PC5500-D 15045-15065 Service Manual

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SERVICE

MANUAL

PC5500

MACHINE MODEL SERIAL NUMBER PC5500-6 Diesel 15045 to 15065

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.

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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.

12. Hints for the hydraulic circuit diagram 13. Hints for the electric circuit diagram 14. ECS-T

15. Lubrication Systems

APPENDIX

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00-1

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 follow ing 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.

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SAFTEY SAFTEY NOTICE

00-2

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.

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00-3

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.

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SAFTEY SAFTEY NOTICE

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 PC5500-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

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00-5

HOISTING

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

)

If a part cannot be smoothly remove d from the machine by hoisting, the following checks should be made:

1. Check for removal of all bolts fast ening 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:

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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, w hich 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.

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00-7

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

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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.

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FOREWORD CONVERSION TABLE

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FOREWORD CONVERSION TABLE

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00-13

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

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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.

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06.10.05 PC5500-6-D_Sec_1-0_rev4.doc

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

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1.0

2

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06.10.05 PC5500-6-D_Sec_1-0_rev4.doc

1. General layout

Legend for illustration (Z 22387):

(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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06.10.05 PC5500-6-D_Sec_1-0_rev4.doc

1.1 Superstructure

Legend for illustration (Z 22386):

(1) Operators Cab with integrated FOPS. (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) Batteries (12) Swing Gear

(13) Grease pump of the Central Lubrication System

(14) Grease pump of the Swing gear pinion Lubrication System (15) Main Control blocks with high pressure filters

(16) Engine 1

(17) Flexible coupling, oil filled (18) PTO gear with hydraulic pumps (19) Main hydraulic pumps 1, 2 and 3 (20) Radiator for the engine cooling system (21) Engine 2

(22) Flexible coupling, oil filled (23) PTO gear with hydraulic pumps (24) Main hydraulic pumps 4, 5 and 6 (25) Radiator for the engine cooling system

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1.0

4

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06.10.05 PC5500-6-D_Sec_1-0_rev4.doc

1.1 Superstructure

1.1.1 Machine house

Legend for illustration (Z 22390):

(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 1 (14) Engine 2

(15) Hydraulic motor for the radiator fan drive (16) Radiator for the engine cooling system

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1.0

5

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06.10.05 PC5500-6-D_Sec_1-0_rev4.doc

1.1 Superstructure

1.1.2 Hydraulic Oil Reservoir Legend for illustration (Z 22391):

(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 (9) Back pressure valves for swing motors

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Main Assembly Groups

Section 1.0

Page 6

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06.10.05 PC5500-6-D_Sec_1-0_rev4.doc

1.1 Superstructure

1.1.3 Hydraulic Oil Cooler Legend for illustration (Z 22392):

(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

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1.0

7

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06.10.05 PC5500-6-D_Sec_1-0_rev4.doc

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 solenoid valves (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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06.10.05 PC5500-6-D_Sec_1-0_rev4.doc

1.1 Superstructure

1.1.5 Counter weight

Legend for illustration (Z 21474):

(1) Counter weight Total weight

40000 kg

(2) Mounting bolts

Quantity Bolt size (mm) Grade SW* (mm) Tightening torque (Nm) 16 M 48 x 380 10.9 75 7500 * SW = Wrench size (3) Lifting points

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1.0

9

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06.10.05 PC5500-6-D_Sec_1-0_rev4.doc

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) 6 M 36 x 320 10.9 55 3100 * SW = Wrench size (3) Mounting bolts

Quantity Bolt size (mm) Grade SW* (mm) Tightening torque (Nm) 6 M 36 x 160 10.9 55 3100 * SW = Wrench size (4) Door (5) Gasket

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1.0

10

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06.10.05 PC5500-6-D_Sec_1-0_rev4.doc

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 (left) Clam closing (E24) Control pedal (right) Clam opening

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1.0

11

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06.10.05 PC5500-6-D_Sec_1-0_rev4.doc

1.1 Superstructure

1.1.8 Control blocks

Legend for illustration (Z 21477a):

(1) Control block carrier (2) Remote control valves (3) Main control blocks (4) High pressure filter

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1.0

12

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06.10.05 PC5500-6-D_Sec_1-0_rev4.doc

1.1 Superstructure

1.1.9 Sw ing gears

Legend for illustration (Z 22395):

(1) Swing gear box

(2) Swing parking brake – Spring loaded multi disk brake (Released by oil pressure) (3) Parking brake Control port (X)

(4) Oil level gauge - gear box (5) Breather – gear box (6) Oil filling plug – gear box

(7) Oil level gauge – motor adapter housing (8) Breather – motor adapter housing (9) Oil drain plug – motor adapter housing (10) Oil drain plug - gear box

(20.1 + 20.2) Swing motor

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1.0

13

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06.10.05 PC5500-6-D_Sec_1-0_rev4.doc

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 bolts, between center body and 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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1.0

14

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06.10.05 PC5500-6-D_Sec_1-0_rev4.doc

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

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Main Assembly Groups

Section 1.0

Page 15

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06.10.05 PC5500-6-D_Sec_1-0_rev4.doc

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 back wall (6) Bucket Cylinders (7) Bullclam

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Table of contents section 2.0

Section Page

2.0 Prime drive assembly

General lay out 2

2.1 Engine and PTO mounts 3 + 4

2.2 Coupling 5

2.3 Air filter 6

2.4 Fan drive and radiator assembly 7 + 8

2.5 Radiator fan drive speed adjustment 9 + 10

2.6 Pump distributor gearbox (PTO) 11

2.7 Pump-spline lubrication 12

2.8 PTO Lubrication and cooling 13 + 14

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2.0

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2.0 Prime drive assembly

Legend for illustration (Z 22395):

(1) Engine 1

(2) Torsion type coupling (2) Pump distributor gear (PTO) (6) Engine 2

(7) Torsion type coupling (8) Pump distributor gear (PTO) (5) Power frame

General

The drive unit, consists of the two PTO gear and the two engines, are bolted to the power frame.

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2.0

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2.1 Engine and PTO mounts

Legend for illustration (Z 21601):

(1) Flexible bearing

(2) Bolt with self locking nut

Quantity Bolt size (mm) Grade SW* (mm) Tightening torque (Nm) 4 per mount M 10 x35 8.8 17 43 (3) Tie bolt

Quantity Bolt size (mm) Grade SW* (mm) Tightening torque (Nm) 4 M 24 x420 10.9 36 snugly

(4) Rubber-bounded metal bar (5) Self locking nut M24

(6) Bolt M16 with self locking nut

Quantity Bolt size (mm) Grade SW* (mm) Tightening torque (Nm) 2 M 16x 80 10.9 24 265

(7) Cup springs, seven per bolt (8) Stop bolt

Quantity Bolt size (mm) Grade SW* (mm) Tightening torque (Nm) 2 M 36 x250 10.9 55 Not specified (9) Nut (10) Bolt

Quantity Bolt size (mm) Grade SW* (mm) Tightening torque (Nm) 10 M 24 x 230 10.9 36 880 (11) Bolt

Quantity Bolt size (mm) Grade SW* (mm) Tightening torque (Nm) 16 M 20 x 120 10.9 30 510 (12) Resilient sleeve (13) Bolt

Quantity Bolt size (mm) Grade SW* (mm) Tightening torque (Nm) 4 M 30 x 200 10.9 46 1770 (14) Resilient sleeve * SW = Wrench size continued

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2.0

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Cont'd

2.1 Engine and PTO mounts General

The flexible bearings are installed to take the vibrations and the torsion forces and they carry the total weight of the engine, the pump distributor gear with all hydraulic pumps.

Check mounting and security of Diesel engine and pump distributor gear, illustration (Z 21601)

Check all flexible bearings (1) for engine and pump distributor gear.

Check the flexible bearings for damage and signs of fatigue. Make sure that there is no contact between the upper and lower metal brackets of the flexible bearings (1). Replace the bearings if necessary. Use new bolts and self locking nuts (2). After new flexible bearings have been installed, check distance (B) on both torque supports.

)

All flexible bearings (1) and all rubber-bounded metal bars (4) should be replaced during engine overhaul.

Check distance (B) between torque support and stop bolt (8).

With setting of the flexible engine bearings (1) the distance (B) increases and must be readjusted. To do this, loosen lock nut (9) and tighten stop bolt (8) until the correct distance (B) is obtained. Tighten lock nut (9) and recheck distance (B). If new flexible engine bearings (1) have been installed, replace also cup springs (7) and adjust distance (B) to 29 mm.

Check tie bolts (3) on front and rear carrier units for looseness.

(four tie bolts)

Check to make sure that the self locking retainer nuts (5) are tight and that there is no gap between nut and rubber-bounded metal bar (4). If necessary retighten retainer nuts (5) snugly.

Check rubber-bounded metal bars (4) for signs of fatigue and damage. Replace as necessary.

)

Check all bolt connections for correct tightening torque.

Check condition of engine carrier and brackets. If any damages, failures or wrong condition are found, corrective action must be taken.

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2.0

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2.2 Coupling

Legend for illustration (Z 21602):

(1) Coupling Assy. (2) Input drive flange (3) Leave spring assy. (4) Output drive flange (5) Dip stick

(6) Bleeder plug (7) O-Rings (8) Spacers

E Engine side

G Gearbox side (PTO-side)

Task:

The coupling is the connecting link between the engine and the PTO

Function: "GEISLINGER COUPLING"

The combination of the high elasticity of its leaf springs with complimentary viscous damping by oil displacement, ensures that the coupling reduces the intensity of torsional vibrations effectively.

The widest engine speed range free of vibration periods and dangerous resonance’s is thus obtained.

The springs (3) together with the inner driving and outer driven member form chambers A and B which are filled with oil.

If the outer member is displaced in relation to the inner member, the

deflection of the leaf springs displaces oil from one chamber to the next, by this action the relative movements of the two members of the coupling are braked and the vibrations are dampened.

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2.3 Air Filter

Legend for illustration (Z 22396):

(1) Wing nut

(2) Washer (3) Seal ring (4) Main filter element (5) Cotter pin

(6) Wing nut with service indicator (7) Safety element

(8) Maintenance switch (9) Flap for pre-separator

(10) Air intake with pre-separation

The air is filtered by a dry-air-filter with pre-separator for coarse impurities. One filter housing includes 2 filter sets. Each one consists of a main filter element (4) and a safety element (7).

The filter condition is monitored by the maintenance switch (8). A fault message like „Engine air filter restricted“ is displayed at the operator's dash board as soon as the restriction is too high.

The wing nut (6) incorporates a service indicator. Green indication = O.K.

Red indication = safety element (7) needs maintenance.

The indication mark must be re-set by blowing through the nut opposite to the normal air flow or by sucking at the other end, this can be done with the mouth.

)

For service intervals and procedure refer to the OPERATION AND MAINTENANCE MANUAL of the corresponding machine.

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2.4 Fan drive and radiator assembly Legend for illustration (Z 22398):

(1) Radiator

(2) Fan motor (Axial piston motor) (3) Intake air fan

(4) Bearing group carrier (5) Ball bearings

(6) Breather filter (7) Oil level plug

(8) Check valve (Anti-cavitation valve)

)

For service intervals and procedure refer to the OPERATION AND MAINTENANCE MANUAL of the corresponding machine.

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Cont'd

2.4 Fan drive and radiator assembly Legend for illustration (Z 22399):

(1) Radiator (2) Intake air fan

(10.1) Axial piston pump Engine 1 (fixed displacement pump, with variable setting)

(10.3) Axial piston pump Engine 2 (fixed displacement pump, with variable setting)

(23.1) Fan motor (Axial piston motor) (23.2) Fan motor (Axial piston motor) (41) Main oil reservoir

(168.3) Pressure relief valve – Engine 1 radiator fan drive (168.4) Pressure relief valve – Engine 2 radiator fan drive

(68.3) Pressure filter with pressure differential switch B21-1 (Engine 1) (68.5) Pressure filter with pressure differential switch B21-2 (Engine 2) (103.3) Check valve engine 1– (Anti cavitation valve for fan drive motor) (103.4) Check valve engine 2– (Anti cavitation valve for fan drive motor) (148.13) 4/3 direction flow valve – Engine 1 radiator fan speed (stop, low and

high speed)

(148.14) 4/3 direction flow valve – Engine 2 radiator fan speed (stop, low and high speed)

(169.3) pressure reduction valve (low fan speed adjusting) engine 1 (169.4) pressure reduction valve (low fan speed adjusting) engine 2 (L) Leak oil (case drain) to tank

(P) Pressure to motor (R) Return oil to tank

Function:

From pump (10.1 / 10.3) flows the oil through the filter (68.3 / 68.5) to the fan motor (23.1 / 23.2) and then back to the tank.

The check valve (103.3 / 103.4) 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 engine has been switched off.

The hydraulic circuit "Fan drive" is secured by the pilot controlled pressure relief valve (168.3 / 168.4). This valve works together with the 4/3 direction flow valve

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Cont'd

(148.13 / 148.14) and the pressure reduction valve (169.1 / 169.4). The 4/3 direction flow valve (148.13 / 148.14) with the solenoids (Y14A-1 and Y14B-1 / Y14A-2 and Y14B-2) operates depending on engine coolant temperature.

The PLC (Programmable Logic Control) in the cab support controls the 4/3 direction valve (148.13 / 148.14) by activating the solenoids (Y14A-1 and Y14B-1 / Y14A-2 and Y14B-2), depending on the engine coolant temperature.

With de-energized solenoids the fan turn with max. speed.

With activated solenoid (Y14A-1 / Y14A2) the fan is running with a very low speed, caused by the flow resistance only.

With activated solenoid (Y14B-1 / Y14B2) the fan is running with middle setted speed, caused by the reduced pilot pressure on port X of pressure relief valve (168.3 / 168.4) with the pressure reduction valve (169.1 / 169.4).

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2.5 Radiator fan drive speed adjustment Basic Adjustment

Legend for illustration (Z 22400):

(1) Dust cap

(2) Lock nut

(3) Set screw

(P) 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)

(168.3) Pressure relief valve - Engine radiator fan drive (Engine 1) (168.4) Pressure relief valve - Engine radiator fan drive (Engine 2) (169.3) pressure reduction valve - Engine radiator fan drive (Engine 1) (169.4) pressure reduction valve - Engine radiator fan drive (Engine 2) (Y14A-1 /Y14B-1)) 4/3 direction flow valve – Engine 1

(Y14A-2 /Y14B-2)) 4/3 direction flow valve – Engine 2 (L1) Measurement of Qmin stop bolt

(L2) Measurement of Qmax stop bolt

(M19-1) Pressure check points - Engine 1 radiator fan drive operating pressure (M19-2) Pressure check points - Engine 2 radiator fan drive operating pressure

)

Basic adjustment has to be carried out whenever one of the following components has been replaced:

- pump - relief valve - hydraulic motor

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2.5 Radiator fan drive speed adjustment Basic Adjustment max fan speed

1. Reduce the output flow of the respective pump (P),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 (1) from relief valve (168.x), loosen lock nut (2) and turn set screw (3) fully clockwise and then a half turn counter clockwise.

3. Disconnect the plug connectors (Y14A-x and Y14B-x) of the 4/3 direction flow valve, to ensure that the full flow of pump P will be delivered to the fan motor. The valve is in neutral position and all ports are blocked.

4. Connect a pressure gauge to check point (M19-x). 5. Start the engine and let it run with max. speed. 6. Check the fan speed with a non-contact rev counter

Required fan speed: 1250 min-1

Be careful not to get caught in the fan or other rotating parts

7. Increase the output flow of pump P ,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).

Do not exceed the maximum permissible operating pressure of 230 bar

)

Note down the lengths ”L1” and ”L2” as reference measurements.

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8. Loosen lock nut (2) of the relief valve (168.x), and decrease the pressure with set screw (3) until the correct fan speed is obtained. 9. Tighten lock nut (2) and fix protection cap (3).

Basic Adjustment middle fan speed

10. Activate the 4/3 direction flow valve (Y14B-x), by connecting the solenoid plug (Y14B-x ) to permanent 24 V. Use the 24V socket at the PTO *).

11. Check the fan speed with a non-contact rev counter Required fan speed: 1000 min-1

12. If adjustment is necessary loosen lock nut (5) of the relief valve (169.x), and decrease the pressure with set screw (4) until the correct fan speed is obtained.

13. Stop engine and reconnect the plugs to the correct positions. 14. Disconnect the pressure gauge from check point (M7).

Fan speed check

If the maximum fan speed is out of adjustment, increase or decrease first the pressure at relief valve (168.x), to change the speed.

Do not exceed the maximum permissible operating pressure of 230 bar

If the speed can not be raised by increasing the pressure then increase the output flow of pump (10.x).

*) 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 (-).

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2.6 Pump distributor gearbox (PTO) Legend for illustration (Z 22409):

(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 (D) Drive flange

(M) Power take off for main pumps

(R) Power take off for engine radiator fan drive pump (C) Power take off for hydraulic oil cooler fan drive pump

Description

The pump distribution gear (PTO gear) is a spur gear design and driven by an diesel engine.

The PTO gear runs in anti friction 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 a 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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2.7 Pump-spline 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 seal ring 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.

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2.8 PTO Lubrication and cooling Legend for illustration (Z 22410e):

The machine is equipped with two engines and gearboxes. The engine close to the counter weight is called engine 1 and the engine to the front is called engine 2. The extension of the component designation shows the mounted position. Example: Pressure filter (69.1) is the pressure filter for the PTO lubrication of engine 1 and (69.2) for engine 2.

(1) Line to the cooler (hot oil)

(2) Return line from the cooler (cooled oil) (3) Return line from valve to PTO (relief line) (4) Suction line from PTO oil pan to the pump (P) Connections to spray nozzles

(8.1)(8.4) Gear pump PTO-gearbox lubrication (69.1)(69.2) Pressure filter - PTO gear lubrication (74.1)(74.2) Pressure relief valve, 7,5 bar

(78.14)(78.15) Solenoid valve (Y53-x), (reduction of relief valve pressure) (105.3+105.4) Oil cooler, part of hydraulic oil cooler engine 1

(105.1+105.2) Oil cooler, part of hydraulic oil cooler engine 2 (M1-1)(M1-2) Pressure check point

(B17-1)(B17-2) Pressure switch, 0,5 bar (B27-1)(B27-2) Maintenance switch, 5 bar (B49-1) Temperature sensor

Function:

Pump (8.1)/(8.4) forces the gear oil from the gear oil pan through filter

(69.1)/(69.2)) to pressure relief valve (74.1/74.2). This pressure relief valve acts as a back pressure valve causing that most of the oil passes through the gear oil coolers (105.3+105.4)/(105.1+105.2).

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) (B49-2). At too high oil temperature a fault message will be displayed on the monitor at the dash board.

If the oil temperature is to low, solenoid valve (Y53-1) (Y53-2) energized and opened port X of the pressure relive valve (74.1) (74.2). This reduced the relieve valve pressure setting. The main gear oil flow direct back to the PTO to quick warm up of the gear oil.

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Cont’d.:

2.8 PTO Lubrication and cooling Legend for illustration (Z 22414)

(1) Pilot operated relief valve (8) Valve spring

(2) Plug screw (9) Seal rings

(3) Valve piston (B27-x) Maintenance switch (4) Port for pressure switch B17-1 (74.x) Pressure relief valve (6) Port for pressure check stud (A) Pressure port

(7) Jet bore (T) Return from valve

Adjustments:

The adjustment of the maximum permissible PTO lube pressure, has to be carried out with cold oil to avoid serious damages to the coolers.

The check for a sufficient PTO lube pressure has to be carried out with warm oil to avoid serious damages gearbox.

Setting the pressure relief valve (74.x) at cold oil.

1. Connect a pressure gauge to check point (M1.x). 2. Disconnect plug of solenoid valve Y53-1/ Y53-2 3. Start the engine and let it run with max. speed. 4. Maximum pressure: 7,5 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/ Y53-2

)

If the pressure of 7,5 bar cannot be adj. 100 % , adj. to the highest visible pressure.

Checking the PTO lube pressure at operating temperature (warm oil)

1. Connect a pressure gauge to check point (M1.x). 2. Start the engine and let it run with max. speed. 3. Required pressure: 2-7,5 bar.

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2.9 Hydraulic pumps – location, drive speed and flow rates Legend for illustration (Z 22415a):

(1 - 6) Axial piston pump (swash plate type) Vg max = 500 cm³/rev

theoretical flow rate, each Qmax = 700 Liter/min

Drive speed* n = 1400 min-1

for all working motions

(10.1), (10.3) Axial piston pump Vg max = 80 cm³/rev

theoretical flow rate Qmax = 158 Liter/min

Drive speed* n = 1973 min-1

for radiator fan drive

(10.2), (10.4) Axial piston pump Vg max = 80 cm³/rev

theoretical flow rate Qmax = 142 Liter/min

Drive speed* n = 1770 min-1

for oil cooler fan drive

(8.1), (8.4) Gear pump Vg = 58,7 cm³/rev

theoretical flow rate Qmax = 82,2 Liter/min

Drive speed* n = 1400 min-1

for PTO gear lubrication

(8.2), (8.5) Gear pump Vg = 58,7 cm³/rev

theoretical flow rate Qmax = 82,2 Liter/min

Drive speed* n = 1400 min-1

for hydraulic oil circulation

(7.1), (7.2) Gear pump Vg = 85,7 cm³/rev

theoretical flow rate Qmax = 120 Liter/min

Drive speed* n = 1400 min-1

for pilot pressure supply

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04.01.07 PC5500-6-E_Sec_3-0_rev2.doc

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

3.6 Return and Leak Oil Filter 8 3.7 Breather Filter 9

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3. General lay out

Legend for illustration (Z 22416b): (1) Filter cover retainer

(2) Filter cover

(3) (A) – Return oil filter – 10 µm (4x) (B) – Case drain filter – 3 µm (1x)

(4) Man hole cover

(5) Hydraulic oil filler plug

(6) Differential pressure switch, screen filter monitoring (7) Test port, back pressure 8 bar

(8) Test port, back pressure swing motor 15 bar

(24) Pressure switch B24 – monitors item (132.1+132.2) (39) Hydraulic oil level gauge

(41) Main oil reservoir

(114) Return oil collector tube with pressure check point M10 (115) Back pressure valve

(118) Oil drain, quick release coupling

(128) Shut off valve (Gate valve) with monitoring switch S31 (129) Compensator

(132.1 + 132.2) Breather filter

(178) Oil cooler filter (screen filter)

The hydraulic oil tank is a welded sheet-metal construction.

The filling capacity is about 3800 litres. The tank contains four return oil filters (3-A) and one case drain filter (3-B).

The breather filter (132.1 + 132.2) cleans the air that streams into the tank. The back pressure valve (115) and the pressure check point (M10) are located at the collector tube (114) for return oil.

The connection to the suction tank can be closed with the shut- off valve (118) to prevent oil flow during repairs on the hydraulic pumps. This unit is

controlled by the switch S31, to prevent a motor start with closed shut-off valve. Fault message ”Start blocked because of main Shut-Off (gate) valve” is displayed at the operators dash board.

The screen filter (178) protect the oil cooler for internal contamination, the filter is monitored by differential pressure switch (178).

The back pressure valves (8) increase the circulation pump pressure to 15 bar for cavitation protection of the swing motors.

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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

(B25) Pressure switch – Pressure leak oil chamber (B26) Pressure switch – Pressure return oil chamber

(B32) Hydraulic oil temperature probe “Temp. gauge cabin” (B42) Oil level sensor “Oil level maximum”

(B50) Oil level sensor “Hydraulic oil refill level” (Y101) Solenoid valve “Back pressure reduction”

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3.2 Suction oil tank with strainers

Legend for illustration (Z 22418): (1) Suction oil reservoir (2) Drain coupling (3) Bolt

(4) Gaskets

(5) Main suction oil strainer (6) Gaskets

(7) Intermediate pipe (8) Nut

(9) Bolt

(10) Compensator

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

The suction oil tank (1) is a welded sheet-metal construction. The capacity is 187 liters.

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3.3 Return oil collector tube with strainer

Legend for illustration (Z 21497a):

(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

(6) Self locking nut (7) Gasket

(8) Differential pressure switch B165

Task:

The strainer is installed to prevent the hydraulic oil coolers from getting clogged up in case of contamination in the main return oil circuit.

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 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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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 (8) Safety filter element (200 micron strainer) (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 sections with 4 filters for the return oil and one for the leak oil. But the five filters are all 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.

Because the filter is oversized for this purpose, the message ”Leak oil filter restricted” is displayed very seldom under normal

circumstances.

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3.7 Breather filter

Legend for illustration (Z 21501a): (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).

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13.02.07 PC5500-6-D_Sec_4-0_rev4a.doc

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 + 6 4.5 Pressure relief valves and solenoid valve 7 + 8 4.6 Fixed Displacement Pump, with variable setting 9

4.7 Radiator fan drive speed adjustment 10 –

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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

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”)

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4.2 Function of the hydraulic oil cooling circuit Legend for illustration (Z 22419)

(107.1-107.4) Restrictor, shock absorbers for the hydraulic oil cooler (106.1-106.4) Hydraulic oil cooler

(41) Main oil reservoir (114) Return oil collector tube (115) Back pressure valve

(L6 + L7) Return line from control blocks

(L8 + L9) 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 (114). On the top of it is the Back Pressure Valve (115) installed.

The back pressure valve (115) causes a back pressure which forces most of the relative hot oil through the lines (H) to the cooler (106.1-106.4).

On its flow through the cooler the hydraulic oil gets cooled and flows than through the restrictors (107.1-107.4) 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 (115) is wide

open, because solenoid valve Y101 is energized, which results in less oil flows through the cooler which causes that the oil gets quicker its optimum operating temperature.

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.

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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 S155in to pos.1 actuated)!

1. Connect a pressure gauge to check point (M10).

2. Disconnect plug connector (13) of solenoid valve Y101. 3. Actuate service switch S155 (pos.1).

4. Start the engine and let it run with maximum speed. 5. Required pressure: 8 ±0,5 bar

If adjustment is required:

a) Take off protective cap (12). b) Loosen lock nut (5).

c) Adjust 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 pos.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 Fan drive (Two stage cooler fan RPM control) Legend for illustration (Z 22420)

(10.2) Axial piston pump Engine 1 (fixed displacement pump, with variable setting)

(10.4) Axial piston pump Engine 2 (fixed displacement pump, with variable setting)

(22.1) Fan motor (Axial piston motor) (22.2) Fan motor (Axial piston motor) (41) Main oil reservoir

(168.1) Pressure relief valve – Engine 1 radiator fan drive (168.2) Pressure relief valve – Engine 2 radiator fan drive

(68.1) Pressure filter with pressure differential switch B28-1 (Engine 1) (68.2) Pressure filter with pressure differential switch B28-2 (Engine 2) (103.1) Check valve engine 1– (Anti cavitation valve for fan drive motor) (103.2) Check valve engine 2– (Anti cavitation valve for fan drive motor) (148.11) 4/3 direction flow valve – Engine 1 radiator fan speed (stop, low and

high speed), solenoid Y6A-1 + Y6B-1

(148.12) 4/3 direction flow valve – Engine 2 radiator fan speed (stop, low and high speed), solenoid Y6A-2 + Y6B-2

(169.1) pressure reduction valve (low fan speed adjusting) engine 1 (169.2) pressure reduction valve (low fan speed adjusting) engine 2 (L) Leak oil (case drain) to tank

(P) Pressure to motor (R) Return oil to tank

1 Engine 1

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Function:

From pump (10.x) flows the oil through the filter (68.x) to the fan motor (22.x) and then back to the tank.

The check valve (103.x) 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 interrupted by solenoid valve (Y6A-x/Y6B-x) or if the engine has been switched off. The hydraulic circuit "Fan drive" is secured by the pilot controlled pressure relief valves (168.x) and (169.x).

These valves are working together with the solenoid valve (Y6A-x/Y6B-x), controlled by the PLC, depending on the hydraulic oil temperature:

• With de-energized solenoids Y6A-x and Y6B-x the relief valve (168.x) is

functioning and the fans are running with max. adjusted speed (1300 RPM) • With solenoid Y6A-x energized the relief valve (168.x) 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 (169.x) is controlling the relief

valve (168.x) and the fans are running with 1000 RPM only. (See also description on next page)

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Figure

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References

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