Vertical X axis adjustment:
3.6 Testing and adjustment tasks
3.6.1 Preparing for testing and adjustment
During the warranty period, only trained and authorised specialist staff may carry out adjustments on the machine.
Make sure that:
– The machine is in maintenance position 2.
– The machine is at operating temperature (except when testing the air conditioning).
– The adjustment data for the machine is available or known.
– Seals and safety caps are at hand.
– The following special tools are available.
Special tools
Number Description ID no.
1 USB dongle for SCULI 1033 3608
1 Data lead for SCULI 1003 5410
2 Manometer, 0 - 40 bar, class 1.0 7361 288 2 Manometer, 0 - 600 bar, class 1.0 5002 866
2 4000 mm test leads 7009 134
2 1500 mm test leads 7002 475
3.6.2 Safety precautions for testing and adjustment
Always observe the accident prevention regulations during mainte-nance work.
See the safety regulations section for measures to ensure safe maintenance.
Make sure that visual contact between the operator in the cab and maintenance personnel is always maintained.
Only carry out adjustments on valves etc. with the machine not running.
Visual contact
LBH/Version 01/10.2006/en/hd/22/02/2007
3.6.3 Bringing the machine up to operating temperature
During testing and adjustment, the machine must be at an operating tempe-rature of 58±5 °C. The temperature is measured by the hydraulic oil sensor and can be seen in SCULI.
Procedure
• Insert a piece of card or similar material between the fuel cooler 1 and the hydraulic oil cooler 2.
• Connect your laptop, start the engine and run the SCULI program.
• In the variables editor in the group structure, select the Adjustment Block Curve folder.
• The cooling system - temperature hydraulic oil variable shows the hydraulic oil temperature during the adjustment.
Bring the machine up to operating temperature as follows:
– Run the engine at around 2000 rpm.
– Activate the tilt-in function as far as it will go and hold the control lever in this position.
– At the same time, move the lift arms up and down with the lever half-way out.
– Operate the travel hydraulics in fixed gear 1.
• Bring the machine up to operating temperature until the hydraulic oil temperature is 58±5 °C.
• When working on the hydraulic system, the hydraulic oil temperature must be within the prescribed range.
• After finishing the adjustment, take the piece of card out of the oil cooler.
3.6.4 Checking the diesel engine speed
You can read the engine speed from the RPM segment indicator in the display unit or use a standard engine speed tester.
The engine speed cannot be mechanically adjusted; it is determined directly by the engine control unit.
Procedure
• Start up the engine.
• Check that the top and bottom engine speeds are correct.
• If it is not correct:
Calibrate the gas pedal using the SCULI program and service the engine.
• Check the top and bottom idle speeds again.
Description Value Unit
Lower idle speed 900±10 min-1
58.1
Cab display unit
LBH/Version 01/10.2006/en/hd/22/02/2007
3.6.5 Check the fan motor and fan control pressure relief valve
Make the following checks on the fan motor:
These tests must be performed at upper engine speed.
– Test the fan according to the temperature (temperature sensor 1 or 2 disconnected).
– Test the pressure relief valve 7 on the fan motor 5 (with the plug on the proportional valve disconnected).
Fan drive components 1 Hydraulic oil temperature sensor
2 Coolant temperature sensor 3 Fan pressure test connection
4 Fan gear pump 5 Fan gear motor
6 Fan proportional valve cap
7 Fan proportional valve 8 Fan proportional solenoid 9 Proportional solenoid connector You can check the fan using the system pressure, measured at the test connection 3 of the gear pump 4.
Make sure that:
– The hydraulic oil temperature is less than 88 °C.
– The coolant temperature is below 97 °C.
If the hydraulic temperature is over 88 °C or the coolant temperature is above 97 °C, the fan speeds up. This makes it impossible to test the fan control.
Checking the fan according to the temperature
The fan speed (system pressure) is tested here in the stated tempera-ture range.
• Connect a manometer (250 bar) to the test connection 3 on the gear pump 4.
• Disconnect the hydraulic oil temperature sensor 1 or coolant temperature sensor 2.
• Start the engine and bring it to top idle speed.
• Check whether the pressure is correct at top engine idle speed.
Valid for: L550 - 456 / from 16978; L556 - 454 / from 15653
Description Value Unit
Fan pressure 110±10 bar
Fan speed 1650 min-1
LBH/Version 01/10.2006/en/hd/19/03/2007
Valid for: L566 - 460 / from 14171; L576 - 457 / from 14171; L580 - 459 / from 14171
Description Value Unit
Fan pressure 175±10 bar
Fan speed 1400 min-1
• If it is not correct:
Check the fan motor pressure relief valve.
Checking the fan motor pressure relief valve
• Connect a manometer (250 bar) to the test connection 3 on the gear pump 4.
• Pull out the plug 9 on the proportional solenoid 8.
• Start the engine and bring it to top idle speed.
• Check whether the pressure is correct at top engine idle speed.
• If it is not correct:
Adjust the pressure relief valve 7 on the fan motor 5 (using the adjusting screw and a 5 mm open-end spanner - the lock nut is a round nut).
Turn clockwise to increase the pressure and anticlockwise to reduce it.
• Remove the cap 6.
• Adjust the screw on the proportional valve.
Valid for: L550 - 456 / from 16978; L556 - 454 / from 15653
Description Value Unit
Fan pressure 220±10 bar
Fan speed approx. 2050 min-1
Valid for: L566 - 460 / from 14171; L576 - 457 / from 14171; L580 - 459 / from 14171
Description Value Unit
Fan pressure 220±10 bar
Fan speed approx. 1600 min-1
• Plug in the disconnected plug again.
3.6.6 Calibrating the pedals
The pedals can only be calibrated using the SCULI software.
During calibration, the MIN and MAX positions of the gas pedal and inch pedal are stored in the master electronics.
Procedure
• Connect your laptop, turn on the start switch and run the SCULI program.
• In the variables editor in the group structure, select the Adjustment Pedals folder.
• Set Throttle - start adjustment to 1.
• Push the gas pedal all the way down.
The MIN and MAX positions of the gas pedal are stored. After 15 seconds the value automatically returns to 0 Æ and calibration is finished.
• Check that Throttle - guide value is 0% when the pedal is not pressed and 100% when the pedal is pressed all the way down.
LBH/Version 01/10.2006/en/hd/22/02/2007
• Set Inch pedal - start adjustment to 1.
• Push the inch pedal all the way down.
The MIN and MAX positions of the gas pedal are stored. After 15 seconds the value automatically returns to 0 Æ and calibration is finished.
• Check that Inch pedal - guide value is 0% when the pedal is not pressed and 100% when the pedal is pressed all the way down.
3.6.7 Checking the replenishing pressure of the variable displacement pump
Measure the replenishing pressure at the test connection G.
Procedure
• Connect a manometer (40 bar) to the test connection G.
• Start the machine and let the engine run at top idling speed.
• Check that the replenishing pressure is correct.
• If it is not correct:
Turn the adjusting screw on the replenishing pressure relief valve 1 until the replenishing pressure is correct.
Valid for: L550 - 456 / from 16978; L556 - 454 / from 15653
Description Value Unit
Replenishing pressure 31±1 bar
Valid for: L566 - 460 / from 14171; L576 - 457 / from 14171; L580 - 459 / from 14171
Description Value Unit
Replenishing pressure 34±1 bar
3.6.8 Checking the pressure relief and replenishing valve of the variable displacement pump
The pressure relief and replenishing valves protect the variable displacement pump from pressure peaks. These can occur when braking the machine.
When a pressure peak occurs, oil flows from the high pressure side via the pressure relief and replenishing valve to the low pressure side in a closed circuit.
Procedure
To attain the set value for the pressure relief and replenishing valves, the pressure cut-off must be set to a higher value.
• Screw in the adjusting screw 1 on the pressure cut-off by one turn.
• Connect a manometer (600 bar) to the test connections MA and MB.
• Use SCULI to set the Inch pedal - function OFF variable to 1 Æ the inching function is disabled.
LBH/Version 01/10.2006/en/hd/22/02/2007
Check the pressure relief and replenishing valve 2 for forward travel on the manometer MA.
Check the pressure relief and replenishing valve 3 for reverse travel on the manometer MB.
• Select fixed gear 2 and forward or reverse travel, and hold the machine in the blocked condition using the service brake.
Caution
Heat is quickly generated when you test the pressure relief and replenish-ing valves.
Excessive heat can irreparably damage the pump.
!
Only test the pressure relief and replenishing valves for a short time.• In the blocked condition, increase the engine speed to the maximum.
• Check that the high pressure at the two pressure relief and replenishing valves is correct.
• If it is not correct:
Turn the adjusting screw on the pressure relief and replenishing valve until the high pressure is correct.
• Loosen the adjusting screw 1 on the pressure cut-off by one turn and check the pressure cut-off.
• Use SCULI to set the Inch pedal - function OFF variable back to 0 Æ the inching function is enabled.
Description Value Unit
High pressure 470±10 bar
3.6.9 Checking the pressure cut-off of the variable displacement pump
The pressure cut-off limits the maximum pressure of the variable displacement pump.
When this pressure is reached, the pump flow is automatically reduced in order to maintain the maximum permitted pressure.
Procedure
• Connect a manometer (600 bar) to the test connection MA.
• Use SCULI to set the Inch pedal - function OFF variable to 1 Æ the inching function is disabled.
• Select fixed gear 2 and forward travel, and hold the machine in the blocked condition using the service brake.
• In the blocked condition, increase the engine speed to the maximum.
• Check that the high pressure on the manometer MA is correct.
• Check that the engine suppression is below the threshold.
• If it is not correct:
Turn the adjusting screw 1 on the pressure cut-off 1 until the manometer MA reaches the correct value.
• Use SCULI to set the Inch pedal - function OFF variable back to 0 Æ the inching function is enabled.
Description Value Unit
High pressure 430±5 bar
Maximum engine suppression at top idle
speed 30 min-1
LBH/Version 01/10.2006/en/hd/22/02/2007
3.6.10 Calibrating the block curve
The block curve can only be calibrated using the SCULI software.
During calibration, the current to the proportional valve on the variable displacement pump is adjusted so that the pump reaches a set pressure at a set engine speed.
Procedure
• Connect a manometer (600 bar) to the test connection MA.
• Connect your laptop, start the engine and run the SCULI program.
• In the variables editor in the group structure, select the Adjustment Block Curve folder.
• Set the Inch pedal - function OFF variable to 1 Æ the inching function is disabled.
• Select fixed gear 2 and forward travel, and hold the machine in the blocked condition using the service brake.
• Increase the engine speed to the levels shown in the table (930 min-1, 1200 min-1, 1400 min-1) and test the high pressure.
• If it is not correct:
Adjust the parameter Travel pump - current at 930, 1200, 1400 rpm until the set value is reached.
• Set the Inch pedal - function OFF variable back to 0 Æ the inching function is enabled.
Valid for: L550 - 456 / from 16978; L556 - 454 / from 15653
Description Value Unit High pressure at 930 min-1 engine speed 50±10 bar
High pressure at 1200 min-1 engine speed 290±10 bar High pressure at 1400 min-1 engine speed 350±10 bar Valid for: L566 - 460 / from 14171; L576 - 457 / from 14171; L580 - 459 / from 14171
Description Value Unit High pressure at 930 min-1 engine speed 50±10 bar
High pressure at 1200 min-1 engine speed 230±10 bar High pressure at 1400 min-1 engine speed 330±10 bar
LBH/Version 01/10.2006/en/hd/22/02/2007
3.6.11 Calibrating the variable displacement motors
The variable displacement motors are calibrated automatically by the master electronics.
Automatically calibrating the variable displacement motors
• Connect your laptop, start the engine and run the SCULI program.
• In the variables editor in the group structure, select the Adjustment Travel motor folder.
• Set the parameter Travel motor - start motor adjustment to 1.
The engine speed is automatically increased to 1000 min-1. After this the motors are successively calibrated across the entire speed range.
After calibration, set the parameter Travel motor - start motor adjustment back to 0.
Note: Once the automatic calibration of the motors is complete, a service code appears in the display.
This can happen if the variable displacement motor current is too high or low. In this case, the variable displacement motors must be manually checked and adjusted to 600±30 mA.
Setting VG max manually
• Connect a manometer (600 bar) to the test connection MA.
• Connect a manometer (600 bar) to the test connections M1 and M2.
• In the variables editor in the group structure, select the Adjustment Travel motor folder.
• Set the Inch pedal - function OFF variable to 1 Æ the inching function is disabled.
• Select fixed gear 1 and forward travel, and hold the machine in the blocked condition using the service brake.
Adjusting variable displacement motor 1:
• In the blocked condition, slowly increase the engine speed until the manometer MA shows exactly 300 bar.
• Lower the current at Travel motor - motor 1 maximal current until the manometer at M1 shows 15±5 bar less than manometer MA.
• When the manometers MA and M1 show the correct levels, increase the current at Travel motor - motor 1 maximal current by 10 mA.
Adjusting variable displacement motor 2:
• In the blocked condition, slowly increase the engine speed until the manometer MA shows exactly 300 bar.
• Lower the current at Travel motor - motor 2 maximal current until the manometer at M1 shows 15±5 bar less than manometer MA.
• When the manometers MA and M2 show the correct levels, increase the current at Travel motor - motor 2 maximal current by 10 mA.
LBH/Version 01/10.2006/en/hd/22/02/2007
Note: The current for both motors must be in the range of 600 mA. If there is any deviation, correct it using the adjusting screws 1 or 2.
• Set the Inch pedal - function OFF variable back to 0 Æ the inching function is enabled.
• Repeat the automatically calibration of the variable displacement motors.
3.6.12 Checking the engine output
Before you check the power of the engine, you must carry out the following tasks:
– Tasks in maintenance schedule (air filter, fuel filter etc.)
– Check the operating pressures according to the adjustment checklist – The machine must be at operating temperature.
At maximum engine power consumption, the variable displacement motor power limiting control is activated. It regulates the pivot angle of the motors so that the engine runs at rated speed. This results in a set high pressure in the closed circuit.
– If the high pressure is is above the set value, the engine power is good.
– If the high pressure is is below the set value, the engine power is poor.
If the engine speed reaches the set value, power limiting control is working correctly.
Procedure
• Connect a manometer (600 bar) to the test connection MA.
• In the variables editor in the group structure, select the Check Dieselengine folder.
• Set the Inch pedal - function OFF variable to 1 Æ the inching function is disabled.
• Start the machine, select fixed gear 2 and forward travel direction.
• Hold the machine with the service brake and run it at full throttle.
• Slowly release the service brake until the machine moves at 13 km/h.
Check that the set values are reached.
• If they are not correct:
Troubleshoot the engine: air filters, fuel filters etc.
Troubleshoot the travel hydraulics: check the operating pressure etc.
• Set the Inch pedal - function OFF variable back to 0 Æ the inching function is enabled.
Valid for: L550 - 456 / from 16978
Description Value Unit
High pressure 300±10 bar
Diesel engine speed 1980±30 min-1
LBH/Version 01/10.2006/en/hd/22/02/2007
Valid for: L556 - 454 / from 15653
Description Value Unit
High pressure 330±10 bar
Diesel engine speed 1980±30 min-1 Valid for: L566 - 460 / from 14171
Description Value Unit
High pressure 340±10 bar
Diesel engine speed 1980±30 min-1 Valid for: L576 - 457 / from 14171; L580 - 459 / from 14171
Description Value Unit
High pressure 340±10 bar
Diesel engine speed 1980±30 min-1
3.6.13 Checking the flow controller (delta p) of the working hydraulics pump
Make sure you have a differential pressure gauge and two pressure sensors for the range up to 600 bar.
Procedure
Measure the difference in pressure between the test connections P and LS.
You can measure the differential pressure, for example by slowly raising the lift arms.
• Connect 600 bar pressure sensors to test connections P and LS.
• Start the engine and let it run at low idling speed.
• Slowly raise the lift arms and check whether the differential pressure is correct.
• If it is not correct:
Turn the adjusting screw on the flow controller 1 until the differential pressure is correct.
Description Value Unit
Differential pressure 22±2 bar
3.6.14 Checking the flow controller (start of delivery) of the working hydraulics pump
The flow controller determines the maximum output of the variable dis-placement pump. At the start of delivers, the indicator on the manometer M1 moves away from 0 bar. The set value on the manometer P should be reached.
Procedure
• Connect a manometer (600 bar) to the variable displacement pump at test connections M1 and P.
• Start the engine, tilt the bucket all the way out and move the lift arms to the bottom position.
• At idle speed, raise the lift arms all the way and check that the start of delivery shown on the manometer M1 is correct.
• If it is not correct:
Turn the adjusting screw on the power controller 1 until the pressure is correct.
LBH/Version 01/10.2006/en/hd/22/02/2007
Description Value Unit
Start of regulation 180±10 bar
3.6.15 Checking the secondary pressure relief valves on the control block
Procedure
To check the secondary pressure relief valve, you must increase the setting of the LS pressure cut-off 5 and the primary pressure relief valve 3.
• Screw in the adjusting screw on the LS pressure cut-off 5 on the control block by two turns.
• Tighten the adjusting screw on the primary pressure relief valve 3 by two turns.
• Connect a manometer (600 bar) to the test connection P on the control block.
Caution
The pump can be irreparably damaged if you lower the lift arms. This function has no secondary pressure relief valve.
! Do not lower the lift arms.
• Start the machine and let the engine run at lower idling speed.
• Raise the lift arms, tilt out the bucket and tilt in the bucket, each to the limit.
• Check that the pressure at each secondary pressure relief valve is correct.
• If it is not correct:
Turn the adjusting screw on the secondary pressure relief valve until it is correct.
• Adjust the primary pressure relief valve 3 and the LS pressure cut off 5 back to the set value. See the sections on testing the primary pressure relief valve and LS pressure cut-off.
Valid for: L550 - 456 / from 16978; L556 - 454 / from 15653
LBH/Version 01/10.2006/en/hd/22/02/2007
3.6.16 Checking the primary pressure relief valves on the control block
Procedure
To check the primary pressure relief valve 3, you must increase the setting of the LS pressure cut-off 5.
• Screw in the adjusting screw on the LS pressure cut-off 5 on the control block by two turns.
• Connect a manometer (600 bar) to the test connection P.
• Start the machine and let the engine run at lower idling speed.
• Raise the lift arms to the limit.
• Check that the pressure is correct.
• If it is not correct:
Turn the adjusting screw on the primary pressure relief valve 3 until the pressure is correct.
• Return the LS pressure cut-off 5 to its normal value. See the section on testing the LS pressure cut-off.
Valid for: L550 - 456 / from 16978; L556 - 454 / from 15653
Description Value Unit
Primary valve (3) 360±5 bar
Valid for: L566 - 460 / from 14171; L576 - 457 / from 14171; L580 - 459 / from 14171
Valid for: L566 - 460 / from 14171; L576 - 457 / from 14171; L580 - 459 / from 14171