Vorlaeufig_#08165_PC4000_#08156-7_Sec_1-0 _rev0.doc 02.03.05
1.3 Attachment
1.3.1 Backhoe attachment (BHA) Legend for illustration (Z 21482):
(1) Boom
(2) Boom Cylinders (3) Stick
(4) Stick Cylinders (5) Bucket
(6) Bucket Cylinders (7) Control arm (8) Linkage
1.0
15Vorlaeufig_#08165_PC4000_#08156-7_Sec_1-0 _rev0.doc 02.03.05
1.3 Attachment
1.3.2 Front Shovel Attachment (FSA) Legend for illustration (Z 21483):
(1) Boom
(2) Boom Cylinders (3) Stick
(4) Stick Cylinders (5) Bucket backwall (6) Bucket Cylinders (7) Bullclam
(8) Bucket Clam cylinders
Table of contents section 2.0
Section Page 2.0 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
2.0
2PC4000-6-E_#08165_Sec_2-0_rev0.doc 02.03.05
2.0 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.
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• The alignment procedure must also be carried out when replacing the electric motor and/or the PTO.2.0
3PC4000-6-E_#08165_Sec_2-0_rev0.doc 02.03.05
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) Grade SW* (mm) Tightening torque (Nm)
16 M 27 x 60 10.9 41 960.0 +110.0
(7) Motor drive shaft
(8) Rubber element (PTO side) (9) Bolt
Quantity Bolt size (mm) Grade SW* (mm) Tightening torque (Nm)
16 M 27 x 60 10.9 41 960.0 +110.0
(10) Bolt
Quantity Bolt size (mm) Grade SW* (mm) Tightening torque (Nm)
22 M 16 x 310 10.9 24 250.0 +30.0
(11) Washer (12) Nut (13) Bolt
Quantity Bolt size (mm) Grade SW* (mm) Tightening torque (Nm)
1 M 36 x 60 8.8 55 2170.0
(14) Bolt
Quantity Bolt size (mm) Grade SW* (mm) Tightening torque (Nm)
10 M 18 x 40 10.9 27 360.0
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.
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• Repair and replacement have to be carried out according to Parts &Service News AH01523, last edition.
2.0
4PC4000-6-E_#08165_Sec_2-0_rev0.doc 02.03.05
2.2 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.
2.0
5PC4000-6-E_#08165_Sec_2-0_rev0.doc 02.03.05
2.3 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.
2.0
6PC4000-6-E_#08165_Sec_2-0_rev0.doc 02.03.05
2.4 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.
2.0
7PC4000-6-E_#08165_Sec_2-0_rev0.doc 02.03.05
2.5 PTO Lubrication and cooling – Adjustments Legend for illustration (Z 21610b):
(1) Pilot operated relief valve
(2) Plug screw
(3) Valve piston
(4) Port for pressure switch B17 (5) "Y"- port (external return to tank)
(5a) "X"- port (external return to tank via solenoid valve Y53-1) (6) Port for pressure check stud
(7) Jet bore
(8) Valve spring (9) Seal rings (A) Pressure port (T) Return from valve (B27) Maintenance switch (29) Pressure relief valve, 10 bar
(M3) Pressure check point (PTO lubrication pressure) (Y53-1) 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
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• If the pressure of 10,0 bar cannot be adj. 100 %, adj. to the lowest visible pressure.2.0
8PC4000-6-E_#08165_Sec_2-0_rev0.doc 02.03.05
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) Axial piston pump
theoretical flow rate 214 Liter/min
Drive speed* n = 2000 min-1
for oil cooler fan drive (5.2) Axial piston pump
theoretical flow rate 214 Liter/min
Drive speed* n = 2000 min-1
for radiator fan drive
(8.1) Gear pump
theoretical flow rate 138 Liter/min
Drive speed* n = 1378 min-1
for pilot pressure supply
(8.2) Gear pump
theoretical flow rate 138 Liter/min
Drive speed* n = 1378 min-1
PTO gear lubrication