Service Manual PC4000-6E.pdf
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PC4000-6-E_#08165_Contents and 00_Foreword_rev0.doc
02.03.05
SERVICE MANUAL
PC4000 MACHINE MODEL
SERIAL NUMBER
PC4000-6- Electro
08165
This service manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice.
PC4000-6-E_#08165_Contents and 00_Foreword_rev0.doc
02.03.05
PC4000-6-E_#08165_Contents and 00_Foreword_rev0.doc
CONTENTS TABLE OF CONTENTS
00 01 02
Safety - Foreword Technical DATA (Leaflet) Assembly PROCEDURE (Brochure)
Section 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Main assembly groups Drive Hydraulic oil tank Hydraulic oil cooling Controlling Components Main hydraulic pumps and pump regulation Operating hydraulic Hydraulic track tensioning system Hydraulic operated access ladder Cable drum Hints for the hydraulic circuit diagram Hints for the electric circuit diagram Electronic Control System - ECS Lubrication System
APPENDIX
)
• Each section includes a detailed table of contents.
02.03.05
PC4000-6-E_#08165_Contents and 00_Foreword_rev0.doc
02.03.05
SAFTEY
SAFTEY NOTICE
SAFETY SAFETY NOTICE • IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. The following Symbols are used in this Manual to designate Instructions of particular Importance.
WARNING -
Serious personal injury or extensive property damage can result if the warning instructions are not followed. To prevent injury to workers, this symbol is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
CAUTION -
Minor personal injury can result or a part, an assembly, or the shovel can be damaged if the caution instructions are not followed.
)
NOTE -
Refers to special information
GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • Always wear safety glasses when hitting parts with a hammer. • Always wear safety glasses when grinding parts with a grinder, etc. continued 00-1
SAFTEY
SAFTEY NOTICE
Cont'd: GENERAL PRECAUTIONS 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them. 6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK 7. Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower bucket, hammer or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out work on the oil or water circuits. continued 00-2
SAFTEY
SAFTEY NOTICE
Cont'd: PRECAUTIONS DURING WORK 13. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first. 14. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16. When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires. 17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18. As a general rule, do not use gasoline to wash parts. 19. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts. • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed. 21. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.
00-3
ENVIRONMENT PROTECTION
Environment NOTICE
RECOMMENDATIONS FOR ENVIRONMENTALLY FRIENDLY OPERATION AND MAINTENANCE OF HYDRAULIC MINING SHOVELS
OPERATION • • •
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. 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. Position trucks in such a way, that loading operation can be carried out in a safe and economic manner. Avoid swing angles over 90°.
MAINTENANCE • • •
Preserve our environment. To prevent environmental pollution, pay careful attention to the method of disposing waste materials. 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. Dispose of harmful material, such as oil, fuel, coolant, solvent, filters and batteries in accordance with environmental regulations and laws.
FOREWORD
FOREWORD GENERAL With this SERVICE MANUAL KOMATSU provides you with the description of the construction and the function of the major systems of the Hydraulic Excavator PC8000-6-E. We describe for you all functions and how to carry out the inspections and adjustments. How do you find "your" desired information? In the table of CONTENT all the functions and components are shown in their sequence of the description. If after reading this SERVICE MANUAL you can give us suggestions and comments for improvements - please do not hesitate to contact us. Komatsu Mining Germany GmbH - Service Training Postfach 180361 40570 Düsseldorf Tel.:0211 / 7109 - 206 Fax.:0211 / 74 33 07 The editorial staff will be pleased about your co-operation. - FROM THE PRACTICE - FOR THE PRACTICE -
)
• This service manual corresponds to the state of development of the machine at the time the manual was produced. Variations based on special customers request and special equipment are not included in this manual
00-4
FOREWORD
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS HOISTING • Heavy parts (25 kg or more) must be lifted with a hoist etc.
)
• If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1. Check for removal of all bolts fastening the part to the relative parts. 2. Check for existence of another part causing interface with the part to be removed.
WIRE ROPES 1. Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "Z" or "S" twist ropes without galvanizing) Rope diameter [mm]
10,0
11,2 12,5 14,0 16,0 18,0 20,0 22,4 30,0 40,0 50,0 60,0
Allowable load [tons]
1,0
1,4
)
1,6
2,2
2,8
3,6
4,4
5,6
10,0 18,0 28,0 40,0
• The allowable load value is estimated to be 1/6 or 1/7 of the breaking strength of the rope used.
2. Sling wire ropes from the middle portion of the hook. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.
continued Cont'd: 00-5
FOREWORD
HOISTING INSTRUCTIONS
WIRE ROPES 3. Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load. • Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 4. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes make a 120° hanging angle. On the other hand, two ropes are subject to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150.
00-6
FOREWORD
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE (1Kgm = 9,806Nm) STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS
Bolt dia.
Wrench size [mm]
Tightening torque [Nm] Quality grades 8.8
10.9
12.9
M 8
13
6
21
31
36
M 10
17
8
43
63
73
M 12
19
10
74
108
127
M 14
22
12
118
173
202
M 16
24
14
179
265
310
M 18
27
14
255
360
425
M 20
30
17
360
510
600
M 22
32
17
485
690
810
M 24
36
19
620
880
1030
M 27
41
19
920
1310
1530
M 30
46
22
1250
1770
2080
M 33
50
24
1690
2400
2800
M 36
55
27
2170
3100
3600
M 39
60
2800
4000
4700
M 42
65
3500
4950
5800
M 45
70
4350
6200
7200
M 48
75
5200
7500
8700
M 52
80
6700
9600
11200
M 56
85
8400
12000
14000
M 60
90
10400
14800
17400
M 64
95
12600
17900
20900
M 68
100
15200
21600
25500
32 35 41 46
Insert all bolts lubricated with MPG, KP2K
00-7
FOREWORD
CONVERSION TABLE
CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. EXAMPLE Method of using the Conversion Table to convert from millimeters to inches. 1. Convert 55 mm into inches. (a) Locate the number 5 in the vertical column at the left side, take this as (A), then draw a horizontal line from (A). (b) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). (c) Take the point where the two lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 millimeters = 2.165 inches. 2. Convert 550 mm into inches. (a) The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to convert it to 55 mm. (b) Carry out the same procedure as above to convert 55 mm to 2.165 inches. (c) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
00-8
FOREWORD
00-9
CONVERSION TABLE
FOREWORD
CONVERSION TABLE
00-10
FOREWORD
00-11
CONVERSION TABLE
FOREWORD
CONVERSION TABLE
00-12
FOREWORD
CONVERSION TABLE
Basic Values in Ohm according to DIN 43 76 For Measuring Resistor PT100
°C
-0
-1
-2
-3
-4
-5
-6
-7
-8
-9
-50
80,31
79,91
79,51
79,11
78,72
78,32
77,92
77,52
77,13
76,73
-40
84,27
83,88
83,48
83,08
82,69
82,29
81,89
81,50
81,10
80,70
-30
88,22
87,83
87,43
87,04
86,64
86,25
85,85
85,46
85,06
84,67
-20
92,16
91,77
91,37
90,98
90,59
90,19
89,80
89,40
89,01
88,62
-10
96,09
95,69
95,30
94,91
94,52
94,12
93,73
93,34
92,95
92,55
0
100,00
99,61
99,22
98,83
98,44
98,04
97,65
97,26
96,87
96,48
°C
0
1
2
3
4
5
6
7
8
9
0
100,00
100,39
100,78
101,17
101,56
101,95
102,34
102,73
103,12
103,51
10
103,90
104,29
104,68
105,07
105,46
105,85
106,24
106,63
107,02
107,40
20
107,79
108,18
108,57
108,96
109,35
109,73
110,12
110,51
110,90
111,28
30
111,67
112,06
112,45
112,83
113,22
113,61
113,99
114,38
114,77
115,15
40
115,54
115,93
116,31
116,70
117,08
117,47
117,85
118,24
118,62
119,01
50
119,40
119,78
120,16
120,55
120,93
121,32
121,70
122,09
122,47
122,86
60
123,24
123,62 124,01, 124,39
124,77
125,16
125,54
125,92
126,31
126,69
70
127,07
127,45
127,84
128,22
128,60
128,98
129,37
129,75
130,13
130,51
80
130,89
131,27
131,66
132,04
132,42
132,80
133,18
133,56
133,94
134,32
90
134,70
135,08
135,46
135,84
136,22
136,60
136,98
137,36
137,47
138,12
100
138,50
138,88
139,26
139,64
140,02
140,39
140,77
141,15
141,53
141,91
110
142,29
142,66
143,04
143,42
143,80
144,17
144,55
144,93
145,31
145,68
120
146,06
146,44
146,81
147,19
147,57
147,94
148,32
148,70
149,07
149,45
130
149,82
150,20
150,57
150,95
151,33
151,70
152,08
152,45
152,83
153,20
140
153,58
153,95
154,32
154,70
155,07
155,45
155,82
156,19
156,57
156,94
150
157,31
157,69
158,06
158,43
158,81
159,18
159,55
159,93
160,30
16067
00-13
FOREWORD
CONVERSION TABLE
TEMPERATURE Fahrenheit – Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.
00-14
Main Assembly Groups
Section 1.0 Page 1
Table of contents section 1.0 Section 1.0
Page Main assembly groups General lay out
2
1.1
Superstructure
3
1.1.1
Machine house
4
1.1.2
Hydraulic Oil Reservoir
5
1.1.3
Hydraulic Oil Cooler
6
1.1.4
Fuel Tank
7
1.1.5
Counter weight
8
1.1.6
Cab support
9
1.1.7
Operators cab
10
1.1.8
Control Blocks
11
1.1.9
Swing gears
12
1.2
Under carriage
1.3
Attachment
13
1.3.1.
Backhoe Attachment (BHA)
14
1.3.2.
Front Shovel Attachment (FSA)
15
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1.0
Section 1.0 Page 2
General lay out Legend for illustration (Z 21463): (1) Superstructure (2) Under carriage (3) Front Shovel Attachment (FSA) (4) Backhoe Attachment (BHA)
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1.0 3
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1.1
Section 1.0 Page 3
Superstructure Legend for illustration (Z 21464): (1) Operators Cab with integrated FOP system (2) Exhaust (3) Air cleaner (4) Cab support (contains the electrical switch board) (5) Swing ring connection (6) Fuel reservoir (7) Hydraulic ladder (8) Counter weight (9) Hydraulic oil cooler with hydraulic driven fans (10) Hydraulic oil reservoir (11) PTO gear with all hydraulic pumps (12) Flexible coupling, oil filled (13) Engine (14) Batteries (15) Radiator for the engine cooling system (16) Control blocks with high pressure filters (17) Swing gears (18) Grease pump of the Central Lubrication System (19) Grease pump of the Swing gear pinion Lubrication System
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1.0 4
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Main Assembly Groups
1.1
Section 1.0 Page 4
Superstructure 1.1.1
Machine house
Legend for illustration (Z 21466): (1) Roof mounted exhaust (2) Roof mounted air cleaners with restriction switches (3) Expansion tank of the radiator for the engine cooling system (4) Hydraulic control and filter panel (5) PTO gear box (6) Main hydraulic pumps (7) Auxiliary pumps, installed at the drive through shaft of the main hydraulic pumps (piggyback pumps) (8) Hydraulic pump for radiator fan drive (9) Hydraulic pump for the hydraulic oil cooler fan drive (10) Suction oil reservoir (11) Flexible coupling, oil filled (12) Batteries (13) Engine (14) Hydraulic motor for the radiator fan drive (15) Radiator for the engine cooling system
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1.0 5
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1.1
Section 1.0 Page 5
Superstructure 1.1.2
Hydraulic Oil Reservoir
Legend for illustration (Z 21467): (1) Breather filter (2) Temperature controlled back pressure valve (3) Drain coupling of the hydraulic oil reservoir (4) Return oil filter (5) Case drain (leak oil) filter (6) Main shut-off valve (Gate valve) with compensator (7) Return oil collector tube (8) Drain coupling of the Return oil collector tube
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Main Assembly Groups
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Section 1.0 Page 6
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1.1
Section 1.0 Page 6
Superstructure 1.1.3
Hydraulic Oil Cooler
Legend for illustration (Z 21472): (1) Cooler frame with swing out facility (2) Hydraulic motor of upper fan (3) Upper fan (4) Fan guard (5) Outer part of the upper radiator set (6) Inner part of the upper radiator set (7) Hydraulic motor of lower fan (8) Lower fan (9) Fan guard (10) Outer part of the lower radiator set (11) Inner part of the lower radiator (12) Swing out doors (13) Locking bars to secure the swing out doors
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1.0 7
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1.1
Section 1.0 Page 7
Superstructure 1.1.4
Fuel tank (Fuel reservoir)
Legend for illustration (Z 21473): (1) Fuel tank (2) Fuel tank breather valve (3) Main shut-off cock (4) Drain coupling with protection cap (5) Shut-off cock for fuel pressure transducer (6) Fuel pressure transducer
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1.0 8
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Section 1.0 Page 8
Main Assembly Groups
1.1
Superstructure 1.1.5
Counter weight
Legend for illustration (Z 21474): (1) Counter weight Total weight 37000 kg (2)
Mounting bolts Quantity 16
Bolt size (mm) M 42 x 520
*
SW = Wrench size
(3)
Lifting points
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Grade
SW* (mm)
10.9
65
Tightening torque (Nm) 4950
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Section 1.0 Page 9
Main Assembly Groups
1.1
Superstructure 1.1.6
Cab support
Legend for illustration (Z 21475): (1) Cab support (Location of electrical switch board “X2”) (2) Mounting bolts Quantity Bolt size Grade SW* Tightening (mm) (mm) torque (Nm) 4
M 36 x 240
10.9
55
Grade
SW* (mm)
10.9
55
3100
* SW = Wrench size (3)
Mounting bolts Quantity Bolt size (mm) 4
M 36 x 240
Tightening torque (Nm) 3100
* SW = Wrench size (4) (5) (6)
Door Gasket Door handle (adjustable)
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1.1
Section 1.0 Page 10
Superstructure 1.1.7
Operators cab
Legend for illustration (Z 21476): (1) (2) (3) (E19)
Monitor panel Switch panel Operators seat Control lever – EURO Control
– KMG Control
(E20)
Control lever – EURO Control
– KMG Control
(E21a)
Control pedal
A - forward Left track B - reverse
(E21b)
Control pedal
A - forward Right track B - reverse
(E22) (E23) (E24)
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Control pedal Control pedal Control pedal -
Swing brake Bucket closing Bucket opening
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1.1
Section 1.0 Page 11
Superstructure 1.1.8
Control blocks
Legend for illustration (Z 21477): (1) Control block carrier (2) Remote control valves (3) Main control blocks (4) High pressure filter
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1.1
Section 1.0 Page 12
Superstructure 1.1.9
Swing gears
Legend for illustration (Z 21478a): (1) Oil level gauge (2) Oil filler plug (3) Breather filter (4) Oil level gauge and filler tube. (5) Breather filter (6) Oil drain plug (7) Drain plug (8) Pinion (60.1 + 60.2) Swing motors (61.1 + 61.2) Swing brake valve blocks (48.1 + 48.2) Swing gear boxes – with integrated spring loaded multi disk brakes (Released by oil pressure)
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1.2
Section 1.0 Page 13
Under carriage Legend for illustration (Z 21481): (1) Undercarriage center body (2) Crawler carrier R.H.-side (3) Crawler carrier L.H.-side (4) Connecting pins, center body to crawler carriers (5) Crawler tracks (6) Rotary distributor (7) Brake valves (8) Travel motors (9) Parking brakes, spring loaded disk type brakes (10) Travel gear (11) Sprocket (12) Track rollers (13) Carrier rollers (14) Guide wheel (Idler)
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1.3
Section 1.0 Page 14
Attachment 1.3.1
Backhoe attachment (BHA)
Legend for illustration (Z 21482): (1) Boom (2) Boom Cylinders (3) Stick (4) Stick Cylinders (5) Bucket (6) Bucket Cylinders (7) Control arm (8) Linkage
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Attachment 1.3.2
Front Shovel Attachment (FSA)
Legend for illustration (Z 21483): (1) Boom (2) Boom Cylinders (3) Stick (4) Stick Cylinders (5) Bucket backwall (6) Bucket Cylinders (7) Bullclam (8) Bucket Clam cylinders
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Drive
Section 2.0 Page 1
Table of contents section 2.0 Section 2.0
Page Prime drive assembly General
2
2.1
Flexible coupling
3
2.2
Pump distributor gearbox (PTO)
4
2.3
Pump – spline shaft lubrication
5
2.4
PTO Lubrication and cooling - Function
6
2.5
PTO Lubrication and cooling – Adjustments
7
2.6
Hydraulic pumps – location, drive speed and flow rates
8
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2.0
Section 2.0 Page 2
Prime drive assembly Legend for illustration (Z 22785a): (1) Electric Motor 1 (2) -(3) Cooling air intake (4) Cooling air exhaust (5) Alignment shims (6) Alignment supports (7) Motor frame (8) Coupling (9) Pump distributor gear (PTO)
General The two electric motors are solid bolted to the motor frame (7). The thickness of alignment shims (5) has to be selected according to the results of the alignment procedure, refer to Parts & Service News AH01523, last edition for more information.
)
• The alignment procedure must also be carried out when replacing the electric motor and/or the PTO.
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Section 2.0 Page 3
Drive
2.1
Flexible coupling Legend for illustration (Z 22786): (1) Housing (Rubber support ring) (2) Input drive hub (Motor side) (3) Output drive hub (PTO side) (4) Output drive flange (5) Rubber element (Motor side) (6) Bolt Quantity Bolt size (mm) 16
(7) (8) (9)
M 27 x 60
Grade 10.9
SW* (mm) 41
Tightening torque (Nm) 960.0 +110.0
Motor drive shaft Rubber element (PTO side) Bolt Quantity Bolt size (mm) 16
(10)
M 27 x 60
22
M 16 x 310
41
Tightening torque (Nm) 960.0 +110.0
Grade 10.9
SW* (mm) 24
Tightening torque (Nm) 250.0 +30.0
Washer Nut Bolt Quantity Bolt size (mm) 1
(14)
10.9
SW* (mm)
Bolt Quantity Bolt size (mm)
(11) (12) (13)
Grade
M 36 x 60
Grade 8.8
SW* (mm) 55
Tightening torque (Nm) 2170.0
Bolt Quantity Bolt size (mm) 10
M 18 x 40
Grade 10.9
SW* (mm) 27
Tightening torque (Nm) 360.0
Design: VULASTIC-L – coupling type are provided with two flexible rubber elements (5 + 8). The flexible ring connect the input drive hub (2) via input drive flange (4) with the output drive hub (3) of the coupling. Function: The high flexible LULASTIC–L coupling transfers the torque without any rotational gap. They are wear-resisting and maintenance free. Because of symmetrical arrangement of the flexible rings, there are no returning forces either by the torque transfer or the centrifugal forces. VULASTIC-L couplings dampen rotating vibrations, reducing same by partial storing of the shock energy and damp noises. The coupling allows in an acceptable range axial, radial and angular misalignment of the shafts.
)
• Repair and replacement have to be carried out according to Parts & Service News AH01523, last edition.
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2.2
Section 2.0 Page 4
Pump distributor gearbox (PTO) Legend for illustration (Z 21607): (1) Oil level gauge (2) Oil filler plug (3) Breather filter (4) Oil collector reservoir for auxiliary pump drive shaft housing (5) Breather filter with oil level gauge (drive shaft housing) (6) Main pump drive shaft housings (7) Oil level plug of main pump drive shaft housing (8) Oil filler plug with breather pipe of main pump drive shaft housing (9) Oil drain plug of main pump drive shaft housing (10) Oil drain plug of PTO gear (11) Flange for heater studs (12) Gear oil temperature probe mounting bore (13) Thermostat switch mounting bore cover plate (14) Suction line connection for gear oil cooling (15) Return line connection from gear oil cooler (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 of a spur gear design and driven by an diesel engine. The PTO gear runs in antifriction bearings and has been provided with a splash lubrication system. The oil supply of the bearings and tooth contacts takes place by an injection. The gearwheels are of case-hardened steel. The hydraulic pumps are directly attached to the gearbox. O-rings included in the supply enable the unit to be reliably sealed statically. The gearbox housing is of one-piece design and made of grey cast iron. Gearbox design allows a direct attachment to the engine via connection flange. The gearbox has been provided with connections for a separate cooling system resp. for heating rods. For more information refer to the REPAIR MANUAL Description for the lubrication see next pages.
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Section 2.0 Page 5
Pump – spline shaft lubrication Drive shaft housings Legend for illustration (Z 21608): (1) Oil filler plug with breather pipe of main pump drive shaft housing (2) Oil collector reservoir for auxiliary pump drive shaft housing (M) Configuration, main pump drives (A) Configuration, auxiliary pump drives All drive shaft housings are filled with the same gear oil as the pump distributor gear. This is done for two reasons: 1. To lubricate the multi-spline connections, to prevent wear and corrosion. 2. It makes it easier to determine a sealring leak at one of the drive shaft connections. Function: M If the oil level increases the oil drops out of the breather pipe (1). If this oil is gear oil it indicates a possible leak at the gearbox side. If the oil is a mixture of gear oil and hydraulic oil it shows a possible leak at the pump side. If at an oil level check a loss of oil is found it may be due to worn or defective radial seal rings. Function: A The oil is filled in via the oil collector reservoir (2). All auxiliary drive shaft housings are connected by pipes with the reservoir. The reservoir is filled approx. one half with oil. If the oil level in the reservoir increases due to leakage the oil drops out from the breather filter (with oil level gauge) on top of the reservoir. Now a check has to be done to find out which one of the drive shafts seals is damaged. It can be done by disconnecting temporary the pipe to the reservoir. Disconnect the pipe at the drive shaft housing, plug the pipe and leave the union open. If now at operation the oil still comes out of the union, this drive shaft seal is gone. Otherwise check sequential all auxiliary drives.
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2.4
Section 2.0 Page 6
PTO Lubrication and cooling Legend for illustration (Z 21609): (1) Line to the cooler (hot oil) (2) Return line from the cooler (cooled oil) (3) Return line from valve (P) Pressure port (8.2) Gear pump PTO-gearbox lubrication (36) Pressure filter - PTO gear lubrication (B27-1) Maintenance switch, 5 bar (29) Pressure relief valve, 10 bar (M3) Pressure check point (B17-1) Pressure switch, 0,5 bar (15.1+15.2) Oil cooler, part of hydraulic oil cooler (B49-1) Temperature sensor Function: Pump (8.2) forces the gear oil from the gear oil pan through filter (20) to pressure relief valve (21). This pressure relief valve acts as a back pressure valve causing that most of the oil passes through the gear oil coolers (17.1+17.2). The gear oil coolers are a small part of the hydraulic oil coolers, thus the gear oil gets cooled by the same air stream as the hydraulic oil. From the coolers the oil flows to the port (P) of the gear and internally via a system of pipes to the several spray nozzles. The spray nozzles in the gear case ensure proper and adequate distribution of the lube oil. The circuit is monitored by the pressure switches (B17-1). At too low lube oil pressure (0.5 bar), a fault message will be displayed on the monitor at the dash board. The gear oil temperature is monitored by the sensor unit (B49-1). At too high oil temperature a fault message will be displayed on the monitor at the dash board.
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2.5
Section 2.0 Page 7
PTO Lubrication and cooling – Adjustments Legend for illustration (Z 21610b): (1) (2) (3) (4) (5) (5a) (6) (7) (8) (9) (A) (T)
Pilot operated relief valve Plug screw Valve piston Port for pressure switch B17 "Y"- port (external return to tank) "X"- port (external return to tank via solenoid valve Y53-1) Port for pressure check stud Jet bore Valve spring Seal rings Pressure port Return from valve
(B27) (29) (M3) (Y53-1)
Maintenance switch Pressure relief valve, 10 bar Pressure check point (PTO lubrication pressure) Solenoid valve (reduced pressure if energized)
•
The adjustment of the maximum permissible PTO lube pressure, has to be carried out with warm oil.
Setting the pressure relief valve (29) 1. Connect a pressure gauge to check point (M3) 2. Disconnect plug of solenoid valve Y53-1 3. Start the motor 4. Required pressure: 10,0 bar. If adjustment is required: 5. Remove protection cap (1a). 6. Loosen lock nut (1b). 7. Set the pressure with set screw (1c). 8. Tighten lock nut (1b) and re-install protection cap (1a) 9. Reconnect plug of Y53-1
)
• If the pressure of 10,0 bar cannot be adj. 100 %, adj. to the lowest visible pressure.
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Section 2.0 Page 8
Drive
2.6
Hydraulic pumps – location, drive speed and flow rates Legend for illustration (Z 21548): (1 - 4) Axial piston pump (swash plate type) theoretical flow rate, each 1033 Liter/min Drive speed* n = 1378 min-1 for all working motions
(5.1)
(5.2)
(8.1)
(8.2)
)
Axial piston pump theoretical flow rate Drive speed* for oil cooler fan drive
214 Liter/min n = 2000 min-1
Axial piston pump theoretical flow rate Drive speed* for radiator fan drive
214 Liter/min n = 2000 min-1
Gear pump theoretical flow rate Drive speed* for pilot pressure supply
138 Liter/min n = 1378 min-1
Gear pump theoretical flow rate Drive speed* PTO gear lubrication
138 Liter/min n = 1378 min-1
• * at 1800 min-1 input drive speed
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Hydraulic Oil Reservoir
Section 3.0 Page 1
Table of contents section 3.0 Section 3.0
Page Hydraulic oil reservoir General lay out
2
3.1
Main oil tank, location of switches, sensors etc.
3
3.2
Suction oil tank with strainers
4
3.3
Return oil collector tube with strainer
5
3.4
Back pressure valve
6
3.5
Transfer pump (Optional Equipment)
7
3.6
Return and Leak Oil Filter
8
3.7
Breather Filter
9
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3.0
Section 3.0 Page 2
General lay out Legend for illustration (Z 21494): (1) Filter cover retainer (2) Filter cover (3) Filter element (A) - Return oil filter - 10 µm (B) - Case drain filter - 3 µm (4) Man hole cover (24) Pressure switch B24 – monitors item (92.1) – (92.2) (30) Hydraulic oil level gauge (41) Main oil reservoir (54) Return oil collector tube with pressure check point M10 (55) Back pressure valve (67) Dust cap for item (77) (77) Oil drain, quick release coupling (87) Shut off valve with S31 (Gate valve) (88) Compensator (92.1 + 92.2) Breather filter The hydraulic oil tank is a welded sheet-metal construction. The capacity is about 3700 litres. The tank contains four return oil filters (3A) and one case drain filter (3-B). The breather filter (92.1 + 92.2) cleans the air that streams into the tank. The back pressure valve (55) and the pressure check point (M10) are located at the collector tube (54) for return oil. The connection to the suction tank can be closed with the shut- off valve (87) to prevent oil flow during repairs on the hydraulic pumps. This unit is controlled by the switch S31, it makes sure a motor start is not possible with a closed shut-off valve. Fault message ”Start blocked because of main Shut-Off (gate) valve” is displayed at the operators dash board
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Hydraulic Oil Reservoir
3.1
Section 3.0 Page 3
Main oil tank, location of switches, sensors etc. Legend for illustration (Z 21495a): (B4) Oil level sensor “Hydraulic oil level too low” (B15) Hydraulic oil temperature probe “Hydraulic oil temperature below: too hot” (B24) Breather filter pressure switch (B50) Oil level sensor “Hydraulic oil refill level” (B105) Pressure transducer – Hydraulic oil level (B163) Pressure transducer – Pressure return oil chamber (B164) Pressure transducer – Pressure leak oil chamber (B165) Pressure transducer – Pressure oil cooler (B166) Pressure transducer – Pressure pre-load (back pressure) valve
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Section 3.0 Page 4
Hydraulic Oil Reservoir
3.2
Suction oil tank with strainers Legend for illustration (Z 21496b): (1) Suction oil reservoir (2) Drain coupling (3) Pressure transducer (B162) – Pressure suction oil tank (4) Plug (5) Bolt Quantity 8
(6) (7) (8) (9) (10) (11) (12) (13)
16
SW* (mm)
8.8
30
Tightening torque (Nm) 360
Bolt size (mm) M 16 x 40
Grade
SW* (mm)
8.8
24
Grade
SW* (mm)
10.9
30
Grade
SW* (mm)
10.9
27
Tightening torque (Nm) 179
Lock nuts Resilient sleeve Bolt Quantity 8
(16) (17)
M 20 x 85
Grade
Nut Gaskets Main suction oil strainer Intermediate pipe Gaskets Suction strainer – one for each main pump Suction hose connection pipe Bolt Quantity
(14) (14a) (15)
Bolt size (mm)
Bolt size (mm) M 20 x 110
Tightening torque (Nm) 510
Resilient sleeve Bolt Quantity 6
Bolt size (mm) M 18 x 90
Tightening torque (Nm) 360
The suction oil tank (40) is a welded sheet-metal construction. The capacity is 187 liters. The suction lines of all hydraulic pumps are connected to the suction tank. * SW = Wrench size
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Hydraulic Oil Reservoir
3.3
Return oil collector tube with strainer Legend for illustration (Z 21497): (1) Return oil collector tube - Part 1 (2) Return oil collector tube - Part 2 (3) Return oil collector tube - Part 3 (4) Strainer (5) Bolt Quantity 8
(6)
M 20 x 80
Grade
SW* (mm)
10.9
30
Grade
SW* (mm)
10.9
30
Tightening torque (Nm) 510
Bolt Quantity 8
(7) (8) *
Bolt size (mm)
Bolt size (mm) M 20 x 70
Tightening torque (Nm) 510
Self locking nut Gasket SW = Wrench size
Task: The strainer is installed to prevent the hydraulic oil coolers from getting clogged up in case of contamination in the main return circuit oil. Excessive increase of the hydraulic oil temperature can be an indication for a restricted strainer, i.e. bad cooling performance due to insufficient oil flow through the coolers. In case that main components such as cylinders or motors are internal fragmentary damaged, the strainer should be inspected for metal chips.
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3.4
Section 3.0 Page 6
Back pressure valve Legend for illustration (Z 21498): (1) Back pressure valve assembly (2) Solenoid valve (Y101)
Task: The back pressure valve has to fulfill two functions in the hydraulic system: 1. To ensure a sufficient pressure within the return oil circuit, i.e. to supply oil via the anticavitaton valves to the low pressure side of cylinders, respectively motors. 2. To force the return oil through the coolers depending on the present hydraulic oil temperature, controlled by solenoid valve Y101. - Low temperature ⇒ low volume through the coolers - High temperature ⇒ high volume through the coolers
)
• Further information about the function principle and adjustments, refer to Section 4.0 this Manual.
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Hydraulic Oil Reservoir
3.5
Section 3.0 Page 7
Transfer pump (Optional Equipment) Legend for illustration (Z 21499): (113) Transfer pump unit at the hydraulic tank - (Electric driven gear pump) (112.1) Shut off valve – suction oil tank (112.2 Shut off valve – return oil collector tube (Manifold) (112.3) Shut off valve – return oil collector tube (Hydr. oil cooler)
Functions of the Transfer Pump: A - Transfusing oil from the suction oil reservoir into the main oil reservoir. Necessary for evacuation of the suction oil reservoir, when changing the hydraulic oil. Prior servicing the main hydraulic pumps it is advisable to empty the suction oil reservoir partially. B - Transfusing oil from return oil collector tube and back-pressure valve pipe into main oil reservoir. Necessary when changing the hydraulic oil and prior to servicing the high pressure filters, the main control valves, or hydraulic oil cooler (oil return system).
)
• Refer to the operation and maintenance manual, for further information.
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3.6
Section 3.0 Page 8
Return and Leak Oil Filter Legend for illustration (Z 21500): (1) Filter cover retainer (2) Filter cover with o-ring (3) Pre-tensioning spring (4) Retainer (5) Filter assembly (6) Filter pot with machined cover (7) Main filter element, 10 micron absolute for return oil 3 micron absolute for leak oil (8) Safety filter element (200 micron strainer) same for return and leak oil (9) By pass-valve, 2.3bar (9.1) Valve cone (9.2) Valve spring (9.3) O-ring (10) Profile gasket (11) Seal ring (12) Self locking nut (13) Self locking nut Function: The returning oil flows into the filter chamber (A) of the hydraulic tank. (The sketch shows one section only). The chamber is split into two sections; one 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 passes then on its way to the entire tank the filter-element (7). "Inside to outside filtration." The filter element condition is monitored by a pressure switch (B25, 0.5 bar for the leak oil filter) and (B26, 2 bar for the return oil filter). As soon as the pressure inside the filter chamber reaches the set pressure of those switches due to the restriction of the filter-element which is caused by foreign matters, the fault message ”Return oil filter restricted" or ”Leak oil filter restricted” is displayed at the operator's dash board The filter elements must be replaced. For safety pre-cautions the filter is equipped with a by-pass valve. As the filter chamber pressure increases the by-pass valve opens at 2.3 bar and protects the element from bursting. But the oil flows not totally unfiltered into the tank because it must flow through the strainer (8).
)
• •
The switch point of the pressure switch for the leak oil has been chosen so low with best intention to protect first of all the radial seal rings of the hydraulic motors. Refer to the maintenance manual, for further information
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3.7
Section 3.0 Page 9
Breather filter Legend for illustration (Z 21501): (1) Nut (2) Cover (3) Filter element (4) Filter pot A breather filter is installed to clean the air that streams into the tank any time the oil level decreases while extending attachment cylinders The filter element condition is monitored by a vacuum type pressure switch (B24, 80mbar).
)
•
Refer to the maintenance manual, for further information
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Hydraulic Oil Cooling
Section 4.0 Page 1
Table of contents section 4.0 Section 4.0
Page Hydraulic oil cooling 4.1
General
2
4.2
Function of the hydraulic oil cooling circuit
3
4.3
Adjustment of the Back Pressure Valve
4
4.4
Fan drive (Two stage cooler fan RPM control)
5
4.5
Pressure relief valves and solenoid valve
6+7
4.6
Fixed Displacement Pump, with variable setting
8
4.7
Adjustment of the cooler fan drive speed
9 + 10 + 11
4.8
Function check of fan speed control
11
4.9
Switch points cooler fan speed (PLC controlled)
12
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Hydraulic Oil Cooling
4.1
Section 4.0 Page 2
General The hydraulic oil cooling system maintains the hydraulic oil at a normal operating temperature. Legend for illustration (Z 21594) (1) Noise shield (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 Design: There are four hydraulic oil coolers in front of the hydraulic tank on the R.H. side of the platform. They are in pairs mounted in one frame, one above the other. The air stream needed for the cooling is produced by hydraulic driven fans. The air flows from inside to outside through the coolers. For a better cleaning, the coolers can be moved to the side. ("Swing out cooler") The bearing group carrier is filled with oil to lubricate the bearings.
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4.2
Section 4.0 Page 3
Function of the hydraulic oil cooling circuit Legend for illustration (Z 21595a) (32.1 - 32.4) Restrictor, shock absorbers for the hydraulic oil cooler (39.1 + 39.2) Hydraulic oil cooler (41) Main oil reservoir (54) Return oil collector tube (55) Back pressure valve (L6 + L7) Return line from control blocks (L13 + L14) Supply line for the anticavitation circuit of the swing motors (M10) Pressure check point (Y101) Solenoid valve – 4/2-directional control valve (H) Lines to cooler (hot oil) (C) Lines to tank (cold oil)
Function: The returning oil from the system flows via the lines (L6 - L7) into the collector tube (54). On the top of it is the Back Pressure Valve (55) installed. The back pressure valve (55) causes a back pressure which forces most of the relative hot oil through the lines (H) to the cooler (39.1 + 39.2). On its flow through the cooler the hydraulic oil gets cooled and flows than through the restrictors (32.1 - 32.4) and the lines (C) into the filter chamber of the main oil reservoir (41). The restrictors are acting like shock absorbers to prevent cooler cracking at pressure peaks. Besides the back pressure valve acts as an oil flow control valve as far as the oil temperature has not reached its steady temperature. During the warm up period (1/2 Qmax) the back pressure valve (55) is wide open, because solenoid valve Y101 is energized, which results in less oil flow through the cooler which causes that the oil gets its optimum operating temperature quicker. With increasing oil temperature the oil gets thinner, so that the main pumps can be shifted to Qmax position and simultaneously solenoid valve Y101 will be de-energized, so that the valve piston will be more closed by the force of the spring thus that more oil passes the cooler. (See sectional drawing on next page.)
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4.3
Section 4.0 Page 4
Adjustment of the Back Pressure Valve Checks and settings only at normal operating temperature of the hydraulic oil, main pumps in maximum flow position and "Idle Time" control eliminated (service switch S155 in position “1”)! 1. Connect a pressure gauge to check point (M10). 2. Disconnect plug connector (13) of solenoid valve Y101. 3. Actuate service switch S155 to position “1”. 4. Start the motor. 5. Required pressure: 10 ±0,5 bar If adjustment is required: a) Take off protective cap (12). b) Loosen lock nut (5). c) Alter the pressure with the set screw (6). d) Tighten lock nut (5) and refit protective cap (12). 6. Disconnect the pressure gauge, reconnect solenoid valve Y101 and switch back service switch S155 to position “0”. Legend for illustration (Z 21596): (1) Control oil port (2) "Y"- port (external return to tank) (2a) "X"- port (external return to tank via solenoid valve Y101) (3) Poppet (4) Valve spring (5) Lock nut (6) Set screw (7) Jet bore (large) (8) Valve spring (9) Valve piston (10) Jet bore (small) (11) Plug screw (12) Protective cap (13) Plug connector (A) Return to tank (Filter chamber) (Z) Pressure oil to valve
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4.4
Section 4.0 Page 5
Fan drive (Two stage cooler fan RPM control) Legend for illustration (Z 21597a) (5.1) Axial piston pump (fixed displacement pump, with variable setting) (31.1) Pressure relief valve (maximum fan speed) (34.1) Pressure filter with pressure differential switch B28 (37.1) Fan motor (Axial piston motor) (37.2) Fan motor (Axial piston motor) (38) Check valve – (Anti cavitation valve for fan drive motor) (124) Pressure relief valve (medium fan speed) (Y6a/b) Solenoid valve (M6) Pressure check point Function: From pump (5.1) flows the oil through the filter (34.1) to the fan motors (37.1 + 37.2) and then back to the tank. The check valve (38) act as an anti cavitation valve and is installed, because the fan motor -driven by inertial force- is running for a short period after the oil flow is inerrupted by solenoid valve (Y6a/b), or if the motor has been switched off. The hydraulic circuit "Fan drive" is secured by the pilot controlled pressure relief valves (31.1) and (124). These valves are working together with the solenoid valve (Y6a/b), controlled by the ECS system, depending on the hydraulic oil temperature: • With de-energized solenoids Y6a and Y6b the relief valve (31.1) is functioning and the fans are running with max. adjusted speed (1250 RPM) • With solenoid Y6a energized the relief valve (31.1) is not functioning and the fans are running with a very low speed caused by the flow resistance only. • With solenoid Y6b energized the relief valve (124) is controlling the relief valve (31.1) and the fans are running with 1000 RPM only. (See also description on next page)
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4.5
Section 4.0 Page 6
Pressure relief valves and solenoid valve Pressure relief valve (31.1) Legend for illustration (Z 21598a) (1) Valve cartridge (2) Spring (3) Spring chamber (4) "X" port (5) Jet bore, Pilot poppet (6) Jet bore, Main piston (7) Main piston (8) Valve housing (9) Pilot poppet (Y) External leak oil port (A) Pressure port (B) Return oil port Function: Pressure in line A affects the main piston (7). At the same time there is pressure via the jet bore (6) on the spring-loaded side of the main piston and via jet bore (5) at the pilot poppet (9) of the relief valve cartridge (1). If system pressure in line A exceeds the value set at the spring (2), pilot poppet (9) opens. The signal for this comes from line A via the jet bores (6) and (5). The oil on the spring-loaded side of the main piston (7) now flows via the jet bore (5) and poppet (9) into the spring chamber (3). From here it is fed internally by means of the control line (Y) to tank (port B). Due to the state of equilibrium at the main piston (7), oil flows from line A to line B, while the set operating pressure is maintained. The pressure relief valve can be unloaded (Remote controlled) by means of the port "X" and the function of the solenoid valve (126).( Function see next page)
continued
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Hydraulic Oil Cooling
Section 4.0 Page 7
Cont’d. 4.5
Pressure relief valves and solenoid valve, illustration (Z 21599b) Function: With de-energized solenoids (Y6a and Y6b), the spool (3) keeps the "X" connection of valve (31.1) and port “B“ to port “P“ closed. The pressure relief valve (31.1) operates normal. The energized solenoid Y6b, operate the spool (3) and a connection is made between port “P“ and port “B“ and port "X" of valve (31.1) The system pressure now opens the main piston (7) of valve (31.1), because via solenoid Y6b (P to B) the oil from the rear side of piston (7) flows from the "X"-port to the “P“ connection of valve (124). The normal valve function is now remote controlled by the pressure adjusted at valve (124). The energized solenoid Y6a, operate the spool (3) and a connection is made between port “P“ and port “A” and port "X" of relief valve (31.1). The system pressure now opens the main piston (7) of valve (31.1) because via the "X"-port the oil from the rear side of piston (7) flows to tank. The normal relief valve function is eliminated.
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Hydraulic Oil Cooling
4.6
Section 4.0 Page 8
Fixed Displacement Pump, with variable setting Legend for illustration (Z 21852) (1) Drive shaft (2) Bearings (3) Cylinder with pistons (4) Center pin (5) Control lens (6) Q-min adjustment bolt (7) Q-max adjustment bolt (8) Pressure port (9) Tank port Description. Pump type A7F0 is a variable displacement pump, designed to operate in open circuits. It has an internal case drain return. The rotary group is a robust self aspirating unit. External forces may be applied to the drive shaft. Changing the swivel angle of the rotary group is achieved by sliding the control lens along a cylindrical formed track by means of an adjusting screw. • With an increase in the swivel angel, the pump output increase together with necessary drive torque. • With an decrease in the swivel angel, the pump output decreases together with the necessary drive torque.
ã
• When increasing to maximum swivel angle, there is a danger of cavitation and over-speeding the hydraulic motor!
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4.7
Section 4.0 Page 9
Adjustment of the cooler fan drive speed Basic Adjustment – Maximum Speed Legend for illustration (Z 21932b): (a + d) Dust cap (b + e) Lock nut (c + f) Set screw (5.1) Axial piston pump (fixed displacement pump, with variable setting) (6) Qmin stop bolt (6.1) Lock nut (7) Qmax stop bolt (7.1) Lock nut (10) Positioning pin (mover) (31.1) Pressure relief valve – Hydraulic oil cooler fan drive (34.1) Pressure filter with pressure differential switch B28 (124) Pressure relief valve (medium fan speed) (Y6a/b) Solenoid valve (L1) Measurement of Qmin stop bolt (L2) Measurement of Qmax stop bolt (M6) Pressure check point
) 1.
2. 3.
4. 5.
• Basic adjustment has to be carried out whenever one of the following components has been replaced: - pump - relief valve - hydraulic motor Reduce the output flow of pump (5.1), by adjusting the minimum possible swivel angle, to avoid over speeding the fan: To do this, loosen both lock nuts (6.1 + 7.1) and turn out bolt (6) and turn in bolt (7) the same length. This is necessary to avoid a loose positioning pin (10), resulting in oscillating of the cylinder barrel. Tighten the lock nuts. Remove protection cap (a) from relief valve (31.1), loosen lock nut (b) and turn set screw (c) fully clockwise and then a half turn counter clockwise. Isolate the function of solenoid valve (Y6a/b), by disconnecting both plug connectors, to ensure that the full flow of pump 5.1 will be delivered to the fan motor. Connect a pressure gauge to check point (M6). Start the motor. Continued
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4.7
Section 4.0 Page 10
Adjustment of the cooler fan drive speed
Cont'd Basic Adjustment – Maximum Speed, illustration (Z 21932b) 6. Check the fan speed with a non-contact rev counter Required fan speed: 1250 min-1
ã
• Be careful not to get caught in the fan or other rotating parts 7. Increase the output flow of pump (5.1), by adjusting the swivel angle, until the fan speed will be 20 min-1 higher than required: To do this, loosen both lock nuts (6.1 + 7.1) and turn in bolt (6) and turn out bolt (7) the same length. This is necessary to avoid a loose positioning pin (10), resulting in oscillating of the cylinder barrel. Tighten the lock nuts (6.1 + 7.1).
ã )
• Do not exceed the maximum permissible operating pressure of 230bar.
• Note down the lengths ”L1” and ”L2” as reference measurements.
8. Loosen lock nut (b) of the relief valve (31.1), and decrease the pressure with set screw (c) until the correct fan speed is obtained. 9. Tighten lock nut (b) and fix protection cap (a).
)
• Both fans have to be checked. A difference of approx. 50 rpm is normal due to the higher resistance for 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.
continued
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4.7
Section 4.0 Page 11
Adjustment of the cooler fan drive speed
Cont'd Basic Adjustment – Medium Speed, illustration (Z 21932c) 10. Activate the function of pressure relief valve (124), by connecting the plug connector of solenoid valve Y6b. 11. In order to ensure a proper function of solenoid valve Y6b during the adjustment, energize the valve by using the manual control “Digital Outputs” of the ECS-System ( refer to section 3.4 of the operation manual), or activate Y6b, by connecting the solenoid plug to permanent 24 V. Use the 24V socket at the PTO *) 12. Loosen lock nut (e) of the relief valve (124), and turn set screw (f) fully counter clockwise and then clockwise until the correct fan speed is obtained. Required fan speed: 1000 min-1 13. Tighten lock nut (e) and fix protection cap (d). 14. Note down the pressure as reference value (expected ~ 150 bar) 15. Disconnect the pressure gauge from check point (M6). 16. Connect the plug connector of solenoid valve Y6a. *) Prepare a test wire with a plug ET-No. 891 039 40, and a plug ET-No. 440 305 99. Connect terminal 1 to positive (+) (center off plug 440 305 99) and terminal 2 to ground (-). 4.8
Function check of fan speed control Switch manually the output signals to Y6a/b and check the fan speed:
)
}
Y6a Y6b
0 0
Y6a Y6b
0 1
Y6a Y6b
1 0
nmaximum ≈ 1250 min-1
}
nmedium ≈ 1000 min-1
}
nminimum ≈ 0 - 50 min-1
• For operating instructions of the ECS system refer to section 3.4 of the operation manual
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Hydraulic Oil Cooling
4.9
Section 4.0 Page 12
Switch points of cooler fan speed (PLC controlled) Switch points with hysteresis: 30°C 39°C 48°C 56°C 65°C
VG22: VG32: VG46: VG68: VG100:
46°C 57°C 67°C 73°C 73°C
Switch point: Speed decrease
Fan speed Maximum
Medium
Minimum Temperature Switch point: Speed increase
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67°C 58°C 50°C 41°C 32°C
VG100: VG68: VG46: VG32: VG22:
75°C 75°C 69°C 59°C 48°C
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Controlling
Table of contents section 5.0 Section 5.0
Page Controlling General lay out
2
5.1
Control and filter panel location of components (valves, switches, sensors etc.)
3+4
5.2
Pilot Pressure Supply and Adjustments
5 +6 + 7
5.3
Remote control valves arrangement
8
5.4
Function principle of the Electro-Hydraulic- Proportional Control
9 + 10
5.5
Potentiometer Control (Lever, Joy Stick)
11
5.6
Potentiometer Control (Pedal)
12
5.7
Proportional amplifier module, Type A (for swing brake only)
13
5.8
Proportional amplifier module, Type B (for Boom, Stick, Bucket, Swing and Travel)
14
5.9
Ramp Time Module (Analogue command value module for Boom, Stick, Travel and Swing function)
15
5.10
Adjustments of Amplifier Modules (General)
16
5.11
Adjusting the Amplifiers Type B
17 + 18
5.12
Adjusting the Amplifiers Type A
19 + 20
5.13
Adjusting the Ramp Time Module
21 + 22 + 23 + 24
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5.0
Section 5.0 Page 2
General lay out Legend for illustration (Z 21631b): (E19) Electro proportional joy stick control (E20) Electro proportional joy stick control (E21a) Electro proportional pedal control, travel left crawler (E21b) Electro proportional pedal control, travel right crawler (E22) Electro proportional pedal control, swing brake (E23) Electro proportional pedal control, bucket closed (E24) Electro proportional pedal control, bucket open (M1.1) Pressure check point X4, Pump bearing lubrication, pump support pressure (60bar) (M1.2) Pressure check point X2 pressure, pilot pressure (45bar) (8.1) Gear pump for Pilot pressure, Pump regulation and Pump bearing lubrication (14) Remote control valve blocks (33) Pressure filter with pressure differential switch B22 (35) Control and filter panel (41) Main oil reservoir (85) Bladder Accumulator – 10 liter, 10bar (located underneath the catwalk in front of the PTO) (252.1) Pressure reducing valve for pilot pressure X2 (45bar) (252.2) Pressure relief valve for pump support pressure X4 (60bar)
General The controlling includes the pilot pressure system and the pump regulation system. The pump (8.1) forces the oil through the filter (33) to all involved valves. The pressure accumulator ensures that under any circumstances enough pilot pressure oil is available. The accumulator (85) is also functioning as a hydraulic battery for a certain time when the motor was shut down or to pressure relieve the system for repair works. When the operator is using his controls an electrical signal causes energizing of the selected solenoid valve of the remote control valves(14). By the function of the remote control valves pilot pressure oil is send to the relevant control block spools which in turn allows operating hydraulic oil to the users.
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5.1
Section 5.0 Page 3
Control and filter panel location of components Legend for illustration (Z 21632d): Solenoid valves (Y5) (Y6a) (Y6b) (Y16) (Y17) (Y17a) (Y53-1) (Y61-1) (Y120) (Y123a) (Y123b) (Y125) (Y126) (Y127) (Y130) (Y131)
Swing parking brake operating pressure Cooler fan RPM control minimum speed Cooler fan RPM control medium speed Travel parking brake operating pressure „Idle time“ control, (Pump control system) ½ Q-max (reduced oil flow at too cold oil) ”Reduction pre-load pressure PTO gear lubrication - oil cooler ” „X1“ pressure, pumps 1 - 4 Hydraulic swing brake, operating pressure Ladder raise Ladder lower Ladder fast movement Flow reduction (Pump 1) Proportional swing brake pressure Fixed pump No1 (max. flow, X1= 45 bar) Fixed pump No3 (max. flow, X1= 45 bar)
Filter: (33) (34.1) (36)
Pilot pressure and pump regulation Hydraulic oil cooler fan drive PTO gear lubrication
Miscellaneous: (29) (31.1) (47) (124) (252.1) (252.2) (253.1) (253.2) (255.4) (257.1) (258.3)
Pressure relief valve – PTO gear lubrication Pressure relief valve - Hydraulic oil cooler fan drive, with solenoid valve Y6a / Y6b for fan RPM control Pressure reducing valve – Track tensioning system (35 bar) Pressure relief valve Medium speed cooler fan Pressure reducing valve for pilot pressure X2 (45bar) Pressure relief valve for pump support pressure X4 (60 bar) Change over valve – Electronic pump regulation or hydraulic constant regulation Pressure reducing valve – hydraulic constant regulation Pressure reducing valve – ½ Qmax Pressure relief valve – Safety valve for Travel brake / Track tensioning system (55 bar) Pressure relief valve – Hydraulic access ladder (70 bar)
continued
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Section 5.0 Page 4
Cont'd: 5.1
Control and filter panel location of components Legend for illustration (Z 21633b): Pressure switches: (B16) (B17) (B22) (B27) (B28) (B48) (B85-1) (B86)
Swing parking brake operating pressure PTO gear lubrication pressure (lowest permissible pressure) Pilot pressure - Filter element monitoring PTO gear lubrication - Filter element monitoring Hydraulic oil cooler fan drive - Filter element monitoring Travel parking brake operating pressure Pressure transducer – X1 pressure Pressure transducer – X2 pressure
Pressure check points: (M1.1) (M1.2) (M2) (M3) (M3-1) (M4) (M5-1) (M6) (M9) (M10) (M30-1) (M33) (M34) (M36) (M37.1) (M37.2) (M39) (M41) (M42)
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X4, Pump support pressure, Pump bearing lubrication (60bar) X2 pressure, pilot pressure (45bar) Bladder Accumulator, pilot pressure (45bar) PTO gear lubrication pressure X1 pressure, hydraulic constant regulation only Travel parking brake operating pressure (35 bar) X1 pressure – general (electronic or hydraulic constant regulation general) Hydraulic oil cooler fan drive operating pressure Travel parking brake safety pressure (55 bar) Swing parking brake operating pressure (45 bar) X4, (60bar) of pump 9.1 only (Motor1) Reduced “X3” pressure – to pump No 1 – ½ Qmax (~ 15 bar) Option operating pressure: “fast motion for travel” not used “X3” pressure – pumps No 3 to No 4 Hydraulic cylinder access ladder “piston side” Hydraulic cylinder access ladder “rod side” Proportional pressure to hydraulic swing brake “X1” pressure - Fixed pump No 3 (max. flow, X1= 45 bar) “X1” pressure - Fixed pump No 1 (max. flow, X1= 45 bar)
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5.2
Section 5.0 Page 5
Pilot Pressure Supply and Adjustments Pilot Pressure Circuit The pilot pressure oil is used for the following functions. To move the control block spools, to supply the main pump regulation system, to lubricate the main pump bearings, to release the travel- and swing gear house brakes (spring loaded multi disk brakes), to drive the grease pumps and to supply the hydraulic track tensioning system. Legend for illustration (Z 21631b): (E19) Electro proportional joy stick control (E20) Electro proportional joy stick control (E21a) Electro proportional pedal control, travel left crawler (E21b) Electro proportional pedal control, travel right crawler (E22) Electro proportional pedal control, swing brake (E23) Electro proportional pedal control, bucket closed (E24) Electro proportional pedal control, bucket open (M1.1) Pressure check point X4, Pump bearing lubrication, pump support pressure (60bar) (M1.2) Pressure check point X2 pressure, pilot pressure (45bar) (8.1) Gear pump for Pilot pressure, Pump regulation and Pump bearing lubrication (14) Remote control valve blocks (33) Pressure filter with pressure differential switch B22 (35) Control and filter panel (41) Main oil reservoir (85) Bladder Accumulator – 10 liter, 10bar (located underneath the catwalk in front of the PTO) (252.1) Pressure reducing valve for pilot pressure X2 (45bar) (252.2) Pressure relief valve for pump support pressure X4 (60bar)
Function: Study together with the hydraulic circuit diagram The pump (8.1) delivers the oil through filter (33) to port A of the pressure relief valve (252.2) to limit the pump support pressure X4 (60bar). The pressure reducing valve (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 (85) holds an 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. continued
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5.2
Section 5.0 Page 6
Pilot Pressure Supply and Adjustments
Cont'd: Pilot Pressure Circuit Legend for illustration (Z 21634a): (41) Main oil reservoir (85) Bladder Accumulator – 10 liter, 10bar (located underneath the catwalk in front of the PTO) (PX2) Pilot pressure line (LX2)
Leak / return oil line from the remote control blocks
Function: The pilot pressure oil flows via line (PX2) to port (P) of each remote control block and is present via a gallery at all proportional and directional solenoid valves. These solenoid valves are energized by the function of the Electro proportional controls (Joy sticks or pedals) and direct the pilot pressure oil to the respective spools of the main control blocks with a variable pilot pressure proportional to the deflection of the controls.
)
• For the location and designation of the proportional and directional solenoid valves of the remote control blocks refer to page 8 in this section.
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5.2
Section 5.0 Page 7
Pilot Pressure Supply and Adjustments Checks and Adjustment of Pilot Pressure Legend for illustration (Z 21635d): (85) Bladder Accumulator – 10 liter, 10bar pre-charge pressure (252.1) Pressure reducing valve for pilot pressure X2 (45bar) (252.2) Pressure relief valve for pump support pressure X4 (60bar) (M1.1) Pressure check point X4, pump support pressure (60bar) (M1.2) Pressure check point X2 pressure, pilot pressure (45bar) (M2) Pressure check point for accumulator
)
• Since the “X2” and the “X4” pressure are influencing each other it is always necessary to adjust both valves 252.1 + 252.2 alternately. 60 bar pressure „X4“, valve 252.2: 1. Connect pressure gauge to check point (M1.1) 2. Start the motor. 3. Read pressure, required = 60-2 bar If readjustment is required proceed as follow: a) Loosen lock nut (1). b) Set pressure with set screw (2). c) Tighten lock nut (1). 45 bar pressure „X2“, valve 252.1: 1. Connect pressure gauge to check point (M1.2) 2. Start the motor. 3. Read pressure, required = 45+3 bar If readjustment is required proceed as follow: a) Loosen lock nut (3). b) Set pressure with set screw (4). c) Tighten lock nut (3). Checking of Accumulator Function 1. Connect pressure gauge to check point (M2). 2. Start the motor. 3. After build-up of pressure stop the drive motor, but do not turn the key switch to zero position. 4. Watch pressure gauge. Pressure should remain constant for at least 5 minutes.
)
• If the pressure droops the system must be checked for leakages. • To check the accumulator charging pressure refer to PARTS & SERVICE NEWS “AH01531a” latest edition.
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Controlling
5.3
Remote control valves arrangement Legend for illustration (Z 21636) Remote control unit Schematic code
(14.1)
(95)
(14.2)
(15)
(14.3)
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Directional solenoid
Proportional solenoid
Y20 Y21 Y22 Y23
Y63
Y24 Y25
Y65
L.H. swing R.H. swing
Y26 Y27
Y66
R.H. swing L.H. swing
Y28 Y29 Y30 Y31
Y67
R.H. Crawler forward R.H. Crawler reverse Stick extending Stick retracting
Y32 Y33
Y69
Boom lowering Bucket filling Boom raising Boom raising
Y34 Y35 Y36 Y37
Y70
L.H. Crawler reverse L.H. Crawler forward Bucket filling Bucket filling Bucket dump Stick extending
Y38 Y39
Y72
Y40 Y41
Y73
Boom raising Boom lowering
Y42 Y43 Y44 Y45
Y74
Stick extending Stick retracting Bucket filling (curl) Bucket emptying
X46 Y47
Y76
Y64
Y68
Y71
Y75
Function BHA
FSA
Boom raising Boom lowering Bucket filling (curl) Bucket emptying
Stick extending Clam closing Stick retracting Clam opening
Boom raising Boom lowering
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5.4
Section 5.0 Page 9
Function principle of the Electro-Hydraulic- Proportional Control Legend for illustration (Z 21637) (1) Pump (2) Filter (3) Pressure relief valve (4) Check valve (5) Pressure Accumulator (6) Directional Solenoid valve, a side (7) Directional Solenoid valve, b side (8) Proportional Solenoid valve (9) Control valve block (10) Battery (11) Electronic units with amplifiers etc. (12) Control lever (Potentiometer control) Function: The electric-hydraulic control system is used to control the direction and volume of oil flow to the operating cylinders and motors via the control valve blocks. Hydraulically: The oil volume of pump (1) flows through filter (2) into the pilot pressure system. The pressure is limited by the pressure relief valve (3). With the pressurized oil stored in accumulator (5), a limited number of spool movements can be carried out with the main drive motor at standstill. When a lever (or pedal) is actuated, proportional solenoid valve (8) and one of the directional solenoid valves (either 6 or 7) are energized, and allows the pilot pressure oil to flow to the spools of the control blocks. Electrical Whenever a lever or a pedal is moved out of its neutral position, an amplifier will created a current between 0 and 1000 mA. (For detailed information refer to page 10 in this section) Depending on the lever direction, simultaneously one of the directional solenoid valves (either 6 or 7) is energized. The proportional solenoid valve alters the pilot pressure, proportional to the lever deflection, this results a spool movement between neutral and full stroke position. continued
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5.4
Section 5.0 Page 10
Function principle of the Electro-Hydraulic- Proportional Control
Cont'd: (Exemplary illustration of the function of two axis with one Amplifier only) Legend for illustration (Z 21638c) (1) Control lever (joystick) (2) Capacitor-Module (3) Ramp time module (4) Proportional-Amplifier-Module (5) Relay (Supply Voltage) (6) Proportional solenoid valve-(Pressure-Reducing Valve) (7) Directional solenoid valve (8) Control block spool General Function Control lever (1) is supplied with 24 VDC battery voltage for the switch contacts and with 24 VDC capacitor supported to create the signal voltage. When moving lever (1) out of its neutral position, 24 VDC battery voltage arrives at relay (5) and energizes the Proportional Amplifier (4) with capacitor supported 24 VDC via terminal 1. Depending on the function of the control lever, 1 to 4 Amplifiers can be involved for the „Y-axis“ (forward/ backwards direction) and 1 to 4 Amplifiers for the „Xaxis“ (left/right direction.) The polarity of the Output Signal from joystick (1), either positive or negative, between 0 and 10 VDC indicates the direction of the lever movement and is proportional to the lever deflection. This is the Input Signal to the ramp time module (3) at terminal 5 which will arrive after the adjusted ramp time delay via terminal 7 to the proportional amplifier (4) at terminal 5. This Input Signal (between 0 and 10 VDC) is amplified to an Output Signal between 0 to 1000 mA and is simultaneously send via terminal 7 (negative) or terminal 8 (positive) to the Proportional Solenoid valve (6) and to the Directional solenoid valve (7) via terminal 3 (negative) or terminal 9 (positive) to the “a” or “b”-side. The proportional Solenoid valve (6) alters the pilot pressure (“X2”) of 45 bar to a value proportional to the Current Signal. This pressure controls the movement of the control block spool (8) between neutral and full stroke position.
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5.5
Section 5.0 Page 11
Potentiometer Control (Lever, Joy Stick) Legend for illustration (Z 21639b) (1) Push button * (2) Toggle switch * (3) Inductive linear transmitter (4) Universal joint (5) Electronics (6) Push pin (7) Shaft seal (8) Reset spring (9) Coil core (10) Coil * Alternative application The non-contacting lever control (inductive linear transmitter) contains both the electronic and mechanical components which converts the lever movement into a proportional electrical voltage. The lever can be operate in two axes: Axis "Y", splitted into the half axis Y- and Y + (backward and forward) Axis "X", splitted into the half axis X- and X + (left and right) Of course the lever can be moved in any other direction (Joy stick function) In order to be able to monitor the direction of the lever movement and the neutral position, the electronics (8) sends a 24V signal as soon as the lever gets moved out of its neutral position. For one axis are used two inductive linear transmitter (3). The motion of the coil core (9) connected to the push pin (6) causes a variation of the induction in the coils (10). The electronics convert this inductive signal into a proportional output signal of –10...0...+10 V for the amplifiers. The electronic part of the lever is equipped with a internal fault detector. In case of a internal electronic fault the electronic send a 24V signal to the test output. The test input is used for a lever system check before motor start. The inductive system is designed as a redundant system with two separate coils.
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Section 5.0 Page 12
Potentiometer Control (Pedal) Legend for illustration (Z 21300a) (1) Potentiometer Control Unit (2) Pedal (3) Standard cable (4) Connection cable for combined operation (5) Push pin (5.1) Coil (6) Switch actuator (7) Direction monitoring (7.1) Directional contacts (8) Neutral position monitoring (8.1) Neutral position contacts (9) Electronic Application for: (A) Swing foot brake (B) Clam Opening/closing (C) Travelling The Potentiometer Control (inductive, linear travel transmitter) contains both the electronic and mechanical components which converts the pedal movement into a proportional electrical voltage. In order to be able to electrically monitor the pedal (2) action a neutral position switch is fitted. This switch closes when the pedal is moved out of the rest position. When using the double unit (B) (combined operation) only the signal output from one unit is used for the Clam Operation. Due to the cross lined connection via the connection cable (4) the signal is once positive and once negative (inverted), depending on the Pedal used. In order to be able to monitor the direction of the pedal movement and the neutral position of travel unit (C), two switches (5 and 6) are fitted; which are actuated by the actuator (4) as soon as the lever gets moved out of its neutral position. For the Output Signal generation are used two coils (3.1), in series connected. The push pin motion causes a variation of the induction and this in turn causes a signal variation at the AC voltage bridge. The AC voltage gets rectified and becomes the DC-Signal Voltage for the amplifiers.
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Proportional Amplifier Module, Type A Legend for illustration (Z 21516) Type A (for swing brake only) (LED) LED for Solenoid A or B (P) Set Potentiometer R1 for the lowest current value R2 for the highest current value The amplifier module contains the necessary electronics for the control of two proportional solenoids. Depending on the input polarity, either solenoid A or solenoid B is operated. The solenoid current (solenoid A - solenoid B) is measured and compared with the external input value. Differences between feed-back and input values, for example caused by changes in solenoid temperature or supply voltage, are compensated. The module also generates a direction-dependent voltage signal (solenoid A solenoid B) as soon as the solenoid current reaches the lowest set value. The lowest and highest values are set externally via the potentiometer R1 + R2. The brightness of the LED's changes with the current. This function should not be used for setting.
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Section 5.0 Page 14
Proportional Amplifier Module, Type B Legend for illustration (Z 21640) Type B (for Boom, Stick, Bucket, Clam, Swing and Travel) (LED) (P) Set Potentiometer: AX: Proportional output AX active - 10% for the lowest current value AS: Switched output AS active - J2 for the highest current value BX: Proportional output BX active (Pt) Set Potentiometer for the „Ramp BS: Switched output BS active Time“ Power: Internal supply voltage Fault: Fault indication The amplifier module contains the necessary electronics for the control of two proportional solenoids and two directional solenoids. The amplifier outputs for proportional solenoids Ax and Bx and the switched outputs As and Bs are activated by connecting a minimum of approx. 10% signal voltage at the amplifier input. A positive signal voltage controls outputs A, a negative signal voltage controls output B. A signal voltage of approx. 10% with respect to +/- 10 V input voltage at the amplifier, produces a stepped output voltage. The height of this 10% jump may be set separately for proportional outputs Ax and Bx via external potentiometer. As the signal voltage rises the solenoid current for the proportional outputs increases linearly. A further step in output current occurs at approx. 90% signal voltage. The maximum current or the 90% jump may be set separately for outputs Ax and Bx via external potentiometers and hence the gradient of the output curve may be influenced. LED`s indicate the current output to each proportional and switched output, whereby the brightness is approx. proportional to the solenoid current in Ax and Bx. This function should not be used for setting. A Ramp Time function is included in the amplifier which may be externally changed by a set potentiometer. The setting range for the ramp time is approx. from 80ms to 1s. The time setting applies to both up and down ramps and to both proportional solenoids. A fault is indicated by the LED „Fault“.
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Ramp Time Module (Analogue command value module for Boom, Stick, Travel and Swing function) Legend for illustration (Z 21518) Potentiometer: "t1" to "t5" ⇒ Ramp times "w1" to "w4" ⇒ Command value call-ups "G" ⇒ Zero point matching "Z" ⇒ Amplitude attenuation for the differential input LED displays: (1) green ⇒ Operational power (2) "4-Q" ⇒ Quadrant recognition (3) "INV" ⇒ Inversion active (4) yellow ⇒ display for potentiometer t1 to t4 (5) yellow ⇒ display for potentiometer w1 to w4 (6)
Measurement sockets: "t" ⇒ "w" ⇒ "⊥" ⇒
Actual ramp time Internal adjustment variable Reference potential / GND
General The Ramp Time Module is snapped onto mounting rails inside the X2-box. The electrical connection is done via screw terminals. The module is operated with 24 VDC. A power supply provides the internally required positive and negative supply voltages. As soon as the power supply is in operation the green LED (power) lights up. Internal command values The internal command value signal is generated from the external command value signal which is being applied to the differential input, a called-up signal and an offset signal (zero point potentiometer "Z"). The external command value signal can, via potentiometer "G", changed from 0% to approx. 110%. Command value call-ups The call-up signals w1 to w4 also have an adjustment range of 0% to 110%. No settings required. (factory set to 100%). Ramp time call up If the quadrant recognition is not activated, then each command value call-up "w1" to "w4" is allocated its own ramp time "t1" to "t4". As long as there is a signal change, the LED allocated to the actual ramp time is alight.
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Controlling
5.10 Adjustments of Amplifier Modules (General) Legend for illustration (Z 21641) (1) Potentiometer control (2) Terminal with a separating possibility (3) Ramp time module (4) Amplifier (5) Solenoid valve (6) Service module Introduction: The illustration shows simplified the route of the signal voltage from Potentiometer Control (1) to Solenoid-Valve (5): A. With ramp time module, i.e. Boom,- Stick,- Bucket (BHA),- Travel,- and Swing Function. B. Without ramp time module, i.e. Bucket (FSA),- Clam,- and Swing Brake Function. The ramp time modules (3) and the amplifiers (4) are adjustable. Adjustments are required: Ramp time modules • When commissioning the machine • When replacing a module
Amplifiers • When replacing a solenoid valve • When replacing an amplifier
For Checking and Setting the Signal Current at the Proportional-Amplifier (4), both separating terminal (2) before and behind the Amplifier (4) must be opened. For the setting procedure the signal voltage from the potentiometer control (1) can be simulated with the potentiometer of Service-Module (6),which is installed on the X2-panel. Accessories required for the adjustments: a) A multimeter, good readable for values between 0 and 1000 mA. b) More convenient is a second meter for reading voltage simultaneously. c) A simple wire, 1m length, or better a prepared test lead same length d) Four test leads, 1m length, with banana type connectors on each end.
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"a"
"b"
mA
VDC
"c" "d"
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5.11 Adjusting the Amplifiers Type B, illustration (Z 21642) Procedure applicable for all amplifiers except the one for the swing brake: (Do not start the motor, turn only the key switch in ON – position.) 1. Open* the respective separating terminal (T1) between the lever unit and the amplifier module to be set. 2. Open* the respective separating terminal (T2) between the amplifier module to be set and the proportional solenoid valve. 3. Disconnect the wire from terminal five. 4. Connect the positive output of the service module with terminal five of the amplifier module, using test lead (2). 5. Attach a multimeter for voltage reading to the service module, using test lead (3). 6. Attach a multimeter (in series) for Amp reading to the terminal between amplifier module and solenoid valve, using test leads (3). 7. Move the lever of the Potentiometer Control into its final position; or override manual the relay which allows 24 V operating voltage to the amplifier module; thus the amplifier gets 24 V operating voltage. The power LED and simultaneously LED A(+) or B(-) lights up, depending on the polarity. 8. Turn the potentiometer (P) of the Service-Module until the multimeter shows 1 VDC (it may be either positive or negative); the multimeter for the current reading will show a value which should correspond to the value giving in the circuit diagram e.g. 330 mA. (The first step (10 %) value) If necessary correct the value with potentiometer (R1). 9. Turn the potentiometer (P) of the Service-Module further until the multimeter shows 9 VDC; the multimeter for the current reading will show a value which should correspond to the value giving in the circuit diagram e.g. 660 mA. (The second step (90 %) value). If necessary correct the value with potentiometer (R2). 10. Repeat settings of item 8 and 9 until both mA values are stabilized, because R1 and R2 influence each other.
* How to open and close the terminal: Push the yellow stud (1) down with a screw driver and turn it 90° to the left to open or to the right to close the terminal. A spring pushes then the stud outwards and the contacts are either open or closed. continued PC4000-6-E_#08165_Sec_5-0_rev0_.doc
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5.11 Adjusting the Amplifiers Type B, illustration (Z 21642) Cont'd: 11.
12. 13.
If the setting with either positive or negative potential was successful, turn the potentiometer (P) of the service module into the opposite direction and check the settings with the other polarity i.e. if the first setting was done with positive potential then turn the pot into negative direction; otherwise vice versa. Repeat the setting as described under item 7 to 10. Remove multimeter, test wire, close* the terminals and reconnect the wire to terminal 5 of the amplifier module.
Adjusting the Ramp Time 1. 2.
Turn potentiometer (Rt) 30 revolutions counter clockwise, to guarantee the correct start position at the complete left side. Turn potentiometer (Rt) so many revolutions clockwise as shown in the table below (part of the electrical circuit diagram).
* How to open and close the terminal: Push the yellow stud (1) down with a screw driver and turn it 90° to the left to open or to the right to close the terminal. A spring pushes then the stud outwards and the contacts are either open or closed.
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5.12 Adjusting the Amplifiers Type B, illustration (Z 21643)
The amplifiers for the crawler foot pedals are adjustable in the same way as the amplifiers for the joy sticks.(refer to page 17 and 18 in this section) The amplifier for the swing foot brake is similar. Procedure for the swing foot brake: 1. Open* the respective separating terminal (T1) between the pedal unit and the amplifier module to be set. 2. Open* the respective separating terminal (T2) between the amplifier module to be set and the proportional solenoid valve. 3. Disconnect the wire from terminal five. 4. Connect the positive output of the service module with terminal five of the amplifier module, using test lead (2). 5. Attach a multimeter for voltage reading to the service module, using test lead (3). 6. Attach a multimeter (in series) for Amp reading to the terminal between amplifier module and solenoid valve, using test lead (3). 7. Press the pedal fully down ; or manual override the relay which allows 24 V operating voltage to the amplifier module; thus the amplifier gets 24 V operating voltage. 8. Turn the potentiometer (P) of the Service-Module until the multimeter shows 1 VDC ; the multimeter for the current reading will show a value which should correspond to the value giving in the circuit diagram e.g. 10 mA. (10 % value) If necessary correct the value with potentiometer (R1).
* How to open and close the terminal: Push the yellow stud (1) down with a screw driver and turn it 90° to the left to open or to the right to close the terminal. A spring pushes then the stud outwards and the contacts are either open or closed. continued
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5.12 Adjusting the Amplifiers Type B, illustration (Z 21643) Cont'd: 9.
) 10. 11.
Turn the potentiometer (P) of the Service-Module further until the multimeter shows 10 VDC; the multimeter for the current reading will show a value which should correspond to the value giving in the circuit diagram e.g. 500 mA. (100 % value). If necessary correct the value with potentiometer (R2). • It is important that the pilot pressure for the pressure increasing valve is 24+/- 1 bar. For more information refer to section 8.2 „Swing Circuit“ Repeat settings of item 8 and 9 until both mA values are stabilized, because R1 and R2 influence each other. Remove multimeter, test wire, close* the terminals and reconnect the wire to terminal 5 of the amplifier module.
* How to open and close the terminal: Push the yellow stud (1) down with a screw driver and turn it 90° to the left to open or to the right to close the terminal. A spring pushes then the stud outwards and the contacts are either open or closed.
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5.13 Adjusting the Ramp Time Module Legend for illustration (Z 21644) (2) Capacitor-Module (3) Ramp time module (6) Service module (P) Potentiometer
)
• The following adjustments have to be done when commissioning the machine and whenever the Ramp Time Module has been replaced. • Do not start the motor, turn only the key switch in ON – position.
Basic Adjustment: 1. Connect 0VDC with a test lead from the red positive terminal of the service module
2.
(6) to terminal 5 of the Ramp Time Module (3) and adjust with "Pot Z" a value of 0 VDC measured at terminal 7. Disconnect the test lead after the setting is done. Connect +10VDC with a test lead from the red positive terminal of the service module (6) to terminal 5 of the Ramp Time Module (3) and adjust with "Pot G" a value of 10 VDC measured at terminal 7. Check the negative voltage as well(- 10 VDC). Disconnect the test lead after the setting is done.
)
• Repeat settings of item 1 and 2 until both values are stabilized, because "Pot Z" and "Pot G" influence each other. • The factory setting of potentiometer "w1" to "w4" for the command value call-ups must not be adjusted.
continued
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5.13 Adjusting the Ramp Time Module Cont'd: Legend for illustration (Z 21645) (1) Control lever (joystick) (2) Capacitor-Module (3) Ramp time module (4) Proportional-Amplifier-Module (5) Relay (Supply Voltage) Ramp time adjustment in relation to the operating movements: 3.
Disconnect the cables at terminal 3 and terminal 5 of the respective module. Connect 24Volt with a test lead to terminal 9, 10, 11 and 12 one after another and adjust with the respective "Pot t1, t2, t3 and t4" the values giving in the table on the next page. (Measure the voltage only at the Measurement socket "t" of the ramp time module)
4.
To check the adjustments under operating conditions reconnect terminal 3 and terminal 5 and measure the ramp time with a stopwatch.
5.
If the above mentioned values are not suitable for the local working conditions, for example due to, different Attachments or different operation feeling of the operator, the ramp time can be changed according to the NOTE on illustration Z 21645, to ensure smooth and efficient working cycles.
continued
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5.13 Adjusting the Ramp Time Module, illustration (Z 21645) Cont'd: E48 Stick 24 Volt at Terminal 9 Terminal 10 Terminal 11 Terminal 12
Joy stick Signal Neutral ⇒ Stick out 0V to +10V Stick out ⇒ Neutral +10V to 0V Neutral ⇒ Stick in 0V to -10V Stick in ⇒ Neutral -10V to 0V
Pot t1 t2 t3 t4
Value to be measured at socket "t" 0,10 Volt = 1000 ms 0,10 Volt = 1000 ms 0,10 Volt = 1000 ms 0,10 Volt = 1000 ms
Joy stick Signal Neutral ⇒ Lower 0V to +10V Lower ⇒ Neutral +10V to 0V Neutral ⇒ Lift 0V to -10V Lift ⇒ Neutral -10V to 0V
Pot t1 t2 t3 t4
Value to be measured at socket "t" 0,2 Volt = 500 ms 0,05 Volt = 2000 ms 0,10 Volt = 1000 ms 0,10 Volt = 1000 ms
Joy stick Signal Neutral ⇒ Lower 0V to +10V Lower ⇒ Neutral +10V to 0V Neutral ⇒ Lift 0V to -10V Lift ⇒ Neutral -10V to 0V
Pot t1 t2 t3 t4
Value to be measured at socket "t" 0,067 Volt = 1493 ms 0,10 Volt = 1000 ms 0,10 Volt = 1000 ms 0,10 Volt = 1000 ms
Joy stick Signal Neutral ⇒ Lower 0V to +10V Lower ⇒ Neutral +10V to 0V Neutral ⇒ Lift 0V to -10V Lift ⇒ Neutral -10V to 0V
Pot t1 t2 t3 t4
Value to be measured at socket "t" 0,05 Volt = 2000 ms 0,2 Volt = 500 ms 0,10 Volt = 1000 ms 0,10 Volt = 1000 ms
Joy stick Signal Neutral ⇒ Lower 0V to +10V Lower ⇒ Neutral +10V to 0V Neutral ⇒ Lift 0V to -10V Lift ⇒ Neutral -10V to 0V
Pot t1 t2 t3 t4
Value to be measured at socket "t" 0,10 Volt = 1000 ms 0,067 Volt = 1493 ms 0,10 Volt = 1000 ms 0,10 Volt = 1000 ms
E49 Boom 24 Volt at Terminal 9 Terminal 10 Terminal 11 Terminal 12
E49a Boom 24 Volt at Terminal 9 Terminal 10 Terminal 11 Terminal 12
E49b Boom 24 Volt at Terminal 9 Terminal 10 Terminal 11 Terminal 12
E49c Boom 24 Volt at Terminal 9 Terminal 10 Terminal 11 Terminal 12
continued
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5.13 Adjusting the Ramp Time Module, illustration (Z 21645) Cont'd: E50 Swing 24 Volt at Terminal 9 Terminal 10 Terminal 11 Terminal 12
Joy stick Signal Neutral ⇒ Swing R 0V to +10V Swing R ⇒ Neutral +10V to 0V Neutral ⇒ Swing L 0V to -10V Swing L ⇒ Neutral -10V to 0V
Pot t1 t2 t3 t4
Value to be measured at socket "t" 0,067 Volt = 1493 ms 0,05 Volt = 2000 ms 0,067 Volt = 1493 ms 0,05 Volt = 2000 ms
Joy stick Signal Neutral ⇒ Swing R 0V to +10V Swing R ⇒ Neutral +10V to 0V Neutral ⇒ Swing L 0V to -10V Swing L ⇒ Neutral -10V to 0V
Pot t1 t2 t3 t4
Value to be measured at socket "t" 0,20 Volt = 500 ms 0,10 Volt = 1000 ms 0,20 Volt = 500 ms 0,10 Volt = 1000 ms
Pot t1 t2 t3 t4
Value to be measured at socket "t" 0,10 Volt = 1000 ms 5,00 Volt = 20ms 0,10 Volt = 1000 ms 5,00 Volt = 20ms
Pot t1 t2 t3 t4
Value to be measured at socket "t" 0,10 Volt = 1000 ms 0,10 Volt = 1000 ms 0,10 Volt = 1000 ms 0,10 Volt = 1000 ms
Joy stick Signal Neutral ⇒ Forward 0V to +10V Forward ⇒ Neutral +10V to 0V Neutral ⇒ Backward 0V to -10V Backward ⇒ Neutral -10V to 0V
Pot t1 t2 t3 t4
Value to be measured at socket "t" 0,10 Volt = 1000 ms 0,10 Volt = 1000 ms 0,10 Volt = 1000 ms 0,10 Volt = 1000 ms
Joy stick Signal Neutral ⇒ Dump 0V to +10V Dump ⇒ Neutral +10V to 0V Neutral ⇒ Fill 0V to -10V Fill ⇒ Neutral -10V to 0V
Pot t1 t2 t3 t4
Value to be measured at socket "t" 0,05 Volt = 2000 ms 0,10 Volt = 1000 ms 0,10 Volt = 1000 ms 0,10 Volt = 1000 ms
E50a Swing 24 Volt at Terminal 9 Terminal 10 Terminal 11 Terminal 12
E50b Swing brake (counter swing) 24 Volt at Terminal 9 Terminal 10 Terminal 11 Terminal 12
Joy stick Signal Neutral ⇒ Swing R 0V to +10V Swing R ⇒ Neutral +10V to 0V Neutral ⇒ Swing L 0V to -10V Swing L ⇒ Neutral -10V to 0V
E51 Left crawler 24 Volt at Terminal 9 Terminal 10 Terminal 11 Terminal 12
Joy stick Signal Neutral ⇒ Forward 0V to +10V Forward ⇒ Neutral +10V to 0V Neutral ⇒ Backward 0V to -10V Backward ⇒ Neutral -10V to 0V
E52 Right crawler 24 Volt at Terminal 9 Terminal 10 Terminal 11 Terminal 12
E59 Bucket 24 Volt at Terminal 9 Terminal 10 Terminal 11 Terminal 12
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Section 6.0 Page 1
Table of contents section 6.0 Section 6.0
Page Components 6.1
Hydraulic 6.1.1 Main Control Blocks and High Pressure Filter FSA
2
6.1.2
Main Control Blocks and High Pressure Filter BHA
3
6.1.3
Distributor Manifold – Restrictor blocks FSA
4
6.1.4
Distributor Manifold – Restrictor blocks BHA
5
6.1.5
Single Control Blocks (Floating) for Stick and Boom
6
6.1.6
Restrictor Block with Pressure Relief Valve
7
6.1.7
Anti Cavitation Valve Block
8
6.1.8
Remote Control Valves
9
6.1.9
Directional Solenoid Valves (Three positions / 4-ways)
10
6.1.10
Proportional Solenoid Valves
11
6.1.11
High Pressure Filter
12
6.1.12
Control Blocks and Valves
6.1.13
Travel Brake Valve
19
6.1.14
Pressure Reducing Valve
20
6.1.15
Directional Solenoid Valves (Two positions / 4-ways)
21
6.1.16
Pressure Increasing Valve
22
6.1.17
Hydraulic Cylinder
23
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6.1.1 Main Control Blocks and High Pressure Filter Front Shovel Attachment Legend for illustration (Z 21829): Pump circuit No. I (10/I) Main Control block (Swing, Bucket fill / Boom raise, Stick) (13.2) High pressure filter(with differential pressure switch B5) (68.1) (66.4)
Anti Cavitation Valve – Stick cylinder piston side 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 (with differential pressure switch B6) (45) (66.5) (68.2) (68.3+68.4)
SRV Clam cylinder piston side SRV Boom cylinder piston side ACV Clam cylinder rod side ACV Travel motors
Pump circuit No. III (9/III) Main Control block (Swing, Clam, Bucket, Boom) (13.1) High pressure filter (with differential pressure switch B7) (66.1) (66.2)
SRV Bucket cylinder piston side SRV Bucket cylinder rod side
Pump circuit No. IV (12/IV) Main Control block (Slew, Boom/Bucket, Stick) (12.3) High pressure filter (with differential pressure switch B8) (66.7) (66.8) (66.9) (66.10) (66.11) (66.12) (68.5) (68.6+68.7)
)
SRV Boom cylinder piston side SRV Boom cylinder rod side SRV Bucket cylinder piston side SRV Bucket cylinder rod side SRV Stick cylinder piston side SRV Stick cylinder rod side ACV Stick cylinder piston side ACV Travel motors
• There is one Main Relief Valve in each control block
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6.1.2 Main Control Blocks and High Pressure Filter Back Hoe Attachment Legend for illustration (Z 21830): Pump circuit No. I (10/I) Main Control block (Swing, Boom, Stick) (13.2) High pressure filter(with differential pressure switch B5) (66.4)
Service-line Relief Valve – Stick cylinder piston side
Pump circuit No. II (11/II) Main Control block (Boom, Stick, Bucket, L.H. Travel) (13.3) High pressure filter (with differential pressure switch B6) (66.5) (66.6) (68.3+68.4)
SRV Boom cylinder piston side SRV Stick cylinder piston side ACV Travel motors
Pump circuit No. III (9/III) Main Control block (Swing, Bucket, Boom) (13.1) High pressure filter (with differential pressure switch B7) (66.3)
SRV Boom cylinder rod side
Pump circuit No. IV (12/IV) Main Control block (Boom, Bucket, Stick, R.H. Travel) (13.4) High pressure filter (with differential pressure switch B8) (66.7) (66.8) (66.12) (68.6+68.7)
)
SRV Boom cylinder piston side SRV Boom cylinder rod side SRV Stick cylinder piston side ACV Travel motors
• There is one Main Relief Valve in each control block
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6.1.3 Distributor Manifold - Location of restrictor blocks and anti cavitation valves Front Shovel Attachment Legend for illustration (Z 21831): (SB) Synchronization (Equalization) block (SL) Synchronization (Equalization) lines (SRV) Service-line Relief Valve Pressure check point (42)
Distributor manifold
(64.1)
ACV Block Section A, Boom cylinder rod side
(70.1+.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+.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
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6.1.4 Distributor Manifold - Location of restrictor blocks and anti cavitation valves Backhoe Attachment Legend for illustration (Z 21832): (SL) Synchronization (Equalization) lines (SRV) Service-line Relief Valve Pressure check point (42)
Distributor manifold
(64.1)
ACV Block Section A, Boom cylinder rod side
(70.1+.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+.9) Restrictor blocks Section J, Stick cylinder rod side with SRVs and pressure check points M21.1 + M21.2 (70.10)
Restrictor block Section K, Stick cylinder rod side with SRV and pressure check point M22
(64.6)
ACV Block Section K, Stick cylinder rod side
(70.11)
Restrictor block Section L, Bucket cylinder rod side with SRV and pressure check point 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
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6.1.5 Single Control Blocks (Floating) for Stick and Boom Front Shovel Attachment Legend for illustration (Z 21833): (Y132)
Single control block - Stick lowering function Floating position
(Y133)
Single control block - Stick lowering function Floating position
(Y134)
Single control block - Stick lowering function Floating position
(Y135)
Single control block - Boom lowering function Floating position
Function: Only Front Shovel Attachment The additionally installed single control blocks (Y132, Y133,Y134 and Y135) connect the piston side of the cylinders with the rod side and also with the tank: Y132, Y133 and Y134 for the Stick cylinders Y135 for the Boom cylinders In normal operation mode (i.e. float position) the pilot pressure oil is directed via de-energized solenoid valves to the single control blocks when lowering the boom or stick. If a pressurized lowering of the cylinders is required the pilot pressure oil is directed 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).
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6.1.6 Restrictor Block with Pressure Relief Valve
)
• A restrictor block is used for limiting cylinder lowering speeds. • A Service Line Relief Valve is installed to limit the maximum system pressure due to external forces.
Legend for illustration (Z 21834): (1) (2 + 3) (4) (5 + 6) (7) (8) (9) (10) (11 (12) (13) (14) (15) (16) A+B M Y
Adjustment spindle O-ring with back-up ring Retainer O-ring with back-up ring Spring Spring cup Throttle sleeve O-ring Housing Return line port, T Pressure relief valve Allen bolt Clip ring Lock nut Line ports Pressure check point Control oil drain port
Function: Setting of the maximum permissible cylinder speed (flow B to A) is carried out by spindle (1). Depending on the spindle setting, the radial holes (9.1) in the valve poppet (9) will be partially opened to achieve the required throttling of the oil flow. The extra holes (fixed throttle 9.2) prevents the valve from becoming completely closed. For the lifting operation (flow A to B), the valve poppet (9), which is guided by the spindle (1), is pressed against spring (7) so that the valve will be completely open.
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6.1.7 Anti Cavitation Valve Block
)
• ACVs are installed to avoid cavitation damages on users (hydraulic cylinders), by compensating a possible lack of oil, when the SRV at the opposite side of the cylinder opens (see circuit diagram).
Legend for illustration (Z 21835): (Type 64.1 to 64.9 of the hydraulic circuit diagram) (1) Housing (2) Valve cone (3) Spring (4) O-ring (5) Control and leak oil bore (6) Cap screw (torque 900 Nm) S Supply line (Return oil pressurized to approximately 10 bar by back pressure valve) A and B Line connections Function: The circuit pressure in the line A and B hold the valve cone (2) closed. The pressure of the supply line S forces onto the valve cone. The valve cone opens, whenever the pressure at the A and B side is lower than the back pressure at return oil port S, to allow necessary oil supply into the circuit.
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6.1.8 Remote control valves
)
• Remote control valves are part of the electric-hydraulic control system
Legend for illustration (Z 21838): (1 - 6) (7) (8) (9) (10) (11)
Pilot pressure lines to the control block Pilot pressure supply port Return to tank port Manifold block Double directional solenoid valve Single proportional solenoid valve
Function: The electric-hydraulic control system is used to control the direction and volume of oil flow to the operating cylinders and motors via the main control valve blocks. When a lever (or pedal) is actuated, a proportional solenoid valve (11) and one of the directional solenoid valves (10 either a or b) are energized, and allows the pilot pressure oil to flow to the spools of the main control blocks. The proportional solenoid valve alters the pilot pressure, proportional to the lever deflection, this results a spool movement between neutral and full stroke position.
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6.1.9 Directional Solenoid Valves (Three positions / 4-ways)
)
• This solenoid operated directional spool valves are installed to control the start, stop and direction of an oil flow.
Legend for illustration (Z 21839): (1) (2) (3) (4) (5) (6)
Housing Solenoids Control spool Reset springs Plunger End cover
Function: In un-operated condition the control spool (3) is held in the neutral or starting position by the reset springs (4). Operation of the control spool is by means of oil immersed solenoids (2). The force of the solenoid (2) acts via the plunger (5) on the control spool (3) and pushes its from its resting position into the required end position. This results in the required free flow from P to A and B to T or from P to B and A to T. When the solenoid (2) is de-energised, the control spool (3) is returned to its original position by the reset springs (4).
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6.1.10 Proportional Solenoid Valve
)
• This valves are responsible for the creation of a variable control pressure proportional to the electrical signal output of an amplifier.
Legend for illustration (Z 21697): (1) (2) (3) (4)
Proportional solenoid Control piston Valve housing Pressure measuring spool
(5) (6) (7) (8)
Pressure measuring spool Connection plug Return spring Bleed screw
Function: In unoperated condition the control spool (2) is held in the neutral or starting position by reset springs. The control spool (2) is directly operated by the proportional solenoid (1). If the solenoid is energized, it produces a force to operate the control spool (2) via the pressure measuring spool (4) and moves the spool to the left. Oil flows from P to A. As pressure in A increases, it passes via the radial borings in the control spool (2) to the inner end of the pressure measuring spool (2). The force generated by the pressure now works against the solenoid force and pushes the control spool (2) to the right (closing direction) until a balance is achieved between the two forces. In order to achieve this, the pressure measuring spool (2) moves to the left until it is supported by the pin (5). When the force balance is achieved, the connection between P and A is interrupted and the pressure in line A is held constant. Any reduction in the solenoid force leads to the pressure force exceeding the solenoid force on the control spool (2). The control spool is then moved to the right causing a connection from A to T allowing the pressure to fall until a balance is re-established at a lower level. At rest, when the solenoid is de-energized, ports A and B are open to tank, whilst port P is blocked from both ports A and B.
W
• In order to achieve optimum functioning of the valve, it must be bleed when commissioning: - Supply pressure to the valve - Remove plug 8 - When no more air bubbles appear screw in plug 8.
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6.1.11 High Pressure Filter
)
• There is one filter in each pump line installed.
Legend for illustration (Z 21696): (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) P1 P2 a b c d e
Filter head Drain plug Filter case Hexagon Filter element Packing ring O-ring Back-up ring O-ring Spring Differential pressure switch Higher static pressure Lower static pressure Electrical connection REED contact Permanent magnet piston Spring Plug screw
Function: High-pressure in-line filters prevent contamination from entering the hydraulic circuits. The spin-on filters are installed between the main hydraulic pumps and multi-valve control blocks. All hydraulic components, behind the pumps, are effectively protected from damage and undue wear. Each filter is equipped with a differential pressure switch to monitor the filter flow restriction. If the pressure reaches an unsafe difference of 8.5 bar, a visual/acoustic warning appears on the display in the cab and the engines will be shifted automatically to low idle.
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6.1.12 Control Blocks and Valves
)
• This is a principle drawing, showing valve block II and IV.
Legend for illustration (Z 21702): (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13)
Control block housing Main relief valve (MRV) Boom lifting / lowering, Spool (special) Long cap ("B" side) "B" side service line ports Centering springs Solid spool Short cap ("A" side) "A" side service line ports Load check valves Pilot oil warm up and flushing grooves Fine controlling grooves Type plate
Control blocks with "Open Center and Closed Ports". Control blocks I and III are 3 spool 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. Between 8 and 19 bar pilot pressure the spools are moved in their fine control range. Spool (3) is special 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.
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6.1.12 Control Blocks and Valves Legend for illustration (Z 21703): (1) (2) (3) (4)
Main relief valve (MRV)Control block housing Load check valve Anti cavitation valve (ACV) Service line relief valve (SRV)
Explanation of the schematic drawing of the control block: The hydraulic oil flows through the control block from port P to T, if all spools are in neutral position ("pressure-less circuit" or “Free circulation“). (A)
E.g. the spools moves down when pilot pressure is build up in the control pipe line a1. (Imagine the upper symbol box moves to the center position.) Now pump oil flows through check valve (2) to the user port A1 because the free flow circulation to the hydraulic reservoir is closed. The main relief valve (1) limits the maximum operation pressure in this circuit. Via port B1 the return oil from the user is flowing back to the hydraulic reservoir. During down hill travelling motion and stopping procedure (e.g. travel motors) the anti cavitation valves (3) prevents cavitation on the hydraulic motors. Because during these short periods of time the hydraulic motor needs a higher oil supply than the pump can deliver.
(B)
E.g. the spool #3 moves up when pilot pressure is build 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. Service line relief valve (4) is additional installed in this circuit to protect the circuit for extreme pressure. The shortly extreme pressure closes also the check valve (2) which secures the hydraulic pump from extreme pressure peaks. The check valves (2) have also the function of load holding valves because during the fine controlling period all lines are connected together (negative over-lapping). The load pressure is for a moment higher than the pump pressure.
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6.1.12 Control Blocks and Valves Legend for illustration (Z 21704): (1) (2) (3)
Reset springs Fine controlling grooves Spool
Function: Reset springs (1) moves the spool (3) in neutral position. Fine control grooves (2) provide for sensitive controlling, because a motion is started always while the pressure oil and the return oil first passes this fine control grooves before spool (3) is inter connecting the entire groove to the user channel. In neutral position of spool (3) 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. Also the connection from the other user side (port B return)is connected to the port T (return line to tank). Return line of the pressure relief valve MRV is also connected to the port T.
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6.1.12 Control Blocks and Valves Legend for illustration (Z 21705): (01) (02) (03) (04) (5) (6) (7) (8)
Service -Line Relief Valve Anti Cavitation Valve Main Relief Valve Closing plate Plug screw Spring Valve cone Dust cap
(9) (10 (11) (12) (13) + 16) (14) (15) (17)
Set screw Lock nut Spring, pilot part Poppet Jet bore Spring, main cone Main valve cone Pilot oil dump line to tank
MRVs and SRVs are pilot operated relief valves. The MRV limits the max. Pump supply line pressure. The SRV limits the max. possible pressure peak in the service-line. The valves have an „opening characteristic“. That means, that in case of contamination after the response procedure no further pressure increasing is possible and damages are avoided. Function: The circuit pressure P forces with the force F1 on the piston surface A of the main valve cone (15). Because there is via the jet bore (16) the same pressure on the back side of the main cone, this results together with the spring (14) force in a force F2 that keeps the main cone closed. Via the jet bore (13) the circuit pressure is in front of the poppet (12). Exceeds the circuit pressure the setting value of the spring (11), the poppet opens against the force of the spring (11). This causes that the force F2 decreases and there is no more balance condition between F1 and F2. Valve cone (15) is moved upwards by the greater force F1. That means there is now a direct connection from port P to T (tank). ACVs serve for compensation possible lack of feed when the SRV at the opposite port is actuated (see circuit diagram) and for avoiding cavitation damages. In addition, to supply a user in case it is continuously moved by acceleration forces at zero position of the control spool. Function: The circuit pressure inside the spring chamber closes the valve cone (7). The back pressure of the return line acts on the surface of the valve cone (7). Whenever the pressure in the service-line is lower than the springs force the valve cone opens by the force of the back pressure and hydraulic oil is additional supplied.
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6.1.12 Control Blocks and Valves Load Holding Valve Legend for illustration (Z 21706): (1) (2) (3) (4) (5) (6)
Valve cone guide Valve spring Valve cone Valve block housing Passage from pump (P) 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. They have three tasks: 1. When circuit pressure due to attachment weight is higher than pump pressure these valves prevent dropping of the attachment, within their sensitive (fine controlling) range. 2. Due suddenly pressure peaks in the service lines the valves also protect the pump. 3. When two pumps flows are used for one user they ensure that at least the flow of one pump reaches the user in case one MRV is defect or not more correct adjusted. That means: Up to the max. Pressure of the defective valve both load holding valves are open allowing the flow of both pumps to the user, then one valve will be closed by the higher pressure and the flow of one pump only flows to the user. Function: The system pressure forces onto the front area of the valve cone (1). This force moves the valve cone against the spring (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 not more in neutral the flow continues to the user. If due to an external force the pressure directed to the pump overcomes the pump line pressure, this pressure forces the valve onto its seat (closed position)
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6.1.12 Control Blocks and Valves Load Holding Valve
)
• This is a principle drawing only, showing the location of Load Holding Valves in valve block I and III.
Legend for illustration (Z 21843): (1) (2) (3) (4) (5)
Spool Valve cone Valve spring Passage from P to A Passage from B to T
Control Blocks I and III (3 spool blocks) The load holding valves are directly fitted into the spools (one on each side). They have three tasks: 1. When circuit pressure due to attachment weight is higher than pump pressure these valves prevent dropping of the attachment, within their sensitive (fine controlling) range. 2. Due suddenly pressure peaks in the service lines the valves also protect the pump. 3. When two pumps flows are used for one user they ensure that at least the flow of one pump reaches the user in case one MRV is defect or not more correct adjusted. That means: Up to the max. Pressure of the defective valve both load holding valves are open allowing the flow of both pumps to the user, then one valve will be closed by the higher pressure and the flow of one pump only flows to the user. Function: In neutral position (upper picture) of the spool (1) both valve cones (2) are closed by the springs (3). In a switched position (lower picture) forces the circuit pressure onto the front area of the valve piston (2). This force moves the piston against spring (3) and allows the oil to flow from the pump supply (4) to the user port (A) and from port B via boring (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). PC4000-6-E_#08165_Sec_6-0_rev0.doc
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6.1.13 Travel Brake Valve Illustration Z 21695 Task: Travel brake valves control the oil flow from the hydraulic motor to the tank depending on operating pressure. This braking action prevents the motors from overspeeding. Function: Spring force keeps the spool in the lowest flow position. with increasing operating pressure the opening for the return oil flow becomes larger. On its way to the hydraulic motor the oil flows from A to A1 respectively from B to B1 depending on the selected travel motion. Example: Operating pressure at port A moves spool (1) against the force of the spring (2) and opens the way for the return oil (B1 to B). Check valve (3) prevents a direct oil flow from B1 to B. If the operating pressure decreases to such an extend that the spring force overcomes the pressure, the flow to the tank becomes restricted, resulting in braking of the machine.
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6.1.14 Pressure Reducing Valve
)
• Pressure reducing valves are installed to reduce the common 45 bar pilot pressure to a lower pressure for other systems, e.g. the pump regulation system.
Legend for illustration (Z 21844): (1) (2) (3) (4) (5) (6) (7) (8)
Set screw Spool Compression spring Threaded sleeve Non return valve Boring Spring chamber Control land
Function: Pressure reducing valves type DR & DP are direct operated valves of 3 way design, e.g. with a pressure relief function on the reduced pressure side. At rest, the valve is normally open, and fluid can flow unhindered from port P to A. Pressure in port A is also present on the end of the spool (2), via control line (6), opposing the compression spring (3). When the pressure in port A reaches the pressure level set at spring (3), spool (2) moves to the control position and holds the pressure in port A constant. Fluid to control the valve is taken from port A via the boring (6). If the pressure in port A rises still further due to external forces, the spool (2) is moved still further towards the compression spring (3). This causes a flow path to be opened over control land (8) in the control spool (2) to tank. Sufficient fluid then flows to tank to prevent any further rise in pressure. An optional non return valve (5) is available to allow free flow from A to P.
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6.1.15 Directional Solenoid Valves (Two positions / 4-ways)
)
• This solenoid operated directional spool valves are installed to control the start, stop and direction of an oil flow.
Legend for illustration (Z 21845): (1) (2) (3) (4) (5) (6)
Housing Solenoid Control spool Return spring Plunger Dust cap with stem for manual operation
Function: When there is no flow through the valve, control spool (3) is held in neutral or output position by means of the return springs (4). The control spool (3) is operated by means of oil immersed solenoid (2). The force of the solenoid (2) effects control spool (3) by means of the plunger (5) and pushes it from its resting position to the required end position. This results in free flow from or P to B and A to T. When solenoid (2) is de-energized, control spool (3) is moved back to its resting position by means of return springs (4). An optional hand emergency (6) allows movement of the control spool (3) without energizing the solenoid.
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6.1.16 Pressure Increasing Valve
)
• The pressure increasing valve is a remote controlled pressure relief valve, actuated by hydraulic pressure. The individual pressure is in such a way determined by the pilot pressure.
Legend for illustration (Z 21846): (1) (2) (3) (4) (5) (6) (7+8) (9) (10) (11+12) (13+14)
Pilot valve with valve seat Valve poppet Compression spring Main valve with sleeve Main piston Closing spring Set screws Piston Pin Jet bore Lock nut
Function: The valve poppet (2) is connected via the jet bores (11) and (12) with the P port. If static pressure increase above the set pressure value, the valve poppet (2) opens and allows oil to flow freely to tank (T1). This oil generates a pressure drop in the spring chamber of the main spool, the closing force of the spring (6) is cancelled, and the main piston (5) opens to allow the pump flow to flow to tank (T2). Damped opening and closing is obtained by the throttled volumetric change. By applying external pressure of Pst max = 45 bar to the main spool (9) via port X, the pre-tensioning of the pressure spring (3) is increased by the amount of the piston stroke "S" and system pressure is increased correspondingly. The 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 (7) and lock nut (13); 1 turn of the screw = 150 bar.
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6.1.17 Hydraulic Cylinder Legend for illustration (Z 22735): General (1) Piston rod (2) Rod eye bushing (3) Piston (4) Cylinder tube (5) Piston fitting key (6) Piston nut (7) Piston nut lock (threaded pin) (8) Foot end eye bushing
B Flange bushing: Clam cylinder B1 Scraper ring B2 „BD“ seal (Dynamic Seal)
A Flange bushing: Boom-, Stick-, Bucket-Cylinder A1 Scraper ring A2 Support bushing A3 Hard-plastic back-up ring A4 Back-up ring A5 Chevrons A6 Header ring A7 Scraper retainer ring A8 Cover A9 Steel shims (splitted)
C = Piston rings C1 Piston seal ring C2 Piston guide rings, hard C3 Piston guide, soft C4 O-ring with back-up rings
Explanation of the cylinder markings 430/290X3150
Piston diameter / Rod diameter X Stroke
430630 40
Cylinder drawing number (identical with part No.).
11 / 97
Assembling Month and year (final figure).
261
Internal counting number.
DB 55.
Assembling crew personal code
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Main Hydraulic Pumps and Pump Regulation System
Section 7.0 Page 1
Table of contents section 7.0 Section 7.0
Page Main hydraulic pumps and pump regulation system General 7.1
7.2
7.3
Main Pumps 7.1.1 Location of Pumps, drive speed and flow rates 7.1.2 Pump bearing flushing / lubrication 7.1.3 Operating Principles 7.1.4 Checks and Adjustments Electronic Pump Regulation System 7.2.1 Electronic load limiting control - General 7.2.2 Components:- Electronic Power Module EPM - Electronic Signal rectifier ESR - Microcontroller MC7 7.2.3 Checks and adjustments - General Method A - With 24V supply to terminals - X1-Pressure - Demanded power - PID - Factor Method B - With the electronic service tool BB-3 - Language selection - Adjustment mode SET1 and SET2 - Number of motor selection - X1-pressure (max. current) adjust. - Demanded power adjustment - PID – Factor adjustment - Storage new settings Method C - With a laptop and BODEM software - Starting the program - Language selection - Entering of the password - Number of Motor selection - X1-pressure (max. current) adjust. - Demanded power adjustment - PID – Factor adjustment Hydraulic Constant Regulation System 7.3.1 General 7.3.2 X1-pressure adjustment (constant-pressure)
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6 7 8 – 15 16 – 20
21 22 23 + 24 25 26 27 28 + 29 30 31 + 32 33 34 35 36 37 38 39 - 40 41 42 43 44 45 + 46 + 47 48 49 50
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Main Hydraulic Pumps and Pump Regulation System 7.0
Section 7.0 Page 2
Main hydraulic pumps and pump regulation system General lay out (Hydraulic only)
Legend for illustration (Z 21547b): (1 - 4) Main hydraulic pumps (8.1) Pilot pressure pumps (33) Pilot pressure filter unit (252.2) 60 bar pressure relief valve (252.1) 45 bar pressure reducing valve (Y17) Solenoid valve: "Idle time control and low hydraulic oil temperature" Q-min flow for all main pumps (Y17a) Solenoid valve: "Remote control pressure" ½ Q-max flow reduction for all main pumps (Y126) Solenoid valve: "Remote control pressure" ½ Q-max flow reduction for pump #1 only (255.4) Pressure reducing valve: "Remote control pressure" ½ Q-max flow reduction for the warming-up period and flow reduction for pump #1 (253.2) Pressure reducing valve: " Pump regulation pressure X1 at hydraulic pump regulation" (Hydraulic constant regulation mode) (Y61-1) Proportional solenoid valve: "Pump regulation pressure X1 at electronic pump regulation " (Standard operation mode) (Y130) Solenoid valve: " Pump regulation pressure X1 = 45 bar for pump #1" (fixed pump for swing) (Y131) Solenoid valve: " Pump regulation pressure X1 = 45 bar for pump #3" (fixed pump for swing) (253.1) Change over valve: "Electronic or Hydraulic pump regulation"
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Main Hydraulic Pumps and Pump Regulation System 7.0
Section 7.0 Page 3
Main hydraulic pumps and pump regulation system Pump regulation system general, illustration (Z 21547b) General Controlled output flow of the main pumps is necessary: • To utilize the available motor power most efficiently in every operating mode. • To limit the power consumption of the hydraulic pumps depending on the load of the motor. (Electronic pump regulation with micro-controller MC7) • For additional functions, such as rotating dependent or temperaturedependent flow reduction. Function: X1 – pump regulation pressure (0 – 34 bar): The power controller of the main pumps can be remotely controlled by applying an external pilot pressure (X1 ) at port X LR to the spring chamber of the power control valve. The start of destroking can be varied in proportion to the applied X1 - pressure. X2 – pilot pressure (45 bar): Constant pilot pressure to regulate the main pumps at special circumstances, e.g. to fix the pumps in Q-max position while servicing the machine. X3 – remote control pressure (0 / 15 / 45bar): Basic setting Q-min (0 bar), the flow rate increases with the pilot pressure X3 at port Pst, up to Q-max (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: Q-min.: X3 = 0 bar ½ Q-max.: X3 = 15 bar Q-max.: 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.
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Section 7.0 Page 4
Main hydraulic pumps and pump regulation system Pump regulation system general, illustration (Z 21547b) Function: Solenoid valve Y17: If de-energized pumps #1-4 are in Q-min 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 Y17a: 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 Q-max. 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 without delay whenever all controls are in neutral position.
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Main hydraulic pumps and pump regulation system Pump regulation system general, illustration (Z 21547b) Function: Solenoid valve Y126: If de-energized, pump #1 is in the same regulation mode like pumps #2, #3 and #4. If energized the flow of pump#1 is limited to ½ Q-max by the function of pressure reducing valve (81.1). It gets 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 swing
Normal operating conditions With swing (fast speed)
Y17
1
1
Y17a
1
1
Y126 (1) = Energized (0) = De-energized
0
1
Proportional Solenoid valve Y61-1: This valve, connected to the MC7 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 Q-max. into Q-min. – position, to keep the engine at rated speed of approx. 1800 RPM. Solenoid valve Y130: If energized, pump regulation pressure X1 = 45 bar for pump #1" (fixed pump for swing) Solenoid valve Y131: If energized, pump regulation pressure X1 = 45 bar for pump #3" (fixed pump for swing with fast speed) Pressure reducing valve 255.4: "Remote control pressure" (X3) ½ Q-max flow reduction during the warming-up period for all pumps by the function of solenoid valve Y17a. ½ Q-max flow reduction only for pump #1 while swinging with max. speed by the function of solenoid valve Y126. Pressure reducing valve 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".
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Main Hydraulic Pumps and Pump Regulation System
7.1
Section 7.0 Page 6
Main Pumps 7.1.1. Location of Pumps Legend for illustration (Z 21548): (1 - 4) Axial piston pump (swash plate type) theoretical flow rate, each 1033 Liter/min Drive speed* n = 1378 min-1 for all working motions
(5.1)
(5.2)
(8.1)
(8.2)
Axial piston pump theoretical flow rate Drive speed* for oil cooler fan drive
214 Liter/min n = 2000 min-1
Axial piston pump theoretical flow rate Drive speed* for radiator fan drive
214 Liter/min n = 2000 min-1
Gear pump theoretical flow rate Drive speed* for pilot pressure supply
138 Liter/min n = 1378 min-1
Gear pump theoretical flow rate Drive speed*
138 Liter/min n = 1378 min-1
PTO gear lubrication
)
• * at 1800 min-1 input drive speed
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Main Hydraulic Pumps and Pump Regulation System 7.1
Section 7.0 Page 7
Main Pumps 7.1.2. Pump bearing flushing / lubrication The installed main pumps are provided with an external cooling and lubrication system for flushing of drive shaft bearing and shaft seal. Oil supply is provided from the X4-pressure circuit. To reach the restricted guidance of the coolant for external bearing flushing, the throttle screw (located behind the union at port U) must screwed in all the way. An information sign is fixed at the pump. Legend for illustration (Z 22356): (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 flushing / lubrication
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Main Hydraulic Pumps and Pump Regulation System 7.1
Section 7.0 Page 8
Main Pumps 7.1.3 Operating Principles Main hydraulic pump A4VSLO 750 LR3DN / 30L Type code explanation: A4VSLO 750 LR 3 D N / 30 L Rotation Series Basic adjustment for minimum displacement With pressure control Hydraulic remote adjustment facility Constant power with hyperbolic curve 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: • The A4VSLO variable displacement axial piston pump in swash plate design is intended for drives in open circuit operation. • The flow volume is proportional to the drive speed and the displacement. By adjusting the swash plate a infinitely variable flow adjustment is possible. • Pumps of the same nominal size can be built onto the trough drive. Combinations with gear pumps are also possible. Legend for illustration (Z 21549): (1) Drive shaft (2) Cylindrical roller bearing (3) Slipper pad (4) Swivel angle indicator (5) Positioning piston (6) Swivel pin (7) Cylinder with pistons (8) Final connecting plate (9) Cylindrical roller bearing (10) Impeller (charging pump) (11) Splints for the through drive coupling (Aux. pump drive) (12) Swivel cradle (13) Q-min stop bolt (14) Power control valve (15) Pressure balance valve (16) Power curve correction (17) Pressure cut off valve (18) Q-max. stop bolt (19) Remote control valve continued
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Main Pumps 7.1.3 Operating Principles Cont'd: Symbol of main hydraulic pump A4VSLO 750 LR3DN / 30L Legend for illustration (Z 21550): (1) Main pump (swash plate pump, variable displacement) (2) Charging pump (impeller type pump) (3) Pump bearing group (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) Nozzle (9) Power control valve (10) Nozzle (11) Pressure cut-off valve (12) Auxiliary pump (Gear pump, fixed displacement (13) Positioning piston (14) Slipper pad piston (15) Lever (16) Cam (17) Through drive shaft • * Factory side adjusted, no field adjustment required
)
B/B1 S MB ML MST R T P PST U XLR
Pressure port Oil intake (suction port) Operating pressure check point Charging pressure check point Control pressure check point Filler and bleeder port Connection port for chip indicator Pump support pressure (”X4”-pressure) Remote control pressure port (”X3”-pressure) Bearing flushing port Regulating pressure port (”X1”-pressure) continued
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Section 7.0 Page 10
Main Pumps 7.1.3 Operating Principles Cont'd: Sectional drawing of Power Controller LR3DN / 30L Legend for illustration (Z 21551): (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
)
• Refer also to illustration Z 21550 on the previous page.
continued
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Main Assembly Groups
7.1
Section 7.0 Page 11
Main Pumps 7.1.3 Operating Principles, illustration (Z 21552) Cont'd: Q-min position: (remember Q means volume) When are the pumps in Q-min position? A: Motor at standstill B: Motor running and the controls are not used for 20 sec. or longer at temperature state between T1 and T3. C: Motor running and service switch S155 activated (Qmin-position) Example C with the following conditions: • Motor running • Pump pressure smaller than X4 = 60 bar (pump support pressure) • X1 = 34 bar (pump regulation pressure), this pressure will not influence the Q-min position under these conditions. • X3 = 0 bar (remote control pressure); Y17 de-energized (S155 Qmin activated) for pumps #2, #3 and #4. For pump #1, Y17 and Y126 de-energized. • 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 will overcome the spring force, since the oil behind nozzle (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 as the small area side, the pump support pressure X4 of 60 bar present on both sides, resulting in stronger force at the large area side, keeps the pump in Q-min position. The pump remains in Q-min position continued
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Main Pumps 7.1.3 Operating Principles, illustration (Z 21553) Cont'd: Q-max position: (remember Q means volume) When does the pumps move into Q-max position? and and and
Motor running hydraulic oil at normal operating temperature (> T2) the controls frequently used. (or Service switch S155 activated – Qmax-position) a pump pressure below start of de-stroking.
Example with the following conditions: • Motor running • Pump pressure between 60 bar and 300 bar, present at the slipper pad of piston #14 and the small area side of the positioning piston #13 • X1 = 34 bar (pump regulation pressure) • X3 = 45 bar (remote control pressure); Y17 and Y17a energized for pumps #2, #3 and #4. For pump #1, Y17 energized and Y126 de-energized • 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 (9) position "a" and pressure balance valve (7) position "a", to the return oil line. The pump moves into Q-max position, because the pump pressure acts only at the small area side of positioning piston #13.
The pump moves into Q-max position
continued
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Section 7.0 Page 13
Main Pumps 7.1.3 Operating Principles, illustration (Z 21554) Cont'd: ½ Q-max position: (remember Q means volume) When does the pumps move into half Q-max position? and and or and
Motor running hydraulic oil below normal operating temperature (< T2) the controls frequently used. the controls not used at a temperature state between T2 and T4 a pump pressure below start of de-stroking.
Example with the following conditions: • Motor running • Pump pressure between 60 bar and 300 bar, present at the slipper pad of piston #14 and the small area side of the positioning piston #13 • X1 = 34 bar (pump regulation pressure) • X3 = 15 bar (remote control pressure); Y17 energized and Y17a deenergized for pumps #2, #3 and #4. For pump #1, Y17 energized and Y126 de-energized • 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 (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 (9) position "a" and pressure balance valve (7), to the return oil line. The pump moves into ½ Q-max position, because the return oil flow through pressure balance valve (7) is restricted (due to its intermediate position), resulting in a pressure at the large area side of the positioning piston (13).
The pump moves into ½ Q-max position
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Section 7.0 Page 13
continued
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Main Pumps 7.1.3 Operating Principles, illustration (Z 21555) Cont'd: Destroking: (Pump moves from Q-max. into of Q-min. direction) When does the pumps start to destroke Motor running and hydraulic at normal operating temperature (> T2) and Service switch S155 deactivated and The hydraulic load is higher than the rated power of the motor ⇒ (The electronic pump regulation system will reduce the X1-pressure) or With pump pressure above ≈ 180 bar (Hydraulic constant regulation) (Constant X1-pressure of approximately 13 bar) Example with the following conditions: • Motor running • Pump pressure 180 bar adjustable at main relief valves, present at the slipper pad of piston #14 and the small area side of the positioning piston #13 • X1 = 13 bar (constant regulation pressure adjustable at pressure reducing valves 253.2) Change over valve (253.1) switched to hydraulic mode. • X3 = 45 bar (remote control pressure); Y17 energized and Y17a energized for pumps #2, #3 and #4. For pump #1, Y17 energized and Y126 de-energized • 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 (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 as the small area side, the operating pressure present on both sides, resulting in stronger force at the large area side, moving the pump in Q-min direction. The pump de-strokes until the forces at positioning piston #13 are balanced continued
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Main Pumps 7.1.3 Operating Principles, illustration (Z 21556) Cont'd: Pressure cut-off valve: (DR control valve, Pump moves into Q-min. position) When is the pressure cut-off valve active? Motor running and With pump pressure above ≈ 300 bar Example with the following conditions: Motor running Pump pressure 300 bar X1 = 34 bar (pump regulation pressure) X3 = 45 bar (remote control pressure) 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 Q-min 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 as the small area side, the operating pressure present on both sides, resulting in stronger force at the large area side, moving the pump in Qmin position. The pump moves into Q-min position
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Main Pumps 7.1.4 Checks / Adjustments Location of Adjustments Legend for , illustration (Z21557) (1) Remote control valve (2) Q-min. stop bolt (3) Pressure balance valve (4) Start of destroking (5) Power curve correction (6) Pressure cut-off valve (7) Q-max. stop bolt (8) Angle indicator The average length of the measurement "L" is: set crews (bolts ) location 1 2 3 4 5 6 7
)
length (mm) 13.8 26.9 8.0 8.1 ---6.0 34.4
• The measurement "L" is an orientation only if the adjustment is totally out of requirements. They must not be used for final adjustments. The detail for (5) shows the position of the housing edge and the edge of the eccentric set bolt. The example shows them in parallel position which is mostly not the case. The adjustment should never be altered.
Further information see next pages
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Main Pumps 7.1.4 Checks / Adjustments Pressure balance valve (∆ P 20bar), illustration (Z21558) 1.
Connect a 60 bar pressure gauge to check point MST.
2.
Eliminate "Idle Time Control" by using the switch ”S155” of the X2-panel, if necessary see Operation Manual.
3.
Unplug solenoid valve Y17a (this causes a remote control. pressure (X3) of approx. 15 bar)
4.
Start the motor.
5.
Gauge reading at MST must be 40 bar (20bar less than the pump support pressure of 60bar Loosen lock nut #4 and adjust with the set bolt #5
6.
Plug-on Y17a
7
Remove the pressure gauge and set S155 for "Idle Time" elimination into normal position.
continued
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Main Pumps 7.1.4 Checks / Adjustments Cont'd: Start of destroking(LR valve), illustration (Z21559) The reason of this check is to make sure, the pump starts destroking at an operating pressure of 180 bar with a pump regulation pressure X1 of 13 bar. 1. 2. 3. 4. 5. 6.
Connect a 400 bar pressure gauge to the pressure check point at the respective high pressure filter for the pumps being checked. Connect a 60 bar pressure gauge to pressure check point M5-1 at the control and filter panel (X1-pressure). Move the change over valve into position “Hydraulic” (constant regulation mode). Insert an Allen key into the angle indicator bolt (see illustration) for better visibility of the start of destroking. Start the motor and adjust at pressure reducing valve (253.2) the X1-pressure to 13 bar. Stall the hydraulic for the pump to be checked and alter the operating pressure with the MRV up and down 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 follow: a) Adjust with the MRV an operating pressure of 180 bar. b) Loosen lock nut #6 (Power control valve). c) Turn set bolt #7, so that the pump is still in Q-max. position, but just at the beginning of destroking. d) Tighten lock nut #6. 7.
Re-adjust the operating pressure at the MRV to 310+10 bar and the X1-
8.
pressure at the pressure reducing valve (253.2) to approx. 12bar. (For exact values refer to the final test report.) Remove Allen key and gauges. continued
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Main Pumps 7.1.4 Checks / Adjustments Cont'd: Pressure cut-off valve (DR control valve), illustration (Z21560) The reason of this check is to make sure that the pump is in Q-min. position at an operating pressure between 300 bar and 310 bar. 1. 2. 3.
4.
Connect a 400 bar pressure gauge to the pressure check point at the respective high pressure filter for the pumps being checked. Insert an Allen key into the angle indicator bolt (see illustration) for better visibility of the start of destroking. Start the motor, stall the hydraulic for the pump to be checked and alter the operating pressure with the MRV up and down between 280 and 310 bar. The angle indicator must indicate Q-min. position at a pressure of 300 bar shown at the gauge connected to the high pressure filter.
If readjustment is required proceed as follow: a) Loosen lock nut #8. b) Turn set bolt #9, so that the pump is in Q-min. position at the required value. c) Tighten lock nut #8. 5.
Re-adjust the operating pressure at the MRV to 310+10 bar
6.
Remove Allen key and gauges.
continued
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Main Pumps 7.1.4 Checks / Adjustments Cont'd: Q-max. and Q-min. stop bolt, illustration (Z21561) 1. 2. 3.
Unscrew box nut (10 or 14). Loosen the lock nut (11 or 13) Turn the stop (12 or 15) in or out until required length Length "X" or "Y" Tighten the lock nut and screw on box nut (12).
5.
ã
• Turning the Q-min. stop bolt too much out can cause serious damage to the pump. The pump moves over 0 (zero) position into the opposite drive direction: (suction line becomes pressure line and pressure line becomes suction line)
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Section 7.0 Page 21
Electronic Pump Regulation System
7.2.1 Electronic load limiting control - general, illustration (Z 22407b) The drive train of the excavator consists of an electric motor, several hydraulic pumps, which supply cylinders and hydraulic motors. The load limiting control ensures optimum use of the power required for the excavator under varying operating conditions and avoiding overload of the motors. Illustration Z22407b shows the principle of the electronic load limiting control. The MC7 (E32) processes the following input signals: • Voltage (Pin 47) from electronic signal rectifier (A32) • Current motor 1 (Pin 45) from electronic signal rectifier (A33) The MC7 (E32) processes the following output signals: • Signal value to control the proportional solenoid valve Y61-1 (Pin 28) Motor 1 • Switch signals (Pin 32 and 33), diagnostic of the MC7 (E32) The electric motor drives four variable displacement pumps by means of a PTOgearbox. Each pump is equipped with a hydraulic power controller (HPC). This controller limits the input torque of the pump to an adjusted command value (X1pressure, for start of destroking). The command value (X1-pressure) is present via proportional solenoid valves Y61-1 at the hydraulic power controllers of each pump.
)
• The auxiliary hydraulic pumps and other consumers can be operated without being directly affected by the load limiting control.
Function: The ESR-Module (A32) transforms an AC Voltage, which is proportional to the net voltage, into a proportional DC Voltage and transfers it into the MC7 (E32). The ESR-Module (A33) transforms an AC Voltage, which is proportional to the motor current, into a proportional DC Voltage and transfers it also into the MC7 (E32). These input signals are the information about the actual load to the motor and serves the MC7 (E32) The control algorithm of the load limiting control (MC7) always compares the actual required power with the rated power. With increasing load the motor torque will rise and in turn the required power. For this reason the electronic load limiting control will be initiated when the required power is higher than the rated power, i.e. the torque of the main pumps will be lowered (by reducing the X1-pressure) until the rated power is attained again.
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7.2.2 Electronic Power Module EPM – Module , illustration (Z 22624b) The EPM – Module transforms the 24 VDC battery voltage into positive/negative 15 VDC and positive 5 VDC which is the supply voltage for the ESR Modules. The LED’s besides the terminals are indicating the function.
Testing the EPM-Module, A31a +A31b Function check: Measure the supply voltage. (24 VDC; GND = 0 V). If the supply voltage is not there, check the supply cable and the circuit breaker. If the circuit breaker always trips there may be a short within the cables to the EPM Module or a short in the unit itself. If the supply voltage is ok. the Output Voltages have to be checked. Check pos. 15 VDC, neg. 15 VDC, 5 VDC to GND. If the supply voltages are not ok. the short circuit monitoring system of the EPM might be activated, therefore disconnect the cables at the terminals (+15 VDC, -15 VDC and +5 VDC) and repeat the voltage check. If now (with disconnected cables) the voltages are as they should be there is either a short within the cables or in the other modules itself. To determine the fault connect the entire modules in sequence. If the voltage is not ok., even when the cables are disconnected from the EPM, the EPM-Module is defect.
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7.2.2 Electronic Signal Rectifier ESR – Modules, illustration (Z 22625b) Function: The ESR-Module transforms an AC signal-voltage, which is proportional to the network voltage respectively the motor current, into a proportional DC Voltage and transfers it into the MC7. Testing the ESR-Module, A32 + A33 Testing the ESR input/output voltage For a transformer function test the AC-Input Voltage and the DC-Output Voltage must be tested.
W
• The potentiometer settings are under no circumstances allowed to be altered, because the setting is possible only with a HFGenerator and an Oscilloscope. • If the potentiometer set-positions have been altered, a new Module, with sealed potentiometers, must be ordered. Procedure: Same procedure for all three Modules 1.
Disconnect the wire from terminal 23 of the ESR Module.
2.
Start the motor and let it run without an extra load on it.
3.
Measure the AC-Voltage between the terminals 21 and 41 and record it.
4.
Measure the DC-Voltage between the terminals 23 and 11 and record it.
5.
The measured DC-Voltage must be 1/4 of the AC-Voltage. Example:
2.5 VDC ----------- = 0,25 (1 % plus/minus is ok) 10 VAC
Small variations are based on amplitude variations of the AC-Input voltage while measuring the DC-Output voltage. Greater variations denotes a faulty ESR Module. continued
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7.2.2 Electronic Signal Rectifier ESR – Modules, illustration (Z 22626c) Cont'd: The DC-Output Voltage (UaDC ) can be compared with a calculated Voltage Value. The calculation can be done with the ratios of the intermediate transformers given in the circuit diagram, and by the Voltmeter and Ammeter readings of the cab gauges.
)
• The picture shows a schematic design only and not the actual circuit diagram, the voltage- and current values may vary, therefore they are exemplary used.
With the below shown formulas the exact Output Voltages UaDC of an ESR can be calculated. Small variations are caused by the transformers. Variations greater than 20% denotes a faulty transformer.
1)
2)
Example for ESR 1: U ESR1 ----------------T1 x T2 x T3
4100 V --------------- = 2,463 VDC 41,6 x 10 x 4
Voltage
Example for ESR 2: I ESR2 -----------------
150 A -----------------
= 1,803 VDC
Current
(Condition
= 1,202 VDC
Current
(Condition
T1 x T2 x T3 I ESR2 ----------------T1 x T2 x T3
41,6 x 0.5 x 4 100 A ----------------41,6 x 0.5 x 4
The AC Input Voltage for an ESR-Module can be calculated with the same formula but without the value for T3. Example for ESR 2: I ESR2 ----------T1 x T2
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7.2.2 Microcontroller MC7, illustration (Z 21716) The MC7 microcontroller is used for the programmable control of a maximum of four proportional solenoids and two additional switching functions. As input signals, the microprocessor processes analog voltages in the 0V to 5V range and switching information. All inputs are protected against overvoltage and electrical interference. As output signals, the output stages of the MC7 deliver closed loop controlled currents for the connection of proportional solenoids. The analog voltage output is suitable for the simple forwarding of analog information to other electronic circuits. Characteristics • Closed loop control of solenoid currents, i.e. independent of voltage and temperature. • Pulse width modulated (PWM) solenoid currents for minimal hysteresis. • Internal buzzer for programmable monitoring of functions or errors. Setting and Display Facilities All calibration operations and the display of functions, faults and system variables are connected via the serial interface to the BB-3 control panel or to a PC running the BODEM software. MC7 - Unit Dimensions
Plug Contacts
8 junior power timer contacts 47 micro timer I contacts MC7 - Block Circuit Diagram
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7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22623a) The adjustment of the X1-pressure can be done with three different methods: A. With 24V supply to separating terminals at the X2-switch board or B. With the electronic service tool (EST) BB-3 connected to the serial interface X13 (located in the operators cab) or C. With a laptop, running the BODEM software, connected to the serial interface X13 (located in the operators cab)
)
• Procedure B and C should only be carried out by authorized personnel. [ Dealer or KMG-factory staff ] Because it is possible to influence the behavior of the pump regulation system. On the following pages are only the necessary setups described. If additional information is required, please contact KMG-Service department.
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7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22628d) Method A - X1-pressure adjustment with 24V supply to separating terminals at the X2-panel. Pre-conditions: Normal operating temperature, correct pilot pressure setting and the system must be free of air. 1. Make sure the change over valve (253.1) is in position “Electronic Pump Regulation” 2. Connect a pressure gauge to check point (M5.1), using a long pressure gauge hose to be able reading the pressure in front of the X2-panel. 3. Selection of adjusting mode: Turn the main key switch in on position and activate the adjusting mode as follows: Connect 24V, simultaneously to terminal 54 and 55 for 10 seconds, using two test leads and disconnect the voltage thereafter. 4. Selection of the motor and in turn the required proportional solenoid valve : With the main key switch still in on position, select the output terminal of proportional solenoid valve Y61-1 is directly selected. Since there is only one motor with one proportional solenoid valve installed, a 24V connection is not required. 5. Adjusting the X1-pressure: Start the motor. Read the pressure, required = 34± 0,5 bar If necessary increase the X1-pressure as follows: Connect 24V to terminal 54. • As long as voltage is supplied, the X1-pressure drops to zero. After interrupting the voltage supply, the gauge pointer will move slowly to the new present X1-pressure. • Example: Keeping voltage supply for two seconds , will increase the X1-pressure of approximately 1bar. • The adjusted value will be saved immediately and will be available after power off. 6. To decrease the X1-pressure connect 24V to terminal 55 and proceed as described under item 5, keeping voltage supply for two seconds , will decrease the X1-pressure of approximately 1bar. 7. After the adjustment is finished, remove the test leads and pressure gauge and turn the main key switch in OFF position to deactivate the adjusting mode. continued
)
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7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22629c) Cont'd: Method A - Demanded power adjustment Pre-conditions: Normal operating temperature, correct pilot pressure setting and the system must be free of air. 1. Connect pressure gauges to check points M11, M12, M13 and M14 at the high pressure filters. 2. Connect pressure a gauge to the X1 pressure check point M5.1. 3. Unplug solenoid valves Y6a and Y6b to ensure that the hydraulic oil cooler fans are running with maximum speed. 4. Start the motor. 5. Set the MRV individually to approx. 120 bar *, to prevent the motor from overloading during the adjustment. 6. Shift the three way cock valves (253.1) to position “Hydraulic (constant) Regulation Mode”. 7. Set the X1-pressure at pressure reducing valves (253.2) > 34 bar **, to ensure that the pumps remain in Q-max. flow position during the adjustment. 8. Apply max. load to all pumps (e.g. extend the bucket cylinders to the stop position until the hydraulic system stalls), and increase the pressure at all 4 MRV’s * equally until the motor draw ≅ 128 Ampere. (reading of text display) Expected system pressure at 128 Ampere = 4 times 172 bar (peak point). Record this pressure for other tests.
)
• If the operating pressure is higher respectively the motor current is lower than required there is probably not the full volume available. *Altering the MRV-Setting: − Remove dust cap (a). − Loosen lock nut (b). − Turning the set screw (c) cw the pressure will increase. − Turning the set screw ccw the pressure will decrease. **Altering the X1-Setting: − Loosen the lock nut (e). − Turning the set screw (f) cw the pressure will increase. − Turning the set screw ccw the pressure will decrease. continued
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7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22629c) Cont'd: Method A - Demanded power adjustment 9.
) 10. 11. 12. 13.
Store the demanded power (peak point) into the MC7 as follows: a) Activate the adjusting mode: Connect 24V, simultaneously to terminal 54 and 55 for 10 seconds, using test leads and disconnect the voltage thereafter. b) Select the demanded power adjusting mode (Motor 1): Connect 24V, simultaneously to terminal 50 and 52 permanent. c) Not used. d) Stall the hydraulic with the values of item 8 (Peak point) 4 times ≅ 172 bar (all pumps Qmax position and cooler fans with max. speed). => ≅ 128 Ampere (each motor) e) Save the actual measured power: Connect 24V to terminal 55 for 1 second and disconnect the voltage thereafter. • The actual measured power will be saved immediately as the demanded power Re-set the X1-pressure at pressure reducing valves (253.2) as recorded**. Shift the three way cock valves (253.1) to position “Electronic Regulation Mode” Reset the MRV’s to 310 bar+5bar , and remove the gauges. After the adjustments are finished, remove the test leads and pressure gauges, stop the motor and turn the main key switch in OFF position to deactivate the adjusting mode. *Altering the MRV-Setting: − Remove dust cap (a). − Loosen lock nut (b). − Turning the set screw (c) cw the pressure will increase. − Turning the set screw ccw the pressure will decrease. **Altering the X1-Setting: − Loosen the lock nut (e). − Turning the set screw (f) cw the pressure will increase. − Turning the set screw ccw the pressure will decrease. continued
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7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22636) Cont'd: Method A - PID - Factor adjustment to obtain the most efficient pump regulation characteristic. Pre-conditions: Normal operating temperature, correct pilot pressure setting and the system must be free of air. • With the PID-Factor adjustment (proportional, integral and differential factors) it is possible to influence the regulation dynamics. • The PID-Factor adjustment range is between 80% and 120% • The voltage at the analogue output (terminal 60) represents the actual adjusted value. (80% = 0VDC / 100% = 2,5VDC / 120%= 5VDC) • This factor is multiplied with all PID parameters.
) 1.
Jerky movements while lifting and swinging at the same time: a) Activate the adjusting mode: Connect 24V, simultaneously to terminal 54 and 55 for 10 seconds, using two test leads and disconnect the voltage thereafter. b) Select the PID-factor adjusting mode: Connect 24V, to terminal 50 permanent, using a test lead. c) Connect a multi-meter to terminal 60 (reading DC-voltage) and note down the value (represents the actual adjusted value) d) Reduce the voltage in steps of 250mV until the system works smoothly, by connecting 24V to terminal 55. (As close as possible to the boarder line)
2.
No Jerky movements: a) Activate the adjusting mode: Connect 24V, simultaneously to terminal 54 and 55 for 10 seconds, using two test leads and disconnect the voltage thereafter. b) Select the PID-factor adjusting mode: Connect 24V, to terminal 50 permanent, using a test lead. c) Connect a multi-meter to terminal 60 (reading DC-voltage) and note down the value (represents the actual adjusted value) e) Increase the voltage in steps of 250 mV until the system jerks, by connecting 24V to terminal 54. (As close as possible to the boarder line) f) Now reduce the voltage in steps of 250mV until the system works smoothly again, as described under item 1d.
3.
After the adjustments are finished, remove the test leads and multi-meter, stop the motors and turn the main key switch in OFF position to deactivate the adjusting mode.
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7.2 Electronic Pump Regulation System 7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22357f) Method B -
With the electronic service tool (EST) BB-3 connected to the serial interface X13 (located in the operators cab) Pre-conditions: Normal operating temperature, correct pilot pressure setting and the system must be free of air. 1. 2. 3. 4.
Make sure the respective change over valve is in position “Electronic Pump Regulation” Connect a pressure gauge to check point M5.1, using long pressure gauge hoses to be able reading the pressure inside the operators cab. Connect the electronic service tool (BB-3) to the data link adapter X13, with key switch (1S1) in OFF position. Turn key switch (1S1) in ON position: After switching on the power for the Control panel BB-3 the following functions are carried out and shown on the display: 4.1 Self-test and baud rate recognition: The BB-3 automatically recognizes the rate of data transmission from the MC electronics. 4.2 Identification: On recognition of the MC electronics the relevant software in the BB-3 will be started up. 4.3 Main menu: Initialization of remote control unit BB-3 is complete. One of the four main menu items can be selected using the given keys.
First screen (main menu) after connection and Key switch turned ON in German.
F1 F2 PROC TE ACH Language selection To change the language press simultaneously the buttons ALT + Clear
ALT
+
CLEAR
Config/Cal. Diagnostic Status Storage
The language selection menu appears
F1 F2 PROC TE ACH
Config/Cal. Diagnostic Status Storage continued
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7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22357f) Method B Cont'd: Language selection Press button 2
2
The language will change to English and the display show the main menu
1. 2. 3. 4.
Deutsch English - - - - -
One of the four main menu items can be selected using the given keys.
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7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22357f) Method B Adjustment mode SET 1 and SET 2 There are two adjustment modes (SET 1 and SET 2) integrated. SET 1 is for the main settings and SET 2 is only for the basic adjustments. SET 2 can only activated with a password. After start up of the MC7 with connected BB3 the adjustment modes SET 1 is active. Main display SET 1 Standard after start up F1 F2 PROC TE ACH
Main display SET 2 Only with password.
Config/Cal. Diagnostic Status Storage
F1’ F2 PROC TE ACH
Config/Cal. Diagnostic Status Storage
F1 F2 PROC TE ACH
Config/Cal. Diagnostic Status Storage
Change from SET 1 to SET 2: Press
F1
Press
ALT
SET 1 Config/Cal
+
in the same time
1 2 3 4
Demand Power Max current PID - Factor Error Lamp
A password will be requested Enter password (number: 570875)
1 Press
...
MENU
9
SET 2 to go back to the main menue
To switch back to SET 1 repeat this procedure or switch off and on the MC7.
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?: _
1 2 3 4
Configuration PID Control Low Voltage –––
F1’ F2 PROC TE ACH
Config/Cal. Diagnostic Status Storage
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7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22357f) Method B Number of motor selection: Activate adjustment mode SET 2 as described on page 33 Press
F1
Press
1
Configuration
Press
2
No of motors
Config/Cal
F1’ F2 PROC TE ACH
Config/Cal. Diagnostic Status Storage
1 2 3 4
Configuration PID Control Low Voltage –––
1 2 3 4
No of valves No of motors –– ––
Select desired number of motors
2
No of motors
use
1
motor
2
No of motors
2
motors
1 2 3 4
No valves No motors –– ––
Press
or
ENTER Acceptation
Press. 2 x MENU Return to sub menu.
F1’ F2 PROC TE ACH
Config/Cal. Diagnostic Status Storage
Save setting to the EEPROM of the MC7 as described at page 38.
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7.2.3 Checks and adjustments Micro-controller MC7, illustration (Z 22357f) Method B X1-Pressure (maximum current) Adjustment:
F1
Press
Config/Cal
If sub menu SET 2 is displayed change to sub menu SET 2 as described on page 33.
2
Press
Max current
F1 F2 PROC TE ACH
Config/Cal. Diagnostic Status Storage
1 2 3 4
Demand Power Max current PID - Factor Error Lamp
1 2 3 4
Valve Valve Valve Valve
Select desired valve Press or Press
1
Valve 1, Motor1
3
Valve 1, Motor2
Example Motor 1, Valve1 Start the respective motor. Do not load the motor. Check the X1-pressure with a pressure gauge and set it to the desired value by: pressing
Press
or
ENTER
Press. 2 x
Acceptation
MENU
Return to main menu
1 2 1 2
Mot. Mot. Mot. Mot.
1 1 2 2
1 Valve 1 Mot. 1 0 – 100±1 71
1 Valve 1 E1 0 – 100±1 78
1 2 3 4
Valve Valve Valve Valve
F1 F2 PROC TE ACH
1 2 1 2
Mot. Mot. Mot. Mot.
1 1 2 2
Config/Cal. Diagnostic Status Storage
Save setting to the EEPROM of the MC7 as described at page 38.
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7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22357f) Method B Demanded power adjustment: Press
F1
Config/Cal
If sub menu SET 2 is displayed change to sub menu SET 2 as described on page 33. Press
1
Configuration
1 2 3 4
Demand Power Max current PID-Factor Error Lamp
1 2 3 4
Set demand m. Set demand m. Demand power Demand power
Select desired demand power adjustment Press or Press
SET 1
1
demand power Motor1
2
demand power Motor2
1 2 1 2
1 Set demand m. 1 0–0±1 0
Example Motor 1 and Load respective Motor with max power Press ENTER
Selection
Start? ––> Cancel? ––>
Press ENTER
Starting
Function ended Saved Press
Press ENTER Confirm Press. 2 x
MENU
Return to main menu
F1 F2 PROC TE ACH
Config/Cal. Diagnostic Status Storage
Save setting to the EEPROM of the MC7 as described at page 38.
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7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22636a) Method B PID-Factor adjustment: Jerky movements while lifting with full bucket and swinging at the same time: Reduce jerking ⇒ Reduce the PID-Factor in short steps. To obtain the most efficient pump regulation characteristic adjust to the PID-Factor until the system jerks as close as possible to the boarder line. Press
F1
F1 F2 PROC TE ACH
Config/Cal
If sub menu SET 2 is displayed change to sub menu SET 1 as described on page 33. SET 1
Press
3
PID-Factor.
Press
1
PID-Factor.
Adjust the PID-Factor by pressing . or
Press
ENTER
Acceptation
and check the machine movement again if necessary repeat PID-Factor adjustment Press. 2 x
MENU
Return to main menu.
Config/Cal. Diagnostic Status Storage
1 2 3 4
Demand Power Max current PID-Factor Error Lamp
1 2 3 4
PID-Factor ––– ––– –––
1 PID-Factor 80–120±1% 100
1 2 3 4
PID-Factor ––– ––– –––
F1 F2 PROC TEACH
Config/Cal. Diagnostic Status Storage
Save setting to the EEPROM of the MC7 as described at page 38.
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7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22357f) Method B Storage all new settings to the MC7: This menu item permits storage of all edited parameters to the EEPROM of the MC electronics
Activate storage menu
F1 F2 PROC TE ACH
Save Params
1 2 3 4
Press ENTER
Store parameters
Teach? ––> Cancel? ––>
Press. MENU
Return to main menu.
1 2 3 4
Press TEACH
Press
1
Config/Cal. Diagnostic Status Storage
Save Params Default Rarams Get EEPROM Send EEPROM
Save Params Default Rarams Get EEPROM Send EEPROM
If all adjustments are correct and stored in the MC7, proceed as follow: • Stop the motors and turn key switch (S1) in OFF position • Disconnect the electronic service tool (BB-3) and the pressure gauges.
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7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22358f) Method C -
With a laptop computer and BODEM software connected to the serial interface X13 (located in the operators cab) Pre-conditions: Normal operating temperature, correct pilot pressure setting and the system must be free of air. Starting the program 1. Connect the laptop computer to the data link adapter X13, with key switch (1S1) in OFF position. 2. Make sure that the dongle is connected to the laptop computer. If not
3. Turn key switch (1S1) in ON position. 4. Start the computer. 5. Click on the Bodem - icon to start the program.
continued
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7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22358f) Method C Cont'd: Starting the program 6. The program starts (only) the first time with the Demo Version.
7. Open menu FILE → INTERFACE , select the required interface connection (Standard COM1), confirm with OK and leave the program.
8. Start the program again. Now the computer is connected to the Microcontroller. During uploading of the MC7 data to the PC a window opened and shows some hardware and software information.
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7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22358f) Method C Language selection Open menu FILE → Language , select the required language and confirm with OK .
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7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22358f) Method C Entering of the password:
)
• The password is only required to adjust the number of valves or engines and for fine tuning of special regulation parameters. All other adjustments are possible without the password.
Open menu Parameters and select Enter password. Write the correct password (570875) and confirm with OK.
)
• After entering a correct password and confirming with OK the BODEM software start a new upload from the MC7 memory to the PC.
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Section 7.0 Page 43
Electronic Pump Regulation System
7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22358f) Method C Number of Motor selection: Pre condition: The correct password was entered as described on page 42. Open Parameters and select Display / Edit Parameters. Then select in the left window Configuration. Now on the right side there are two pull down menus. Example: select for PC 8000 1 valve per motor and 2 Motors. Write new setting permanent to the MC7 EEPROM with Apply and confirm with OK.
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Main Hydraulic Pumps and Pump Regulation System 7.2
Section 7.0 Page 44
Electronic Pump Regulation System
7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22358f) Method C X1-Pressure (maximum current) Adjustment: Make sure the change over valve is in position “Electronic Pump Regulation” Connect a pressure gauge to check point M5.1, using a long pressure gauge hose to be able reading the pressure inside the operators cab. Open menu Parameters select Display/Edit parameters and Max current, start the motor without load and wait 30 sec. The X1-pressure will raise to the max. adjusted value. If necessary adjust the required pressure (according to the final test report or hydraulic diagram) with the slide bar. (Valve 1 Mot. 1 is the X1 pressure). Write new setting permanent to the MC7 EEPROM with Apply and confirm with OK.
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Main Hydraulic Pumps and Pump Regulation System 7.2
Section 7.0 Page 45
Electronic Pump Regulation System
7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22358f) Method C Demand power adjustment:
)
• The adjustment has to be carried out separately for each motor
Pre-conditions: Normal operating temperature, correct pilot pressure setting and the system must be free of air. Open menu Parameters and in the pull down window the menu point Display / Edit Parameters. Now the window with the demand power adjustment will be on screen.
Screen with password Screen without password. The demand power adjustment is possible in both modes. continued
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Main Hydraulic Pumps and Pump Regulation System 7.2
Section 7.0 Page 46
Electronic Pump Regulation System
7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22639f) Method C Cont'd: Demand power adjustment: Pre-conditions: Normal operating temperature, correct pilot pressure setting and the system must be free of air. 1. 2. 3. 4. 5. 6. 7. 8.
Connect pressure gauges to check points M11, M12, M13 and M14 at the high pressure filters. Connect a pressure gauge to the X1 pressure check point M5.1. Unplug solenoid valves Y6a and Y6b to ensure that the hydraulic oil cooler fans are running with maximum speed. Shift the three way cock valve (253.1) to position “Hydraulic (constant) Regulation Mode”. Start the motor. Set the MRV’s of main valve block I, II, III and IV individually to approx. 120 bar *, to prevent the motor from overloading during the test. Set the X1-pressure at pressure reducing valve (253.2) > 34 bar **, to ensure that the pumps remain in Q-max. flow position during the adjustment. Apply max. load to all pumps (e.g. extend the bucket cylinders to the stop position until the hydraulic system stalls), and increase the pressure at all 4 MRV’s * equally to the demand power pressure written in the final test report e.g. PC4000, S/N 08165 = 172 bar. Check the current drawn of the respective motor at this stage (reading of text display) Expected: approx. ~ 128 Ampere. Record this values for other tests. continued *Altering the MRV-Setting: − Remove dust cap (a). − Loosen lock nut (b). − Turning the set screw (c) cw the pressure will increase. − Turning the set screw ccw the pressure will decrease. **Altering the X1-Setting: − Loosen the lock nut (e). − Turning the set screw (f) cw the pressure will increase. − Turning the set screw ccw the pressure will decrease.
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Main Hydraulic Pumps and Pump Regulation System
Section 7.0 Page 47
7.2 Electronic Pump Regulation System 7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22639f) Method C Cont'd: Demand power adjustment: 9.
Select Execute of menu point Set demand m. 1 for motor 1 . Select Start to set the actual power as demand power. Confirm with OK. The new actual demand power will be only shown after a new upload of the MC7 settings. Exit the BODEM software and start again. 10. Stop the motor.
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Main Hydraulic Pumps and Pump Regulation System 7.2
Section 7.0 Page 48
Electronic Pump Regulation System 7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22636b) Method C PID Factor adjustment: This adjustment is required to obtain the most efficient pump regulation characteristic. Pre-conditions: Normal operating temperature, correct pilot pressure setting and the system must be free of air. • With the PID-Factor adjustment (proportional, integral and differential factors) it is possible to influence the regulation dynamics. • This factor is multiplied with all PID parameters. • Only one factor / adjustment for both motors
)
Open Parameters and select Display / Edit Parameters. Select in the left window PID control. Adjust now the PID-Factor with the slide bar or write direct the requested value to the window with the % value. Write new adjustment permanent to the MC7 EEPROM with Apply and confirm with OK. •
Jerky movements while lifting and swinging at the same time: Reduce the PID-Factor in short steps until the system works smoothly. (As close as possible to the boarder line) • No Jerky movements: 1. Increase the PID-Factor in short steps until the system jerks. (As close as possible to the boarder line) 2. Now reduce the PID-Factor in short steps until the system works smoothly again.
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Main Hydraulic Pumps and Pump Regulation System 7.3
Section 7.0 Page 49
Hydraulic Constant Regulation System 7.3.1. General The pilot pressure pump (8.1) delivers the oil through the pressure filter (33) to port A of the pressure relief valve (252.2) for limiting the pump support pressure X4 to 60 bar. By the function of pressure reducing valve (252.1), the X4 pressure of 60 bar is reduced to the pilot pressure X2 of 45 bar. The common X2 pressure will be reduced by the function of pressure reducing valves (253.2) to the necessary constant X1 pressure, to prevent the motor from overloading.
)
• For testing purposes the pump regulation system can be changed to the hydraulic operation mode. In case of a failure in the electronic regulation system the hydraulic operation mode can also be used for emergency operation. • The standard operation mode of the pump regulation system is the Electronic Operation Mode.
Legend for illustration (Z 22359a): (1 - 4) Main hydraulic pumps (8.1) Pilot pressure pumps (33) Pilot pressure filter unit (252.2) 60 bar pressure relief valve (252.1) 45 bar pressure reducing valve (253.1) Change over valve: "Electronic or Hydraulic pump regulation" (253.2) Pressure reducing valve: " Pump regulation pressure X1 at hydraulic pump regulation" (Hydraulic constant regulation mode) (Y61-1) Proportional solenoid valve: "Pump regulation pressure X1 at electronic pump regulation " (Standard operation mode) (Y130) Solenoid valve: " Pump regulation pressure X1 = 45 bar for pump #1" (fixed pump for swing) (Y131) Solenoid valve: " Pump regulation pressure X1 = 45 bar for pump #3" (fixed pump for swing)
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Main Hydraulic Pumps and Pump Regulation System 7.3
Section 7.0 Page 50
Hydraulic Constant Regulation System 7.3.2. X1-pressure adjustment (constant-pressure), illustration (Z 22639f) Connect pressure gauges to check points M11, M12, M13 and M14 at the high pressure filters. 2. Connect a pressure gauge to the X1 pressure check point M5.1 . 3. Unplug solenoid valves Y6a and Y6b to ensure that the hydraulic oil cooler fans are running with maximum speed. 4. Shift the three way cock valves (253.1) to position “Hydraulic (constant) Regulation Mode”. 5. Start the motor. 6. Set the MRV’s of main valve block I, II, III and IV individually to approx. 120 bar *, to prevent the motor from overloading during the test. 7. Set the X1-pressure at pressure reducing valve (253.2) to approx. 11 bar ** 8. Apply max. load to all pumps (e.g. extend the bucket cylinders to the stop position until the hydraulic system stalls), and increase the pressure at all 4 MRV’s * equally to 260 bar. Check the current drawn of the motor at this stage (reading of text display) Expected approx. 120 Ampere. Record this values for other tests. 9. Shift the three way cock valves (253.1) to position “Electronic regulation“. 10. Reset the MRV’s * to 310 bar+5bar , stop the motor and remove the gauges. 1.
*Altering the MRV-Setting: − Remove dust cap (a). − Loosen lock nut (b). − Turning the set screw (c) cw the pressure will increase. − Turning the set screw ccw the pressure will decrease. **Altering the X1-Setting: − Remove dust cap (d). − Loosen the lock nut (e). − Turning the set screw (f) cw the pressure will increase. − Turning the set screw ccw the pressure will decrease.
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Operating Hydraulic
Section 8.0 Page 1
Table of contents section 8.0 Section 8.0
Page Operating Hydraulic General 8.1
Hydraulic for the attachment cylinder FSA and BHA
8.2
Hydraulic for the swing circuit
8.3
Hydraulic for the travel circuit
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Operating Hydraulic
8.0
Section 8.0 Page 2
General Overall view of the Hydraulic system, illustration (Z 21955): (1 – 4) (5) (6) (7) (8) (9) (10) (11)
Main pumps High pressure filters Main control blocks Distributor manifold Attachment cylinders Swing motors Rotary joint Travel motors
General information The control blocks, the piping to the distributor manifold and the connecting hoses to the attachment are different between the Backhoe Attachment (BHA) and the Front Shovel Attachment (FSA). If a conversion is required, contact the service department for further information. Function:
)
• •
Study together with the circuit diagram. The following numbering refers to the hydraulic circuit diagram.
Each main pump (1 to 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 leaves the block at port T and returns via return oil pipes, return oil collector manifold (107), return oil pipes (L6 and L7), return oil collector tube (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: - sufficient oil supply for all anticavitation valves - and that sufficient oil is forced through the oil coolers. If a control lever or pedal is actuated, pilot pressure oil moves the spools of the control blocks, directing the oil flow from the main pumps to one side of the user (either cylinders or motors). From the opposite side of the user the oil returns to the control block and from there via the return oil circuit back into the tank. Each circuit is provided with one MRV (also called primary valve, at least one SRV (also called secondary valve) and at least one flow restrictor. continued PC4000-6-E_#08165_Sec_8-0_rev0.doc
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Operating Hydraulic
8.0
Section 8.0 Page 3
General Cont'd: Floating function of boom and stick cylinders FSA: illustration (Z 22005): The Excavator operates automatically with the float position for boom and stick activated. That means the lowering movement of boom and stick is always done in the float position. For deactivation of the float position, two push buttons are installed: a) S95 in the right joy stick (E19) for the Boom function b) S95a in the left joy stick (E20) for the Stick function Press the respective button and keep it depressed as long as the float position shall be deactivated. When releasing the button the float position is activated again. Function: The additionally installed single control blocks (Y132, Y133,Y134 and Y135) connect the piston side of the cylinders with the rod side and also with the tank: Y132, Y133 and Y134 for the Stick cylinders Y135 for the Boom cylinders In normal operation mode (i.e. float position) the pilot pressure oil is directed via Y132a, Y133a and Y135a 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 Y132a, Y133a and Y135a to the main control blocks. The solenoid valves Y132a, Y133a and Y135a (4/2-directional control valves) are controlled by push button S95 and S95a. Boom: S95 ON ⇒ Y135a ON ⇒ Float position deactivated S95 OFF ⇒ Y135a OFF ⇒ Float position activated S95a ON ⇒ Y132a + Y133a ON ⇒ S95a OFF ⇒ Y132a + Y133a OFF ⇒
Stick:
)
•
Float position deactivated Float position activated
Due to the two different operation modes for lowering, the lowering speed of boom and stick cylinder must be adjusted twice: A. Float position deactivated B. Float position activated
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Hydraulic for the Attachment Cylinders
Section 8.1 Page 1
Table of contents section 8.1 Section 8.1
Page Hydraulic for the attachment cylinder FSA and BHA 8.1.1 Electric / Hydraulic Flowchart Boom raising 8.1.2 Electric / Hydraulic Flowchart Boom lowering 8.1.3 Electric / Hydraulic Flowchart Stick extending 8.1.4 Electric / Hydraulic Flowchart Stick retracting 8.1.5 Electric / Hydraulic Flowchart Bucket filling (curl) 8.1.6 Electric / Hydraulic Flowchart Bucket emptying 8.1.7 Electric / Hydraulic Flowchart Clam opening 8.1.8 Electric / Hydraulic Flowchart Clam closing 8.1.9 Checks and adjustments of the Main Relief Valves (Primary valves) 8.1.10 Checks and adjustments of the Service Line Relief Valves (Secondary valves) Boom cylinder piston side FSA + BHA Boom cylinder piston rod side FSA + BHA Stick cylinder piston side FSA Stick cylinder piston side BHA Stick cylinder piston rod side FSA Stick cylinder piston rod side BHA Bucket cylinder piston side FSA Bucket cylinder piston side BHA Bucket cylinder piston rod side FSA Bucket cylinder piston rod side BHA Clam cylinder piston rod side FSA Clam cylinder piston side FSA 8.1.11 Checks and adjustments for the lowering speed. General: Flow Restrictors and single control blocks Boom cylinder FSA (Float position activated / deactivated) Boom cylinder BHA Stick cylinder FSA (Float position activated / deactivated) Stick cylinder BHA Bucket cylinder FSA Bucket cylinder BHA Clam cylinder
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2+3 4+5 6+7 8+9 10 + 11 12 + 13 14 15 16 + 17
18 + 19 20 + 21 22 + 23 24 + 25 26 + 27 28 + 29 30 + 31 32 + 33 34 + 35 36 + 37 38 39 40 41 + 42 43 44 + 45 46 47 48 49
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8.1 2
E19 D32
gn
YD X2
482
X2
481
E49
5
Bucket
7
2
6
(boom up)
10
K58
-10V
K76
4
8
K78
12
(left crawler)
6 10
(right crawler)
5
5
2
5
5
A10b
A10
A10a
A10c
7-8
7-8
7-8
7-8 3
X2
3
235
X2
234
3
207
206
X2
3
226
X2
225
251
250
15 14.2 Y73
2
3
4
1
2
5
6
3
4
7
8
5
6
1
2
3
4
5
6
b1
b2
b3
b1
b2
b3
b4
I B1 B2
B3
II B1
B2
B3
B4
A1
A2
A3
A4
a1
a2
a3
a4
Y69
A1 a1
A2 a2
Y33
95 1
A3 a3
A
B
2
C
D
E
F
14.3
14.1
1
Y40
Y63
b1
b2
III B1 B2
A1
A2
a1 G
H
J
K
a2 L
Y76 Y20
Y46
1
2
3
4
5
6
b3
b1
b2
b3
b4
B3
IVB1
B2
B3
B4
A3
A1
A2
A3
A4
a1
a2
a3
a4
a3 M
N
O
P
42
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Hydraulic for the Attachment Cylinders
Section 8.1 Page 2
8.1.1 Electric / Hydraulic flowchart “ Boom raising ” FSA Legend for illustration (Z 21956): (E19) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (YD) Direction (axis) of joy stick (-10V) Signal voltage (Maximum) (gn) Colour code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E49) Ramp time module (A10) Amplifier module – Boom (A10a) Amplifier module – Boom (A10b) Amplifier module – Boom up or Bucket when not raising the boom. (A10c) Amplifier module – Boom (K58) Relay – pilot control: Contacts 6 / 10 only closed while lifting the boom. (K76) Relay – pilot control: Contacts 8 / 12 only closed while traveling the left crawler. (K78) Relay – pilot control: Contacts 6 / 10 only closed while traveling the right crawler. (14.1 – 14.3) Remote control valves (15) Remote control valves (95) Remote control valves (Y63 + Y69) Proportional solenoid valve (Y73 + Y76) Proportional solenoid valve (Y20 + Y40) Directional solenoid valve (Y33 + Y46) Directional solenoid valve (I – IV) Main control blocks I – IV (42) Distributor manifold Electrical signal flow. Signal voltage of joy stick (E19) arrives via ramp time module (E49) at terminal 5 of the amplifier modules (A10 to A10c) and further to the proportional and directional solenoid valves of the remote control blocks (14.1, 14.2, 14.3, and 15). 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 arrives via distributor manifold (42) at the hydraulic cylinders.
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Hydraulic for the Attachment Cylinders
Section 8.1 Page 3
8.1.1 Electric / Hydraulic flowchart “ Boom raising ” BHA Legend for illustration (Z 21957b): (E19) Control lever (Joy stick) (YD) Direction (axis) of joy stick (-10V) Signal voltage (Maximum) (gn) Colour code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E49 – E49c) Ramp time module (A10) Amplifier module – Boom (A10a) Amplifier module – Boom (A10b) Amplifier module – Boom (A10c) Amplifier module – Boom (K76) Relay – pilot control: Contacts 8 / 12 only closed while traveling the left crawler. (K78) Relay – pilot control: Contacts 6 / 10 only closed while traveling the right crawler. (14.1 – 14.3) Remote control valves (15) Remote control valves (Y63 + Y69) Proportional solenoid valve (Y73 + Y76) Proportional solenoid valve (Y40) Directional solenoid valve (Y33 + Y46) Directional solenoid valve (I – IV) Main control blocks I – IV (42) Distributor manifold Electrical signal flow. Signal voltage of joy stick (E19) arrives via ramp time modules (E49 to E49c) at terminal 5 of the amplifier modules (A10 to A10c) and further to the proportional and directional solenoid valves of the remote control blocks (14.1, 14.2, 14.3, and 15). 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 arrives via distributor manifold (42) at the hydraulic cylinders.
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8.1 4 YC
+10V
E19 D32
gn
X2
482
X2
481
E49
5
Bucket
7
K58
2
6
K76
10
(boom up)
4
8
K78
12
(left crawler)
6 10
(right crawler)
5
5
2
5
5
A10b
A10
A10a
A10c
7-8 9
7-8 9
7-8 9
7-8
X2 207 215
X2 226 227
X2F
8
3
9
X2 251 256
15 14.2 Y73 1
2
3
4
5
6
2
3
4
1
2
5
6
3
4
7
8
5
6
95 1
14.3
14.1
1
2
Y41
Y63
Y76 Y21
Y47
1
2
3
4
5
6
Y135a b1
b2
b3
I B1 B2
B3
A1 a1
A2 a2
b1
b2
b3
b4
II B1 B2
B3
B4
A3 a3
A
B
b1
A1
A2
A3
A4
a1
a2
a3
a4
C
D
E
F
b2
III B1 B2
A1
A2
a1 G
H
J
K
a2 L
b1
b3
B3
A3 a3 M
N
O
b2
b3
b4
IVB1 B2
B3
B4
A1
A2
A3
A4
a1
a2
a3
a4
P
42
Y135 P
A
T B
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Hydraulic for the Attachment Cylinders
Section 8.1 Page 4
8.1.2 Electric / Hydraulic flowchart “ Boom lowering ” FSA Legend for illustration (Z 21958): (E19) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (YC) Direction (axis) of joy stick (+10V) Signal voltage (Maximum) (gn) Colour code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E49) Ramp time module (A10) Amplifier module – Boom (A10a) Amplifier module – Boom (A10b) Amplifier module – Boom up or Bucket (A10c) Amplifier module – Boom (K58) Relay – pilot control: Contacts 6 / 10 only closed while lifting the boom. (K76) Relay – pilot control: Contacts 8 / 12 only closed while traveling the left crawler. (K78) Relay – pilot control: Contacts 6 / 10 only closed while traveling the right crawler. (14.1 – 14.3) Remote control valves (15) Remote control valves (95) Remote control valves (Y63) Proportional solenoid valve (Y73 + Y76) Proportional solenoid valve (Y21 + Y41) Directional solenoid valve (Y47) Directional solenoid valve (Y135a) Directional solenoid valve (Y135) Single control block (I – IV) Main control blocks I – IV (42) Distributor manifold Electrical signal flow. Signal voltage of joy stick (E19) arrives via ramp time module (E49) at terminal 5 of the amplifier modules (A10, A10a and A10c) and further to the proportional and directional solenoid valves of the remote control blocks (14.1, 14.3, and 15). 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 (Y135). 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 (42) through the main control blocks (II and III) and single control block (Y135) back to tank.
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Hydraulic for the Attachment Cylinders
Section 8.1 Page 5
8.1.2 Electric / Hydraulic flowchart “ Boom lowering ” BHA Legend for illustration (Z 21959a): (E19) Control lever (Joy stick) (YC) Direction (axis) of joy stick (+10V) Signal voltage (Maximum) (gn) Colour code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E49 – E49c) Ramp time module (A10) Amplifier module – Boom (A10a) Amplifier module – Boom (A10b) Amplifier module – Boom up or Bucket (A10c) Amplifier module – Boom (K76) Relay – pilot control: Contacts 8 / 12 only closed while traveling the left crawler. (K78) Relay – pilot control: Contacts 6 / 10 only closed while traveling the right crawler. (14.1 – 14.3) Remote control valves (15) Remote control valves (Y63 + Y69) Proportional solenoid valve (Y73 + Y76) Proportional solenoid valve (Y21 + Y41) Directional solenoid valve (Y32 + Y47) Directional solenoid valve (I – IV) Main control blocks I – IV (42) Distributor manifold Electrical signal flow. Signal voltage of joy stick (E19) arrives via ramp time modules (E49 to E49c) at terminal 5 of the amplifier modules (A10 to A10c) and further to the proportional and directional solenoid valves of the remote control blocks (14.1, 14.2, 14.3, and 15). 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 arrives via distributor manifold (42) at the hydraulic cylinders.
.
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8.1 6 YC
+10V
E20 D32
gn
X2
480
X2
479
E48
5 7
Bucket fill
1
5
K74 (Stick out)
K78
9
K76
5
2
5
7-8 9 5
A9
X2 237 236
X2 254 253
7-8 9 X2 210 203
14.2
Y68
A8a
10
9
2
3
4
5
6
14.3
15 Y30 Y71
1
2
3
4
5
6
7
8
Y74
b3
b1
b2
b3
b4
I B1 B2
B3
II B1
B2
B3
B4
A1
A2
A3
A4
A1
a1
a2
a3
a4
a1
A1 a1
A2 a2
A3 a3
A
B
C
D
E
F
b1
G
H
J
K
L
1
2
3
4
5
6
Y42
Y37
b2
b1
12
6
(left crawler)
1
8
(right crawler)
A8 7-8
4
M
N
O
b2
b3
b4
IVB1 B2
B3
B4
A2
A3
A4
a2
a3
a4
P
42
Y132 P
A
T B
Y133
Y134
P
P
A
T B
A
T B
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Hydraulic for the Attachment Cylinders
Section 8.1 Page 6
8.1.3 Electric / Hydraulic flowchart “ Stick extending ” FSA Legend for illustration (Z 21960): (E20) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (YC) Direction (axis) of joy stick (+10V) Signal voltage (Maximum) (gn) Colour code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E48) Ramp time module (A8) Amplifier module – Stick (A8a) Amplifier module – Stick (A9) Amplifier module – Stick extend or Bucket fill (K74) Relay – pilot control: Contacts 5 / 9 only closed while extending the stick. (K76) Relay – pilot control: Contacts 6 / 10 only closed while traveling the left crawler. (K78) Relay – pilot control: Contacts 8 / 12 only closed while traveling the right crawler. (14.2 + 14.3) Remote control valves (15) Remote control valves (Y68) Proportional solenoid valve (Y71 + Y74) Proportional solenoid valve (Y30 + Y37) Directional solenoid valve (Y42) Directional solenoid valve (Y132 – Y134) Single control blocks (closed ports while extending the stick) (I, II + IV) Main control blocks I – IV (42) Distributor manifold Electrical signal flow. Signal voltage of joy stick (E20) arrives via ramp time module (E48) at terminal 5 of the amplifier modules (A8, A8a and A9) and further to the proportional and directional solenoid valves of the remote control blocks (14.2, 14.3, and 15). 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 arrives via distributor manifold (42) at the hydraulic cylinders.
PC4000-6-E_#08165_Sec_8-1_rev0.doc
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8.1 7
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Hydraulic for the Attachment Cylinders
Section 8.1 Page 7
8.1.3 Electric / Hydraulic flowchart “ Stick extending ” BHA Legend for illustration (Z 21961a): (E20) Control lever (Joy stick) (YC) Direction (axis) of joy stick (+10V) Signal voltage (Maximum) (gn) Colour code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E48) Ramp time module (A8) Amplifier module – Stick (A8a) Amplifier module – Stick (A11) Amplifier module – Stick (K76) Relay – pilot control: Contacts 7 / 11 only closed while traveling the left crawler. (K78) Relay – pilot control: Contacts 8 / 12 only closed while traveling the right crawler. (14.2 + 14.3) Remote control valves (15) Remote control valves (Y68) Proportional solenoid valve (Y72 + Y74) Proportional solenoid valve (Y30 + Y38) Directional solenoid valve (Y42) Directional solenoid valve (I, II + IV) Main control blocks I, II + IV (42) Distributor manifold Electrical signal flow. Signal voltage of joy stick (E20) arrives via ramp time module (E48) at terminal 5 of the amplifier modules (A8, A8a and A11) and further to the proportional and directional solenoid valves of the remote control blocks (14.2, 14.3, and 15). 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 arrives via distributor manifold (42) at the hydraulic cylinders.
PC4000-6-E_#08165_Sec_8-1_rev0.doc
02.03.05
8.1 8
E20 D32
gn
YD X2
480
X2
479
E48
-10V
5 7
Bucket fill
1
5
K74 (Stick out)
K78
9
K76
5
2
5
A8a
10
7-8 3
3
5
A9
14
X2F 51
7-8 9
14.2
Y68
2
3
4
5
6
Y31 Y74
Y132a b3
I B1 B2
B3
A2 a2
1
2
3
4
5
6
Y43
Y133a
b1 b2
a1
52
14.3
1
A1
12
6
(left crawler)
X2F 10
8
(right crawler)
A8 7-8
4
99.5
A3 a3
A
B
C
D
E
F
G
H
J
K
L
M
N
O
b1
b2
b3
b4
IVB1
B2
B3
B4
A1
A2
A3
A4
a1
a2
a3
a4
P
42
Y132 P
A
T B
PC4000-6-E_#08165_Sec_8-1_rev0.doc
Y133
Y134
P
P
A
T B
A
T B
02.03.05 Z 21962
Hydraulic for the Attachment Cylinders
Section 8.1 Page 8
8.1.4 Electric / Hydraulic flowchart “ Stick retracting ” FSA Legend for illustration (Z 21962): (E20) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (YD) Direction (axis) of joy stick (-10V) Signal voltage (Maximum) (gn) Colour code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E48) Ramp time module (A8) Amplifier module – Stick (A8a) Amplifier module – Stick (A9) Amplifier module – Stick extend or Bucket fill (K74) Relay – pilot control: Contacts 5 / 9 only closed while extending the stick. (K76) Relay – pilot control: Contacts 6 / 10 only closed while traveling the left crawler. (K78) Relay – pilot control: Contacts 8 / 12 only closed while traveling the right crawler. (14.2 + 14.3) Remote control valves (99.5) Check valve (necessary for combined operation of travel right and retracting the stick) (Y68 + Y74) Proportional solenoid valve (Y31 + Y43) Directional solenoid valve (Y132a + Y132a) Directional solenoid valve (Y42) Directional solenoid valve (Y132 – Y134) 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 joy stick (E20) arrives via ramp time module (E48) at terminal 5 of the amplifier modules (A8, A8a) and further to the proportional and directional solenoid valves of the remote control blocks (14.2 and 14.3). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the single control blocks (Y132, Y133 and Y134). 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 (42) through the single control blocks (Y132, Y133 and Y134) back to tank.
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8.1 9
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Hydraulic for the Attachment Cylinders
Section 8.1 Page 9
8.1.4 Electric / Hydraulic flowchart “ Stick retracting ” BHA Legend for illustration (Z 21963a): (E20) Control lever (Joy stick) (YD) Direction (axis) of joy stick (-10V) Signal voltage (Maximum) (gn) Colour code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E48) Ramp time module (A8) Amplifier module – Stick (A8a) Amplifier module – Stick (A11) Amplifier module – Stick (K76) Relay – pilot control: Contacts 7 / 11 only closed while traveling the left crawler. (K78) Relay – pilot control: Contacts 8 / 12 only closed while traveling the right crawler. (14.2 + 14.3) Remote control valves (15) Remote control valves (Y68) Proportional solenoid valve (Y72 + Y74) Proportional solenoid valve (Y31 + Y39) Directional solenoid valve (Y43) Directional solenoid valve (I, II + IV) Main control blocks I, II + IV (42) Distributor manifold Electrical signal flow. Signal voltage of joy stick (E20) arrives via ramp time module (E48) at terminal 5 of the amplifier modules (A8, A8a and A11) and further to the proportional and directional solenoid valves of the remote control blocks (14.2, 14.3, and 15). 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 arrives via distributor manifold (42) at the hydraulic cylinders.
PC4000-6-E_#08165_Sec_8-1_rev0.doc
02.03.05
8.1 10
E19
XB -10V ws/gn
D32
X2
477
X2
476 10
K50
6
2
9
(Hydr. oil not overheat )
5
1
K58 (Boom up )
10
9
K71
6
2
1
(Bucket fill )
5
K74
9
K58
6
2
K76
(Boom up )
1
(Bucket fill )
(Stick out )
2
6
K78
10
(left crawler)
10
K71
5
7 11
(right crawler)
5
5
3
5
5
A10b
A9
A9a
A9b
7-8 3
7-8 3
7-8 3
7-8 3
X2 235 230
X2 210 205
X2 224 220
X2 252 249
15 14.2 Y69
Y32
1
2
3
4
5
6
7
8
1
2
3
4
5
6
b1
b2
b3
b1
b2
b3
b4
I B1 B2
B3
II B1
B2
B3
B4
A1
A2
A3
A4
a1
a2
a3
a4
A1 a1
A2 a2
Y71
A3 a3
A
B
C
D
E
F
Y36
Y64
b1
b2
III B1 B2
A1
A2
a1 G
14.3
14.1
H
J
K
a2 L
1
2
3
4
5
6
Y22
Y75
1
2
3
4
5
6
Y44
b3
b1
b2
b3
b4
B3
IVB1
B2
B3
B4
A3
A1
A2
A3
A4
a1
a2
a3
a4
a3 M
N
O
P
42
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Z 21965
Hydraulic for the Attachment Cylinders
Section 8.1 Page 10
8.1.5 Electric / Hydraulic flowchart “ Bucket filling ” FSA Legend for illustration (Z 21965): (E19) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (XB) Direction (axis) of joy stick (-10V) Signal voltage (Maximum) (ws / gn) Colour code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (A9) Amplifier module – Bucket (A9a) Amplifier module – Bucket (A9b) Amplifier module – Bucket (A10b) Amplifier module – Boom up or Bucket when not raising the boom. (K50) Relay – pilot control: Bucket cut-off Contacts 6 / 10 only closed if the hydraulic oil is overheated. (K58) Relay – pilot control: Contacts 6 / 10 and 5 / 9 only closed while lifting the boom. (K71) Relay – pilot control: Contacts 6 / 10 and 5 / 9 only closed while filling the bucket. (K74) Relay – pilot control: Contacts 5 / 9 only closed while extending the stick. (K76) Relay – pilot control: Contacts 6 / 10 only closed while traveling the left crawler. (K78) Relay – pilot control: Contacts 7 / 11 only closed while traveling the right crawler. (14.1 – 14.3) Remote control valves (15) Remote control valves (Y63 + Y64) Proportional solenoid valve (Y71 + Y75) Proportional solenoid valve (Y22 + Y32) Directional solenoid valve (Y36 + Y44) Directional solenoid valve (I – IV) Main control blocks I – IV (42) Distributor manifold Electrical signal flow. Signal voltage of joy stick (E19) arrives via relay contacts at terminal 5 of the amplifier modules (A9, A9a, A9b and A10b) and further to the proportional and directional solenoid valves of the remote control blocks (14.1, 14.2, 14.3, and 15). 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 arrives via distributor manifold (42) at the hydraulic cylinders.
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8.1 11
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Hydraulic for the Attachment Cylinders
Section 8.1 Page 11
8.1.5 Electric / Hydraulic flowchart “ Bucket filling ” BHA Legend for illustration (Z 21966a): (E19) Control lever (Joy stick) (XB) Direction (axis) of joy stick (-10V) Signal voltage (Maximum) (ws / gn) Colour code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (A9) Amplifier module – Bucket (A9a) Amplifier module – Bucket (A9b) Amplifier module – Bucket (K50) Relay – pilot control: Bucket cut-off Contacts 6 / 10 only closed if the hydraulic oil is overheated. (K76) Relay – pilot control: Contacts 6 / 10 only closed while traveling the left crawler. (K78) Relay – pilot control: Contacts 7 / 11 only closed while traveling the right crawler. (14.1 + 14.3) Remote control valves (15) Remote control valves (Y64) Proportional solenoid valve (Y71 + Y75) Proportional solenoid valve (Y22 + Y44) Directional solenoid valve (Y36) Directional solenoid valve (II, III + IV) Main control blocks II, III + IV (42) Distributor manifold Electrical signal flow. Signal voltage of joy stick (E19) arrives via relay contacts at terminal 5 of the amplifier modules (A9, A9a, A9b) and further to the proportional and directional solenoid valves of the remote control blocks (14.1, 14.3, and 15). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks . Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (II, III, IV) and arrives via distributor manifold (42) at the hydraulic cylinders.
PC4000-6-E_#08165_Sec_8-1_rev0.doc
02.03.05
8.1 12
E19 XA +10V
ws/gn
X2
477
X2
476
D32
10
K50
6
2
9
(Hydr. oil not overheat )
5
1
K58 (Boom up )
9
K71
5
1
(Bucket fill )
K78
3
7 11
(right crawler)
5
5
A9a
A9b
7-8
7-8 9
9
X2 252 247
X2 224 218
14.3
14.1 1
Y64
b1 b2
A2
a1 A
B
C
D
E
F
G
H
J
K
3
4
5
6
Y23
b1
b3
III B1 B2
A1
2
a2 L
B3
b2
IVB1 B2
A3 a3 M
Y75
N
O
1
2
3
4
5
6
Y45
b3
b4
B3
B4
A1
A2
A3
A4
a1
a2
a3
a4
P
42
PC4000-6-E_#08165_Sec_8-1_rev0.doc
02.03.05 Z 21967
Hydraulic for the Attachment Cylinders
Section 8.1 Page 12
8.1.6 Electric / Hydraulic flowchart “ Bucket emptying ” FSA Legend for illustration (Z 21967): (E19) Control lever (Joy stick) (D32) Time relay – Pilot control: Neutral position monitoring (XA) Direction (axis) of joy stick (+10V) Signal voltage (Maximum) (ws / gn) Colour code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (A9a) Amplifier module – Bucket (A9b) Amplifier module – Bucket (K50) Relay – pilot control: Bucket cut-off Contacts 6 / 10 only closed if the hydraulic oil is overheated. (K58) Relay – pilot control: Contacts 5 / 9 only closed while lifting the boom. (K71) Relay – pilot control: Contacts 5 / 9 only closed while filling the bucket. (K78) Relay – pilot control: Contacts 7 / 11 only closed while traveling the right crawler. (14.1 + 14.3) Remote control valves (Y64 + Y75) Proportional solenoid valve (Y23 + Y45) Directional solenoid valve (III + IV) Main control blocks III + IV (42) Distributor manifold Electrical signal flow. Signal voltage of joy stick (E19) arrives via relay contacts at terminal 5 of the amplifier modules (A9a and A9b) and further to the proportional and directional solenoid valves of the remote control blocks (14.1 and 14.3). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks . Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (II, III, IV) and arrives via distributor manifold (42) at the hydraulic cylinders.
PC4000-6-E_#08165_Sec_8-1_rev0.doc
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8.1 13
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Hydraulic for the Attachment Cylinders
Section 8.1 Page 13
8.1.6 Electric / Hydraulic flowchart “ Bucket emptying ” BHA Legend for illustration (Z 21968a): (E19) Control lever (Joy stick) (XA) Direction (axis) of joy stick (+10V) Signal voltage (Maximum) (ws / gn) Colour code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (A9) Amplifier module – Bucket (A9a) Amplifier module – Bucket (A9b) Amplifier module – Bucket (K50) Relay – pilot control: Bucket cut-off Contacts 6 / 10 only closed if the hydraulic oil is overheated. (K76) Relay – pilot control: Contacts 6 / 10 only closed while traveling the left crawler. (K78) Relay – pilot control: Contacts 7 / 11 only closed while traveling the right crawler. (14.1 + 14.3) Remote control valves (15) Remote control valves (Y64) Proportional solenoid valve (Y71 + Y75) Proportional solenoid valve (Y23 + Y45) Directional solenoid valve (Y37) Directional solenoid valve (II, III + IV) Main control blocks II, III + IV (42) Distributor manifold Electrical signal flow. Signal voltage of joy stick (E19) arrives via relay contacts at terminal 5 of the amplifier modules (A9, A9a, A9b) and further to the proportional and directional solenoid valves of the remote control blocks (14.1, 14.3, and 15). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks . Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (II, III, IV) and arrives via distributor manifold (42) at the hydraulic cylinders.
PC4000-6-E_#08165_Sec_8-1_rev0.doc
02.03.05
8.1 14
E24 D32
-10V rs
X2 484
K76
3
7 11
(left crawler)
5
A11 7-8 X2
3
209 214
15
Y72
b1
b2
II B1 B2
A
B
b3
b4
B3
B4
A1
A2
A3
A4
a1
a2
a3
a4
C
D
E
F
G
H
1
2
3
4
5
6
7
8
J
Y39
K
L
M
N
O
P
42
Z 21970 PC4000-6-E_#08165_Sec_8-1_rev0.doc
02.03.05
Hydraulic for the Attachment Cylinders
Section 8.1 Page 14
8.1.7 Electric / Hydraulic flowchart “ Clam opening ” FSA Legend for illustration (Z 21970): (E24) Control pedal (D32) Time relay – Pilot control: Neutral position monitoring (-10V) Signal voltage (Maximum) (rs) Colour code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (A11) Amplifier module – Clam (K76) Relay – pilot control: Contacts 7 / 11 only closed while traveling the left crawler. (15) Remote control valves (Y72) Proportional solenoid valve (Y39) Directional solenoid valve (II) Main control block II (42) Distributor manifold Electrical signal flow. Signal voltage of control pedal (E24) arrives via relay contact at terminal 5 of the amplifier module (A11) and further to the proportional and directional solenoid valves of the remote control block (15). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure port of the main control block . Hydraulic oil flow Now the oil of the main pump flows through the main control block (II) and arrives via distributor manifold (42) at the hydraulic cylinders.
PC4000-6-E_#08165_Sec_8-1_rev0.doc
02.03.05
8.1 15
E23 D32
+ 10V rs
X2 484
K76
3
7 11
(left crawler)
5
A11 7-8 9 X2
209 208
15
Y72
b1
b2
II B1 B2
A1 a1 A
B
C
A2 a2 D
b3
b4
B3
B4
A3
A4
a3 E
1
2
3
4
5
6
7
8
Y38
a4 F
G
H
J
K
L
M
N
O
P
42
Z 21971 PC4000-6-E_#08165_Sec_8-1_rev0.doc
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Hydraulic for the Attachment Cylinders
Section 8.1 Page 15
8.1.8 Electric / Hydraulic flowchart “ Clam closing ” FSA Legend for illustration (Z 21971): (E23) Control pedal (D32) Time relay – Pilot control: Neutral position monitoring (+10V) Signal voltage (Maximum) (rs) Colour code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (A11) Amplifier module – Clam (K76) Relay – pilot control: Contacts 7 / 11 only closed while traveling the left crawler. (15) Remote control valves (Y72) Proportional solenoid valve (Y38) Directional solenoid valve (II) Main control block II (42) Distributor manifold Electrical signal flow. Signal voltage of control pedal (E23) arrives via relay contact at terminal 5 of the amplifier module (A11) and further to the proportional and directional solenoid valves of the remote control block (15). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure port of the main control block . Hydraulic oil flow Now the oil of the main pump flows through the main control block (II) and arrives via distributor manifold (42) at the hydraulic cylinders.
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8.1 16
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Hydraulic for the Attachment Cylinders
Section 8.1 Page 16
8.1.9 Checks and adjustments of the Main Relief Valves (MRV), illustration (Z 21972): There are four main relief valves (primary valves) installed, one in each main control block, to limit the maximum pump supply line pressure (operating pressure).
Pump circuit I
MRV in control block I
Check point M14
Pump circuit II
II
M12
Boom
Pump circuit III Pump circuit IV
III IV
M11 M13
Swing Boom Bucket
Functions FSA Swing Clam
Bucket filling Boom raise Bucket filling Stick extending Bucket Stick
Stick Travel Boom Travel
Each Pump circuit can be checked or adjusted individually by selecting one function of the required pump circuit. Checking: 1. Connect the gauge to the required check point M11 - M14. 2. Start engine and let it run with max. speed. 3. Extend or retract the cylinder to the stop position for the valve being tested until the hydraulic system stalls. 4. Read the pressure. Required: 310 + 5 bar If the pressure is not correct, carry out a comparative measurement with an other function, in order to avoid wrong measuring results caused by wrongly adjusted SRV or other defects in the system. Adjusting: 1. Remove protective cap (a). 2. Loosen lock nut (b). 3. Turn set screw (c) -clockwise to increase pressure, Counterclock wise to decrease pressure. 4. Tighten lock nut (b) and install cap (a).
)
• It is important that the valve body of MRV-valve and the SRV-valve are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.
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8.1 17
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Section 8.1 Page 17
Hydraulic for the Attachment Cylinders
8.1.9 Checks and adjustments of the Main Relief Valves (MRV), illustration (Z 21972): There are four main relief valves (primary valves) installed, one in each main control block, to limit the maximum pump supply line pressure (operating pressure).
Pump circuit I Pump circuit II Pump circuit III Pump circuit IV
MRV in control block I II III IV
Check point M14 M12 M11 M13
Functions BHA Swing Boom Stick Swing Boom Bucket
Boom Bucket Bucket Stick
Stick Travel Boom Travel
Each Pump circuit can be checked or adjusted individually by selecting one function of the required pump circuit. Checking: 1. Connect the gauge to the required check point M11 - M14. 2. Start engine and let it run with max. speed. 3. Extend or retract the cylinder to the stop position for the valve being tested until the hydraulic system stalls. 4. Read the pressure. Required: 310 + 5 bar If the pressure is not correct, carry out a comparative measurement with an other function, in order to avoid wrong measuring results caused by wrongly adjusted SRV or other defects in the system. Adjusting: 1. Remove protective cap (a). 2. Loosen lock nut (b). 3. Turn set screw (c) -clockwise to increase pressure, Counterclock wise to decrease pressure. 5. Tighten lock nut (b) and install cap (a).
)
• It is important that the valve body of MRV-valve and the SRV-valve are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.
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8.1 18
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Hydraulic for the Attachment Cylinders 8.1.10
Section 8.1 Page 18
Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 21973): Boom cylinder “Piston side” FSA + BHA There are six service line relief valves (secondary valves) installed, four at the distributor manifold (42), one in main control block II and one in block IV, to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV’s is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve SRV 66.5 SRV 66.7 SRV 65.4 SRV 70.13 SRV 70.2 SRV 70.1 MRV circuit II MRV circuit IV 1. 2. 3. 4.
)
Press. check point M12 (High pressure filter) M13 (High pressure filter) M26.2 M26.1 M16.2 M16.1 M12 (High pressure filter) M13 (High pressure filter)
Location Control block II, section A1 Control block IV, section A1 Manifold (42) section O Manifold (42) section O Manifold (42) section B Manifold (42) section B Control block II Control block IV
Connect gauges to all above listed check points. Start engine and let it run with max. speed. Extend the boom cylinder to the stop position until the hydraulic system stalls. Increase slowly the pump supply line pressure, by turning in set screws (3) of both MRV’s in control block II and IV, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar. • Since the piston side of the boom cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Even when the gauges show the required pressure it is possible that one or more valves have a higher setting. • To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of both MRV’s.
5. 6. 7. 8.
PC4000-6-E_#08165_Sec_8-1_rev0.doc
Remove protective cap (1) of MRV. Loosen lock nut (2). Turn set screw (3) of both MRV’s ½ turn further in, the gauge pointers will remain at the value shown at item #4 (350 bar + 5 bar). Tighten lock nut (2) and install cap (1). continued 02.03.05
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Section 8.1 Page 19
Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 21973): Cont'd: Boom cylinder “Piston side” FSA +BHA 9. Adjust all six SRV’s equally, until all gauges show a pressure of 360 bar. Adjust in steps of ¼ turn of set screw (3) in the following sequence: 70.1 Ì 70.2 Ì 70.13 Ì 65.4 Ì 66.5 Ì 66.7 Remove protective cap (1) of SRV’s. Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). 10. Reduce the pressure, at SRV- 70.1 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges.
) 11.
ã 12.
)
•
Now all gauges will show the same value of 350 bar, but only SRV-70.1 has the correct setting. Proceed with the other valves in the same manner in the following sequence: 70.2 Ì 70.13 Ì 65.4 Ì 66.5 Ì 66.7
• Strong pulsation of the return line hoses, indicates deviation in opening pressure of SRV’s and must be avoided. Repeat the adjusting procedure until the oil returns well-balanced via all six service line relief valves. Reset the MRV’s to 310 bar + 5 bar after the check / adjustment is finished, as follows: Remove protective cap (1). Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). • It is important that the valve body of MRV-valve and the SRV-valve are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.
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Section 8.1 Page 20
Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 21974): Boom cylinder “Piston rod side” FSA +BHA There are service line relief valves (secondary valves) installed in the main control blocks, to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV’s is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve SRV 66.3 SRV 66.8 MRV circuit III MRV circuit IV 1. 2. 3. 4.
)
Press. check point M11 (High pressure filter) M13 (High pressure filter) M11 (High pressure filter) M13 (High pressure filter)
Location Control block III, section B3 Control block IV, section B1 Control block III Control block IV
Connect gauges to all above listed check points. Start engine and let it run with max. speed. Retract the boom cylinder to the stop position until the hydraulic system stalls. Increase slowly the pump supply line pressure, by turning in set screws (3) of MRV’s in the control blocks, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar. • If the piston rod side of the boom cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Even when the gauges show the required pressure it is possible that one or more valves have a higher setting. • To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of both MRV’s.
5. 6. 7. 8.
Remove protective cap (1) of MRV. Loosen lock nut (2). Turn set screw (3) of both MRV’s ½ turn further in, the gauge Tighten lock nut (2) and install cap (1). continued
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Section 8.1 Page 21
Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 21974): Cont'd: Boom cylinder “Piston rod side” FSA +BHA 9. Adjust all SRV’s equally, until all gauges show a pressure of 360 bar. Adjust in steps of ¼ turn of set screw (3). Remove protective cap (1) of SRV’s. Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). 10. Reduce the pressure, at SRV- 68.8 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges.
) 11.
ã 12.
)
•
Now all gauges will show the same value of 350 bar, but only SRV-68.8 has the correct setting. Proceed with the other valves in the same manner.
• Strong pulsation of the return line hoses, indicates deviation in opening pressure of SRV’s and must be avoided. Repeat the adjusting procedure until the oil returns well-balanced via all service line relief valves. Reset the MRV’s to 310 bar + 5 bar after the check / adjustment is finished, as follows: Remove protective cap (1). Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). • It is important that the valve body of MRV-valve and the SRV-valve are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.
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Section 8.1 Page 22
Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 21977): Stick cylinder “Piston side” FSA There are four service line relief valves (secondary valves) installed, three at the distributor manifold (42) and one in main control block IV, to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV’s is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve SRV 66.11 SRV 65.2 SRV 70.8 SRV 70.9 MRV circuit IV 1. 2. 3. 4.
)
Press. check point M13 (High pressure filter) M20 M21.1 M21.2 M13 (High pressure filter)
Location Control block IV, section A3 Manifold (42) section G Manifold (42) section J Manifold (42) section J Control block IV
Connect gauges to all above listed check points. Start engine and let it run with max. speed. Extend the stick cylinder to the stop position until the hydraulic system stalls. Increase slowly the pump supply line pressure, by turning in set screws (3) of the MRV in control block IV, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar. • Since the piston side of the stick cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Even when the gauges show the required pressure it is possible that one or more valves have a higher setting. • To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of the MRV’s.
5. 6. 7. 8.
PC4000-6-E_#08165_Sec_8-1_rev0.doc
Remove protective cap (1) of MRV. Loosen lock nut (2). Turn set screw (3) of the MRV ½ turn further in, the gauge pointers will remain at the value shown at item #4 (350 bar + 5 bar). Tighten lock nut (2) and install cap (1). continued
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Section 8.1 Page 23
Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 21977): Cont'd: Stick cylinder “Piston side” FSA 9. Adjust all four SRV’s equally, until all gauges show a pressure of 360 bar. Adjust in steps of ¼ turn of set screw (3) in the following sequence: 65,2 Ì 70.8 Ì 70.9 Ì 66.11 Remove protective cap (1) of SRV’s. Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). 10. Reduce the pressure, at SRV- 65.2 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges.
) 11.
ã 12.
)
•
Now all gauges will show the same value of 350 bar, but only SRV-65.2 has the correct setting. Proceed with the other valves in the same manner in the following sequence: 70.8 Ì 70.9 Ì 66.11
• 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 four service line relief valves. Reset the MRV to 310 bar + 5 bar after the check / adjustment is finished, as follows: Remove protective cap (1). Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). • It is important that the valve body of MRV-valve and the SRV-valve are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.
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Section 8.1 Page 24
Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 21978): Stick cylinder “Piston side” BHA There are three service line relief valves (secondary valves) installed, in main control blocks I, II and IV, to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV’s is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve SRV 66.4 SRV 66.6 SRV 66.12 MRV circuit I MRV circuit II MRV circuit IV 1. 2. 3. 4.
)
Press. check point M14 (High pressure filter) M13 (High pressure filter) M12 (High pressure filter) M14 (High pressure filter) M13 (High pressure filter) M12 (High pressure filter)
Location Control block I, section B3 Control block II, section B2 Control block IV, section B3 Control block I Control block II Control block IV
Connect gauges to all above listed check points. Start engine and let it run with max. speed. Retract the stick cylinder to the stop position until the hydraulic system stalls. Increase slowly the pump supply line pressure, by turning in set screws (3) of the MRV’s in the control blocks, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar. • Since the piston side of the stick cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Even when the gauges show the required pressure it is possible that one or more valves have a higher setting. • To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of the MRV’s.
5. 6. 7. 8.
PC4000-6-E_#08165_Sec_8-1_rev0.doc
Remove protective cap (1) of MRV. Loosen lock nut (2). Turn set screw (3) of the MRV’s ½ turn further in, the gauge pointers will remain at the value shown at item #4 (350 bar + 5 bar). Tighten lock nut (2) and install cap (1). continued
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Section 8.1 Page 25
Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 21978): Cont'd: Stick cylinder “Piston side” BHA 9. Adjust all three SRV’s equally, until all gauges show a pressure of 360 bar. Adjust in steps of ¼ turn of set screw (3) in the following sequence: 66,4 Ì 66.6 Ì 66.12 Remove protective cap (1) of SRV’s. Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). 10. Reduce the pressure, at SRV- 66.4 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges.
) 11.
ã 12.
)
•
Now all gauges will show the same value of 350 bar, but only SRV-66.4 has the correct setting. Proceed with the other valves in the same manner in the following sequence: 66.6 Ì 66.12
• Strong pulsation of the return line hoses, indicates deviation in opening pressure of SRV’s and must be avoided. Repeat the adjusting procedure until the oil returns well-balanced via all three service line relief valves. Reset the MRV to 310 bar + 5 bar after the check / adjustment is finished, as follows: Remove protective cap (1). Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). • It is important that the valve body of MRV-valve and the SRV-valve are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.
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Section 8.1 Page 26
Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 21979): Stick cylinder “Piston rod side” FSA There are two service line relief valves (secondary valves) installed, in main control blocks I and IV, to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV’s is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve SRV 66.4 SRV 66.12 MRV circuit I MRV circuit IV 1. 2. 3. 4.
)
Press. check point M14 (High pressure filter) M13 (High pressure filter) M14 (High pressure filter) M13 (High pressure filter)
Location Control block I, section B3 Control block IV, section B3 Control block I Control block IV
Connect gauges to all above listed check points. Start engine and let it run with max. speed. Retract the stick cylinder to the stop position until the hydraulic system stalls. Increase slowly the pump supply line pressure, by turning in set screws (3) of MRV’s in the control blocks, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar. • Since the piston rod side of the stick cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Even when the gauges show the required pressure it is possible that one or more valves have a higher setting. • To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of both MRV’s.
5. 6. 7. 8.
Remove protective cap (1) of MRV. Loosen lock nut (2). Turn set screw (3) of both MRV’s ½ turn further in, the gauge Tighten lock nut (2) and install cap (1). continued
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Section 8.1 Page 27
Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 21979): Cont'd: Stick cylinder “Piston rod side” FSA 9. Adjust both SRV’s equally, until all gauges show a pressure of 360 bar. Adjust in steps of ¼ turn of set screw (3) in the following sequence: 66,4 Ì 66.12 Remove protective cap (1) of SRV’s. Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). 10. Reduce the pressure, at SRV- 66.4 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges.
) 11.
ã 12.
)
•
Now all gauges will show the same value of 350 bar, but only SRV-66.4 has the correct setting. Proceed with the other valves in the same manner.
• Strong pulsation of the return line hoses, indicates deviation in opening pressure of SRV’s and must be avoided. Repeat the adjusting procedure until the oil returns well-balanced via all service line relief valves. Reset the MRV’s to 310 bar + 5 bar after the check / adjustment is finished, as follows: Remove protective cap (1). Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). • It is important that the valve body of MRV-valve and the SRV-valve are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.
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Section 8.1 Page 28
Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 21980a): Stick cylinder “Piston rod side” BHA There are three service line relief valves (secondary valves) installed at the distributor manifold (42), to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV’s is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve SRV 70.8 SRV 70.9 SRV 70.10 MRV circuit I 1. 2. 3. 4.
)
Press. check point M21.1 M21.2 M22 M14 (High pressure filter)
Location Manifold (42) section J Manifold (42) section J Manifold (42) section K Control block I
Connect gauges to all above listed check points. Start engine and let it run with max. speed. Retract the stick cylinder to the stop position until the hydraulic system stalls. Increase slowly the pump supply line pressure, by turning in set screws (3) of MRV’s in the control blocks, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar. • Since the piston rod side of the stick cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Even when the gauges show the required pressure it is possible that one or more valves have a higher setting. • To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of both MRV’s.
5. 6. 7. 8.
Remove protective cap (1) of MRV. Loosen lock nut (2). Turn set screw (3) of both MRV’s ½ turn further in, the gauge Tighten lock nut (2) and install cap (1). continued
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Section 8.1 Page 29
Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 21980a): Cont'd: Stick cylinder “Piston rod side” BHA 9. Adjust all SRV’s equally, until all gauges show a pressure of 360 bar. Adjust in steps of ¼ turn of set screw (3) in the following sequence: 70.8 Ì 70.9Ì 70.10 Remove protective cap (1) of SRV’s. Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). 10. Reduce the pressure, at SRV- 70.8 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges.
) 11.
ã 12.
)
•
Now all gauges will show the same value of 350 bar, but only SRV-70.8 has the correct setting. Proceed with the other valves in the same manner in the following sequence: 70.9 Ì 70.10
• Strong pulsation of the return line hoses, indicates deviation in opening pressure of SRV’s and must be avoided. Repeat the adjusting procedure until the oil returns well-balanced via all service line relief valves. Reset the MRV’s to 310 bar + 5 bar after the check / adjustment is finished, as follows: Remove protective cap (1). Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). • It is important that the valve body of MRV-valve and the SRV-valve are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.
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Section 8.1 Page 30
Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 21997): Bucket cylinder “Piston side” FSA There are six service line relief valves (secondary valves) installed, four at the distributor manifold (42), one in main control block III and one in block IV, to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV’s is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve SRV 66.1 SRV 66.9 SRV 65.1 SRV 70.4 SRV 70.12 SRV 65.3 MRV circuit III MRV circuit IV 1. 2. 3. 4.
)
Press. check point M11 (High pressure filter) M13 (High pressure filter) M17.1 M17.2 M24 M25 M11 (High pressure filter) M13 (High pressure filter)
Location Control block III, section A2 Control block IV, section A2 Manifold (42) section C Manifold (42) section C Manifold (42) section M Manifold (42) section N Control block III Control block IV
Connect gauges to all above listed check points. Start engine and let it run with max. speed. Extend the Bucket cylinder to the stop position until the hydraulic system stalls. Increase slowly the pump supply line pressure, by turning in set screws (3) of both MRV’s in control block III and IV, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar. • Since the piston side of the bucket cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Even when the gauges show the required pressure it is possible that one or more valves have a higher setting. • To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of both MRV’s.
5. 6. 7. 8.
PC4000-6-E_#08165_Sec_8-1_rev0.doc
Remove protective cap (1) of MRV. Loosen lock nut (2). Turn set screw (3) of both MRV’s ½ turn further in, the gauge pointers will remain at the value shown at item #4 (350 bar + 5 bar). Tighten lock nut (2) and install cap (1). continued 02.03.05
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Section 8.1 Page 31
Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 21997): Cont'd: Bucket cylinder “Piston side” FSA 9. Adjust all six SRV’s equally, until all gauges show a pressure of 360 bar. Adjust in steps of ¼ turn of set screw (3) in the following sequence: 65.1 Ì 70.4 Ì 70.12 Ì 65.3 Ì 66.1 Ì 66.9 Remove protective cap (1) of SRV’s. Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). 10. Reduce the pressure, at SRV- 65.1 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges.
) 11.
ã 12.
)
•
Now all gauges will show the same value of 350 bar, but only SRV-65.1 has the correct setting. Proceed with the other valves in the same manner in the following sequence: 70.4 Ì 70.12 Ì 65.3 Ì 66.1 Ì 66.9
• Strong pulsation of the return line hoses, indicates deviation in opening pressure of SRV’s and must be avoided. Repeat the adjusting procedure until the oil returns well-balanced via all six service line relief valves. Reset the MRV’s to 310 bar + 5 bar after the check / adjustment is finished, as follows: Remove protective cap (1). Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). • It is important that the valve body of MRV-valve and the SRV-valve are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.
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Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 21998): Bucket cylinder “Piston side” BHA There are three service line relief valves (secondary valves) installed at the distributor manifold (42), to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV’s is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve SRV 70.3 SRV 70.4 SRV 70.12 MRV circuit III 1. 2. 3. 4.
)
Press. check point M17.1 M17.2 M24 M11 (High pressure filter)
Location Manifold (42) section C Manifold (42) section C Manifold (42) section M Control block III
Connect gauges to all above listed check points. Start engine and let it run with max. speed. Extend the Bucket cylinder to the stop position until the hydraulic system stalls. Increase slowly the pump supply line pressure, by turning in set screws (3) of MRV in control block III, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar. • Since the piston side of the bucket cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Even when the gauges show the required pressure it is possible that one or more valves have a higher setting. • To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of both MRV’s.
5. 6. 7. 8.
PC4000-6-E_#08165_Sec_8-1_rev0.doc
Remove protective cap (1) of MRV. Loosen lock nut (2). Turn set screw (3) of both MRV’s ½ turn further in, the gauge pointers will remain at the value shown at item #4 (350 bar + 5 bar). Tighten lock nut (2) and install cap (1). continued
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Section 8.1 Page 33
Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 21998): Cont'd: Bucket cylinder “Piston side” BHA 9. Adjust all three SRV’s equally, until all gauges show a pressure of 360 bar. Adjust in steps of ¼ turn of set screw (3) in the following sequence: 70.3 Ì 70.4 Ì 70.12 Remove protective cap (1) of SRV’s. Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). 10. Reduce the pressure, at SRV- 70.3 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges.
) 11.
ã 12.
)
•
Now all gauges will show the same value of 350 bar, but only SRV-70.3 has the correct setting. Proceed with the other valves in the same manner in the following sequence: 70.4 Ì 70.12
• Strong pulsation of the return line hoses, indicates deviation in opening pressure of SRV’s and must be avoided. Repeat the adjusting procedure until the oil returns well-balanced via all three service line relief valves. Reset the MRV’s to 310 bar + 5 bar after the check / adjustment is finished, as follows: Remove protective cap (1). Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). • It is important that the valve body of MRV-valve and the SRV-valve are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.
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Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 21999): Bucket cylinder “Piston rod side” FSA There are two service line relief valves (secondary valves) installed, one in main control block III and one in block IV, to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV’s is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve SRV 66.2 SRV 66.10 MRV circuit III MRV circuit IV 1. 2. 3. 4.
)
Press. check point M11 (High pressure filter) M13 (High pressure filter) M11 (High pressure filter) M13 (High pressure filter)
Location Control block III, section B2 Control block IV, section B2 Control block III Control block IV
Connect gauges to all above listed check points. Start engine and let it run with max. speed. Retract the bucket cylinder to the stop position until the hydraulic system stalls. Increase slowly the pump supply line pressure, by turning in set screws (3) of MRV’s in the control blocks, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar. • Since the piston rod side of the bucket cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Even when the gauges show the required pressure it is possible that one or more valves have a higher setting. • To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of the MRV’s.
5. 6. 7. 8.
Remove protective cap (1) of MRV. Loosen lock nut (2). Turn set screw (3) of both MRV’s ½ turn further in, the gauge Tighten lock nut (2) and install cap (1). continued
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Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 21999): Cont'd: Bucket cylinder “Piston rod side” FSA 9. Adjust both SRV’s equally, until all gauges show a pressure of 360 bar. Adjust in steps of ¼ turn of set screw (3) in the following sequence: 66,2 Ì 66.10 Remove protective cap (1) of SRV’s. Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). 10. Reduce the pressure, at SRV- 66.2 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges.
) 11.
ã 12.
)
•
Now all gauges will show the same value of 350 bar, but only SRV-66.2 has the correct setting. Proceed with the other valve in the same manner.
• Strong pulsation of the return line hoses, indicates deviation in opening pressure of SRV’s and must be avoided. Repeat the adjusting procedure until the oil returns well-balanced via all service line relief valves. Reset the MRV’s to 310 bar + 5 bar after the check / adjustment is finished, as follows: Remove protective cap (1). Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). • It is important that the valve body of MRV-valve and the SRV-valve are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.
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Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22000): Bucket cylinder “Piston rod side” BHA There are three service line relief valves (secondary valves) installed at the distributor manifold (42), to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV’s is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve SRV 70.5 SRV 70.7 SRV 70.11 MRV circuit III 1. 2. 3. 4.
)
Press. check point M18 M20 M23 M11 (High pressure filter)
Location Manifold (42) section D Manifold (42) section G Manifold (42) section L Control block III
Connect gauges to all above listed check points. Start engine and let it run with max. speed. Extend the Bucket cylinder to the stop position until the hydraulic system stalls. Increase slowly the pump supply line pressure, by turning in set screws (3) of MRV in control block III, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar. • Since the piston rod side of the bucket cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Even when the gauges show the required pressure it is possible that one or more valves have a higher setting. • To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of the MRV.
5. 6. 7. 8.
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Remove protective cap (1) of MRV. Loosen lock nut (2). Turn set screw (3) of both MRV’s ½ turn further in, the gauge pointers will remain at the value shown at item #4 (350 bar + 5 bar). Tighten lock nut (2) and install cap (1). continued
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Section 8.1 Page 37
Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22000): Cont'd: Bucket cylinder “Piston rod side” BHA 9. Adjust all three SRV’s equally, until all gauges show a pressure of 360 bar. Adjust in steps of ¼ turn of set screw (3) in the following sequence: 70.5 Ì 70.7 Ì 70.11 Remove protective cap (1) of SRV’s. Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). 10. Reduce the pressure, at SRV- 70.5 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges.
) 11.
ã 12.
)
•
Now all gauges will show the same value of 350 bar, but only SRV-70.5 has the correct setting. Proceed with the other valves in the same manner in the following sequence: 70.7 Ì 70.11
• Strong pulsation of the return line hoses, indicates deviation in opening pressure of SRV’s and must be avoided. Repeat the adjusting procedure until the oil returns well-balanced via all three service line relief valves. Reset the MRV’s to 310 bar + 5 bar after the check / adjustment is finished, as follows: Remove protective cap (1). Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). • It is important that the valve body of MRV-valve and the SRV-valve are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.
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Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22001): Clam cylinder “Piston rod side” FSA There is one service line relief valve (secondary valve) installed at the distributor manifold (42), to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve SRV 70.6 MRV circuit II 1. 2. 3.
Connect gauges to the above listed check points. Start engine and let it run with max. speed. Retract the clam cylinder (open the bucket) to the stop position until the hydraulic system stalls. Increase slowly the pump supply line pressure, by turning in set screws (3) of MRV in control block II, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar. If necessary correct the adjustment as follows: Remove protective cap (1) of MRV. Loosen lock nut (2). Turn set screw (3) of the MRV ½ turn further in, the gauge pointers will remain at the value shown at item #4 (350 bar + 5 bar). Tighten lock nut (2) and install cap (1). Reduce the pressure, at SRV- 70.6 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges. Reset the MRV to 310 bar + 5 bar after adjustment is finished, as follows: Remove protective cap (1). Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1).
4.
5. 6. 7. 8. 9.
10.
)
Press. check point Location M19 Manifold (42) section E M12 (High pressure filter) Control block II
• It is important that the valve body of MRV-valve and the SRV-valve are firmly tightened (with 300 Nm). Otherwise, the internal sealing is not properly which results in loud flow noises and wrong adjustments.
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Section 8.1 Page 39
Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22002): Clam cylinder “Piston side” FSA There are two service line relief valves (secondary valves) installed, one at distributor manifold (42) and one in main control block II, to limit the maximum possible pressure in the service line when closing the bucket. To avoid damages at the clam shell, due to improper operation, the SRV’s should be adjusted in a way that the pressure is just sufficient to keep the bucket closed. Valve SRV 18 SRV 45 1. 2. 3.
Press. check point Location M18 Manifold (42) section K M12 (High pressure filter) Control block II
Connect gauges to all above listed check points. Start engine and let it run with max. speed. Raise the attachment and bring the back wall of the bucket in a horizontal position. Depress pedal “bucket closing” until the hydraulic system stalls. Release the pedal back to neutral position. The bucket must stay closed. That means the clam-cylinders must not be retracted by the force (weight) of the clam shell. Adjust the SRV’s as follows: Remove protective cap (1) of SRV’s. Loosen lock nut (2).
4.
Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). Adjust both SRV’s equally, until the gauges show a pressure of 220 bar. Now reduce the pressure at both SRV’s equally in steps of 5 bar until the bucket opens by gravity. Read the pressure and increase the setting with 10%, to compensate the weight of material stuck at the clam shell.
)
•
•
Since the piston side of the clam cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. For standard buckets the pressure is 150 bar, reinforced or with heavy wear package attached, the pressure maybe raised up to 200 bar.
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Section 8.1 Page 40
Checks and adjustments of the lowering speed, illustration (Z 22033): General On excavators equipped with Face Shovel Attachment (FSA) there are two different operation modes for lowering the boom and stick: I.
Float position activated the lowering speed has to be adjusted by altering the stroke limiters (4) of the single control blocks (3).
II.
Float position deactivated the lowering speed has to be adjusted by altering the flow restrictors (throttle valves) at the distributor manifold (42).
On excavators equipped with Backhoe Attachment (BHA) the lowering speed has to be adjusted at the flow restrictors only.
Purpose of the Flow Restrictors: • To avoid an interruption of the pump delivery. • To provide an uniform and smooth cylinder travel. • To limit the return oil flow through the control block to the maximum permissible volume. Checks and Adjustments: • Activate service switch S151 (located in the cab base) during the checks and adjustments, to ensure that the main pumps are in Qmax position. •
•
)
Standard test method is measuring the total cylinder running time by using a stop watch. If it is impossible to move the cylinder over the whole way, mark a distance of one meter with permanent pen P/N 621 566 40 on the piston rod and measure the time for only one meter movement. Adjust the Restrictor as follows: - For easy turning of set screw (2) lower the attachment to ground, stop motor and allow pressure equalising by moving the joy sticks several times. - Loosen the lock nut (1) and turn the bolt (2) 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. During commissioning, a throttle adjustment has to be carried out on all machines. For safety reasons, the throttle valves are completely screwed in before each machine is leaving the factory.
For more information refer to the respective Parts & Service News PC4000-6-E_#08165_Sec_8-1_rev0.doc
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Section 8.1 Page 41
Checks and adjustments of the lowering speed, illustration (Z 22006): Boom cylinder FSA Due to the two different operation modes for lowering the boom, the lowering speed must be adjusted twice: I. Float position activated II. Float position deactivated Maximum permissible lowering speed: Boom FSA Float position activated
Cylinder retracting time/meter (s /m) 1,8
Total time (s) 5,0
Adjustments / Checks: I. Float position activated: 1. Use a stop watch to measure the cylinder running time. 2. Raise the fully extended attachment with empty bucket to the maximum height position (A). 3. Shift the engine to high idle speed. 4. Rapidly move the control lever (E19) to the front end position (start the stop watch) and hold it until the final position (B) is reached.(stop the stop watch).
ã
• Lower the boom so, that the bucket stops just above the ground.
5. If the lowering speed is too high, i.e. the measured time is less than the permissible time, the speed must be reduced by altering the stroke limiter of the single control block (Y135). Adjust as follows: To decrease the lowering speed loosen the lock nut (1) and turn the bolt (2) cw. To increase the lowering speed loosen the lock nut (1) and turn the bolt (2) ccw. 6. Check lowering speed again and repeat the adjustment if necessary. 7. If the adjustment is finished tighten lock nut (1). continued
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Checks and adjustments of the lowering speed, illustration (Z 22021): Cont'd: Boom cylinder FSA Maximum permissible lowering speed: Boom FSA Float position deactivated
Cylinder retracting time/meter (s /m) 1,8
Total time (s) 5,0
Adjustments / Checks: II. Float position deactivated (with push button S95): 1. Use a stop watch to measure the cylinder running time. 2. Raise the fully extended attachment with empty bucket to the maximum height position (A). 3. Shift the engine to high idle speed. 4. Press push button S95 and keep it depressed while lowering the attachment. Rapidly move the control lever (E19) to the front end position (start the stop watch) and hold it until the final position (B) is reached.(stop the stop watch).
ã
• Lower the boom so, that the bucket stops just above the ground.
5. If the lowering speed is too high, i.e. the measured time is less than the permissible time, the speed must be reduced by altering the throttle valves 70.1 70.2 and 70.13 at the distributor manifold (42). Adjust as follows: To decrease the lowering speed loosen the lock nut (1) and turn the bolt (2) cw. To increase the lowering speed loosen the lock nut (1) and turn the bolt (2) ccw. Since there are several valves throttling the return oil flow of the boom cylinder the valves must be set synchronously. The adjusting screws have to be turned in by the same amount of revolutions.
O.K.
6. Check lowering speed again and repeat the adjustment if necessary. 7. If the adjustment is finished tighten lock nut (1).
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Checks and adjustments of the lowering speed, illustration (Z 22022): Boom cylinder BHA Maximum permissible lowering speed:
Boom BHA
Cylinder retracting time/meter (s /m) 1,4
Total time (s) 5,0
Adjustments / Checks: 1. Use a stop watch to measure the cylinder running time. 2. Raise the fully extended attachment with empty bucket to the maximum height position (A). 3. Shift the engine to high idle speed. 4. Rapidly move the control lever (E19) to the front end position (start the stop watch) and hold it until the final position (B) is reached.(stop the stop watch).
ã
• Lower the boom so, that the bucket stops just above the ground.
5. If the lowering speed is too high, i.e. the measured time is less than the permissible time, the speed must be reduced by altering the throttle valves 70.1, 70.2 , 70.13 and 70.14 at the distributor manifold (42). Adjust as follows: To decrease the lowering speed loosen the lock nut (1) and turn the bolt (2) cw. To increase the lowering speed loosen the lock nut (1) and turn the bolt (2) ccw. Since there are several valves throttling the return oil flow of the boom cylinder the valves must be set synchronously. The adjusting screws have to be turned in by the same amount of revolutions.
O.K.
6. Check lowering speed again and repeat the adjustment if necessary. If the adjustment is finished tighten lock nut (1).
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Checks and adjustments of the lowering speed, illustration (Z 22025): Stick cylinder FSA Due to the two different operation modes for lowering the stick, the lowering speed must be adjusted twice: I. Float position activated II. Float position deactivated Maximum permissible lowering speed: Stick FSA Float position activated
Cylinder retracting time/meter (s /m) 2,3
Total time (s) 5,5
Adjustments / Checks: I. Float position activated: 1. Use a stop watch to measure the cylinder running time. 2. Raise the fully extended attachment with empty bucket to the maximum height position (A). 3. Shift the engine to high idle speed. 4. Rapidly move the control lever (E20) to the rear end position (start the stop watch) and hold it until the final position (B) is reached.(stop the stop watch). 5. If the lowering speed is too high, i.e. the measured time is less than the permissible time, the speed must be reduced by altering the stroke limiters of the single control blocks (Y132, Y133 and Y134). Adjust as follows: To decrease the lowering speed loosen the lock nut (1) and turn the bolt (2) cw. To increase the lowering speed loosen the lock nut (1) and turn the bolt (2) ccw. Since there are several single control blocks used for the stick movement, make sure that all stroke limiter are equally adjusted.
O.K.
6. Check lowering speed again and repeat the adjustment if necessary. 7. If the adjustment is finished tighten lock nut (1). Continued
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Checks and adjustments of the lowering speed, illustration (Z 22026): Cont'd: Stick cylinder FSA Maximum permissible lowering speed: Stick FSA Float position activated
Cylinder retracting time/meter (s /m) 2,3
Total time (s) 5,5
Adjustments / Checks: II. Float position deactivated (with push button S95a): 1. Use a stop watch to measure the cylinder running time. 2. Raise the fully extended attachment with empty bucket to the maximum height position (A). 3. Shift the engine to high idle speed. 4. Press push button S95a and keep it depressed while lowering the stick. Rapidly move the control lever (E20) to the rear end position (start the stop watch) and hold it until the final position (B) is reached.(stop the stop watch). 5. If the lowering speed is too high, i.e. the measured time is less than the permissible time, the speed must be reduced by altering the throttle valves 70.8 and 70.9 at the distributor manifold (42). Adjust as follows: To decrease the lowering speed loosen the lock nut (1) and turn the bolt (2) cw. To increase the lowering speed loosen the lock nut (1) and turn the bolt (2) ccw. Since there are several valves throttling the return oil flow of the stick cylinder the valves must be set synchronously. The adjusting screws have to be turned in by the same amount of revolutions.
O.K.
6. Check lowering speed again and repeat the adjustment if necessary. 7. If the adjustment is finished tighten lock nut (1).
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Checks and adjustments of the lowering speed, illustration (Z 22029): Stick cylinder BHA Maximum permissible lowering speed:
Stick BHA
Cylinder retracting time/meter (s /m) 2,6
Total time (s) 5,3
Adjustments / Checks: 1. Use a stop watch to measure the cylinder running time. 2. Raise the fully extended attachment with empty bucket to the maximum height position (A). 3. Shift the engine to high idle speed. 4. Rapidly move the control lever (E20) to the rear end position (start the stop watch) and hold it until the final position (B) is reached.(stop the stop watch). 5. If the lowering speed is too high, i.e. the measured time is less than the permissible time, the speed must be reduced by altering the throttle valves 70.8, 70.9 and 70.10 at the distributor manifold (42). Adjust as follows: To decrease the lowering speed loosen the lock nut (1) and turn the bolt (2) cw. To increase the lowering speed loosen the lock nut (1) and turn the bolt (2) ccw. Since there are several valves throttling the return oil flow of the stick cylinder the valves must be set synchronously. The adjusting screws have to be turned in by the same amount of revolutions.
O.K.
6. Check lowering speed again and repeat the adjustment if necessary. If the adjustment is finished tighten lock nut (1).
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Section 8.1 Page 47
Checks and adjustments of the lowering speed, illustration (Z 22030): Bucket cylinder FSA Maximum permissible lowering speed:
Bucket FSA
Cylinder retracting time/meter (s /m) 2,1
Total time (s) 5,0
Adjustments / Checks: 1. Use a stop watch to measure the cylinder running time. 2. Raise the fully extended attachment with empty bucket to the maximum height position (A). 3. Shift the engine to high idle speed. 4. Rapidly move the control lever (E19) to the r.h. end position (start the stop watch) and hold it until the final position (B) is reached.(stop the stop watch). 5. If the lowering speed is too high, i.e. the measured time is less than the permissible time, the speed must be reduced by altering the throttle valves 70.4 and 70.12 at the distributor manifold (42). Adjust as follows: To decrease the lowering speed loosen the lock nut (1) and turn the bolt (2) cw. To increase the lowering speed loosen the lock nut (1) and turn the bolt (2) ccw. Since there are several valves throttling the return oil flow of the bucket cylinder the valves must be set synchronously. The adjusting screws have to be turned in by the same amount of revolutions.
O.K.
6. Check lowering speed again and repeat the adjustment if necessary. 7. If the adjustment is finished tighten lock nut (1).
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Checks and adjustments of the lowering speed, illustration (Z 22031): Bucket cylinder BHA Maximum permissible lowering speed:
Bucket BHA
Cylinder retracting time/meter (s /m) 2,4
Total time (s) 5,2
Adjustments / Checks: 1. Use a stop watch to measure the cylinder running time. 2. Raise the fully extended attachment with empty bucket to the maximum height position (A). 3. Shift the engine to high idle speed. 4. Rapidly move the control lever (E19) to the r.h. end position (start the stop watch) and hold it until the final position (B) is reached.(stop the stop watch). 5. If the lowering speed is too high, i.e. the measured time is less than the permissible time, the speed must be reduced by altering the throttle valves 70.3, 70.4 and 70.12 at the distributor manifold (42). Adjust as follows: To decrease the lowering speed loosen the lock nut (1) and turn the bolt (2) cw. To increase the lowering speed loosen the lock nut (1) and turn the bolt (2) ccw. Since there are several valves throttling the return oil flow of the bucket cylinder the valves must be set synchronously. The adjusting screws have to be turned in by the same amount of revolutions.
O.K.
6. Check lowering speed again and repeat the adjustment if necessary. 7. If the adjustment is finished tighten lock nut (1).
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Checks and adjustments of the lowering speed, illustration (Z 22032): Clam cylinder BHA Maximum permissible lowering speed:
Clam
Cylinder retracting time/meter (s /m) -----
Total time (s) 5,0
Adjustments / Checks: 1. Use a stop watch to measure the cylinder running time. 2. Open the clam of the empty bucket to the maximum height position (A). 3. Shift the engine to high idle speed. 4. Rapidly push the control pedal (E23) to the end position (start the stop watch) and hold it until the final position (B) is reached.(stop the stop watch). 5. If the lowering speed is too high, i.e. the measured time is less than the permissible time, the speed must be reduced by altering the throttle valve 70.6 at the distributor manifold (42). Adjust as follows: To decrease the lowering speed loosen the lock nut (1) and turn the bolt (2) cw. To increase the lowering speed loosen the lock nut (1) and turn the bolt (2) ccw. 6. Check lowering speed again and repeat the adjustment if necessary. 7. If the adjustment is finished tighten lock nut (1).
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Hydraulic for the Swing Circuit
Section 8.2 Page 1
Table of contents section 8.2 Section 8.2
Page Hydraulic for the swing circuit 8.2.1 Swing Circuit (Brief description)
2+3
8.2.2
Swing Motor
4+5
8.2.3
Swing Gear Box
6
8.2.4
Swing Parking Brake (Gear house Brake)
7
8.2.5
Swing Brake Valve
8+9
8.2.6
Electric / Hydraulic flowchart “Swing Left”
10
8.2.7
Electric / Hydraulic flowchart “Swing Right”
11
8.2.8
Checks and adjustments for the swing circuit
12 + 13 +14
8.2.9
Function check for the hydraulic swing brake
15
8.2.10
Function check for the swing parking brake
16
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Hydraulic for the Swing Circuit
Section 8.2 Page 2
8.2.1 Swing Circuit Legend for illustration (Z 21937a): (1 + 3) (9 / III) (10 / I) (16.1 + 16.2) (60.1+ 60.2)
Main pumps Control block Control block Manifold Swing motors
Brief description (Service circuits) The machine is equipped with a two speed swing system. (Study together with the for the machine valid hydraulic and electric circuit diagram). The swing motors (60.1 + 60.2) are driven by the pumps (1 + 3). The oil flows from the pumps through high pressure filters to the control block (9/III) and (10/I). With the spools in neutral position oil flows via the return oil line into the collector tube (107) and further via the return oil lines (L6 + L7) into the collector tube (54) and further to the tank. On its way to tank the oil must flow through the back pressure valve (55) and the return oil filter (59.1 - 59.4). (Back pressure valve function see section 4.) When operating the control lever for "Swinging" the pump line is connected in the control blocks (9/III and 10/I) with the corresponding service line (A1 or B1) to the swing motors (60.1 + 60.2). The oil flows from the control block through each one of the swing brake valves (61.1 + 61.2; description see page 8 and 9) and the swing motors (60.1 + 60.2). Each swing gear includes one spring loaded multi disk brake (House brake) for locking the superstructure. The leak oil (case drain) flows through the line (L18 + L19) and the leak oil filter (53) back to tank.
continued
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Cont'd.: 8.2.1 Swing Circuit: Legend for illustration (Z 21939a): (1 + 3) (9 / III) (10 / I) (14.1) (16.1 + 16.2) (60.1+ 60.2) (95) Y24 + Y25 Y26 + Y27 Y65 + Y66 Y120 + Y126 Y127 Y130 + Y131
Main pumps Control block Control block Remote control valve block Manifold Swing motors Remote control valve block directional solenoid valves directional solenoid valves proportional solenoid valves directional solenoid valve proportional solenoid valve (foot brake pedal) directional solenoid valve
Brief description (Control circuits) When the lever (E19) is moved out of its neutral position, proportional solenoid valve Y65 and solenoid valve Y131 (pump #3 fixed in Qmax position) are energized. Simultaneously the directional solenoid valves Y24 (R.H.-swing) or Y25 (L.H.-swing) are energized. At the same time, by the function of proportional solenoid valve Y127, pilot pressure is present at port „X“ of each brake valve block thus a pressure built up in the service lines is possible. i.e. Swing speed low = Only oil flow of pump #3
If swing speed switch S154 is activated, also proportional solenoid valve Y66 and depending on the swing direction directional solenoid valves Y26 (R.H.-swing) or Y27 (L.H.-swing) are energized. Simultaneously solenoid valves Y130 and Y126 (pump #1 fixed in ½ Qmax position) are energized, so that only a reduced of oil flow from pump #1 will be added to increase the swing. i.e. Swing speed fast = oil flow of pump #3 + reduced oil flow of pump #1
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Section 8.2 Page 4
8.2.2 Swing Motor Axial piston motor A2FLM (with SL-bearing) 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. Legend for illustration (Z 21936): (1) (2) (3) (4) (5) (5a) (6a) (6b) (7) (8)
Drive shaft Housing Case drain port Retaining plate Piston Pivot (center) pin Upper dead point Lower dead point Cylinder Control lens
(9) (10) (11) (12) (13) (14) (15) (16) (17) (18)
End plate Centering spring Taper roller bearing Spring Slipper pads Thrust washer Roller bearing Circlip Sealing flange Radial seal ring
Description of the SL-bearing (SL = slipper bearing) The main part of the axial forces is supported by the slipper pads (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 (5). The slipper pads support themselves on the thrust washer (14) and discharge axially the tapered roller bearing (11). Without pressure the slipper pads are kept on the thrust washer by means of spring (12).
continued
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Section 8.2 Page 5
Cont'd.: 8.2.2 Swing Motor, illustration (Z 21936) Axial piston motor A2FLM (with SL-bearing) Function: The pressure oil inlet (A or B) and consequent oil outlet (B or A) determine the output drive direction of the drive shaft (1). Direction of rotation: "Clockwise" = Direction of flow A to B "Counter-Clockwise" = Direction of flow B to A with view onto drive shaft! Via the control lens (8) the oil is directed to the cylinder bores. The piston (5) is moved from the lower (6b) to the up- per dead point (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 (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.
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Section 8.2 Page 6
8.2.3 Swing Gear Box Legend for illustration (Z 22438a): (1) Drive housing (2) Drive shaft (3) Sun gear shaft (4) House brake (Multi disk brake) (5) Breather filter Drive shaft housing (6) Oil level gauge (dipstick) Drive shaft housing (7) Disk brake housing (8) Cylindrical roller bearing (9) Internal ring gear (10) Cylindrical roller bearing
(11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22)
Bearing ring Cartridge Spherical roller bearing Oil drain plug, gear box Cylindrical roller bearing Oil level gauge (dipstick) Gear box First planetary stage Drive shaft to second stage Second planetary stage Radial seal ring Drive pinion Grease line port
The swing gear is of compact design with a two stage planetary gear including a multi disk house brake. The gear is bolted to the superstructure and fits firmly due to the machined diameter (A) and the bolt torque. The torque loaded on the hydraulic motor is transmitted by drive shafts (2) and sun gear shaft (3) to the first planetary stage (17). The sun shaft (17) of the first planetary stage transmits the torque into the second planetary stage (19). By the planetary gears the output drive shaft is rotated and transmits the torque to the pinion (21). The drive housing, and the gearbox are filled with gear oil. Aeration is done by breather filters. To lubricate the pinion bearing port (22) is connected to the central lubrication system.
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Section 8.2 Page 7
8.2.4 Swing Parking Brake (Gear house Brake) The Spring Loaded Multi-disk Brake is a safety brake; applied by spring force and released by oil pressure. Legend for illustration (Z 22439a): (1) Disk housing (2) Thrust washer (3) Inner disks (lamellas) (4) Outer disks (lamellas) (5) Sinus (spacing) ring (6) Piston (7) Quad-Rings with back- up rings (8) Quad-Rings with back- up rings (9) Springs (10) Thrust washer (11) Circlip (12) Drive shaft (13) Oil pressure port Function: Brake applied: The outer disks (4) engaged to the housing by serration and the inner disks (3) in serrated connection with drive shaft (12) are pressed together by the springs (9). This results in a fixed connection between housing and drive shaft. Brake released: Oil pressure via port (13) reaches the bottom of the piston (6) and forces the piston upwards against the thrust washer (10). This function eliminates the spring force onto the disks so that the sinus (spacing) rings can keep the outer disks (4) apart, thus the brake is released. The releasing pressure is 19 - 20 bar, the maximum permissible pressure 60 bar. This is a so named "Wet Brake" because the brake housing is splash lubricated by gear oil.
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Section 8.2 Page 8
8.2.5 Swing Brake Valve Legend for illustration (Z 21935): (1) Pressure increasing valve (items 6 - 13) (2) Check valve circuit A (3) Check valve circuit B (4) Anti-cavitation valve circuit B (5) Anti-cavitation valve circuit A (6) Jet bore, of main piston plug Ports: (Y) (T) (A) (A1) (B) (B1)
(7) (8) (9) (10) (11) (12) (13)
Spring of main piston Jet bore Valve poppet Spring Intermediate piston Pilot pressure piston Main piston
Leak oil Return oil Service line from control block Service line to the motor Service line from control block Service line to the motor
Pressure check points: (MA) Circuit A (MB) Circuit B Explanation of the function by the symbol: When ever a swing motion is carried out or the foot brake is used, pilot pressure arrives the pressure increasing valve (1) at port "X". The pilot pressure pre-loads these valves. The oil for the hydraulic motor from the control block arrives the service line port A or B, depending if a R.H. or a L.H. swing motion is carried out. The ports A and B are internally connected to the ports A1 and B1 and these ports in turn with the hydraulic motor. The operating pressure, at either port A or B closes the anti-cavitation valves (4 or 5) and opens the check valves (2 or 3). That means by the check valves (2 or 3) the service lines are connected to the pressure increasing valve. When ever the pressure is higher than the setting of the pressure increasing valve, this valves opens and dumps the oil into the return line (T) to tank. The pressure can be checked at the check points MA or MB. continued
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Section 8.2 Page 9
Cont'd.: 8.2.5 Swing Brake Valve, illustration (Z 21935) If after a swing motion the joy stick 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, and oil is forced through the anti-cavitation valves into the service line. Function of the pressure increasing valve. When ever a swing motion is carried out or the foot brake is used, pilot pressure arrives the pressure increasing valve (1) at port "X". The pilot pressure pre-loads these valves. By applying pilot pressure via the external port X to piston (12), the pretensioning of the pressure spring (10) is increased by the amount of the piston stroke "S", which results in the actual valve setting. The system pressure is in front of the main piston (13) and via the jet bore (6) also in the chamber of the spring (7) and via the jet bore (8) at the pressure relief valve poppet (9). Due to the force balance the piston (13) is kept in its position supported by the spring (7). Overcomes the system pressure the setting of the valve (9), this valve opens a channel to the dump line port (Y). Due to the drop of force the piston (13) is moved to the right. The pressure line gets connected with the return line (T). Damped opening and closing are obtained by the throttled volumetric change that is caused by the jet bores.
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Section 8.2 Page 10
8.2.6 Electric / Hydraulic flowchart “Swing Left” Legend for illustration (Z 21945b): (E19) Control lever (Joy stick) (E22) Control pedal swing brake (-X) Direction (axis) of joy stick (-10V) Signal voltage (Maximum) (ws/gn) Colour code of signal voltage cable ( Joy stick) – white/green (br – gn) Colour code of voltage cable ( brake pedal) – brown – green (X2...) Terminal rail with number (E50, E50a, E50b) Ramp time modules (A7) Amplifier module – Swing (Y65 + Y24/25 – Block III) (A7a) Amplifier module – Swing (Y66 + Y26/27 – Block I) (A16) Amplifier module – Swing brake (K80) Relay – Contacts 7 / 11 only closed while rotating with swing speed switch S154 activated. (K190) Relay – Swing brake without ramp time – Contacts 5 / 9 and 6 / 10 only closed while using the brake pedal. (14.1) Remote control valve block (95) Remote control valve block (Y65 + Y66) Proportional solenoid valve (Y24 + Y26) Directional solenoid valve (Y127) Proportional solenoid valve (I + III) Main control blocks I +III (16.2) Distributor manifold (61.1 + 61.2) Swing brake valve blocks (PIV) Pressure increasing valve (60.1 + 60.2) Swing motors Illustration Z21945 shows: The electrical signal. Signal voltage of joy stick (E19) arrives via ramp time modules (E50,-a) at terminal 5 of the amplifier modules (A7 + A7a) and further to the proportional and directional solenoid valves of the remote control blocks (14.1+ 95). Simultaneously signal voltage arrives via ramp time modules (E50b) at terminal 5 of the amplifier modules (A16) and further to the proportional valve (Y127) The hydraulic signal. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pressure ports of the main control blocks and to the pressure increasing valves (PIV). The hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I + III) and arrives via swing brake valves (61.1 + 61.2) at the swing motors (60.1 + 60.2).
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Section 8.2 Page 11
8.2.7 Electric / Hydraulic flowchart “Swing Right” Legend for illustration (Z 21946b): (E19) Control lever (Joy stick) (E22) Control pedal swing brake (+X) Direction (axis) of joy stick (+10V) Signal voltage (Maximum) (ws/gn) Colour code of signal voltage cable ( Joy stick) – white/green (br – gn) Colour code of voltage cable ( brake pedal) – brown – green (X2...) Terminal rail with number (E50, E50a, E50b) Ramp time modules (A7) Amplifier module – Swing (Y65 + Y24/25 – Block III) (A7a) Amplifier module – Swing (Y66 + Y26/27 – Block I) (A16) Amplifier module – Swing brake (K80) Relay – Contacts 7 / 11 only closed while rotating with swing speed switch S154 activated. (K190) Relay – Swing brake without ramp time – Contacts 5 / 9 and 6 / 10 only closed while using the brake pedal. (14.1) Remote control valve block (95) Remote control valve block (Y65 + Y66) Proportional solenoid valve (Y24 + Y26) Directional solenoid valve (Y127) Proportional solenoid valve (I + III) Main control blocks I +III (16.1) Distributor manifold (61.1 + 61.2) Swing brake valve blocks (PIV) Pressure increasing valve (60.1 + 60.2) Swing motors Illustration Z21945 shows: The electrical signal. Signal voltage of joy stick (E19) arrives via ramp time modules (E50,-a) at terminal 5 of the amplifier modules (A7 + A7a) and further to the proportional and directional solenoid valves of the remote control blocks (14.1+ 95). Simultaneously signal voltage arrives via ramp time modules (E50b) at terminal 5 of the amplifier modules (A16) and further to the proportional valve (Y127) The hydraulic signal. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pressure ports of the main control blocks and to the pressure increasing valves (PIV). The hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I + III) and arrives via swing brake valves (61.1 + 61.2) at the swing motors (60.1 + 60.2).
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Section 8.2 Page 12
8.2.8 Checks and adjustments for the swing circuit Maximum permissible swing speed Flow reduction for pump No 1 with pressure reducing valve 255.4 (Q reduced while swinging with high speed) Legend for illustration (Z 21949b): (M33) pressure – to pressure increasing valves (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) (Y126) Solenoid valve – flow reduction (Pump 1) (Y130) Solenoid valve – Fixed pump (Pump 1) (Y131) Solenoid valve – Fixed pump (Pump 3) 1. 2. 3.
4.
Connect a pressure gauges to check points M33, M41 and M42. Start the engine and let it run with max. speed. Move the control lever(E19) to the end position (L.H. or R.H.) with activated and deactivated swing speed switch (S154), swing one turn as an approach swing and start counting the number of revolutions in one minute. Read pressure while swinging. Required values: S154 = OFF (normal) S154 = ON (max.) M33 = 15 bar M33 = 45 bar M41 = 45 bar M41 = 45 bar M42 = 45 bar M42 = 34 bar RPM = 4 ± 0,3 RPM = 2,75 ± 0,3
ã
• Do not exceed the maximum permissible swing speed of 4 ± 0,3 RPM
)
• Note down the pressures and speeds as reference values.
If adjustment is necessary: 5. Loosen lock nut (e) 6. Adjust the pressure with set screw (f) 7. Tighten lock nut and remove the gauges. PC4000-6-E_#08165_Sec_8-2_rev0.doc
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Section 8.2 Page 13
8.2.8 Checks and adjustments for the swing circuit, illu. (Z 21948b)
)
• It is important that the complete MRV-valve and the Pressure Increasing Valve is firmly (with 300 Nm) tightened. Otherwise, internal leaks could occur which result in: problems of correct adjustment, loud flow noises and high temperatures. • Whenever pressure checks are carried out, they must be carried out for both, R.H. and L.H. Swing, to make sure the double check valves in the control lines and the check valves in the brake valve blocks are in good condition. • Because the Swing motors are working hydraulically in combined operation, the pressure gauge shows the pressure of the pressure increasing valve with the lowest setting. Even when the gauge shows the required pressure it is possible that one valve has a higher setting. Therefore lower the pressure on one valve below the required pressure and then increase up to required pressure. Proceed with next valve in the same manner.
High pressure check / adjustment 1. Connect gauges to check point M11 and M14 at the high pressure filter units. 2. Disconnect the pilot pressure lines from the T-unions and close the lines with a suitable plug (P). 3. Loosen lock nut (3) of both pressure increasing valves (PIV) and screw in set screw (4) until piston (5) comes to stop. 4. Start the engine and let it run with max. speed. 5. Lower attachment to ground and apply house brake with switch S29. 6. Adjust the MRV-pressure to ~350 bar. 7. Actuate either L.H. or R.H. rotation (S154 ON) until the hydraulic system stalls. Read the pressure, required = 330 ±5 bar. 8. If the gauge shows a smaller or greater value the pressure increasing valve must be adjusted: a) Loosen lock nut (1) of the first pressure increasing valve PIV. b) Adjust pressure with set screw (2) to ~340 bar. If the pressure won’t increase, turn set crew (2) of the second PIV a ¼ turn further in (c.w.). c) Secure by tightening lock nut (1). d) Loosen lock nut (1) of the second PIV. e) Reduce the pressure with set screw (2) to a value of about 320 bar, and then increase up to the required pressure of 330 bar. f) Secure adjusted set screw (2) by tightening lock nut (1) g) Reduce the pressure with set screw (2) of the first to a value of about 320 bar, and then increase up to the required pressure of 330 bar. h) Secure adjusted set screw (2) by tightening lock nut (1)
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Section 8.2 Page 14
8.2.8 Checks and adjustments for the swing circuit, illu. (Z 21948b) Low pressure check / adjustment (Swinging down path (drifting) (with still disconnected pilot pressure line ) 9.
Actuate either L.H. or R.H. rotation (S154 ON) until the hydraulic system stalls. a) Loosen lock nut (3) of both (PIV’s) and reduce the pressure equally with set screws (4) to a value of about 130 bar, secure setting with lock nut (3) b) Loosen lock nut (3) of the first PIV. c) Reduce the pressure with set screw (4) of the first PIV to a value of about 110 bar, and then increase up to the required pressure of 120 bar. d) Secure adjusted set screw (4) by tightening lock nut (3) e) Loosen lock nut (3) of the second PIV. f) Reduce the pressure with set screw (4) of the second PIV to a value of about 110 bar, and then increase up to the required pressure of 120 bar. g) Secure adjusted set screw (4) by tightening lock nut (3) 10. Re-connect the pilot pressure line. 11. Re-set MRV-pressure and remove the gauges after the check / adjustment is finished
ã
• Strong pulsation of the return line hoses, indicates deviation in opening pressure of PIV’s and must be avoided. Repeat the adjusting procedure until the oil returns well-balanced via all three pressure increasing valves.
Brake pilot pressure - check / adjustment 1. Connect the gauge to the check point M27. 2. Start engine and let it run with max. speed. 3. Depress fully the foot brake pedal (E22) and read the pressure. The pressure must be 24 +1 bar. If adjustment is required: Alter the position of the potentiometer R2 of the amplifier A16 until the pressure is 24 +1 bar. Basic adjustment for A16 see section 5
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Section 8.2 Page 15
8.2.9 Function check for hydraulic swing brake Legend for illustration (Z 23051): (M39) Pressure check point – (Pressure to pressure increasing valve) (S22) Switch – Position of access ladder (S28) Switch – Operators seat (Y120) Solenoid valve – hydraulic swing brake ON - OFF (Y127) 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 lifted position and/or if the operators seat is not occupied. Brake apply pressure 1. Connect gauge to check point (M39). 2. Start the motors. 3. Lift the access ladder to the end position. 4. Check the pressure at check point(M39) under the following conditons: a) Seat is occupied and access ladder complete up. 0 bar=> released. No message should appear on the text display b) Seat is occupied and access ladder down. The message “ Pilot control cut out “ should appear
45 bar=> applied.
c) Seat is not occupied and access ladder complete up. The message “ 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 the a counter action of the joystick is required. As a result, proportional valve Y127 will vary the pilot pressure at the pressure increasing valves (PIV) in relation to the lever deflection. Brake apply pressure 5. Apply the parking brake. Therefore move toggle switch (S29) in 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.
)
• In case of malfunction check the electrical control system and the function of solenoid valve Y120 and/or Y127.
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Section 8.2 Page 16
8.2.10 Function check for the swing parking brake Legend for illustration (Z 22533b): (M1.2) Pressure check point – (X2 - pilot pressure) (M10) Pressure check point – (Pressure to swing parking brake) (B16) Pressure switch (Y5) Solenoid valve –swing parking brake ON - OFF (252.1) Pressure reducing valve Parking Brake Release Pressure. (House Brake Pressure) 1. Connect gauge to check point (M1.2). 2. Start the motor and read the pressure. Required = 45 ±3 bar. If not, correct the pilot pressure adjustment. (refer to Section 5). 3. Apply the parking brake. Therefore move toggle switch (S29) in position “1”, now the following message should appear:
Swing gear house brake ON
4. Actuate either L.H. or R.H. rotation, the machine should not turn. • If the machine turns the parking brake must be repaired. 5. Release the parking brake. Therefore move toggle switch (S29) in position “0”, now the swing function must be possible again and the monitor returns to standard display.
)
• In case of malfunction check the electrical control system and the function of solenoid valve Y5.
Function Check of pressure switch B16 1. Connect pressure gauge to check point (M10). 2. Start the motor. Gauge must show normal pilot pressure X2 = 45 ±3 bar. 3. Move toggle switch (S29) in position “0” 4. Set pilot pressure reducing valve (252.1) to 22 bar. 5. Unplug and reconnect solenoid valve Y5 to allow pressure relieve from pilot pressure line to house brake. The text display must show “Swing gear house brake ON” 6. Increase the pilot pressure up to 26 bar. “Swing gear house brake ON” must disappear. 7. Reset pilot pressure X2 to 45 ±3 bar.
)
• Pressure at B16 Brake applied (ON) • Pressure at B16 >24 bar => Brake released (OFF)
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Hydraulic for the Travel Circuit
Section 8.3 Page 1
Table of contents section 8.3 Section 8.3
Page Hydraulic for the swing circuit 8.3.1 Travel Circuit (Brief description)
2+3
8.3.2 Travel Motor
4
8.3.3 Rotary distributor
5
8.3.4 Travel Gear Box
6
8.3.5 Travel Parking Brake (Gear house Brake)
7
8.3.6 Travel Brake Valve
8
8.3.7 Electric / Hydraulic flowchart “Travel forward”
9
8.3.8 Electric / Hydraulic flowchart “Travel backward”
10
8.3.9 Checks and adjustments for the travel circuit
11
8.3.10 Function check for the travel parking brake
12
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Section 8.3 Page 2
8.3.1 Travel Circuit Legend for illustration (Z 22506a): (2 + 4) (II) (IV) (14.2) (15) (19) (21.1+ 21.2) (41) (55) (56.1+ 56.2) (57.1+ 57.2) (B48) (M4) (Y16) (L9) (ST)
Main pumps Control block Control block Remote control valve block Remote control valve block Rotary distributor Travel motors Main oil reservoir Back pressure valve Travel brake valves Travel parking (house) brakes Pressure switch, parking brake release pressure Pressure check point for parking brake release pressure Solenoid valve for travel parking brake Case drain (leak oil) line Pilot pressure line to the travel parking brake
Brief description (Control circuits) (Study together with the hydraulic and electric circuit diagram). When the pedals E21a and E21b are moved out of there neutral position, proportional solenoid valves Y67 and Y70 and simultaneously the directional solenoid valves Y28 or Y29 (L.H.-crawler) and Y34 or Y35 (R.H.- crawler) are energized. (E21a) Control pedal A – forward => Y70 +Y35 Left track B – reverse => Y70 +Y34
(E21b) Control pedal A – forward => Y67 +Y28 Right track B – reverse => Y67 +Y29
continued
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Section 8.3 Page 3
Cont'd.: 8.3.1 Travel Circuit Illustration (Z 22506a): Brief description (Service circuits) (Study together with the hydraulic and electric circuit diagram). The travel motors (21.1 + 21.2) are driven by the pumps (2 + 4). The oil flows from the pumps through the high pressure filters to the control blocks (II + IV). In neutral position of the spools the oil flows via the return oil lines into the collector tube (107) and further via the return oil lines (L6 + L7) into the tank collector tube (54) and further to the tank. On its way to tank the oil must flow through the back pressure valve (55) and the return oil filter (59.1 - 59.4). (Back pressure valve function see section 4.) When operating the foot pedal for "Travelling" the pump line of each control block is connected with the corresponding service line (A1 or B1) via the rotary distributor (19) and travel brake valves (56.1 + 56.2) to the travel motors (21.1 + 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 brakes (House brakes 57.1 57.2). They are used as parking brakes, automatically applied by the function of Y16 whenever the engine is switched OFF. The brake release pressure is monitored by the pressure switch (B48). The leak oil (case drain) flows through the line (L9) and the leak oil filter (53) back to tank.
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Section 8.3 Page 4
8.3.2 Travel Motor 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. Legend for illustration (Z 22505): (1) (2) (3) (4) (5) (5a) (6a) (6b) (7)
Drive shaft Housing Case drain port Retaining plate Piston Pivot (center) pin Upper dead point Lower dead point Cylinder
(8) (9) (10) (11) (12) (13) (14) (15) (16)
Control lens End plate Taper roller bearing Roller bearing Thrust washer Circlip Circlip Sealing flange Radial seal ring
Function: The pressure oil inlet (A or B) and consequent oil outlet (B or A) determine the output drive direction of the drive shaft (1). Direction of rotation: "Clockwise" = Direction of flow A to B "Counter-Clockwise" = Direction of flow B to A with view onto drive shaft! Via the control lens (8) the oil is directed to the cylinder bores. The piston (5) is moved from the lower (6b) to the upper dead point (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 (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.
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Section 8.3 Page 5
8.3.3 Rotary Distributor Task: The rotary distributor (joint) permits a hydraulic connection between the superstructure and the under- carriage, that means between the rotating and the stationary part. Legend for illustration (Z 21828): (1) (2) (3) (4) (5)
Rotor Rotary distributor housing Cover Bearing ring (splitted) Sealing element
(6) (7) (8) (9) (10)
Seal Rotor guide rings O-ring Plug screws Mover
Ports: A-D Service lines K1 / K2 Control oil track tensioning L Leak oil ST Control oil T Return oil to tank The letters punch marked, beside the ports are marked as they are used in the hydraulic diagram.
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 (A-D) of the housing (2). The oil flows to the outlet ports (A-D), of the rotor (1), via ring grooves as well as longitudinal and cross holes. The rotor is bolted to the under carriage. The sealing of the ring grooves among one another is done by sealing elements (5). The hydraulic connection for case drain, house brake and the track tensioning cylinders is done via the ports (L), (St), (K1) and (K2). The entering of dirt gets blocked by the seal ring (6) and the collar of the cover (3). The rotor (1) is at the top and bottom section guided in the housing by the guide rings (7).
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Section 8.3 Page 6
8.3.4 Travel gear The travel gear consists of one spur gear set and two planetary stages. The travel gearbox is fitted to the side frame with bolts. Legend for illustration (Z 21700): (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 Function: Spur gear (2) is driven by a hydraulic motor and input drive shaft (1). The planetary carrier first stage (5) is driven by sun gear (3) which is connected to spur gear (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 second stage (8) is turned by sun gear (7) which is connected to the sprocket drive shaft.
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Section 8.3 Page 7
8.3.5 Travel parking brake (Gear house brake) The Spring Loaded Multi-disk Brake is a safety brake; applied by spring force and released by oil pressure. Legend for illustration (Z 21701): (1) Radial seal rings (2) Retainer (3) Springs (4) O-ring (5) Piston (6) Plug screw (7+8) Quad-Ring with back-up rings (9) Release pressure port (10+11) Quad-Ring with back-up rings (12) O-ring
(13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24)
Intermediate ring Outer disks (lamellas) Inner disks Outer disk carrier O-ring Seeger clip ring Bolt Retainer O-ring Seeger clip ring Inner disk carrier Radial seal ring
Function: Brake applied: The outer disks (14) engaged to the housing by serration and the inner disks (15) in serration connection with the disk carrier, are pressed together by the springs (3). This results in a fixed connection between housing and inner disk carrier (23). Brake released: Oil pressure via port (9) forces the piston (5) against the springs (3) towards the retainer (2). This function eliminates the spring force onto the disks thus the brake is released. The minimum releasing pressure is 21 - 23 bar, the maximum permissible pressure 100 bar. This is a so named "Wet Brake" because the brake housing is filled with oil.
)
• For more information refer to the OPERATION AND MAINTENANCE MANUAL, PARTS BOOK and REPAIR MANUAL of the corresponding machine.
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Section 8.3 Page 8
8.3.6 Travel Brake Valve Illustration Z 21695 Task: Travel brake valves control the oil flow from the hydraulic motor to the tank depending on operating pressure. This braking action prevents the motors from over speeding. Function: Spring force keeps the spool in the lowest flow position. with increasing operating pressure the opening for the return oil flow becomes larger. On its way to the hydraulic motor the oil flows from A to A1 respectively from B to B1 depending on the selected travel motion. Example: Operating pressure at port A moves spool (1) against the force of the spring (2) and opens the way for the return oil (B1 to B). Check valve (3) prevents a direct oil flow from B1 to B. If the operating pressure decreases to such an extend that the spring force overcomes the pressure, the flow to the tank becomes restricted, resulting in braking of the machine.
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Section 8.3 Page 9
8.3.7 Electric / Hydraulic flowchart “ Traveling forward ” Legend for illustration (Z 22517a): (E21a) Foot pedal left crawler (E21b) Foot pedal right crawler (+10V) Signal voltage (Maximum) (rs) Colour code of signal voltage cable ( footpedal) (X2...) Terminal rail with number (E51) Ramp time module (E52) Ramp time module (A12) Amplifier module – left crawler (A13) Amplifier module – right crawler (K177) Relay – Controlled by cable drum switches 5S6 and 5S7. Contacts 5/9 and 6/10 closed in normal operating condition. (14.2) Remote control valves (15) Remote control valves (Y67 + Y70) Proportional solenoid valve (Y28 + Y35) Directional solenoid valve (II – IV) Main control blocks (19) Rotary distributor (21.1 – 21.2) Hydraulic motors (56.1 – 56.2) Travel brake valves Electrical signal flow. Signal voltage of foot pedals (E21a + E21b) arrives via ramp time module (E51 + E52) at terminal 5 of the amplifier modules (A12 and A13) and further to the proportional and directional solenoid valves of the remote control blocks (14.2 and 15). 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 and IV) and arrives via Rotary distributor (19) and travel brake valves (56.1 – 56.2) at the hydraulic travel motors.
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Section 8.3 Page 10
8.3.8 Electric / Hydraulic flowchart “ Traveling backward ” Legend for illustration (Z 22518): (E21a) Foot pedal left crawler (E21b) Foot pedal right crawler (D32) Time relay – Pilot control: Neutral position monitoring (-10V) Signal voltage (Maximum) (rs) Colour code of signal voltage cable ( footpedal) (X2...) Terminal rail with number (E51) Ramp time module (E52) Ramp time module (A12) Amplifier module – left crawler (A13) Amplifier module – right crawler (K178) Relay – Controlled by cable drum switches 5S6 and 5S4. Contacts 5/9 and 6/10 closed in normal operating condition. (K179) Relay – Controlled by cable drum switches 5S8. Contacts 5/9 closed in normal operating condition. (K180) Relay – Controlled by cable drum switches 5S9. Contacts 6/10 closed in normal operating condition. (14.2) Remote control valves (15) Remote control valves (Y67 + Y70) Proportional solenoid valve (Y29 + Y34) Directional solenoid valve (II – IV) Main control blocks (19) Rotary distributor (21.1 – 21.2) Hydraulic motors (56.1 – 56.2) Travel brake valves Electrical signal flow. Signal voltage of foot pedals (E21a + E21b) arrives via ramp time module (E51 + E52) at terminal 5 of the amplifier modules (A12 and A13) and further to the proportional and directional solenoid valves of the remote control blocks (14.2 and 15). 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 and IV) and arrives via Rotary distributor (19) and travel brake valves (56.1 – 56.2) at the hydraulic travel motors.
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8.3.9 Checks and adjustments for the travel circuit Legend for illustration (Z 22519): (1) Protective cap (56.1 + 56.2) (2) Locknut (68.3 + 68.4) (3) Set screw (68.3 + 68.4) (19) Rotary distributor (M12 – M28.4)
Section 8.3 Page 11
Travel brake valves Anti cavitation valves L.H. Anti cavitation valves R.H Pressure check points
Pressure check of the Service Line Relief Valves (SRV) 1. Connect pressure gauge to the required check points : L.H. track
R.H. track
M12 = Operating pressure for the L.H.-motor M13 = Operating pressure for the R.H.-motor M28.1 = SRV- pressure L.H.-travel forward M28.3 = SRV- pressure R.H.-travel forward M28.2 = SRV- pressure L.H.-travel backward M28.4 = SRV- pressure R.H.-travel backward
2. Unplug solenoid valve Y16 (located at the control and filter panel) to keep the parking brake applied. 3. Start engine and let it run with max. speed 4. Engage carefully the desired travel motion and keep the pedal in final position to built up max. pressure. 5. Increase slowly the MRV-pressure while observing the pressure gauge. Gauge value must remain at 310bar + 5bar. If the gauge shows a smaller or greater value the SRV must be adjusted
)
• A faulty Anti-cavitation Valve (68.3 + 68.4, 68.6 + 68.7) or a leaking seal of the rotary joint (19) can influence the SRV pressure reading / setting. Repair or replace faulty parts if necessary
Adjusting the SRV’s : + 1. Set MRV’s to 320 bar 10 bar (using an attachment cylinders) 2. Engage carefully the desired travel motion and keep the pedal in final position to built up max. pressure. 3. Lower the pressure at the required SRV to 290 bar and then increase up to the required pressure of 310bar. Proceed with next valves in the same manner. + 4. Re-set MRV’s to 310 bar 5 bar (using an attachment cylinders) and replug the solenoid valve Y16. How to adjust MRV’s and SRV’s: a) Remove protective cap (1) and loosen lock nut (2). b) Adjust pressure with set screw (3). c) Secure adjustment by tightening lock nut (2) and replace cap (1). d) Re-check pressure setting.
)
• It is important that the complete MRV-valve and SRV-valve is firmly (with 300 Nm) tightened. Otherwise, internal leaks could occur which result in: problems of correct adjustment, loud flow noises and high temperatures.
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8.3.10 Function check for the travel parking brake Legend for illustration (Z 22520b): (252.1) Pressure reducing valve (M1.2) (B48) Pressure switch (M4) (E35) Text display (Y16)
Section 8.3 Page 12
Pressure check points Pressure check points Solenoid valve
Parking Brake Release Pressure. (House Brake Pressure) 1. Connect gauge to check point (M1.2). 2. Start the motor and read the pressure. Required = 45 ±3 bar. If not, the X-2 pilot pressure adjustment must be corrected. (refer to Section 5). 3. Disconnect plug connection from solenoid valve Y16, now the following message should appear: Travel gear house brake ON
4. Operate the travel pedals, the machine should not travel.
ã
• If the machine moves the parking brake must be repaired.
5. Reconnect plug connection to solenoid valve Y16, now the travel function must be possible again and the monitor returns to standard display.
)
• In case of malfunction check the electrical control system and the function of solenoid valve Y16.
Function Check of pressure switch B48 1. Connect pressure gauge to check point (M4). 2. Start the motor. Gauge must show reduced pilot pressure X2 = 35 +2 bar. 3. Set pilot pressure relief valve (252.1) to 22 bar. 4. Unplug and reconnect solenoid valve Y16 to allow pressure relieve from pilot pressure line to house brake. The text display must show “Travel gear house brake ON” 5. Increase the pilot pressure up to 26 bar. “ Travel gear house brake ON” must disappear. 6. Reset pilot pressure X2 to 45 ±3 bar.
)
• Pressure at B48 real time monitor 0 => Brake applied (ON) • Pressure at B48 >24 bar => real time monitor 1 => Brake released (OFF)
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Hydraulic Track Tensioning System Section 9.0 Page 1
Table of contents section 9.0 Section 9.0
Page Hydraulic Track Tensioning System General
2
9.1
Functional description
3+4
9.2
Pressure Increasing Valve
5
9.3
Tensioning Cylinder
6
9.4
Adjustments / Checks
7 + 8 + 9 + 10
9.5
Functional test
10
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9.0
General: Legend for illustration (Z 21398a): (59) Rotary distributor (joint). (ST) Supply line, pilot pressure from travel parking brake circuit (118.1) Supply line shut-off cock. "O" = open (118.2 + 118.3) Service shut-off cocks. "C" = closed (118.4) Main shut-off cocks. (119.1 + 119.2) Membrane accumulator, 1,3 liter (pre-charge pressure 31bar) (120.1 – 120.4) Bladder accumulator, 5 liter (pre-charge pressure 150bar) (121.1 + 121.2) Check valves (prevents feedback pressure to pilot pressure) (124.1 – 124.4) Track tensioning cylinders (125.1 + 125.2) Check valves (prevents a cross-over flow) (141) Pressure increasing valve.
*
The hydraulic track tensioning system ensures automatically the correct track tension. The pilot pressure pumps (9.1 and 9.3) will supply oil to all four tensioning cylinders (124.1 – 124.4). The maximum pressure is limited by pressure increasing valves (141). The pressure in the tensioning cylinders transmits the required force to move the guide wheels to the front, until the correct track tension is obtained. External forces acting at the guide wheels will be absorbed through the pressure accumulators (119.1 + 119.2, first stage) and (120.1 – 120.4, second stage).
)
• For information about the preventative track inspection, refer to the Operation and Maintenance Manual.
Functional description on next page
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9.1
Functional description: Illustration Z 22756 and Z 22757 (on next page):
)
• Under normal operating condition shut-off cock (118.4) located on the valve block (140) in the car body is closed. The shut-off cock (118.1) located on the valve block (140) in the car body and (118.2 and 118.3) located inside the side frames are open.
The oil flow of the pilot pressure pumps (9.1 + 9.3), filtered by pressure filters (68.1 + 68.7) enters port "P" of solenoid valve Y16, via the common pilot pressure supply line (45 bar) of the central control and filter panel (36). If solenoid valve Y16 is actuated (i.e. pressure at sensor B48), the oil for the travel parking brake (reduced to 35 bar by the function of valve 147), flows via rotary joint (59), shut-off cock (118.1), the orifice, the two check valves (121.1 + 121.2) and the shut-off cocks (118.2 + 118.3) the into the tensioning cylinders (124.1 – 124.4). The resulting force moves the guide wheels toward the front, until the correct track tension is obtained. Simultaneously the system is via check valves (125.1 + 125.2) connected to the pressure increasing valve (141). External forces acting at the guide wheels will be absorbed through the pressure accumulators (119.1 + 119.2, first stage) and (120.1 – 120.4, second stage). Purpose of the pressure increasing valve The two system pressures • 35 bar with engine stopped • 310 bar with engine running are controlled by the pressure increasing valve as follows. With stopped motor and switched off ignition there is no pilot pressure (L39) at pressure increasing valve (141) and only the lowest adjusted pressure of 35 bar remains in the system. As soon as the motor has been started, the pilot pressure acts on the pressure increasing valve. As a result the system pressure can rise to the adjusted pressure of 310 bar. continued
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9.1
Functional description: Cont'd.: Illustration (Z 22757): Cushioning Function When the tensioning cylinders (124.1 – 124.4) are moved in by external forces, the none return valves (121.1 + 121.2) will be closed. A certain amount from the displaced oil of the tensioning cylinders is taken up by the pressure accumulators. First stage:
at a pressure higher than 31 bar, oil is taken up by the side frame accumulators (119.1 + 119.2).
Second stage: at a pressure higher than 150 bar, oil is taken up by the center section accumulators (120.1 – 120.4). The system pressure can rise up to 310 bar pressure increasing valve (141) setting. With reduction of external forces, the oil is pushed back by the accumulator pressure into the tensioning cylinders. If the displaced oil volume was higher than the accumulators could take up, oil is added from the pilot pressure circuit, as soon as the pressure in the lines to the tensioning cylinder is lower than 35 bar. To avoid serious damages to the pilot pressure system in case of a faulty check valve, pressure relief valve (257.1) with a 55 bar setting is installed.
)
• For information about the preventative track inspection, refer to the Operation and Maintenance Manual. • To check the accumulator charging pressure refer to PARTS & SERVICE NEWS “AH01531a” latest edition.
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9.2
Pressure Increasing Valve
)
• The pressure increasing valve is a remote controlled pressure relief valve.
Legend for illustration (Z 21846): (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11+12) (13+14)
Pilot valve with valve seat Valve poppet Compression spring Main valve with sleeve Main piston Closing spring Set screw - low pressure 35 bar Set screw - high pressure 310bar Piston Pin Jet bore Lock nut
Function: The valve poppet (2) is connected via the jet bores (11) and (12) with the P port. If static pressure increases above the set pressure value, the valve poppet (2) opens and allows oil to flow freely to tank (T1). This oil generates a pressure drop in the spring chamber of the main spool, the closing force of the spring (6) is cancelled, and the main piston (5) opens to allow the pump flow to flow to tank (T2). Damped opening and closing is obtained by the throttled volumetric change. By applying external pressure of Pst max = 60 bar to the main spool (9) via port X, the pre-tensioning of the pressure spring (3) is increased by the amount of the piston stroke "S" and system pressure is increased correspondingly. The setting is fixed by means of the setting screw (7) and lock nut (13); 1 turn of the screw ~ 150 bar.
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9.3
Tensioning cylinder: Legend for illustration (Z 21929a): (1)
Cylinder tube
(2)
Piston
(3)
Piston guide ring
(4)
Piston guide strap
(5)
Seal ring (light)
(6)
O-ring
(7)
Scraper
(8)
Retracting device
(9)
Seal ring (dark)
(M) Bleeder port (P)
ã
Oil supply
• Maximum permissible piston stroke 360mm! During bench test an external stroke limitation must be used!
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9.4
Adjustments / Checks Legend for illustration (Z 22758a): (1+3+5) Lock nut (2+4+6) Set screw (147) Pressure reducing valve – Track tensioning system (35 bar) (252.1) Pressure reducing valve for pilot pressure X2 (45bar) (252.2) Pressure relief valve for pump support pressure X4 (60bar) (257.1) Pressure relief valve – Safety valve for Travel brake / Track tensioning system (55 bar) (M1.1) Check point – X4 pressure (60 bar) (M1.2) Check point – X2 pressure (45 bar) (M9.1) Check point – Travel parking brake / Track tensioning safety pressure (55 bar) (M9.2) Check point – Track tensioning operating pressure (35 bar) (Y16) Solenoid valve travel parking brake Checking / Setting the 55 bar pressure relief valve (257.1) – safety valve 1. Connect pressure gauges to check point M1.1 + M1.2 + M9.1 2. Start the both motors. 3. Check the X4-pressure at M1.1, required 60 bar. If necessary correct the setting by the function of valve 252.1 as follow: a) Loosen lock nut (1). b) Set pressure with set screw (2). c) Tighten lock nut (1). 4. Unplug solenoid valve Y16. 5. Increase the pilot pressure X2 by the function of valve 252.2 to ~ 60 bar. a) Loosen lock nut (3). b) Set pressure with set screw (4). c) Tighten lock nut (3). 6. Check the Safety-pressure at M9.1, required 55bar. If necessary correct the setting by the function of valve 257.1 as follow: a) Loosen lock nut (5). b) Set pressure with set screw (6). c) Tighten lock nut (5). 7. Re-connect solenoid valve Y16. 8. Re-set the X2-pressure to 45 bar by the function of valve 252.2 Checking / Setting the 35 bar pressure reducing valve (147) – supply pressure 1. Connect a pressure gauge to check point M9.2. 2. Start the both motors. 3. Read pressure, required = 35+2 bar If readjustment is required proceed as follow a) remove dust cap (a) and loosen lock nut (b). b) Set pressure with set screw (c). c) Tighten lock nut (b) and re-install cap (a). continued
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9.4
Adjustments / Checks Legend for illustration (Z 22759): (1) Piston (2) Lock nut (3) Set screw - high pressure (4) Lock nut (5) Set screw - low pressure (P) Plug (X) Pilot pressure port (141) (118.1) (118.3) (118.4) (119.2) (120.3 / .4) (124.3 / .4) (M11.5) (M29.2) (M29.4) (MRV)
Cont'd.:
310bar 35 bar
Pressure increasing valve Service shut-off cock – supply line Service shut-off cock in the side frame (or the L.H.-side) Main shut-off cock Membrane accumulator 31 bar Bladder accumulators 150 bar Track tensioning cylinders Pressure check point (Main control block IV) pump 5 Pressure check point at the track tensioning cylinders L.H.-side Pressure check point at the bladder accumulators L.H.-side Main relief valve – Operating pressure of main control block IV
Checking / Setting the pressure increasing valve Pre-conditions: Correct MRV, SRV and pilot pressure setting and the system must be free of air. The description is only for the R.H. track. The same procedure applies also for the L.H. side. Basic Adjustment: 1. 2. 3. 4.
Connect a pressure gauge to check point M11.5 Start the motors. Increase the MRV-setting (Block IV), to ~ 330 to 340 bar. Switch OFF the motors, open cock valve (118.4) to allow pressure relieve of track cylinders, and close it again.
continued
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Hydraulic Track Tensioning System Section 9.0 Page 9
9.4
Adjustments / Checks Cont'd.: 5. Move the pressure gauge from M11.5 to M29.4 6. Connect pressure check point M11.5 with pressure check point M29.2, using a long pressure gauge hose. (required for the oil supply) 7. Disconnect the pilot pressure line at port X of the pressure increasing valve (141) and close the hose with a plug (P). 8. Loosen lock nut (4) of the pressure increasing valve and screw in set sleeve (5) until piston (1) comes to stop. (substitution of 35bar pilot pressure) 9. Start the motors 10. Stall the hydraulic with the clam opening function (clam cylinders completely retracted) and observe pressure at check point M29.4. A pressure of 310 + 5 bar must reached within a time period of 10 – 15 minutes and must remain at this value.
W
The maximum pressure will be shown only after the accumulators are completely filled with oil. When the pressure reaches the pre-charge gas pressure ( 31 bar and 150 bar) the gauge pointer moves slower depending on the gas compression. If the gauge shows a lower or higher value the pressure increasing valve must be adjusted. Setting procedure, high pressure stage (Valve 141) a) Loosen lock nut (2). b) Adjust pressure with set screw (3). c) Secure adjustment by tightening lock nut (2). d) Re-check pressure setting. 11.
The low pressure setting of the pressure increasing valve must now be reset (with the pilot pressure line at port X still disconnected): Setting procedure, low pressure stage (Valve 141) a) Stall the hydraulic with the clam opening function (clam cylinders completely retracted) and observe pressure at check point M29.4. b) loosen lock nut (4) and turn set screw (5) ccw until gauge at check-point M29.8 shows 35 bar. c) Tighten lock nut (4). d) Re-check pressure setting. continued
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Hydraulic Track Tensioning System Section 9.0 Page 10
9.4
Adjustments / Checks Cont'd.: 12. 13.
Switch OFF the motors and open cock (118.4) to allow pressure relieve. Re-connect the pilot pressure line to port X of the pressure increasing valve (141). Remove the pressure gauge hose between pressure check point M11.5 and pressure check point M29.2. Close the cock (118.4). Re-set MRV (Block IV)to 310 + 5 bar after the check / adjustment is finished.
13. 15. 16.
9.5
Functional Test After all adjustments are finished, do the following: a) Bleed all air from the system b) Place shutoff and pressure relief cocks into correct operating position. c) Connect pressure gauge to check point (M29.4). d) Start motors. e) Travel approx. 10 m with the shovel. f) Stop the motors. g) The pressure must drop to 35 bar. If the pressure remains the at a higher or lower pressure*, re-adjust the low pressure setting at the pressure increasing valve (141).
)
*
The pressure may drop below 35 bar after a longer time, this is o.k. because of internal leakage.
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Access ladder hydraulically operated
Section 10.0 Page 1
Table of contents section 10.0 Section 10.0
Page Access ladder hydraulically operated 10.0 General
2
10.1
Function of hydraulically operated access ladder
3+4
10.2
Adjustments / Checks
5
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Access ladder hydraulically operated
Section 10.0 Page 2
10.0 Access ladder hydraulically operated General Legend for illustration Z22813a (A) Access ladder in lowered position (B) Access ladder in upper position (Working position) (C) Stop bar (D) Inner pivot bracket of the access ladder (E) Pull chain for emergency lowering of the access ladder (Z) Hydraulic cylinder (36) Central control and filter panel (S84) Ladder control switch for lowering the Ladder (S84B) Ladder control switch for lifting the Ladder (S84A) Safety switch for emergency lowering of the access ladder. When the chain (E) is being pulled down with the motor running the pilot control system is made inoperative preventing further movement of the shovel. (S22) Safety sensor, located on ladder pivot bracket Function of sensor (S22): Cut out of the pilot control system and actuation of the hydraulic swing brake with the ladder in lowered position. (S91) Monitor and control sensor Function of sensor (S91): This sensor monitors the ladder position and controls the moving speed of the ladder. In case the sensor (S22) fails to function properly, the sensor (S91) prevents unintended movement of the ladder.
The access ladder is hydraulically operated by the hydraulic cylinder (Z) with the pilot pressure X2 of 45 bar. The movement of the ladder is controlled by the function of switch: S84: => Lowering the ladder S84B => Lifting the ladder Lifting the ladder is only possible with the motor running. The lowering movement is possible by hydraulic force with the motor running or by the force of gravity with the motor at stand sill.
)
If the ladder is not in the final upper position the pilot control is switched off and solenoid valve Y120 activates the hydraulic swing brake. The display in the operators cab shows a message.
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Access ladder hydraulically operated
Section 10 Page 3
10.1 Function of hydraulically operated access ladder Legend for illustration Z22814a (2) Main pump (8.1) Pilot pump (33) Filter with filter monitoring switch B22 (115) Hydraulic cylinder (157) Solenoid valve Y123a/b (252.1) Pressure reducing valve (45 bar) – X2-pressure (252.2) Pressure relieve valve (60 bar) – X4-pressure (258.1) Solenoid valve Y125 (258.3) Pressure relieve valve (safety valve 70 bar) (258.4) Shuttle valve (258.5 + 258.6) Check valves (258.7) Orifice Y125 Solenoid valve: lowering speed control (OFF => reduced speed) Y123A Solenoid valve: ON => ladder up Y123B Solenoid valve: ON => ladder down Prime drive is running Study together with illustration Z22814a and the electric diagram on the next page. The pump (8.1) delivers the oil through filter (33) to port A of pressure relief valve (252.2). The pressure relief valve (252.2) maintains the adjusted pressure of 60 bar, called „X4“-pressure. By the function of pressure reducing valve (252.1) the „X4“-pressure will be reduced to 45 bar (called „X2“-pressure) and is present at port P of solenoid valve Y123A/B. If solenoid valve Y123 A or B is energized the oil flows to the cylinder and the ladder will move up or down. By the function of shuttle valve (258.4) both service lines are connected to safety valve (258.3), which limits the pressure to 70 bar. Return oil from cylinder (115) flows back via solenoid valve Y123A/B to solenoid valve Y125. Y125 = ON => Maximum cylinder speed, return oil flow not restricted when both proximity switches S22 and S91 are not activated (ladder between top and bottom end position) Y125 = OFF => Reduced cylinder speed, return oil flow is restricted by orifice (258.7) when one of the proximity switches S22 (ladder up) or S91 (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 S22 de-energizes Y125 and energizes Y123A, with the result that the cylinder of the ladder is always charged with pressure in this position. If switch S84 is in neutral position and the ladder in “ bottom – position” sensor S91 de-energise all solenoids (Y125; Y123 A+B) and the ladder is “blocked”. continued PC4000-6-E_#08165_Sec_10-0_rev0.doc
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Access ladder hydraulically operated
Section 10.0 Page 4
10.1 Function of hydraulically operated access ladder Cont'd: Prime drive is not running and the ladder is in the “final upper position” With switch S84 activated in position 2 (ladder down) solenoid valve Y123B and relay K132 are active. Y123B connects the piston side of the cylinder to the return line and K132 activates Y125, so that the oil can return without resistance to the tank. Now the ladder can move down only by its own mass (due to the force of gravity). The operator has to push the ladder slightly until it starts moving down by its own weight. The rod site of the cylinder receives oil via anti-cavitation valve (258.5). It is not necessary to activate the key switch, because the involved components are directly battery supplied via fuse F17. There is an additional pull switch S84A below the ladder support. With this switch activated the ladder can moved down from the ground. • Make sure that there are no obstacles in the moving range of the ladder. Stop raising the ladder by releasing the control switch (S84) if there are any obstacles in the moving range. • Mount the ladder only in completely lowered position. • Do not lift persons or objects (tools) with the hydraulic access ladder. Serious injury or death could occur.
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Access ladder hydraulically operated
9
Section 10.0 Page 5
10.2 Adjustments / Checks Legend for illustration Z22815a (1 + 3 + 5) Lock nut (2 + 4 + 6) Set screw (252.1) Pressure reducing valve (45 bar) – X2-pressure (252.2) Pressure relieve valve (60 bar) – X4-pressure (258.3) Pressure relieve valve (safety valve 70 bar) (A) Access ladder in lowered position (B) Access ladder in upper position (Working position) (C) Stop bar (D) Inner pivot bracket of the access ladder (E) Pull chain for emergency lowering of the access ladder (S84) Ladder control switch for lowering the Ladder (S84B) Ladder control switch for lifting the Ladder (S84A) Safety switch for emergency lowering of the access ladder. When the chain (E) is being pulled down with the motor running the pilot control system is made inoperative preventing further movement of the shovel. (S22) Safety sensor, located on ladder pivot bracket Function of sensor (S22): Cut out of the pilot control system and actuation of the hydraulic swing brake with the ladder in lowered position. (S91) Monitor and control sensor Function of sensor (S91): This sensor monitors the ladder position and controls the moving speed of the ladder. In case the sensor (S22) fails to function properly, the sensor (S91) prevents unintended movement of the ladder. Checking / Setting the 70 bar pressure relief valve (258.3) – safety valve 1. Connect pressure gauges to check point M1.1; M1.2 and M37.1. 2. Start the motor. 3. Lift the ladder to the final upper (working) position, using switch (S84B) 4. Increase the X4-pressure to 80 bar, by turning in set screws (2) of pressure relieve valve (252.2). 5. Increase the X2-pressure to 75 bar, by turning in set screws (4) of pressure deducing valve (252.1). 6. Check the setting of pressure relieve valve (258.3) at check point M37.1. Required 70 bar. If necessary correct the setting as follow: a) Reduce the pressure with set screw (6) at valve (258.3) to 60 bar b) Set the pressure to 70 bar ± 2 bar. c) Tighten lock nut (5). 7. Reset valve (252.2) to 60 bar, valve (252.1) to 45 bar and tighten lock nuts (1 + 3), adjustment is finished.
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Cable drum
Section 11.0 Page 1
Table of contents section 11.0 Section 11.0 Cable drum 11.0 General 11.1
Components
11.2
Function
Page 2 3
11.2.1 Controlling of the drive motor
4
11.2.2 Travel motion control
5
11.3
Checks and Adjustments
6
11.4
Description and operating instruction for cam switch 5S4 and 5S6
7
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Cable drum
Section 11.0 Page 2
11.0 Cable drum General Legend for Illustration Z 22831a (5M6) Brake motor (5S3) Rotation direction indicator (switch) (5R1) Resistor for brake motor torque adjustment (5S4) Gear type cam switch for resistor controlling and for monitoring of the two last cable windings. (5S6) Pendulum control cam switch, to detect slack or tight cable (5S8, 5S9) Proximity switch to detect cable deflection to right or left (5S10, 5S11) Proximity switch for ground contact protection.
)
Task: The cable drum, driven by a brake motor with slip ring rotor, is installed to wind up or unwind the power supply cable automatically. 1. To considerably improve the mobility of the excavator. 2. To make the operation safer (Material and personnel) i.e. less risk to damage the cable when travelling backwards and less danger of injury because the cable must not manual moved. 3. To increase the lifetime of the cable, because the cable is not dragging on the ground. For the optimal use of the cable drum it is necessary that the operator understands the system very well. Regular maintenance is essential
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Cable drum
Section 11.0 Page 3
11.1 Components Legend for Illustration Z 22832a (5M6) Brake motor (5S1) Service switch for manual actuation of cable drum. (5S3) Rotation direction indicator (switch) (5R1) Resistor for brake motor torque adjustment (5S4) Gear type cam switch for resistor controlling and for monitoring of the two last cable. (5S6) Pendulum control cam switch, to detect slack or tight cable. (5S8, 5S9) Proximity switch to detect cable deflection to right or left (5S10, 5S11) Proximity switch to detect ground contact (5K7, 5K8, 5K12, 5K13) Relay for brake motor direction controlling (5K10, 5K11) Relay for brake motor torque controlling (5F13) Circuit breakers (5B79) Brake motor temperature probe (F79) Motor temperature control unit (X8) Terminal box The resistor 5R1 serves as a series resistor for a three- phase motor with a slip ring rotor (stand still, sliding rotor-brake motor) It is a resistor with one or more taps (as a function of drum design), to make a selection of different star bridges possible. The taps serve to regulate the motor and brake torque during winding up and unwinding. With service switch 5S1 is it possible to control the cable drum manually in both directions (windup, unwind, stop and automatic) The terminal box X8 contains the terminal rails , the relays 5K7, 5K8, 5K10, 5K11, circuit breakers 5F13 + 5F14 and motor temperature control unit F79. Direction of rotation monitoring switch 5S3 opens its contact and de-energizes 5K10 and 5K11 while unwinding (traveling forward) and eliminates the resistor which controls the star bridge. (Lowest tensioning force) Gear type cam switch 5S4* reduces the tensioning as soon as half of the cable is unwinded (contact 21/22 opens and de-energizes 5K11) or stops reverse travelling as soon as the max. length of the cable is winded up (contact 31/32 opens and deenergizes K178) or stops forward travelling as soon as the safety cable length on the drum gets unwinded (contact 11/12 opens and de-energizes relay K177). The proximity switch 5S8 stops L.H. crawler reverse travelling at too much deflection of the power supply cable to the left (contact br/sw opens and de-energizes K179). The proximity switch 5S9 stops R.H. crawler reverse travelling at too much deflection of the power supply cable to the right (contact br/sw opens and de-energizes K180). The proximity switch 5S10 and 5S11 stops reverse travelling with ground contact. Pendulum control cam switch 5S6* stops forward travelling at too tight power supply cable (contact 11/12 opens and de-energizes K177) or reverse travelling at too much slack of power supply cable (contact 21/22 opens and de-energizes K178). The motor temperature control unit F79 interrupts all travel motions as soon as drive motor 5M6 reaches a critical temperature (monitored by sensor 5B79). *Refer to page 7 for adjustment procedure
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Cable drum
Section 11.0 Page 4
11.2 Function Legend for Illustration Z 22834a (5M6) Brake motor (5S3) Rotation direction indicator (switch) (5R1) Resistor for brake motor torque adjustment (5S4) Gear type cam switch for resistor controlling (5K7, 5K8) Relay for brake motor direction controlling (5K10, 5K11) Relay for brake motor torque controlling (5F13) Circuit breakers (F79) Motor temperature control unit (X2 + X8) Terminal board D53 Time relay at the X2 board 11.2.1 Controlling of the drive motor General: In the automatic mode of control switch 5S1, the power supply to drive motor 5M6 is controlled by the function of the travel control system, which controls relay 5K7, i.e. while traveling the contacts of 5K7 are closed and kept closed for further 10 seconds after stopping the travelling motion (controlled by time relay D53), before the power supply will be interrupted and the motor brake is active. The torque of drive motor 5M6 is controlled by the function of the relay 5K10 and 5K11; which changes the resistance at the star bridge (5R1). Both relay are simultaneously controlled by switch 5S3 (Direction of rotation monitoring switch), to ensure the lowest tensioning force while unwinding (i.e. traveling forward) Winding up (automatic mode of control switch 5S1): While winding up the NC-contact of switch 5S3 remains closed which allows voltage to the relay 5K10 and (if the contact 21/22 of switch 5S4 is closed) also to 5K11. Example travelling reverse: Cable length on drum: ½Max. – Max. => 5K10 ON + 5K11 ON => max. torque Cable length on drum: Min. – ½Max. => 5K10 ON + 5K11 OFF => reduced torque Unwinding (automatic mode of control switch 5S1): The NC-contact of switch 5S3 opens while traveling forward and de-energizes simultaneously 5K10 and 5K11, with the result that there is just enough torque to hold the cable tight.
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Section 11.0 Page 5
Cable drum
11.2 Function 11.2.2 Travel motion control, illustration Z 22835 General: The cable drum is equipped with safety switches for the protection of the power supply cable during travelling and turning operations. Movements which could damage the power cable are automatically switched off.
Cable condition
Monitored by
Travel shut off relay
Directional Solenoid valves
Travel response
K177
Y20b + Y28b
crawler left + crawler right
Switch / contacts 1. Too tight
5S6 / 11–12
forward motion stopped 2. Too slack
5S6 / 21–22
K178
Y20a + Y28a
crawler left + crawler right reverse motion stopped
3. Too strong deflection to the left
5S8 / br–sw
K179
Y20a
crawler left reverse motion stopped
4. Too strong deflection to the right
5S9 / br–sw
K180
Y28a
crawler right reverse motion stopped
5. Maximum permissible cable length on the drum
5S4 / 31–32
6. Safety cable winding unwinded
5S4 / 11–12
K178
Y20a + Y28a
crawler left + crawler right reverse motion stopped
K177
Y20b + Y28b
crawler left + crawler right forward motion stopped
7. Ground contact
5S10 and/or 5S11
K178
Y20a + Y28a
crawler left + crawler right reverse motion stopped
) )
If the reverse motion stopped because of a activated ground contact switch 5S10 or 5S11 it is possible to activate the reverse motion manually via activation of horn switch at the left control lever in the cab.
Refer to section 8.3 in this Manual for further information.
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Cable drum
Section 11.0 Page 6
11.3 Checks and Adjustments Legend for Illustration Z 22836a (5S3) Rotation direction indicator (switch) No adjustment required. Check the function of contact 2/P. The built-in switch must open while unwinding. (5S4)
Gear type cam switch for resistor controlling and safety switch to detect full cable drum and the last two safety cable windings. The contact 31/32 must open as soon as the maximum permissible cable length is on the drum, travel reverse will stop by deactivated relay K178. As soon as the last second winding comes up contact 11/12 opens and travel forward will stop by deactivated relay K177. Adjusting procedure see section 11.4 on next page and check the function under operating conditions.
(5S6)
Pendulum control cam switch, to detect slack or tight cable. Adjust the switch in such a way that contact 11/12 opens at too tight cable and contact 21/22 opens at too slack cable. Check the function under operating conditions. Make sure that the shock absorber at the pendulum will work in its permissible range. Adjusting procedure see section 11.4 on next page.
(5S8, 5S9)
Proximity switch to detect cable deflection to right or left. Adjust the distance between switch and metal bar to 7mm. Check the function under operating conditions.
(5S10, 5S11)
Proximity switch to detect ground contact. Adjust the distance between switch and metal bar to 7mm.
(F79)
Motor temperature control unit with monitoring LED’s. (R) – red LED on => motor temperature to high. (G) – green LED on => permissible temperature range. Hysteresis: Rcold ≤ 1kΩ, Rswitch point ≥ 3kΩ (Sensor between P1 and P2) Check the function with potentiometer.
(D53)
Time relay for power cut off after 10 seconds without travelling. Check adjustment, refer to service Bulletin 21-584 for more information.
(X2 + X8)
Terminal board
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Cable drum
Section 11.0 Page 7
11.4 Description and operating instruction for cam switch 5S4 and 5S6 Legend for Illustration Z 22837 (1) Micro switch housing (2) Actuator (Roller lever) (3) Cam disc (4) Adjusting spanner (5) Cup spring (6) Tension nut The cam discs (3), arranged in pairs on the centering discs, can be adjusted individually and continuously by means of a adjusting spanner (4) The centering discs can be reversed and are fixed to the square shaft without clearance. Adjustment can be performed in any position without having to turn the control shaft. The cam discs, separated from each other by the guard plate, slide past each other without touching during adjustment. The cam ring next to the cam ring to be adjusted will not shift and remains in the set position. Hollow-type rivets prevent accidental shifting of the cam discs. By selecting the appropriate contact - either make or brake - any angle between 0° and 350° can be set without changing the cam rings. When the cam hits the actuator (2), the latter will operate the micro switch (1). Adjustment of the switch mechanism. 1. Loosen the tensioning nut (6) with the handle of the adjusting spanner (4). 2. Bring the adjusting spanner (4) in the position shown on illustration Z22837. 3. Set the cam discs (3) to the required position. 4. Adjust all other cam discs, following this procedure. 5. When all cam discs have been adjusted, tighten the tensioning nut.
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Hints for reading the Hydraulic Circuit Diagram
Section 12.0 Page 1
Table of contents section 12.0 Section 12.0
Page Hints for reading the hydraulic circuit diagram General
3
12.1
5
12.2
02.03.05
Symbols 12.1.1
Lines, unions
5-6
12.1.2
Components, valves
7
12.1.3
Sensors
8
12.1.4
Valves, valve components
9-12
12.1.5
Pumps, motors, cylinders
13-14
12.1.6
Assemblies and main components
15-16
Legend for the circuit diagram (929 663 40)
17-24
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Hints for reading the Hydraulic Circuit Diagram
Section 12.0 Page 3
12.0 General: Legend for Illustration Z22987
) Item
• • • • • • • •
• • 02.03.05
• • •
The illustrations are used for exemplary explanations only. Use original circuit diagram for detailed reading There are more symbols on the following pages shown as in the diagrams drawn. Some symbols of the diagrams not shown in the following pages. Description
Number / Code
Explanation
A
Diagram No. and Type of the 897 895 40 a respective machine PC8000-E
Diagram No. only for the respective machine
B
Respective Serial No.
C
Sheet-No. / Quantity of sheets 01 / 04
1st of four sheets
D
Co-ordinates to describe the location of a component
Page 1 on co-ordinate C vertical and 10 horizontal Remote control valve 102.1
E
Component-No. 127
F
Line-No. with cross hint,
12041 1 C 10
127 L37/3B9
Main control block I Case drain line (Line No.37) comes from / goes to sheet 2 coordinate E7
All the components drawn in neutral and pressure less position. Full wide continues black line shows a main component or assembly. (Ex.: Valve and Filter panel, Main pump, Hydraulic tank, ...) Continues black line shows a main hydraulic line. This lines are temporary or continues load with high or pilot pressure. Broken line shows a return, drain or control oil line. Black dot shows a connection point. The position of this connection is not definitely fixed. White dot shows a connection or port of a component with a fix definitely position or port number. Page 1 shows the high pressure main hydraulic circuits with all pilot control valves, control blocks, distributor manifold and cylinders or motors. Page 2 shows all main pumps and pilot pressure pumps with the main pump control system and the other auxiliary pilot pressure circuits as lubrication system and ladder. Page 3 shows the main pump control arrangement, the auxiliary circuits with oil cooling system and the hydraulic tank. Page 4 shows the car body hydraulic with travel brakes, travel motors and track PC4000-6-E_#08165_Sec_12-0_rev0.doc
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Hints for reading the Hydraulic Circuit Diagram 12.1
Section 12.0 Page 5
Symbols Illustration Z 22988 12.1.1 Lines, unions Symbol
Description
Used as / at / on
1
Oil supply line, can be a hose or a pipe.
2
Return oil line, can be a hose or a pipe.
3
Case drain (leak) oil line, can be a hose or a pipe.
4
Control oil line, can be a hose or a pipe.
5
Crossed lines
Pipes or hoses not connected
6
Connection point, is a connection of hydraulic lines without definite position Component connection point, is a connection with a definite position at a component Plugged connection point, can be plugged with any kind of plugs.
Connection between several lines
7
8
9
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Plugged line inside of a manifold, can be plugged with different kind of plugs.
Suction line or pressurized line of main hydraulic circuit or pilot pressure circuit or auxiliary circuits (e.g. fan drive). Return lines, connected to the return oil filter chamber of the main oil reservoir. Return lines, connected to the case drain (leak) oil filter chamber of the main oil reservoir. Pilot control line, pump regulation line and parking brake control lines.
Connection to components like, valve blocks, tanks, pumps, ... Not used connection points. Not used connection points.
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12.0 6 12.1
Symbols 12.1.1 Line, union Symbol
10
Description
Used as / at / on
Compensator, Compensate line length differences depend on vibration and temperature. Quick coupling, is a special union with integrated check valve
Oil tank outlet to the pumps
12
Blind, Orifice, not adjustable with orifice diameter in mm
e.g. Oil cooler inlet,
13
Pressure check point With a special quick coupling.
HP Filter, Fan valve block....at all important circuits
14
Distributor block
Connection of lines with the same destination e.g. return lines to tank
11
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Tank drain couplings, often removed lines (e.g. at grease systems with removable barrels).
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Hints for reading the Hydraulic Circuit Diagram 12.1
Section 12.0 Page 7
Symbols 12.1.2 Components, valves Symbol
Description
Used as / at / on
Accumulator, is filled with nitrogen gas with for the respective accumulator specified pressure Screen filter, the screen size is 1.0 mm
Input line to the remote control valves, return oil collecting tube, track tensioning system
17
Oil cooler,
Hydraulic oil cooler, PTO oil cooler
18
Breather filter,
On top of PTO or hydraulic tank
19
Spray nozzles, inside of a case for cooling and lubricating
Gearbox (PTO) cooling and lubricating system
15
16
Installed in suction lines to the pumps, oil tank outlet, return oil collecting tube
continued
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12.0 8 12.1
Symbols 12.1.3 Sensors Symbol
Description
Used as / at / on
20
Pressure switch / sensor Input = pressure Output = electrical signal analogue or digital
e.g. return / leak oil chamber (digital), high pressure filter (analogue)
21
Pressure switch Input = pressure Output = digital electrical The switch point is 24 bar
e.g. swing or travel detection PC3000,
22
Temperature sensor, Input = temperature Output = electric signal proportional to the temperature
e.g. hydraulic tank
23
Level sensor, Input = fluid level Output = electrical signal analogue or digital
Hydraulic tank, fuel tank
24
Chip sensor, Input = contaminate oil Output = electrical digital signal
Main pumps
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Hints for reading the Hydraulic Circuit Diagram 12.1
Section 12.0 Page 9
Symbols 12.1.4 Valves, valve components Symbol
Description
Used as / at / on
25
Manuel operated unit Lever
Valve in track tensioning system,
26
Electric / magnetic operated unit Solenoid
Solenoid valve
27
Pilot pressure controlled unit
Pressure relief valve, disc brake, ...
28
Spring, with fixed force
Solenoid valves,
29
Spring adjustable spring force is adjustable
Pressure relieve valves,....
30
Check valve In drawn pos.: from right to left free flow, from left to right blocked flow.
31
Check valve spring loaded Opened in flow direction only against spring force = pressure Double check valve, in drawn pos.: opened only from the left to the bottom or from the right to bottom
e.g. main pump outlet, swing brake valve block, anti cavitation valves at main control blocks or distribution manifold By pass of the return oil filter, by pass of secondary filter
32
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Swing brake control,
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12.0 10 12.1
Symbols
Symbol
33
12.1.4 Valves, valve components Description Used as / at / on Shut-off Valve with Gate valve between main oil monitoring switch, reservoir and suction tank the adjustable switch monitors the valve position
34
2/2 control valve manual operated, 2/2 cock valve
Track tensioning system
35
3/2 control valve manual operated, 3/2 cock valve
Change over valve from electronically pump regulation to emergency mode (hydraulically pump regulation)
36
4/2 directional control valve as solenoid valve 4/2 way solenoid valve, electrically controlled. Neutral position: P-A and B-T connected. Variable throttle valve hydraulically controlled pilot control port pressure less = maximum restriction 3/2 directional control solenoid valve, seat design = leak oil free 3/2 way solenoid valve, neutral = port P-A open 4/3 directional control solenoid valve 4/2 way solenoid valve, in neutral all ports closed External pilot controlled proportional floating valve
e.g. swing parking brake, travel parking brake, ladder controlling,,
37
38
39
40
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Travel brake valve, located in the car body
Service arm controlling
Ladder controlling, service arm controlling
PC 3000 and PC4000 with floating system
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Hints for reading the Hydraulic Circuit Diagram 12.1
Section 12.0 Page 11
Symbols 12.1.4 Valves and valve components Symbol
Description
Used as / at / on
41
Main control valve Standard control valve for “standard function” two directions of cylinder or In neutral position: motor. open pump flow (P-PU) and control port flushing (T – a, T – b), in position a or b closed circulation port (P- PU)
42
Main control valve “pressure less lowering” Neutral position: open pump flow (P-PU), control port flushing (T– a, T– b) Position b: closed circulation port (P-PU), normal function P – B and B - T, Position a: open circulation port P – PU, only port B – T connected Main control valve “floating function” Neutral position: open pump flow (P-PU), control port flushing (T– a, T– b), Position b: closed circulation port (P-PU), normal function P – B and B - T, Position a: open circulation port (P – PU) = A, B, T, P connected together via tank Pressure reducing valve, assembly Variable inlet pressure at port B and constant lower output pressure at port A, output pressure is adjustable.
43
44
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Control valve for pressure less lowering. Used to assist the floating function of boom and stick,
Control valve with floating function in position a, e.g. floating valve for boom or stick, .
Emergency mode pressure (X3-pressure), pilot oil pressure
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12.0 12 12.1
Symbols 12.1.4 Valves and valve components Symbol
Description
Used as / at / on
45
Pressure relief valve, direct controlled and adjustable
e.g. ladder controlling, service arm controlling ..
46
Pressure relief valve with anti cavitation valve (check valve) Assembly, external drain at port Y
Secondary relieve valve at main control blocks
47
Pressure increasing valve pressure relieve valve with variable setting, pilot pressure controlled via port X. Low pilot pressure = low relieve pressure
Swing brake block, track tensioning system.
48
Proportional pressure valve, reduce the pressure in port A proportional to the solenoid current. 4 port proportional pressure relief valve, direct operated by a proportional solenoids.
Remote control valves to control the main control blocks,
50
Pressure relief valve, mechanical and hydraulically via pilot port X adjustable, oil drain port Y
Radiator and oil cooler fan drive
51
Throttle check valve with secondary relieve valve, throttle and secondary valve mechanical adjustable, external drain at port Y.
Distribution manifold normally in the line to the cylinder piston side.
49
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Pump regulation, only output port A is used for our systems
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Hints for reading the Hydraulic Circuit Diagram 12.1
Section 12.0 Page 13
Symbols 12.1.5 Pump, motor, cylinder Symbol
Description
Used as / at / on
52
Single acting Cylinder, pressurised moving only in one direction, return by external force
Track tensioning system
53
Double acting Cylinder, Cylinder in which the fluid pressure operates alternately in both directions (forward and backward strokes) A = Piston side B = Rod side
Attachment i.e. boom, stick, bucket or clam cylinder
54
Drive shaft of a motor or pump with one direction
Main pumps, swing motor, fan drive, travel drive
55
Hydraulic pump with fix volume per revolution suction port S and pressure outlet P
Fan pump, circulation pump, pilot pump, PTO lubrication pump
56
Hydraulic pump with variable output volume per revolution with external case drain
Main pumps
57
Hydraulic pump assembly with pump bearing lubrication, one direction and external case drain
Main pumps
A
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B
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12.0 14 12.1
Symbols 12.1.5 Pump, motor, cylinder Symbol
Description
Used as / at / on
58
Variable hydraulic pump with charge pump and external drive shaft bearing lubrication
Main pump
59
Hydraulic motor can be used in both direction, with external case drain L
Fan motor
60
Motor with disc brake disc brake is spring loaded it means: pressure less pilot line = maximal brake torque
Travel motor
61
Variable swing motor with integrated control valves and flushing valves
Swing motor PC5500
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Hints for reading the Hydraulic Circuit Diagram 12.1
Section 12.0 Page 15
Symbols 12.1.6 Assembly and main components Symbol
Description
Used as / at / on
62
Lubricant pump drive differential cylinder with integrated control valves to propel the grease pump
Lubricant pump station for central lubrication system and swing ring lubrication system
63
Swing brake valve assembly, act as a hydraulical back pressure system parallel to a motor with variable pressure setting and independent pressure side. Input port A or B and outlet on the opposite connection to the motor..
Swing brake system.
64
Rotary joint Upper part with connections drawn to the top, lower part with connections drawn to the bottom
Hydraulical connection between superstructure and car body
65
Travel brake valve block with secondary pressure relieve valve is connected in the line to the travel motors. The return oil flow is restricted according to the pressure inlet.
mounted in the supply line to the travel motors, is located in the car body
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12.0 16 12.1
Symbols 12.1.6 Assembly and main components Symbol
Description
Used as / at / on
66
Remote control lever to control the main control blocks
Control lever in the operators cabin
67
Remote control pedal to control the main control blocks
Control lever in the operators cabin
68
Remote control valve to direct the pilot pressure proportional to the lever deflection to the “A” or “B”-side of the main control blocks. P= Pilot pressure line L= Return line 1 + 2 = Controlled output
Electric-hydraulic control system. Electrical signals from the joysticks or pedals are used to operate the remote control valves.
69
Hydraulic oil tank with leak and return oil filter, back pressure valve and sensors
Main hydraulic tank
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Hints for reading the Hydraulic Circuit Diagram
Section 12.0 Page 17
12.2 Legend for the circuit diagram (929 663 40): (1) - (4) (5.1) (5.2) (6) (7) (8.1) (8.2) (9) (10) (11) (12) (13.1) (13.2) (13.3) (13.4) (14.1) (14.2) (14.3) (15) (16.1 + 16.2) (17.1) (17.2) (18) (19) (20.1) (20.2) (20.3) (20.4)
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Main hydraulic pumps A4VSLO 750 LR3DN / 30L Axial piston pump (swash plate type) Fan drive pump Hydraulic oil cooler A7FO 63RNZB01 Axial piston pump (fixed displacement with, variable setting) Not used Not used Oil intake pipe with bleeder screw (Gear pump 8.2) Gear pump R1A5100C3A1A Pilot pressure - Pump regulation - Pump bearing lubrication Gear pump R1A5100C3A1A PTO-gearbox lubrication Control block III MO-3469-00 / 3MO-40 Special spool for lowering the boom (without pump pressure) Control block I MO-3468-00 / 3MO-40 Control block II MO-3455-00 / 4MO-40 Special spool for lowering the boom (without pump pressure) Control block IV MO-3454-00 / 4MO-40 High pressure filter at Control block III High pressure filter at Control block I High pressure filter at Control block II High pressure filter at Control block IV Remote control valve block Remote control valve block Remote control valve block Remote control valve block Manifold Grease pump (Hydraulic Cylinder)Lincoln Power Master Central Lubrication System Grease pump (Hydraulic Cylinder)Lincoln Power Master Slew ring Lubrication System Service line relief valve (SRV) Clam closing 150 bar Rotary distributor Orifice - bearing lubrication Main pump I Orifice - bearing lubrication Main pump II Orifice - bearing lubrication Main pump III Orifice - bearing lubrication Main pump IV
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12.0 18 12.2 Legend for the circuit diagram (929 663 40): (21.1) (21.2) (22) (23) (24) (25) (26) (27.1 – 27.11) (28.1 – 28.16) (29) (30) (31.1) (31.2) (32.1 – 32.4) (33) (34.1) (34.2) (35) (36) (37.1) (37.2) (38) (39.1 + 39.2) (40) (41) (42) (43.1) (43.5) (44.1 + 44.2)
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Travel gear drive L.H. Axial piston motor A2FM 500 /60W-VZH-01 Travel gear drive R.H. Axial piston motor A2FM 500 /60W-VZH-01 Not used Not used Pressure switch B24 – monitors item (92.1) – (92.2) Not used Not used Base plate for solenoid valves Solenoid valves – 4/2-directional control valve Pressure relief valve – PTO gear lubrication Hydraulic oil level gauge Pressure relief valve - Hydraulic oil cooler fan drive, with solenoid valve Y6a / Y6b for fan RPM control Not used Restrictor, shock absorbers for the hydraulic oil cooler Pressure filter (B22) – pilot pressure, pump regulation, pump bearing lubrication, track tensioning, grease pumps Pressure filter (B28)– Hydraulic oil cooler fan drive Not used Control and filter panel Pressure filter (B27) - PTO gear lubrication Hydraulic oil cooler fan drive Axial piston motor A2FM 63 /61W-PAB-03 Hydraulic oil cooler fan drive Axial piston motor A2FM 63 /61W-PAB-03 Check valve - ACV for hydraulic oil cooler fan drive Hydraulic oil cooler Suction oil tank Main oil reservoir Distributor manifold Temperature transmitter B49-1 – PTO gear oil temp. Temperature transmitter B15 – Hydraulic oil temp. Adapter
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Hints for reading the Hydraulic Circuit Diagram
Section 12.0 Page 19
12.2 Legend for the circuit diagram (929 663 40): (45) (46.1 + 46.2) (47) (48.1 + 48.2) (49) (50) (51.1 + 51.2) (52) (53) (54) (55) (56.1 + 56.2) (57.1 + 57.2) (58) (59.1 – 59.4) (60.1) (60.2) (61.1 + 61.2) (62.1 – 62.3) (63) (64.1 – 64.9) (65.1 – 65.4) (66.1 – 66.12) (67.1 – 67.4) (68.1 – 68.7) (69.1 – 69.23) (70.1 – 70.13) (71) (72) (73) (74) 02.03.05
Service line relief valve (SRV) Clam closing 150 bar the main control block II Block Pressure reducing valve – Track tensioning system Swing parking brakes – Spring loaded multi disk brake Not used Not used PTO gear oil cooler Not used Case drain filter Return oil collector tube Back pressure valve Travel brake valve block Travel parking brakes – Spring loaded multi disk brake Not used Return oil filter Slew gear drive L.H. Axial piston motor A2FLM 355 /60W-VZH-01 Slew gear drive R.H. Axial piston motor A2FLM 355 /60W-VZH-01 Swing brake valve block Shut-off valve – Truck tensioning system 2/2-directional control valve (manual operated) Pressure switch B17 – Min. PTO gear lubrication pressure Anti cavitation valves (ACV) at the distributor manifold (42) Restrictor block with service line relief valve (SRV) at the distributor manifold (42) Service line relief valve (SRV) at the main control blocks Dust cap for item (77.1 – 77.4) Check valve – Anti cavitation valve at the main control blocks Cover plate at the main control blocks Restrictor block with service line relief valve (SRV) at the distributor manifold (42) Not used Not used Not used Not used PC4000-6-E_#08165_Sec_12-0_rev0.doc
12.0 20 12.2 Legend for the circuit diagram (929 663 40): (75.1) (75.2) (76) (77.1 – 77.4) (78) (79) (80) (81) (82.1 + 82.2) (83.1 – 83.4) (84) (85)
Pressure transducer B164 Case drain filter camber Pressure transducer B163 Return oil filter camber Not used Oil drain, quick release coupling Not used Not used Proportional pressure reducing valve Y61 – Pump regulation Not used Bladder Accumulator – 5 liter, 150 bar Track tensioning cylinder B32 Bladder Accumulator – 10 liter, 10 bar
(86.1) (86.2) (87) (88) (89.1 + 89.2) (90) (90.1) (90.2)
Level switch B4 – Minimum hydraulic oil level Level switch B50 – Hydraulic oil refilling indication Shut off valve with S31 (Gate valve) Compensator Membrane accumulator – 1,3 liter, 31 bar Strainer Pressure switch B48 – travel parking brake operating pressure Pressure switch B16 – Swing parking brake operating pressure Not used Breather filter Not used Not used Remote control valve block Not used Solenoid valves – 4/3-directional control valve Not used Check valve Not used Hydraulic cylinder – access ladder Not used Not used Not used
(91) (92.1 + 92.2) (93) (94) (95) (96) (97.3) (98) (99.5) (100) (101) (102) (103) (104)
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Hints for reading the Hydraulic Circuit Diagram
Section 12.0 Page 21
12.2 Legend for the circuit diagram (929 663 40): (105) (106) (107) (108) (109) (110) (111) (112) (113.1 + 113.2) (114) (115)
Not used Pulsation damper, accumulator – 0,65 liter, 1 bar Return oil collector tube Not used Oil drain, quick release coupling Junction block Oil intake pipe with bleeder screw (Gear pump 8.1) Not used Pressure transducer (B85-1 & B86) Not used Not used
(116) (117) (118) (119.1 – 119.4) (120.1 + 120.2) (121) (122) (123) (124) (125) (126.3) (126.4) (127) (128.1 – 128.4) (129.1 – 129.4) (130) (131) (132.1 + 132.2) (133 – 135) (136) (137.1 + 137.2) (138.1 + 138.2) (140) (141)
Not used Not used Strainer – return oil collector tube Strainer – suction line of main pumps Adapter Not used Not used Not used Pressure relief valve Medium speed cooler fan Not used Pressure transducer – Back pressure valve (B166) Pressure transducer – pressure Hydraulic oil cooler (B165) Pressure transducer – Hydraulic oil level (B105) Pressure transducer – main pumps (B87a/ B87b/ B87c/ B87d) Floating valves (single control blocks) used Valve block (Track tensioning system) Pressure transducer – suction oil tank (B162) Block Block Junction block Check valves Check valves Pressure increasing valve (track tensioning system) Shut-off valve – Truck tensioning system 2/2-directional control valve (manual operated)
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12.0 22 12.2 Legend for the circuit diagram (929 663 40): (247) (248.1)
Option: “fast motion for travel” not used Solenoid valve – 4/2-directional control valve (swing brake)
(248.2) (249) (250) (251) (252.1) (252.2) (253.1)
Solenoid valve – 4/2-directional control valve (swing parking brake) Solenoid valves – 4/3-directional control valve (ladder) Cartridge valve block (complete) Manifold of cartridge valve block Pressure reducing valve for pilot pressure X2 (45bar) Pressure relief valve for pump support pressure X4 (60bar) Change over valve – Electronic pump regulation or hydraulic constant regulation 3/2-directional control valve (manual operated) (253.2) Pressure reducing valve – hydraulic constant regulation (253.3) Orifice (255.1) Solenoid valves – 3/2-directional control valve (Y126) (255.2) Solenoid valves – 3/2-directional control valve (Y17) (255.3) Solenoid valves – 3/2-directional control valve (Y17a) (255.4) Pressure reducing valve – ½ Qmax (256.3) Proportional pressure reducing valve Y127 – Swing brake (256.4) Double check valve (shuttle valve) (256.5) + (256.6) Check valves (257.1) Pressure relief valve (55 bar) – safety valve to protect the travel parking brakes in case of a defect rotary distributor (257.2) Solenoid valves – 3/2-directional control valve (Y16) (257.3) Check valve (257.4) Not used (258.1) Solenoid valve (Y125) (258.3) Pressure relief valve – access ladder (258.4) Double check valve (258.5 + 258.6) Check valve (258.7) Orifice
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Hints for reading the Hydraulic Circuit Diagram
Section 12.0 Page 23
12.2 Legend for the circuit diagram (929 663 40): Pressure check points: M1.1 M1.2 M2 M3 M3-1 M4 M5-1 M6 M7 M8 M9 M9 M10 M10 M11 M12 M13 M14 M16.1 + M16.2 M17.1 + M17.2 M19 M20 M21.1 + M21.2 M22 M24 + M25 M26.1 + M26.2 M27
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X4, Pump bearing lubrication, pump support pressure (60bar) X2 pressure, pilot pressure (45bar) Bladder Accumulator, pilot pressure (45bar) PTO gear lubrication pressure X1 pressure, hydraulic constant regulation only Release pressure for travel parking brake and operating pressure of the track tensioning system X1 pressure – general (electronic or hydraulic constant regulation general) Hydraulic oil cooler fan drive operating pressure Back pressure inside return oil filter chamber Travel parking brake safety pressure (55 bar) Back pressure inside case drain filter chamber Back pressure for hydraulic oil cooling system Swing parking brake operating pressure (45 bar) Operating pressure, Pump 3 Operating pressure, Pump 2 Operating pressure, Pump 4 Operating pressure, Pump 1 Boom cylinder piston side Bucket cylinder piston side Clam cylinder rod end Stick cylinder piston side Stick cylinder piston side Clam cylinder piston side Bucket cylinder piston side Boom cylinder piston side Pilot pressure / swing operation brake
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12.0 24 12.2 Legend for the circuit diagram (929 663 40): Pressure check points: M28.1 M28.2 M28.3 M28.4 M29.1 + M29.2 M29.5 + M29.6 M29.3 + M29.4 M30-1 M33 M34
Operating pressure, track tensioning system X4, Pump bearing lubrication, pump support pressure (60bar) Reduced “X3” pressure – to pump No 1 – ½ Qmax (~ 15 bar) Option operating pressure: “fast motion for travel” not used
M36 M36.1 + M37.2 M36.2 + M37.1 M37.1 M37.2 M39 M40 M41 M42
“X3” pressure – pumps No 2 + No 3 + No 4 Operating pressure, L.H. swing Operating pressure, R.H. swing Hydraulic cylinder access ladder “piston side” Hydraulic cylinder access ladder “rod side” Proportional pressure to hydraulic swing brake Bladder Accumulator, pilot pressure (45bar) “X1” pressure - Fixed pump No 3 (max. flow, X1= 45 bar) “X1” pressure - Fixed pump No 1 (max. flow, X1= 45 bar)
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Operation pressure L.H.-crawler forward Operation pressure L.H.-crawler backwards Operation pressure R.H.-crawler backwards Operation pressure R.H.-crawler forward Bleeder and pressure check point, track tensioning cylinder
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Hints for reading the Electric Circuit Diagram
Section 13.0 Page 1
Table of contents section 13.0 Section 13.0
Page Hints for reading the electric circuit diagram 13.1
Designation of electrical devices
2
13.2
Symbols
3+4
13.3
General information
5+6
13.4
Reading a circuit diagram
7+8
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Hints for reading the Electric Circuit Diagram
Section 13.0 Page 2
13.1 Designation of electrical devices Indicating letter A B
C D E F G H K L M N P Q R S T U V W X Y Z
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Kind of component System, subassembly, parts group, trigger boxes, control units Transducer for conversion of non-electrical variables to electrical variables, and vice versa. Speed sensors, pressure sensors, pressure switches, oil-pressure switches, temperature sensors Condenser, capacitor, Condensers and capacitors, general Elements with time lag, memory elements, binary elements Various devices and equipment Protection device Fuses, current protection circuits Power supply, generator Batteries, generators, alternators Monitor, alarm, signaling device Indicator lights, signal lights, headlights, warning buzzers, horn Relay, contactors Inductor Coils, windings Motor Regulators, amplifiers Measuring instrument High voltage switching units Resistors, heating devices Switches, selectors Transformer Modulator, converter from one electrical in an other electrical value Semiconductor, electron tubes, diodes, rectifiers, zener diodes Transmission path, conductor, antenna Terminal, Plug, Plug and socket connection Electrically actuated mechanical device Solenoid-operated valves Compensating units, filters, limiters cable connection
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13.0 3
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Hints for reading the Electric Circuit Diagram
Section 13.0 Page 3
13.2 Symbols Legend for illustration (Z 21816): Our common used symbols in accordance to VDE/IEC (Association of German Electrical Engineers DIN 40710 - 40716 and the International Electrical Commission) differ for the most part from the symbols in accordance to JIC/ASA (Joint Industrial Concil and American Standard Association) USA and Canada JIC EMP-1-1967 and ASA 2 32-3). For this reason the following comparative chart. 1) Normally open contact
2) Maintained contact
4) Normally closed contact
5)
7) Manual operated switch isolator, disconnect switch 10) NC contact with time lag
8) Foot-operated push-button switch 11) Multi-position switch selector
13) Contacts with time lag
14) Resistor general
16) Battery
17) Tapped resistor
18) Voltmeter
19) Inductive resistance
20) Continuously adjustable, general
21) Recording instrument
22) With iron core
23) Adjustable in steps
24) Signal lamps pilot lights
25) Continuously adjustable
26) Potentiometer rhesostat
27) Operating coil solenoid
28) Transformer
29) Capacitor general, continuously adjustable
30) Rectifier, semi conductor
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Push-button switch
3) Single pole two way contact break before make 6) Limit switch NO contact NC contact 9) Pressure operated switch 12) Indicating instrument (general) symbol 15) Ammeter
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13.0 4
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Hints for reading the Electric Circuit Diagram
Section 13.0 Page 4
13.2 Symbols Legend for illustration (Z 21817): 31) Rectifier bridge
32) Thermal over load limit
33) Phase, 4-wire system
34) Current transformer
35) Undervoltage relay
36) Junction of conductors
37) Voltage transformer
38) Temperature relay
39) Junction
40) Circuit interrupter
41) Contactor
42) Terminal
43) Circuit breaker, three phase
44) Generator (G)Motor (M)
45) Terminal
46) Thermal over- ground, load protection
47) 3-phase-motor
48) Earthing, general
49) Magnetic over- socket current protection
50) 3-phase squirrel cage
51) Plug and
52) Slipring motor
53) Fuse with bolted contacts 54) 3-phase squirrel cage induction motor in Star-delta starting 55) Thermal over- load relay 55) Two speed motor (tapped windings) (for ex. 8 to 4 poles)
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13.0 5
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Hints for reading the Electric Circuit Diagram
Section 13.0 Page 5
13.3 General information Legend for illustration (Z 21823): Komatsu circuit diagrams Each sheet has the following information in the bottom right hand corner: Diagram Number example: 897 844 40 Machine Type example: PC4000-6 Sheet Number and Total Number of sheets 01/63 - 02/ . etc. Each sheet is numbered from 8 (at the left corner) to 1 (at the right corner) along the top and bottom lines, and lettered down from F (at the top) to A (at the bottom) along the left and right side lines. This coordinate system enables you to find components easily. On the table of contents, page one, the individual circuits are listed up with the respective page number. Example: The circuit for the superstructure lighting is shown on page 39. Pages number two, three and four are cross reference lists of component codes related to page numbers. Example: The relay with the component code “K1-1” is shown on page 8. On page five is a list of answers to frequently asked questions (FAQ) concerning abbreviations, function of components (e.g. time relays) mathematical symbols etc. used in the diagram. All electrical components are connected via cable harnesses to the main switch board “X2”. There is only one Plug connector in between, which is always located close to the respective component like sensors, solenoids etc. All 24 volt wires are blue and have a printed code (every 10 cm) at each end of the wire. (see illustration) The first part of the code shows the required connection and the second part gives the information what is connected at the other side of the wire. Example: going to coming from coming from going to
X2S 45
= X2-Board, terminal group “S” = Terminal No 45
Y136 = Plug connector to solenoid .1 = Terminal 1 of connector
All circuits are shown currentless and all relays and switches are in neutral position.
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13.0 6
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Hints for reading the Electric Circuit Diagram
Section 13.0 Page 6
13.3 General information Legend for illustration (Z 21824): Explanation of the Drawing Concept (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16)
Drawing number Sheet number / quantity of sheets Designation of drawing Designation of component or assembly Column (vertical sections) Lines (horizontal sections) Component symbol Neutral wire / machine ground Designation of phase Phase strip Terminal strip and terminal Cable plug and pin number Relay coil Relay contacts, partially with detailed information Cross reference for the continuation, Page / Column Indication where the relay contact opens or closes
Location of the Main Terminal Boxes (X1) Dashboard inside the cabin (X2) Main switch board inside the cab base (3E14-1) Electronic control module (ECM- Quantum) left bank of the engine (3E54-1) Electronic control module (ECM- Cense) flywheel end of the engine
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13.0 7
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Hints for reading the Electric Circuit Diagram
Section 13.0 Page 7
13.4 Reading a Circuit Diagram. Legend for illustration (Z 21825):
)
• Examples are shown by sectional drawings out of the electric circuit diagram 897 844 40 page 08.
(1)
Section F8 / sheet 08 The hint F11/06.1 indicates that the wire from F11 is continued on sheet 06 column 1.
(2)
Section C4 / sheet 08 Shown is the relay coil K51-1 only and not its contacts. The contacts are shown somewhere else in the diagram. Switching and contact positions are shown below at the foot of that particular circuit in row C-C as shown below.
Example for K51-1: 08.5 : : :
1 5 2 6 3 7 4 8
9 10 11 12
opens on sheet 8 section 5 when relay is energized Not used Not used Not used
When diodes are fitted to a relay, they are fitted to allow a current flow in one direction only. An LED* (Light Emitting Diode) indicates a current flow if it lights up. When diodes ** are fitted anti-parallel to a relay coil, they absorb the high induced voltage caused by making and breaking the current flow through the coil. This occurs each time we operate a switch supplying current to the coil. The diode effect allows the induced current to circulate within the coil windings and decay when the energy to the coil is cut. * **
LED between A1 and coil Diode between A1 and A2.
(3)
Section F7 / sheet 08 Connectors and Terminals are identified by a letter and number code. X2 o 23-28 = Terminal box X2 Terminals 23 to 28 are linked with a metal bridge. continued
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Hints for reading the Electric Circuit Diagram
Section 13.0 Page 8
Cont.: 13.4 Reading a Circuit Diagram. Legend for illustration (Z 21826): (4)
Section E 1 sheet 08 The components have a letter and a number prefix, and these are explained below in rows A and B. Components are depicted in a system unique to VDE/IEC (Association of German Electrical Engineers DIN 40710-40716 and the International Electrical Commission) or to KMG standard. S27 = Toggle switch (with non-automatic return)
a.
F11
b.
F11 / 10.5 =
c.
S27 / 20.7 = Line S27, comes from switch S27, sheet 08 section 1 and continues on sheet 20 section 7.
=
Circuit breaker (24V power supply) Power line F11, comes from circuit breaker F11, sheet 08 section 8 and continues on sheet 10 section 5.
Function: If switch S27 is actuated, terminal A and B are connected and 24VDC will energize the coils of K121 and K121a on page 08 and simultaneously via line S27 a digital input to the PLC on sheet 20 section 7. Now the machine can be operated in emergency mode and a warning text appears on the display.
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Electronic Control System ECS
Section 14.0 Page 1
Table of contents section 14.0 Section 14.0
Page Electronic Control System ECS 14.1
14.2
14.3
14.4
14.5
14.6
General Design of the ECS-T System
2
14.1.1
Input and outputs of the PLC
3
14.1.2 14.1.3 14.1.4
Task PLC DIGSY plus ® Definitions; Symbols and Abbreviations
3 4 5 + 6 +7
How to Proceed due Maintenance and Installation
8+9
14.2.1 14.2.2 14.2.3
10 + 11 12 13
Meaning of the Status LED’s Short Circuit Marker -LED “MK” Diagnostic for Temperature-Module “ANM”
Front Connector Arrangement
14
14.3.1 14.3.2 14.3.3 14.3.4
14 + 15 16 + 17 18 19
Front Connector Arrangement BIM-Module Front Connector Arrangement, ANM-Module Ground connection of the Control Unit Interface-Connection COM SP /SK
Power supply
20
14.4.1 14.4.2 14.4.3 14.4.4 14.4.5
20 21 22 22 22
Operation Voltages +24 V Safety Precautions for Faultfinding CPU Voltage Range Electric Classification Fuse
Function explanations with electrical diagram
23
14.5.1 14.5.2 14.5.3 14.5.4
23 24 25 + 26 27
General Pressure Measuring Temperature Measuring Temperature – Resistance Chart PT100
Hints for reading the functional flow charts
28
14.6.1 14.6.2
28 29
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General Example
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Electronic Control System ECS
Section 14.0 Page 2
14.1 General Design of the ECS System ECS
Electronic Control System
Legend:
Illust. Z 21407a
(1)
PLC Programmable Logic Control (DIGSY plus ®)
(2) (3) (4) (5) (6) (7) (8) I/ O
Text display Keys for function control and pre-adjustments Outlet “X27” for data transfer Field computer system (like MODULAR MINING) Printer Memory card unit Laptop Input / Output data transfer
)
•
Items 5 to 8 are optional equipment
Meaning of the PLC front cover codes • BIM Binary Module • ANM Analogous Module • MK Short Circuit Memory • A Digital Output • E Digital Input • DIAG Diagnostic More in detail see page 4
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Electronic Control System ECS 14.1.1
Section 14.0 Page 3
Input and Output of the PLC, Illust. Z 21408 PLC = Programmable Logic Control (Programmable Logic Control = Control system with a write-readingmemory, whose content can be altered (via an serial interface) by a PC and the resp. Software. No mechanical action necessary.)
14.1.2
Task The PLC receives from the monitored excavator components the actual values and does an evaluation. The evaluation results in a control and display function. See I / O connection table (chapter 10) and electric circuit diagram for I / O levels and ports.
)
•
The picture shows as an example the application for a two motor version.
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Section 14.0 Page 4
PLC DIGSY plus ® (circuit diagram code E6) Legend for illustration Z 21409b 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Central Processing Unit (CPU) board. Binary Module (BIM) board. Analogues Module (ANM) board. MK Output short circuit marker LED red Input state-LED green, Inputs E1.1 - E1.8 up to E14.1-E14.8 Input or Output State-LED red (A2/ E9, Af/E10, A6/E11, A8/E12, A14/E21) Can be used as Inputs or Outputs Output state-LED red, Output A1.1 - A1.8 up to A13.1-E13.8 Diagnostic-LED (DIAG), (green flashing = OK.) 5Volt Voltage-LED (+5V), (green = OK.) Diagnostic LED for ANM COM SP Interface (COM SP) (Text display connection) COM SK Interface (COM SK) (PC-Connection) Binary Module BIM-plug-in location (slots) (X1-X5) Analogous Module ANM-plug-in location (slots) (X6-X8) Ground Connection (GND)
)
• The quantity and configuration of the BIM and ANM Module can be vary, depend on the excavator typ and additional options.
MK-LED, The short circuit marker are used to indicate an external short to GND • MK1, MK3, MK5, MK7 & MK9- LED for outputs A1.1 - A1.8 A3.1 - A3.8, A5.1 - A5.8, A7.1 - A7.8 & A13.1 – A13.8 • MK2, MK4 , MK6, MK8 and MK10 if there groups as outputs used • A MK-marker is placed, if an output (e.g. A1.1) gets from the program an output signal and at the same output happens an external short. The red MK 1-LED lights ON
)
• If there is a short all outputs of the resp. Output group i.e.. A1.1 - A1.8) are switched Off • The short circuit marker remains until the control system gets switched Off/ON (after eliminating the short).
State-LED Input lights up with a present 24 Volt signal. State-LED Output lights up with a switched On output. 5V-LED, indicate specified operation states by different colors and duration of lightning (Continuos On or flashing). For detail information see Section 4. DIAG-LED, indicate specified operation states by different colors and duration of lightning (Continuos On or flashing). For detail information see Section 4.
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Electronic Control System ECS 14.1.4
Section 14.0 Page 5
Definitions; Symbols and Abbreviations
≡ ≠ Bit
Sign used for “corresponds to” Sign used for “not equal to” A bit is the smallest unit for information. It can assume only two conditions: logical 0 or logical 1 ( also referred to as logical L-Level and logical H-Level).
Boolean algebra Mathematical rules for binary variables and conditions. For Boolean equations the following signs are used: Logical AND operation (AND or &) ∧ Logical OR operation (OR or >=1) ∨ Logical Negation (NOT or 0) ¬ Byte
Unit for Information unit comprised of 8 bits. A byte can assume a value between 0 and 255.
Word
Memory unit comprised of 2 byte or 16 bit. A word covers the numeric range from –32767 to +32767.
Clock
Signal pulse
VWP
VerWaltungProgramm: (management program) A control program created by the user.
AWP
AnWender Program: (Application program, user program) A control program created by the user.
AWL
AnWeisungsListe: (instruction sequence) Representation of a program using alphanumeric signs and symbols as defined in DIN 19239. Programming in AWL (selection logic) is the at present widely applied method of programming.
CMOS
Complementary Metal-Oxide Semiconductor: Complementary metaloxide semiconductor technology with very low-level closed circuit current. These semiconductors are used above all for accumulator and battery buffering.
RAM
Random Access Memory: Read-write memory in which each memory cell can be addressed in order to read, write or delete at any time. RAM losses all of its information when the computer is turned off which is why it is often buffered by accumulators or batteries.
EPROM
Erasable Programmable Read Only Memory: Read-only memory erasable by ultraviolet light and electrically programmable. With this memory type, the contents remain intact in the event of a power failure. In the case of DIGSY plus ® this memory contains the management program (firmware). continued
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Section 14.0 Page 6
Definitions; Symbols and Abbreviations
Cont'd: EEPROM
Electrically Erasable Programmable Read-Only Memory (also called E2PROM):Electrically erasable and programmable memory. In the event of a power failure, the contents of this type of memory remain intact. The DIGSY plus ® application program (AWP) is loaded into this type of memory.
COMPILER A program that translates the instructions of a programming language (e.g. instruction sequence [AWL]) into machine code (processor instructions). EDITOR
Utility program for the creation and changing of programs.
Loop
Program loop.
Off-Line
Operational method of a programming device without attached automation device.
On-Line
Operational method of a programming device (PC) is connected to the automation device thereby enabling data and programs to be read or changed.
PC
Personal Computer: Programmable unit for the DIGSY plus ®.
Watch-Dog: Internal supervisory unit in computers and automation devices used to recognize system and memory errors. CPU
Central Processing Unit: Control and central unit in an automation device usually based on a microprocessor. It can read the application program code and run the instructions contained therein.
Cycle Time
Time required for the application program to run through once. continued
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Electronic Control System ECS 14.1.4
Section 14.0 Page 7
Definitions; Symbols and Abbreviations
Cont'd: Coding Types and Number Systems ASCII
American Standard Code for Information Interchange: A standardized information processing code developed in the USA based on 7 bits = 0 – 127 (7-bit code), (extended ASCII-code of 8-bit = 0 - 255)
Digital
(Eng. Digit) is the representation of a continuos value or a physical quantity (e.g. voltage) in several levels as a numeric value. With regard to automation devices one also refers to “word processing” in which case a “word” is a number (e.g. 573).
Analogue
is the representation of a continuos physical quantity (e.g. current or voltage) which corresponds to the value of a proportional condition (e.g. rotational speed, routing, temperature, etc.) For an automation device this physical value converted into 1024 levels, for example (10-bit analogues-digital conversion). The digitalized value thus acts within a defined range (e.g. 0 ≡ 0 volts to 1024 ≡ 10 volts) in proportion to a certain input quantity (e.g. voltage). Conversely, by using a digital-analog conversion, a digitalized value can be converted into a continuous output signal (current, voltage).
Numeral
A value expressed in one digit: from 0 to 9 in the decimal system and 0-F in the hexadecimal system.
Number
Value consisting of one or more numeric characters.
Baud
Unit used in serial transmission of data: bits per second (bit/s).
Baud Rate
Modulation rate or transmission speed of serial transmission of binary numbers. The DIGSY plus uses a baud rate of 2400 baud for communication and down-loading.
Binary
Numbers, data and information which are exclusively expressed using the two values 0 and 1 are bivalent = binary dates and information, exclusive with the use of digits 0 and 1 (e.g. 1 = current 0 = no current).
Dual(Binary) Number (Dual = 2) is the simplest binary numeric expression. Each position is arranged according to increasing powers of 2. Example: 13463dec. = 0011 0100 1001 0111dual
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Electronic Control System ECS 14.2
Section 14.0 Page 8
How to Proceed due Maintenance and Installation
Keep in mind • - BE CAREFUL • - BE ALERT • - THINK ABOUT WHAT YOU ARE DOING Any PERSON doing any work in or around the machine must be familiar with the local SAFETY INSTRUCTIONS and with the specific SAFETY INSTRUCTIONS REGARDING TO HIS OCCUPATION. • Serious damage may happen at unqualified actions at the System or Unit or when not paying attention to the hints given in this manual or on labels at the units Qualified persons in sense of the safety relevant hints in this manual or on the product, are persons which are • either as project engaged person familiar with the safety concept for automatic control systems; • or as operating personal for the use of an automatic control system being instructed; • or having the authorization and occupation to put such systems into operation or doing repair work as well as having the authorization and occupation to put such systems/units into operation regarding the power circuits and there safety standards and, to earth and to mark it. continued
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Section 14.0 Page 9
How to Proceed due Maintenance and Installation
Cont’d.: • Serious damage may happen at irrelevant opening and improper repair. Open always the resp. circuit breaker before opening a unit. I/O – cables may only be connect or disconnect in a powerless state. A BIM module will be damaged while supplying an external power of 24VDC to the inputs and/ or outputs. If it is necessary for faultfinding or external unit checks the connection to the PLC has to be interrupted. • Without power interruption the interface cable are only allowed to be disconnect or connect when following preconditions are given: 1. The cable must be shielded and the shield must be connected to the cover of the plug-in connector. 2. A potential balance must be made by connecting the GND potential parts of the plug connector parts before connecting the cables. • Replace the fuses only by fuses which matches the values given in the technical dates
ã
• Do not through batteries into open flame and do not solder at their cell body, explosion can occur (max. Temperature 100° C). Do not open and do not recharge batteries that contain lithium or mercury. Replace them by same type only! • Dispose batteries and accumulators as special waste.
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Section 14.0 Page 10
Meaning of the Status LED’s, Illust. Z 21431b The DIGSY plus performs by the function of the Status LED’s (5V and DIAG) and the so named Diagnostic Words* (DW1 up to DW256) many data and statuses. With a PC and the Program- and Diagnostic Software the. Diagnostic Words are visible on a monitor. The following sections explain the diagnostic possibilities more in detail. * Can be called-up by PC assistance only. Table: Statuses of the +5 V-LED and their meaning LED Effect Cause 5 V-LED Voltage green o.k. 5 V-LED CPU not working Supply red (RESET) < 4,65V DIAG-LED red 5 V-LED CPU not working Supply OFF (except the is missing LED is defect) Fuse S1 defect
Remedy Check the +24 V Supply if not o.k. *) Check the +24 Volt Replace the ** Fuse F1
LED defect (if DIAG LED is ON)
*)
others
*)
Watchdog in operation
*)
5 V-LED flashing red/green
cyclically new starts
red/ orange Continuos Reset Component fault *) ** Replacement only after co-ordination with Komatsu Mining Germany, Dept. 8124.1 *) = Return PLC to manufacturer continued
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14.2.1 Meaning of the Status LED’s, Illust. Z 21431b Cont’d.: Table: State of the DIAG-LED and their meaning LED Effect Cause DIAG-LED Program Communication via green in operation Interface COM-SP not active (interrupted) COM-SP Text display DIAG-LED ProgramTemperature orange state inside housing unchanged too high +24 VCPU < 14 V
Increase the voltage
Accumulator voltage too low
Replace the accumulator module
Fixed operands deleted
Check the accumulator connections
SPS in start loop after voltage ON
wait
programming in operation EEPROM not Initialized
Stop the programming *1) Initialize EEPROM *1)
EEPROM- or RAM- fault
Initialize EEPROM *1) if the fault is still present *2) Start program *1)
DIAG-LED RED
DIAG-LED OFF
Program not running (stopped)
Program not running (except LED defect)
Program stopped
No Program otherwise LED defect DIAG ProgramCommunication via flashing state Interface COM-SP or COM-SK active unchanged Color State COM-SP⇔ Text depending Display COM-SK⇔ (PC) *1) Function of the Programming Software PROSYD *2) = Return PLC to manufacturer
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Remedy Check the cable connection and the Interface port
External cooling
Load program *1) *2)
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Section 14.0 Page 12
Short Circuit Marker -LED “MK” The short circuit markers are used to indicate a short of the outputs at an external short to GND. A “MK” marker will be initialized if by the user-program an output signal is given and at the same output is an external short present. The “MK” marker remains until (after short elimination) the control system is switched OFF and ON. See also Section 14.1.3 page 4
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Section 14.0 Page 13
Diagnostic for Temperature-Module “ANM” For the function control a two-color LED is used, visible at the front cover. The diagnostic - LED indicates following states: - LED red: System in reset mode or range overflow of one or more analogous outputs. - LED green:
Ordinary operation, no range overflow.
- LED red/green flashing (2Hz) Watch-dog timer response or cyclically overflow of one ore more analogous outputs.
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Section 14.0 Page 14
14.3 Front Connector Arrangement 14.3.1
Front Connector Arrangement, BIM Module (Digital Input / Output)
)
• .This is an example for the first Slot. Additional BIM Modules can be vary depend on configuration of the variable input/output port A2/E9/ A4E10, A6/E11, A8/E12 or A14/E21. • The configuration for the respective excavator is written in the EA-Configuration chart (EA-Belegungsliste) see Apendix.
Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
Symbol Input 1.1 Input 1.2 Input 1.3 Input 1.4 Input 1.5 Input 1.6 Input 1.7 Input 1.8 Input 9.1 Input 9.2 Input 9.3 Input 9.4 Input 9.5 Input 9.6 Input 9.7 Input 9.8 0 V (GND) Input 2.2 Input 2.4 Input 2.6 Input 2.8
Operand E 1.1 E 1.2 E 1.3 E 1.4 E 1.5 E 1.6 E 1.7 E 1.8 E 9.1 E 9.2 E 9.3 E 9.4 E 9.5 E 9.6 E 9.7 E 9.8 E2.2 E2.4 E2.6 E2.8
Definition Input 1 of the input group. 1 Input 2 of the input group. 1 Input 3 of the input group 1 Input 4 of the input group 1 Input 5 of the input group 1 Input 6 of the input group 1 Input 7 of the input group 1 Input 8 of the input group 1 Input 1 of the output group 2 Input 2 of the output group 2 Input 3 of the output group 2 Input 4 of the output group 2 Input 5 of the output group 2 Input 6 of the output group 2 Input 7 of the output group 2 Input 8 of the output group 2 Ground Input 2 of the input group 2 Input 4 of the input group 2 Input 6 of the input group 2 Input 8 of the input group 2
continued
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14.3 Front Connector Arrangement 14.3.1
Front Connector Arrangement, BIM Module (Digital Input / Output)
Cont’d.: Pin 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
Symbol Output 1.1 Output 1.2 Output 1.3 Output 1.4 Output 1.5 Output 1.6 Output 1.7 Output 1.8 UE/A UE/A UE/A UCPU Input 2.1 Input 2.3 Input 2.5 Input 2.7 Output 1.1 Output 1.2 Output 1.3 Output1.4 Output1.5 Output 1.6 Output 1.7 Output 1.8 UE/A UE/A UE/A UCPU 0 V (GND)
Operand A 1.1 A 1.2 A 1.3 A 1.4 A 1.5 A 1.6 A 1.7 A1.8
E 2.1 E 2.3 E 2.5 E 2.7 A 1.1 A 1.2 A 1.3 A 1.4 A 1.5 A 1.6 A 1.7 A1.8
Definition Output 1 of the output group 1 Output 2 of the output group 1 Output 3 of the output group 1 Output 4 of the output group 1 Output 5 of the output group 1 Output 6 of the output group 1 Output 7 of the output group 1 Output 8 of the output group 1 Under Load Voltage Under Load Voltage Under Load Voltage DIGSY (plus)- Operation Voltage Input 1 of the input group 2 Input 3 of the input group 2 Input 5 of the input group 2 Input 7 of the input group 2 Output 1 of the output group 1 Output 2 of the output group 1 Output 3 of the output group 1 Output 4 of the output group 1 Output 5 of the output group 1 Output 6 of the output group 1 Output 7 of the output group 1 Output 8 of the output group 1 Under Load Voltage Under Load Voltage Under Load Voltage DIGSY (plus)- Operation Voltage. Ground / GND
UE/A = Voltage. Input / Output
There are two pins (two channels) parallel connected only for output A1.1 – A1.8 (the same for additional boards A3, A5, A7, A13). • • •
E1, E2,...E7, E13 and E14 input port fix configured. A2/E9, A4/E10, A6/E11, A8/E12 and A14/E21 variable input or output ports depend on software programming. A1/A9, A3/A10, A5/A11, A7/A12 and A13/A21 output ports fix configured.
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14.3 Front Connector Arrangement 14.3.2
)
PIN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 •
Front Connector Arrangement, ANM-Module (Analogues Input) • .This is an example for the first ANM slot. Additional ANM modules configuration can be vary depend on configuration (temperature or pressure). • The configuration for the respective excavator is written in the EAConfiguration chart (EA-Belegungsliste) see Appendix and the respective electric diagram.
PIN-NAME KR KG KA GND/ANA GND/ANA GND/ANA GND/ANA A1I A1U A2I A2U A3I A3U A4I A4U A4G A3G A2G GND/ANA GND/ANA GND/ANA E8G E7G E6G E5G
OPERAND
AW Z.1 AW Z.1 AW Z.2 AW Z.2 AW Z.3 AW Z.3 AW Z.4 AW Z.4
COMMENTARY Relay contact Relay contact Relay contact Analogous GND Analogous GND Analogous GND Analogous GND Current output 1 Tension output 1 Current output 2 Tension output 2 Current output 3 Tension output 3 Current output 4 Tension output 4 GND – Output 4 GND – Output 3 GND – Output 2 Analogues - GND Analogues - GND Analogues - GND GND – input 8 GND – input 7 GND – input 6 GND – input 5
All pins are internal connected continued
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14.3 Front Connector Arrangement 14.3.2
Front Connector Arrangement, ANM-Module (Analogues Input)
Cont’d.: PIN 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
PIN-NAME A1G 4U+E4G A2G E3G A3G E2G A4G E1G GND/ANA E8 GND/ANA E7 GND/ANA E6 GND/ANA E5 A1G E4 E4 E3 E3 E2 E2 E1 E1
OPERAND
EW Z+1.4 EW Z +1.3 EW Z +1.3 EW Z +1.3 EW Z.4 EW Z.4 EW Z.3 EW Z.3 EW Z.2 EW Z.2 EW Z.1 EW Z.1
COMMENTARY GND - Output 1 GND - Input 4 GND - Output 2 GND - Input 3 GND - Output 3 GND - Input 2 GND - Output 4 GND - Input 1 Analogues – GND Input (U/I) 8 Analogues – GND Input (U/I) 7 Analogues – GND Input (U/I) 6 Analogues – GND Input (U/I) 5 GND – Output 1 Input (U/I) 4 Input (U/I) 4 Input (U/I) 3 Input (U/I) 3 Input (U/I) 2 Input (U/I) 2 Input (U/I) 1 Input (U/I) 1
• All pins are internal connected
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14.3 Front Connector Arrangement 14.3.3
Ground connection of the Control Unit Attention: The complete shield of the analogous cable must be connected to the ground (GND) bolt of the PLC housing. This bolt must be connected to the X2 frame / machine ground by a cable (as short as possible) with 2,5 mm2 cross section. When using plug connectors with metal boxes and connected shield the additional complete shielding of the analogous cable with the ground bolt is not necessary. But attention must be played that the metal box is connected by screws with the PLC housing. The twisted signal lines are pair wise shielded and already via the 50-pol female part of the connector connected to ground. The single shielding at the free end of the cable must not be connected with earth.
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14.3 Front Connector Arrangement 14.3.4
Interface-connection COM SK / SP
Legend for illustration Z 21425a (Exemplary picture about what possible) (1) Text display (2) PLC (3) Plug socket “X27” (4) Laptop computer (5) Memory card system (6) Portable printer (7) Field dispatch system Cables: VL3 VL4 VL5 VL6 VL7 VL8
X27 to Laptop X27 to Memory Card System 24V Power supply to Memory Card System X27 to Portable Printer 24V Power supply to Portable Printer X27 to Field Computer System
Communication interface: COM-SK => Programming interface (Baud rate 19200) COM-SP => Communication with text display (Baud rate 9600)
)
• Data cables and/or communication systems are optional equipment. • For more detailed information see OPERATION MANUAL of the shovel and the Software Program for the individual Communication System
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14.4 Power supply 14.4.1 Operation Voltages +24 V, Illust. Z 21426 Study together with the relevant circuit diagram 50-pin SUB Connector: + 24 V CPU-Supply: GND: + 24 V I/O-Supply:
Pin 33 and 49 Pin 17 and 50 Pin 30 - 32, 46 – 48
This supply voltage is the operating voltage for the module outputs. It must be strong enough to carry the load current of all outputs. It is provided with a LOAD-DUMP protection to protect (for short times) wrong polarity and over voltage peaks. • Wrong polarity causes destroying of the module! • External 24 V supply to the outputs causes destroying of the module!
See next page for more information
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Electronic Control System ECS
Section 14.0 Page 21
14.4 Power supply 14.4.2
Safety Precautions for Faultfinding, Illust. Z21427
• As already mentioned no external 24 V supply is allowed to the outputs of the BIM modules of the PLC. • If it is necessary while tracing faults, the cable to the PLC must be disconnected subsequent to a component check, thus as relays, solenoids or others by the PLC controlled components. Procedure: Study together with the relevant circuit diagram 1. Find the terminal between the component and the PLC. 2. Example terminal 8X2-280 for the solenoid valve 8Y6.1. 3. Disconnect the wire on one side of the terminal. 4. Now supply 24 V to the solenoid and check function of it. 5. Finally re-connect the wire to the terminal Binary Outputs A 2A-Short circuit proof Each single Output of the Output group can withstand a load of 2A, but the total load must not exceed 10 A. The Output group will be switched OFF if one of the Output becomes overloaded (> 2 A), the short circuit marker will be set and the “MK”- LED comes ON. (A1¿ MK1, A3¿ MK3, A5¿ MK5)
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Electronic Control System ECS
Section 14.0 Page 22
14.4 Power supply 14.4.3 CPU Voltage Range • Electrical requirements +24 supply volt • 14 V up to 36 V without any restrictions regarding the max. current consumption of 4 amps out of the +5 V logic voltage. • At voltage drops below 18 V the 2amps-outputs switched OFF due to safety reasons. The short circuit markers initiated. • The +24 V CPU is monitored on the CPU plus DB16.1 After the diagnostic bit “Under-voltage UCPU “ DB16.1 has been set, all access to the EEPROM memory of the CPU plus is blocked • A drop below 9V results in a reset. • During and after voltage drops according to DIN 40839 part 2 operates the CPU plus normally.
14.4.4 Electric classification The voltage supply meets the requirements according to: • ISO 7637-2 Automotive Technique 24V • DIN 0871-B • IEC 801-4 step 4, VDE 0843-4. • DIN/VDE 0470 part1 (old DIN 40050)
14.4.5 Fuse TR5 / 2.5AT IEC 127-3 Manufacturer Wickmann,
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Electronic Control System ECS
Section 14.0 Page 23
14.5 Function explanations with electrical diagram 14.5.1
General
Signal Status Voltage level: „1“ = 24 V* between E (Input) and GND „0“ =
0 V** between E (Input) and GND
* 13 V up to actual supply voltage ** 0V up to 5 V
The left half of the picture shows so named PULL-DOWN resistors and the right half PULL-UP resistors. The resistors are installed to get a low ohmical input. A system with contacts only leads to a (high ohmical) input if dust or moisture bridges the contacts. PULL-DOWN resistors are installed with a normal NC contact (means with a de-energized relay or normal closed switch contact) thus the ECS recognize a fault after switching ON the system. PULL-UP resistors are installed with a normal NO contact (means with a deenergized relay or normal open switch contact) thus the ECS recognize a fault after switching ON the system.
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Section 14.0 Page 24
14.5 Function explanations with electrical diagram 14.5.2
Pressure Measuring (Hydraulic System), Illustration Z 22805 (study with the respective circuit diagram) (Program run see Flowchart)
Analogous Inputs: „EW 14.1“ for pressure sensor B87A (0 up to 500 bar) Measuring channel: 0......10 V Function: - Voltage supply for the pressure sensor: 24 V - Output voltages Ua (OUT+, pin 2) of the pressure sensors: Sensor 0 – 0,4 bar ¿ K= 25 V / bar Sensor 0 – 60 bar ¿ K= 0,1667 V / bar Sensor 0 – 500 bar ¿ K= 0,02 V / bar (Pressure sensors with +1 V Offset) Possible voltage checks: 24 V Supply between supply line 15 (start at circuit breaker) and GND. Output voltage OUT (pin 2) of the sensor between GND. Use respective circuit diagram for terminal numbers. * How to calculate the Output voltage Ua: Ua = output voltage proportional to the pressure input. P = input pressure K = calculation factor for the respective pressure sensor. Ua = (P x K) + 1 V Example for 200 bar and a 0 – 500 bar sensor: Ua = (200 x 0,02) + 1 V = 5 V
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Electronic Control System ECS
Section 14.0 Page 25
14.5.3 Temperature Measuring and trouble shooting Illustration Z22803a General: (study with the respective circuit diagram) The signal of the PT100 temperature probe can’t connect direct to the ANM – Module (Analog input of the PLC). A temperature transducer module change the PT100 signal (Ohm) into a suitable current (mA) signal for the ANM – Module. The temperature probe is connected with a four wire technique to compensate the line resistance of the long wire between the X2 switch board and the temperature probe. Analogous Inputs (eg.: Hydraulic oil temperature sensor B15) The temperature probe B15 is with 4-wire technology (distorting compensation) connected to the transducer U15 terminal 1, 4, 2, and 3 (measuring range: -50° C......+150° C). The output terminal 5 and 6 of the transducer is connected to the ECS analogues input „EW 2.1“ (input range 4 – 20 mA). The transducer need 24 V power supply via terminal 7 and 8 (+24V, ground). Function: The temperature transducer convert the measured values from the PT100 temperature probe into electrically standardized analog signals. With the four wire technique the length and the cross section of the wires are not important; because the electrical resistance of the two current lines gets compensated. The sensor is supplied with a low electrical current from the temperature transducer (I+ and I-). Additional to the temperature probe (PT100) resistance the line resistance influence the current “flow” what falsified the PT100 measurement. To compensate the line resistance there are two additional lines (U+ and U-) close to the PT100 connected. Via this lines the transducer measure exact a tension drop between in- and output of the PT100 probe witch is only created by the PT100 resistance. Because there is no current “flow” through this lines witch are influenced by the line resistance (compared to hydraulic system- it’s like a test hose with a pressure gauge). The module convert this tension drop into a current signal (4-20mA) which is proportional to the temperature. In the interest of proper function must the line resistance not exceed 50 Ω. Additional the lines must be shielded according to the standards. The picture shows the wiring of a PT100 probe to a temperature transducer in four wire technique. continued PC4000-6-E_#08165_Sec_14-0_rev0.doc
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Section 14.0 Page 26
Temperature Measuring and trouble shooting, illustration Z22803a Cont’d.: Possible measurements PT100: Disconnect the wires at the resistor and measure the resistance across the resistor. Compare the measured resistance with the values given in the table on next page. If the value correspond to the temperature measured with an other temperature gauge the PT100 resistor is OK.; otherwise replace resistor. Wiring: Disconnect the wires at the resistor and inside X2-box at the temperature transducer terminal 1, 2, 3, and 4. Measure the line resistance to the ground. All single wire resistance must be the same. Transducer: Connect a Ampere-meter in line between terminal 5 of the transducer and the disconnected wire to the ECS. Select mA range and check the current. The value must compare to the PT100 resistance with the following calculation: I = [( 50 + t ) x 0,08 ] + 4 t = temperature [°C] (Check temperature via PT100 resistance and temperature chart next page) I = current [mA] to the ECS
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Electronic Control System
Section 14.0 Page 27
ECS 14.5 Function explanations with electrical diagram 14.5.4
Temperature – Resistance Chart PT100 Basic Values in Ohm according to DIN 43 76 For Measuring Resistor PT100
°C
-0
-1
-2
-3
-4
-5
-6
-7
-8
-9
-50
80,31
79,91
79,51
79,11
78,72
78,32
77,92
77,52
77,13
76,73
-40
84,27
83,88
83,48
83,08
82,69
82,29
81,89
81,50
81,10
80,70
-30
88,22
87,83
87,43
87,04
86,64
86,25
85,85
85,46
85,06
84,67
-20
92,16
91,77
91,37
90,98
90,59
90,19
89,80
89,40
89,01
88,62
-10
96,09
95,69
95,30
94,91
94,52
94,12
93,73
93,34
92,95
92,55
0
100,00
99,61
99,22
98,83
98,44
98,04
97,65
97,26
96,87
96,48
°C
0
1
2
3
4
5
6
7
8
9
0
100,00
100,39
100,78
101,17
101,56
101,95
102,34
102,73
103,12
103,51
10
103,90
104,29
104,68
105,07
105,46
105,85
106,24
106,63
107,02
107,40
20
107,79
108,18
108,57
108,96
109,35
109,73
110,12
110,51
110,90
111,28
30
111,67
112,06
112,45
112,83
113,22
113,61
113,99
114,38
114,77
115,15
40
115,54
115,93
116,31
116,70
117,08
117,47
117,85
118,24
118,62
119,01
50
119,40
119,78
120,16
120,55
120,93
121,32
121,70
122,09
122,47
122,86
60
123,24
123,62 124,01, 124,39
124,77
125,16
125,54
125,92
126,31
126,69
70
127,07
127,45
127,84
128,22
128,60
128,98
129,37
129,75
130,13
130,51
80
130,89
131,27
131,66
132,04
132,42
132,80
133,18
133,56
133,94
134,32
90
134,70
135,08
135,46
135,84
136,22
136,60
136,98
137,36
137,47
138,12
100
138,50
138,88
139,26
139,64
140,02
140,39
140,77
141,15
141,53
141,91
110
142,29
142,66
143,04
143,42
143,80
144,17
144,55
144,93
145,31
145,68
120
146,06
146,44
146,81
147,19
147,57
147,94
148,32
148,70
149,07
149,45
130
149,82
150,20
150,57
150,95
151,33
151,70
152,08
152,45
152,83
153,20
140
153,58
153,95
154,32
154,70
155,07
155,45
155,82
156,19
156,57
156,94
150
157,31
157,69
158,06
158,43
158,81
159,18
159,55
159,93
160,30
16067
Example:
84 ° C
Ì 80° + 4° = 132,42 Ω
124,4 Ω
Ì 124,4 ≈ 124,39 = 60° + 3° = 63 °C
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Electronic Control System ECS
Section 14.0 Page 28
14.6 Hints for reading the functional flow charts 14.6.1
)
General
• Probably the best aid for trouble shooting is the confidence of knowing the system and how to use the ECS. Every component has a purpose in the system. The construction and operating characteristics of each one should be understood. • Use always the electric/hydraulic circuit diagram the flowchart and the operation manual for the specific machine.
1. Select on page 1 of the flow chart, (which contains the table of contents and the main program) the respective subprogram, for example the Power-Master lube system. 2. Components in the flow chart, have the same identification code as in the electric/hydraulic circuit diagram, as shown in cross reference list (page 2-4). For example: Relay K50 = ? On page 2 (cross reference list) you find out that relay K50 is shown on page 43 of the flowchart. 3. On each page of the respective subprogram you will find the functional description in plain text. In case of problems concerning reading the program loops, you may find answers in the frequently asked questions list on page 6 and 7 of the flow chart.
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Electronic Control System ECS
Section 14.0 Page 29
14.6 Hints for reading the functional flow charts 14.6.2
Example: Monitoring the X1-pressure for pump control, illustration Z25072 Grey shaded fields in the table below shows the normal way , used from the program, if the excavator is in “standard condition”. Item 1)
query Sensor or cable defect?
Yes No B85-X : 5 sec. < --6bar B85-X : 5 sec. : Voltage i.e. +55,3bar i.e. > 11V at EW13.3
⇓
2) 3)
_running_motor-x > 15 sec ? X1-pressure to high?
Fault message No 1190 Motor X is running for more than 15 seconds B85-X : 2 sec. > 40bar i.e. > 6,5V at EW13.3
⇓
Motor X is not running B85-X : 5 sec. : Voltage below 6,5V at EW13.3
Fault message No 962
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Section 15.0 Page 1
Lubrication System
Table of contents Page General Function Oscillation Cylinder and Control Block Adjustments One line system Electrical function Capacitive analog sensor for lubricant level monitoring Adjustments End Line pressure switch Injectors Function Pinion type (dummy wheel) system Electrical Function (dummy wheel) system Capacitive analog sensor for lubricant level monitoring Adjustments End-Of-Line Switch setting Injectors Components Hydraulically driven lube pump Injectors End-Line Switch In line Filter Vent valve (Solenoid valve)
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Lubrication System
Section 15.0 Page 3
Lubrication System
General Function
Legend: illustration Z 24042a (1) Lubricant pump drive (Hydraulic cylinder) (2) Solenoid valve (Oil pressure supply) (3) Flow control valve (4) Pressure reducing valve (5) Hydraulic oil supply line (Pilot pressure) (6) Hydraulic oil return line (7) Vent valve (Solenoid valve, de-energized open to barrel) (8) Grease supply line to injectors (9) Lubricant level indication (capacitively analog sensor) (10) Lubricant barrel (11) Pump mechanism (12) Lubricant filter (13) Hydraulic pressure test plug (Operating pressure) (14) Lubricant pressure gauge (Operating pressure) (15) Vent line to barrel (16) Breather (17) Electrical terminal box
)
• Cylinder pressure must not exceed 650 psi (45 bar)
continued
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Lubrication System
Cont'd.
X-axis Y-axis
Time Lubricant supply line pressure
PI S+ PH SPR PT
Pressure Increasing Switch point ON of the end of line pressure switch Pressure Holding Switch point OFF of the end of line pressure switch Pressure Relieve Pause Time
Lubrication System
Function of a lubrication cycle
Section 15.0 Page 5
illustration Z24042c and Z22023a
PT-phase With the pump and controller system in a rest state a pre-set pause time interval occurs as determined by the PLC. Diagram position (a): A 24 VDC signal from the PLC activate solenoid valve (2) that opens and activate the lubrication pump. (*). As solenoid valve (2) opens hydraulic oil flows through the pressure reducing valve (4), it lowers the hydraulically pilot oil pressure to the operating range of the hydraulic driven lube pump. The reduced pilot oil pressure operates now the grease pump. The oil cylinder 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.) At the same time a 24 V signal energize release valve (7), it close now the release line to the lubrication container. PI-phase With energized release valve (7) (*) and solenoid valve (2) the pump continues to cycle until maximum pressure is achieved and the injectors have metered lubricant to the bearings. S+ point, diagram position (b) When the maximum system pressure is reached the end-of-line switch (*) open its contact. In the normal application is the end-of-line switch adjusted to 185 bar (2630 psi. ).The pressure increasing phase is now finished. The open pressure switch (*) signals the controller to stop the pumping cycle and the controller terminates the signal to the solenoid valves (2) The pilot oil flow to the pump stops.
Solenoid valve 2 Y7, CLS
Vent valve 7 Y7a, CLS (1)
end-of-line switch B43, CLS
Y8a, CLS (2) Y9, SLS
Y9a, SLS
B46, SLS
SLS = Slew Ring Teeth Lubrication System CLS = Central Lubrication System (*) check respective circuit diagram continued PC4000-6-E_#08165_Sec_15-0_rev0.doc
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Lubrication System
Cont'd.
X-axis Y-axis
Time Lubricant supply line pressure
PI S+ PH SPR PT
Pressure Increasing Switch point ON of the end of line pressure switch Pressure Holding Switch point OFF of the end of line pressure switch Pressure Relieve Pause Time
Lubrication System
Section 15.0 Page 7
Cont'd.
PH-phase Release valve (7) is still energized to keep the pressure in the lubricant line for a fix adjusted time (pressure holding time normally 5 min). Diagram position (c): With expired pressure holding time vent valve (7) de-energize. It opens the release line to the lubricant container. The lubricant line pressure drop to zero so the injectors can recharge for the next lubricant injection. (PR-phase). PR-phase In the pressure relieve phase the end of line switch (*) move back to neutral contact position it signals the PLC that the lube pressure relieve phase is now active. PT-phase The system is now at rest (pause time), ready for another lube cycle and the sequence repeats itself.
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Lubrication System
Lubrication System
Section 15.0 Page 9
Oscillation Cylinder and Control Block, illustration Z 21174
Description: Oscillation cylinder (6) is auto directional controlled, non pressure related. This differential cylinder is connected to the pilot pressure suppliy line (P) and a tank line (T). The speed is contolled by a flow contol valve (3) and the maximum working pressure is controlled by a pressure reducing valve (2).
Function: The Oscillatin cylinder (6) starts as soon pilot pressure is send via the connection (P) to the control block (1). Design related the cylinder (6) retract always first after start or from any position the piston has stopped before. When the cylinder reaches the fully retracted position the flow will be redirected automatically and the cylinders moves in the extending position. If the cylinder comes to an stop in between the end positions weather the oil supply get stopped or the cylinder is hold back by a higher work resistance than the supply pressure, the cylinder changes direction and retracts.
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Lubrication System
Lubrication System
Adjustments
Section 15.0 Page 11
(illustration Z21175b):
Stroke speed For a sufficient lube pump operation 18 – 20 double strokes / min for the pump drive cylinder are required. Therefore the flow reducing valve (3) has to be adjusted accordingly. Procedure: 1. Remove electrical plug connection form the discharge valve (7), so no pressure built up will take place during the following test. 2. Start motor. 3. Switch “ON” the lube system annually and count strokes per minute, visible on the moving up and down of pipe (1). If adjustment is required: a. Loosen lock nut (3.1) b. Turn adjustment (3) until the right number of strokes is achieved. turn set screw ccw for more speed and cw to reduce the speed c. Tighten lock nut (3.1). Working pressure The pressure reducing valve (2) mounted in the oscillation control block reduce the supply pressure internally to maximal allowed 45 bar. The pressure ration is 6,55 to 1, that means 45 bar supply pressure result in 295 bar maximum lubricant pressure. At the end of line pressure switch the pressure should be 180 ±0,5 bar. With the lubricant line resistance and different lubricant viscosity the pressure at the lubricant pump output must be higher as 180 bar. For standard condition adjust the maximum pump pressure to 220 bar –250 bar, depend on lubricant line resistance and different lubricant viscosity. Procedure: 1. Disconnect quick coupling (8), so the pump will be blocked when started. 2. Start motor. 3. Switch “ON” the lube system manually, the gauge should show 220-250 bar. If adjustment is required: a. Loosen lock nut (2.1) d. Turn adjustment (2) until the right pressure is shown at the gauge. turn set screw ccw for lower pressure and cw to increase the pressure b. Tighten lock nut (2.1). c. Reconnect quick coupling (8).
)
• If the required pressure can’t be adjusted, check adjustment of the 60 bar pilot pressure valve (X-4 pressure) at the filter and control panel in the machinery house.
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Lubrication System
Lubrication System
Section 15.0 Page 13
One line system Legend: illustr. Z 21176 (1) Lubricant pump drive (Hydraulic cylinder) (2) Solenoid valve (Oil pressure supply) (3) Flow control valve (4) Pressure reducing valve (5) Hydraulic oil supply line (Pilot pressure) (6) Hydraulic oil return line (7) Vent valve (Solenoid valve, de-energized open to barrel) (8) Grease supply line to injectors (9) Lubricant level indication (capacitively analog sensor) (10) Lubricant barrel (11) Pump mechanism (12) Lubricant filter (13) Hydraulic pressure test plug (Operating pressure) (14) Lubricant pressure gauge (Operating pressure) (15) Vent line to barrel (16) End-of-line switch (17) (Pressure check point) (18) Injector block (19) Lubricant feed line to bearing
Function: As soon as the adj. "Pause-Time" is finished the solenoid valves (2) and (7) are energized. The lubricant pump (1) start to pump lubricant in the lubricant supply line. By the function of the solenoid valve (7) the port to the vent line (15) (return line to the lubricant container) is closed, thus a pressure built up is possible. The high-pressure barrel pump (1) supplies lubricant into the supply line (8). It continuos through the lubricant filter (12) to the injectors (metering valves) (18).
)
• The picture shows an example only. The hole system includes much more injectors which are connected via pipes or hoses to the supply line (8).
In the Injectors the lubricant forced with full pump pressure via the feed lines (19) to the lube points. The actual operating pressure can be monitored at the pressure gauge (14) and checked at the pressure check point (17). continued
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Lubrication System
Lubrication System
Section 15.0 Page 15
Cont'd. Illustr. Z 21176 When all injectors pistons have reached there final position no more lubricant is accepted from the supply line which causes a pressure increase in the supply line (8). As soon as the pressure reaches the adjusted value of the end-of-line switch (16) the solenoid valves (2) de-energized and the lubricant pump switched Off. Depend on different factory settings vent valve (7) de energize together with solenoid valve (2) or after a fix adjusted time of max. 5 minutes. With de-energized solenoid valve (7) the port to vent line (15) ( return line to the lubricant container ) opened and release the lubricant and lubricant pressure in to the container. With the diminishing pressure in the main line the pistons of the injector (18) are forced by spring force in their initial position and the discharge chambers are filled with grease for the following lubrication cycle. The system is now prepared for a new lubrication cycle. The operation is reinitiated after the next "Pause Time" is elapsed. The proper build-up of the pressure in the supply line (8) is monitored by the end-of-line switch (16). If the pressure adjusted at the end-of-line switch will not reached within the adjusted "Monitoring Time" the fault message ”Central lubrication system fault” comes up on the text display and the system switch off
W
• Grease qualities to be used: According to NLGI classes 000, 00, 0 and 1 according to the lowest ambient temperature in the operation area
)
1. The content of molybdenum must not exceed 5 %. 2. Only synthetic graphite allowed in graphite contained lubricants
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Lubrication System
Lubrication System
Section 15.0 Page 17
Electrical function. illustr. Z 21177a
)
• It follows an exemplary explanation for a central lubrication system for machines equipped with PLC System. For details see the circuit diagram of the respective machine. The Lubrication Systems are PLC controlled. No relay adjustment necessary. Central lubrication system controlling : The PLC from the ECS System controls the whole lubrication systems. The solenoid valves (Y7, Y7A or Y9, Y9A) on top of the lubrication stations are direct connected to digital output ports of the PLC. On a few machines there are additional relays between PLC outputs and the solenoid valves. Depend on a PLC input from the end-of-line pressure switch (B43 or B46) and a PLC internal time counter the grease system start a lubrication cycle. The lubrication cycle starts. If the pause time elapsed the PLC energize both solenoid valves (Y7, Y7A or Y9, Y9A) of the respective lubrication system. The motor must run. The pilot pump pressure activate now the lubrication pump and the lubrication pressure to the injectors increase. If the lubricant pressure reach the adjusted pressure of the end-of-line pressure switch (B43 or B46) its contact change and the PLC input signal change. The PLC de energize the respective lubrication pump supply valve (Y7 or Y9) to stop the pump. For the next 5 min the respective pressure releasing valve (Y7A or Y9A) are continued energized to keep the lubricant pressure still on a high level to be able all injectors inject the hole adjusted amount of lubricant. After the 5 min. pressure holding time the PLC de energize the respective pressure releasing valve (Y7A or5 Y9A) The lubricant pressure drops and the injectors move by spring load back in its initial position. A PLC internal counter is still counting a additional decreasing time to monitor the end-of-line pressure switch (B43 or B46) position. The PLC internal time counter is still counting up to the next lubrication cycle. The lubrication cycle is finished. continued
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Cont'd: Illustr. Z 21177a The next lubrication cycle starts after the decreasing time and pause time has expired. With the switch S24 an additional lubrication can be carried out any time provided the end of line pressure switch (B43) contact is closed.
Monitoring: The orderly built-up of the pressure in the lubricant supply line is monitored by the end-of-line switch (B43 or B46). If the pressure adjusted at the end-of-line switch is not reached within the adjusted maximal increasing time the PLC switch off both solenoid (Y7 and Y7A or Y9 and Y9A) valves and send the fault message ”Central lubrication system fault” or “Swing ring lubrication system fault” to the text display at the dash board. If the excavator is still working additional four hours with faulty lubrication system the PLC stop the bucket function. This function is to prevent trouble depend on a lack of lubricant.
Continued
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Capacitive analog sensor for lubricant level monitoring, Illustration Z 21179f Task: A lubricant (L) maximum filling level monitoring is necessary to prevent an overfilling of the grease barrel (C) via the refilling system (only systems with refilling arm). The PLC use the analog level signal from the sensor to activate a lamp at the refilling arm just in the moment when the lubricant container is full. The sensor (S) is mounted on top of the lubricant container and reaches into the lubricant. The refilling level activate only a message at the text display to inform that the lubricant level must be filled up. The message comes up if the lubricant level reach 5% (910 mm from the cover plate). The minimum level stop the respective lubrication pump and release the lubricant pressure until the lubricant level reach the 0% mark (950 mm from the cover plate). It is necessary to stop the lubrication system with empty lubricant container to prevent the lubrication pump from running dry. With empty lubricant container the bucket motion will be switched off after four hours. Function: The capacitively level sensor (S) check continuous the lubricant level (L) and convert the capacitive signal into a current signal between 4 and 20mA. The current signal increase with increasing lubricant level. Use the specific electric circuit diagram and program flow charts.
)
• The capacitively proximity switch used in our machines are programmed by the supplier and therefor no adjustment or settings required.
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Adjustments End line switch setting. Illustration Z 21180 1.
)
)
Connect pressure gauge to check point.
• Use an other gauge as for checking hydraulic pressures because the gauge remains filled with grease after the test 2. 3. 4.
Start motor. Start a lube cycle with the dashboard switch S24. + Watch pressure gauge. At a pressure of 180 10 bar the end-line switch must react and the lubricants pump must stop.*
*
If at the same time the pressure shown at the built-in gauge is noted down, this pressure can be taken for later on checks as a reference pressure.
• 180 bar is the normal setting. Under particular circumstances it may be necessary to increase the pressure slightly If re-setting is required: 5. Screw out screw 1 and take off cover 2. 6. Alter the spring tension with adjustment screw 3 that the switch operates at 180 bar. 7. Install cover 2 and screw 1.
continued
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Cont'd: Injectors, illustr. 21181: Series SL-1 injector: Lubricant output adjustable from 0.13 up to 1.3 cm³ per cycle. Hydraulic type fitting with screw type cover cap is provided for initial filling of feeder line, and may also be used for visual check of injector operation. Series SL-1 injectors incorporate a stainless steel visual indicator. Series SL-11 injector: Lubricant output adjustable from 0.82 up to 8.2 cm³ per cycle. Designed for systems where a high amount of lubricant is required. Principle of operation similar to series SL-1. Adjusting the lubricant output: 1. Loosen lock nut (C). 2. Turn adjusting screw (A) counterclockwise (OUT) for more lubricant output or clockwise (IN) for less lubricant output. 3. Tighten lock nut (C).
)
• The max. lubricant output is adjusted if the indicator stem (B) moves not more further outwards
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Function Pinion type (dummy wheel) system. Legend: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17)
Z 21183a Lubricant pump drive (Hydraulic cylinder) Solenoid valve Y9 (Oil pressure supply) Flow control valve Pressure reducing valve Hydraulic oil supply line (Pilot pressure) Hydraulic oil return line Vent valve Y9A (Solenoid valve, de-energized open) Grease supply line to injectors Lubricant level indication Lubricant barrel Pump mechanism Lubricant filter Hydraulic pressure test plug (Operating pressure) Lubricant pressure gauge (Operating pressure) Vent line to barrel Breather Electrical terminal box
Principle of operation: By the lubricant pump, the lubricant is supplied to the centered bore hole (B) of the lubrication type pinion (R). Bore hole (B) must be perfectly aligned to the center of the lubrication type pinion (A) to be greased, so that lubricant leaves the tooth flank always when the gear tooth is in contact. The grease outlet (D) of the lubricating type pinion is arranged at a different angle for each tooth, so that the lubricant is distributed in a uniform and perfect manners on the tooth flank of the drive pinion to be lubricated. Function: As soon as the adjusted "Pause-Time" elapse the solenoid valves (2 + 7). energized and the lubricant pump (1) start to pump lubricant. By the function of the solenoid valve (8) the port to the vent line (15) (return line to the lubricant container) closed, thus a pressure built up is possible. The high-pressure lubricant pump (1) supplies lubricant into the supply line (8). It continuos through the lubricant filter (12) to the injectors (metering valves) (18). •
The picture shows an example with one pinion only. There are also machines which have more lubrication type pinion (dummy wheel). By the injectors the lubricant is forced with full pump pressure via the feed line (19) to the centered bore hole (B) of the lubricating type pinion (R). continued
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Cont'd. Illustr. Z 21183a The actual operating pressure can be monitored at the pressure gauge (14) and checked at the pressure check point (17). When all injector pistons have reached there final position no more lubricant will accepted from the supply line (8) which causes a pressure increase in the supply line. Depend on different factory settings vent valve (7) de energize together with solenoid valve (2) or after a fix adjusted time of max. 5 minutes. With de-energized solenoid valve (7) the port to vent line (15) ( return line to the lubricant container ) opened and release the lubricant and lubricant pressure in to the container. With the diminishing pressure in the main line the pistons of the injector (18) are forced by spring force in their initial position and the discharge chambers fill up with grease for the following lubrication cycle. The system is prepared for the next lubrication cycle. The operation is reinitiated after the next "Pause Time". The proper build-up of the pressure in the supply line (8) is monitored by the end-of-line switch (16). If the pressure adjusted at the end-of-line switch is not reached within the adjusted "Monitoring Time" the fault message ”Slew ring gear lubrication system fault” is shown on the text display and the pump switch off.
• Grease qualities to be used: According to NLGI classes 000, 00, 0 and 1 according to the lowest ambient temperature in the operation area
)
1. The content of molybdenum must not exceed 5 %. 2. Only synthetic graphite must be contained in graphic lubricants
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Electrical function.
)
Section 15.0 Page 31
Illustration Z 21177b
• It follows an exemplary explanation for a Slew Ring Lubrication System for machines equipped with ECS System. For details see the circuit diagram of the respective machine. The Lubrication Systems are controlled through the ECS. No relay adjustment required. Slew Ring Gear Lubrication (Teeth lubrication) controlling : The PLC from the ECS System control the whole lubrication systems. Solenoid valves (Y9, Y9A) on top of the lubrication container are direct connected to digital output ports of the PLC. On few machines there are additional relays between PLC and the solenoid valves. Depend on a PLC input from the end-of-line pressure switch (B43 or B46) and a PLC internal time counter the grease system start a lubrication cycle. The lubrication cycle starts. If the pause time elapsed and the swing function was activated for a short time the PLC energize both solenoid valves ( Y9 , Y9A ). To start one swing ring gear lubrication cycle the swing function must be activated one time. If the lubricant pressure reach the adjusted pressure of the end of line pressure switch its contact change the position now the input port of the PLC change. The PLC de energize the respective lubrication pump supply valve (Y9) to stop the pump. For the next 5 min the respective pressure releasing valve (Y9A) are continued energized to keep the lubricant pressure still on a high level to be able all injectors inject the hole amount of lubricant. After 5 min. pressure holding time the PLC de energize the respective pressure releasing valve (Y9A) The lubricant pressure drops and the injectors move by spring load back in its initial position. A internal counter is still counting a additional decreasing time to prevent a to early new lubrication cycle with the risk of not complete reset injectors. The lubrication cycle is finished. continued
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Cont'd: Illustr. Z 21177b The next lubrication cycle starts after the decreasing time and pause time has expired. With the switch S26 an additional lubrication can be carried out any time provided the end of line pressure switch (B46) contact is closed.
Monitoring: The orderly built-up of the pressure in the lubricant supply line is monitored by the end-of-line switch (B46). If the pressure adjusted at the end-of-line switch is not reached within the adjusted maximal increasing time the PLC switch off both solenoid valves (Y9 and Y9A) and send the fault message ”Central lubrication system fault” to the text display at the dash board. If the excavator was working additional four hours with faulty lubrication system the PLC stop the bucket function. This function is to prevent trouble depend on a lack of lubricant.
Continued
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Capacitive analog sensor for lubricant level monitoring, Illustration Z 21179f Task: A lubricant (L) maximum filling level monitoring is necessary to prevent an overfilling of the grease barrel (C) via the refilling system (only systems with refilling arm). The PLC use the analog level signal from the sensor to activate a lamp at the refilling arm just in the moment when the lubricant container is full. The sensor (S) is mounted on top of the lubricant container and reaches into the lubricant. The refilling level activate only a message at the text display to inform that the lubricant level must be filled up. The message comes up if the lubricant level reach 5% (910 mm from the cover plate). The minimum level stop the respective lubrication pump and release the lubricant pressure until the lubricant level reach the 0% mark (950 mm from the cover plate). It is necessary to stop the lubrication system with empty lubricant container to prevent the lubrication pump from running dry. With empty lubricant container the bucket motion will be switched off after four hours. Function: The capacitively level sensor (S) check continuous the lubricant level (L) and convert the capacitive signal into a current signal between 4 and 20mA. The current signal increase with increasing lubricant level. Use the specific electric circuit diagram and program flow charts.
)
• The capacitively proximity switch used in our machines are programmed by the supplier and therefor no adjustment or settings required.
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Adjustments End of line switch setting, illustration Z 21185 1.
)
Connect pressure gauge to check point close to the end of line pressure switch.
• Use an other gauge as for checking hydraulic pressures because the gauge remains filled with grease after the test 2. 3. 4. 5.
Block the swing function with the swing ring parking, use the switch at the dash board. Start motor. Start a lube cycle with the dashboard switch S26 and activate for a short time the swing function to the left or right. + Watch pressure gauge. At a pressure of 180 10 bar the end of line switch must react and the lubricants pump must be stopped.*
*
)
If at the same time the pressure shown at the built-in gauge is noted down, this pressure can be taken for later on checks as a reference pressure. But be careful this pressure is higher than the pressure shown at the test gauge because of the long distance between pump and end of the supply line.
• 180 bar is the normal setting. Under particular circumstances it may be necessary to increase the pressure slightly If re-setting is required: 6. 7. 8.
Screw out screw (1) and take off cover (2). Alter the spring tension with adjustment screw (3) that the switch operates at 180 bar. Install cover (2) and screw (1). continued
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Cont'd: Injectors, illustr. 21181: Series SL-1 injector: Lubricant output adjustable from 0.13 up to 1.3 cm³ per cycle. Hydraulic type fitting with screw type cover cap is provided for initial filling of feeder line, and may also be used for visual check of injector operation. Series SL-1 injectors incorporate a stainless steel visual indicator. Series SL-11 injector: Lubricant output adjustable from 0.82 up to 8.2 cm³ per cycle. Designed for systems where a high amount of lubricant is required. Principle of operation similar to series SL-1. Adjusting the lubricant output: 1. Loosen lock nut (C). 2. Turn adjusting screw (A) counterclockwise (OUT) for more lubricant output or clockwise (IN) for less lubricant output. 3. Tighten lock nut (C).
)
• The max. lubricant output is adjusted if the indicator stem (B) moves not more further outwards
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Hydraulically driven “Power Master III” lube pump, illustr. Z 21186 Legend: (more detailed see parts list 90-0781) Fig.: 12 (P) Hydraulic oil supply (T) Hydraulic oil return (Pr) Pressure reducing valve (Q) Flow regulator valve (1) Hydr. actuator piston (2) Oscillator control block (3) Pump tube (4) Breather port (5) Grease outlet port (6) Piston rod (7) 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 HINT: Loss of pressure or to short pump strokes indicates: A
Foreign material lodged under Piston Ball Checks or between Upper and Lower Inlet Checks (8 + 9). To correct this problem the upper lower inlet checks (8 + 9) and inlet valve (13) should be removed and cleaned thoroughly. If sealing surfaces between upper and lower inlet checks (8 + 9) are rough or pitted, replace or resurface if damages are slight.
B
Shovel rod packing worn or damaged. Before installing new packing, inspect surface of shovel rod and replace if rough or pitted. Do not grip shovel rod when disassembling lower pump tube assembly. continued
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Trouble shooting, illustr. Z 21186 If the following procedures do not correct the problem, contact a factory authorized service center. PROBLEMS: CYLINDER PRESSURE GAUGE DOES NOT REGISTER PRESSURE. A. Check system pressure to pump. B. Check for 24 VDC signal at solenoids. C. Pressure reducing valve set too low. Check pressure. PUMP PRESSURE BUILT UP VERY SLOWLY OR NOT AT ALL. A. No oscillation of pump, check oscillation control block (2). B. Pressure reducing valve (Pr) may be setting too low. C. Grease viscosity may be too high for the actual ambient temperature. D. If pressure is not building up at all, solenoid valve (pilot pressure supply solenoid) may be inoperative. E. Pump piston (11) and inlet checks may have foreign matter trapped causing leakage. Remove, inspect and clean if necessary. F. Inspect sealing surface on upper and lower checks (8 + 9). Replace if rough or pitted. G. Replace scoop piston if rough or pitted. Replace rod packing (15) if it is leaking. H. Inspect lubricant supply line for leaks or breaks.
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Lubricant Injector (metering valve), illustr. Z 21187
TASK: A readjusted (at the injector) volume of grease is pushed with the injectors to the bearings or to the progressive distributors. Design: (model SL1) (01+02) Metering valve, assy. (03+04) Injector bar (05) Adjusting screw (06) Nut (07) Plug screw (08) Seal ring (09) Disk (10) Seal ring (11) Bolt with nut (12) Disk (13) Seal ring (14) Piston (15) Compression spring (16) Spring retainer (17) Seal ring (18) Disk (19) Seal ring (20) Disk (21) Piston (22) Seal (23) Adapter bolt (24) Valve housing (25) Union
Design: (model SL11) (01) Metering valve, assy. (02) Adjusting screw (03) Nut (04) Plug screw (05) O-ring (06) Disk (07) Seal ring (08) Disk (09) Guide (10) Indicator pin (11) Seal ring (12) Piston (13) Seal ring (14) Pin (15) Compression spring (16) Spring retainer (17) Bolt with piston (18) Seal ring (19) Valve housing (20) Union
continued
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Cont'd: Function: illustr. Z 21188 Pos. 1
The injector piston (2) is in its normal or rest position. The discharge chamber (9) is filled with lubricant from the previous cycle. Under the pressure of incoming lubricant the slide valve (4) is about to open the passage (5) leading to the piston.
Pos. 2
When the slide valve (4) uncovers the passage lubricant is admitted to the top of piston (2) forcing the piston down. The piston force lubricant from the discharge chamber (9) through the outlet port (10) to the bearing or progressive distributor. The lubricant pressure at the bearing or the progressive distributor is always the same as the pump pressure.
Pos. 3
As the piston completes its stroke, it pushes the slide valve (4) past the passage, cutting off further admission of lubricant to the passage. Piston and slide valve remain in this position until lubricant pressure in the supply line is vented (relieved) at the pump. This is indicated by the injector stem (8). (fully in)
Pos. 4
After pressure is relieved the compressed spring (3) moves the slide valve (4) to closed position. This opens the port from the measuring chamber and permits the lubricant to be transferred from the top of the piston to the discharge chamber. This is also indicated by the injector stem (8) (fully out) continued
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Cont'd: Connection of one or more injectors, illustr. Z 21189 The injectors are designed so that the lubricant out- put of two or more injectors can be combined without the use of tees. The injector body (1) has two outlets ports (a + b), one above the other. The connector tube (2) is used to couple the injectors together. Lubricant from injector No. 1 is directed through the connector tube into the discharge chamber of injector No. 2 but simply combines with the lubricant delivery of injector No. 2 to yield double output from the out- let of injector No. 2. This does not interfere with the operation of injector No. 2.
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End-line switch
TASK: The pressure control unit is monitoring and controlling the centralized lube system. Design: (1) (2) (3) (4) (5) (6) (7) (8)
illustr. Z 21190 Piston Disk Switch contact Spring Pressure switch Adjustment sleeve Connection to pressure circuit Electrical connection
Function: One pressure control unit is installed in each greasing circuit. The grease pressure, produced by the pneumatic barrel pump, is with his force also at the piston (1) If the grease pressure reaches the tension of the spring (4), the piston (1) is forced against the disk (2), thus that the contacts of the switch (5) are operated and a electric impulse is given to the electronic control unit of the greasing equipment. Adjusting has to be done with the sleeve (6). Clockwise - higher switch point, counterclockwise - lower switch point.
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In-line filter
Legend: illustr. Z 21191 (1) Plug screw (2) Plug screw gasket (3) Filter element (4) Filter housing (5) Spring guide (6) Spring • Before servicing stop the motor and remove ignition key in order to prevent operation of the system.
)
• A clogged filter element will be moved against the spring force by the lubricant pressure and unfiltered lubricant reaches the system! For maintenance proceed as follows: 1. Remove plug screw (1) using 36 mm width wrench. 2. Remove plug screw gasket (2). 3. Take out spring (6), spring guide (5) and filter element (3). 4. Clean all parts and inspect for damage. Replace as necessary. 5. Insert filter element, spring guide (5) and spring. 6. Install plug screw (1) with gasket (2) and tighten with a wrench.
)
• For service intervals see SERVICE LITERATURE chapter 6.6
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Vent valve, illustr. Z 21192 TASK: By the function of the vent valve the lubricant supply line gets pressurerelieved, after the lubrication cycle is finished. The injector pistons can move into their initial position. Legend: (Valve VP1 S-G). Fig. 19 (1) Solenoid (2) Valve assy. (3) Solenoid stem (4) Lever (5) Main valve cone (6) Auxiliary valve cone (7) Reset spring Function: The solenoid gets energized. When the lubrication starts. The connection from A to B gets closed, thus a pressure build-up is possible. The solenoid gets de-energized, as soon as the lubrication cycle is finished. This causes opening of the connection A to B, thus the supply line to the lubricant barrel is open. The lubricant flows from A to B or vice versa along the main valve cone (5).
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