Yes
Go to next step.
No
Locate the problem and repair as necessary. After repair recheck the system for proper function.
Rmax 1Ω
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00162 - Trouble monitoring charging-/discharging current [2/3] Possible cause
Step
Test condition & Inspection
Procedure
Nominal value
► Keep the main key switch 20S001 in ON position.
The power supply wiring (+/-) at the module 51T017 may cause the problem
3
Refer to the wiring diagrams. Check at the following terminals of the module: - terminal 7 for supply voltage (B+) - terminal 8 for proper ground connection. Is the power supply wiring (+/-) of the module ok?
Yes
Go to next step.
No
Locate the problem and repair as necessary. After repair recheck the system for proper function.
Vmin 22V Vmax 24V
► Keep the main key switch 20S001 in OFF position.
The signal lines between shunt 71T003 module 51T017 and node 17 are disturbed
Final check
4
5
PC4000-6 S/N 08199 and up
Refer to the wiring diagrams. Check the following cables for continuity: - between module pin 5, and node connector 2, pin 7 - between module pin 4/2, and shunt connection B/L Is the continuity as specified in both cables?
Yes
Replace module 51T017 and recheck for proper function.
No
Locate the problem and repair as necessary. After repair recheck the system for proper function.
Rmax 1Ω
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
245
40 Troubleshooting
Part IV
Wiring diagram related to trouble code G00162 [3/3]
246
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00163 - Trouble monitoring pilot control [1/3] Trouble code G00163 Contents of trouble
Trouble
Trouble monitoring pilot control
• The message is displayed if any malfunction in the monitoring circuit for the time relay 11K032 (electrical pilot control) is detected. • The power supply of the electrical pilot control may be disturbed. • A contact inside time relay 11K032 may be stuck. • The time relay 11K032 is a redundant relay and it is energized when one (or more) of the control levers or pedals is moved away from the resting (zero) position. • If one of the power supply circuits (11F013 & 11F043) fails, the trouble message (G00163) is displayed. • The fixed time relay setting is 1 second. • If any control is activated the time relay is energized at terminal A1
Legend for figure Z 27289 (1)
Time delay relay 11K032
(2)
Green LED (power supply ok)
Related information
Action of controller
• Background colour of the trouble code information: yellow
Problem that appears on machine
• Monitoring is no longer redundant. Only one circuit of the delay control is present.
Instruction message
17
PC4000-6 S/N 08199 and up
• Inform service till end of shift and then press cancel button.
247
40 Troubleshooting
Part IV
G00163 - Trouble monitoring pilot control [2/3] Possible cause
Step
Test condition & Inspection
Procedure
Nominal value
► Keep the main key switch 20S001 in ON position.
1 Incorrect or no supply voltage at the time delay relay 11K032
2
Measure the supply voltage between 11K032, terminal 28 and ground. Also measure the supply voltage between relay terminal 16, and ground. Is supply voltage present at terminals 28 and 16?
Check if trouble code G00090 "No power supply" is set: Is trouble code G00090 set?
Yes
Go to next step.
No
Refer to the wiring diagram. Check the insufficient supply circuit including the involved relays for malfunction. Locate the problem and replace or repair as necessary. After repair verify that the system function is orderly.
Yes
Follow the troubleshooting chart for trouble code G00090.
No
Go to next step.
Vmin 22V Vmax 24V
► Keep the main key switch 20S001 in OFF position.
Malfunction in the contact wiring between 11K032 and ground / node input
3
Refer to the wiring diagram. At the time relay, measure for continuity between: • terminal 15 (11F013 circuit) → node 3, terminal 39 • terminal 27 (11F043 circuit) → 11Q111, terminal A1 • 11Q111, terminal A2 → ground Is continuity present at all of the three tested terminals of the time relay?
Yes
Go to next step.
No
Disconnection or short circuit in the concerned wiring between time relay and ground/ node. Locate the problem and repair as necessary.
Rmax 1Ω
► Main key switch 20S001 ON - control lever in neutral position
Relay test: 11K126
Final check
248
4
5
Check if on-board voltage is present at both relay terminals 13 and 14 (the contact should be closed). Is the relay contact closed?
Yes
Go to next step.
No
Check the time relay and its wiring. Repair the wiring, if necessary, or replace the time relay. After repair recheck for proper function.
Vmin 22V Vmax 24V
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
Wiring diagram related to trouble code 00163 [3/3]
PC4000-6 S/N 08199 and up
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40 Troubleshooting
Part IV
G00164 - Trouble air cleaner 1 [1/2] Trouble code G00164
Trouble
Trouble air cleaner 1
Contents of trouble
• The message is displayed if the sensors 52B018-1 & 52B019-1 of the engine air filters detect clogged air filters. • The system assumes that the monitoring circuits of the engine air filter sensors are not disturbed.
Related information
• The sensors 52B018-1 & 52B019-1 watch the vacuum pressure in the inlet manifolds between air filters and engine.
Action of controller
• Background colour of the trouble code information: yellow
Problem that appears on machine
• With clogged air filter(s) the following problems occur: - Loss in rated engine power - Poor exhaust emission quality - Increased fuel consumption - Increased exhaust gas temperature - Reduced engine lifetime Remark: If machines are operated at locations higher than 3600 m, they sooner will be affected by the above mentioned effects, even though the system does not yet display any trouble message.
Instruction message Possible cause
17
Step
• Inform service till end of shift and then press cancel button.
Test condition & Inspection
Procedure
Nominal value
► Main key switch 20S001 OFF – Engine OFF – Maintenance safety switch 50S058 OFF & locked Replace the outer filter elements (4 pieces) and check the inner filter elements at the service indicators. If necessary or if the indicators are switched to red, replace the inner filter elements.
Service advice
The engine air filters (inner and outer elements) are clogged
1
• How to identify a clogged outer engine air filter element The only correct method to identify the clogged condition of an outer engine air filter element is to compare the weights of a new and a clogged outer air filter element. Sample: Weight unit
Weight of a new air filter element
Weight of a clogged air filter element
[kg]
approx. 9
approx 20
• The replacement interval depends on the respective environmental conditions. Always monitor the engine air filter elements according to your local operations conditions. • After every 2nd replacement of the outer engine air filter elements the inner air filter elements must be replaced too. • The air filter box must be cleaned thoroughly after the period of every 1000 operating hours. Go to final step 2. Final check
250
2
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
View onto the engine air cleaner [2/2]
Legend for figure Z 27279 (1)
Wing nut
(4)
Outer air filter element
(2)
Lock washer
(5)
Indicator
(3)
Washer
(6)
Inner air filter element
PC4000-6 S/N 08199 and up
251
40 Troubleshooting
Part IV
G00165 - Trouble breather filter hydraulic oil tank [1/2] Trouble code G00165
Trouble
Trouble breather filter hydraulic oil tank
Contents of trouble
• The message is displayed if sensor 40B024 (on top of the hydraulic oil tank) detects a clogged breather filter. • The system assumes that the monitoring circuit of the breather filter sensor 40B024 is not disturbed.
Related information
• Sensor 40B024 (2 pcs) watches the vacuum pressure of the breather and ventilation of the hydraulic oil tank.
Action of controller
• Background colour of the trouble code information: yellow
Problem that appears on machine
• A clogged breather adversely affects the circulation of the hydraulic oil in the tank.
Instruction message Possible cause
17
Step
• Inform service till end of shift and then press cancel button.
Test condition & Inspection
Procedure
Nominal value
► Keep the main key switch 20S001 in OFF position. Replace the breather filter(s) as necessary. For details refer to the OPERATION & MAINTENANCE MANUAL, section HYDRAULIC SYSTEM - FILTER SERVICE.
A breather filter is clogged
1
Final check
2
252
Remark: Only use steel made filter elements. If this trouble message appears frequently in-between the replacement intervals, make sure that: (a) the hydraulic oil tank is not overfilled when the machine is in its defined position, and (b) consider the dependency on the temperature range.
Go to final check 2.
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
Label showing temperature information and defined positions [2/2]
Legend for figure Z 27341 (1)
Hydraulic oil tank
(2)
Temperature information
(3)
Defined positions
PC4000-6 S/N 08199 and up
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40 Troubleshooting
Part IV
G00166 - Trouble oil filter gear (PTO 1) [1/2] Trouble code G00166 Contents of trouble
Trouble
Trouble oil filter gear (PTO 1)
• Pressure sensor 57B027-1 (NO*) signals, that the filter for the PTO gear lubrication system is clogged. *NO = Normally Open
• A problem with the pressure sensor 57B027-1 or its wiring (G00151) may also cause the trouble. • The trouble code is not set until the hydraulic oil temperature reached T2 + 18°C Sample Hydraulic oil: T2:
VG100 39°C
In this case the trouble code is not set until the hydraulic oil temperature reached: 39 + 18 = 57°C
Related information
Basic sensor data (57B027-1) No pressure present
24 V
Switch open
Pressure present
0V
Switch closed
Switch point
5 bar
Action of controller
• Background colour of the trouble code information: yellow
Problem that appears on machine
• Unfiltered PTO gear oil flows through the bypass of the filter.
Instruction message Possible cause
17
Step
• Inform service till end of shift and then press cancel button.
Test condition & Inspection
Procedure
Nominal value
► Main key switch 20S001 OFF - Engine OFF - Maintenance safety switch 50S058 OFF & locked
The PTO gear oil filter is clogged
1
Screw off the filter case and check for clogging. Is the filter element clogged?
Yes
Replace the filter element if necessary. If the filter element was clogged check the PTO lubrication pump for wear.
No
Go to next step.
► Main key switch 20S001 OFF - Engine OFF - Maintenance safety switch 50S058 OFF & locked The pressure sensor 57B027-1 is defective
2
Final check
3
254
The pressure sensor has an internal stuck in closed position. Remove the sensor and replace it by a new Go to final step 3. one. After that recheck the system for proper function. Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
View onto the PTO gear oil filter with pressure sensor 57B027-1 [2/2]
PC4000-6 S/N 08199 and up
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40 Troubleshooting
Part IV
G00169 - Trouble return oil filter hydraulic oil tank [1/1] Trouble code G00169 Contents of trouble
Trouble
Trouble return oil filter hydraulic oil tank
• Pressure sensor 40B163 signals, that the back pressure in the return oil filter exceeds 2 bar. • The system assumes that sensor 40B163 and the respective wiring are not defective. • The Qmin / Qmax setting via VHMS must be in ’Automatic’ position. • The trouble code is not set until the hydraulic oil temperature reached T2 + 18°C Sample Hydraulic oil: T2:
Related information
VG100 39°C
In this case the trouble code is not set until the hydraulic oil temperature reached: 39 + 18 = 57°C Action of controller
• Background colour of the trouble code information: yellow
Problem that appears on machine
• Unfiltered return oil flows through the bypass of the filter into the hydraulic oil tank.
Instruction message Possible cause
17
Step
• Inform service till end of shift and then press cancel button.
Test condition & Inspection
Procedure
Nominal value
► Main key switch 20S001 OFF - Engine OFF - Maintenance safety switch 50S058 OFF & locked
The return oil filter is clogged
1
Remove both filter cover retainers (two-armed & three-armed) on top of the hydraulic oil tank. For details refer to the OPERATION & MAINTENANCE MANUAL, section HYDRAULIC SYSTEM - FILTER SERVICE. Are one or more filters clogged?
Yes
Replace return oil filters as described in the OPERATION & MAINTENANCE MANUAL. Locate the cause of the contamination and rectify the problem.
No
Go to next step.
► Main key switch 20S001 OFF - Engine OFF - Maintenance safety switch 50S058 OFF & locked The pressure sensor 40B163 is defective
2
Final check
3
256
The pressure sensor has an internal stuck. Remove the sensor and replace it by a new one. After that recheck the system for proper function.
Go to final step 3.
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00170 - Trouble leak oil filter hydraulic oil tank [1/1] Trouble code G00170 Contents of trouble
Trouble
Trouble leak oil filter hydraulic oil tank
• Pressure sensor 40B164 signals, that the leak oil filter in the hydraulic tank is clogged. • The trouble code is set if the pressure in the leak oil chamber exceeds 0.5 bar. • The trouble code is not set until the hydraulic oil temperature reached T2 + 18°C Sample Hydraulic oil: T2:
Related information
VG100 39°C
In this case the trouble code is not set until the hydraulic oil temperature reached: 39 + 18 = 57°C Action of controller
• Background colour of the trouble code information: yellow
Problem that appears on machine
• Unfiltered leak oil flows through the bypass of the filter into the hydraulic oil tank.
Instruction message Possible cause
17
Step
• Inform service till end of shift and then press cancel button.
Test condition & Inspection
Procedure
Nominal value
► Main key switch 20S001 OFF - Engine OFF - Maintenance safety switch 50S058 OFF & locked
The leak oil filter is clogged
1
Remove the two-armed filter cover retainer on top of the hydraulic oil tank. For details refer to the OPERATION & MAINTENANCE MANUAL, section HYDRAULIC SYSTEM - FILTER SERVICE. Is the leak oil filter clogged?
Yes
Replace the leak oil filter as described in the OPERATION & MAINTENANCE MANUAL. Locate the cause of the contamination and rectify the problem.
No
Go to next step.
► Main key switch 20S001 OFF - Engine OFF - Maintenance safety switch 50S058 OFF & locked The pressure sensor 40B164 is defective
2
Final check
3
PC4000-6 S/N 08199 and up
The pressure sensor has an internal stuck. Remove the sensor and replace it by a new one. After that recheck the system for proper function.
Go to final step 3.
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
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40 Troubleshooting
Part IV
G00176 - Trouble battery voltage too low [1/2] Trouble code G00176
Trouble
Trouble battery voltage too low
Contents of trouble
• Via the resistor 11T080 the system detects too low battery voltage.
Related information
• If the battery voltage at 11T080 is =60°C
The X2 pressure is too low
1
Connect a pressure gauge (0-60 bar) to the pressure test port M1.2 at the valve cartridge block. Measure the pilot pressure X2. Is the X2 pressure too low (less than 30 bar)?
Yes
Go to next step.
No
Replace the pressure sensor 57B086. Verify that trouble code G00180 is not set again. If the repair was successful, go to final step 3.
Wrong X2 pressure adjustment
2
After successful Refer to the SERVICE MANUAL, section CHECKS AND ADJUSTMENT OF PILOT PRESSURE and follow adjustment go to final the adjustment procedures for the X2 pressure. step 3.
Final check
3
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
264
X2 pressure 45±2bar
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
View onto the valve cartridge block with X2 pressure sensor 57B086 & M1.2 [2/2]
PC4000-6 S/N 08199 and up
265
40 Troubleshooting
Part IV
G00181 - Trouble pilot pressure X2 too high [1/2] Trouble code G00181
Trouble
Trouble pilot pressure X2 too high
Contents of trouble
• The message is displayed if the pilot pressure X2 is too high. • The system assumes that the monitoring circuit for the X2 pressure is not disturbed.
Related information
• The pressure sensor 57B086 detected a pressure of more than 52 bar during 2 seconds.
Action of controller
• Background colour of the trouble code information: yellow
Problem that appears on machine
• A too high X2 pressure affects the hydraulic system adversely.
Instruction message Possible cause
17
Step
• Inform service till end of shift and then press cancel button.
Test condition & Inspection
Procedure
Nominal value Temp
► Keep the engine running at high idle and operation temperature.
hydr.oil
>=60°C
The X2 pressure is too high
1
Connect a pressure gauge (0-60 bar) to the pressure test port M1.2 at the valve cartridge block. Measure the pilot pressure X2. Is the X2 pressure too high (more than 52 bar)?
Yes
Go to next step.
No
Replace the pressure sensor 57B086. Verify that trouble code G00181 is not set again. If the repair was successful, go to final step 3.
Wrong X2 pressure adjustment
2
Refer to the SERVICE MANUAL, section CHECKS After successful AND ADJUSTMENT OF PILOT PRESSURE and follow adjustment go to final the adjustment procedures for the X2 pressure. step 3.
Final check
3
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
266
X2 pressure 45±2bar
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
View onto the valve cartridge block with X2 pressure sensor 57B086 & M1.2 [2/2]
PC4000-6 S/N 08199 and up
267
40 Troubleshooting
Part IV
G00184 - Central lubrication system empty G00187 - Slew ring gear lubrication system empty [1/1] Trouble code G00184 G00187
Trouble
G00184 - Central lubrication system empty G00187 - Slew ring gear lubrication system empty
Contents of trouble
• The message is displayed if the corresponding grease barrel needs refilling.
Related information
• The sensing range of the ultrasonic grease level sensors 62B108 & 62B109 is pre-adjusted ex factory. Further settings are not possible. • For more information about the ultrasonic grease level sensors 62B108 & 62B109 also refer to the PARTS & SERVICE NEWS AH10510, latest version.
Action of controller Problem that appears on machine
• Background colour of the trouble code information: yellow • Risk, to operate the machine without grease. • Bucket cut-off after approx. 4 hours (option).
Instruction message Possible cause
20
Step
• Inform service and then press cancel button.
Test condition & Inspection Using the dipstick, verify if the relating grease barrel needs refilling. Is the grease barrel empty?
Procedure
Yes
Press the cancel button and refill the specified grease. Verify that trouble code G00184 or G00187 is not displayed again.
No
Go to next step.
Yes
Go to final step 3.
No
Verify if other relevant trouble codes are displayed. If so, follow the troubleshooting procedures of the corresponding troubleshooting chart.
Definition of the grease levels
The concerned grease barrel (CLS or SLS) needs refilling
The trouble message is wrong. The concerned grease barrel (CLS or SLS) doesn’t need refilling
1
2
Refer to trouble code G00012/G00013 for: → Information about the LEDs at the ultrasonic sensor → Testing the sensor reaction → Troubleshooting procedures Could you rectify the problem?
Final check
268
Nominal value
3
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again.
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00185 - Trouble central lubrication system G00188 - Trouble slew ring gear lubrication system [1/4] Trouble code G00185 G00188
Trouble
G00185 - Trouble central lubrication system G00188 - Trouble slew ring gear lubrication system
Contents of trouble
• The grease pressure increase time (CLS or SLS) is too long.
Related information
• It is not possible to build up the grease pressure (CLS or SLS) in the pre-set time frame. • For further details concerning the lubrication system refer to the SERVICE MANUAL, section LUBRICATION SYSTEMS.
Action of controller
• Background colour of the trouble code information: yellow
Problem that appears on machine
• Risk, to run the machine without CLS/SLS lubrication. • Optional function: If the function Bucket Cut-Off is activated via the CoDeSys Visualization software, and if the machine is operated further on, after trouble code G00185 or G00188 is set, the bucket function will be disabled after approx. 4 hours.
Instruction message Possible cause
20
Step
• Inform service and then press cancel button.
Test condition & Inspection
Procedure
Nominal value
► Keep the engine running at high idle.
Grease pump: malfunction, worn or defective
The electrical function of the vent valve is disturbed
The grease may be soiled
The mechanical function of the vent valve is disturbed
The mechanical part of the vent valve is defective
1
Check the performance of the relating grease pump (CLS or SLS) and arrange preparations for testing the grease pressure. For detailed test & adjustment procedures refer to the SERVICE MANUAL, section LUBRICATION SYSTEMS. Make sure that the vent valve is closed. Does the relating grease pump build up grease pressure as specified?
Qvolume 19-21 doublestrokes/min Ppump drive Yes
Go to next step.
Grease pressure max. 180+5bar No
Grease pump defective, replace the grease pump.
Check the electrical function of the respective vent valve solenoid. Is the electrical function ok?
Yes
Go to next step.
No
Replace the vent valve solenoid.
3
Refill the grease barrel through a filter. Is grease pressure built up with clean grease?
Yes
The problem is solved, perform the final check in step 7.
No
Go to next step.
Yes
Go to next step.
4
Remove the mechanical part from the electrical part of the respective vent valve. Disassemble and check the lower part and clean as necessary. Is the mechanical part of the vent valve blocked?
No
Replace the vent valve.
2
5
PC4000-6 S/N 08199 and up
hydr.pressure
45±2bar
Repair or replace the mechanical part of the respective vent valve as necessary. Go to next step. Clean the respective contaminated grease system. Replace the grease filter and the screen.
269
40 Troubleshooting
Part IV
G00185 - Trouble central lubrication system G00188 - Trouble slew ring gear lubrication system [2/4] Possible cause End-of-line switch (grease main line): wrong adjustment or defective
Final check
270
Step
Test condition & Inspection
Procedure
6
Refer to the SERVICE MANUAL, section LUBRICATION SYSTEMS, and follow the adjustment procedure. Did you need to correct any wrong adjustment?
7
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again. Verify that the operation cycles of the lubrication systems correspond to the following time diagram Z 28055-1 (taken from the flowchart).
Yes
Go to next step.
No
Replace the respective end-of-line switch.
Nominal value
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
Trouble codes G00185 and G00188 - view onto the vent valve [3/4]
Legend for figure Z 26959 (1)
Solenoid
(5)
Reset spring
(2)
Valve assembly
(6)
Auxiliary valve cone
(3)
Solenoid stem
(7)
Main valve cone
(4)
Lever
PC4000-6 S/N 08199 and up
271
40 Troubleshooting
Part IV
Allocation of vent valves and end-of-line switches [4/4] Lubrication system
Vent valve
End-of-line switch
CLS
62Q507a
80B043
SLS
62Q509a
62B046
Wiring diagram related to trouble codes G00185 and G00188
272
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00186 - Trouble central lubrication system G00189 - Trouble slew ring gear lubrication system [1/3] Trouble code Trouble
G00186 G00189
G00186 - Trouble central lubrication system G00189 - Trouble slew ring gear lubrication system
Contents of trouble
• The grease pressure decrease time (CLS or SLS) is too long.
Related information
• It is not possible to release the grease pressure (CLS or SLS) in the pre-set time frame. • For further details concerning the lubrication system refer to the SERVICE MANUAL, section LUBRICATION SYSTEMS.
Action of controller
• Background colour of the trouble code information: yellow
Problem that appears on machine
• Risk, to run the machine without CLS/SLS lubrication. • Optional function: If the function Bucket Cut-Off is activated via the CoDeSys Visualization software, and if the machine is operated further on, after trouble code G00186 or G00189 is set, the bucket function will be disabled after approx. 4 hours.
Instruction message Possible cause
The electrical function of the respective vent valve is disturbed
The mechanical part of the vent valve is blocked or defective
Final check
20
• Inform service and then press cancel button.
Step
Test condition & Inspection
Procedure Yes
Go to next step.
No
Locate the problem and repair or replace the faulty component of the wiring as necessary. Replace the faulty vent valve solenoid if necessary.
1
Check the electrical function of the respective vent valve solenoid and its wiring. Is the electrical function ok?
2
Remove the mechanical part from the electrical part of the respective vent valve. Disassemble and check the lower part and clean as necessary. If it is necessary repair or replace the mechanical part. Clean the respective contaminated grease system.
3
Bring the machine back into the original condition. Start the machine and verify that the trouble code does not arise again. Verify that the operation cycles of the lubrication systems correspond to the following time diagram Z 28055-1 (taken from the flowchart).
Nominal value
Go to next step.
Allocation of the vent valves Lubrication system
Vent valve
CLS
62Q507a
SLS
62Q509a
PC4000-6 S/N 08199 and up
273
40 Troubleshooting
Part IV
Time diagram for the operation cycles of the lubrication systems CLS and SLS [2/3]
274
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
Trouble codes G00186 and G00189 - view onto the vent valve [3/3]
Legend for figure Z 26959 (1) Solenoid (2) Valve assembly (3) Solenoid stem (4) Lever (5) Reset spring (6) Auxiliary valve cone (7) Main valve cone
PC4000-6 S/N 08199 and up
275
40 Troubleshooting
Part IV
G00207 - Engine remote oil tank 1 empty [1/1] Trouble code G00207 Contents of trouble
Trouble
Engine remote oil tank 1 empty
• Sensor 63B103 in the remote engine oil tank signals that the tank is nearly empty. • The system assumes that the level sensor 63B103 in the remote engine oil tank or the wiring of this monitoring circuit system is not defective. • The remote engine oil tank is part of the engine oil management system.
Related information
Remark: The remote engine oil tank is also equipped with an oil level sight gauge.
Action of controller
• Background colour of the trouble code information: yellow
Problem that appears on machine
• Risk, to run out of remote engine oil.
Instruction message Possible cause
2
• Inform service.
Test condition & Inspection
Procedure
Nominal value
Keep the main key switch 20S001 in ON position. Check the remote engine oil level at the sight gauge of the tank and refill specified engine oil as necessary. Do not overfill.
Information - Engine oil management For the engine oil management system an engine oil consumption (for internal lubrication) of max.1% of the fuel flow-rate is determined. The engine remote oil tank is empty
If the engine oil consumption considerably exceeds the specification, contact the Cummins service.
Information - Engine oil specifications For the engine oil specifications refer to the Cummins Operation and Maintenance Manual QSK45 and QSK60 Series Engines, section Cummins Engine recommended fluids and lubricants. The minimum oil quality requirement is CF-4 and higher.
276
PC4000-6 S/N 08199 and up
Part IV
40 Troubleshooting
G00240 - Trouble hydraulic oil temperature [1/1] Trouble code
Trouble
G00240
Trouble hydraulic oil temperature
Contents of trouble
• Sensor 59B015 in the hydraulic oil tank signals that the hydraulic oil temperature (< T1) is far below the operating temperature (T2). • Below the hydraulic oil operating temperature T2 the pump regulation is automatically set to ½Qmax. • The system assumes that the hydraulic oil temperature sensor 59B015 and its wiring circuit are not defective.
Related information
• The sensor 59B015 detects an hydraulic oil temperature 0.5mm). area E has to be remachined until the original dimension, is reached. If the amount of axial play is less than 0.2 mm, area F has to be remachined until the original dimension, is reached. Type H 185S H 241 H 285/ H 285S PC4000 H 485/ H485S H 685S/SX H 655S/ PC8000 •
Original 0.2 – 0.9 0.2 – 0.5 0.2 – 0.9 0.2 – 0.9 0.2 – 0.9 0.2 – 0.9 0.2 – 0.9
Wear limit 2.75 2.00 2.75 2.75 2.75 2.75 2,75
Suspend sprocket (T/R) to crane, pull out hollow shaft (9), lift sprocket (T/R) out.
AH00514
Page 10 of 11
5
29
9
29
50
AH00514
Page 11 of 11
8. Assembly • • • • • • • • • • • • •
Mount dual-cone seal (29) according to SB 10-33 into flange bearing (3). Mount dual-cone seals (29) according to SB 10-33 into sprocket (T/R). Place sprocket (T/R) into the side frame by using a crane, align and underpin sprocket in mounting position. Mount hollow shaft (9). Mount dual-cone seal (29) according to SB 21-558 into flange bearing (7). Mount flange bearing (7). The lubrication grooves of the bushing(4) have to be displaced by 22.5° to the vertical line. Tighten bolts (22), according to the tightening torques below. Insert O-ring(6) in cover (2). Mount cover (2) with bolts (14). Tighten bolts (14), according to the tightening torques below. Insert O-ring (10). Suspend travel gear (1) to a crane and mount to side frame. Tighten bolts (34), according to the tightening torques below. Refill oil and check levels.
.
• When selecting tightening torques, observe size and quality grade of the bolts.
9. Torque Data for Standard Application
Bolt dia. [mm] M 10 M 12 M 14 M 16 M 18 M 20 M 22 M 24 M 27 M 30 M 33 M 36
Wrench size [mm] 17 19 22 24 27 30 32 36 41 46 50 55
8.8 43/32 74/54.6 118/87 179/132 255/188 360/265 485/358 620/457 920/679 1250/922 1690/1246 2170/1600
Tightening torque Nm/lbs.ft. Quality grades 10.9 63/47 108/80 173/128 265/196 360/265 510/376 690/509 880/649 1310/966 1770/1305 2400/1770 3100/2286
12.9 73/54 127/94 202/149 310/229 425/313 600/443 810/597 1030/760 1530/1128 2080/1534 2800/2065 3600/2655
Insert all bolts lubricated with MPG, KP2K type lubricant.
AH00514
Appendix
6.5.3
Service Bulletins
AH00519 Adhesive lubricants for the Slew Ring Gear
6 - 21
Service Bulletins
Appendix
This page was left blank intentionally.
6 - 22
PARTS & SERVICE NEWS
COMPONENT CODE:
2500
REF NO.
AH00519c
DATE
June 23, 2006 Page 1 of 4
This PARTS & SERVICE NEWS supercedes the previous issue AH00519b which should be discarded. SUBJECT:
Adhesive lubricants for the Slew Ring Gear
PURPOSE:
Revision
APPLICATION:
All types
FAILURE CODE:
2500Z9
DESCRIPTION: The transmission of a torque from the slew pinion to the toothing of the slew ring causes the slewing of the superstructure. The existing extreme force in this section requires the separating of the engaged gears by means of grease film, to ensure a proper damping of shocks and to prevent metallic abrasion. Adhesive lubricants may be applied by means of an automatic slew ring gear lubrication system or manually by a spatula, brush, spray tin. Automatically tooth lubrication systems provides the upper most protection because of the continuously uninterrupted lubrication, permanent checks are not required.
AH00519c
Page 2 of 4
)
• Independent of the lubricant and lubrication system, the toothing should be visually checked approx. every 500 working hours. If the check is not possible because of applied lubricant, the toothing has to be cleaned at several points equally distributed on the circumference of the slew ring. In case of wear or damages, Dept. 8151 has to be informed to discuss suitable remedies.
ã
• These adhesive lubricants provide totally different features compared to the Bearing greases / MPG (e.g. used in the central lubrication system). Hence, those lubricants must not replace against each other or mixed. Example:
This may happen when grease (1) pressed out of the upper sealing system of the races forms too big collar at
the slew ring and penetrates into the toothing (2). This eventuality must be avoided by removing the excess grease.
AH00519c
Page 3 of 4 The following table includes several adhesive lubricants providing excellent results on several machines under different working conditions. The use of other lubricants is not recommended before consultation of Dept. 8151. Note: Use these Greases for Swing Circle open Gear Lubrication only Ambient Temperature °C ⇒ °F ⇒ Supplier
-50 -58
-40 -40
-30 -22
-20 -4
-10 14
0 32
10 50
20 68
30 86
40 104
50 122
60 140
Castrol Molub-Alloy 936 SF Heavy NG Castrol Molub-Alloy 936 SF Heavy Castrol Industrie GmbH
Castrol Molub-Alloy 958 SF Castrol Molub-Alloy 936 SF Arctic BERULIT GA 2500 / BERUGEAR W4000
BECHEM
BERULIT GA 800 BERUGEAR W 3000 Beru Gear FG 34 (Biodegradable) Molub unee lubricant 7059
BEL RAY Molub Gear Tac 6895 Molub Gear Tac 6894 / 6899 ESSO
Dynagear Extra Ceplattyn KG 10 ECO (Biodegradable)
FUCHS LUBRITECH
Ceplattyn KG 10 HMF URETHYN HGO *1)
MOLYBOND
TSG Heavy Malleus GL 500
SHELL
Malleus GL 400 Malleus GL 25
TEXACO *1)
*2)
Crater 2X Fluid *2)
The URETHYN HGO Grease should only be used in Arctic climates where the ambient temperatures fall to –50° C. In regions where the ambient temperatures do not fall below –40° C, a grease of the temperature range to –40° C should be used. Use the Crater 2X Fluid for Spray systems only.
AH00519c
Page 4 of 4 The manually lubrication has to be carried out with the following adhesive lubricants. Those lubricants are suitable for all temperature ranges.
Company
Product
T1 -5°C ⇒ +60°C +23°F ⇒ +140°F
T2 -20°C ⇒ +10°C -4°F ⇒ +10°F
T3 -40°C ⇒ -10°C -40°F ⇒ +14°F
Voler Compound
KOMATSU
2000 E Spray (0,625kg)
P/N 500 893 98
Voler Compound
Special grease
)
2000 E Adhesive lub (indicate quantity in kg)
P/N 006 057 98
• What has to be done in case of grease exchange according to the chart on page 03 ? • The new adhesive grease may directly be changed without a complete cleaning of the toothing. An increased grease supply after the exchange is recommended until the toothing is completely applied.
AH00519c
Appendix
6.5.4
Service Bulletins
AH01512 Setup - procedure of the VHMS Integrated Tool Soft
6 - 23
Service Bulletins
Appendix
This page was left blank intentionally.
6 - 24
PARTS & SERVICE NEWS
COMPONENT CODE:
DB20
REF NO.
AH01512
DATE
05182001 Page 1 of 8
SUBJECT:
Setup – procedure of the VHMS Integrated Tool Soft
PURPOSE:
Presentation of the VHSM – System for PC4000-6
APPLICATION:
PC4000-6
FAILURE CODE:
DB20Z9
DESCRIPTION: This Bulletin shows the installation procedure of the VHMS* - software on your PC /Laptop. 1.
Preparation Before proceeding the setup, exit from ALL other applications that are currently running. Also, exit from the resident programs such as Virus Buster, if possible. Then prepare the VHMS Integrated Tool Soft Setup Disk 1 to 6.
2.
Insert the Setup Disk 1. (1) Click on the “Start” button on your Desktop and select “Settings”; (2) Click on “Control panel”; (3) Double click on “Software”; (4) Click on “Install”; (5) Click on “Next”; (6) Click on “Finish” to proceed the “Setup.exe” on drive A:\.
.
• Setup can be proceeded up to ten times. The following message will appear at the eleventh time, and the setup will not be proceeded further.
* VHMS – Vehicle Health Monitoring System
AH01512
Page 2 of 8
3.
“Welcome” screen is displayed.
Click on Next: 4.
Continue with the setup program.
“Choose Destination Location” screen is displayed
Click on Next:
Decide the destination folder, and continue with the setup.
AH01512
Page 3 of 8
5.
“Choose Destination Location” screen is displayed.
Click on Next:
6.
Decide the destination folder of VHMS data, and continue with the setup program.
“Select Program Folder” screen is displayed.
Click on Next:
Decide the program folder, and continue with the setup program.
AH01512
Page 4 of 8
7.
“Setup Needs The Next Disk” screen is displayed. The following instruction screen will appear when the Disk 2, 3, 4 and 5 are required accordingly.
(If you see a mistake message after changing a Disk – please click: Ignore) Please click on OK: Set the next disk, and continue with the setup program.
8.
“Read Only File Detected” screen is displayed.
During installing the program, if the above screen is displayed, you need to click the “Yes” button.
AH01512
Page 5 of 8
10.
“Setup Complete” screen is displayed.
Please click on Finish:
.
Finish the setup.
• After the setup procedure, a Restart Screen for the Windows might appear. In this case, please do restart it by choosing “Yes, I will restart the computer immediately”. We cannot guarantee the performance of the program if you did not restart. In the worst case, it could result in the malfunctioned Windows.
AH01512
Page 6 of 8
Finishing of the installation In order to start up the VHMS Integrated Tools Soft System, double-click the icon of VHMS, which is displayed on the desktop of the Windows . Password Input Screen is displayed then. Followings are the descriptions of each screen. 0. Start-Up Check Screen (only appears at the first start-up after the installation) The following screen will appear at an initial start of the system. Please turn off the write-protect switch of the Setup Disk 1 and then insert the floppy disk.
Please click on OK:
If the initialization check was properly completed,
1. Password Input Screen Input the user name and the password here.
User name: Password: Please click on OK:
Input “ user “. Input “ password” Go to “2. Start Option” screen.
AH01512
Page 7 of 8
2. Start Option Screen
Click on “Tool” Select with a click: “Add Failure code defined file”. Please insert Disk 6. Input necessary setups to add or update the fault code definition file.
PC4000 -6
Model: Input Model Type: Input Minor Variation Code: Input Please click on Reference:
” PC4000”. “-6”. “LC”. - Select Floppy (A:); - Highlight the file “DOWNLOAD_TEXTS.... .CSV” with click on
DOWNLOAD_TEXTS_ENGLISH_892 201 40.CSV
Click on “Open”
AH01512
Page 8 of 8
Click on OK:
Register information that was input.
Confirmation of Registration Result Screen is displayed. If successful, Screen as shown below is displayed.
Push OK Button
Setup of the VHMS Integrated Tool Soft is completed.
Close the program with click on the cross (x) up in the right corner of the screen. Then click on the OK Button.
AH01512
Appendix
6.5.5
Service Bulletins
AH01521A Diesel engine suspension
6 - 25
Service Bulletins
Appendix
This page was left blank intentionally.
6 - 26
COMPONENT CODE:
A2
REF NO.
AH01521a
PARTS & SERVICE NEWS
DATE
20 Sept. 2002 Page 1 of 9
This PARTS & SERVICE NEWS supersedes the previous issue No.: AH01521 dated November 2001 which should be discarded. SUBJECT:
Diesel engine suspension
PURPOSE:
Hints for checking
APPLICATION:
H 185; H 255; H 285; H 455; H 485; H 655; H 685; PC3000; PC4000; PC5500; PC8000
FAILURE CODE:
A2T0EH
DESCRIPTION:
Diesel engines are mounted on elastic elements. With increase of life the flexible mountings will show setting effects. 1.
Inspection intervals
• Damages to the engine might arise if the bolts of the flexible mountings are not tightened correctly.
1.1 Therefore check bolts after the following intervals: • Prior to putting the machine into operation or after replacement of the flexible mountings • after the first 250 operating hours • every 1000 operating hours or every 6 month latest
1.2 The elastic engine suspension must be checked (visual check): • Every 6 month or every 1000 operation hours (check the flexible mountings for damage). 1.3
Check the fatigue of the rubber elements according to the appendix (pages 5 to 9) once a year and give the records to our service department. Take a calliper.
AH01521a
Page 2 of 9
2.
Kinds of mounts
There are two types of mounts at each location: Type A: Flexible engine mountings Type B: Flexible engine mountings with self locking nut item (3) for limiting of the flexible distance.
3.
Control measures (see also in your Operation and Maintenance Manual) (Caterpillar-Engine fig.1; Cummins/Komastu - Engine fig.2) • All tests during motor stop!
The bolts of the flexible engine mountings have to be checked as follows: 1. Tighten the bolt (2) to 880 Nm (649 lbf ft). 2. Position the nut (3) so it just touches the steel plate of the rubber mount item (6). Tighten the nut an additional ¼ turn (90°).
F
Over tightening of this nut will result in removing the required elasticity of the rubber mounts and may cause engine failure.
3. Only by Cummins Engines Check distance „C“ between torque support and stop bolt(4). With setting of the flexible engine mountings the distance „C“ increases and must be readjusted. To do this, loosen lock nut (7) and tighten stop bolt (4) until the correct distance „C“ is obtained. Tighten lock nut (7) and recheck distance (C). 4. Check all rubber metal bars (1) and all strips (6) for damage.
F
• All rubber metal bars(1), all strips(6) and all cup springs(5) should be replaced during engine overhaul.
AH01521a
Page 3 of 9 Fig. 1: For example PC8000 with Caterpillar - engine
1
2 A
A B 6
3
2
B A 3 2
M24x150
M24x150 M24x350
A
A
B
Legend: (A); (B) Two types of engine mounts (1) Rubber metal bar (2) Bolt of engine mount type (A (3) Self locking retainer nut of the engine mount type (B)) (6) Strip
3
AH01521a
Page 4 of 9 Fig. 2: For example PC4000 with Cummins/Komatsu - engine
LEGEND: (A); (B) Two types of engine mounts (C) Distance between torque support and stop bolt(4) (1) Rubber metal bar (2) Bolt of the engine mount type (A) (3) Self locking retainer nut of the engine mount type (B) (4) Stop bolt (5) Cup spring package (6) Stip (7) Lock nut
6
4
5 C
7 2 6 B
1 A
A
Lock nut tighten snugly
B 3 AH01521a
Page 5 of 9
Record of measurement - fatigue of the engine bearings Excavator model:
PC3000
Inspector:
Serial number:
Date:
Engine manufacturer:
Signature:
Measuring point
Value (X) (mm)
1 2 3 4 5 6 7 8 AH01521a
Page 6 of 9
Record of measurement - fatigue of the engine bearings Excavator model:
PC4000
Inspector:
Serial number:
Date:
Engine manufacturer:
Signature:
Measuring point
Value (X) (mm)
1 2 3 4 5 6 7 8
AH01521a
Page 7 of 9
Record of measurement - fatigue of the engine bearings Excavator model:
PC5500
Inspector:
Serial number:
Date:
Engine manufacturer:
Signature:
5
Measuring points PC5500
1
Pump distributer gear
Measuring point
Value (X) (mm)
1 6
2 Engine
7
2 3
3
4 5 6 7
8
4
8 AH01521a
Page 8 of 9
Record of measurement - fatigue of the engine bearings Excavator model:
PC8000
Inspector:
Serial number:
Date:
Engine manufacturer:
Signature:
5
1
Measuring points PC 8000
6
2 Engine 7
3
Measuring point
Value (X) (mm)
1 2 3 4 5
Pump distributer gear
6 7 8
4
8 AH01521a
Page 9 of 9
Record of measurement - fatigue of the engine bearings Excavator model:
PC8000
Inspector:
Serial number:
Date:
Engine manufacturer:
Signature:
5
Measuring points PC 8000 (CAT)
1
Measuring point
Engine 6
2
7
3
Value (X) (mm)
1 2 3 4 5
Pump distributer gear
6 7
8
4
8 AH01521a
Appendix
6.5.6
Service Bulletins
AH01531A Hydraulic accumulators - testing and refilling
6 - 27
Service Bulletins
Appendix
This page was left blank intentionally.
6 - 28
COMPONENT CODE:
30; 63
REF NO.
AH01531A
PARTS & SERVICE NEWS
DATE
06122002 Page 1 of 9
This PARTS & SERVICE NEWS supersedes the previous issues No. 21-426; 21-549 and AH01531 which should be discarded. SUBJECT:
Hydraulic accumulators – testing and refilling
PURPOSE:
Regular check
APPLICATION:
All types
FAILURE CODE:
307EPB; 6347PB
DESCRIPTION: The testing and refilling of the hydraulic accumulators have to be performed by testing- and refilling device Part no. 761 520 73. When ordering this particular device, please always indicate country of destination.
1. Testing of existing gas pressure at piston and diaphragm accumulators For testing of existing gas pressure at bladder accumulators, refer to page 7 – 9. •
Stop engine.
•
Allow pressure relief of the system to be checked.
•
Remove protective cap from accumulator.
•
Unscrew a union of the feeding line in order to allow the hydraulic oil to pour out.
AH01531A
Page 2 of 9
The testing- and refilling device includes following pressure gauges:
0 to 25 bar 0 to 100 bar 0 to 250 bar •
Screw the pressure gauge with the correct pressure range into the testing and refilling device.
•
Screw home screw (14) at the filling device.
•
Loosen the socket-head screw of the gas valve by ½ turn with a hex key 6 mm.
•
Screw filling device without hose carefully by hand onto accumulator.
•
Observe correct position of the o-ring.
. •
• Check valve in hose connection is operative only if hose is not connected.
Turn T-handle (12) several times in both directions until it is engaged in socket head of gas filler screw (11).
•
By means of the T-handle unscrew gas filler screw (11) by 4 to 5 turns until pressure gauge indicates the existing gas pressure.
AH01531A
Page 3 of 9
For the specified gas pressure of the piston-diaphragm and bladder type accumulator, refer to the circuitry diagrams in the Operation Manual.
Compare the pressure reading on the gauge with the specified gas pressure.
If the pressure reading is too low, the accumulator has to be refilled. • To fill the accumulator, a pressure – reducing valve must be used. • Only nitrogen must be used to fill the accumulator.
2. Filling of the accumulator •
Close shut-off valve (5) at the bottle pressure – reducing valve. Turn in completely outlet screw (14) of filling device and install the hose.
AH01531A
Page 4 of 9
•
Open valve (8) of nitrogen bottle and check bottle pressure. The bottle pressure must always be higher than the pressure specified for the accumulator.
•
adjust specified accumulator pressure with pressure-reducing valve (6).
•
Turn out the filling screw (11) by means of the T-handle of the filling device.
•
Open slowly shut-off valve at bottle pressure reducing valve and let nitrogen flow into accumulator, until pressure gauge on filling device indicates the specified pressure. Then close shut – off valve.
AH01531A
Page 5 of 9
•
Wait for temperature to be equalized (approx. 5 min.) and open outlet screw (14) to let the pressure drop to the specified value.
•
Close outlet screw (14).
•
Screw in tightly screw (11) by means of T – handle (12).
•
Open outlet screw to let nitrogen escape from filling device.
•
Disconnect hose connection and unscrew filling device.
•
Fasten O - ring (13) to the testing device.
•
Tighten the screw (11) by means of a hex key 6 mm.
AH01531A
Page 6 of 9
•
Reinstall protective card and retighten union in feeding line.
•
Close bottle valve (8).
•
Turn out completely the T – handle at the pressure reducing valve (6).
AH01531A
Page 7 of 9
3. Testing of existing gas pressure bladder accumulators The testing- and refilling device includes pressure gauges: 0 to 25 bar 0 to 100 bar 0 to 250 bar. •
• • • •
Screw the pressure gauge with the correct pressure range in the testing- and refilling device. Shut down the engine. Allow pressure relief of the system to be checked. Unscrew the feeding line in order to allow the hydraulic oil to pour out. Remove cap (1) and nut (2). Do not remove O - ring (3).
. • • • • • • •
• Check valve in hose connection is operative only when hose is not connected.
Turn the socket head screw (4) installed in the adapter (2) a little bit. Mount testing- and refilling device to adapter (2). Install adapter (2) to testing connection (3). Turn in completely outlet screw of the filling device. Turn T – handle (12) several times in both directions until it is engaged in the screw (4) of the adapter (2). By means of the T – handle (12) turn in the screw so far that the existing gas pressure is indicated by the pressure gauge. Do not turn in the screw any further; the gas valve may be destroyed.
AH01531A
Page 8 of 9
If the pressure reading does not correspond with the nominal filling pressure, the accumulator has to be refilled.
4. Filling of the bladder accumulator • To fill the accumulator, a pressure – reducing valve must be used. • Only nitrogen must be used to fill the accumulator. •
Close the shut off valve (5) on the pressure-reducing valve.
•
Turn in completely the outlet screw (14), see illustration on page 5.
•
By means of the T-handle (12), turn out the screw (4) of the adapter (2) until the gas valve in the testing connection (3) of the accumulator is closed. After that, install connecting hose.
•
Open the valve (8) at the nitrogen bottle and check the gas pressure of the bottle. The gas pressure of the nitrogen bottle must always be higher than the specified filling pressure of the accumulator.
•
Adjust the specified filling pressure by means of setting screw (6) of the pressure reducing valve. Open the gas valve in the testing connection (3) of the accumulator ba turning in screw (4).
•
Slowly open the shut off valve (5) at the pressure reducing valve and fill the accumulator until the pressure gauge (7) of the testing and refilling device indicates the specified filling pressure. Then close the shut-off valve (5).
AH01531A
Page 9 of 9
•
Wait for temperature to be equalized (approx. 5 min) and, if necessary, reduce pressure with outlet screw (14) or let the pressure reach the specified value according to page o4.
•
Close outlet screw (14).
By means of T-handle (12) turn out screw (4) from the adapter (2) till the gas valve in the testing connection (3) is closed. • •
•
Open outlet screw (14) that the nitrogen can escape from the filling and testing device. Close the nitrogen bottle and remove the filling- and testing device, filling hose and pressure –reducing valve. Turn out completely screw (6) of the pressure-reducing valve. By doing so, the spring-reducing valve is discharged.
•
Re-install protection cap in the testing connection.
•
Re-tighten the hydraulic line.
AH01531A
Appendix
6.5.7
Service Bulletins
AH02513B Testing wear and tear of the swing circle bearing
6 - 29
Service Bulletins
Appendix
This page was left blank intentionally.
6 - 30
COMPONENT CODE:
25
REF NO.
AH02513b
PARTS & SERVICE NEWS
DATE
January 4, 2005 Page 1 of 4
This PARTS & SERVICE NEWS supersedes the previous issue No. AH02513a which should be discarded. SUBJECT:
Testing wear and tear of swing circle bearing
PURPOSE:
In time ordering of a new swing circle in order to prevent unexpected downtime
APPLICATION:
All types
FAILURE CODE:
2500CA
DESCRIPTION: For assessing the condition of the swing circle bearing, we recommend that its normal wear rate is determined. The first measurement must be performed when the excavator is put into operation in order to obtain a base value for subsequent repeat measurements. The following measurements have to be effected: 1. Period of the first 10.000 h: 2. Period more than 10.000 h:
every 5.000 working hours; every 2.500 working hours.
After finishing the measurements, record the values obtained in a tabular form. The diagram shows the principle of bearing wear progression. If the “increased wear” situation is reached, prepare the changing of the swing circle.
)
• We recommend to turn the swing circle (180°) after 20 000 working hours.
normal wear
increased extrem wear wear
Axial movement/wear
mm
Base value
Working hours
h AH02513b
Page 2 of 4 Measurement procedure
1. Park the machine on level ground. 2. Slew the attachment to the normal working position (idler wheel in front). 3. Remove cover as shown in the photos (Illust. 7 and 8). 4. Clean the center slew gear tooth and the contact point on the superstructure. 5. Install the dial gauge* as shown in the photos. 6. Turn the swing brake switch in the on position. 7. Straighten the attachment fully (lmax) and raise the shovel approx. A=3 m over the ground (Illust. 1, 3 or 5). 8. Set measuring instrument (dial gauge*) to zero.
ã
• Make sure the area below and around the excavator is clear of all persons before you start operating.
9. Move the attachment in the shown position (Illust. 2, 4 or 6). Lower the attachment until the track lift off the ground up to the sprocket (B).
)
• Use for all measurements the same distances “A” and “B”.
10. Move the attachment in the normal parking position. 11. Read measurement “M 1” (out of the memory) and record in the table (page 4). 12. Repeat the measuring procedure at the same point for a 2nd value (M 2). 13. Remove the dial gauge, swing the superstructure 180 degrease and repeat the measuring procedure two times. * We recommend to use a digital dial gauge with min. / max. measuring value memory (Part No. 794 537 73).
Photo only as example
AH02513b
Page 3 of 4
AH02513b
Page 4 of 4
Excavator Typ:
Planned h 0
Actual h
Date
Serial number:
Front M1
Front M2
Mfront = (M1 + M2)/2
Rear M1
Rear M2
Mrear = (M1 + M2)/2
5 000 10 000 12 500 15 000 17.500 20 000 22.500 25 000 27.500 30 000 32.500 35 000 37.500 40.000
AH02513b
Appendix
6.5.8
Service Bulletins
AH02521 Track group – wear measurement
6 - 31
Service Bulletins
Appendix
This page was left blank intentionally.
6 - 32
COMPONENT CODE:
75
REF NO.
AH02521
DATE
06212002
PARTS & SERVICE NEWS
Page 1 of 6 This PARTS & SERVICE NEWS supersedes the previous issue Number 21-205b which should be discarded. SUBJECT:
Track group – wear measurement
PURPOSE:
Increasing the service life and avoiding unforeseen standstill
APPLICATION:
H 185 to PC8000
FAILURE CODE:
752DCA
DESCRIPTION: The professional and regular inspection increases the service life of the track group and can avoid early and very expensive repairs, including unforeseen standstill of the machine. It is recommended to perform the inspections every 3 month or 1500 working hours according to the description and to fill in the measured values to the table on page 06.
The measurements are described in detail and illustrated on pages 02 - 05.
To prevent unnecessary problems and standstills and to assure fast help when wear limits are reached, it is recommended to send the filled-in tables in the mentioned intervals to Komatsu Mining Germany, Service Department 8151.
AH02521
Page 2 of 6 Preconditions for the measurements: 1.
Cleaning of the track group, according to the Lubrication and Maintenance Manual.
2. Track sag (A): On Machines without the hydraulic track - tensioning system.
ð ð
On Machines with hydraulic track - tensioning system.
H 185S - up to max. 230 mm H 285 - H 285S - up to max. 300 mm H 485 - H 485S - up to max. 420 mm
No specification, since self-regulating
AH02521
Page 3 of 6
Chain elongation / measured over three track pads (4 pins) This wear check has to be carried out in 4 equally distributed areas of the track chain (L1 to L4 - l.h. and R1 to R4 - r.h.). • Turn superstructure 90° to the travel direction. • Retract attachment and lower bucket on the ground until the chain has no longer contact with the ground (see illustration). • Turn sprocket until the first measuring area (L1) is located at the deepest point of sag (“T“). (To measure the areas L2-L4 turn the chain always forward until point “T“ is reached) To obtain a comparable measuring result, stop the main drive motor of short duration, so that the track tensioning system is released to 35 bar. For the track sag refer to page 02.
Place the points of the dividers into the centre bores of pins 1 and 4 of the measuring area L1 / R1, determine the distance and record in the table on page 06. Repeat measuring procedure at measuring areas L2 / R2 - L4 / R4.
AH02521
Page 4 of 6 Circular pitch (Sprocket / Track pad) For this inspection, the excavator has to be placed on an even surface, and only one chain has to be moved, like turning. • Diesel engine: Operate in low idle. • Electric motor: Operate joy-stick slightly. • Move l.h. track group forward (Sprocket rotation F = forward), until the contact area of the uppermost sprocket tooth (0) and the track-pad lug (0) is in the illustrated position, see ill. A, on page 05. • Measure gaps (X1) according to ill. A. Measure inside and outside of the sprocket between the sprocket teeth (7) and track-pad lug (7) at 3 points, equally distributed on the chain. • Record the values into table -circular pitch A- on page 06. • Repeat the measurements on the r.h. track group. • Move l.h. track group back (Sprocket rotation R = backwards), until the contact area of the lowest sprocket tooth (0) and the track-pad lug (0) is in the illustrated position, see ill. B, on page 05. • Measure gaps (X2) according to ill. B. Measure inside and outside of the sprocket between the sprocket teeth (7) and track-pad lug (7) at 3 points, equally distributed on the chain. • Record the values to the table -circular pitch B- on page 06. • Repeat the measurements at the r.h. track group.
F
• The minimum permissible X1/X2 dimension amounts 0.5mm. If this dimension is reached, an oversized sprocket has to be installed, to bring the X1/X2 dimension to the new condition. • If the dimension X becomes a negative amount (less than 0mm). the lugs of the track pads will be damaged so strongly, that a complete exchange of the track pads will be the required. Therefore, make sure that the X1/X2 dimension never falls below 0.5mm.
For the exchange of the oversize sprockets, refer to Service Bulletin AH00514.
Wear of track pads (Roller contact surface) • Stop the engine/motor and secure the machine against unintentional movement. • Mark 3 track pads of each track group (l.h. track group and r.h. track group) to make repeated measurements in the future comparable. • Take a ruler to measure the wear of the roller contact surface. The ruler needs an even contact surface, if not exist, prepare the track pad as necessary, see illust.. C, page 05. • Record the measuring results in the form sheet on page 06.
AH02521
Page 5 of 6
L.h. track group is illustrated
AH02521
Page 6 of 6
Machine-Type : Customer : Oversize sprocket ? : (left hand side)
Oversize sprocket ? : (right hand side)
NO
YES
NO
YES
Chain elongation:
Serial-No. : Location : ð Date of installation: ................... at operating hours: ..................... ð Date of installation: ................... at operating hours: .....................
Operating hours : Date of measurement : Part-No. of track pad :
left hand crawler track “L“
Measuring area W-dimension [mm] via 4 pins
Chain elongation:
L1
L2
L3
L4
L3
L4
right hand crawler track “R“
Measuring area W-dimension [mm] via 4 pins
L1
L2
Circular pitch: Illustration “A“
3
inside
3 points (equally distributedon the chain) 2 outside inside outside inside
3
inside
3 points (equally distributedon the chain) 1 2 outside inside outside inside
1 Sprocket side X1-dimension [mm]
outside
L.H
X1-dimension
[mm]
R.H
Illustration“B“ Sprocket side X2-dimension [mm]
outside
L.H
X2-dimension
[mm]
R.H
Wear of Track pads (Roller contact surface): Track pad
Side
No.1 No.2 No.3 No.4 No.5 No.6
L.H. L.H. L.H. R.H. R.H. R.H.
Dimension “B“ [mm]
Number of cracked track pads left hand crawler track
right hand crawler track
AH02521
Appendix
6.5.9
Service Bulletins
AH03506B Hydraulic oil cooler and water cooler fan bearings
6 - 33
Service Bulletins
Appendix
This page was left blank intentionally.
6 - 34
COMPONENT CODE:
03
REF NO.
AH03506b
PARTS & SERVICE NEWS
DATE
October 25, 2003 Page 1 of 5
This PARTS & SERVICE NEWS supersedes the previous issue AH03506a which should be discarded. SUBJECT:
Hydraulic oil cooler and water cooler fan bearings
PURPOSE:
Replacement of the bearings
APPLICATION:
PC4000; PC5500; PC8000
FAILURE CODE:
0373CA
DESCRIPTION: Two types of bearing units are used for the cooler fans at the above mentioned excavator models: 1. Grease lubricated bearings
)
2. Gear oil lubricated bearings
• We recommend to replace these bearings to avoid consequential damages according to the following table: Bearing unit Replacing time after: Grease lubricated bearings 8 000 working hours Gear oil lubricated bearings 10 000 working hours * * or if damage or a leak has occurred.
)
• The hydraulic motors for the fans should be replaced preventively every 10.000 working hours.
AH03506b
Page 2 of 5
Hints for replacement: 1. Grease lubricated bearings
1 Bearing retainer 2 Shaft 3 Hydraulic motor 4 Fan 5 Bearing 6 Grease nippel 7 Circlip 8 Bolt 9 Bolt 10 Locking plate
1. Remove the hydraulic and the grease lines; the fan; and then the motor. 2. Remove the bearings and the fan shaft. 3. Clean all parts carefully. 4. Install the first bearing (5) and fill the chamber between the bearings to 50% with grease. 5. Install the shaft with the first bearing (5) and the grease into the bearing retainer. 6. Install the second bearing and fix it with the circlip (7). (Install also the sleeve between the bearings if applicable.) 7. Grease the hydraulic motor drive shaft with “Optimol paste white T” and fill the chamber in the fan shaft to 50% with normal grease according to the drawing above. 8. Reinstall the bearing hub, the fan and the motor. 9. Reconnect all lines. • Grease the bearings every 500 working hours with maximal 2 strokes with the hand greasing pump.
AH03506b
Page 3 of 5
2. Gear oil lubricated bearings 2. Gear oil lubricated bearings 1 Bearing retainer 2 Shaft 3 Circlip 4 Bearing 5 Shaft grommet 6 Shaft seal 7 Plug Fill the chamber at the lip type seal with grease.
1. Remove the hydraulic lines; the fan, then the complete unit. 2. Drain off the gear oil and remove the motor, the bearings, the fan shaft, the shaft grommet and the shaft seal. 3. Clean all parts carefully. 4. Check the dia. “d” according to drawing and table at the next page. 5. Install a new shaft grommet with the flanged end at first (press it into depth “a” see next page). 6. Do not remove the seam of the shaft grommet. 7. Install the 1st bearing and the shaft seal into the bearing retainer. 8. Grease the shaft and install it. 9. Mount the 2nd bearing(4) and the circlip. 10. Check the spline and grease the hydraulic motor drive shaft with “Optimol paste white T”. 11. Reinstall the motor by using a new O – ring and mount then the fan. 12. Fill in the bearing retainer gear oil according to the Maintenance Manual. 13. Reconnect the hydraulic lines.
AH03506b
Page 4 of 5
PC4000
PC5500
PC8000
Oil cooler
Water cooler
Oil cooler
Water cooler
Oil cooler
Water cooler*
Part no.
Part no.
Part no.
Part no.
Part no. Part no.**
Part no.
Fan mounting 89590740 90202640 91091140 90479140 90389040 93394140 90968540b (assy.) Repair kit *** Press depht "a" (mm) Shaft dia. "d" (mm)
79296573 79296673 79296573 79296673 79296773 79484873 79296873
4 -0,5
3,7 +0,2
4 -0,5
3,7 +0,2
∅80 ±0,05
∅110 ±0,05
∅80 ±0,05
∅110 ±0,05
4 -0,5
6,4 ±0,8
∅100±0,05 ∅130−0,025
4,3 ±0,8 ∅ 85 ±0,05
* Serial No. 12040 up – see drawing next page ** Serial No. 12048/12049 only *** The Repair kit includes: 2 bearings; 1 shaft seal; 1 shaft grommet; 1 O-ring
Fill the chamber at the lip type seal with grease.
AH03506b
Page 5 of 5
PC8000-6 Water cooler fan bearings
Intermediate ring
AH03506b
Appendix
Service Bulletins
6.5.10 AH03509A Slew gear GFB 174 E 9017 (Part No. 917 915 40)
6 - 35
Service Bulletins
Appendix
This page was left blank intentionally.
6 - 36
COMPONENT CODE:
26
REF NO.
AH03509a
PARTS & SERVICE NEWS
DATE
22nd July 2003 Page 1 of 25
This PARTS & SERVICE NEWS supersedes the previous issue AH03509 which should be discarded. SUBJECT:
Slew gear GFB 174 E 9017 (Part No. 917 915 40)
PURPOSE:
Modification to slew gear GFB 174 E 9020 (Part No. 92432540) including exchanging the sun gear shaft
APPLICATION:
PC8000 (12037 – 39); PC5500 (15012 – 15017); PC4000 (08151); PC3000 (06194)
FAILURE CODE:
2600Z9
DESCRIPTION:
General In order to increase the lifetime of the parking brake discs the swing gear oil filling capacity should be reduced by approximately 20 liters. The new filling capacity is approx. 42 liters. The present oil level gauge on the gear can no longer be used for checking the oil level. There are two possibilities to modify the oil level checking system. For increasing the lifetime of the slew gear the sun gear shaft should be changed during the slew gear modification. Page 1. Modification Kits 2 2.
Variant (A) – Modification by replacing of the swing gear cover with the complete parking brake unit,
6
3.
Variant (B) – Modification by machining the swing gear cover. 3.1 Modification of the swing gear cover a) Dismounting b) Machining of the swing gear cover c) Reassembly
8 11 11 12 13
4.
Completion of the swing gear cover
24
5.
Oil level checking procedure
25
AH03509a
Page 2 of 25 1. 1.0
Modification Kits One new gear shaft is required for one slew gear (Part No. 757 360 73 – differences to the old sun gear shaft: refer to illustration 6) 1.1 Kits for modification of the slew gear(s) according to Variant (A) 1.1.1 PC3000-1 Part No.: 794 016 73 Pos.
Part-No.
1 15 16 17 14 18 1 20 1 2
79227073 37441299 90635240 37126599 92582540 31318499 90756840 92582940 972111 50774898
Qty. Description 1 4 4 4 4 4 1 1 1 1
Cover/brake assy. Socket Cutting ring Union nut Oil level gauge tube Plug Oil level gauge Oil level gauge bracket O-ring O-ring
Illustration 3 6 6 6 6 6 6 6 2 2
1.1.2 PC4000-6 Part No.: 794 017 73 Pos.
Part-No.
1 15 16 17 14 18 19 20 1 2
79227073 37441299 90635240 37126599 92582540 31318499 90756840 92582940 972111 50774898
Qty. Description 2 12 12 12 12 12 2 2 2 2
Cover/brake assy. Socket Cutting ring Union nut Oil level gauge tube Plug Oil level gauge Oil level gauge bracket O-ring O-ring
Illustration 3 6 6 6 6 6 6 6 2 2
(Cover plates must be adapted.)
AH03509a
Page 3 of 25 1.1.3 PC5500 Part No.: 794 018 73 Pos.
Part-No.
1 15 16 17 14 18 19 20 1 2
79227073 37441299 90635240 37126599 92582440 31318499 90756940 92582840 972111 50774898
Qty. Description 2 10 10 10 10 10 1 1 2 2
Cover/brake assy. Socket Cutting ring Union nut Oil level gauge tube Plug Oil level gauge Oil level gauge bracket O-ring O-ring
Illustration 3 6 6 6 6 6 6 6 2 2
1.1.4 PC8000 Part No.: 794 019 73 Pos.
Part-No.
1 15 16 17 14 18 19 20 1 2 1 1
79227073 37441299 90635240 37126599 92582440 31318499 90756940 92582840 972111 50774898 92583240 92583140
Qty. Description 3 14 14 14 14 14 2 2 3 3 1 1
Cover/brake assy. Socket Cutting ring Union nut Oil level gauge tube Plug Oil level gauge Oil level gauge bracket O-ring O-ring Cover plate Cover plate
Illustration 3 6 6 6 6 6 6 6 2 2 -
AH03509a
Page 4 of 25 1.2 Kits for modification of the slew gear(s) according to Variant (B) 1.2.1 PC3000-1 Part No.: 794 020 73 Pos.
Part-No.
15 16 17 14 18 19 20 99 504 1; 3; 4 2
37441299 90635240 37126599 92582540 31318499 90756840 92582940 33132299 79224973 972111 50774898
Qty. Description 4 4 4 4 4 1 1 1 1 3 1
Socket Cutting ring Union nut Oil level gauge tube Plug Oil level gauge Oil level gauge bracket Plug Disc (thickness: 8.5-0.1mm) O-ring O-ring
Illustration 6 6 6 6 6 6 6 4 4 2 2
1.2.2 PC4000 Part No.: 794 021 73 Pos.
Part-No.
15 16 17 14 18 19 20 99 504 1; 3; 4 2
37441299 90635240 37126599 92582540 31318499 90756840 92582940 33132299 79224973 972111 50774898
Qty. Description 12 12 12 12 12 2 2 2 2 6 2
Socket Cutting ring Union nut Oil level gauge tube Plug Oil level gauge Oil level gauge bracket Plug Disc (thickness: 8.5-0.1mm) O-ring O-ring
Illustration 6 6 6 6 6 6 6 4 4 2 2
(Cover plates must be adapted.)
AH03509a
Page 5 of 25 1.2.3 PC5500 Part No.: 794 022 73 Pos.
Part-No.
15 16 17 14 18 19 20 99 504 1; 3; 4 2
37441299 90635240 37126599 92582440 31318499 90756940 92582840 33132299 79224973 972111 50774898
Qty. Description 10 10 10 10 10 1 1 2 2 6 2
Socket Cutting ring Union nut Oil level gauge tube Plug Oil level gauge Oil level gauge bracket Plug Disc (thickness: 8.5-0.1mm) O-ring O-ring
Illustration 6 6 6 6 6 6 6 4 4 2 2
1.2.4 PC8000 Part No.: 794 023 73 Pos.
Part-No.
15 16 17 14 18 19 20 99 504 1; 3; 4 2 1 1
37441299 90635240 37126599 92582440 31318499 90756940 92582840 33132299 79224973 972111 50774898 92583240 92583140
Qty. Description 14 14 14 14 14 2 2 3 3 9 3 1 1
Socket Cutting ring Union nut Oil level gauge tube Plug Oil level gauge Oil level gauge bracket Plug Disc (thickness: 8.5-0.1mm) O-ring O-ring Cover plate Cover plate
Illustration 6 6 6 6 6 6 6 4 4 2 2 -
AH03509a
Page 6 of 25 2. Variant (A) – Modification by replacing of the swing gear cover with the complete parking brake unit 1. 2. 3. 4.
Prepare the swing gear cover as described on page 23. Drain the motor adapter housing (about 0.6l oil). Remove the 8 bolts (7) M16 mm at the hydraulic motor (refer to illustration 1). Remove the motor with connected hoses and place it beside or if this is not possible, disconnect the hydraulic lines and close the ports. 5. Remove the 34 gearbox fastening bolts (8) M24 and the 8 mounting screws (8) M16 from the gear box. 6. Install 2 eye bolts M16 and lift the gearbox cover with the brake unit. 7. Replace the sun gear shaft (5) (refer to illustration 2). 8. Install the new Cover-Brake-Unit by using a new O-ring. 9. Modify the Swing gear type on the type plate old: GFB 174 E9017 to new: GFB 174 E9020 with punch marks. 10. Reinstall the hydraulic motor with the brake valve block by using a new O-ring. 11. Fill the motor adapter housing with oil according to the Maintenance Manual. 12. Weld on the oil level gauge brackets (20) on the hydraulic oil reservoir carrier and if so planed a second one onto the machinery house wall. 13. Insert the attached oil level gauges (19)into the brackets. 14. Check the oil level in the swing gear as described on page 25.
AH03509a
Page 7 of 25
Illustration 1 Illustration 1 – before modification 1
Oil level gauge swing machinery
2
Oil filler plug swing machinery
3
Breather filter swing machinery
4
Oil level gauge motor adapter housing
5
Breather filter motor adapter housing
6
Oil drain plug
7
Motor fastening bolts
8
- Gearbox fastening bolts (quantity: 34) - Mounting screws (quantity: 8)
AH03509a
Page 8 of 25 3. Variant (B) – Modification by machining the swing gear cover 1. Drain the motor adapter housing (about 0.6l oil). 2. Remove the 8 bolts (7) M16 at the hydraulic motor (refer to illustration 1). 3. Remove the motor with connected hoses and place it beside or if this is not possible, disconnect the hydraulic lines and close the ports. 4. Remove the 34 gearbox fastening bolts (8) M24 and the 8 mounting screws (8) M16 from the gear box (refer to illustration 1). 5. Install 2 eye bolts M16 and lift the gearbox cover with the brake unit. 6. Replace the sun gear shaft (5) (refer to illustration 2). 7. Remove the old O-ring and clean the groove. 8. Modify the swing gear cover as described on pages 11 - 22. 8. Install the modified Cover-Brake-Unit by using a new O-ring. 9. Modify the Swing gear type on the type plate old: GFB 174 E9017 Part No. 917 915 40 to new: GFB 174 E9020 Part No. 924 325 40 with punch marks. 10. Reinstall the hydraulic motor with the brake valve block by using a new O-ring. 11. Fill the motor adapter housing with oil according to the Maintenance Manual. 12. Weld on an oil level gauge bracket (20) on the hydraulic oil reservoir carrier and if so planed a second one onto the machinery house wall. 13. Insert the attached oil level gauges (19)into the brackets. 14. Check the oil level in the swing gear as described on page 24.
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Page 9 of 25 Illustration 2 – Overview before modification 1
3
4 5
2
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Page 10 of 25 Illustration 3 – Cover with brake (partly)
1
Pressure connection (M18x1.5) – max 60 bar
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Page 11 of 25 3.1 Modification of the swing gear cover a) Dismounting 1. Remove the old oil level gauge assy. (390) and close the opening with a plug (99). 2. Remove the both snap rings (508; 549). 3. Loosen the 8 socket head cap screws (519). 4. Remove the bearing ring (503) by using of 2 eyebolts (M 16). 5. Before reinstallation apply the piston (116) with pressure (max. 60 bar) (see also illustration 4), otherwise the 2 screws (316)are prestressed (springloaded). 6. Remove the 2 socket head cap screws (316). Remove the piston (116). 6. Dismount the 10 Inner discs (505); the 11 outer discs (506) and the 10 sinus rings (551). 7. Remove the drive shaft (130). 501 8. Remove the disc (504). 99 501 390 316 551 505 503 506 504
130 549
508
116
519 Illustration 4
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Page 12 of 25 b) Machining of the swing gear cover (501 – disc housing) 1. Mill at the swing gear cover six areas as shown. 2. Drill 6 holes in the milled areas and tap 1 ¼ inch. Illustration 5
45°
45°
R31.5 30
30°
+0.5
30°
Ø524 Ø660 R 1.6 30
G 5/4 AH03509a
Page 13 of 25
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Page 14 of 25 c) Reassembly 3. Install the new disc (504) as shown.
4. Reinstall the drive shaft (130) with the ball bearing (51353298).
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Page 15 of 25
5. Install the new discs. At first an outer disc (grease it with oil), then an inner disc and then a sinus ring ... and so on.
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Page 16 of 25
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Page 17 of 25
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Page 18 of 25 Before installation supply the piston (116) with pressure (max. 60 bar). Do not forget to exchange the O-ring.
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Page 24 of 25 4. Completion of the swing gear cover 1. Remove plugs* (A3) from the swing gear cover. * numbers depends on type of the excavator 2. Install the oil level gauge tubes (14; 15; 16; 17) as shown in the illustration 6. 3. Close the tubes with plugs M24 (18).
20
19
Illustration 6
A3 – Plug 14 – Oil level gauge tube 15 – Socket 16 – Cutting ring 17 – Union nut 18 – Plug 19 – Oil level gauge 20 – Oil level gauge bracket AH03509a
Page 25 of 25 5. Oil level checking procedure (engine at standstill) The design of the swing gear requires four or five locations for oil level checking. The correct oil level is below the upper planetary stage. To reach this level between the planetary gears it is necessary to find out at which of the four, five or six tubes the oil level gauge can be insert to the stop.
Proceed as follow: 1. Take out oil level gauge (19) from bracket (20). 2. Remove plug (18) from one tube (14) and insert gauge (19). If the gauge can not be moved in to the stop use the next tube (14). Repeat this procedure until the gauge can be inserted to the stop. 3. The oil level should be between the MIN and MAX marking on the gauge. Add oil if necessary. 4. Remove oil level gauge from the tube and insert into bracket (20). 5. Close the tubes with the plugs (18).
• Do not leave the gauge (19) in the tube (14). If the gauge is left in the tube the swing gear and the gauge will be damaged when the swing gear operates.
AH03509a
Appendix
Service Bulletins
6.5.11 AH03510 ESCO bucket tooth system
6 - 37
Service Bulletins
Appendix
This page was left blank intentionally.
6 - 38
COMPONENT CODE:
71
REF NO.
AH03510
PARTS & SERVICE NEWS
DATE
2nd June 2003 Page 1 of 18
SUBJECT:
ESCO bucket tooth system
PURPOSE:
Hints for handling
APPLICATION:
PC4000; PC5500 (15012 - ); PC8000
FAILURE CODE:
7168Z9
DESCRIPTION: At our excavators PC4000; PC5500 (15012-) and PC8000 the new bucket tooth system “POSILOK” is used. In the following is showed how to handle the parts of this system. Page 2
1.
Overview
1.1 1.2
Komatsu standard version Optional version
2.
The Points
3
2.1 2.2
Removing the points Installing the points
4 5
2 2
3.
The Adapters
3.1 3.2 3.2.1 3.2.2 3.2.3 3.3 3.4
Adapter removal Nose rebuild Nose end and sides rebuild Nose flats rebuild Rear corner rebuild Adapter installation Retighten Sidewinder Pin
6 8 8 9 9 10 11
6
4.
Wear Caps
11
4.1 4.1.1 4.1.2 4.2
11 11 12 13
4.2.1 4.2.2
Lock style wear caps (PC4000) Removal Installation Non lock style wear caps (Option PC4000; PC5500; PC8000) Removal Installation
5.
The Shrouds
14
5.1 5.2 5.2.1 5.2.2 5.2.3 5.3 5.4
Removal the shrouds Installing the shrouds Prepare the surface Position the bosses Welding the bosses Inspecting Worn Shrouds Installing (Shrouds and Pins)
14 15 15 16 17 17 18
13 13
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Page 2 of 18 1. 1.1
Overview Komatsu standard version
Additional wearcap for plate lips version (PC4000) Wearcap
1.2
Optional version
!
• For changing to optional version new points, new adapters and the wearcaps are required.
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Page 3 of 18 Classification of the Tooth Systems to the Excavator Types Type of Excavator PC4000 PC5500 PC8000 - ( 12030) - ( 12034)
Shovel Version S 110 S 130 S 145 S 130 S 130
Backhoe Version S 95 S 130 S 145 -
Component Preparation Prior to installing the new tooth system components: • Thoroughly clean all bearing surfaces on the tooth base, adapter and pin. • Visually inspect top and bottom of tooth base for wear, refer to following sections. • Replace all damaged components.
2.
The points
4 2
3
6
5 1 1
Point
2
Posilok Locking Pin
3
Integral rubber lock
4
Adapter
5
Mating rails between point and adapter
6
Stabilizing flats
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Page 4 of 18 2.1
Removing the points
!
• All persons performing maintenance work should wear a approved hard hat, safety glasses, steel-toed shoes and gloves. • To avoid injury to others, keep people not directly involved well out of the way.
1. Removal tool between the (PART NO. 79350273) Posilok Pin and the lock
2. Drive the Posilok Pin out using a removal tool
(Part No. 793 502 73)
Use this end to start the Posilok Pin out.
• • •
Use this end to drive it through.
Remove the vertical drive-through pin using a hammer and a pin removal tool (Part No. 79350273). Make sure to insert the tip of the removal tool between the Posilok Pin and the rubber lock. In order to loosen the point for removal from the adapter, it may be necessary to tap the sides of the point to loosen fines.
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Page 5 of 18 2.2
Installing the points
Preparation Prior to point replacement, make sure adapters are clean and free of damage. Carefully inspect adapters for excessive wear. If the nose is worn or if insufficient wear metal remains to see adapters through their work cycle, they should be replaced with new ones. Vertical locking pins: Locking pins may be reused provided they do not show signs of significant wear, damage or distortion. Points: If you are going to install new points, make sure the rubber lock is installed so the arrows embossed on the surface of the lock are pointing forward (toward the tip of the point).
Position the locking pin and drive it in.
Vertical locking pin
Point • •
Install the points onto the adapters. After positioning a point onto its adapter, drive in the vertical locking pin using an 4 kg (8lb) hammer. The rubber lock keeps the Posilok Pin securely in place.
Posilok Pin engages the lock.
Topside and forward •
Drive in the Posilok Pin until it engages the lock. When the Posilok Pin is correctly in place, the rubber lock fits into the slot of the Posilok Pin to secure it.
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Page 6 of 18 3.
The adapters
3.1
Adapter removal Prior to using an adapter tool be sure that the following safety precautions are followed at all times: • Always wear proper safety equipment including hardhat, gloves, safety glasses and steel-toed shoes. • Never exceed the lifting capacity of the tool. Lifting tool 122K (Part No. 793 503 73) rated capacity 270kg (600lb) - for the S145 tooth system. Lifting tool 112K (Part No. 793 504 73) rated capacity 230kg (500lb) - for the S130 tooth system. • Tool is intended for vertical lift only. • Always stand clear of the raised adapter. • Never allow anyone to work under the adapter until it is secured to the lip by the appropriate locking mechanism. • Always use the safety features (lock and safety pin) as indicated. Never use hand tools or other fastener to secure the sleeve. Never use anything other than the sleeve provided to support the adapter. • Replace the tool when it becomes visibly damaged or distorted. Do not attempt to repair a damaged tool.
• •
Position the bucket with the nose tilted slightly upward. Clean debris from adapter Sidewinder Pin head slot and remove cap from Sidewinder Pin head. (The fastening Sidewinder Pin may become frozen in the nose hole by cemented fines. In this event, use either a hammer and drift or a porta-power, applied directly against the end of the Sidewinder Pin sleeve, to force the Sidewinder Pin out. Use a striking plate, as needed, to avoid hammering the end of the Sidewinder Pin base. With body completely retracted, insert drift that fits inside hex recess and hammer Sidewinder Pin through nose hole. Alternately, drift can be placed against outer sleeve. Avoid hammering over hex recess and thereby peening over the edges of this recess.)
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•
Insert Allen hex bit (14; 17 or 19 mm) into the head of Sidewinder Pin and turn counterclockwise (only for S 95 clockwise) until the Sidewinder Pin body is fully retracted. Do not continue to turn after “stop” is felt. The Sidewinder Pin is designed for operation with a ratchet wrench and should not normally require use of an air-impact wrench.
! •
• For removing the adapter the Sidewinder Pin need not to remove out off the adapter base if it is in good condition. • If the Sidewinder Pin have to be removed the end opposite the hex socket must be removed at first.
Lifting tools (refer to drawing next page): 122K (793 503 73): (for S145)
- Remove the safety pin of the adapter tool and slide the sleeve off the arm. - Guide the arm through the square hole in the nose of the adapter. - Arm must be pointed towards rear of the adapter. - Slide the sleeve onto the arm, align the holes in the arm and sleeve and install safety pin.
112K (793 504 73): (for S130)
- Guide the lug on the end of the arm through the D-shaped hole in the nose of the adapter. - Rotate the arm towards the rear of the adapter until the tool is aligned with the adapter 90° and slide the lock down through the D-shaped hole and insert the safety pin.
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Page 8 of 18
Part No. 793 503 73 (for S145) Part No. 793 504 73 (for S130) Rotate the arm 90° for fixing
Safety pin of the adapter tool Sleeve •
Using a boom rated at 270 kg (600 lb) or greater (PC5500 and PC8000) or a boom rated at 230 kg (500 lb) or greater (PC4000), hook into the shackle at the top of the arm and remove the adapter.
3.2 Nose rebuild Nose fit: This tooth system is designed to operate with movement of the adapter on the nose. However, movement may become excessive over long term service because of nose wear. In this event, the nose can be rebuilt in the indicated areas with welding and grinding.
3.2.1 Nose end and sides rebuild
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Page 9 of 18
•
Place the nose side template on the centerline of nose. Nose side template Size S 95 S 110 S 130 S 145
• •
Nose Side Template 79350573 79350773 79350973 79400373
Nose Flats Template 79350673 79350873 79351073 79400473
Weld–rebuild nose end surface and grind flat until gage ends align with front edge of pin hole. Weld stringer beads should run parallel to the nose width. Rebuild nose end radii as necessary.
3.2.2 Nose flats rebuild • •
Place the nose flats template over the nose as shown. Weld buildup nose flats and radii and grind flat until template contacts nose end. Nose flat template
3.2.3 Rear corner rebuild • • • •
Weld rebuild rear corners of nose. Chalk or paint weld buildup areas, place adapter as far as possible on nose and then remove. High spots will be indicated by missing chalk or paint. Grind weld buildup areas until a new adapter has a little or no movement up and down. Grind blend smoothly into rear shoulders.
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Page 10 of 18 3.3
Adapter installation Prior to using an adapter tool be sure that the following safety precautions are followed at all times: • Always wear proper safety equipment including hardhat, gloves, safety glasses and steel-toed shoes. • Never exceed the lifting capacity of the tool. Lifting tool 122K (Part No. 793 503 73) rated capacity 270kg (600lb) - for the S145 tooth system. Lifting tool 112K (Part No. 793 504 73) rated capacity 230kg (500lb) - for the S130 tooth system. • Tool is intended for vertical lift only. • Always stand clear of the raised adapter. • Never allow anyone to work under the adapter until it is secured to the lip by the appropriate locking mechanism. • Always use the safety features (lock and safety pin) as indicated. Never use hand tools or other fastener to secure the sleeve. Never use anything other than the sleeve provided to support the adapter. • Replace the tool when it becomes visibly damaged or distorted. Do not attempt to repair a damaged tool.
•
The Sidewinder Pin must be fully retracted in the adapter base. Sidewinder Pin can be inserted from either side of base. Recommend corner positions be installed from inside.
•
Position the bucket with the nose tilted slightly upward.
•
Use a lifting tool and a lifting boom for the movement of the adapter as described in section 3.1. Test lift the adapter to check for satisfactory adapter tilt angle.
!
• The adapter should tilt downwards at the rear for easy installation onto the nose.
•
Lower the adapter and reposition the shackle as needed to achieve appropriate tilt angle.
•
Lift the adapter and slide it onto the nose. With the lifting boom still holding the adapter, install the adapter locking pin:
!
• For applications where soil fines pack and harden, it is recommended that the outer sleeve of the pin be covered in grease.
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Page 11 of 18
•
Using hex bit and socket drive, turn hex socket end of Sidewinder Pin clockwise to extend the pin into the pin hole in the opposite side of the adapter. Tighten to the specified torque value shown below. Size S 95 S 110 S 130 S 145
•
3.4
Allen type wrench size 14 mm 17 mm 19 mm 19 mm
Recommended pin torque 160-200 Nm (120-150ft-lb) 200-260 Nm (150-190ft-lb) 260-390 Nm (190-290 ft-lb) 260-390 Nm (190-290 ft-lb)
Insert the Sidewinder Pin cap to prevent the pin hex socket from filling with soil fines. Cap should snap into place. Retighten Sidewinder Pin
Retighten the Sidewinder Pin every 600 to 1200 hours of operating service depending on the severity of application.
!
• Some loosening of pin ½ - ¾ turns is normal. It is not necessary to keep it tightened to the recommended torque.
4. Wear Caps 4.1 Lock style wear caps (PC4000) 4.1.1 Removal • •
•
Clean debris from the gaps around the wearcap lock. Do not strike corners or edges with hammer! Rotate Lock : Use a drift and a 2-4 kg/4-8 lb hammer to rotate the lock to the unlocked position.
It may be necessary to partially rotate the lock in both directions to break loose soil fines, before fully rotating it.
!
• Lock must be rotated completely (180 degrees) to release the wearcap. • Lock can rotate either way.
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Page 12 of 18
Remove Wearcap: Slide wearcap out of adapter slots. Use appropriate lifting devices to support and remove wearcap. It may be necessary to place a pry bar between the adapter and the rear inside face of the wearcap to lift and free it from soil fines.
4.1.2 Installation
!
• Wearcap tabs, adapter tab slots, and lock recesses must be thoroughly cleaned. Inspect all components for damage. Replace any damaged parts.
•
Position Wearcap Lock First place the lock flat side down against the inside of the wearcap, adjacent to the lock opening. Slide it toward the wearcap lug. One of the lock shafts will enter the hole in the lug. Push the lock up tight against the lug. Then, using a drift placed in one of the lock pockets, tap the drift with a hammer to cause the lock to rotate halfway around, until the flat side of the lock is facing you and is lined up with the inside face of the wearcap.
•
Wearcap Installation Place the wearcap on the adapter. The tabs on the inside of the wearcap fit into the tab slots in the adapter.
•
Lock Wearcap Use an suitable tool and hammer to rotate the lock to the locked position. If lock resists rotation, this indicates more cleaning of the adapter slots is required. When flat is facing out, the lock is in a locked position.
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Page 13 of 18
4.2
Non lock style wear caps (Option PC4000; PC5500; PC8000)
!
• For using of these kind of wear caps special points and special adapters are required.
4.2.1 Removal • •
Drive out the point pin and remove the point. Slide the worn wearcap off the adapter.
!
• If soil packs tightly between the wearcap and the adapter, it may be necessary to strike the flat sides of the wearcap several times with a hammer, to loosen it for removal. • Do not strike corners or edges with hammer!
4.2.2 Installation • • •
Inspect all components for damage. Replace any damaged parts. Slide wearcaps onto the adapter top and bottom surfaces, so that the wearcap rear central and two forward side tabs insert fully into the respective slots of the adapter. Install and pin the point.
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Page 14 of 18 5. 5.1
The Shrouds Removal the shrouds
The Toplok shroud system is engineered to make change-out easy. Before following these simple steps shown to the Figures, it’s important to clean fines from pin area by tapping the shroud to loosen them, then scraping them using a chisel or needle gun (if fines are heavily packed). • •
Use a small bar with flat end (19 mm wide maximum) to retract the latch and lift the pin out. Pins can be reused if not worn below the locator flange and the insert latch rubber is fully bonded to the steel tip and fully seated in the pin body.
Place a pry bar or pinch bar behind the latch as shown, as a lever to compress it.
!
Lift out and remove the lock. Slide the shroud off the lip base.
• In severe applications assist removal by inserting a pry bar under the lock from the rear of the shroud and lifting up the latch end of the pin while prying as shown.
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Page 15 of 18
5.2 Installing the shroud 5.2.1 Prepare the surface In order to provide sufficient support for the boss as well as its pin, the mounting surface must: • Be relatively smooth and free of debris, weld spatter, and other irregularities. • Have a profile that produces a gap no greater than 3 mm or 1/16" at the boss weld. Any gap greater than 3 mm or 1/16" must be shimmed. Checking the Fit Pad Areas • • • •
The fit pad surface (1) & (2) should be perpendicular to each other. Make sure 70% of the fit pad surfaces (1) & (2) are in contact with the gauge. After achieving this, the fit pad surface (3) should be checked. Use a straight edge to help check the surface consistency.
Plate lips (PC4000)
Cast lips (PC5500 and PC8000)
Templates Part numbers for checking and preparation the lips Type of Excavator PC4000 PC5500 PC8000
Shovel Version Lip Shroud Template 654 547 40 654 548 40 794 005 73 655 867 40 or 907 281 40 907 006 40
794 007 73
Backhoe Lip Shroud 654 627 40 654 628 40 654 629 40 655 867 40
Version Template
794 008 73
907 448 40 On request
794 006 73 794 007 73
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Page 16 of 18
5.2.2 Position the bosses Checking the Boss Position To insure the boss is located correctly, the gap between the gauge and the boss rails should not exceed 1mm/.04in. If the gap exceeds 1mm/.04in.,the boss has to be removed and a new boss installed (see below). The back of the boss should line up with the back of the gauge rail. If the boss does not line up with the back of the gauge rail, then two repair options are possible: • (A) If the gap does not exceed 1.5mm/.06in., build up the back of the boss; or • (B) Weld build the leading edge fit pad (2). This may result in the ramp fit pad (3) also requiring weld build up.
Weld Rebuilding Fit Pads When weld rebuilding fit pads ensure the weld surface is clean and free of any contamination that might prevent a good weld. Follow the preheat, interpass and post heat guidelines below. Summary of Welding Specifications • Electrodes: E7016 or E7018 low hydrogen (keep dry!) • Wires: E70T-5, E71T-1, or E70T-1 with CO 2 gas. • Preheat: 200°F/95°C (350-400°F/175-205°C if air temperature is 40°F/5°C or lower.) • Interpass: Maintain interpass temperature less than 500°F/260°C. • Postheat: If air temperature is 40°F or lower, postheat 350-400°F, then let air cool. • Remove slag after each pass and peen each bead. New Boss installation • Set the boss onto the gauge rails and locate the back of the boss with the back of the gauge rails. If no gauge is available, use a new shroud to locate the boss. • Move the gauge onto the lip, making sure the gauge is centered between the nose bases and the gauge is in contact with fit pad surfaces (1) & (2). • Practice has shown, that the boss will suck down 1/16" during welding. To equalize this use a 1/16" shim under the boss, even if there is no gap between the fit pad (1) and the boss. This will ensure the boss height is correct after welding. • If there is a gap between the fit pad surface (1) and the boss, use a thicker shim accordingly.
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Page 17 of 18 5.2.3 Welding the bosses The weld surface must be clean and free of any contamination that might prevent a good weld. Follow the preheat interweld and post heat guidelines below. Summary of Welding Specifications • Electrodes: E7016 or E7018 low hydrogen (keep dry!) • Wires: E70T-5, E71T-1, or E70T-1 with CO 2 gas. • Preheat: 200°F/95°C (350-400°F/175-205°C if air temperature is 40°F/5°C or lower.) • Interpass: Maintain interpass temperature less than 500°F/260°C. • Postheat: If air temperature is 40°F or lower, postheat 350-400°F, then let air cool. • Remove slag after each pass and peen each bead. Weld the boss to the lip. Make sure that the boss is shimmed, so that the height of the boss will be correct after welding. Weld area (A) completely before welding areas (B) & (C). Welding Guide Weld Location Boss TAB TBB TCB
(A) Depth of weld plug holes mm/in Plug Weld 10/.38 Plug Weld 13/.50 Plug Weld 16/.62
(B) Size of fillet weld-on ends mm/in Fillet 10/.38 Fillet 13/.50 Fillet 13/.50
(C) Size of fillet weld-on ends mm/in Fillet 3/.19 Fillet 6/.25 Fillet 6/.25
5.3 Inspecting Worn Shrouds Toplok shrouds protect the bucket lip and wings from abrasive wear. Use of ESCO 12S abrasion resistant alloy assures long life before change out. • Periodic inspection should be made to determine when to replace a shroud. • Monitor high wear surfaces of the Toplok shroud for wear. • Special “wear indicators” are special panels that will open up to alert the user of the need for changing shrouds.
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Page 18 of 18
5.4
Installing
Installing the shroud •
Slide the shroud over the lip and boss to install the pin. If installing a new shroud, the pin must have contact with the back of the boss and with the back of the shroud without losing contact at the leading edge.
Installing the pin •
Position the pin in the shroud cavity as shown.
•
A light blow with a hammer will engage the pin.
•
The shroud is now securely attached.
AH03510
Appendix
Service Bulletins
6.5.12 AH03526A Downloading of VHMS Data from VHMS memory to a connected PC/Laptop
6 - 39
Service Bulletins
Appendix
This page was left blank intentionally.
6 - 40
COMPONENT CODE:
DB
REF NO.
AH03526a
PARTS & SERVICE NEWS
DATE
June 14, 2004 Page 1 of 1
This PARTS & SERVICE NEWS supersedes the previous issue AH03526 which should be discarded. SUBJECT:
Downloading of VHMS Data from VHMS memory to a connected PC/Laptop
PURPOSE:
Introduction of the VHSM – System for PC4000-6
APPLICATION:
PC4000-6 with VHMS - system
FAILURE CODE:
DB20Z9
DESCRIPTION: To carry out the data transfer from VHMS – system memory to a PC/Laptop, the necessary soft-/ hardware can be ordered individually. For machines up to Serial No. 08155: No 01 02
Designation Data transfer cable VHMS Technical analysis tool box (Download software + instruction manual)
Part No. 913 273 40 792 504 73
For machines up Serial No. 08156: No 01 02
Designation Data transfer cable VHMS Technical analysis tool box (Download software + instruction manual)
For price and delivery time contact:
Part No. 894 580 40 792 504 73
Komatsu Mining Germany Parts and Service Department 8152 Dinglerstr. 1 66440 Bierbach Germany
AH03526a
Appendix
Service Bulletins
6.5.13 AH03538 Replacing of the VHMS - Controller on PC4000-6
6 - 41
Service Bulletins
Appendix
This page was left blank intentionally.
6 - 42
PARTS & SERVICE NEWS
COMPONENT CODE:
DA
REF NO.
AH03538
DATE
December 4, 2003 Page 1 of 26
SUBJECT:
Replacing of the VHMS – Controller on PC4000-6
PURPOSE:
To expound on the steps for replacing the existing VHMS controller with new one and the latter's setting
APPLICATION:
PC4000-6
FAILURE CODE:
DA00Z9
DESCRIPTION:
1. 2. 3. 4. 5.
Introduction Part number Precautions for Controller Replacement Appendix VHMS initial setting check sheet
1. Introduction PC4000 are equipped with a VHMS controller as part of their standard specifications. The VHMS controller is a device to control the CGC display and to record the history of machine operation. The VHMS controller is constantly powered direct by a battery and its function is to compile and record the day's operation in the VHMS memory, after the engine is switched off, while checking data consistency with the record up to the previous day. This work takes a certain amount of time, i.e. approx. 10 seconds. For this reason, cautions have to be taken in advance, when disconnecting the power to the VHMS. Such disconnection usually takes place with machines equipped with a battery isolator and a turbo-timer, when switching off the engine for emergency, right after the turbo timer has been set in operation, or when the battery terminal is disconnected immediately after switching off the starting switch, say for welding. In such case, the compilation and write-in work in the VHMS memory is interrupted, resulting in the controller program being damaged and the initial screen remaining in the CGC display unchanged. Hence be sure to provide an interval of more than 3 minutes after the engine is switched off and before disconnecting all the electric circuits. This Parts and Service News describes the procedures for you to follow when replacing the existing VHMS controller with a new one.
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Page 2 of 26
2. Part No.
3.
Part No.
Part Name
89200040
Controller
Precautions for Controller Replacement
3.1 Before starting with the replacement A. Download the VHMS data, if possible. First download the data on failure history in the existing VHMS controller that have been stored up to that moment, since they will likely be lost by the replacement. Next send them to WebCare. B
Disconnect the normal VHMS power source.
i)
Terminate the normal power supply by turning off the ignition key.
ii)
Maintain constant power supply for the controller at least for more than two minutes.
iii)
Then terminate constant power supply for the controller by disconnecting the power source.
3.2 Procedures for replacement and setting of VHMS system and actions after replacement A. Precautions for replacement: Replace the existing VHMS system with new one, taking care that no excessive force or shock is applied to the main body, the harness, etc. Relative to the VHMS connectors, disconnect CN1 first and connect it last, since it serves as a power supply cable, too.
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Page 3 of 26
B. Controller setting after replacement When a VHMS controller is replaced, data setting has to be done anew. Make correct setting, referring to the instructions on the following pages. Items to be newly set.
No. 1
Settings Operator: USER ID; Truck counter
Page 4; 5
2 3 4 5 6 7 8 9 10 11
Service: Machine model; Serial No. (Machine) Engine model; Serial No. (Engine) Maintenance Acknowledgement Central Lubrication System Swing Lubrication System Language; Operating Hours; Date Time; GMT Ref. Hydraulic Oil Viscosity; Gear Oil Viscosity Message ON/OFF; PLC-autom. ON/OFF Shut-Down ON/OFF
6; 7 8; 9 10; 11 12; 13 14; 15 16; 17 18; 19 20; 21 22; 23 24; 25
C. Disposal of replaced VHMS controller Return the replaced VHMS controller to the KMG Service Department, in accordance with its request for return of fault parts. When returning the controller, be sure to attach a tag to it, declaring that it is the VHMS controller replaced under this Parts and Service News. Also the attached form “VHMS initial setting check sheet” has to be send to KMG-Service Department.
AH03538
Page 4 of 26
4. Appendix 1.2 Date 31.08.01 Time 23:59 25 °C 2587.9 h Tr1 Tr2 12 15 1/min 1800
Fuel Level
Hyd Oil Temp
F
E
Oil Press Eng
H
L
H
L
Maint Mess Next Monitor 1
1.3 Date 31.08.01 Time 23:59 25 °C 2587.9 h Tr1 Tr2 12 15 1/min 1800
1.2.3
Operator ID
1.2.4 1.2.5
Maintenance Monitor Current Messages
0.0 1.1
H
L
Coolant Eng
1.2 1.3 1.4 1.2.1 1.2.2
Operator Menu Initialization Information Machine Conditions: Monitor1 Standard monitor Monitor2 Expansion monitor Monitor3 Expansion monitor Screen Adjustment Consumption
1.2.3 Oil Temp Eng
Oil Temp PTO
H
L
L
Boardnet Volt
SETTING for Operator
H
USER ID
12345678901
Reset Truck Counter 1
16
Reset Truck Counter 2
17
Charging AMP
+
H
-
L
Maint Mess Next Monitor 2
1.4 Date 31.08.01 Time 23:59 25 °C 2587.9 h Tr1 Tr2 12 15 RPM 1800
Oil Level Hyd
Oil Level Eng
H
L
H
L
Gre Level CLS
Gre Level SLS H
H
L
L
Maint Mess Next Monitor 3
AH03538
Page 5 of 26
14.1.7 Settings for Operator, Screen (No. 1.2.3)
See illust. (Z 21576)
When the button -Settings for Operator is pressed, the screen No. 1.2.3 is displayed.
)
• There are two hidden touch switches on the SETTING for Operator screen, see (1) and (2) illust. (Z 21576). These switches are used by service personnel for entering the Service Menu. To enter the Service Menu, first press the lower button (1) and then the upper button(2).
Entry of the Operator identification number (USER ID button): In the selection menu for settings (1.2.3) appears on the right side of the button ”USER ID” the actual eleven-digit Operator identification number. The use of the button ”USER ID” branches into the setting mode for the Operator identification number, see illust. (Z 21578). Without prior entry, 0 is predetermined as identification number. To distinguish Operators, it is possible to enter a eleven-digit Operator identification number. To this effect, the Clear-button puts the cursor onto the first position (left side). Data entry may be started via the number buttons. If eleven numbers were entered each further entry will be ignored. Using the Enter-button the identification number will be taken over and branched back to the selection menu (1.2.3). Resetting the Truck Counter: Press the button ”Reset Truck Counter 1” the display changes to ”YES – NO” decision screen, picture (Z 21577). When pressing the ”YES” button the counter 1 will be reset to zero. Truck counter 2 is reset in the same way.
AH03538
Page 6 of 26
1.2 Date 31.08.01 Time 23:59 25 °C 2587.9 h Tr1 Tr2 12 15 1/min 1800
Fuel Level
⇒
Hyd Oil Temp
F
H
E
L
Coolant Eng
Oil Press Eng
H
H
L
1.2.3 SETTING for Operator
2
USER ID
12345678901
Reset Truck Counter 1
16
Reset Truck Counter 2
17
L
Maint Mess Next Monitor 1
2.0 Please Input Service ID 1
2
3
4
5
6
7
8
9
⇓
1
******
Please Input Service ID
0
Clear Enter
STO P
4.3.1 SERIAL NO. SETTING (MACHINE) MACHINE MODEL
PC4000
Variation Code
BHA
Type
-6
SERIAL No.
12345678901
MENU MACHINE
⇐
3.1 SERVICE MENU SELECT
⇓
Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
ENGINE
AH03538
Page 7 of 26
14.2.6 Serial No. Setting (No. 4.3.1) Machine
1 2 3 4
4.3.1 SERIAL NO. SETTING (MACHINE) MACHINE MODEL
PC4000
Variation Code
BHA
Type
-6
SERIAL No.
12345678901
MENU MACHINE
(1)
5
ENGINE
Machine model setup button: When you press this button, the model name selection menu appears.
SERIAL NO. SETTING (MACHINE) MACHINE MODEL PC4000 PC1000 PC6000 Variation Code PC2000
PC8000
Type PC3000
-6
PC10000
SERIAL No. PC4000 MENU
BHA
12345678901
MACHINE
ENGINE
SERIAL NO. SETTING (MACHINE)
(2)
Variation code setup button: When you press this button, the LBA and BHA selection menu appears.
MACHINE MODEL Variation Code LBA
PC4000 BHA
BHA
Type
-6
SERIAL No.
12345678901
MENU MACHINE
ENGINE
SERIAL NO. SETTING (MACHINE)
(3)
Type setup button: When you press this button, the type selection menu appears.
MACHINE MODEL
PC4000
Variation Code -1 -6
BHA
-2 Type-7
-6
-3 SERIAL-8No. -4
12345678901
-9
MENU -5 MACHINE
ENGINE
SERIAL No. SETTING
(4)
Serial number setup switch: Press this switch to set the serial number.
1
2
3
Please input SERIAL No.
4
5
6
12345678901
7
8
9
0
Clear Enter
EXIT
(5)
Engine serial number setup switch: Press this switch to change the display to the engine serial number setup screen.
AH03538
Page 8 of 26
1.2 Date 31.08.01 Time 23:59 25 °C 2587.9 h Tr1 Tr2 12 15 1/min 1800
Fuel Level
⇒
Hyd Oil Temp
F
H
E
L
Coolant Eng
Oil Press Eng
H
H
L
1.2.3 SETTING for Operator
2
USER ID
12345678901
Reset Truck Counter 1
16
Reset Truck Counter 2
17
L
Maint Mess Next Monitor 1
2.0 Please Input Service ID 1
2
3
4
5
6
7
8
9
⇓
1
******
Please Input Service ID
0
Clear Enter
STO P
4.3.1 SERIAL NO. SETTING (MACHINE) MACHINE MODEL
PC4000
Variation Code
BHA
Type
-6
SERIAL No.
12345678901
MENU MACHINE
⇐
3.1 SERVICE MENU SELECT
⇓
Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
ENGINE
AH03538
Page 9 of 26
14.2.6 Serial No. Setting (No. 4.3.2) Machine
1 2
4.3.2 SERIAL NO. SETTING (ENGINE) ENGINE MODEL
QSK60
#1 S/N
12345678901
MENU MACHINE
(1)
3
ENGINE
Engine model setup button: When you press this button, selectable engine models are displayed. Select a desired one.
SERIAL NO. SETTING (ENGINE) ENGINE MODEL QSK60
QSK60
#1 S/N
12345678901
MENU MACHINE
(2)
ENGINE
Serial number setup button: Press this button and then set the serial number in the screen below. SERIAL No. SETTING 1
2
3
Please input SERIAL No.
4
5
6
12345678901
7
8
9
0
Clear Enter
EXIT
(3)
Machine serial number setup switch: Press this switch to change the display to the machine serial number setup screen.
AH03538
Page 10 of 26
1.2 Date 31.08.01 Time 23:59 25 °C 252.1 h Tr1 Tr2 12 15 1/min 1800
Fuel Level F
E
⇒
Hyd Oil Temp H
L
Coolant Eng
Oil Press Eng
H
L
H
1.2.3 SETTING for Operator
2
USER ID
12345678901
Reset Truck Counter 1
16
Reset Truck Counter 2
17
L
Maint Mess Next Monitor 1
2.0 Please Input Service ID 1
2
3
4
5
6
7
8
9
⇓
1
******
Please Input Service ID
0
Clear Enter
STO P
4.5 MAINTENANCE MONITOR
⇐
3.1 SERVICE MENU SELECT
⇓
h
Real Time Monitor
Failure History
h
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
250h Maintenance
-2
500h Maintenance
248
1000h Maintenance
748
2000h Maintenance
1748
h
3000h Maintenance
2748
h
h
MENU
AH03538
Page 11 of 26
14.2.8
Maintenance Monitor (No. 4.5 – 4.5.1) Maintenance Acknowledgement
Maintenance confirmation through Service Personnel Maintenance indicated with yellow or red background color should be confirmed through Service Personnel in the Service Menu subsequent to the execution of the maintenance. With the confirmation the actual value maintenance number is increased by 1. Thus, the length of the maintenance cycle is added to the display value and the gray color will appear in the maintenance display. The button in the Service Menu used for maintenance confirmation then turns gray instead of yellow and is then without any function. The confirmation of the maintenance is then stored. Example: 250h Maintenance is required (yellow), service meter reading is 252 Hours.
When you select the yellow button, again, it changes to blue and starts blinking. MAINTENANCE MONITOR
When you press the blinking button the following screen appears. MAINTENANCE MONITOR
250h Maintenance
-2
h
500h Maintenance
248
h
1000h Maintenance
748
h
2000h Maintenance
1748
h
3000h Maintenance
2748
h
⇒
MENU
MENU
If the display color changes from yellow to grey, also the "MAINT" color button changes to grey blinking
-2
h
500h Maintenance
248
h
1000h Maintenance
748
h
2000h Maintenance
1748
h
3000h Maintenance
2748
h
⇓
When you press the YES button, the changes back to grey and stops
MAINTENANCE MONITOR
MAINTENANCE MONITOR
250h Maintenance
248
h
500h Maintenance
248
h
1000h Maintenance
748
h
2000h Maintenance
1748
h
3000h Maintenance
2748
h
MENU
250h Maintenance
⇐
-2
h
248 Really Reset 250h Maintenance? 500h Maintenance
h
1000h Maintenance
748
h
2000h Maintenance YES
NO 1748
h
3000h Maintenance
2748
h
MENU
⇓
Date 31.08.01 Time 23:59 25 °C 252.1 h Tr1 Tr2 12 15 1/min 1800
250h Maintenance
Fuel Level
Hyd Oil Temp
F
E
H
L
Coolant Eng
Oil Press Eng
H
L
H
L
Maint Mess Next Monitor 1
AH03538
Page 12 of 26
1.2 Date 31.08.01 Time 23:59 25 °C 2587.9 h Tr1 Tr2 12 15 1/min 1800
Fuel Level
⇒
Hyd Oil Temp
F
H
E
L
Coolant Eng
1.2.3 SETTING for Operator
Oil Press Eng
H
H
L
2
USER ID
12345678901
Reset Truck Counter 1
16
Reset Truck Counter 2
17
L
Maint Mess Next Monitor 1
2.0 Please Input Service ID 1
2
3
4
5
6
7
8
9
⇓
1
******
Please Input Service ID
0
Clear Enter
STO P
4.8.1
3.1
CLS SETTINGS Pause Time
60
min
Monitoring Time
3
min
Press. Relief Time
10
min
Lub. Cycle Counter
32000
Times
⇐
SERVICE MENU SELECT
⇓
Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
MENU
AH03538
Page 13 of 26
14.2.11 Settings (No. 4.8.1 – No. 4.8.10) Central Lubrication System CLS Only an integer can be entered as a numerical value. Decimal numbers cannot be entered.
(No. 4.8.1) CLS SETTINGS
Set CLS Pause Time
Pause (10 - 60)
60
min
Monitor. (1 – 20)
3
min
Relief (10 – 15)
10
min
Lub. Cycle Counter
32000
Times
⇒
MENU
1
2
3
4
5
6
7
8
9
0
Please input CLS Pause Time 60 min
Clear Enter
EXIT
Pause Time setting button:
Enter the time depending on the operating conditions. Only values between 10 and 60 minutes can be entered.
CLS SETTINGS
Set CLS Monitoring Time
Pause (10 - 60)
60
min
Monitor. (1 – 20)
3
min
Relief (10 – 15)
10
min
Lub. Cycle Counter
32000
Times
⇒
1
2
3
4
5
6
7
8
9
0
MENU
Please input CLS Monitoring Time 3 min
Clear Enter
EXIT
Monitoring Time setting button:
Enter the time depending on the operating conditions. Only values between 1 and 20 minutes can be entered.
CLS SETTINGS
Set CLS Press. Relief Time
Pause (10 - 60)
60
min
Monitor. (1 – 20)
3
min
Relief (10 – 15)
10
min
Lub. Cycle Counter
32000
Times
⇒
MENU
1
2
3
Please input CLS Press. Relief Time
4
5
6
10
7
8
9
0
min
Clear Enter
EXIT
Pressure Relief setting button:
Enter the time depending on the operating conditions. Only values between 10 and 15 minutes can be
entered. CLS SETTINGS
Set CLS Lub. Cycle Counter
Pause (10 - 60)
60
min
Monitor. (1 – 20)
3
min
Relief (10 – 15)
10
min
Lub. Cycle Counter
32000
Times
MENU
Lub. Cycle Counter setting button:
⇒
1
2
3
Please input CLS Lub. Cycle Counter
4
5
6
32000
7
8
9
0
Times
Clear Enter
EXIT
It is recommendable to keep the counter reading over the live time of the machine. If necessary enter the number of the last download.
AH03538
Page 14 of 26
1.2 Date 31.08.01 Time 23:59 25 °C 2587.9 h Tr1 Tr2 12 15 1/min 1800
Fuel Level
⇒
Hyd Oil Temp
F
H
E
L
Coolant Eng
1.2.3 SETTING for Operator
Oil Press Eng
H
H
L
2
USER ID
12345678901
Reset Truck Counter 1
16
Reset Truck Counter 2
17
L
Maint Mess Next Monitor 1
2.0 Please Input Service ID 1
2
3
4
5
6
7
8
9
⇓
1
******
Please Input Service ID
0
Clear Enter
STO P
4.8.1
3.1
CLS SETTINGS Pause Time
60
min
Monitoring Time
3
min
Press. Relief Time
10
min
Lub. Cycle Counter
32000
MENU
4.8.2
⇓
Times
⇐
SERVICE MENU SELECT
⇓
Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
1X
SLS SETTINGS
Pause Time
10
min
Monitoring Time
2
min
Press. Relief Time
10
min
Lub. Cycle Counter
32000
Times
MENU
AH03538
Page 15 of 26
14.2.11 Settings (No. 4.8.1 – No. 4.8.10) Swing Lubrication System SLS Only an integer can be entered as a numerical value. Decimal numbers cannot be entered.
(No. 4.8.2) SLS SETTINGS
Set SLS Pause Time
Pause (10 - 20)
10
min
Monitor. (1 – 20)
2
min
Relief (10 – 15)
10
min
Lub. Cycle Counter
32000
Times
⇒
MENU
1
2
3
4
5
6
7
8
9
0
Please input SLS Pause Time 10 min
Clear Enter
EXIT
Pause Time setting button:
Enter the time depending on the operating conditions. Only values between 10 and 20 minutes can be entered.
SLS SETTINGS
Set SLS Monitoring Time
Pause (10 - 20)
10
min
Monitor. (1 – 20)
2
min
Relief (10 – 15)
10
min
Lub. Cycle Counter
32000
Times
⇒
1
2
3
4
5
6
7
8
9
0
MENU
Please input SLS Monitoring Time 2 min
Clear Enter
EXIT
Monitoring Time setting button:
Enter the time depending on the operating conditions. Only values between 1 and 20 minutes can be entered.
SLS SETTINGS
Set SLS Press. Relief Time
Pause (10 - 20)
10
min
Monitor. (1 – 20)
2
min
Relief (10 – 15)
10
min
Lub. Cycle Counter
32000
Times
⇒
MENU
1
2
3
Please input SLS Press. Relief Time
4
5
6
10
7
8
9
0
min
Clear Enter
EXIT
Pressure Relief setting button:
Enter the time depending on the operating conditions. Only values between 10 and 15 minutes can be entered.
SLS SETTINGS
Set SLS Lub. Cycle Counter
Pause (10 - 20)
10
min
Monitor. (1 – 20)
2
min
Relief (10 – 15)
10
min
Lub. Cycle Counter
32000
Times
MENU
Lub. Cycle Counter setting button:
⇒
1
2
3
Please input SLS Lub. Cycle Counter
4
5
6
32000
7
8
9
0
Times
Clear Enter
EXIT
It is recommendable to keep the counter reading over the live time of the machine. If necessary enter the number of the last download.
AH03538
Page 16 of 26
1.2 Date 31.08.01 Time 23:59 25 °C 2587.9 h Tr1 Tr2 12 15 1/min 1800
Fuel Level
⇒
Hyd Oil Temp
F
H
E
L
Coolant Eng
1.2.3 SETTING for Operator
Oil Press Eng
H
H
L
2
USER ID
12345678901
Reset Truck Counter 1
16
Reset Truck Counter 2
17
L
Maint Mess Next Monitor 1
2.0 Please Input Service ID 1
2
3
4
5
6
7
8
9
⇓
1
******
Please Input Service ID
0
Clear Enter
STO P
4.8.1
3.1
CLS SETTINGS Pause Time
60
min
Monitoring Time
3
min
Press. Relief Time
10
min
Lub. Cycle Counter
32000
MENU
4.8.3
⇓
Times
⇐
SERVICE MENU SELECT
⇓
Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
2X
OTHER SETTINGS (1/2) Language
English
Operating hours
650.2
Date
2001
Time
16 : 16
GMT Ref. MENU
3
19
8.5 Summer
AH03538
Page 17 of 26
14.2.11 Settings (No. 4.8.1 – No. 4.8.10) Other Settings 1/2 (No. 4.8.3) OTHER SETTINGS (1/2) Language Operating hours
OTHER SETTINGS (1/2)
English 650.2
Date
2001
Time
16 : 16
GMT Ref.
3
19
⇒
Operating German hours
8.5
MENU
English
Language English
2001
Time
16 : 16
MENU
Summer
3
19
8.5
GMT Ref.
Language selector button:
650.2
Date
Summer
When the language menu appears, select a desired language.
The CGC is reset on a software basis. The screen disappears and then the software is restarted from the opening screen.
OTHER SETTINGS (1/2) Language Operating hours
Operating Hours SETTING
English 650.2
Date
2001
Time
16 : 16
GMT Ref.
3
19
⇒
8.5
MENU
1
2
3
4
5
6
7
8
9
0 Summer
SMR setting button:
Please input operating hours 650 .0 hour
Clear Enter
EXIT
Only an integer can be entered as a numerical value. Decimal numbers cannot be entered.
Set the service meter only while the engine is stopped.
OTHER SETTINGS (1/2)
OTHER SETTINGS (1/2)
Language
English
Operating hours
650.2
Date
2001
Time
16 : 16
GMT Ref. MENU
3
19
8.5
⇒
Language
English
Operating hours
650.2
Date Year Time Month GMT DayRef.
Summer
DATE SETTING
MENU
2001
3
19
16 : 16
⇒
8.5
1
2
3
Please input year
4
5
6
2001
7
8
9
0 Summer
Clear Enter
⇓
EXIT
OTHER SETTINGS (1/2)
For all DATE SETTINGS, i.e. Year Month and Day it is necessary to confirm the new settings by using the SET button.
Language Operating hours
English 650.2
Date
2001
3
Time
16 : 16
19 SET
GMT Ref. MENU
8.5 Summer
AH03538
Page 18 of 26
1.2 Date 31.08.01 Time 23:59 25 °C 2587.9 h Tr1 Tr2 12 15 1/min 1800
Fuel Level
⇒
Hyd Oil Temp
F
H
E
L
Coolant Eng
1.2.3 SETTING for Operator
Oil Press Eng
H
H
L
2
USER ID
12345678901
Reset Truck Counter 1
16
Reset Truck Counter 2
17
L
Maint Mess Next Monitor 1
2.0 Please Input Service ID 1
2
3
4
5
6
7
8
9
⇓
1
******
Please Input Service ID
0
Clear Enter
STO P
4.8.1
3.1
CLS SETTINGS Pause Time
60
min
Monitoring Time
3
min
Press. Relief Time
10
min
Lub. Cycle Counter
32000
MENU
4.8.3
⇓
Times
⇐
SERVICE MENU SELECT
⇓
Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
2X
OTHER SETTINGS (1/2) Language
English
Operating hours
650.2
Date
2001
Time
16 : 16
GMT Ref. MENU
3
19
8.5 Summer
AH03538
Page 19 of 26
14.2.11 Settings (No. 4.8.1 – No. 4.8.10) Other Settings 1/2 (No. 4.8.3) OTHER SETTINGS (1/2)
OTHER SETTINGS (1/2)
TIME SETTING
Language
English
Language
English
Operating hours
650.2
Operating hours
650.2
Date
2001
Time
16 : 16
GMT Ref.
3
19
8.5
MENU
⇒
Summer
Date
2001
3
Time Hour
16 : 16
19
8.5
GMT Ref. Minute MENU
⇒
Summer
1
2
3
Please input hour
4
5
6
16
7
8
9
0
Clear Enter
EXIT
⇓
OTHER SETTINGS (1/2)
For all TIME SETTINGS, i.e. Hour and Minute it is necessary to confirm the new settings by using the SET button.
Language Operating hours
English 650.2
Date
2001
3
Time
16 : 16
19 SET
GMT Ref. MENU
OTHER SETTINGS (1/2) Language
English 650.2
Date
2001
Time
16 : 16
3
19
⇒
8.5
MENU
Summer
Time difference entry button:
2
3
4
5
6
7
8
9
0
.5
-
Please input GMT Reference 8.5
Clear Enter
To set the local time difference (from the international standard time) in the VHMS controller, press the GMT Ref.-button and then enter time with the combination of the numeric keypad and the 0.5h setting.
OTHER SETTINGS (1/2)
Language
English
Operating hours
650.2
MENU
1
EXIT
OTHER SETTINGS (1/2)
Date
2001
Time
16 : 16
GMT Ref.
Summer
DATE GMT Reference
Operating hours
GMT Ref.
8.5
3
Language
19
8.5
⇒
Operating hours
Summer time setup switch:
MENU
650.2
Date
2001
Time
17 : 16
GMT Ref. Summer
English
3
19
8.5 Summer
When pressed, a check mark appears and the time increases by 1 hour.
AH03538
Page 20 of 26
1.2 Date 31.08.01 Time 23:59 25 °C 2587.9 h Tr1 Tr2 12 15 1/min 1800
Fuel Level
⇒
Hyd Oil Temp
F
H
E
L
Coolant Eng
1.2.3 SETTING for Operator
Oil Press Eng
H
H
L
2
USER ID
12345678901
Reset Truck Counter 1
16
Reset Truck Counter 2
17
L
Maint Mess Next Monitor 1
2.0 Please Input Service ID 1
2
3
4
5
6
7
8
9
⇓
1
******
Please Input Service ID
0
Clear Enter
STO P
4.8.1
3.1
CLS SETTINGS Pause Time
60
min
Monitoring Time
3
min
Press. Relief Time
10
min
Lub. Cycle Counter
32000
MENU
4.8.4
⇓
Times
⇐
SERVICE MENU SELECT
⇓
Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
3X
OTHER SETTINGS (2/2) Oil viscosity hydraulic
VG46
Oil viscosity gear
CLP150
Message ON/OFF
ON
PLC-autom.ON/OFF
ON
MENU
AH03538
Page 21 of 26
14.2.11 Settings (No. 4.8.1 – No. 4.8.10) Other Settings 2/2 (No. 4.8.4) OTHER SETTINGS (2/2) Oil viscosity hydraulic
VG46
⇒
OTHER SETTINGS (2) Oil viscosity hydraulic
VG46
Oil viscosity gear
CLP150
VG22 7 13 Oil viscosity gear VG32 8 14
Message ON/OFF
ON
Message ON/OFF VG46 9 15
-- ON
--
PLC-autom.ON/OFF
ON
VG68 10 16 PLC-autom.ON/OFF
--
--
VG100 MENU
MENU6
Hydraulic oil selector button: now
19 -CLP150 ---
ON
11
17
--
--
12
18
--
--
⇒
OTHER SETTINGS (2/2) Oil viscosity hydraulic
VG22
Oil viscosity gear
CLP150
Message ON/OFF
ON
PLC-autom.ON/OFF
ON
MENU
When the selection menu appears, The selected hydraulic oil is select the required hydraulic oil.
OTHER SETTINGS (2/2)
displayed. OTHER SETTINGS (2/2)
OTHER SETTINGS (2)
Oil viscosity hydraulic
VG46
Oil viscosity gear
CLP150
Message ON/OFF
ON
CLP150 Message ON/OFF--
PLC-autom.ON/OFF
ON
PLC-autom.ON/OFF
⇒
MENU
PTO - gear oil selector button:
Oil viscosity hydraulic Oil viscosity gear T32 75W-140
MENU
⇒
Oil viscosity hydraulic
VG46
Oil viscosity gear
T32
ON
Message ON/OFF
ON
ON
PLC-autom.ON/OFF
ON
VG46 CLP150 --
MENU
When the selection menu appears, The selected gear oil is now select the required gear oil. displayed.
Select the required oil out of the table from the specific flowchart.
AH03538
Page 22 of 26
1.2 Date 31.08.01 Time 23:59 25 °C 2587.9 h Tr1 Tr2 12 15 1/min 1800
Fuel Level
⇒
Hyd Oil Temp
F
H
E
L
Coolant Eng
1.2.3 SETTING for Operator
Oil Press Eng
H
H
L
2
USER ID
12345678901
Reset Truck Counter 1
16
Reset Truck Counter 2
17
L
Maint Mess Next Monitor 1
2.0 Please Input Service ID 1
2
3
4
5
6
7
8
9
⇓
1
******
Please Input Service ID
0
Clear Enter
STO P
4.8.1
3.1
CLS SETTINGS Pause Time
60
min
Monitoring Time
3
min
Press. Relief Time
10
min
Lub. Cycle Counter
32000
MENU
4.8.4
⇓
Times
⇐
SERVICE MENU SELECT
⇓
Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
3X
OTHER SETTINGS (2/2) Oil viscosity hydraulic
VG46
Oil viscosity gear
CLP150
Message ON/OFF
ON
PLC-autom.ON/OFF
ON
MENU
AH03538
Page 23 of 26
14.2.11 Settings (No. 4.8.1 – No. 4.8.10) Other Settings 2/2 (No. 4.8.4) OTHER SETTINGS (2/2)
OTHER SETTINGS (2/2)
Oil viscosity hydraulic
VG46
Oil viscosity hydraulic
VG46
Oil viscosity gear
CLP150
Oil viscosity gear
CLP150
Message ON/OFF
ON
Message ON/OFF
OFF
PLC-autom.ON/OFF
ON
PLC-autom.ON/OFF
ON
⇒
MENU
MENU
Message ON/OFF selector button:
When pressed the display changes from ON to OFF or vice versa.
Messages ON/OFF With the button "Messages ON/OFF" is shut down only the automatic display of actual messages for service purposes. In this case, setting works are not interrupted by accidentally occurred messages and the memory will not be filled with messages caused by testing operations. Control and monitoring functions remain active. Each operation of the button "Messages ON/OFF" is saved in the service memory, invisible for the operator. OTHER SETTINGS (2/2)
OTHER SETTINGS (2/2)
Oil viscosity hydraulic
VG46
Oil viscosity hydraulic
VG46
Oil viscosity gear
CLP150
Oil viscosity gear
CLP150
Message ON/OFF
ON
Message ON/OFF
OFF
PLC-autom.ON/OFF
ON
PLC-autom.ON/OFF
ON
⇒
MENU
MENU
PLC-autom. ON/OFF selector button:
When pressed the display changes from ON to OFF or vice versa.
PLC-autom. ON/OFF. With the button "PLC-autom. ON/OFF" it is possible to shut down all control and monitoring functions of the PLC. The PLC does not evaluate any entry signals and does not change any exit signals. With the menu pictures 5.10.1 "REAL TIME MONITOR (OUTPUT SIGNALS) (1)" up to 5.10.6 "REAL TIME MONITOR (OUTPUT SIGNALS) (6)" it is then possible to shut on and off any exit for service purposes without any interference. Each operation of the button "PLC-autom. ON/OFF" is saved in the service memory, invisible for the operator.
Example: 5.10.1 REAL TIME MONITOR (OUTPUT SIGNALS) (1) ACOUSTIC SIGNAL
H22
0
0/1
CLS PUMP
K29
0
0/1
SLS PUMP
K36
0
0/1
RPM SHIFTING
K45
0
0/1
EXIT
W
⇒
Output Signal 0/1 selector button: When pressed the display changes from0 to 1 and the
REAL TIME MONITOR (OUTPUT SIGNALS) (1) ACOUSTIC SIGNAL
H22
1
0/1
CLS PUMP
K29
0
0/1
SLS PUMP
K36
0
0/1
RPM SHIFTING
K45
0
0/1
EXIT
• With the function PLC-AUTOM. (evaluation)switched OFF all monitoring and control functions of the PLC are inoperative.
AH03538
Page 24 of 26
1.2 Date 31.08.01 Time 23:59 25 °C 2587.9 h Tr1 Tr2 12 15 1/min 1800
Fuel Level
⇒
Hyd Oil Temp
F
H
E
L
Coolant Eng
1.2.3 SETTING for Operator
Oil Press Eng
H
H
L
2
USER ID
12345678901
Reset Truck Counter 1
16
Reset Truck Counter 2
17
L
Maint Mess Next Monitor 1
2.0 Please Input Service ID 1
2
3
4
5
6
7
8
9
⇓
1
******
Please Input Service ID
0
Clear Enter
STO P
4.8.1
3.1
CLS SETTINGS Pause Time
60
min
Monitoring Time
3
min
Press. Relief Time
10
min
Lub. Cycle Counter MENU
32000
⇓
⇐
Times
SERVICE MENU SELECT
⇓
Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
4X – 9X
4.8.5 - 4.8.10
SHUT-DOWN ON/OFF (1) Shut-Off (gate) valve
ON
Reserve 11
ON
Reserve 10
ON
Hydraulic oil level
ON
MENU
AH03538
Page 25 of 26
14.2.11 Settings (No. 4.8.1 – No. 4.8.10) Shut Down ON / OFF (No. 4.8.5 - 4.8.10) For purposes of initial start-up and repair each Shutdown may be closed down individually. The shutdown remains without any time limit. With the operation of the button the logical state of the respective Flag in the interface changes to the PLC. With the Flag set, the PLC will not activate the shutdown. However, there will result a shutdown message. Each operation of the button is saved in the service memory invisible for the operator. Example: 4.8.5
⇒
SHUT-DOWN ON/OFF (1) Shut-Off (gate) valve
ON
Reserve 11
ON
Reserve 10
ON
Hydraulic oil level
ON
SHUT-DOWN ON/OFF (1) Shut-Off (gate) valve
OFF
Reserve 11
ON
Reserve 10
ON
Hydraulic oil level
ON
Shut-Down ON/OFF selector button: When pressed the display changes MENU
MENU
4.8.6
4.8.7
SHUT-DOWN ON/OFF (2)
4.8.8
SHUT-DOWN ON/OFF (3)
SHUT-DOWN ON/OFF (4)
Reserve 9
ON
Monitoring HPF3/Chip3 (Start bl.)
ON
Trouble HPF3/Chip3 (Low idle)
ON
Shut-Off (gate) valve (Start bl.)
ON
Monitoring HPF4/Chip4 (Start bl.)
ON
Trouble HPF4/Chip4 (Low idle)
ON
Monitoring HPF1/Chip1 (Start bl.)
ON
Trouble HPF1/Chip1 (Low idle)
ON
Hydr. Oil temp. (Bucket cut off)
ON
Monitoring HPF2/Chip2 (Start bl.)
ON
Trouble HPF1/Chip1 (Low idle)
ON
Lubrication syst. (Bucket cut off)
ON
MENU
MENU
4.8.9
4.8.10 SHUT-DOWN ON/OFF (6)
SHUT-DOWN ON/OFF (5)
MENU
MENU
Reserve 8
ON
Reserve 4
ON
Reserve 7
ON
Reserve 3
ON
Reserve 6
ON
Reserve 2
ON
Reserve 5
ON
Reserve 1
ON
MENU
AH03538
Page 26 of 26
5. VHMS initial setting check sheet In case you replace the VHMS controller, you require to conduct the VHMS controller setting. In order to avoid miss setting, please check setting item with this sheet and report it to VHMS / WebCARE support center and KMG by FAX or e-mail. This check sheet will be used when we receive the data downloaded by New VHMS controller in WebCARE, in order to check the download data if the setting has been done correctly or not. If the check sheet is not received by Komatsu, the download data will not be entered in WebCARE system.
Checking item Setting date Distributor & Branch Subsidiary Person in charge Model name Serial no. SMR (Hour meter reading) Engine Serial No. PTO Serial No. Down load date & time Before (by watch) replacement After replacement Reference No. (FC No. or Claim No.) Please send the downloads (from old VHMS controller if possible and from new VHMS controller) to the following e-mail addresses:
1.
[email protected] 2.
[email protected]
AH03538
Appendix
Service Bulletins
6.5.14 AH04518 Welding procedure for welded counterweight
6 - 43
Service Bulletins
Appendix
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6 - 44
PARTS & SERVICE NEWS
COMPONENT CODE:
46
REF NO.
AH04518a
DATE
June 29, 2005 Page 1 of 2
This PARTS & SERVICE NEWS supersedes the previous issue AH04518 which should be discarded. SUBJECT: Welding procedure for welded counterweight PURPOSE:
Emphasize the importance of expelling the accumulate gases from the counterweight chambers before welding
APPLICATION:
H 255; PC3000; PC5500(SN15011 and up); PC4000; PC8000(SN12037 and up)
FAILURE CODE:
4621Z9
DESCRIPTION:
ã
• Avoid injury or death! • Do not perform welding operation before expelling the accumulated gases from the counterweight chambers! • The gases may explode!
The welded counterweights are filled with a mixture of iron ore and breech blocks. They are not fully filled. It is possible that in the separate chambers explosive gases have collected. There is a risk of explosion during welding, grinding, cutting and drilling without coolant.
The following outlines the proper gas expelling procedure from counterweight (Illustrations 1 and 2) 1. Counterweights with a thread connection point(1): Connect a hose to this point and blow compressed air toward the inside. At these counterweights all chambers are connected to each other. 2. Counterweights without thread connection point: Make the holes (2) larger by means of a 10 mm drill. Blow out carefully all chambers separately through the holes (2).
AH04518a
Page 2 of 2
(1)
(2)
Illustration 2 AH04518a
Appendix
Service Bulletins
6.5.15 AH05510 Bearing flushing of the A4VS variable displacement axial piston pump
6 - 45
Service Bulletins
Appendix
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6 - 46
PARTS & SERVICE NEWS
COMPONENT CODE:
K1
REF NO.
AH05510
DATE
February 16, 2005 Page 1 of 1
SUBJECT:
Bearing flushing of the A4VS variable displacement axial piston pump
PURPOSE:
Activate the external flushing of bearing by mounting a new pump
APPLICATION:
PC4000 (SN08151 up); PC5500 (SN15011 up); H 455S (SN15007; 15009); PC8000 (SN12037 up); H685SP (SN12020; 12030)
FAILURE CODE:
K100FA
DESCRIPTION: 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 direct the external cooling oil to the bearing and shaft seal it is necessary to turn in the throttle screw all the way. Observe also the information plate fixed at the pump.
Drawing and photos as example
AH05510
Appendix
Service Bulletins
6.5.16 AH05511 Dual cone seal ring mouting
6 - 47
Service Bulletins
Appendix
This page was left blank intentionally.
6 - 48
COMPONENT CODE:
30
REF NO.
AH05511
PARTS & SERVICE NEWS
DATE
March 23, 2005 Page 1 of 4
This PARTS & SERVICE NEWS supersedes the previous issue No. 21-558 which should be discarded. SUBJECT:
Dual cone seal ring mounting
PURPOSE:
Mounting hints
APPLICATION:
all types
FAILURE CODE:
3047AA
DESCRIPTION: Leaky dual cone seal rings must be replaced, in order to prevent damages through "dry running". Dual cone seals have also to be replaced in case of component repairs. Dual cone seals are precision parts made from chilled cast iron. Therefore, sharp knocks and blows should be avoided. The correct way to install dual cone seals is as follows: • Only remove the seal (1) from its original wrapping just before installing. This protects the super - finished seal faces (2) from damage and contamination. • Seal housing (3) must be free of dirt and machining residues; all edges in the housing bore must be rounded. • The illustration shows the preloaded seal (1). • Install the face seal by means of the assembly tool (4). Pressure is applied directly via the O-ring (5). • For easier assembly, moisten the housing bore and O-rings with spirit (no oil or grease!). • Order number for assembly tool (4), refer to the table on page 2. For the machining dimensions of the assembly tool, refer to the illustration and Fig. on page 3. • The illustration shows the dual cone seal (1) before mounting it with tool (4) into housing (3).
AH05511
Page 2 of 4 • Press the seal ring (1) with the special tool like a push button into the housing (3). Take care that afterwards the housing surface (6) lies parallel to the seal face (2). The O-ring (1) must not sit wave-like in the housing bore or bulge partially looped out of the bore. C = correct W = wrong
• Before the seal rings (1) are clamped to the installation dimensions, apply a thin grease or oil film to the seal faces (2), preferably with a soaked chamois leather cloth. Fig. 1 2 3 4 5 6
Description Seal ring Seal face Seal housing Tool O – ring Housing surface
Table for selection of the assembly tool (other tools on inquiry) Part No. Dual Cone Seal 145 800 40 180 472 40 180 624 40 202 986 40 226 424 40 226 425 40 255 058 40 269 454 40 270 460 40
Order-No. Assembly tool 766 311 73 766 308 73 766 312 73 766 315 73 766 322 73 766 317 73 766 314 73 766 312 73 766 316 73
Part No. Dual Cone Seal 323 823 40 324 067 40 461 627 40 461 628 40 696 523 73 696 525 73 804 595 73 963 754
Order-No. Assembly tool 766 323 73 766 309 73 766 318 73 766 307 73 766 310 73 766 311 73 766 313 73 766 321 73
AH05511
Page 3 of 4 Assembly tool (locally made) The assembly tool consists of two half-shells that are closed around the seal ring. The two halves are joined by a hinge. Step (d) grips between the O-ring (5) and the land of the seal ring. The pressure required to insert the seal is then applied directly via the O-ring (5). Measure dimension "b" at the dual cone seal. Determine the machining dimensions "a", "b", "c" and "d" according to this measured dimension in the chart. The dimension "X" can be chosen freely.
∅b mm 95 99 104 110 111 112 121 127 126 139 142 141,5 143 146 157 162 175 159 174,5 177 169 172,5 169 171 170 176 182 194
∅a mm 100 107 118 115 118 120 128 131 134 148 150 149 150 153 163 169 182 166 181,5 185 176 180 175 177 176 183 190 201
∅c mm 89,5 92,5 98 104 105 107 115 121 120 133 135 133 137 137,7 150,5 155 169 153,5 162 168 161 166,5 165 168 165 167,5 177 182,5
d mm 1,8 3,5 3 2,5 4 3 4 3,5 3 3 4 3 4 4 4 3 4,5 3 4 4 2,8 3,5 2 2,5 4 3,5 3 4
∅b mm 191 200 202 213 217 231 229,5 242 254 270,5 282,8 295,5 326 343,5 348 377,5 397 418 458 503 536,5 563 593 611 703 626 753 890
∅a mm 198 208 209 220 225 238 236,5 249 261 279 292 302,5 334 350,5 357 384,5 407 426 468 518 545 578 608 620 710 642 768 898
∅c mm 185 192 196 201 210 220 220,5 232 242,5 258,5 269 282 321 335 342 369 385 410 446 495 528,4 555 585 603 694 618 745 878
d mm 4 4 4 4 4 4 4 4 4 4 4 4 4 4 7 4 4 5 4 7 5 7 7 5 5 7 7 10
AH05511
Page 4 of 4
Assembly tools for mounting of dual cone seal
AH05511
Appendix
Service Bulletins
6.5.17 AH05546 Automatic lubrication system - Vent valve (PN 769 879 73)
6 - 49
Service Bulletins
Appendix
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6 - 50
COMPONENT CODE:
8D
REF NO.
AH05546
PARTS & SERVICE NEWS
DATE
December 6, 2005 Page 1 of 2
SUBJECT:
Automatic lubrication system - Vent valve (PN 769 879 73)
PURPOSE:
Hints for trouble shooting
APPLICATION:
All types with “Lincoln” Lubrication System
FAILURE CODE:
8D00ME
DESCRIPTION:
Manual actuation (Vent valve: PN 769 879 73)
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. TASK (Refer to illustration next page): By the function of the vent valve (7) the lubricant supply line gets pressure released, after the lubrication cycle is finished. The injector pistons can move into their initial position.
AH05546
Page 2 of 2
Troubleshooting: The solenoid valve (7) sometimes is blocked by dirt and causing that the pumping pressure will be not built correctly due to bypassed pressure back to grease barrel. On the monitor in the operators cab any failure in lubrication system will be indicated.
Manual actuation
To make easy troubleshooting the 2/2 – Directional valve (7) is equipped with the possibility of manual actuation. The valve had a push button on the top to verify whether the electric problem or the vent valve itself causing the lubrication pressure bypassed. For manual actuating of the valve (7) push down the pin on top of the valve e.g. with a screwdriver.
AH05546
Appendix
Service Bulletins
6.5.18 AH06524 Hydraulic cylinder
6 - 51
Service Bulletins
Appendix
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6 - 52
COMPONENT CODE:
PARTS & SERVICE NEWS
REF NO. DATE
AH06524 September 6, 2006 Page 1 of 2
This PARTS & SERVICE NEWS supersedes the previous issue 21 – 199b which should be discarded. SUBJET:
Hydraulic cylinder
PURPOSE:
Hints for bleeding
APPLICATION:
All types
FAILURE CODE:
H100BJ
DESCRIPTION: To avoid damages to the hydraulic system caused by air in the cylinders, a bleeding procedure has to be carried out after each opening or cylinder exchange. • Read the safety instruction in the Operation and Maintenance Manual carefully, before starting any work on the excavator.
1. Standard procedure for bleeding of hydraulic cylinder 1. Run the engine at low idle. PC5500 and PC8000: Start for the bleeding procedure only one engine. Electric driven excavators: Set the service switch S155 (X2 – main board) to position “2” for “QMIN” control of the main pumps. 2. Extend and retract each cylinder 4 or 5 times without going to the end of its stroke (stop approx. 100 mm before the end of the stroke). At first there can be a large amount of air inside the cylinders, so the cylinder may not move for the first ten seconds. In such cases, do not operate the joy stick to the end of its travel. Be carefully! 3. Keep the engine running at low idle/or QMIN* and operate each cylinder from a point 100 mm from the end of its stroke slowly (take at least 10 seconds) to the end of its stroke (fully extended) and hold the work equipment joy stick at the full stroke position for 3 minutes.
AH06524
Page 2 of 2 4. Next run the engine at high idle/or QMAX* and operate each cylinder from a point 100 mm from the end of its stroke slowly (take at least 10 seconds) to the end of its stroke (fully extended) and hold the work equipment joy stick at the full stroke position for 1 minutes. 5. Repeat steps 2 – 4 if necessary. 6. Make sure that the switch S155 is set to the “0” position as soon as the bleeding procedure of the hydraulic cylinders is finished.* * Electric driven excavator
• After bleeding the cylinders check oil level in the hydraulic tank according to the Maintenance Manual and add oil if necessary.
AH06524
Appendix
Service Bulletins
6.5.19 AH06530 Relieving of the track chain tension
6 - 53
Service Bulletins
Appendix
This page was left blank intentionally.
6 - 54
COMPONENT CODE:
32
REF NO.
AH06530
PARTS & SERVICE NEWS
DATE
July 24, 2006 Page 1 of 2
SUBJET:
Relieving of the track chain tension
PURPOSE:
Hints for working at the crawler unit
APPLICATION:
PC3000; PC4000; PC5500; PC8000
FAILURE CODE:
3200FA
DESCRIPTION:
)
• Read the safety instruction in the Operation and Maintenance Manual carefully, before starting repair works.
For avoiding damages at the travel brakes (4) the following procedure should be used: • Turn the superstructure (90°) and lift the machine. • Shut off the engine. • Open cock (2) for releasing the pressure. • Close cocks (1) and cock (3) if installed. • Close cock (2) (important!). • Now the engine can be started and the sprocket can be turned to the working position. The travel brake is released by pilot pressure.
Illustration as example
AH06530
Page 2 of 2
AH06530
