Service Manual PC4000-6E.pdf

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

CONTENTS

TABLE OF CONTENTS

00 Safety - Foreword

01 Technical DATA (Leaflet)

02 Assembly PROCEDURE (Brochure)

Section

1. Main assembly groups 2. Drive

3. Hydraulic oil tank 4. Hydraulic oil cooling 5. Controlling 6. Components

7. Main hydraulic pumps and pump regulation 8. Operating hydraulic

9. Hydraulic track tensioning system 10. Hydraulic operated access ladder 11. Cable drum

12. Hints for the hydraulic circuit diagram 13. Hints for the electric circuit diagram 14. Electronic Control System - ECS 15. Lubrication System

APPENDIX

SAFTEY SAFTEY NOTICE

00-1

SAFETY

SAFETY NOTICE

• IMPORTANT SAFETY NOTICE

Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose.

The 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.

)

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.

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.

SAFTEY SAFTEY NOTICE

00-3

Cont'd:

PRECAUTIONS DURING WORK

13. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.

14. When raising heavy components, use a hoist or crane.

Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity.

Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.

15. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.

16. When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires.

17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires.

18. As a general rule, do not use gasoline to wash parts.

19. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts.

• When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated.

20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed.

21. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly.

22. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.

23. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements.

24. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.

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

00-4

FOREWORD

GENERAL

With this SERVICE MANUAL KOMATSU provides you with the

description of the construction and the function of the major systems of the Hydraulic Excavator 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 -

)

machine at the time the manual was produced.

Variations based on special customers request and special equipment are not included in this manual

HOISTING

• Heavy parts (25 kg or more) must be lifted with a hoist etc.

)

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

)

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:

FOREWORD HOISTING INSTRUCTIONS

00-6

WIRE ROPES

3. Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load.

• Slinging with one rope may cause turning of the load during hoisting,

untwisting of the rope, or slipping of the rope from its original winding position on the load, 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.

Bolt

Tightening torque

dia.

Wrench

size [mm]

_[Nm]

Quality

grades

8.8 10.9 12.9

M 8

13

6

21 31 36

M 10

17

8

43 63 73

M 12

19

10

74 108 127

M 14

22

12

118 173 202

M 16

24

14

179 265 310

M 18

27

14

255 360 425

M 20

30

17

360 510 600

M 22

32

17

485 690 810

M 24

36

19

620 880 1030

M 27

41

19

920 1310 1530

M 30

46

22

1250 1770 2080

M 33

50

24

1690 2400 2800

M 36

55

27

2170 3100 3600

M 39

60

2800 4000 4700

M 42

65

32

3500 4950 5800

M 45

70

4350 6200 7200

M 48

75

35

5200 7500 8700

M 52

80

6700 9600 11200

M 56

85

41

8400 12000 14000

M 60

90

10400 14800 17400

M 64

95

46

12600 17900 20900

M 68

100

15200 21600 25500

FOREWORD CONVERSION TABLE

00-8

CONVERSION TABLE

METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below.

EXAMPLE

Method of using the Conversion Table to convert from millimeters to inches. 1. Convert 55 mm into inches.

(a) Locate the number 5 in the vertical column at the left side, take this as (A), then draw a horizontal line from (A).

(b) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B).

(c) Take the point where the two lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 millimeters = 2.165 inches.

2. Convert 550 mm into inches.

(a) The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to convert it to 55 mm.

(b) Carry out the same procedure as above to convert 55 mm to 2.165 inches. (c) The original value (550 mm) was divided by 10, so multiply 2.165 inches

by 10 (move the decimal one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

FOREWORD CONVERSION TABLE

FOREWORD CONVERSION TABLE

° 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

FOREWORD CONVERSION TABLE

00-14

TEMPERATURE

Fahrenheit – Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vise versa is to enter the accompanying table in the center or boldface column of figures.

These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.

If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.

Main Assembly Groups

Page 1

Vorlaeufig_#08165_PC4000_#08156-7_Sec_1-0 _rev0.doc 02.03.05

Table of contents section 1.0

Section Page 1.0 Main assembly groups

General lay out 2

1.1 Superstructure 3

1.1.1 Machine house 4

1.1.2 Hydraulic Oil Reservoir 5

1.1.3 Hydraulic Oil Cooler 6

1.1.4 Fuel Tank 7 1.1.5 Counter weight 8 1.1.6 Cab support 9 1.1.7 Operators cab 10 1.1.8 Control Blocks 11 1.1.9 Swing gears 12 1.2 Under carriage 13 1.3 Attachment

1.3.1. Backhoe Attachment (BHA) 14

Main Assembly Groups

Page 2

Vorlaeufig_#08165_PC4000_#08156-7_Sec_1-0 _rev0.doc 02.03.05

1.0 General lay out

Legend for illustration (Z 21463): (1) Superstructure

(2) Under carriage

(3) Front Shovel Attachment (FSA) (4) Backhoe Attachment (BHA)

Main Assembly Groups

Page 3

Vorlaeufig_#08165_PC4000_#08156-7_Sec_1-0 _rev0.doc 02.03.05

1.1 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

Main Assembly Groups

Page 4

Vorlaeufig_#08165_PC4000_#08156-7_Sec_1-0 _rev0.doc 02.03.05

1.1 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

Main Assembly Groups

Page 5

Vorlaeufig_#08165_PC4000_#08156-7_Sec_1-0 _rev0.doc 02.03.05

1.1 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

Main Assembly Groups

Page 6

Vorlaeufig_#08165_PC4000_#08156-7_Sec_1-0 _rev0.doc 02.03.05

1.1 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

Main Assembly Groups

Page 7

Vorlaeufig_#08165_PC4000_#08156-7_Sec_1-0 _rev0.doc 02.03.05

1.1 Superstructure

1.1.4 Fuel tank (Fuel reservoir) Legend for illustration (Z 21473): (1) Fuel tank

(2) Fuel tank breather valve (3) Main shut-off cock

(4) Drain coupling with protection cap (5) Shut-off cock for fuel pressure transducer (6) Fuel pressure transducer

Main Assembly Groups

Page 8

Vorlaeufig_#08165_PC4000_#08156-7_Sec_1-0 _rev0.doc 02.03.05

1.1 Superstructure

1.1.5 Counter weight Legend for illustration (Z 21474): (1) Counter weight

Total weight 37000 kg

(2) Mounting bolts

Quantity Bolt size (mm) Grade SW* (mm) Tightening torque (Nm) 16 M 42 x 520 10.9 65 4950 * SW = Wrench size (3) Lifting points

Main Assembly Groups

Page 9

Vorlaeufig_#08165_PC4000_#08156-7_Sec_1-0 _rev0.doc 02.03.05

1.1 Superstructure

1.1.6 Cab support

Legend for illustration (Z 21475):

(1) Cab support (Location of electrical switch board “X2”) (2) Mounting bolts

Quantity Bolt size (mm) Grade SW* (mm) Tightening torque (Nm) 4 M 36 x 240 10.9 55 3100 * SW = Wrench size (3) Mounting bolts

Quantity Bolt size (mm) Grade SW* (mm) Tightening torque (Nm) 4 M 36 x 240 10.9 55 3100 * SW = Wrench size (4) Door (5) Gasket

Main Assembly Groups

Page 10

Vorlaeufig_#08165_PC4000_#08156-7_Sec_1-0 _rev0.doc 02.03.05

1.1 Superstructure

1.1.7 Operators cab

Legend for illustration (Z 21476):

(1) Monitor panel

(2) Switch panel

(3) Operators seat

(E19) Control lever

– EURO Control

– KMG Control

(E20) Control lever

– EURO Control

– KMG Control

(E21a) Control pedal A - forward

Left track

B - reverse

(E21b) Control pedal A - forward

Right track

B - reverse (E22) Control pedal - Swing brake

(E23) Control pedal - Bucket closing (E24) Control pedal - Bucket opening

Main Assembly Groups

Page 11

Vorlaeufig_#08165_PC4000_#08156-7_Sec_1-0 _rev0.doc 02.03.05

1.1 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

Main Assembly Groups

Page 12

Vorlaeufig_#08165_PC4000_#08156-7_Sec_1-0 _rev0.doc 02.03.05

1.1 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)

Main Assembly Groups

Page 13

Vorlaeufig_#08165_PC4000_#08156-7_Sec_1-0 _rev0.doc 02.03.05

1.2 Under carriage

Legend for illustration (Z 21481): (1) Undercarriage center body (2) Crawler carrier R.H.-side (3) Crawler carrier L.H.-side

(4) Connecting 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)

Main Assembly Groups

Page 14

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

15

Vorlaeufig_#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

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

2.0

2

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.

)

2.0

3

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.

)

2.0

4

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

5

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.

2.0

6

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

7

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

)

2.0

8

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

Hydraulic Oil Reservoir

Page 1

PC4000-6-E_#08165_Sec_3-0_rev0.doc 02.03.05

Table of contents section 3.0

Section Page 3.0 Hydraulic oil reservoir

General lay out 2

3.1 Main oil tank, location of switches, sensors etc. 3

3.2 Suction oil tank with strainers 4

3.3 Return oil collector tube with strainer 5

3.4 Back pressure valve 6

3.5 Transfer pump (Optional Equipment) 7

3.6 Return and Leak Oil Filter 8

Hydraulic Oil Reservoir

Page 2

PC4000-6-E_#08165_Sec_3-0_rev0.doc 02.03.05

3.0 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 (3-A) 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

Hydraulic Oil Reservoir

Page 3

PC4000-6-E_#08165_Sec_3-0_rev0.doc 02.03.05

3.1 Main oil tank, location of switches, sensors etc.

Legend for illustration (Z 21495a):

(B4) Oil level sensor “Hydraulic oil level too low” (B15) Hydraulic oil temperature probe

“Hydraulic oil temperature below: too hot” (B24) Breather filter pressure switch

(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

Hydraulic Oil Reservoir

Page 4

PC4000-6-E_#08165_Sec_3-0_rev0.doc 02.03.05

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 Bolt size (mm) Grade SW* (mm) Tightening torque (Nm) 8 M 20 x 85 8.8 30 360 (6) Nut (7) Gaskets

(8) Main suction oil strainer (9) Intermediate pipe (10) Gaskets

(11) Suction strainer – one for each main pump (12) Suction hose connection pipe

(13) Bolt

Quantity Bolt size (mm) Grade SW* (mm) Tightening torque (Nm) 16 M 16 x 40 8.8 24 179 (14) Lock nuts

(14a) Resilient sleeve (15) Bolt

Quantity Bolt size (mm) Grade SW* (mm) Tightening torque (Nm) 8 M 20 x 110 10.9 30 510 (16) Resilient sleeve (17) Bolt

Quantity Bolt size (mm) Grade SW* (mm) Tightening torque (Nm) 6 M 18 x 90 10.9 27 360

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

Hydraulic Oil Reservoir

Page 5

PC4000-6-E_#08165_Sec_3-0_rev0.doc 02.03.05

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 Bolt size (mm) Grade SW* (mm) Tightening torque (Nm) 8 M 20 x 80 10.9 30 510 (6) Bolt

Quantity Bolt size (mm) Grade SW* (mm) Tightening torque (Nm) 8 M 20 x 70 10.9 30 510

(7) Self locking nut (8) 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.

Hydraulic Oil Reservoir

Page 6

PC4000-6-E_#08165_Sec_3-0_rev0.doc 02.03.05

3.4 Back pressure valve

Legend for illustration (Z 21498): (1) Back pressure valve assembly (2) Solenoid valve (Y101)

Task:

The back pressure valve has to fulfill two functions in the hydraulic system: 1. To ensure a sufficient pressure within the return oil circuit, i.e. to supply

oil via the anticavitaton valves to the low pressure side of cylinders, respectively motors.

2. To force the return oil through the coolers depending on the present hydraulic oil temperature, controlled by solenoid valve Y101. - Low temperature ⇒ low volume through the coolers

- High temperature ⇒ high volume through the coolers

)

Hydraulic Oil Reservoir

Page 7

PC4000-6-E_#08165_Sec_3-0_rev0.doc 02.03.05

3.5 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).

)

Hydraulic Oil Reservoir

Page 8

PC4000-6-E_#08165_Sec_3-0_rev0.doc 02.03.05

3.6 Return and Leak Oil Filter

Legend for illustration (Z 21500): (1) Filter cover retainer (2) Filter cover with o-ring (3) Pre-tensioning spring (4) Retainer

(5) Filter assembly

(6) Filter pot with machined cover

(7) Main filter element, 10 micron absolute 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).

)

chosen so low with best intention to protect first of all the radial seal rings of the hydraulic motors.

Hydraulic Oil Reservoir

Page 9

PC4000-6-E_#08165_Sec_3-0_rev0.doc 02.03.05

3.7 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).

Table of contents section 4.0

Section Page 4.0 Hydraulic oil cooling

4.1 General 2

4.2 Function of the hydraulic oil cooling circuit 3

4.3 Adjustment of the Back Pressure Valve 4

4.4 Fan drive (Two stage cooler fan RPM control) 5

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

4.0

2

4.1 General

The hydraulic oil cooling system maintains the hydraulic oil at a normal operating temperature.

Legend for illustration (Z 21594) (1) Noise shield

(2) Cooler (Radiator) (3) Cooler frame (4) Fan

(5) Fan motor (Axial piston motor) (6) Bolt

(7) Bolt (8) Drive shaft

(9) Shaft protecting Sleeve (10) Drive shaft seal

(11) Ball bearings (12) Seeger clip ring (13) Bearing group carrier (14) Oil level plug

(15) Breather filter (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")

4.0

3

4.2 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.

4.0

4

4.3 Adjustment of the Back Pressure Valve

Checks and settings only at normal operating temperature of the hydraulic oil, main pumps in maximum flow position and "Idle Time" control eliminated (service switch 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

4.0

5

4.4 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)

4.0

6

4.5 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)

4.0

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.

4.0

8

4.6 Fixed Displacement Pump, with variable setting

Legend for illustration (Z 21852) (1) Drive shaft

(2) Bearings (3) Cylinder with pistons (4) Center pin (5) Control lens (6) Q-min adjustment bolt (7) Q-max adjustment bolt (8) Pressure port (9) Tank port

Description.

Pump type A7F0 is a variable displacement pump, designed to operate in open circuits. It has an internal case drain return. The rotary group is a robust self aspirating unit. External forces may be applied to the drive shaft.

Changing the swivel angle of the rotary group is achieved by sliding the control lens along a cylindrical formed track by means of an adjusting screw. • With an increase in the swivel angel, the pump output increase together

with necessary drive torque.

• With an decrease in the swivel angel, the pump output decreases together with the necessary drive torque.

ã

4.0

9

4.7 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

)

components has been replaced:

- pump - relief valve - hydraulic motor

1. 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.

2. 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. 3. 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.

4. Connect a pressure gauge to check point (M6). 5. Start the motor.

4.0

10

4.7 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

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

)

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).

)

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.

4.0

11

4.7 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 connectingtheplug 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 connectingthesolenoidplug 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 Y6a Y6b Y6a Y6b

)

operation manual

0

0

}

0

1

}

1

0

}

4.0

12

PC4000-6-E_#08165_Sec_4-0_rev0.doc 02.03.05

4.9 Switch points of cooler fan speed (PLC controlled) Switch points with hysteresis:

30°C VG22: 46°C

39°C VG32: 57°C

48°C VG46: 67°C Switch point: Speed decrease

56°C VG68: 73°C 65°C VG100: 73°C Fan speed Maximum Medium Minimum Temperature 67°C VG100: 75°C 58°C VG68: 75°C

Switch point: Speed increase 50°C VG46: 69°C

41°C VG32: 59°C

Controlling

Page 1

PC4000-6-E_#08165_Sec_5-0_rev0_.doc 02.03.05

Table of contents section 5.0

Section Page 5.0 Controlling

General lay out 2

5.1 Control and filter panel location of components (valves, switches, sensors etc.)

3 + 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