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PC4000_Contents and 00_Foreword_rev0.doc 06.09.02

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SMPC 4 000 8152

Shopanual

PC4000 - 6 HYDRAULIC MINING SHOVEL SERIAL NUMBERS PC 4 000 -6 8152

This material is proprietary to Komatsu Mining Germany GmbH and is not to be reproduced, used, or disclosed exceptin accordance with written authorization from Komatsu Mining Germany GmbH .

It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right tomake changes or improvements at any time without incurring any obligation to install such changes on productssold previously.

Due to this continuous program of research and development, revisions may be made to this publication. It isrecommended that customers contact their distributor for information on the latest revision.

Copyright 2006 KomatsuPrinted in U.S.A.Komatsu Mining Germany

Ju ne 2006

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PC4000_Contents and 00_Foreword_rev0.doc 06.09.02

CONTENTSTABLE 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 excess ladder

11. Central refilling system

12. Hints for the hydraulic circuit diagram

13. Hints for the electric circuit diagram

14 VHMS / ECS-T / ETM

15 Lubrication Systems

APPENDIX

• Each section includes a detailed table of contents.

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SAFETY SAFETY NOTICE

00-1

SAFETYSAFETY NOTICE

• IMPORTANT SAFETY NOTICEProper service and repair is extremely important for safe machine operation. The

service and repair techniques recommended by Komatsu and described in this manualare both effective and safe. Some of these techniques require the use of tools speciallydesigned by Komatsu for the specific purpose.

The following Symbols are used in this Manual to designate Instructions of

particular Importance.

ã WARNING - Serious personal injury or extensive property damage canresult 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.

W CAUTION - Minor personal injury can result or a part, an assembly, or the shovel can be damaged if the caution instructions are notfollowed.

NOTE - Refers to special information

GENERAL PRECAUTIONS

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE

MANUAL carefully BEFORE operating the machine.1. Before carrying out any greasing or repairs, read all the precautions given on the decals

which are fixed to the machine.

2. When carrying out any operation, always wear safety shoes and helmet. Do not wear

loose work clothes, or clothes with buttons missing.• Always wear safety glasses when hitting parts with a hammer.• Always wear safety glasses when grinding parts with a grinder, etc.

continued

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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 theoperating procedure before starting. Always inform your fellow workers before starting

any step of the operation. Before starting work, hang UNDER REPAIR signs on the

controls in the operator's compartment.

5. Keep all tools in good condition and learn the correct way to use them.

6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the

tools and parts in their correct places. Always keep the work area clean and make sure

that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking.

Never smoke while working.

PREPARATIONS FOR WORK

7. Before adding oil or making repairs, park the machine on hard, level ground, and block

the wheels or tracks to prevent the machine from moving.

8. Before starting work, lower bucket, hammer or any other work equipment to the ground.

If this is not. possible, insert the safety pin or use blocks to prevent the work equipment

from falling. In addition, be sure to lock all the control levers and hang warning signs on

them.

9. When disassembling or assembling, support the machine with blocks, jacks or stands

before starting work.

10. Remove all mud and oil from the steps or other places used to get on and off the machine.

Always use the handrails, ladders or steps when getting on or off the machine. Never

jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a

stand to provide safe footing.

PRECAUTIONS DURING WORK

11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs,

loosen them slowly to prevent the oil from spurting out.Before disconnecting or removing components of the oil, water or air circuits, first

remove the pressure completely from the circuit.

12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to

get burned.

Wait for the oil and water to cool before carrying out work on the oil or water circuits.

continued

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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. In particular, use only the minimum

of gasoline when washing electrical 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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00-4

FOREWORDGENERAL

With this SERVICE MANUAL KOMATSU provides you with the

description of the construction and the function of the major systems of theHydraulic Excavator PC4000 .

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 18036140570 Düsseldorf

Tel.:0211 / 7109 - 206Fax.: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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FOREWORD HOISTING INSTRUCTIONS

00-5

HOISTING INSTRUCTIONSHOISTING

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

• If a part cannot be smoothly removed from the machine by hoisting,

the following checks should be made:

1. Check for removal of all bolts fastening the part to the relative

parts.

2. Check for existence of another part causing interface with the part

to be removed.

WIRE ROPES

1. Use adequate ropes depending on the weight of parts to be hoisted, referring to

the table below:

Wire ropes

(Standard "Z" or "S" twist ropes without galvanizing)

Rope diameter

[mm]

10,0 11,2 12,5 14,0 16,0 18,0 20,0 22,4 30,0 40,0 50,0 60,0

Allowable

load [tons]

1,0 1,4 1,6 2,2 2,8 3,6 4,4 5,6 10,0 18,0 28,0 40,0

• The allowable load value is estimated to be 1/6 or 1/7 of the breaking

strength of the rope used.

2. Sling wire ropes from the middle portion of the hook. Slinging near the edge

of the hook may cause the rope to slip off the hook during hoisting, and a

serious accident can result. Hooks have maximum strength at the middle

portion.

continuedCont'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.

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

untwisting of the rope, or slipping of the rope from its originalwinding 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 thehook. When hoisting a load with two or more ropes, the force subjected toeach rope will increase with the hanging angles. The table below shows thevariation 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 besuspended. This weight becomes 1000 kg when two ropes make a 120 Ehanging angle. On the other hand, two ropes are subject to an excessive forceas large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150 .

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FOREWORD STANDARD TIGHTENING TORQUE

00-7

STANDARD TIGHTENING TORQUE (1Kgm = 9,806Nm)STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS

Bolt Wrench Tightening torque Nmdia. size [mm] lbs.ft.

Quality grades 8.8 10.9 12.9

M 10 17 43 63 7332 47 54

M 12 19 74 108 127 54.6 80 94

M 14 22 118 173 20287 128 149

M 16 24 179 265 310132 196 229

M 18 27 255 360 425188 265 313

M20 30 360 510 600265 376 443

M 22 32 485 690 810358 509 597

M 24 36 620 880 1030457 649 760M 27 41 920 1310 1530

679 966 1128M 30 46 1250 1770 2080

922 1305 1534M 33 50 1690 2400 2800

1246 1770 2065M 36 55 2170 3100 3600

1600 2286 2655M 39 60 2800 4000 4700

2065 2950 3466M 42 65 3500 4950 5800

2580 3650 4277Insert all bolts lubricated with MPG KP2K

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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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00-9

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00-10

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00-13

Basic Values in Ohm according to DIN 43 76

For Measuring Resistor PT100

° C -0 -1 -2 -3 -4 -5 -6 -7 -8 -9

-50 80,31 79,91 79,51 79,11 78,72 78,32 77,92 77,52 77,13 76,73

-40 84,27 83,88 83,48 83,08 82,69 82,29 81,89 81,50 81,10 80,70

-30 88,22 87,83 87,43 87,04 86,64 86,25 85,85 85,46 85,06 84,67

-20 92,16 91,77 91,37 90,98 90,59 90,19 89,80 89,40 89,01 88,62

-10 96,09 95,69 95,30 94,91 94,52 94,12 93,73 93,34 92,95 92,55

0 100,00 99,61 99,22 98,83 98,44 98,04 97,65 97,26 96,87 96,48

° C 0 1 2 3 4 5 6 7 8 9

0 100,00 100,39 100,78 101,17 101,56 101,95 102,34 102,73 103,12 103,51

10 103,90 104,29 104,68 105,07 105,46 105,85 106,24 106,63 107,02 107,40

20 107,79 108,18 108,57 108,96 109,35 109,73 110,12 110,51 110,90 111,28

30 111,67 112,06 112,45 112,83 113,22 113,61 113,99 114,38 114,77 115,15

40 115,54 115,93 116,31 116,70 117,08 117,47 117,85 118,24 118,62 119,01

50 119,40 119,78 120,16 120,55 120,93 121,32 121,70 122,09 122,47 122,86

60 123,24 123,62 124,01, 124,39 124,77 125,16 125,54 125,92 126,31 126,69

70 127,07 127,45 127,84 128,22 128,60 128,98 129,37 129,75 130,13 130,51

80 130,89 131,27 131,66 132,04 132,42 132,80 133,18 133,56 133,94 134,32

90 134,70 135,08 135,46 135,84 136,22 136,60 136,98 137,36 137,47 138,12

100 138,50 138,88 139,26 139,64 140,02 140,39 140,77 141,15 141,53 141,91

110 142,29 142,66 143,04 143,42 143,80 144,17 144,55 144,93 145,31 145,68

120 146,06 146,44 146,81 147,19 147,57 147,94 148,32 148,70 149,07 149,45

130 149,82 150,20 150,57 150,95 151,33 151,70 152,08 152,45 152,83 153,20

140 153,58 153,95 154,32 154,70 155,07 155,45 155,82 156,19 156,57 156,94

150 157,31 157,69 158,06 158,43 158,81 159,18 159,55 159,93 160,30 16067

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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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Main Assembly Groups Section 1.0Page 1

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

1.3.2. Front Shovel Attachment (FSA) 15

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1. General lay out

Legend for illustration (Z 21463):

(1) Superstructure

(2) Under carriage

(3) Front Shovel Attachment (FSA)

(4) Backhoe Attachment (BHA)

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1.03

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1.1 Superstructure


(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 C entral L ubrication System

(19) Grease pump of the Swing gear pinion L ubrication System

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1.04

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1.1 Superstructure

1.1.1 Machine house


(1) Roof mounted exhaust

(2) Roof mounted air cleaners with restriction switches

(3) Expansion tank of the radiator for the engine cooling system

(4) Hydraulic control and filter panel

(5) PTO gear box

(6) Main hydraulic pumps

(7) Auxiliary pumps, installed at the drive through shaft of the main

hydraulic pumps (piggyback pumps)

(8) Hydraulic pump for radiator fan drive

(9) Hydraulic pump for the hydraulic oil cooler fan drive

(10) Suction oil reservoir

(11) Flexible coupling, oil filled

(12) Batteries

(13) Engine

(14) Hydraulic motor for the radiator fan drive

(15) Radiator for the engine cooling system

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1.1 Superstructure

1.1.2 Hydraulic Oil Reservoir


(1) Breather filter

(2) Temperature controlled back pressure valve

(3) Drain coupling of the hydraulic oil reservoir

(4) Return oil filter

(5) Case drain (leak oil) filter

(6) Main shut-off valve (Gate valve) with compensator

(7) Return oil collector tube

(8) Drain coupling of the Return oil collector tube

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1.1 Superstructure

1.1.3 Hydraulic Oil Cooler


(1) Cooler frame with swing out facility

(2) Hydraulic motor of upper fan

(3) Upper fan

(4) Fan guard

(5) Outer part of the upper radiator set

(6) Inner part of the upper radiator set

(7) Hydraulic motor of lower fan

(8) Lower fan

(9) Fan guard

(10) Outer part of the lower radiator set

(11) Inner part of the lower radiator

(12) Swing out doors

(13) Locking bars to secure the swing out doors

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1.07

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1.1 Superstructure

1.1.4 Fuel tank (Fuel reservoir)


(1) Fuel tank

(2) Fuel tank breather valve

(3) Main shut-off cock

(4) Drain coupling with protection cap

(5) Shut-off cock for fuel pressure transducer

(6) Fuel pressure transducer

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1.08

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1.1 Superstructure

1.1.5 Counter weight

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

Total weight

33000 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

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1.1 Superstructure

1.1.6 Cab support

Legend for illustration (Z 21475):(1) Cab support (Location of electrical switch board “X2”)

(2) Mounting boltsQuantity Bolt size

(mm)Grade SW*

(mm)Tighteningtorque (Nm)

4 M 36 x 240 10.9 55 3100

*SW = Wrench size

(3) Mounting bolts

Quantity Bolt size(mm)

Grade SW*(mm)

Tighteningtorque (Nm)

4 M 36 x 240 10.9 55 3100

*SW = Wrench size

(4) Door

(5) Gasket

(6) Door handle (adjustable)

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1.1 Superstructure

1.1.7 Operators cab


(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

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1.011

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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

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1.1 Superstructure

1.1.9 Swing gears

Legend for illustration (Z 21478):(1) Swing gear box

(2) Swing parking brake – Spring loaded multi disk brake

(Released by oil pressure)

(3) Equalizing reservoir - gear box oil

(4) Oil level gauge - gear box

(5) Oil drain plug – motor adapter housing

(6) Oil level gauge - motor adapter housing

(7) Breather filter – brake housing

(8) Oil level gauge – brake housing(9) Pinion

(10) Oil drain plug - gear box

(60.1 + 60.2) Swing motor

(61.1 + 61.2) Swing brake valve block

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1.013

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1.2 Under carriage


(1) Undercarriage center body

(2) Crawler carrier R.H.-side(3) Crawler carrier L.H.-side

(4) Connecting pins, center body to crawler carriers

(5) Crawler tracks

(6) Rotary distributor

(7) Brake valves

(8) Travel motors

(9) Parking brakes, spring loaded disk type brakes

(10) Travel gear

(11) Sprocket(12) Track rollers

(13) Carrier rollers

(14) Guide wheel (Idler)

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1.3 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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1.015

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1.015

1.3 Attachment

1.3.2 Front Shovel Attachment (FSA)

Legend for illustration (Z 21483):(1) Boom

(2) Boom Cylinders

(3) Stick

(4) Stick Cylinders

(5) Bucket backwall

(6) Bucket Cylinders

(7) Bullclam

(8) Bucket Clam cylinders

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Drive Section 2.0Page 1


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

2.9 Hydraulic pumps – location, drive speed and flow rates 15

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2.0 Prime drive assembly


(1) Engine

(2) Torsion type coupling(3) Pump distributor gear (PTO)

(4) Adapter flange

(5) Power frame

General

The drive unit, consists of the PTO gear and the engine, is bolted to the power

frame.

The connection between engine and PTO gear is a flexible coupling.

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2.1 Engine and PTO mounts

Legend for illustration (Z 21601):(1) Flexible bearing

(2) Bolt with self locking nutQuantity Bolt size

(mm)Grade SW*


4 per mount M 10 x35 8.8 17 43

(3) Tie boltQuantity Bolt size

(mm)Grade SW*


4 M 24 x400 10.9 36 snugly

(4) Rubber-bounded metal bar

(5) Self locking nut(6) Bolt M16 with self locking nut


Grade SW*(mm)


2 M 16x 80 10.9 24 265

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


Grade SW*(mm)


2 M 36 x250 10.9 55 Not specified

(9) Nut(10) Bolt


Grade SW*(mm)


10 M 24 x 200 10.9 36 880

(11) BoltQuantity Bolt size

(mm)Grade SW*


16 M 20 x 120 10.9 30 510

(12) Resilient sleeve(13) Bolt


Grade SW*(mm)


4 M 30 x 200 10.9 46 1770

(14) Resilient sleeve

* SW = Wrench sizecontinued

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2.1 Engine and PTO mounts

Cont'd

GeneralThe flexible bearings are installed to take the vibrations and the torsion forcesand they carry the total weight of the engine, the pump distributor gear withall 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 thereis 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 torquesupports.

• 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 thecorrect 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 isno gap between nut and rubber-bounded metal bar (4). If necessary retightenretainer 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.• For more information, refer to Parts & Service News REF NO AH01521.

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2.2 Coupling


(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.

The spacers (8) limits the movement of the leaf springs.

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2.3 Air Filter


(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


(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.

continued

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2.4 Fan drive and radiator assembly

Cont'd


(1) Radiator

(2) Intake air fan

(5.2) Axial piston pump (fixed displacement pump, with variable setting)

(23) Fan motor (Axial piston motor)

(31.2) Pressure relief valve - Engine radiator fan drive

(34.2) Pressure filter with pressure differential switch B21

(41) Main oil reservoir

(52) Check valve – (Anti cavitation valve for fan drive motor)

(Y136) Proportional solenoid valve - Engine radiator fan speed (infinitely

variable)

(L) Leak oil (case drain) to tank

(P) Pressure to motor

(R) Return oil to tank

Function:

From pump (5.2) flows the oil through the filter (34.2) to the fan motor (23) and

then back to the tank.

The check valve (52) 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 (31.2). This valve works together with the proportional solenoid valve (Y136).

The proportional solenoid valve(Y136) operates depending on engine coolant

temperature.

The ECM (Electronic Control Module) of the engine controls the proportional

solenoid valve (Y136) by sending variable current signals, depending on the engine

coolant temperature.

Which in turn changes the fan speed.

With a low current signal to the proportional solenoid the relief valve is functioning

and the fans are running with the max. set- speed. With a high current signal to the

proportional solenoid the relief valve is not functioning and the fans are running

with a very low speed, caused by the flow resistance only.

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2.5 Radiator fan drive speed adjustment

Basic Adjustment

Legend for illustration (Z 21606):(1) Dust cap(2) Lock nut(3) Set screw(5.2) Axial piston pump (fixed displacement pump, with variable setting)(6) Q min stop bolt(6.1) Lock nut(7) Q max stop bolt(7.1) Lock nut(10) Positioning pin (mover)

(31.2) Pressure relief valve - Engine radiator fan drive(Y136) Proportional solenoid valve - Engine radiator fan speed (infinitely variable)(L1) Measurement of Q min stop bolt(L2) Measurement of Q max stop bolt(M7) Pressure check points - Engine 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 motor1. Reduce the output flow of pump (5.2),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 (31.2), loosen lock nut (2) and

turn set screw (3) fully clockwise and then a half turn counter clockwise.3. Isolate the function of p roportional solenoid valve (Y136), by disconnecting

the plug connector, to ensure that the full flow of pump 5.2 will be

delivered to the fan motor.

4. Connect a pressure gauge to check point (M7).

5. Start the engine and let it run with max. speed.

continued

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2.5 Radiator fan drive speed adjustment

Cont'd

Basic Adjustment

6. Check the fan speed with a non-contact rev counter

Required fan speed: 1250 min -1

ã • Be careful not to get caught in the fan or other rotating parts7. Increase the output flow of pump (5.2),by adjusting the swivel angle,

until the fan speed will be 20 min -1 higher than required:

To do this, loosen both lock nuts (6.1 + 7.1) and turn in bolt (6)

and turn out bolt (7) the same length .This is necessary to avoid a loose positioning pin (10), resulting in

oscillating of the cylinder barrel.

Tighten the lock nuts (6.1 + 7.1).

ã • Do not exceed the maximum permissible operating pressure of 230bar.

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

8. Loosen lock nut (2) of the relief valve (31.2), 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).

10. Activate the function of proportional solenoid valve (Y136), by connecting

the plug connector. (Fan speed controlled in relation to the engine

temperature)

11. Disconnect the pressure gauge from check point (M7).

Fan speed check If the fan speed is out of adjustment, increase or decrease first the pressure at

relief valve (31.2), to change the speed.

ã • Do not exceed the maximum permissible operating pressure of 230bar.If the speed can not be raised by increasing the pressure then increase the

output flow of pump (5.2).

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2.6 Pump distributor gearbox (PTO)

Legend for illustration (Z 21607):(1) Oil level gauge

(2) Oil filler plug(3) Breather filter (4) Oil collector reservoir for auxiliary pump drive shaft housing(5) Breather filter with oil level gauge (drive shaft housing)(6) Main pump drive shaft housings(7) Oil level plug of main pump drive shaft housing(8) Oil filler plug with breather pipe of main pump drive shaft housing(9) Oil drain plug of main pump drive shaft housing(10) Oil drain plug of PTO gear (11) Flange for heater studs(12) Gear oil temperature probe mounting bore(13) Thermostat switch mounting bore cover plate(14) Suction line connection for gear oil cooling(15) Return line connection from gear oil cooler (16) Return line connection from cooling system relief valve(D) Drive flange(M) Power take off for main pumps(R) Power take off for engine radiator fan drive pump(C) Power take off for hydraulic oil cooler fan drive pump

Description

The pump distribution gear (PTO gear) is of a spur gear design and driven by

an diesel engine.

The PTO gear runs in antifriction bearings and has been provided with a

splash lubrication system. The oil supply of the bearings and tooth contacts

takes place by an injection. The gearwheels are of case-hardened steel.

The hydraulic pumps are directly attached to the gearbox. O-rings included in

the supply enable the unit to be reliably sealed statically.

The gearbox housing is of one-piece design and made of grey cast iron.Gearbox design allows a direct attachment to the engine via connection flange.

The gearbox has been provided with connections for a separate cooling system

resp. for heating rods. For more information refer to the REPAIR MANUAL

Description for the lubrication see next pages.

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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 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 possibleleak 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 outfrom 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 shaftsseals 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 leavethe union open.If now at operation the oil still comes out of the union, this drive shaftseal is gone.Otherwise check sequential all auxiliary drives.

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2.8 PTO Lubrication and cooling


(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 coolersthe 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 thelube 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 oiltemperature a fault message will be displayed on the monitor at the dash board.

continued

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Cont`d.

2.8 PTO Lubrication and cooling

Legend for illustration (Z 21610):(1) Pilot operated relief valve(2) Plug screw(3) Valve piston(4) Port for pressure switch

B17-1(-) --------(6) Port for pressure check stud

(7) Jet bore(8) Valve spring(9) Seal rings(B27-1) Maintenance switch(29) Pressure relief valve(A) Pressure port(T) Return from valve

Adjustments:

W • The adjustment of the maximum permissible PTO lube pressure, hasto 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 (29) at cold oil.


2. Start the engine and let it run with max. speed.

3. Required pressure: 10 ±±±± 1 bar.

If adjustment is required:4. Remove protection cap (1a).

5. Loosen lock nut (1b).

6. Set the pressure with set screw (1c).

7. Tighten lock nut (1b) and re-install protection cap (1a)

• If the pressure of 10 ±±±± 1 bar cannot be adj. 100 %, adj. to the lowest

visible pressure.

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

1. Connect a pressure gauge to check point (M3).2. Start the engine and let it run with max. speed.

3. Required pressure: 10 ±±±± 1 bar.

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2.9 Hydraulic pumps – location, drive speed and flow rates


(1 - 4) Axial piston pump (swash plate type)

theoretical flow rate, each 1033 Liter/minDrive 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



for radiator fan drive

(8.1) Gear pump



for pilot pressure supply

(8.2) Gear pump



PTO gear lubrication

• * at 1800 min -1 input drive speed

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Hydraulic Oil Reservoir Section 3.0Page 1


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

3.7 Breather Filter 9

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3. General lay out


(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


(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

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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

(B50) Oil level sensor “Hydraulic oil refill level”

(B105) Pressure transducer – Hydraulic oil level

(B163) Pressure transducer – Pressure return oil chamber

(B164) Pressure transducer – Pressure leak oil chamber

(B165) Pressure transducer – Pressure oil cooler

(B166) Pressure transducer – Pressure pre-load (back pressure) valve

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3.2 Suction oil tank with strainers

Legend for illustration (Z 21496a):

(1) Suction oil reservoir

(2) Drain coupling(3) Pressure transducer (B162) – Pressure suction oil tank

(4) Plug


(mm)Grade SW*


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


(mm)Grade SW*


16 M 16 x 40 8.8 24 179

(14) Lock nuts(15) Bolt


Grade SW*(mm)


8 M 20 x 90 10.9 30 510

(16) Resilient sleeve


(mm)Grade SW*


8 M 16 x 90 10.9 24 265

The suction oil tank (40) is a welded sheet-metal construction.

The capacity is 187 liters.

The suction lines of all hydraulic pumps are connected to the suction tank.

* SW = Wrench size

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3.3 Return oil collector tube with strainer


(1) Return oil collector tube - Part 1 -

(2) Return oil collector tube - Part 2 -(3) Return oil collector tube - Part 3 -

(4) Strainer


(mm)Grade SW*


8 M 20 x 80 10.9 30 510


(mm)Grade SW*


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.

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3.4 Back pressure valve


(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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3.5 Transfer pump (Optional Equipment)


(113) Transfer pump unit at the hydraulic tank - (Electric driven

gear pump)(112.1) Shut off valve – suction oil tank

(112.2 Shut off valve – return oil collector tube (Manifold)

(112.3) Shut off valve – return oil collector tube (Hydr. oil cooler)

Functions of the Transfer Pump:

A - Transfusing oil from the suction oil reservoir into the main oil reservoir.

Necessary for evacuation of the suction oil reservoir, when changing the

hydraulic oil. Prior servicing the main hydraulic pumps it is advisable to

empty the suction oil reservoir partially.

B - Transfusing oil from return oil collector tube and back-pressure valve

pipe into main oil reservoir. Necessary when changing the hydraulic oil

and prior to servicing the high pressure filters, the main control valves,

or hydraulic oil cooler (oil return system).

• Refer to Section 6.15 of the operation and maintenance manual, for

further information.

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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 nutFunction :The returning oil flows into the filter chamber (A) of the hydraulic tank. (Thesketch shows one section only).The chamber is split into two sections; one sections with 4 filters for the return oiland one for the leak oil. But the five filters are all the same. The hydraulic oilenters 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 thoseswitches due to the restriction of the filter-element which is caused by foreignmatters, the fault message ”Return oil filter restricted" or ”Leak oil filter restricted” is displayed at the operator's dash board The filter elements must bereplaced. For safety pre-cautions the filter is equipped with a by-pass valve. As thefilter chamber pressure increases the by-pass valve opens at 2.3 bar and protectsthe 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 sealrings of the hydraulic motors.Because the filter is oversized for this purpose, the message ”Leak oil filter restricted” is displayed very seldom under normalcircumstances.

• Maintenance see chapter. 6.5 of MAINTENANCE MANUAL

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9 Hydraulic Oil Reservoir Section 3.0Page 9

3.7 Breather filter


(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).

Maintenance see chapter 6.5 of MAINTENANCE MANUAL

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Hydraulic Oil Cooling Section 4.0Page 1


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

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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")

The bearing group carrier is filled with oil to lubricate the bearings.

• MESABI cooler are available on request.

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4.2 Function of the hydraulic oil cooling circuit


(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


(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 (37.1 - 37.4) 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 Q max ) the back pressure valve (55) 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 Q max position and simultaneously solenoid valve Y101 will

be de-energized, so that the valve piston will be more closed by the force of

the spring thus that more oil passes the cooler.

(See sectional drawing on next page.)

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4.3 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 S151 actuated)!


2. Disconnect plug connector (13) of solenoid valve Y101.

3. Actuate service switch S151.

4. Start the engine and let it run with maximum speed.

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 S151.


(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)


(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


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 engine 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

VHMS system, depending on the hydraulic oil temperature:• With de-energized solenoids Y6a and Y6b the relief valve (31.1) is

functioning and the fans are running with max. adjusted speed (1250 RPM)• With solenoid Y6a energized the relief valve (31.1) is not functioning and the

fans are running with a very low speed caused by the flow resistance only.• With solenoid Y6b energized the relief valve (124) is controlling the relief

valve (31.1) and the fans are running with 1000 RPM only.

(See also description on next page)

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4.5 Pressure relief valves and solenoid valve

Pressure relief valve (31.1)


(1) Valve cartridge(2) Spring

(3) Spring chamber

(4) "X" port

(5) Jet bore, Pilot poppet

(6) Jet bore, Main piston

(7) Main piston

(8) Valve housing

(9) Pilot poppet

(Y) External leak oil port(A) Pressure port

(B) Return oil port

Function:

Pressure in line A affects the main piston (7). At the same time there is pressure

via the jet bore (6) on the spring-loaded side of the main piston and via jet bore

(5) at the pilot poppet (9) of the relief valve cartridge (1).

If system pressure in line A exceeds the value set at the spring (2), pilot poppet

(9) opens. The signal for this comes from line A via the jet bores (6) and (5).The oil on the spring-loaded side of the main piston (7) now flows via the jet

bore (5) and poppet (9) into the spring chamber (3).

From here it is fed internally by means of the control line (Y) to tank (port B).

Due to the state of equilibrium at the main piston (7), oil flows from line A to

line B, while the set operating pressure is maintained.

The pressure relief valve can be unloaded (Remote controlled) by means of the

port "X" and the function of the solenoid valve (126).( Function see next page)

continued

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Cont’d.

4.5 Pressure relief valves and solenoid valve, illustration (Z 21599)

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 a

normal relief valve function is eliminated.

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4.5 Fixed Displacement Pump, with variable setting


(1) Drive shaft

(2) Bearings(3) Cylinder with pistons

(4) Center pin

(5) Control lens

(6) Q-min adjustment bolt

(7) Q-max adjustment bolt

(8) Pressure port

(9) Tank port

Description.Pump type A7F0 is a variable displacement pump, designed to operate in open

circuits. It has an internal case drain return. The rotary group is a robust self

aspirating unit. External forces may be applied to the drive shaft.

Changing the swivel angle of the rotary group is achieved by sliding the

control lens along a cylindrical formed track by means of an adjusting screw.• With an increase in the swivel angel, the pump output increase together

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

with the necessary drive torque.

ã • When increasing to maximum swivel angle, there is a danger of cavitation and over-speeding the hydraulic motor!

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Controlling Section 5.0Page 1


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 – 7

5.3 Remote control valves arrangement 8

5.4 Function principle of the

Electro-Hydraulic- Proportional Control

9 + 10

5.5 Potentiometer Control (Lever, Joy Stick) 11

5.6 Potentiometer Control (Pedal) 12

5.7 Proportional amplifier module, Type A

(for swing brake only)

13

5.8 Proportional amplifier module, Type B

(for Boom, Stick, Bucket, Swing and Travel)

14

5.9 Ramp Time Module

(Analogue command value module for Boom, Stick,

Travel and Swing function)

15

5.10 Adjustments of Amplifier Modules (General) 16

5.11 Adjusting the Amplifiers Type B 17 + 18

5.12 Adjusting the Amplifiers Type A 19 + 20

5.13 Adjusting the Ramp Time Module 21 + 23

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5.0 General lay out

Legend for illustration (Z 21631):(E19) Electro proportional joy stick control

(E20) Electro proportional joy stick control(E21a) Electro proportional pedal control, travel left crawler (E21b) Electro proportional pedal control, travel right crawler (E22) Electro proportional pedal control, swing brake(E23) Electro proportional pedal control, bucket closed(E24) Electro proportional pedal control, bucket open(M1) Pressure check point

X4, Pump bearing lubrication, pump support pressure (60bar)(M2) Pressure check point

X2 pressure, pilot pressure (45bar)(8.1) Gear pump for Pilot pressure, Pump regulation and Pump bearing

lubrication(14) Remote control valve blocks(33) Pressure filter with pressure differential switch B22(35) Control and filter panel(41) Main oil reservoir (49) Check valve(85) Bladder Accumulator – 10 liter, 10bar (located underneath the

catwalk in front of the PTO)

(108.1) Pressure relief valve for pump support pressure X4 (60bar)(108.1) Pressure relief valve for pilot pressure X2 (45bar)

General

The controlling includes the pilot pressure system and the pump regulation

system.

The pump (8.1) forces the oil through the filter (33) to all involved valves.

The pressure accumulator ensures that under any circumstances enough pilot

pressure oil is available. The accumulator (85) is also functioning as a

hydraulic battery for a certain time when the engine was shut down or to pressure relive the system for repair works.

When the operator is using his controls an electrical signal causes energising

of the selected solenoid valve of the remote control valves(14).

By the function of the remote control valves pilot pressure oil is send to the

relevant control block spools which in turn allows operating hydraulic oil to

the users.

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Solenoid valves

(Y5) Swing parking brake operating pressure(Y6a) Cooler fan RPM control minimum speed(Y6b) Cooler fan RPM control medium speed(Y16) Travel parking brake operating pressure(Y17) „Idle time“ control, (Pump control system)(Y17a) ½ Q-max (reduced oil flow at too cold oil)(Y61) „X1“ pressure, pumps 1 - 4(Y120) Hydraulic swing brake, operating pressure(Y123a) Ladder raise(Y123b) Ladder lower (Y124a) Refilling arm raise(Y124b) Refilling arm lower (Y124c) Refilling arm stop (fix) – arm park valve(Y125) Ladder fast movement(Y126) Flow reduction (Pump 1)(Y127) Proportional swing brake pressure(Y128) Track tension left crawler (Y129) Track tension right crawler (Y130) Fixed pump No1 (max. flow, X1= 45 bar)(Y131) Fixed pump No3 (max. flow, X1= 45 bar)(Y136) Engine radiator fan speed (infinitely variable)

Filter:(33) Pilot pressure and pump regulation(34.1) Hydraulic oil cooler fan drive(34.2) Engine radiator fan drive(36) PTO gear lubrication

Miscellaneous:(22) Change over valve – Electronic pump regulation or hydraulic constant regulation(26) Pressure relief valve – safety valve to protect the travel parking brakes in case of

a defect rotary distributor (29) Pressure relief valve – PTO gear lubrication(31.1) Pressure relief valve - Hydraulic oil cooler fan drive, with solenoid valve Y6a /

Y6b for fan RPM control(31.2) Pressure relief valve - Engine radiator fan drive, with proportional solenoid valve

Y136 for fan RPM control(58.1) Pressure increasing valve – Track tensioning system L.H.(58.2) Pressure increasing valve – Track tensioning system R.H.(62.3) Shut-off valve – Truck tensioning system L.H.(62.4) Shut-off valve – Truck tensioning system R.H.(81.1) Pressure reducing valve – ½ Qmax(81.2 Pressure reducing valve – hydraulic constant regulation(98) Pressure relief valve – climbing ladder (108.1) Pressure relief valve for pump support pressure X4 (60bar)(108.2) Pressure relief valve for pilot pressure X2 (45bar)(124) Pressure relief valve Medium speed cooler fan

continued

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Cont'd:



Pressure switches:(B16) Swing parking brake operating pressure(B17-1) PTO gear lubrication pressure (lowest permissible pressure)(B21) Engine radiator fan drive - Filter element monitoring(B22) Pilot pressure - Filter element monitoring(B27) PTO gear lubrication - Filter element monitoring(B28) Hydraulic oil cooler fan drive - Filter element monitoring(B48) Travel parking brake operating pressure(B85-1) Pressure transducer – X1 pressure(B86) Pressure transducer – X2 pressure(B100) Track tensioning system L.H.(B101) Track tensioning system R.H.

Pressure check points:(M1) X4, Pump bearing lubrication, pump support pressure (60bar)(M2) X2 pressure, pilot pressure (45bar)(M3) PTO gear lubrication pressure(M4) Travel parking brake operating pressure(M5) Swing parking brake operating pressure(M6) Hydraulic oil cooler fan drive operating pressure(M7) Engine radiator fan drive operating pressure(M15) “X1” pressure(M29.7) Track tensioning system L.H. - operating pressure(M29.8) Track tensioning system R.H. - operating pressure(M30) “X3” pressure – to pump No 2, No 3 and No 4(M31) Reduced “X3” pressure(M32) Reduced “X3” pressure – to pump No 1

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5.2 Pilot Pressure Supply and Adjustments

Pilot Pressure Circuit

The pilot pressure oil is used for the following functions.

To move the control block spools, to supply the main pump regulationsystem, to lubricate the main pump bearings, to release the travel- and swing

gear house brakes (spring loaded multi disk brakes), to drive the Lincoln

Lubrication pumps and to supply the hydraulic track tensioning system.

Legend for illustration (Z 21631):(E19) Electro proportional joy stick control(E20) Electro proportional joy stick control(E21a) Electro proportional pedal control, travel left crawler (E21b) Electro proportional pedal control, travel right crawler

(E22) Electro proportional pedal control, swing brake(E23) Electro proportional pedal control, bucket closed(E24) Electro proportional pedal control, bucket open(M1) Pressure check point

X4, Pump bearing lubrication, pump support pressure (60bar)(M2) Pressure check point

X2 pressure, pilot pressure (45bar)(8.1) Gear pump for Pilot pressure, Pump regulation and Pump bearing

lubrication(14) Remote control valve blocks(33) Pressure filter with pressure differential switch B22(35) Control and filter panel(41) Main oil reservoir (49) Check valve(85) Bladder Accumulator – 10 liter, 10bar(located underneath the

catwalk in front of the PTO)(108.1) Pressure relief valve for pump support pressure X4 (60bar)(108.1) Pressure relief valve for pilot pressure X2 (45bar)

Function: Study together with the hydraulic circuit diagram

The pump (8.1) delivers the oil through filter (33) to port A of the pressure

relief valve (108.2).

The pressure relief valve (108.2) maintains the adjusted pressure of 45 bar („X2“) for the pilot pressure system, the pump regulation system and the

supply for some auxiliary systems.

The pressure accumulator (85) holds an amount of oil under pressure to

provide sufficient pilot pressure during normal operation and to ensure a

limited number of lowering operations with the main drive motor at standstill.

The check valve (49) prevents return flow of the pilot pressure oil.continued

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Cont'd:

Pilot Pressure Circuit



(49) Check valve

(85) Bladder Accumulator – 10 liter, 10bar (located underneath the

catwalk in front of the PTO)

(PX2) Pilot pressure line

(LX2) Leak / return oil line from the remote control blocks

Function:

The pilot pressure oil flows via line (P X2) to port (P) of each remote control

block and is present via a gallery at all proportional and directional solenoid

valves.

These solenoid valves are energized by the function of the Electro

proportional controls (Joy sticks or pedals) and direct the pilot pressure oil to

the respective spools of the main control blocks with a variable pilot pressure

proportional to the deflection of the controls.

• For the location and designation of the proportional and directional

solenoid valves of the remote control blocks refer to page 8 in this

section.

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Checks and Adjustment of Pilot PressureLegend for illustration (Z 21635):

(85) Bladder Accumulator – 10 liter, 10bar pre-charge pressure(located underneath the catwalk in front of the PTO)(108.1) Pressure relief valve for pump support pressure X4 (60bar)(108.2) Pressure relief valve for pilot pressure X2 (45bar)(M1) Pressure check point X4, pump support pressure (60bar)(M2) Pressure check point X2 pressure, pilot pressure (45bar)(Ma) Pressure check point for accumulator (If not factory installed, fit a

T-union with test connector as shown in illustration Z 21635) • Since the “X2” and the “X4” pressure are influencing each other it is

always necessary to adjust both valves 108.1+108.2 alternately.

45 bar pressure „X2“, valve 108.2:1. Connect pressure gauge to check point (M2)2. Start the engine at let it run with maximum speed.3. Read pressure, required = 45 +3 bar

If readjustment is required proceed as follow:a) Remove dust cap (1).

b) Loosen lock nut (2).c) Set pressure with set screw (3).d) Tighten lock nut (2) and re-fit dust cap (1).

60 bar pressure „X4“, valve 108.1:1. Connect pressure gauge to check point (M1a)2. Start the engine at let it run with maximum speed.3. Read pressure, required = 60 -2 bar

If readjustment is required proceed as follow:a) Remove dust cap (1).

b) Loosen lock nut (2).c) Set pressure with set screw (3).d) Tighten lock nut (2) and re-fit dust cap (1).

Checking of Accumulator Function1. Connect pressure gauge to check point (Ma).2. Start the engine at let it run with maximum speed.3. After build-up of pressure stop the drive motor, but do not turn the

key switch to zero position.4. Watch pressure gauge. Pressure should remain constant for at

least 5 minutes.

• If the pressure droops the system must be checked for leakages.• To check the accumulator charging pressure refer to SERVICE

BULLETIN 21-426 latest edition.

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5.3 Remote control valves arrangement


Remote control unit Directional Pro ortional FunctionSchematic code solenoid solenoid

Y20

Y21Y63 Boom raising

Boom lowerin(14.1) Y22

Y23Y64 Bucket filling (curl)

Bucket em t in

Y24

Y25Y65 L.H. swing

R.H. swin

(95) Y26Y27

Y66 R.H. swingL.H. swin

Y28

Y29Y67 R.H. Crawler forward

R.H. Crawler reverse(14.2) Y30

Y31Y68 Stick extending

Stick retractin

Y32


Boom raisin

Y34

Y35Y70 L.H. Crawler reverse

L.H. Crawler forward(15) Y36


Stick extendin

Y38

Y39Y72 Clam closing

Clam o enin

Y40

Y41Y73 Boom raising

Boom lowerin

Y42Y43

Y74 Stick extendingStick retractin

(14.3) Y44


Bucket emptying

X46

Y47Y76 Boom raising

Boom lowering

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5.4 Function principle of the Electro-Hydraulic- Proportional Control


(1) Pump

(2) Filter (3) Pressure relief valve

(4) Check valve

(5) Pressure Accumulator

(6) Directional Solenoid valve, a side

(7) Directional Solenoid valve, b side

(8) Proportional Solenoid valve

(9) Control valve block

(10) Battery

(11) Electronic units with amplifiers etc.(12) Control lever (Potentiometer control)

Function:

The electric-hydraulic control system is used to control the direction and

volume of oil flow to the operating cylinders and motors via the control valve

blocks.

Hydraulically:

The oil volume of pump (1) flows through filter (2) into the pilot pressure

system. The pressure is limited by the pr

Documents

SM PC4000-6 8152 SMPC40008152