Service Manual PC4000-6E PDF

PC4000-6-E_#08165_Contents and 00_Foreword_rev0.
doc
02.03.05
SERVICE
MANUAL
PC4000
MACHINE MODEL
SERIAL NUMBER
PC4000-6- Electro
08165
This service manual may contain attachments and optional equipment that are not
available in your area.
Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
PC4000-6-E_#08165_Contents and 00_Foreword_rev0.doc
02.03.05
CONTENTS
TABLE OF CONTENTS
00
01
02
Safety - Foreword
Technical DATA (Leaflet)
Assembly PROCEDURE (Brochure)
Section
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Main assembly groups

Drive
Hydraulic oil tank
Hydraulic oil cooling
Controlling
Components
Main hydraulic pumps and pump regulation
Operating hydraulic
Hydraulic track tensioning system
Hydraulic operated access ladder
Cable drum
Hints for the hydraulic circuit diagram
Hints for the electric circuit diagram
Electronic Control System - ECS
Lubrication System
APPENDIX
Each section includes a detailed table of contents.
02.03.05
02.03.05
SAFTEY
SAFTEY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The
service and repair techniques recommended by Komatsu and described in this manual
are both effective and safe. Some of these techniques require the use of tools specially
designed by Komatsu for the specific purpose.
The following Symbols are used in this Manual to designate Instructions of
particular Importance.
WARNING -
Serious personal injury or extensive property damage can

result if the warning instructions are not followed.
To prevent injury to workers, this symbol is used to mark
safety precautions in this manual. The cautions
accompanying these symbols should always be followed
carefully. If any dangerous situation arises or may possibly
arise, first consider safety, and take the necessary actions to
deal with the situation.
CAUTION -
Minor personal injury can result or a part, an assembly, or

the shovel can be damaged if the caution instructions are not
followed.
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
00-1
SAFTEY
SAFTEY NOTICE
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.
continued
00-2
SAFTEY
SAFTEY NOTICE
Cont'd:
PRECAUTIONS DURING WORK
13. Before starting work, remove the leads from the battery. ALWAYS remove the lead from
the negative (-) terminal first.
14. When raising heavy components, use a hoist or crane.
Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity.
Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly
to prevent the component from hitting any other part. Do not work with any part still
raised by the hoist or crane.
15. When removing covers which are under internal pressure or under pressure from a spring,
always leave two bolts in position on opposite sides. Slowly release the pressure, then
slowly loosen the bolts to remove.
16. When removing components, be careful not to break or damage the wiring, Damaged
wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to
the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can
even start fires.
18. As a general rule, do not use gasoline to wash parts.
19. Be sure to assemble all parts again in their original places. Replace any damaged part
with new parts.
When installing hoses and wires, be sure that they will not be damaged by contact
with other parts when the machine is being operated.
20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes
are dangerous, so be extremely careful when installing tubes for high pressure circuits.
Also check that connecting parts are correctly installed.
21. When assembling or installing parts, always use the specified tightening torques. When
installing protective parts such as guards, or parts which vibrate violently or rotate at high
speed, be particularly careful to check that they are installed correctly.
22. When aligning two holes, never insert your fingers or hand. Be careful not to get your
fingers caught in a hole.
23. When measuring hydraulic pressure, check that the measuring tool is correctly assembled
before taking any measurements.
24. Take care when removing or installing the tracks of track-type machines. When removing
the track, the track separates suddenly, so never let anyone stand at either end of the
track.
00-3
ENVIRONMENT PROTECTION
Environment NOTICE
RECOMMENDATIONS FOR ENVIRONMENTALLY FRIENDLY OPERATION

AND MAINTENANCE OF HYDRAULIC MINING SHOVELS
OPERATION
Avoid engine idling over long periods. Long periods of idling, more than 10 minutes,
will not only waste fuel, but is also harmful to the engine.
Avoid operation against the main relief valves of the hydraulic system. Move control
lever to neutral position before the loader attachment stalls due to overload.
Position trucks in such a way, that loading operation can be carried out in a safe and
economic manner. Avoid swing angles over 90.
MAINTENANCE
Preserve our environment. To prevent environmental pollution, pay careful attention

to the method of disposing waste materials.
Always drain fluids from your machine into containers. Never drain fluids onto the
ground or dump it into the sewage system, rivers, the sea or lakes.
Dispose of harmful material, such as oil, fuel, coolant, solvent, filters and batteries in
accordance with environmental regulations and laws.
FOREWORD
FOREWORD
GENERAL
With this SERVICE MANUAL KOMATSU provides you with the
description of the construction and the function of the major systems of the
Hydraulic Excavator PC8000-6-E.
We describe for you all functions and how to carry out the inspections and
adjustments.
How do you find "your" desired information?
In the table of CONTENT all the functions and components are shown in
their sequence of the description.
If after reading this SERVICE MANUAL you can give us suggestions and
comments for improvements - please do not hesitate to contact us.
Komatsu Mining Germany GmbH
- Service Training Postfach 180361
40570 Dsseldorf
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
00-4
FOREWORD
HOISTING INSTRUCTIONS
HOISTING
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.
continued
Cont'd:
00-5
FOREWORD
WIRE ROPES
3. Do not sling a heavy load with one rope alone, but sling with two or more
ropes symmetrically wound on to the load.
Slinging with one rope may cause turning of the load during hoisting,
untwisting of the rope, or slipping of the rope from its original
winding position on the load, which can result in a dangerous
accident.
4. Do not sling a heavy load with ropes forming a wide hanging angle from the
hook. When hoisting a load with two or more ropes, the force subjected to
each rope will increase with the hanging angles. The table below shows the
variation of allowable load (kg) when hoisting is made with two ropes, each of
which is allowed to sling up to 1000 kg vertically, at various hanging angles.
When two ropes sling a load vertically, up to 2000 kg of total weight can be
suspended. This weight becomes 1000 kg when two ropes make a 120
hanging angle. On the other hand, two ropes are subject to an excessive force
as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150.
00-6
FOREWORD
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE (1Kgm = 9,806Nm)

STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS
Bolt
dia.
Wrench
size [mm]
Tightening torque
[Nm]
Quality grades
8.8
10.9
12.9
M 8
13
21
31
36
M 10
17
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
3500
4950
5800
M 45
70
4350
6200
7200
M 48
75
5200
7500
8700
M 52
80
6700
9600
11200
M 56
85
8400
12000
14000
M 60
90
10400
14800
17400
M 64
95
12600
17900
20900
M 68
100
15200
21600
25500
32
35
41
46
Insert all bolts lubricated with MPG, KP2K
00-7
FOREWORD
CONVERSION TABLE
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.
00-8
FOREWORD
00-9
CONVERSION TABLE
FOREWORD
CONVERSION TABLE
00-10
FOREWORD
00-11
CONVERSION TABLE
FOREWORD
CONVERSION TABLE
00-12
FOREWORD
CONVERSION TABLE
Basic Values in Ohm according to DIN 43 76

For Measuring Resistor PT100
-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
100,00
99,61
99,22
98,83
98,44
98,04
97,65
97,26
96,87
96,48
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
00-13
FOREWORD
CONVERSION TABLE
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.
00-14
Main Assembly Groups
Section 1.0
Page 1
Table of contents section 1.0

Section
1.0
Page
Main assembly groups
General lay out
1.1
Superstructure
1.1.1
Machine house
1.1.2
Hydraulic Oil Reservoir
1.1.3
Hydraulic Oil Cooler
1.1.4
Fuel Tank
1.1.5
Counter weight
1.1.6
Cab support
1.1.7
Operators cab
10
1.1.8
Control Blocks
11
1.1.9
Swing gears
12
1.2
Under carriage
1.3
Attachment
13
1.3.1.
Backhoe Attachment (BHA)
14
1.3.2.
Front Shovel Attachment (FSA)
15
Vorlaeufig_#08165_PC4000_#08156-7_Sec_1-0 _rev0.doc
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1.0
2
02.03.05
1.0
Section 1.0
Page 2
General lay out

Legend for illustration (Z 21463):
(1)
Superstructure
(2)
Under carriage
(3)
(4)
Backhoe Attachment (BHA)
02.03.05
1.0
3
02.03.05
1.1
Section 1.0
Page 3
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 Central Lubrication System
(19)
Grease pump of the Swing gear pinion Lubrication System
02.03.05
1.0
4
02.03.05
1.1
Section 1.0
Page 4
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
02.03.05
1.0
5
02.03.05
1.1
Section 1.0
Page 5
Superstructure
1.1.2

(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
02.03.05
Section 1.0
Page 6
02.03.05
1.1
Section 1.0
Page 6
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
02.03.05
1.0
7
02.03.05
1.1
Section 1.0
Page 7
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
02.03.05
1.0
8
02.03.05
Section 1.0
Page 8
1.1
Superstructure
1.1.5
Counter weight

(1)
Counter weight
Total weight
37000 kg
(2)
Mounting bolts
Quantity
16
Bolt size
(mm)
M 42 x 520
SW = Wrench size
(3)
Lifting points
Grade
SW*
(mm)
10.9
65
Tightening
torque (Nm)
4950
02.03.05
1.0
9
02.03.05
Section 1.0
Page 9
1.1
Superstructure
1.1.6
Cab support

(1)
Cab support (Location of electrical switch board X2)
(2)
Mounting bolts
Quantity
Bolt size
Grade SW*
Tightening
(mm)
(mm) torque (Nm)
4
M 36 x 240
10.9
55
Grade
SW*
(mm)
10.9
55
3100
* SW = Wrench size
(3)
Mounting bolts
Quantity
Bolt size
(mm)
4
M 36 x 240
Tightening
torque (Nm)
3100
* SW = Wrench size
(4)
(5)
(6)
Door
Gasket
Door handle (adjustable)
02.03.05
1.0
10
02.03.05
1.1
Section 1.0
Page 10
Superstructure
1.1.7
Operators cab

(1)
(2)
(3)
(E19)
Monitor panel
Switch panel
Operators seat
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)
(E23)
(E24)
Control pedal Control pedal Control pedal -
Swing brake
Bucket closing
Bucket opening
02.03.05
1.0
11
02.03.05
1.1
Section 1.0
Page 11
Superstructure
1.1.8
Control blocks

(1)
Control block carrier
(2)
Remote control valves
(3)
Main control blocks
(4)
High pressure filter
02.03.05
1.0
12
02.03.05
1.1
Section 1.0
Page 12
Superstructure
1.1.9
Swing gears
Legend for illustration (Z 21478a):

(1)
Oil level gauge
(2)
Oil filler plug
(3)
Breather filter
(4)
Oil level gauge and filler tube.
(5)
Breather filter
(6)
Oil drain plug
(7)
Drain plug
(8)
Pinion
(60.1 + 60.2) Swing motors
(61.1 + 61.2) Swing brake valve blocks
(48.1 + 48.2) Swing gear boxes with integrated spring loaded multi disk brakes
(Released by oil pressure)
02.03.05
1.0
13
02.03.05
1.2
Section 1.0
Page 13
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)
02.03.05
1.0
14
02.03.05
1.3
Section 1.0
Page 14
Attachment
1.3.1
Backhoe attachment (BHA)

(1)
Boom
(2)
Boom Cylinders
(3)
Stick
(4)
Stick Cylinders
(5)
Bucket
(6)
Bucket Cylinders
(7)
Control arm
(8)
Linkage
02.03.05
1.0
15
02.03.05
1.0
15
1.3
Attachment
1.3.2

(1)
Boom
(2)
Boom Cylinders
(3)
Stick
(4)
Stick Cylinders
(5)
Bucket backwall
(6)
Bucket Cylinders
(7)
Bullclam
(8)
Bucket Clam cylinders
02.03.05
Drive
Section 2.0
Page 1

Section
2.0
Page
Prime drive assembly
General
2.1
Flexible coupling
2.2
Pump distributor gearbox (PTO)
2.3
Pump spline shaft lubrication
2.4
PTO Lubrication and cooling - Function
2.5
PTO Lubrication and cooling Adjustments
2.6
Hydraulic pumps location, drive speed and flow rates
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2
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2.0
Section 2.0
Page 2
Prime drive assembly

(1)
Electric Motor 1
(2)
-(3)
Cooling air intake
(4)
Cooling air exhaust
(5)
Alignment shims
(6)
Alignment supports
(7)
Motor frame
(8)
Coupling
(9)
Pump distributor gear (PTO)
General
The two electric motors are solid bolted to the motor frame (7).
The thickness of alignment shims (5) has to be selected according to the
results of the alignment procedure, refer to Parts & Service News AH01523,
last edition for more information.
The alignment procedure must also be carried out when replacing the
electric motor and/or the PTO.
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Section 2.0
Page 3
Drive
2.1
Flexible coupling
(1)
Housing (Rubber support ring)
(2)
Input drive hub (Motor side)
(3)
Output drive hub (PTO side)
(4)
Output drive flange
(5)
Rubber element (Motor side)
(6)
Bolt
Quantity Bolt size (mm)
16
(7)
(8)
(9)
M 27 x 60
Grade
10.9
SW* (mm)
41
Tightening torque (Nm)

960.0 +110.0
Motor drive shaft

Rubber element (PTO side)
Bolt
16
(10)
M 27 x 60
22
M 16 x 310
41

960.0 +110.0
Grade
10.9
SW* (mm)
24

250.0 +30.0
Washer
Nut
Bolt
1
(14)
10.9
SW* (mm)
Bolt
(11)
(12)
(13)
Grade
M 36 x 60
Grade
8.8
SW* (mm)
55

2170.0
Bolt
10
M 18 x 40
Grade
10.9
SW* (mm)
27

360.0
Design:
VULASTIC-L coupling type are provided with two flexible rubber
elements (5 + 8). The flexible ring connect the input drive hub (2) via input
drive flange (4) with the output drive hub (3) of the coupling.
Function:
The high flexible LULASTICL coupling transfers the torque without any
rotational gap. They are wear-resisting and maintenance free. Because of
symmetrical arrangement of the flexible rings, there are no returning forces
either by the torque transfer or the centrifugal forces.
VULASTIC-L couplings dampen rotating vibrations, reducing same by
partial storing of the shock energy and damp noises.
The coupling allows in an acceptable range axial, radial and angular
misalignment of the shafts.
Repair and replacement have to be carried out according to Parts &

Service News AH01523, last edition.
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4
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2.2
Section 2.0
Page 4
Pump distributor gearbox (PTO)

(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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5
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2.3
Section 2.0
Page 5
Pump spline shaft lubrication

Drive shaft housings
(1)
Oil filler plug with breather pipe of main pump drive shaft housing
(2)
Oil collector reservoir for auxiliary pump drive shaft housing
(M)
Configuration, main pump drives
(A)
Configuration, auxiliary pump drives
All drive shaft housings are filled with the same gear oil as the pump
distributor gear.
This is done for two reasons:
1. To lubricate the multi-spline connections, to prevent wear and corrosion.
2. It makes it easier to determine a sealring leak at one of the drive shaft
connections.
Function:
M
If the oil level increases the oil drops out of the breather pipe (1).
If this oil is gear oil it indicates a possible leak at the gearbox side.
If the oil is a mixture of gear oil and hydraulic oil it shows a possible
leak at the pump side.
If at an oil level check a loss of oil is found it may be due to worn or
defective radial seal rings.
Function:
A
The oil is filled in via the oil collector reservoir (2). All auxiliary drive
shaft housings are connected by pipes with the reservoir. The reservoir
is filled approx. one half with oil.
If the oil level in the reservoir increases due to leakage the oil drops out
from the breather filter (with oil level gauge) on top of the reservoir.
Now a check has to be done to find out which one of the drive shafts
seals is damaged.
It can be done by disconnecting temporary the pipe to the reservoir.
Disconnect the pipe at the drive shaft housing, plug the pipe and leave
the union open.
If now at operation the oil still comes out of the union, this drive shaft
seal is gone.
Otherwise check sequential all auxiliary drives.
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2.4
Section 2.0
Page 6
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 coolers
the oil flows to the port (P) of the gear and internally via a system of pipes to
the several spray nozzles.
The spray nozzles in the gear case ensure proper and adequate distribution of the
lube oil.
The circuit is monitored by the pressure switches (B17-1). At too low lube oil
pressure (0.5 bar), a fault message will be displayed on the monitor at the dash
board.
The gear oil temperature is monitored by the sensor unit (B49-1). At too high oil
temperature a fault message will be displayed on the monitor at the dash board.
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7
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2.5
Section 2.0
Page 7
PTO Lubrication and cooling Adjustments

Legend for illustration (Z 21610b):
(1)
(2)
(3)
(4)
(5)
(5a)
(6)
(7)
(8)
(9)
(A)
(T)
Pilot operated relief valve

Plug screw
Valve piston
Port for pressure switch B17
"Y"- port (external return to tank)
"X"- port (external return to tank via solenoid valve Y53-1)
Port for pressure check stud
Jet bore
Valve spring
Seal rings
Pressure port
Return from valve
(B27)
(29)
(M3)
(Y53-1)
Maintenance switch
Pressure relief valve, 10 bar
Pressure check point (PTO lubrication pressure)
Solenoid valve (reduced pressure if energized)
The adjustment of the maximum permissible PTO lube pressure,

has to be carried out with warm oil.
Setting the pressure relief valve (29)

1.
Connect a pressure gauge to check point (M3)
2.
Disconnect plug of solenoid valve Y53-1
3.
Start the motor
4.
Required pressure: 10,0 bar.
If adjustment is required:
5.
Remove protection cap (1a).
6.
Loosen lock nut (1b).
7.
Set the pressure with set screw (1c).
8.
Tighten lock nut (1b) and re-install protection cap (1a)
9.
Reconnect plug of Y53-1
If the pressure of 10,0 bar cannot be adj. 100 %, adj. to the lowest
visible pressure.
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8
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Section 2.0
Page 8
Drive
2.6
Hydraulic pumps location, drive speed and flow rates

(1 - 4)
Axial piston pump (swash plate type)
theoretical flow rate, each
1033 Liter/min
Drive speed*
n = 1378 min-1
for all working motions
(5.1)
(5.2)
(8.1)
(8.2)
Axial piston pump

theoretical flow rate
Drive speed*
for oil cooler fan drive
214 Liter/min
n = 2000 min-1
Axial piston pump

Drive speed*
for radiator fan drive
214 Liter/min
n = 2000 min-1
Gear pump
Drive speed*
for pilot pressure supply
138 Liter/min
n = 1378 min-1
Gear pump
Drive speed*
PTO gear lubrication
138 Liter/min
n = 1378 min-1
* at 1800 min-1 input drive speed
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Section 3.0
Page 1

Section
3.0
Page
Hydraulic oil reservoir
General lay out
3.1
Main oil tank, location of switches, sensors etc.
3.2
Suction oil tank with strainers
3.3
Return oil collector tube with strainer
3.4
Back pressure valve
3.5
Transfer pump (Optional Equipment)
3.6
Return and Leak Oil Filter
3.7
Breather Filter
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2
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3.0
Section 3.0
Page 2
General lay out

(1)
Filter cover retainer
(2)
Filter cover
(3)
Filter element
(A) - Return oil filter - 10 m
(B) - Case drain filter - 3 m
(4)
Man hole cover
(24)
Pressure switch B24 monitors item (92.1) (92.2)
(30)
Hydraulic oil level gauge
(41)
Main oil reservoir
(54)
Return oil collector tube with pressure check point M10
(55)
Back pressure valve
(67)
Dust cap for item (77)
(77)
Oil drain, quick release coupling
(87)
Shut off valve with S31 (Gate valve)
(88)
Compensator
(92.1 + 92.2)
Breather filter
The hydraulic oil tank is a welded sheet-metal construction.
The capacity is about 3700 litres. The tank contains four return oil filters (3A) 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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3.0
3
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3.1
Section 3.0
Page 3
Main oil tank, location of switches, sensors etc.

(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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4
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Section 3.0
Page 4
3.2
Suction oil tank with strainers

(1)
Suction oil reservoir
(2)
Drain coupling
(3)
Pressure transducer (B162) Pressure suction oil tank
(4)
Plug
(5)
Bolt
Quantity
8
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
16
SW*
(mm)
8.8
30
Tightening
torque (Nm)
360
Bolt size
(mm)
M 16 x 40
Grade
SW*
(mm)
8.8
24
Grade
SW*
(mm)
10.9
30
Grade
SW*
(mm)
10.9
27
Tightening
torque (Nm)
179
Lock nuts
Resilient sleeve
Bolt
Quantity
8
(16)
(17)
M 20 x 85
Grade
Nut
Gaskets
Main suction oil strainer
Intermediate pipe
Gaskets
Suction strainer one for each main pump
Suction hose connection pipe
Bolt
Quantity
(14)
(14a)
(15)
Bolt size
(mm)
Bolt size
(mm)
M 20 x 110
Tightening
torque (Nm)
510
Resilient sleeve
Bolt
Quantity
6
Bolt size
(mm)
M 18 x 90
Tightening
torque (Nm)
360
The suction oil tank (40) is a welded sheet-metal construction.

The capacity is 187 liters.
The suction lines of all hydraulic pumps are connected to the suction tank.
* SW = Wrench size
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5
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Section 3.0
Page 5
3.3
Return oil collector tube with strainer

(1)
Return oil collector tube - Part 1 (2)
Strainer
(5)
Bolt
Quantity
8
(6)
M 20 x 80
Grade
SW*
(mm)
10.9
30
Grade
SW*
(mm)
10.9
30
Tightening
torque (Nm)
510
Bolt
Quantity
8
(7)
(8)
*
Bolt size
(mm)
Bolt size
(mm)
M 20 x 70
Tightening
torque (Nm)
510
Self locking nut

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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6
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3.4
Section 3.0
Page 6
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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7
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3.5
Section 3.0
Page 7
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 the operation and maintenance manual, for further

information.
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8
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3.6
Section 3.0
Page 8
Return and Leak Oil Filter

(1)
Filter cover retainer
(2)
Filter cover with o-ring
(3)
Pre-tensioning spring
(4)
Retainer
(5)
Filter assembly
(6)
Filter pot with machined cover
(7)
Main filter element, 10 micron absolute for return oil
3 micron absolute for leak oil
(8)
Safety filter element (200 micron strainer) same for return and leak oil
(9)
By pass-valve, 2.3bar
(9.1)
Valve cone
(9.2)
Valve spring
(9.3)
O-ring
(10)
Profile gasket
(11)
Seal ring
(12)
Self locking nut
(13)
Self locking nut
Function:
The returning oil flows into the filter chamber (A) of the hydraulic tank. (The
sketch shows one section only).
The chamber is split into two sections; one section with 4 filter elements for the
return oil (10 micron) and another section with one filter element for the leak oil
(3 micron). But the structure of the five filter assemblies is basically the same.
The hydraulic oil enters the filter at the top and passes then on its way to the
entire tank the filter-element (7). "Inside to outside filtration."
The filter element condition is monitored by a pressure switch (B25, 0.5 bar for
the leak oil filter) and (B26, 2 bar for the return oil filter).
As soon as the pressure inside the filter chamber reaches the set pressure of those
switches due to the restriction of the filter-element which is caused by foreign
matters, the fault message Return oil filter restricted" or Leak oil filter
restricted is displayed at the operator's dash board The filter elements must be
replaced. For safety pre-cautions the filter is equipped with a by-pass valve. As
the filter chamber pressure increases the by-pass valve opens at 2.3 bar and
protects the element from bursting.
But the oil flows not totally unfiltered into the tank because it must flow through
the strainer (8).
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.
Refer to the maintenance manual, for further information
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3.7
Section 3.0
Page 9
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).
Refer to the maintenance manual, for further information
PC4000-6-E_#08165_Sec_3-0_rev0.doc
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Hydraulic Oil Cooling
Section 4.0
Page 1

Section
4.0
Page
Hydraulic oil cooling
4.1
General
4.2
Function of the hydraulic oil cooling circuit
4.3
Adjustment of the Back Pressure Valve
4.4
Fan drive (Two stage cooler fan RPM control)
4.5
Pressure relief valves and solenoid valve
6+7
4.6
Fixed Displacement Pump, with variable setting
4.7
Adjustment of the cooler fan drive speed
9 + 10 + 11
4.8
Function check of fan speed control
11
4.9
Switch points cooler fan speed (PLC controlled)
12
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2
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4.1
Section 4.0
Page 2
General
The hydraulic oil cooling system maintains the hydraulic oil at a normal
operating temperature.
Legend for illustration (Z 21594)
(1)
Noise shield
(2)
Cooler (Radiator)
(3)
Cooler frame
(4)
Fan
(5)
Fan motor (Axial piston motor)
(6)
Bolt
(7)
Bolt
(8)
Drive shaft
(9)
Shaft protecting Sleeve
(10)
Drive shaft seal
(11)
Ball bearings
(12)
Seeger clip ring
(13)
Bearing group carrier
(14)
Oil level plug
(15)
Breather filter
(16)
Bolt
Design:
There are four hydraulic oil coolers in front of the hydraulic tank on the R.H.
side of the platform.
They are in pairs mounted in one frame, one above the other. The air stream
needed for the cooling is produced by hydraulic driven fans. The air flows
from inside to outside through the coolers.
For a better cleaning, the coolers can be moved to the side. ("Swing out
cooler")
The bearing group carrier is filled with oil to lubricate the bearings.
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3
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4.2
Section 4.0
Page 3
Function of the hydraulic oil cooling circuit

Legend for illustration (Z 21595a)
(32.1 - 32.4)
Restrictor, shock absorbers for the hydraulic oil cooler
(39.1 + 39.2)
Hydraulic oil cooler
(41)
Main oil reservoir
(54)
(55)
Back pressure valve
(L6 + L7)
Return line from control blocks
(L13 + L14)
Supply line for the anticavitation circuit of the swing
motors
(M10)
(Y101)
Solenoid valve 4/2-directional control valve
(H)
Lines to cooler (hot oil)
(C)
Lines to tank (cold oil)
Function:
The returning oil from the system flows via the lines (L6 - L7) into the
collector tube (54). On the top of it is the Back Pressure Valve (55) installed.
The back pressure valve (55) causes a back pressure which forces most of the
relative hot oil through the lines (H) to the cooler (39.1 + 39.2).
On its flow through the cooler the hydraulic oil gets cooled and flows than
through the restrictors (32.1 - 32.4) and the lines (C) into the filter chamber of
the main oil reservoir (41).
The restrictors are acting like shock absorbers to prevent cooler cracking at
pressure peaks.
Besides the back pressure valve acts as an oil flow control valve as far as the
oil temperature has not reached its steady temperature.
During the warm up period (1/2 Qmax) the back pressure valve (55) is wide
open, because solenoid valve Y101 is energized, which results in less oil flow
through the cooler which causes that the oil gets its optimum operating
temperature quicker.
With increasing oil temperature the oil gets thinner, so that the main pumps
can be shifted to Qmax position and simultaneously solenoid valve Y101 will
be de-energized, so that the valve piston will be more closed by the force of
the spring thus that more oil passes the cooler.
(See sectional drawing on next page.)
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4
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4.3
Section 4.0
Page 4
Adjustment of the Back Pressure Valve

Checks and settings only at normal operating temperature of the hydraulic oil,
main pumps in maximum flow position and "Idle Time" control eliminated
(service switch S155 in position 1)!
1.
Connect a pressure gauge to check point (M10).
2.
Disconnect plug connector (13) of solenoid valve Y101.
3.
Actuate service switch S155 to position 1.
4.
Start the motor.
5.
Required pressure: 10 0,5 bar
a) Take off protective cap (12).
b) Loosen lock nut (5).
c) Alter the pressure with the set screw (6).
d) Tighten lock nut (5) and refit protective cap (12).
6.
Disconnect the pressure gauge, reconnect solenoid valve Y101 and
switch back service switch S155 to position 0.
(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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5
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4.4
Section 4.0
Page 5
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
(M6) Pressure check point
Function:
From pump (5.1) flows the oil through the filter (34.1) to the fan motors (37.1 + 37.2)
and then back to the tank.
The check valve (38) act as an anti cavitation valve and is installed, because the fan
motor -driven by inertial force- is running for a short period after the oil flow is
inerrupted by solenoid valve (Y6a/b), or if the motor has been switched off.
The hydraulic circuit "Fan drive" is secured by the pilot controlled pressure relief
valves (31.1) and (124).
These valves are working together with the solenoid valve (Y6a/b), controlled by the
ECS system, depending on the hydraulic oil temperature:
With de-energized solenoids Y6a and Y6b the relief valve (31.1) is
functioning and the fans are running with max. adjusted speed (1250 RPM)
With solenoid Y6a energized the relief valve (31.1) is not functioning and the
fans are running with a very low speed caused by the flow resistance only.
With solenoid Y6b energized the relief valve (124) is controlling the relief
valve (31.1) and the fans are running with 1000 RPM only.
(See also description on next page)
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4.5
Section 4.0
Page 6
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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7
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Section 4.0
Page 7
Contd.
4.5
Pressure relief valves and solenoid valve, illustration (Z 21599b)

Function:
With de-energized solenoids (Y6a and Y6b), the spool (3) keeps the "X"
connection of valve (31.1) and port B to port P closed. The pressure relief
valve (31.1) operates normal.
The energized solenoid Y6b, operate the spool (3) and a connection is made
between port P and port B and port "X" of valve (31.1)
The system pressure now opens the main piston (7) of valve (31.1), because via
solenoid Y6b (P to B) the oil from the rear side of piston (7) flows from the
"X"-port to the P connection of valve (124). The normal valve function is
now remote controlled by the pressure adjusted at valve (124).
The energized solenoid Y6a, operate the spool (3) and a connection is made
between port P and port A and port "X" of relief valve (31.1).
The system pressure now opens the main piston (7) of valve (31.1) because via
the "X"-port the oil from the rear side of piston (7) flows to tank. The normal
relief valve function is eliminated.
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4.6
Section 4.0
Page 8
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.
When increasing to maximum swivel angle, there is a danger of

cavitation and over-speeding the hydraulic motor!
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9
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4.7
Section 4.0
Page 9

Basic Adjustment Maximum Speed
(a + d) Dust cap
(b + e) Lock nut
(c + f) Set screw
(5.1)
Axial piston pump (fixed displacement pump, with variable setting)
(6)
Qmin stop bolt
(6.1)
Lock nut
(7)
Qmax stop bolt
(7.1)
Lock nut
(10)
Positioning pin (mover)
(31.1) Pressure relief valve Hydraulic oil cooler fan drive
(34.1) Pressure filter with pressure differential switch B28
(124) Pressure relief valve (medium fan speed)
(Y6a/b) Solenoid valve
(L1)
Measurement of Qmin stop bolt
(L2)
Measurement of Qmax stop bolt
(M6) Pressure check point
)
1.
2.
3.
4.
5.
Basic adjustment has to be carried out whenever one of the following

components has been replaced:
- pump
- relief valve
- hydraulic motor
Reduce the output flow of pump (5.1), by adjusting the minimum possible
swivel angle, to avoid over speeding the fan:
To do this, loosen both lock nuts (6.1 + 7.1) and turn out bolt (6)
and turn in bolt (7) the same length.
This is necessary to avoid a loose positioning pin (10), resulting in
oscillating of the cylinder barrel.
Tighten the lock nuts.
Remove protection cap (a) from relief valve (31.1), loosen lock nut (b) and
turn set screw (c) fully clockwise and then a half turn counter clockwise.
Isolate the function of solenoid valve (Y6a/b), by disconnecting both plug
connectors, to ensure that the full flow of pump 5.1 will be delivered to the
fan motor.
Connect a pressure gauge to check point (M6).
Start the motor.
Continued
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10
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4.7
Section 4.0
Page 10
Cont'd
Basic Adjustment Maximum Speed, illustration (Z 21932b)
6. Check the fan speed with a non-contact rev counter
Required fan speed: 1250 min-1
Be careful not to get caught in the fan or other rotating parts

7. Increase the output flow of pump (5.1), 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 230bar.
Note down the lengths L1 and L2 as reference measurements.
8. Loosen lock nut (b) of the relief valve (31.1), and decrease the pressure
with set screw (c) until the correct fan speed is obtained.
9. Tighten lock nut (b) and fix protection cap (a).
Both fans have to be checked. A difference of approx. 50 rpm is

normal due to the higher resistance for the air stream for the lower
fan. If the speed difference between both fans is higher than 50 rpm, a
possible cause could be a worn hydraulic motor or defective bearings.
continued
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11
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4.7
Section 4.0
Page 11
Cont'd
Basic Adjustment Medium Speed, illustration (Z 21932c)
10. Activate the function of pressure relief valve (124), by connecting the plug
connector of solenoid valve Y6b.
11. In order to ensure a proper function of solenoid valve Y6b during the
adjustment, energize the valve by using the manual control Digital Outputs
of the ECS-System ( refer to section 3.4 of the operation manual), or
activate Y6b, by connecting the solenoid plug to permanent 24 V. Use the
24V socket at the PTO *)
12. Loosen lock nut (e) of the relief valve (124), and turn set screw (f) fully
counter clockwise and then clockwise until the correct fan speed is obtained.
Required fan speed: 1000 min-1
13. Tighten lock nut (e) and fix protection cap (d).
14. Note down the pressure as reference value (expected ~ 150 bar)
15. Disconnect the pressure gauge from check point (M6).
16. Connect the plug connector of solenoid valve Y6a.
*) Prepare a test wire with a plug ET-No. 891 039 40, and a plug ET-No. 440
305 99. Connect terminal 1 to positive (+) (center off plug 440 305 99) and
terminal 2 to ground (-).
4.8
Function check of fan speed control

Switch manually the output signals to Y6a/b and check the fan speed:
Y6a
Y6b
0
0
Y6a
Y6b
0
1
Y6a
Y6b
1
0
nmaximum 1250 min-1
nmedium 1000 min-1
nminimum 0 - 50 min-1
For operating instructions of the ECS system refer to section 3.4 of the
operation manual
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4.9
Section 4.0
Page 12
Switch points of cooler fan speed (PLC controlled)

Switch points with hysteresis:
30C
39C
48C
56C
65C
VG22:
VG32:
VG46:
VG68:
VG100:
46C
57C
67C
73C
73C
Switch point: Speed decrease
Fan speed
Maximum
Medium
Minimum
Temperature
Switch point: Speed increase
PC4000-6-E_#08165_Sec_4-0_rev0.doc
67C
58C
50C
41C
32C
VG100:
VG68:
VG46:
VG32:
VG22:
75C
75C
69C
59C
48C
02.03.05
Section 5.0
Page 1
Controlling

Section
5.0
Page
Controlling
General lay out
5.1
Control and filter panel location of components

(valves, switches, sensors etc.)
3+4
5.2
Pilot Pressure Supply and Adjustments
5 +6 + 7
5.3
Remote control valves arrangement
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 + 22 + 23 + 24
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5.0
2
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Controlling
5.0
Section 5.0
Page 2
General lay out

(E19) 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
(M1.1) Pressure check point
X4, Pump bearing lubrication, pump support pressure (60bar)
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
(85)
Bladder Accumulator 10 liter, 10bar (located underneath the
catwalk in front of the PTO)
(252.1) Pressure reducing valve for pilot pressure X2 (45bar)
(252.2) Pressure relief valve for pump support pressure X4 (60bar)
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 motor was shut down or to
pressure relieve the system for repair works.
When the operator is using his controls an electrical signal causes energizing
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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3
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Controlling
5.1
Section 5.0
Page 3

Legend for illustration (Z 21632d):
Solenoid valves
(Y5)
(Y6a)
(Y6b)
(Y16)
(Y17)
(Y17a)
(Y53-1)
(Y61-1)
(Y120)
(Y123a)
(Y123b)
(Y125)
(Y126)
(Y127)
(Y130)
(Y131)
Swing parking brake operating pressure

Cooler fan RPM control minimum speed
Cooler fan RPM control medium speed
Travel parking brake operating pressure
Idle time control, (Pump control system)
Q-max (reduced oil flow at too cold oil)
Reduction pre-load pressure PTO gear lubrication - oil cooler
X1 pressure, pumps 1 - 4
Hydraulic swing brake, operating pressure
Ladder raise
Ladder lower
Ladder fast movement
Flow reduction (Pump 1)
Proportional swing brake pressure
Fixed pump No1 (max. flow, X1= 45 bar)
Fixed pump No3 (max. flow, X1= 45 bar)
Filter:
(33)
(34.1)
(36)
Pilot pressure and pump regulation

Hydraulic oil cooler fan drive
Miscellaneous:
(29)
(31.1)
(47)
(124)
(252.1)
(252.2)
(253.1)
(253.2)
(255.4)
(257.1)
(258.3)
Pressure relief valve PTO gear lubrication

Pressure relief valve - Hydraulic oil cooler fan drive, with solenoid valve Y6a /
Y6b for fan RPM control
Pressure reducing valve Track tensioning system (35 bar)
Pressure relief valve Medium speed cooler fan
Pressure reducing valve for pilot pressure X2 (45bar)
Pressure relief valve for pump support pressure X4 (60 bar)
Change over valve Electronic pump regulation or hydraulic constant regulation
Pressure reducing valve hydraulic constant regulation
Pressure reducing valve Qmax
Pressure relief valve Safety valve for Travel brake / Track tensioning system
(55 bar)
Pressure relief valve Hydraulic access ladder (70 bar)
continued
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5.0
4
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Controlling
Section 5.0
Page 4
Cont'd:
5.1

Pressure switches:
(B16)
(B17)
(B22)
(B27)
(B28)
(B48)
(B85-1)
(B86)
Swing parking brake operating pressure

PTO gear lubrication pressure (lowest permissible pressure)
Pilot pressure - Filter element monitoring
PTO gear lubrication - Filter element monitoring
Hydraulic oil cooler fan drive - Filter element monitoring
Travel parking brake operating pressure
Pressure transducer X1 pressure
Pressure transducer X2 pressure
Pressure check points:

(M1.1)
(M1.2)
(M2)
(M3)
(M3-1)
(M4)
(M5-1)
(M6)
(M9)
(M10)
(M30-1)
(M33)
(M34)
(M36)
(M37.1)
(M37.2)
(M39)
(M41)
(M42)
PC4000-6-E_#08165_Sec_5-0_rev0_.doc
X4, Pump support pressure, Pump bearing lubrication (60bar)

Bladder Accumulator, pilot pressure (45bar)
PTO gear lubrication pressure
X1 pressure, hydraulic constant regulation only
Travel parking brake operating pressure (35 bar)
X1 pressure general (electronic or hydraulic constant regulation general)
Hydraulic oil cooler fan drive operating pressure
Travel parking brake safety pressure (55 bar)
Swing parking brake operating pressure (45 bar)
X4, (60bar) of pump 9.1 only (Motor1)
Reduced X3 pressure to pump No 1 Qmax (~ 15 bar)
Option operating pressure: fast motion for travel not used
X3 pressure pumps No 3 to No 4
Hydraulic cylinder access ladder piston side
Hydraulic cylinder access ladder rod side
Proportional pressure to hydraulic swing brake
X1 pressure - Fixed pump No 3 (max. flow, X1= 45 bar)
02.03.05
5.0
5
PC4000-6-E_#08165_Sec_5-0_rev0_.doc
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Controlling
5.2
Section 5.0
Page 5

Pilot Pressure Circuit
The pilot pressure oil is used for the following functions.
To move the control block spools, to supply the main pump regulation
system, to lubricate the main pump bearings, to release the travel- and swing
gear house brakes (spring loaded multi disk brakes), to drive the grease
pumps and to supply the hydraulic track tensioning system.
(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
(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)
(41)
Main oil reservoir
(85)
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 (252.2) to limit the pump support pressure X4 (60bar).
The pressure reducing valve (252.1) 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.
continued
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6
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Controlling
5.2
Section 5.0
Page 6
Cont'd:
Pilot Pressure Circuit
(41)
Main oil reservoir
(85)
(PX2)
Pilot pressure line
(LX2)
Leak / return oil line from the remote control blocks
Function:
The pilot pressure oil flows via line (PX2) 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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7
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02.03.05
Controlling
5.2
Section 5.0
Page 7

Checks and Adjustment of Pilot Pressure
Legend for illustration (Z 21635d):
(85)
Bladder Accumulator 10 liter, 10bar pre-charge pressure
(M1.1) Pressure check point X4, pump support pressure (60bar)
(M1.2) Pressure check point X2 pressure, pilot pressure (45bar)
(M2) Pressure check point for accumulator
Since the X2 and the X4 pressure are influencing each other it is

always necessary to adjust both valves 252.1 + 252.2 alternately.
60 bar pressure X4, valve 252.2:
1.
Connect pressure gauge to check point (M1.1)
2.
Start the motor.
3.
Read pressure, required = 60-2 bar
If readjustment is required proceed as follow:
a) Loosen lock nut (1).
b) Set pressure with set screw (2).
c) Tighten lock nut (1).
45 bar pressure X2, valve 252.1:
1.
Connect pressure gauge to check point (M1.2)
2.
Start the motor.
3.
Read pressure, required = 45+3 bar
Checking of Accumulator Function
1.
Connect pressure gauge to check point (M2).
2.
Start the motor.
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 PARTS &
SERVICE NEWS AH01531a latest edition.
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8
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02.03.05
Section 5.0
Page 8
Controlling
5.3
Remote control valves arrangement

Remote control unit
Schematic code
(14.1)
(95)
(14.2)
(15)
(14.3)
PC4000-6-E_#08165_Sec_5-0_rev0_.doc
Directional
solenoid
Proportional
solenoid
Y20
Y21
Y22
Y23
Y63
Y24
Y25
Y65
L.H. swing
R.H. swing
Y26
Y27
Y66
R.H. swing
L.H. swing
Y28
Y29
Y30
Y31
Y67
R.H. Crawler forward

R.H. Crawler reverse
Stick extending
Stick retracting
Y32
Y33
Y69
Boom lowering Bucket filling

Boom raising
Boom raising
Y34
Y35
Y36
Y37
Y70
L.H. Crawler reverse

L.H. Crawler forward
Bucket filling
Bucket filling
Bucket dump
Stick extending
Y38
Y39
Y72
Y40
Y41
Y73
Boom raising
Boom lowering
Y42
Y43
Y44
Y45
Y74
Stick extending
Stick retracting
Bucket filling (curl)
Bucket emptying
X46
Y47
Y76
Y64
Y68
Y71
Y75
Function
BHA
FSA
Boom raising
Boom lowering
Bucket filling (curl)
Bucket emptying
Stick extending Clam closing

Stick retracting Clam opening
Boom raising
Boom lowering
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5.4
Section 5.0
Page 9
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 pressure relief valve (3).
With the pressurized oil stored in accumulator (5), a limited number of spool
movements can be carried out with the main drive motor at standstill.
When a lever (or pedal) is actuated, proportional solenoid valve (8) and one
of the directional solenoid valves (either 6 or 7) are energized, and allows the
pilot pressure oil to flow to the spools of the control blocks.
Electrical
Whenever a lever or a pedal is moved out of its neutral position, an amplifier
will created a current between 0 and 1000 mA. (For detailed information refer
to page 10 in this section)
Depending on the lever direction, simultaneously one of the directional
solenoid valves (either 6 or 7) is energized.
The proportional solenoid valve alters the pilot pressure, proportional to the
lever deflection, this results a spool movement between neutral and full
stroke position.
continued
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Section 5.0
Page 10
Function principle of the Electro-Hydraulic- Proportional Control
Cont'd:
(Exemplary illustration of the function of two axis with one Amplifier only)
Legend for illustration (Z 21638c)
(1)
Control lever (joystick)
(2)
Capacitor-Module
(3)
Ramp time module
(4)
Proportional-Amplifier-Module
(5)
Relay (Supply Voltage)
(6)
Proportional solenoid valve-(Pressure-Reducing Valve)
(7)
Directional solenoid valve
(8)
Control block spool
General Function
Control lever (1) is supplied with 24 VDC battery voltage for the switch contacts
and with 24 VDC capacitor supported to create the signal voltage.
When moving lever (1) out of its neutral position, 24 VDC battery voltage arrives
at relay (5) and energizes the Proportional Amplifier (4) with capacitor
supported 24 VDC via terminal 1.
Depending on the function of the control lever, 1 to 4 Amplifiers can be involved
for the Y-axis (forward/ backwards direction) and 1 to 4 Amplifiers for the Xaxis (left/right direction.)
The polarity of the Output Signal from joystick (1), either positive or negative,
between 0 and 10 VDC indicates the direction of the lever movement and is
proportional to the lever deflection. This is the Input Signal to the ramp time
module (3) at terminal 5 which will arrive after the adjusted ramp time delay via
terminal 7 to the proportional amplifier (4) at terminal 5.
This Input Signal (between 0 and 10 VDC) is amplified to an Output Signal
between 0 to 1000 mA and is simultaneously send via terminal 7 (negative) or
terminal 8 (positive) to the Proportional Solenoid valve (6) and to the
Directional solenoid valve (7) via terminal 3 (negative) or terminal 9 (positive)
to the a or b-side.
The proportional Solenoid valve (6) alters the pilot pressure (X2) of 45 bar to a
value proportional to the Current Signal.
This pressure controls the movement of the control block spool (8) between
neutral and full stroke position.
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Section 5.0
Page 11
Potentiometer Control (Lever, Joy Stick)

Legend for illustration (Z 21639b)
(1)
Push button *
(2)
Toggle switch *
(3)
Inductive linear transmitter
(4)
Universal joint
(5)
Electronics
(6)
Push pin
(7)
Shaft seal
(8)
Reset spring
(9)
Coil core
(10)
Coil
* Alternative application
The non-contacting lever control (inductive linear transmitter) contains both
the electronic and mechanical components which converts the lever
movement into a proportional electrical voltage. The lever can be operate in
two axes:
Axis "Y", splitted into the half axis Y- and Y + (backward and forward)
Axis "X", splitted into the half axis X- and X + (left and right)
Of course the lever can be moved in any other direction (Joy stick function)
In order to be able to monitor the direction of the lever movement and the
neutral position, the electronics (8) sends a 24V signal as soon as the lever
gets moved out of its neutral position.
For one axis are used two inductive linear transmitter (3). The motion of the
coil core (9) connected to the push pin (6) causes a variation of the induction
in the coils (10). The electronics convert this inductive signal into a
proportional output signal of 10...0...+10 V for the amplifiers.
The electronic part of the lever is equipped with a internal fault detector. In
case of a internal electronic fault the electronic send a 24V signal to the test
output. The test input is used for a lever system check before motor start. The
inductive system is designed as a redundant system with two separate coils.
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5.6
Section 5.0
Page 12
Potentiometer Control (Pedal)

(1)
Potentiometer Control Unit
(2)
Pedal
(3)
Standard cable
(4)
Connection cable for combined operation
(5)
Push pin
(5.1)
Coil
(6)
Switch actuator
(7)
Direction monitoring
(7.1)
Directional contacts
(8)
Neutral position monitoring
(8.1)
Neutral position contacts
(9)
Electronic
Application for:
(A)
Swing foot brake
(B)
Clam Opening/closing
(C)
Travelling
The Potentiometer Control (inductive, linear travel transmitter) contains both
the electronic and mechanical components which converts the pedal movement
into a proportional electrical voltage.
In order to be able to electrically monitor the pedal (2) action a neutral position
switch is fitted.
This switch closes when the pedal is moved out of the rest position.
When using the double unit (B) (combined operation) only the signal output from
one unit is used for the Clam Operation.
Due to the cross lined connection via the connection cable (4) the signal is once
positive and once negative (inverted), depending on the Pedal used.
In order to be able to monitor the direction of the pedal movement and the neutral
position of travel unit (C), two switches (5 and 6) are fitted; which are actuated by
the actuator (4) as soon as the lever gets moved out of its neutral position.
For the Output Signal generation are used two coils (3.1), in series connected. The
push pin motion causes a variation of the induction and this in turn causes a signal
variation at the AC voltage bridge. The AC voltage gets rectified and becomes the
DC-Signal Voltage for the amplifiers.
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Section 5.0
Page 13
Proportional Amplifier Module, Type A

Type A (for swing brake only)
(LED) LED for Solenoid A or B
(P)
Set Potentiometer
R1 for the lowest current value
R2 for the highest current value
The amplifier module contains the necessary electronics for the control of
two proportional solenoids. Depending on the input polarity, either solenoid
A or solenoid B is operated.
The solenoid current (solenoid A - solenoid B) is measured and compared
with the external input value. Differences between feed-back and input
values, for example caused by changes in solenoid temperature or supply
voltage, are compensated.
The module also generates a direction-dependent voltage signal (solenoid A solenoid B) as soon as the solenoid current reaches the lowest set value.
The lowest and highest values are set externally via the potentiometer R1 + R2.
The brightness of the LED's changes with the current.
This function should not be used for setting.
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Section 5.0
Page 14
Proportional Amplifier Module, Type B

Type B (for Boom, Stick, Bucket, Clam, Swing and Travel)
(LED)
(P) Set Potentiometer:
AX: Proportional output AX active
- 10% for the lowest current value
AS: Switched output AS active
- J2 for the highest current value
BX: Proportional output BX active (Pt) Set Potentiometer for the Ramp
BS: Switched output BS active
Time
Power: Internal supply voltage
Fault: Fault indication
The amplifier module contains the necessary electronics for the control of
two proportional solenoids and two directional solenoids. The amplifier
outputs for proportional solenoids Ax and Bx and the switched outputs As
and Bs are activated by connecting a minimum of approx. 10% signal voltage
at the amplifier input.
A positive signal voltage controls outputs A, a negative signal voltage
controls output B.
A signal voltage of approx. 10% with respect to +/- 10 V input voltage at the
amplifier, produces a stepped output voltage. The height of this 10% jump
may be set separately for proportional outputs Ax and Bx via external
potentiometer. As the signal voltage rises the solenoid current for the
proportional outputs increases linearly.
A further step in output current occurs at approx. 90% signal voltage.
The maximum current or the 90% jump may be set separately for outputs Ax
and Bx via external potentiometers and hence the gradient of the output curve
may be influenced.
LED`s indicate the current output to each proportional and switched output,
whereby the brightness is approx. proportional to the solenoid current in Ax
and Bx. This function should not be used for setting.
A Ramp Time function is included in the amplifier which may be externally
changed by a set potentiometer. The setting range for the ramp time is
approx. from 80ms to 1s. The time setting applies to both up and down ramps
and to both proportional solenoids.
A fault is indicated by the LED Fault.
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Section 5.0
Page 15
Ramp Time Module

(Analogue command value module for Boom, Stick, Travel and Swing function)
Potentiometer:
"t1" to "t5"
Ramp times
"w1" to "w4" Command value call-ups
"G"
Zero point matching
"Z"
Amplitude attenuation for the differential input
LED displays:
(1)
green Operational power
(2)
"4-Q" Quadrant recognition
(3)
"INV" Inversion active
(4)
yellow display for potentiometer t1 to t4
(5)
yellow display for potentiometer w1 to w4
(6)
Measurement sockets: "t"

"w"
""
Actual ramp time

Internal adjustment variable
Reference potential / GND
General
The Ramp Time Module is snapped onto mounting rails inside the X2-box.
The electrical connection is done via screw terminals.
The module is operated with 24 VDC. A power supply provides the internally
required positive and negative supply voltages.
As soon as the power supply is in operation the green LED (power) lights up.
Internal command values
The internal command value signal is generated from the external command
value signal which is being applied to the differential input, a called-up signal
and an offset signal (zero point potentiometer "Z").
The external command value signal can, via potentiometer "G", changed from
0% to approx. 110%.
Command value call-ups
The call-up signals w1 to w4 also have an adjustment range of 0% to 110%.
No settings required. (factory set to 100%).
Ramp time call up
If the quadrant recognition is not activated, then each command value call-up
"w1" to "w4" is allocated its own ramp time "t1" to "t4".
As long as there is a signal change, the LED allocated to the actual ramp time
is alight.
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Controlling
5.10 Adjustments of Amplifier Modules (General)

(1)
Potentiometer control
(2)
Terminal with a separating possibility
(3)
Ramp time module
(4)
Amplifier
(5)
Solenoid valve
(6)
Service module
Introduction:
The illustration shows simplified the route of the signal voltage from
Potentiometer Control (1) to Solenoid-Valve (5):
A.
With ramp time module,
i.e. Boom,- Stick,- Bucket (BHA),- Travel,- and Swing Function.
B.
Without ramp time module,
i.e. Bucket (FSA),- Clam,- and Swing Brake Function.
The ramp time modules (3) and the amplifiers (4) are adjustable.
Adjustments are required:
Ramp time modules
When commissioning the machine
When replacing a module
Amplifiers
When replacing a solenoid valve
When replacing an amplifier
For Checking and Setting the Signal Current at the Proportional-Amplifier (4),
both separating terminal (2) before and behind the Amplifier (4) must be opened.
For the setting procedure the signal voltage from the potentiometer control (1) can
be simulated with the potentiometer of Service-Module (6),which is installed on
the X2-panel.
Accessories required for the adjustments:
a) A multimeter, good readable for
values between 0 and 1000 mA.
b) More convenient is a second meter
for reading voltage simultaneously.
c) A simple wire, 1m length, or better
a prepared test lead same length
d) Four test leads, 1m length, with
banana type connectors on each
end.
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"a"
"b"
mA
VDC
"c" "d"
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5.11 Adjusting the Amplifiers Type B, illustration (Z 21642)

Procedure applicable for all amplifiers except the one for the swing
brake:
(Do not start the motor, turn only the key switch in ON position.)
1.
Open* the respective separating terminal (T1) between the lever unit and
the amplifier module to be set.
2.
Open* the respective separating terminal (T2) between the amplifier module
to be set and the proportional solenoid valve.
3.
Disconnect the wire from terminal five.
4.
Connect the positive output of the service module with terminal five of the
amplifier module, using test lead (2).
5.
Attach a multimeter for voltage reading to the service module, using test
lead (3).
6.
Attach a multimeter (in series) for Amp reading to the terminal between
amplifier module and solenoid valve, using test leads (3).
7.
Move the lever of the Potentiometer Control into its final position; or
override manual the relay which allows 24 V operating voltage to the
amplifier module; thus the amplifier gets 24 V operating voltage. The
power LED and simultaneously LED A(+) or B(-) lights up, depending on
the polarity.
8.
Turn the potentiometer (P) of the Service-Module until the multimeter
shows 1 VDC (it may be either positive or negative); the multimeter for the
current reading will show a value which should correspond to the value
giving in the circuit diagram e.g. 330 mA. (The first step (10 %) value)
If necessary correct the value with potentiometer (R1).
9.
Turn the potentiometer (P) of the Service-Module further until the
multimeter shows 9 VDC; the multimeter for the current reading will show
a value which should correspond to the value giving in the circuit diagram
e.g. 660 mA. (The second step (90 %) value).
10. Repeat settings of item 8 and 9 until both mA values are stabilized, because
R1 and R2 influence each other.
* How to open and close the terminal:

Push the yellow stud (1) down with a screw driver and turn it 90 to the left to
open or to the right to close the terminal. A spring pushes then the stud
outwards and the contacts are either open or closed.
continued
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Section 5.0
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Cont'd:
11.
12.
13.
If the setting with either positive or negative potential was successful, turn
the potentiometer (P) of the service module into the opposite direction and
check the settings with the other polarity i.e. if the first setting was done
with positive potential then turn the pot into negative direction; otherwise
vice versa.
Repeat the setting as described under item 7 to 10.
Remove multimeter, test wire, close* the terminals and reconnect the wire
to terminal 5 of the amplifier module.
Adjusting the Ramp Time

1.
2.
Turn potentiometer (Rt) 30 revolutions counter clockwise, to guarantee the

correct start position at the complete left side.
Turn potentiometer (Rt) so many revolutions clockwise as shown in the
table below (part of the electrical circuit diagram).

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The amplifiers for the crawler foot pedals are adjustable in the same way as
the amplifiers for the joy sticks.(refer to page 17 and 18 in this section)
The amplifier for the swing foot brake is similar.
Procedure for the swing foot brake:
1.
Open* the respective separating terminal (T1) between the pedal unit and
the amplifier module to be set.
2.
Open* the respective separating terminal (T2) between the amplifier module
to be set and the proportional solenoid valve.
3.
Disconnect the wire from terminal five.
4.
Connect the positive output of the service module with terminal five of the
amplifier module, using test lead (2).
5.
Attach a multimeter for voltage reading to the service module, using test
lead (3).
6.
Attach a multimeter (in series) for Amp reading to the terminal between
amplifier module and solenoid valve, using test lead (3).
7.
Press the pedal fully down ; or manual override the relay which allows 24 V
operating voltage to the amplifier module; thus the amplifier gets 24 V
operating voltage.
8.
Turn the potentiometer (P) of the Service-Module until the multimeter
shows 1 VDC ; the multimeter for the current reading will show a value
which should correspond to the value giving in the circuit diagram e.g. 10
mA. (10 % value)

continued
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Section 5.0
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Cont'd:
9.
)
10.
11.
Turn the potentiometer (P) of the Service-Module further until the

multimeter shows 10 VDC; the multimeter for the current reading will show
a value which should correspond to the value giving in the circuit diagram
e.g. 500 mA. (100 % value).
It is important that the pilot pressure for the pressure increasing valve
is 24+/- 1 bar.
For more information refer to section 8.2 Swing Circuit
Repeat settings of item 8 and 9 until both mA values are stabilized, because
R1 and R2 influence each other.
Remove multimeter, test wire, close* the terminals and reconnect the wire
to terminal 5 of the amplifier module.

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5.13 Adjusting the Ramp Time Module

(2) Capacitor-Module
(3) Ramp time module
(6) Service module
(P) Potentiometer
The following adjustments have to be done when commissioning the

machine and whenever the Ramp Time Module has been replaced.
Do not start the motor, turn only the key switch in ON position.
Basic Adjustment:
1.
Connect 0VDC with a test lead from the red positive terminal of the service module
2.
(6) to terminal 5 of the Ramp Time Module (3) and adjust with "Pot Z" a value of 0
VDC measured at terminal 7. Disconnect the test lead after the setting is done.
Connect +10VDC with a test lead from the red positive terminal of the service
module (6) to terminal 5 of the Ramp Time Module (3) and adjust with "Pot G" a
value of 10 VDC measured at terminal 7. Check the negative voltage as well(- 10
VDC). Disconnect the test lead after the setting is done.
Repeat settings of item 1 and 2 until both values are stabilized, because
"Pot Z" and "Pot G" influence each other.
The factory setting of potentiometer "w1" to "w4" for the command
value call-ups must not be adjusted.
continued
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5.13 Adjusting the Ramp Time Module

Cont'd:
(1) Control lever (joystick)
(2) Capacitor-Module
(3) Ramp time module
(4) Proportional-Amplifier-Module
(5) Relay (Supply Voltage)
Ramp time adjustment in relation to the operating movements:
3.
Disconnect the cables at terminal 3 and terminal 5 of the respective module.

Connect 24Volt with a test lead to terminal 9, 10, 11 and 12 one after another and
adjust with the respective "Pot t1, t2, t3 and t4" the values giving in the table on the
next page. (Measure the voltage only at the Measurement socket "t" of the ramp
time module)
4.
To check the adjustments under operating conditions reconnect terminal 3 and

terminal 5 and measure the ramp time with a stopwatch.
5.
If the above mentioned values are not suitable for the local working conditions, for
example due to, different Attachments or different operation feeling of the operator,
the ramp time can be changed according to the NOTE on illustration
Z 21645, to ensure smooth and efficient working cycles.
continued
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Section 5.0
Page 23
5.13 Adjusting the Ramp Time Module, illustration (Z 21645)

Cont'd:
E48 Stick
24 Volt at
Terminal 9
Terminal 10
Terminal 11
Terminal 12
Joy stick Signal

Neutral Stick out
0V to +10V
Stick out Neutral
+10V to 0V
Neutral Stick in
0V to -10V
Stick in Neutral
-10V to 0V
Pot
t1
t2
t3
t4
Value to be measured at socket "t"

0,10 Volt = 1000 ms
0,10 Volt = 1000 ms
0,10 Volt = 1000 ms
0,10 Volt = 1000 ms
Joy stick Signal

Neutral Lower
0V to +10V
Lower Neutral
+10V to 0V
Neutral Lift
0V to -10V
Lift Neutral
-10V to 0V
Pot
t1
t2
t3
t4

0,2 Volt = 500 ms
0,05 Volt = 2000 ms
0,10 Volt = 1000 ms
0,10 Volt = 1000 ms
Joy stick Signal

Neutral Lower
0V to +10V
Lower Neutral
+10V to 0V
Neutral Lift
0V to -10V
Lift Neutral
-10V to 0V
Pot
t1
t2
t3
t4

0,067 Volt = 1493 ms
0,10 Volt = 1000 ms
0,10 Volt = 1000 ms
0,10 Volt = 1000 ms
Joy stick Signal

Neutral Lower
0V to +10V
Lower Neutral
+10V to 0V
Neutral Lift
0V to -10V
Lift Neutral
-10V to 0V
Pot
t1
t2
t3
t4

0,05 Volt = 2000 ms
0,2 Volt = 500 ms
0,10 Volt = 1000 ms
0,10 Volt = 1000 ms
Joy stick Signal

Neutral Lower
0V to +10V
Lower Neutral
+10V to 0V
Neutral Lift
0V to -10V
Lift Neutral
-10V to 0V
Pot
t1
t2
t3
t4

0,10 Volt = 1000 ms
0,067 Volt = 1493 ms
0,10 Volt = 1000 ms
0,10 Volt = 1000 ms
E49 Boom
24 Volt at
Terminal 9
Terminal 10
Terminal 11
Terminal 12
E49a Boom
24 Volt at
Terminal 9
Terminal 10
Terminal 11
Terminal 12
E49b Boom
24 Volt at
Terminal 9
Terminal 10
Terminal 11
Terminal 12
E49c Boom
24 Volt at
Terminal 9
Terminal 10
Terminal 11
Terminal 12
continued
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Section 5.0
Page 24
5.13 Adjusting the Ramp Time Module, illustration (Z 21645)

Cont'd:
E50 Swing
24 Volt at
Terminal 9
Terminal 10
Terminal 11
Terminal 12
Joy stick Signal

Neutral Swing R
0V to +10V
Swing R Neutral
+10V to 0V
Neutral Swing L
0V to -10V
Swing L Neutral
-10V to 0V
Pot
t1
t2
t3
t4

0,067 Volt = 1493 ms
0,05 Volt = 2000 ms
0,067 Volt = 1493 ms
0,05 Volt = 2000 ms
Joy stick Signal

Neutral Swing R
0V to +10V
Swing R Neutral
+10V to 0V
Neutral Swing L
0V to -10V
Swing L Neutral
-10V to 0V
Pot
t1
t2
t3
t4

0,20 Volt = 500 ms
0,10 Volt = 1000 ms
0,20 Volt = 500 ms
0,10 Volt = 1000 ms
Pot
t1
t2
t3
t4

0,10 Volt = 1000 ms
5,00 Volt = 20ms
0,10 Volt = 1000 ms
5,00 Volt = 20ms
Pot
t1
t2
t3
t4

0,10 Volt = 1000 ms
0,10 Volt = 1000 ms
0,10 Volt = 1000 ms
0,10 Volt = 1000 ms
Joy stick Signal

Neutral Forward
0V to +10V
Forward Neutral
+10V to 0V
Neutral Backward 0V to -10V
Backward Neutral -10V to 0V
Pot
t1
t2
t3
t4

0,10 Volt = 1000 ms
0,10 Volt = 1000 ms
0,10 Volt = 1000 ms
0,10 Volt = 1000 ms
Joy stick Signal

Neutral Dump
0V to +10V
Dump Neutral
+10V to 0V
Neutral Fill
0V to -10V
Fill Neutral
-10V to 0V
Pot
t1
t2
t3
t4

0,05 Volt = 2000 ms
0,10 Volt = 1000 ms
0,10 Volt = 1000 ms
0,10 Volt = 1000 ms
E50a Swing
24 Volt at
Terminal 9
Terminal 10
Terminal 11
Terminal 12
E50b Swing brake (counter swing)

24 Volt at
Terminal 9
Terminal 10
Terminal 11
Terminal 12
Joy stick Signal

Neutral Swing R
0V to +10V
Swing R Neutral
+10V to 0V
Neutral Swing L
0V to -10V
Swing L Neutral
-10V to 0V
E51 Left crawler

24 Volt at
Terminal 9
Terminal 10
Terminal 11
Terminal 12
Joy stick Signal

Neutral Forward
0V to +10V
Forward Neutral
+10V to 0V
Neutral Backward 0V to -10V
Backward Neutral -10V to 0V
E52 Right crawler

24 Volt at
Terminal 9
Terminal 10
Terminal 11
Terminal 12
E59 Bucket
24 Volt at
Terminal 9
Terminal 10
Terminal 11
Terminal 12
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Components
Section 6.0
Page 1

Section
6.0
Page
Components
6.1
Hydraulic
6.1.1
Main Control Blocks and High Pressure Filter FSA
6.1.2
Main Control Blocks and High Pressure Filter BHA
6.1.3
Distributor Manifold Restrictor blocks FSA
6.1.4
Distributor Manifold Restrictor blocks BHA
6.1.5
Single Control Blocks (Floating) for Stick and Boom
6.1.6
Restrictor Block with Pressure Relief Valve
6.1.7
Anti Cavitation Valve Block
6.1.8
Remote Control Valves
6.1.9
Directional Solenoid Valves (Three positions / 4-ways)
10
6.1.10
Proportional Solenoid Valves
11
6.1.11
High Pressure Filter
12
6.1.12
Control Blocks and Valves
6.1.13
Travel Brake Valve
19
6.1.14
Pressure Reducing Valve
20
6.1.15
Directional Solenoid Valves (Two positions / 4-ways)
21
6.1.16
Pressure Increasing Valve
22
6.1.17
Hydraulic Cylinder
23
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Section 6.0
Page 2
6.1.1 Main Control Blocks and High Pressure Filter

Front Shovel Attachment
Pump circuit No. I
(10/I)
Main Control block (Swing, Bucket fill / Boom raise, Stick)
(13.2)
High pressure filter(with differential pressure switch B5)
(68.1)
(66.4)
Anti Cavitation Valve Stick cylinder piston side

Service-line Relief Valve Stick cylinder rod side
Pump circuit No. II

(11/II)
Main Control block (Boom, Clam, Bucket fill / Stick
extend, L.H. Travel)
(13.3)
High pressure filter (with differential pressure switch B6)
(45)
(66.5)
(68.2)
(68.3+68.4)
SRV Clam cylinder piston side

SRV Boom cylinder piston side
ACV Clam cylinder rod side
ACV Travel motors
Pump circuit No. III

(9/III)
Main Control block (Swing, Clam, Bucket, Boom)
(13.1)
(66.1)
(66.2)
SRV Bucket cylinder piston side

SRV Bucket cylinder rod side
Pump circuit No. IV

(12/IV)
Main Control block (Slew, Boom/Bucket, Stick)
(12.3)
(66.7)
(66.8)
(66.9)
(66.10)
(66.11)
(66.12)
(68.5)
(68.6+68.7)

SRV Boom cylinder rod side
SRV Bucket cylinder piston side
SRV Bucket cylinder rod side
SRV Stick cylinder piston side
SRV Stick cylinder rod side
ACV Stick cylinder piston side
ACV Travel motors
There is one Main Relief Valve in each control block
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Section 6.0
Page 3
6.1.2 Main Control Blocks and High Pressure Filter

Back Hoe Attachment
Pump circuit No. I
(10/I)
Main Control block (Swing, Boom, Stick)
(13.2)
High pressure filter(with differential pressure switch B5)
(66.4)
Service-line Relief Valve Stick cylinder piston side
Pump circuit No. II

(11/II)
Main Control block (Boom, Stick, Bucket, L.H. Travel)
(13.3)
(66.5)
(66.6)
(68.3+68.4)

ACV Travel motors
Pump circuit No. III

(9/III)
Main Control block (Swing, Bucket, Boom)
(13.1)
(66.3)
Pump circuit No. IV

(12/IV)
Main Control block (Boom, Bucket, Stick, R.H. Travel)
(13.4)
(66.7)
(66.8)
(66.12)
(68.6+68.7)

ACV Travel motors
There is one Main Relief Valve in each control block
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Section 6.0
Page 4
6.1.3 Distributor Manifold - Location of restrictor blocks and anti cavitation valves
(SB)
Synchronization (Equalization) block
(SL)
Synchronization (Equalization) lines
(SRV)
Service-line Relief Valve
(42)
Distributor manifold
(64.1)
ACV Block Section A, Boom cylinder rod side
(70.1+.2) Restrictor blocks Section B, Boom cylinder piston side

with SRVs and pressure check points M16.1 + M16.2
(65.1)
SRV Section C, Bucket cylinder piston side

with SRV and pressure check point M17.1
(70.4)
Restrictor block Section C, Bucket cylinder piston side

with pressure check point M17.2
(64.2)
ACV Block Section C, Bucket cylinder piston side
(64.3)
ACV Block Section D, Bucket cylinder rod side
(70.6)
Restrictor block Section E, Clam cylinder rod side

with SRV and pressure check point M19
(64.4)
ACV Block Section F, Stick cylinder rod side
(65.2)
SRV Section G, Stick cylinder piston side

with pressure check point M20
(64.5)
ACV Block Section H, Stick cylinder rod side
(70.8+.9) Restrictor blocks Section J, Stick cylinder piston side

(18)
SRV Section K, Clam cylinder piston side

with pressure check points M22
(64.6)
ACV Block Section K, Clam cylinder piston side
(64.7)
ACV Block Section L, Bucket cylinder rod side
(64.8)
ACV Block Section M, Bucket cylinder piston side
(70.12)
Restrictor block Section M, Bucket cylinder piston side

(65.3)
SRV Section N, Bucket cylinder piston side

with pressure check point M25
(65.4)
SRV Section O, Boom cylinder piston side

with pressure check point M26.2
(70.13)
Restrictor blocks Section O, Boom cylinder piston side

(64.9)
ACV Block Section P, Boom cylinder rod side
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Components
Section 6.0
Page 5
6.1.4 Distributor Manifold - Location of restrictor blocks and anti cavitation valves
Backhoe Attachment
(SL)
Synchronization (Equalization) lines
(SRV)
Service-line Relief Valve
(42)
(64.1)
ACV Block Section A, Boom cylinder rod side
(70.1+.2) Restrictor blocks Section B, Boom cylinder piston side

(70.3)

(70.4)

(64.2)
ACV Block Section C, Bucket cylinder piston side
(64.3)
ACV Block Section D, Bucket cylinder rod side
(70.5)
Restrictor block Section D, Bucket cylinder rod side

(64.4)
ACV Block Section F, Stick cylinder piston side
(70.7)
Restrictor block Section G, Bucket cylinder rod side

(64.5)
ACV Block Section H, Stick cylinder piston side
(70.8+.9) Restrictor blocks Section J, Stick cylinder rod side

(70.10)
Restrictor block Section K, Stick cylinder rod side

(64.6)
ACV Block Section K, Stick cylinder rod side
(70.11)
Restrictor block Section L, Bucket cylinder rod side

(64.7)
ACV Block Section L, Bucket cylinder rod side
(70.12)
Restrictor block Section M, Bucket cylinder piston side

(64.8)
ACV Block Section M, Bucket cylinder piston side
(70.13)

(70.14)

(64.9)
ACV Block Section P, Boom cylinder rod side
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Section 6.0
Page 6
6.1.5 Single Control Blocks (Floating) for Stick and Boom

(Y132)
Single control block - Stick lowering function

Floating position
(Y133)

Floating position
(Y134)

Floating position
(Y135)
Single control block - Boom lowering function

Floating position
Function:
Only Front Shovel Attachment
The additionally installed single control blocks (Y132, Y133,Y134 and Y135)
connect the piston side of the cylinders with the rod side and also with the tank:
Y132, Y133 and Y134 for the Stick cylinders
Y135 for the Boom cylinders
In normal operation mode (i.e. float position) the pilot pressure oil is directed via
de-energized solenoid valves to the single control blocks when lowering the
boom or stick.
If a pressurized lowering of the cylinders is required the pilot pressure oil is
directed via energized solenoid valves to the main control blocks.
The solenoid valves (4/2-directional control valves) are controlled by push
buttons located in the control levers (joysticks).
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Section 6.0
Page 7
6.1.6 Restrictor Block with Pressure Relief Valve
A restrictor block is used for limiting cylinder lowering speeds.

A Service Line Relief Valve is installed to limit the maximum system
pressure due to external forces.

(1)
(2 + 3)
(4)
(5 + 6)
(7)
(8)
(9)
(10)
(11
(12)
(13)
(14)
(15)
(16)
A+B
M
Y
Adjustment spindle
O-ring with back-up ring
Retainer
O-ring with back-up ring
Spring
Spring cup
Throttle sleeve
O-ring
Housing
Return line port, T
Allen bolt
Clip ring
Lock nut
Line ports
Control oil drain port
Function:
Setting of the maximum permissible cylinder speed (flow B to A) is carried
out by spindle (1). Depending on the spindle setting, the radial holes (9.1) in
the valve poppet (9) will be partially opened to achieve the required throttling
of the oil flow.
The extra holes (fixed throttle 9.2) prevents the valve from becoming
completely closed.
For the lifting operation (flow A to B), the valve poppet (9), which is guided
by the spindle (1), is pressed against spring (7) so that the valve will be
completely open.
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Section 6.0
Page 8
6.1.7 Anti Cavitation Valve Block
ACVs are installed to avoid cavitation damages on users (hydraulic

cylinders), by compensating a possible lack of oil, when the SRV at the
opposite side of the cylinder opens (see circuit diagram).

(Type 64.1 to 64.9 of the hydraulic circuit diagram)
(1)
Housing
(2)
Valve cone
(3)
Spring
(4)
O-ring
(5)
Control and leak oil bore
(6)
Cap screw (torque 900 Nm)
S
Supply line
(Return oil pressurized to approximately 10 bar by
back pressure valve)
A and B Line connections
Function:
The circuit pressure in the line A and B hold the valve cone (2) closed. The
pressure of the supply line S forces onto the valve cone.
The valve cone opens, whenever the pressure at the A and B side is lower
than the back pressure at return oil port S, to allow necessary oil supply into
the circuit.
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Section 6.0
Page 9
6.1.8 Remote control valves
Remote control valves are part of the electric-hydraulic control system

(1 - 6)
(7)
(8)
(9)
(10)
(11)
Pilot pressure lines to the control block

Pilot pressure supply port
Return to tank port
Manifold block
Double directional solenoid valve
Single proportional solenoid valve
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 main control
valve blocks.
When a lever (or pedal) is actuated, a proportional solenoid valve (11) and
one of the directional solenoid valves (10 either a or b) are energized, and
allows the pilot pressure oil to flow to the spools of the main control blocks.
The proportional solenoid valve alters the pilot pressure, proportional to the
lever deflection, this results a spool movement between neutral and full
stroke position.
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Section 6.0
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6.1.9 Directional Solenoid Valves (Three positions / 4-ways)
This solenoid operated directional spool valves are installed to control

the start, stop and direction of an oil flow.

(1)
(2)
(3)
(4)
(5)
(6)
Housing
Solenoids
Control spool
Reset springs
Plunger
End cover
Function:
In un-operated condition the control spool (3) is held in the neutral or
starting position by the reset springs (4). Operation of the control spool is by
means of oil immersed solenoids (2).
The force of the solenoid (2) acts via the plunger (5) on the control spool (3)
and pushes its from its resting position into the required end position. This
results in the required free flow from P to A and B to T or from P to B and
A to T.
When the solenoid (2) is de-energised, the control spool (3) is returned to its
original position by the reset springs (4).
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Section 6.0
Page 11
6.1.10 Proportional Solenoid Valve
This valves are responsible for the creation of a variable control

pressure proportional to the electrical signal output of an amplifier.

(1)
(2)
(3)
(4)
Proportional solenoid
Control piston
Valve housing
Pressure measuring spool
(5)
(6)
(7)
(8)
Pressure measuring spool

Connection plug
Return spring
Bleed screw
Function:
In unoperated condition the control spool (2) is held in the neutral or starting
position by reset springs.
The control spool (2) is directly operated by the proportional solenoid (1).
If the solenoid is energized, it produces a force to operate the control spool (2) via
the pressure measuring spool (4) and moves the spool to the left. Oil flows from P
to A. As pressure in A increases, it passes via the radial borings in the control
spool (2) to the inner end of the pressure measuring spool (2).
The force generated by the pressure now works against the solenoid force and
pushes the control spool (2) to the right (closing direction) until a balance is
achieved between the two forces. In order to achieve this, the pressure measuring
spool (2) moves to the left until it is supported by the pin (5).
When the force balance is achieved, the connection between P and A is
interrupted and the pressure in line A is held constant.
Any reduction in the solenoid force leads to the pressure force exceeding the
solenoid force on the control spool (2). The control spool is then moved to the
right causing a connection from A to T allowing the pressure to fall until a
balance is re-established at a lower level.
At rest, when the solenoid is de-energized, ports A and B are open to tank, whilst
port P is blocked from both ports A and B.
In order to achieve optimum functioning of the valve, it must be bleed

when commissioning:
- Supply pressure to the valve
- Remove plug 8
- When no more air bubbles appear screw in plug 8.
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Page 12
6.1.11 High Pressure Filter
There is one filter in each pump line installed.

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
P1
P2
a
b
c
d
e
Filter head
Drain plug
Filter case
Hexagon
Filter element
Packing ring
O-ring
Back-up ring
O-ring
Spring
Differential pressure switch
Higher static pressure
Lower static pressure
Electrical connection
REED contact
Permanent magnet piston
Spring
Plug screw
Function:
High-pressure in-line filters prevent contamination from entering the
hydraulic circuits. The spin-on filters are installed between the main
hydraulic pumps and multi-valve control blocks. All hydraulic components,
behind the pumps, are effectively protected from damage and undue wear.
Each filter is equipped with a differential pressure switch to monitor the filter
flow restriction. If the pressure reaches an unsafe difference of 8.5 bar, a
visual/acoustic warning appears on the display in the cab and the engines will
be shifted automatically to low idle.
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Section 6.0
Page 13
6.1.12 Control Blocks and Valves
This is a principle drawing, showing valve block II and IV.

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Control block housing

Main relief valve (MRV)
Boom lifting / lowering, Spool (special)
Long cap ("B" side)
"B" side service line ports
Centering springs
Solid spool
Short cap ("A" side)
"A" side service line ports
Load check valves
Pilot oil warm up and flushing grooves
Fine controlling grooves
Type plate
Control blocks with "Open Center and Closed Ports".

Control blocks I and III are 3 spool blocks II and IV are 4 spool blocks.
See hydraulic circuit diagram for spool details.
Each spool is provided with "Fine Controlling Grooves", ring grooves for
hydraulically centering of the spool and Pilot oil warm up and flushing
grooves.
Between 8 and 19 bar pilot pressure the spools are moved in their fine control
range.
Spool (3) is special designed, to keep the pressure channel connected to the
center channel during the function Boom lowering is selected, so that pump
flow is available for other functions.
The Load Holding Valves are installed beneath a plug from the service port
side of the control block.
The MRV is a pilot operated pressure relief valve.
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Section 6.0
Page 14

(1)
(2)
(3)
(4)
Main relief valve (MRV)Control block housing

Load check valve
Anti cavitation valve (ACV)
Service line relief valve (SRV)
Explanation of the schematic drawing of the control block:

The hydraulic oil flows through the control block from port P to T, if all
spools are in neutral position ("pressure-less circuit" or Free circulation).
(A)
E.g. the spools moves down when pilot pressure is build up in the
control pipe line a1. (Imagine the upper symbol box moves to the
center position.)
Now pump oil flows through check valve (2) to the user port A1
because the free flow circulation to the hydraulic reservoir is closed.
The main relief valve (1) limits the maximum operation pressure in
this circuit. Via port B1 the return oil from the user is flowing back
to the hydraulic reservoir.
During down hill travelling motion and stopping procedure (e.g.
travel motors) the anti cavitation valves (3) prevents cavitation on
the hydraulic motors. Because during these short periods of time the
hydraulic motor needs a higher oil supply than the pump can deliver.
(B)
E.g. the spool #3 moves up when pilot pressure is build up in the

control pipe b3. Now the user port B3 is supplied with pump
pressure. Via port A3 the return oil from the user is flowing back to
the hydraulic reservoir. Service line relief valve (4) is additional
installed in this circuit to protect the circuit for extreme pressure.
The shortly extreme pressure closes also the check valve (2) which
secures the hydraulic pump from extreme pressure peaks.
The check valves (2) have also the function of load holding valves
because during the fine controlling period all lines are connected
together (negative over-lapping). The load pressure is for a moment
higher than the pump pressure.
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Section 6.0
Page 15

(1)
(2)
(3)
Reset springs
Fine controlling grooves
Spool
Function:
Reset springs (1) moves the spool (3) in neutral position.
Fine control grooves (2) provide for sensitive controlling, because a motion is
started always while the pressure oil and the return oil first passes this fine
control grooves before spool (3) is inter connecting the entire groove to the
user channel.
In neutral position of spool (3) the pump oil is flowing back via port PU to the
tank.
Lower picture:
Example. The spool is moved to left position: Port PU is closed and the
connection through the check valve RP1 to the user (port A) is open. Also the
connection from the other user side (port B return)is connected to the port T
(return line to tank).
Return line of the pressure relief valve MRV is also connected to the port T.
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Section 6.0
Page 16

(01)
(02)
(03)
(04)
(5)
(6)
(7)
(8)
Service -Line Relief Valve

Anti Cavitation Valve
Main Relief Valve
Closing plate
Plug screw
Spring
Valve cone
Dust cap
(9)
(10
(11)
(12)
(13) + 16)
(14)
(15)
(17)
Set screw
Lock nut
Spring, pilot part
Poppet
Jet bore
Spring, main cone
Main valve cone
Pilot oil dump line to tank
MRVs and SRVs are pilot operated relief valves. The MRV limits the max.
Pump supply line pressure. The SRV limits the max. possible pressure peak in
the service-line.
The valves have an opening characteristic. That means, that in case of
contamination after the response procedure no further pressure increasing is
possible and damages are avoided.
Function:
The circuit pressure P forces with the force F1 on the piston surface A of the
main valve cone (15). Because there is via the jet bore (16) the same pressure on
the back side of the main cone, this results together with the spring (14) force in
a force F2 that keeps the main cone closed. Via the jet bore (13) the circuit
pressure is in front of the poppet (12). Exceeds the circuit pressure the setting
value of the spring (11), the poppet opens against the force of the spring (11).
This causes that the force F2 decreases and there is no more balance condition
between F1 and F2. Valve cone (15) is moved upwards by the greater force F1.
That means there is now a direct connection from port P to T (tank).
ACVs serve for compensation possible lack of feed when the SRV at the
opposite port is actuated (see circuit diagram) and for avoiding cavitation
damages. In addition, to supply a user in case it is continuously moved by
acceleration forces at zero position of the control spool.
Function:
The circuit pressure inside the spring chamber closes the valve cone (7).
The back pressure of the return line acts on the surface of the valve cone (7).
Whenever the pressure in the service-line is lower than the springs force the
valve cone opens by the force of the back pressure and hydraulic oil is additional
supplied.
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Page 17

Load Holding Valve
(1)
(2)
(3)
(4)
(5)
(6)
Valve cone guide

Valve spring
Valve cone
Valve block housing
Passage from pump (P)
Passage to control block spool A/B
Control Blocks II and IV (4 spool blocks)

The load holding valves are fitted into separate spaces of the control block
housing, one valve for each spool.
They have three tasks:
1.
When circuit pressure due to attachment weight is higher than pump
pressure these valves prevent dropping of the attachment, within their
sensitive (fine controlling) range.
2.
Due suddenly pressure peaks in the service lines the valves also protect
the pump.
3.
When two pumps flows are used for one user they ensure that at least
the flow of one pump reaches the user in case one MRV is defect or not
more correct adjusted.
That means: Up to the max. Pressure of the defective valve both load holding
valves are open allowing the flow of both pumps to the user, then one valve will
be closed by the higher pressure and the flow of one pump only flows to the
user.
Function:
The system pressure forces onto the front area of the valve cone (1). This force
moves the valve cone against the spring (2) and allows the oil to flow from the
pump to the spool.
In neutral position of the spool no further flow is possible. (see circuit diagram)
If the spool is not more in neutral the flow continues to the user.
If due to an external force the pressure directed to the pump overcomes the
pump line pressure, this pressure forces the valve onto its seat (closed position)
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Components
Section 6.0
Page 18

Load Holding Valve
This is a principle drawing only, showing the location of Load Holding

Valves in valve block I and III.

(1)
(2)
(3)
(4)
(5)
Spool
Valve cone
Valve spring
Passage from P to A
Passage from B to T
Control Blocks I and III (3 spool blocks)

The load holding valves are directly fitted into the spools (one on each side).
They have three tasks:
1.
When circuit pressure due to attachment weight is higher than pump
pressure these valves prevent dropping of the attachment, within their
sensitive (fine controlling) range.
2.
Due suddenly pressure peaks in the service lines the valves also protect
the pump.
3.
When two pumps flows are used for one user they ensure that at least
the flow of one pump reaches the user in case one MRV is defect or not
more correct adjusted.
That means: Up to the max. Pressure of the defective valve both load holding
valves are open allowing the flow of both pumps to the user, then one valve will
be closed by the higher pressure and the flow of one pump only flows to the
user.
Function:
In neutral position (upper picture) of the spool (1) both valve cones (2) are
closed by the springs (3).
In a switched position (lower picture) forces the circuit pressure onto the
front area of the valve piston (2).
This force moves the piston against spring (3) and allows the oil to flow from
the pump supply (4) to the user port (A) and from port B via boring (5) to the
return oil passage.
If due to an external force the pressure directed to the pump overcomes the
pressure in the pump line; this pressure (force) closes the valve
(direction P to A).
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19
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Components
Section 6.0
Page 19
6.1.13 Travel Brake Valve

Illustration Z 21695
Task:
Travel brake valves control the oil flow from the hydraulic motor to the tank
depending on operating pressure. This braking action prevents the motors from
overspeeding.
Function:
Spring force keeps the spool in the lowest flow position. with increasing
operating pressure the opening for the return oil flow becomes larger.
On its way to the hydraulic motor the oil flows from A to A1 respectively from
B to B1 depending on the selected travel motion.
Example:
Operating pressure at port A moves spool (1) against the force of the spring (2)
and opens the way for the return oil (B1 to B).
Check valve (3) prevents a direct oil flow from B1 to B.
If the operating pressure decreases to such an extend that the spring force
overcomes the pressure, the flow to the tank becomes restricted, resulting in
braking of the machine.
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20
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Components
Section 6.0
Page 20
6.1.14 Pressure Reducing Valve
Pressure reducing valves are installed to reduce the common 45 bar

pilot pressure to a lower pressure for other systems, e.g. the pump
regulation system.

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Set screw
Spool
Compression spring
Threaded sleeve
Non return valve
Boring
Spring chamber
Control land
Function:
Pressure reducing valves type DR & DP are direct operated valves of 3 way
design, e.g. with a pressure relief function on the reduced pressure side.
At rest, the valve is normally open, and fluid can flow unhindered from port P
to A. Pressure in port A is also present on the end of the spool (2), via control
line (6), opposing the compression spring (3). When the pressure in port A
reaches the pressure level set at spring (3), spool (2) moves to the control
position and holds the pressure in port A constant.
Fluid to control the valve is taken from port A via the boring (6).
If the pressure in port A rises still further due to external forces, the spool (2)
is moved still further towards the compression spring (3).
This causes a flow path to be opened over control land (8) in the control spool (2)
to tank. Sufficient fluid then flows to tank to prevent any further rise in pressure.
An optional non return valve (5) is available to allow free flow from A to P.
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Components
Section 6.0
Page 21
6.1.15 Directional Solenoid Valves (Two positions / 4-ways)
This solenoid operated directional spool valves are installed to control

the start, stop and direction of an oil flow.

(1)
(2)
(3)
(4)
(5)
(6)
Housing
Solenoid
Control spool
Return spring
Plunger
Dust cap with stem for manual operation
Function:
When there is no flow through the valve, control spool (3) is held in neutral
or output position by means of the return springs (4). The control spool (3) is
operated by means of oil immersed solenoid (2).
The force of the solenoid (2) effects control spool (3) by means of the plunger
(5) and pushes it from its resting position to the required end position.
This results in free flow from or P to B and A to T.
When solenoid (2) is de-energized, control spool (3) is moved back to its
resting position by means of return springs (4).
An optional hand emergency (6) allows movement of the control spool (3)
without energizing the solenoid.
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Components
Section 6.0
Page 22
6.1.16 Pressure Increasing Valve
The pressure increasing valve is a remote controlled pressure relief

valve, actuated by hydraulic pressure. The individual pressure is in
such a way determined by the pilot pressure.

(1)
(2)
(3)
(4)
(5)
(6)
(7+8)
(9)
(10)
(11+12)
(13+14)
Pilot valve with valve seat

Valve poppet
Compression spring
Main valve with sleeve
Main piston
Closing spring
Set screws
Piston
Pin
Jet bore
Lock nut
Function:
The valve poppet (2) is connected via the jet bores (11) and (12) with the P
port.
If static pressure increase above the set pressure value, the valve poppet (2)
opens and allows oil to flow freely to tank (T1). This oil generates a pressure
drop in the spring chamber of the main spool, the closing force of the spring
(6) is cancelled, and the main piston (5) opens to allow the pump flow to flow
to tank (T2).
Damped opening and closing is obtained by the throttled volumetric change.
By applying external pressure of Pst max = 45 bar to the main spool (9) via
port X, the pre-tensioning of the pressure spring (3) is increased by the amount
of the piston stroke "S" and system pressure is increased correspondingly.
The possible pressure increase p is 440 bar max. or 440 bar minus the basic
setting.
The setting is fixed by means of the setting screw (7) and lock nut (13); 1 turn
of the screw = 150 bar.
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Components
Section 6.0
Page 23
6.1.17 Hydraulic Cylinder

General
(1) Piston rod
(2) Rod eye bushing
(3) Piston
(4) Cylinder tube
(5) Piston fitting key
(6) Piston nut
(7) Piston nut lock (threaded pin)
(8) Foot end eye bushing
B
Flange bushing: Clam cylinder
B1 Scraper ring
B2 BD seal (Dynamic Seal)
A
Flange bushing: Boom-, Stick-, Bucket-Cylinder
A1 Scraper ring
A2 Support bushing
A3 Hard-plastic back-up ring
A4 Back-up ring
A5 Chevrons
A6 Header ring
A7 Scraper retainer ring
A8 Cover
A9 Steel shims (splitted)
C = Piston rings
C1 Piston seal ring
C2 Piston guide rings, hard
C3 Piston guide, soft
C4 O-ring with back-up rings
Explanation of the cylinder

markings
430/290X3150
Piston diameter / Rod diameter X Stroke
430630 40
Cylinder drawing number (identical with part

No.).
11 / 97
Assembling Month and year (final figure).
261
Internal counting number.
DB 55.
Assembling crew personal code
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Main Hydraulic Pumps

and
Pump Regulation System
Section 7.0
Page 1

Section
7.0
Page
Main hydraulic pumps and pump regulation system
General
7.1
7.2
7.3
Main Pumps
7.1.1
Location of Pumps, drive speed and flow rates
7.1.2
Pump bearing flushing / lubrication
7.1.3
Operating Principles
7.1.4
Checks and Adjustments
Electronic Pump Regulation System
7.2.1
Electronic load limiting control - General
7.2.2
Components:- Electronic Power Module EPM
- Electronic Signal rectifier ESR
- Microcontroller MC7
7.2.3
Checks and adjustments - General
Method A - With 24V supply to terminals
- X1-Pressure
- Demanded power
- PID - Factor
Method B - With the electronic service tool BB-3
- Language selection
- Adjustment mode SET1 and SET2
- Number of motor selection
- X1-pressure (max. current) adjust.
- Demanded power adjustment
- PID Factor adjustment
- Storage new settings
Method C - With a laptop and BODEM software
- Starting the program
- Language selection
- Entering of the password
- Number of Motor selection
- X1-pressure (max. current) adjust.
- Demanded power adjustment
- PID Factor adjustment
Hydraulic Constant Regulation System
7.3.1
General
7.3.2
X1-pressure adjustment (constant-pressure)
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25
6
7
8 15
16 20
21
22
23 + 24
25
26
27
28 + 29
30
31 + 32
33
34
35
36
37
38
39 - 40
41
42
43
44
45 + 46 + 47
48
49
50
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and
7.0
Section 7.0
Page 2

General lay out (Hydraulic only)

(1 - 4) Main hydraulic pumps
(8.1)
Pilot pressure pumps
(33)
Pilot pressure filter unit
(252.2) 60 bar pressure relief valve
(252.1) 45 bar pressure reducing valve
(Y17) Solenoid valve: "Idle time control and low hydraulic oil temperature"
Q-min flow for all main pumps
(Y17a) Solenoid valve: "Remote control pressure"
Q-max flow reduction for all main pumps
(Y126) Solenoid valve: "Remote control pressure"
Q-max flow reduction for pump #1 only
(255.4) Pressure reducing valve: "Remote control pressure" Q-max flow
reduction for the warming-up period and flow reduction for pump #1
(253.2) Pressure reducing valve: " Pump regulation pressure X1 at hydraulic
pump regulation" (Hydraulic constant regulation mode)
(Y61-1) Proportional solenoid valve: "Pump regulation pressure X1 at electronic
pump regulation " (Standard operation mode)
(Y130) Solenoid valve: " Pump regulation pressure X1 = 45 bar for pump #1"
(fixed pump for swing)
(253.1) Change over valve: "Electronic or Hydraulic pump regulation"
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and
7.0
Section 7.0
Page 3

Pump regulation system general, illustration (Z 21547b)
General
Controlled output flow of the main pumps is necessary:
To utilize the available motor power most efficiently in every operating
mode.
To limit the power consumption of the hydraulic pumps depending on the
load of the motor. (Electronic pump regulation with micro-controller MC7)
For additional functions, such as rotating dependent or temperaturedependent flow reduction.
Function:
X1 pump regulation pressure (0 34 bar):
The power controller of the main pumps can be remotely controlled by
applying an external pilot pressure (X1 ) at port X LR to the spring chamber of
the power control valve. The start of destroking can be varied in proportion to
the applied X1 - pressure.
X2 pilot pressure (45 bar):
Constant pilot pressure to regulate the main pumps at special circumstances,
e.g. to fix the pumps in Q-max position while servicing the machine.
X3 remote control pressure (0 / 15 / 45bar):
Basic setting Q-min (0 bar), the flow rate increases with the
pilot pressure X3 at port Pst, up to Q-max (45 bar).
The hyperbolic power control is superimposed on the pilot pressure
signal and keeps the specified drive power constant. (p x Vg = constant).
The flow rates are:
Q-min.:
X3 = 0 bar
Q-max.: X3 = 15 bar
Q-max.:
X3 = 45 bar
X4 pump support pressure (60 bar):
Constant pilot pressure to support the regulation function at low operating
pressure and to lubricate the main pump bearings.
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and
7.0
Section 7.0
Page 4

Function:
Solenoid valve Y17:
If de-energized pumps #1-4 are in Q-min position.
It gets energized as soon as one of the control levers/pedals has been operated
and stays energized as long as the temperature state is above T3.
It gets de-energized whenever all controls are in neutral position for more
than 20 seconds and a temperature state between T1 and T3.
Solenoid valve Y17a:
The solenoid is de-energized as long as the temperature state is below T2
(depending on the filled in hydraulic oil) shown in the table. ( pumps #1-4 are
in Q-max. position for warm up)
It gets energized at a temperature state between T2 and T4 as soon as one of
the control levers/pedals has been operated and gets de-energized without
delay whenever all controls are in neutral position.
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and
7.0
Section 7.0
Page 5

Function:
Solenoid valve Y126:
If de-energized, pump #1 is in the same regulation mode like pumps #2, #3
and #4. If energized the flow of pump#1 is limited to Q-max by the
function of pressure reducing valve (81.1).
It gets energized when the swing function in main control block 1 is activated,
or when the hydraulic oil temperature is below T2.
Normal operating conditions
Without swing
Normal operating conditions

With swing (fast speed)
Y17
Y17a
Y126
(1) = Energized
(0) = De-energized
Proportional Solenoid valve Y61-1:

This valve, connected to the MC7 micro-controller (electronic pump
regulation), creates a X1-pressure depending on the load of the engine.
This X1-pressure is the information for the pumps to destroke from Q-max.
into Q-min. position, to keep the engine at rated speed of approx. 1800 RPM.
If energized, pump regulation pressure X1 = 45 bar for pump #1"
If energized, pump regulation pressure X1 = 45 bar for pump #3"
(fixed pump for swing with fast speed)
Pressure reducing valve 255.4:
"Remote control pressure" (X3)
Q-max flow reduction during the warming-up period for all pumps by
the function of solenoid valve Y17a.
Q-max flow reduction only for pump #1 while swinging with max. speed
by the function of solenoid valve Y126.
Pressure reducing valve 253.2:
Pump regulation pressure X1 at "hydraulic pump regulation" (Hydraulic
constant regulation mode) by the function of change over valve (22).
Change over valve 253.1:
Change over three way cock valve to select "Electronic or constant regulation
mode".
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and
7.1
Section 7.0
Page 6
Main Pumps
7.1.1. Location of Pumps
(1 - 4)
Axial piston pump (swash plate type)
theoretical flow rate, each
1033 Liter/min
Drive speed*
n = 1378 min-1
for all working motions
(5.1)
(5.2)
(8.1)
(8.2)
Axial piston pump

Drive speed*
for oil cooler fan drive
214 Liter/min
n = 2000 min-1
Axial piston pump

Drive speed*
for radiator fan drive
214 Liter/min
n = 2000 min-1
Gear pump
Drive speed*
for pilot pressure supply
138 Liter/min
n = 1378 min-1
Gear pump
Drive speed*
138 Liter/min
n = 1378 min-1
* at 1800 min-1 input drive speed
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and
7.1
Section 7.0
Page 7
Main Pumps
7.1.2. Pump bearing flushing / lubrication
The installed main pumps are provided with an external cooling and lubrication
system for flushing of drive shaft bearing and shaft seal.
Oil supply is provided from the X4-pressure circuit.
To reach the restricted guidance of the coolant for external bearing flushing, the
throttle screw (located behind the union at port U) must screwed in all the way.
An information sign is fixed at the pump.
(1 4)
Main pumps
(20.1 20.4) Orifice (one for each main pump)
(33)
Filter for pilot pressure
(B E)
Ports for X4-pressure (pump support pressure)
(U)
Port for the pump bearing flushing / lubrication
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and
7.1
Section 7.0
Page 8
Main Pumps
7.1.3 Operating Principles
Main hydraulic pump A4VSLO 750 LR3DN / 30L
Type code explanation:
A4VSLO 750 LR 3 D N / 30 L
Rotation
Series
Basic adjustment for minimum displacement
With pressure control
Hydraulic remote adjustment facility
Constant power with hyperbolic curve
Displacement in cm3 at one (1) revolution
Axial piston pump series 4, variable displacement ,swash plate design for open circuits with charge pump
Function and characteristics:

The A4VSLO variable displacement axial piston pump in swash plate
design is intended for drives in open circuit operation.
The flow volume is proportional to the drive speed and the displacement.
By adjusting the swash plate a infinitely variable flow adjustment is
possible.
Pumps of the same nominal size can be built onto the trough drive.
Combinations with gear pumps are also possible.
(1)
Drive shaft
(2)
Cylindrical roller bearing
(3)
Slipper pad
(4)
Swivel angle indicator
(5)
Positioning piston
(6)
Swivel pin
(7)
Cylinder with pistons
(8)
Final connecting plate
(9)
(10)
Impeller (charging pump)
(11)
Splints for the through drive coupling (Aux. pump drive)
(12)
Swivel cradle
(13)
Q-min stop bolt
(14)
Power control valve
(15)
Pressure balance valve
(16)
Power curve correction
(17)
Pressure cut off valve
(18)
Q-max. stop bolt
(19)
Remote control valve
continued
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and
7.1
Section 7.0
Page 9
Main Pumps
Cont'd:
Symbol of main hydraulic pump A4VSLO 750 LR3DN / 30L
(1)
Main pump (swash plate pump, variable displacement)
(2)
Charging pump (impeller type pump)
(3)
Pump bearing group
(4)
Drive shaft
(5)
Non return valves
(6)
(6.1)
Mechanical stroke limitation*
(6.2)
Remote pressure (PST) operated piston for item 6
(6.3)
Mechanical stroke limitation*
(7)
Spool valve (pressure balance valve)
(8)
Nozzle
(9)
Power control valve
(10)
Nozzle
(11)
Pressure cut-off valve
(12)
Auxiliary pump (Gear pump, fixed displacement
(13)
Positioning piston
(14)
Slipper pad piston
(15)
Lever
(16)
Cam
(17)
Through drive shaft
* Factory side adjusted, no field adjustment required
B/B1
S
MB
ML
MST
R
T
P
PST
U
XLR
Pressure port
Oil intake (suction port)
Operating pressure check point
Charging pressure check point
Control pressure check point
Filler and bleeder port
Connection port for chip indicator
Pump support pressure (X4-pressure)
Remote control pressure port (X3-pressure)
Bearing flushing port
Regulating pressure port (X1-pressure)
continued
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and
7.1
Section 7.0
Page 10
Main Pumps
Cont'd:
Sectional drawing of Power Controller LR3DN / 30L
(6)
(6.1)
Mechanical stroke limitation
(6.2)
Remote pressure (PST) operated piston for item 6
(6.3)
Mechanical stroke limitation
(7)
Spool valve (pressure balance valve)
(9)
Power control valve
(11)
(13)
Positioning piston
(14)
Slipper pad piston
(15)
Lever
Refer also to illustration Z 21550 on the previous page.
continued
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11
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7.1
Section 7.0
Page 11
Main Pumps
7.1.3 Operating Principles, illustration (Z 21552)
Cont'd:
Q-min position: (remember Q means volume)
When are the pumps in Q-min position?
A: Motor at standstill
B: Motor running and the controls are not used for 20 sec. or longer
at temperature state between T1 and T3.
C: Motor running and service switch S155 activated (Qmin-position)
Example C with the following conditions:
Motor running
Pump pressure smaller than X4 = 60 bar (pump support pressure)
X1 = 34 bar (pump regulation pressure), this pressure will not influence
the Q-min position under these conditions.
X3 = 0 bar (remote control pressure); Y17 de-energized (S155 Qmin activated)
for pumps #2, #3 and #4.
For pump #1, Y17 and Y126 de-energized.
X4 = 60 bar (pump support pressure)
Pump support pressure is present at valve #7, the slipper pad of
piston #14 and the small area side of the positioning piston #13
Response of pump control mechanism:
Valve #7 moves to position "b" because the X4-pressure will overcome the
spring force, since the oil behind nozzle (8) flows through valve #6 (which is
in position "a", due to the missing remote control pressure X3) back to tank.
Pump support pressure X4 passes valve #7 position "b" and flows via power
control valve #9 position "a" to the large area side of positioning piston #13
Because the large area side of positioning piston #13 is approximately three
times larger as the small area side, the pump support pressure X4 of 60 bar
present on both sides, resulting in stronger force at the large area side, keeps
the pump in Q-min position.
The pump remains in Q-min position
continued
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and
7.1
Section 7.0
Page 12
Main Pumps
Cont'd:
Q-max position: (remember Q means volume)
When does the pumps move into Q-max position?
and
and
and
Motor running
hydraulic oil at normal operating temperature (> T2)
the controls frequently used.
(or Service switch S155 activated Qmax-position)
a pump pressure below start of de-stroking.
Example with the following conditions:

Motor running
Pump pressure between 60 bar and 300 bar, present at the slipper pad
of piston #14 and the small area side of the positioning piston #13
X1 = 34 bar (pump regulation pressure)
X3 = 45 bar (remote control pressure); Y17 and Y17a energized
For pump #1, Y17 energized and Y126 de-energized
X4 = 60 bar (pump support pressure), present at valve #7.
Valve #7 moves to position "a" because the spring force is supported by the
X4-pressure, since the oil flow back to tank is blocked at valve #6 (which is
in position "b", due to the 45 bar remote control pressure X3).
The large area side of positioning piston #13 is connected, via power control
valve (9) position "a" and pressure balance valve (7) position "a", to the
return oil line.
The pump moves into Q-max position, because the pump pressure acts only
at the small area side of positioning piston #13.
The pump moves into Q-max position
continued
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and
7.1
Section 7.0
Page 13
Main Pumps
Cont'd:
Q-max position: (remember Q means volume)
When does the pumps move into half Q-max position?
and
and
or
and
Motor running
hydraulic oil below normal operating temperature (< T2)
the controls frequently used.
the controls not used at a temperature state between T2 and T4
a pump pressure below start of de-stroking.

Motor running
Pump pressure between 60 bar and 300 bar, present at the slipper pad
of piston #14 and the small area side of the positioning piston #13
X3 = 15 bar (remote control pressure); Y17 energized and Y17a deenergized
Valve #7 moves to an intermediate position (in-between "a" and "b"), since a
certain amount of oil behind nozzle (8) flows through valve #6 (which is also
in an intermediate position, due to the 15 bar remote control pressure X3)
back to tank.
The large area side of positioning piston #13 is connected, via power control
valve (9) position "a" and pressure balance valve (7), to the return oil line.
The pump moves into Q-max position, because the return oil flow through
pressure balance valve (7) is restricted (due to its intermediate position),
resulting in a pressure at the large area side of the positioning piston (13).
The pump moves into Q-max position
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and
Section 7.0
Page 13
continued
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and
7.1
Section 7.0
Page 14
Main Pumps
Cont'd:
Destroking: (Pump moves from Q-max. into of Q-min. direction)
When does the pumps start to destroke
Motor running
and hydraulic at normal operating temperature (> T2)
and Service switch S155 deactivated
and The hydraulic load is higher than the rated power of the motor
(The electronic pump regulation system will reduce the X1-pressure)

or
With pump pressure above 180 bar (Hydraulic constant regulation)
(Constant X1-pressure of approximately 13 bar)
Motor running
Pump pressure 180 bar adjustable at main relief valves, present at the
slipper pad of piston #14 and the small area side of the positioning piston
#13
X1 = 13 bar (constant regulation pressure adjustable at pressure reducing
valves 253.2) Change over valve (253.1) switched to hydraulic mode.
X3 = 45 bar (remote control pressure); Y17 energized and Y17a energized
Valve #7 moves to position "a" because the spring force is supported by the
X4-pressure, since the oil flow back to tank is blocked at valve #6 (which is
in position "b", due to the 45 bar remote control pressure X3).
The operating pressure (with the value for start of de-stroking) at the slipper
pad of piston #14 moves the power control valve (9) into position "b" (against
the spring force supported by the X1-pressure).
This in turn connects the operating pressure to the large area side of
positioning piston #13.
times larger as the small area side, the operating pressure present on both sides,
resulting in stronger force at the large area side, moving the pump in Q-min
direction.
The pump de-strokes until the forces at positioning piston #13 are
balanced
continued
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and
7.1
Section 7.0
Page 15
Main Pumps
Cont'd:
Pressure cut-off valve: (DR control valve, Pump moves into Q-min. position)
When is the pressure cut-off valve active?
Motor running
and With pump pressure above 300 bar
Motor running
Pump pressure 300 bar
X3 = 45 bar (remote control pressure)
X4 = 60 bar (pump support pressure)
Independent of the position of power control valve #9 the pressure cut-off
valve #11 causes the pump to de-stroke to the pre-adjusted Q-min position.
The operating pressure moves the pressure cut-off valve #11 (at set pressure)
into position "b" and flows to the large area side of positioning piston #13.
times larger as the small area side, the operating pressure present on both
sides, resulting in stronger force at the large area side, moving the pump in Qmin position.
The pump moves into Q-min position
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and
7.1
Section 7.0
Page 16
Main Pumps
7.1.4 Checks / Adjustments
Location of Adjustments
Legend for , illustration (Z21557)
(1)
(2)
Q-min. stop bolt
(3)
Pressure balance valve
(4)
Start of destroking
(5)
Power curve correction
(6)
(7)
Q-max. stop bolt
(8)
Angle indicator
The average length of the measurement "L" is: set crews (bolts )
location
1
2
3
4
5
6
7
length (mm)
13.8
26.9
8.0
8.1
---6.0
34.4
The measurement "L" is an orientation only if the adjustment is

totally out of requirements.
They must not be used for final adjustments.
The detail for (5) shows the position of the housing edge and the edge
of the eccentric set bolt. The example shows them in parallel position
which is mostly not the case. The adjustment should never be altered.
Further information see next pages
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and
7.1
Section 7.0
Page 17
Main Pumps
Pressure balance valve ( P 20bar), illustration (Z21558)
1.
Connect a 60 bar pressure gauge to check point MST.
2.
Eliminate "Idle Time Control" by using the switch S155 of

the X2-panel, if necessary see Operation Manual.
3.
Unplug solenoid valve Y17a (this causes a remote control.

pressure (X3) of approx. 15 bar)
4.
Start the motor.
5.
Gauge reading at MST must be 40 bar (20bar less than the pump
support pressure of 60bar
Loosen lock nut #4 and adjust with the set bolt #5
6.
Plug-on Y17a
Remove the pressure gauge and set S155 for "Idle Time"
elimination into normal position.
continued
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and
7.1
Section 7.0
Page 18
Main Pumps
Cont'd:
Start of destroking(LR valve), illustration (Z21559)
The reason of this check is to make sure, the pump starts destroking at an
operating pressure of 180 bar with a pump regulation pressure X1 of 13 bar.
1.
2.
3.
4.
5.
6.
Connect a 400 bar pressure gauge to the pressure check point at the
respective high pressure filter for the pumps being checked.
Connect a 60 bar pressure gauge to pressure check point M5-1 at
the control and filter panel (X1-pressure).
Move the change over valve into position Hydraulic (constant
regulation mode).
Insert an Allen key into the angle indicator bolt (see illustration)
for better visibility of the start of destroking.
Start the motor and adjust at pressure reducing valve (253.2) the
X1-pressure to 13 bar.
Stall the hydraulic for the pump to be checked and alter the
operating pressure with the MRV up and down between 160 and
200 bar.
Start of destroking should be at an operating pressure of 180 bar,
shown at the gauge connected to the high pressure filter.

a)
Adjust with the MRV an operating pressure of 180 bar.
b)
Loosen lock nut #6 (Power control valve).
c)
Turn set bolt #7, so that the pump is still in Q-max. position,
but just at the beginning of destroking.
d)
Tighten lock nut #6.
7.
Re-adjust the operating pressure at the MRV to 310+10 bar and the X1-
8.
pressure at the pressure reducing valve (253.2) to approx. 12bar.

(For exact values refer to the final test report.)
Remove Allen key and gauges.
continued
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19
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and
7.1
Section 7.0
Page 19
Main Pumps
Cont'd:
Pressure cut-off valve (DR control valve), illustration (Z21560)
The reason of this check is to make sure that the pump is in Q-min. position
at an operating pressure between 300 bar and 310 bar.
1.
2.
3.
4.
Connect a 400 bar pressure gauge to the pressure check point at the
respective high pressure filter for the pumps being checked.
Insert an Allen key into the angle indicator bolt (see illustration) for
better visibility of the start of destroking.
Start the motor, stall the hydraulic for the pump to be checked and
alter the operating pressure with the MRV up and down between 280
and 310 bar.
The angle indicator must indicate Q-min. position at a pressure of
300 bar shown at the gauge connected to the high pressure filter.

a)
Loosen lock nut #8.
b)
Turn set bolt #9, so that the pump is in Q-min. position at
the required value.
c)
Tighten lock nut #8.
5.
Re-adjust the operating pressure at the MRV to 310+10 bar
6.
Remove Allen key and gauges.
continued
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20
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and
7.1
Section 7.0
Page 20
Main Pumps
Cont'd:
Q-max. and Q-min. stop bolt, illustration (Z21561)
1.
2.
3.
Unscrew box nut (10 or 14).

Loosen the lock nut (11 or 13)
Turn the stop (12 or 15) in or out until required length
Length "X" or "Y"
Tighten the lock nut and screw on box nut (12).
5.
Turning the Q-min. stop bolt too much out can cause serious damage
to the pump.
The pump moves over 0 (zero) position into the opposite drive
direction: (suction line becomes pressure line and pressure line
becomes suction line)
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and
7.2
Section 7.0
Page 21
7.2.1 Electronic load limiting control - general, illustration (Z 22407b)

The drive train of the excavator consists of an electric motor, several hydraulic
pumps, which supply cylinders and hydraulic motors.
The load limiting control ensures optimum use of the power required for the excavator
under varying operating conditions and avoiding overload of the motors.
Illustration Z22407b shows the principle of the electronic load limiting control.
The MC7 (E32) processes the following input signals:
Voltage (Pin 47) from electronic signal rectifier (A32)
Current motor 1 (Pin 45) from electronic signal rectifier (A33)
The MC7 (E32) processes the following output signals:
Signal value to control the proportional solenoid valve Y61-1 (Pin 28) Motor 1
Switch signals (Pin 32 and 33), diagnostic of the MC7 (E32)
The electric motor drives four variable displacement pumps by means of a PTOgearbox. Each pump is equipped with a hydraulic power controller (HPC).
This controller limits the input torque of the pump to an adjusted command value (X1pressure, for start of destroking).
The command value (X1-pressure) is present via proportional solenoid valves Y61-1 at
the hydraulic power controllers of each pump.
The auxiliary hydraulic pumps and other consumers can be operated

without being directly affected by the load limiting control.
Function:
The ESR-Module (A32) transforms an AC Voltage, which is proportional to the net
voltage, into a proportional DC Voltage and transfers it into the MC7 (E32).
The ESR-Module (A33) transforms an AC Voltage, which is proportional to the motor
current, into a proportional DC Voltage and transfers it also into the MC7 (E32).
These input signals are the information about the actual load to the motor and serves the
MC7 (E32)
The control algorithm of the load limiting control (MC7) always compares the actual
required power with the rated power.
With increasing load the motor torque will rise and in turn the required power.
For this reason the electronic load limiting control will be initiated when the required
power is higher than the rated power, i.e. the torque of the main pumps will be lowered
(by reducing the X1-pressure) until the rated power is attained again.
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and
7.2
Section 7.0
Page 22
7.2.2 Electronic Power Module EPM Module , illustration (Z 22624b)

The EPM Module transforms the 24 VDC battery voltage into
positive/negative 15 VDC and positive 5 VDC which is the supply voltage for
the ESR Modules. The LEDs besides the terminals are indicating the function.
Testing the EPM-Module, A31a +A31b

Function check:
Measure the supply voltage. (24 VDC; GND = 0 V).
If the supply voltage is not there, check the supply cable and the circuit
breaker. If the circuit breaker always trips there may be a short within the
cables to the EPM Module or a short in the unit itself.
If the supply voltage is ok. the Output Voltages have to be checked. Check
pos. 15 VDC, neg. 15 VDC, 5 VDC to GND.
If the supply voltages are not ok. the short circuit monitoring system of the
EPM might be activated, therefore disconnect the cables at the terminals (+15
VDC, -15 VDC and +5 VDC) and repeat the voltage check.
If now (with disconnected cables) the voltages are as they should be there
is either a short within the cables or in the other modules itself. To determine
the fault connect the entire modules in sequence.
If the voltage is not ok., even when the cables are disconnected from the
EPM, the EPM-Module is defect.
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and
7.2
Section 7.0
Page 23
7.2.2 Electronic Signal Rectifier ESR Modules, illustration (Z 22625b)

Function:
The ESR-Module transforms an AC signal-voltage, which is proportional to the
network voltage respectively the motor current, into a proportional DC Voltage and
transfers it into the MC7.
Testing the ESR-Module, A32 + A33
Testing the ESR input/output voltage
For a transformer function test the AC-Input Voltage and the
DC-Output Voltage must be tested.
The potentiometer settings are under no circumstances

allowed to be altered, because the setting is possible only with a HFGenerator and an Oscilloscope.
If the potentiometer set-positions have been altered, a new Module,
with sealed potentiometers, must be ordered.
Procedure: Same procedure for all three Modules
1.
Disconnect the wire from terminal 23 of the ESR Module.
2.
Start the motor and let it run without an extra load on it.
3.
Measure the AC-Voltage between the terminals 21 and 41 and record it.
4.
Measure the DC-Voltage between the terminals 23 and 11 and record it.
5.
The measured DC-Voltage must be 1/4 of the AC-Voltage.

Example:
2.5 VDC
----------- = 0,25 (1 % plus/minus is ok)
10 VAC
Small variations are based on amplitude variations of the AC-Input voltage

while measuring the DC-Output voltage.
Greater variations denotes a faulty ESR Module.
continued
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24
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and
7.2
Section 7.0
Page 24
7.2.2 Electronic Signal Rectifier ESR Modules, illustration (Z 22626c)

Cont'd:
The DC-Output Voltage (UaDC ) can be compared with a calculated Voltage
Value. The calculation can be done with the ratios of the intermediate
transformers given in the circuit diagram, and by the Voltmeter and Ammeter
readings of the cab gauges.
The picture shows a schematic design only and not the actual circuit
diagram, the voltage- and current values may vary, therefore they are
exemplary used.
With the below shown formulas the exact Output Voltages UaDC of an ESR
can be calculated.
Small variations are caused by the transformers.
Variations greater than 20% denotes a faulty transformer.
1)
2)
Example for ESR 1:

U
ESR1 ----------------T1 x T2 x T3
4100 V
--------------- = 2,463 VDC
41,6 x 10 x 4
Voltage
Example for ESR 2:

I
ESR2 -----------------
150 A
-----------------
= 1,803 VDC
Current
(Condition
= 1,202 VDC
Current
(Condition
T1 x T2 x T3
I
ESR2 ----------------T1 x T2 x T3
41,6 x 0.5 x 4
100 A
----------------41,6 x 0.5 x 4
The AC Input Voltage for an ESR-Module can be calculated with the same
formula but without the value for T3.
Example for ESR 2:
I
ESR2 ----------T1 x T2
PC4000-6-E_#08165_Sec_7-0_rev0.doc
150
----------- = 7,212 VAC
41,6 x 0.5
02.03.05

and
PC4000-6-E_#08165_Sec_7-0_rev0.doc
Section 7.0
Page 24
02.03.05
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25
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and
7.2
Section 7.0
Page 25
7.2.2 Microcontroller MC7, illustration (Z 21716)

The MC7 microcontroller is used for the programmable control of a maximum of four
proportional solenoids and two additional switching functions.
As input signals, the microprocessor processes analog voltages in the 0V to 5V range and
switching information. All inputs are protected against overvoltage and electrical interference.
As output signals, the output stages of the MC7 deliver closed loop controlled currents for the
connection of proportional solenoids.
The analog voltage output is suitable for the simple forwarding of analog information to other
electronic circuits.
Characteristics
Closed loop control of solenoid currents, i.e. independent of voltage and temperature.
Pulse width modulated (PWM) solenoid currents for minimal hysteresis.
Internal buzzer for programmable monitoring of functions or errors.
Setting and Display Facilities
All calibration operations and the display of functions, faults and system variables are
connected via the serial interface to the BB-3 control panel or to a PC running the BODEM
software.
MC7 - Unit Dimensions
Plug Contacts
8 junior power timer contacts

47 micro timer I contacts
MC7 - Block Circuit Diagram
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and
7.2
Section 7.0
Page 26
7.2.3 Checks and adjustments

Microcontroller MC7, illustration (Z 22623a)
The adjustment of the X1-pressure can be done with three different methods:
A.
With 24V supply to separating terminals at the X2-switch board
or
B.
With the electronic service tool (EST) BB-3 connected to the serial
interface X13 (located in the operators cab)
or
C.
With a laptop, running the BODEM software, connected to the serial
Procedure B and C should only be carried out by authorized

personnel. [ Dealer or KMG-factory staff ]
Because it is possible to influence the behavior of the pump regulation
system.
On the following pages are only the necessary setups described.
If additional information is required, please contact KMG-Service
department.
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and
7.2
Section 7.0
Page 27
7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22628d)

Method A - X1-pressure adjustment with 24V supply to separating
terminals at the X2-panel.
Pre-conditions: Normal operating temperature, correct pilot pressure setting
and the system must be free of air.
1. Make sure the change over valve (253.1) is in position Electronic Pump
Regulation
2. Connect a pressure gauge to check point (M5.1), using a long pressure gauge
hose to be able reading the pressure in front of the X2-panel.
3. Selection of adjusting mode:
Turn the main key switch in on position and activate the adjusting mode as
follows:
Connect 24V, simultaneously to terminal 54 and 55 for 10 seconds, using two
test leads and disconnect the voltage thereafter.
4. Selection of the motor and in turn the required
proportional solenoid valve :
With the main key switch still in on position, select the output terminal of
proportional solenoid valve Y61-1 is directly selected.
Since there is only one motor with one proportional solenoid valve installed,
a 24V connection is not required.
5. Adjusting the X1-pressure:
Start the motor.
Read the pressure, required = 34 0,5 bar
If necessary increase the X1-pressure as follows:
Connect 24V to terminal 54.
As long as voltage is supplied, the X1-pressure drops to zero.
After interrupting the voltage supply, the gauge pointer will move
slowly to the new present X1-pressure.
Example: Keeping voltage supply for two seconds , will increase the
X1-pressure of approximately 1bar.
The adjusted value will be saved immediately and will be available
after power off.
6. To decrease the X1-pressure connect 24V to terminal 55 and proceed as
described under item 5, keeping voltage supply for two seconds , will
decrease the X1-pressure of approximately 1bar.
7. After the adjustment is finished, remove the test leads and pressure gauge and
turn the main key switch in OFF position to deactivate the adjusting mode.
continued
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and
7.2
Section 7.0
Page 28
7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22629c)

Cont'd:
Method A - Demanded power adjustment
Pre-conditions: Normal operating temperature, correct pilot pressure setting and
the system must be free of air.
1. Connect pressure gauges to check points M11, M12, M13 and M14 at the high
pressure filters.
2. Connect pressure a gauge to the X1 pressure check point M5.1.
3. Unplug solenoid valves Y6a and Y6b to ensure that the hydraulic oil cooler fans
are running with maximum speed.
4. Start the motor.
5. Set the MRV individually to approx. 120 bar *, to prevent the motor from
overloading during the adjustment.
6. Shift the three way cock valves (253.1) to position Hydraulic (constant)
Regulation Mode.
7. Set the X1-pressure at pressure reducing valves (253.2) > 34 bar **, to ensure that
the pumps remain in Q-max. flow position during the adjustment.
8. Apply max. load to all pumps (e.g. extend the bucket cylinders to the stop position
until the hydraulic system stalls), and increase the pressure at all 4 MRVs *
equally until the motor draw 128 Ampere. (reading of text display)
Expected system pressure at 128 Ampere = 4 times 172 bar (peak point).
Record this pressure for other tests.
If the operating pressure is higher respectively the motor current is

lower than required there is probably not the full volume available.
*Altering the MRV-Setting:
Remove dust cap (a).
Loosen lock nut (b).
Turning the set screw (c) cw the pressure will increase.
Turning the set screw
ccw the pressure will decrease.
**Altering the X1-Setting:
Loosen the lock nut (e).
Turning the set screw (f) cw the pressure will increase.
continued
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and
7.2
Section 7.0
Page 29
7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22629c)

Cont'd:
Method A - Demanded power adjustment
9.
)
10.
11.
12.
13.
Store the demanded power (peak point) into the MC7 as follows:
a) Activate the adjusting mode:
Connect 24V, simultaneously to terminal 54 and 55 for 10 seconds, using test
leads and disconnect the voltage thereafter.
b) Select the demanded power adjusting mode (Motor 1):
Connect 24V, simultaneously to terminal 50 and 52 permanent.
c) Not used.
d) Stall the hydraulic with the values of item 8 (Peak point)
4 times 172 bar (all pumps Qmax position and cooler fans with max. speed).
=> 128 Ampere (each motor)
e) Save the actual measured power:
Connect 24V to terminal 55 for 1 second and disconnect the voltage thereafter.
The actual measured power will be saved immediately as the
demanded power
Re-set the X1-pressure at pressure reducing valves (253.2) as recorded**.
Shift the three way cock valves (253.1) to position Electronic Regulation Mode
Reset the MRVs to 310 bar+5bar , and remove the gauges.
After the adjustments are finished, remove the test leads and pressure gauges, stop
the motor and turn the main key switch in OFF position to deactivate the adjusting
mode.
continued
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and
7.2
Section 7.0
Page 30
7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22636)

Cont'd:
Method A - PID - Factor adjustment to obtain the most efficient pump
regulation characteristic.
With the PID-Factor adjustment (proportional, integral and
differential factors) it is possible to influence the regulation dynamics.
The PID-Factor adjustment range is between 80% and 120%
The voltage at the analogue output (terminal 60) represents the actual
adjusted value. (80% = 0VDC / 100% = 2,5VDC / 120%= 5VDC)
This factor is multiplied with all PID parameters.
)
1.
Jerky movements while lifting and swinging at the same time:

b) Select the PID-factor adjusting mode:
Connect 24V, to terminal 50 permanent, using a test lead.
c) Connect a multi-meter to terminal 60 (reading DC-voltage) and note down the
value (represents the actual adjusted value)
d) Reduce the voltage in steps of 250mV until the system works smoothly, by
connecting 24V to terminal 55. (As close as possible to the boarder line)
2.
No Jerky movements:
b) Select the PID-factor adjusting mode:
Connect 24V, to terminal 50 permanent, using a test lead.
c) Connect a multi-meter to terminal 60 (reading DC-voltage) and note down the
value (represents the actual adjusted value)
e) Increase the voltage in steps of 250 mV until the system jerks, by connecting
24V to terminal 54. (As close as possible to the boarder line)
f) Now reduce the voltage in steps of 250mV until the system works smoothly
again, as described under item 1d.
3.
After the adjustments are finished, remove the test leads and multi-meter, stop the
motors and turn the main key switch in OFF position to deactivate the adjusting
mode.
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and
Section 7.0
Page 31
7.2 Electronic Pump Regulation System

7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22357f)
Method B -
With the electronic service tool (EST) BB-3 connected to the serial
1.
2.
3.
4.
Make sure the respective change over valve is in position Electronic Pump
Regulation
Connect a pressure gauge to check point M5.1, using long pressure gauge
hoses to be able reading the pressure inside the operators cab.
Connect the electronic service tool (BB-3) to the data link adapter X13,
with key switch (1S1) in OFF position.
Turn key switch (1S1) in ON position:
After switching on the power for the Control panel BB-3 the following
functions are carried out and shown on the display:
4.1
Self-test and baud rate recognition:
The BB-3 automatically recognizes the rate
of data transmission from the MC electronics.
4.2
Identification:
On recognition of the MC electronics the
relevant software in the BB-3 will be started up.
4.3
Main menu:
Initialization of remote control unit BB-3 is complete.
One of the four main menu items can be selected using the given keys.
First screen (main menu) after connection and Key switch turned ON in German.
F1
F2
PROC
TE ACH
Language selection
To change the language press simultaneously
the buttons ALT + Clear
ALT
CLEAR
Config/Cal.
Diagnostic
Status
Storage
The language selection menu appears
F1
F2
PROC
TE ACH
Config/Cal.
Diagnostic
Status
Storage
continued
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and
7.2
Section 7.0
Page 32

Method B
Cont'd:
Language selection
Press button 2
The language will change to English

and the display show the main menu
1.
2.
3.
4.
Deutsch
English
- - - - -
One of the four main menu items can be selected using the given keys.
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33
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and
7.2
Section 7.0
Page 33

Method B
Adjustment mode SET 1 and SET 2
There are two adjustment modes (SET 1 and SET 2) integrated. SET 1 is for the main settings
and SET 2 is only for the basic adjustments. SET 2 can only activated with a password.
After start up of the MC7 with connected BB3 the adjustment modes SET 1 is active.
Main display SET 1
Standard after start up
F1
F2
PROC
TE ACH
Main display SET 2

Only with password.
Config/Cal.
Diagnostic
Status
Storage
F1
F2
PROC
TE ACH
Config/Cal.
Diagnostic
Status
Storage
F1
F2
PROC
TE ACH
Config/Cal.
Diagnostic
Status
Storage
Change from SET 1 to SET 2:

Press
F1
Press
ALT
SET 1
Config/Cal
in the same time
1
2
3
4
Demand Power
Max current
PID - Factor
Error Lamp
A password will be requested

Enter password (number: 570875)
1
Press
...
MENU
SET 2
to go back to the main menue
To switch back to SET 1 repeat this procedure

or switch off and on the MC7.
PC4000-6-E_#08165_Sec_7-0_rev0.doc
?: _
1
2
3
4
Configuration
PID Control
Low Voltage
F1
F2
PROC
TE ACH
Config/Cal.
Diagnostic
Status
Storage
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34
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and
7.2
Section 7.0
Page 34

Method B
Number of motor selection:
Activate adjustment mode SET 2 as
described on page 33
Press
F1
Press
Configuration
Press
No of motors
Config/Cal
F1
F2
PROC
TE ACH
Config/Cal.
Diagnostic
Status
Storage
1
2
3
4
Configuration
PID Control
Low Voltage
1
2
3
4
No of valves
No of motors
Select desired number of motors
No of motors
use
motor
No of motors
motors
1
2
3
4
No valves
No motors
Press
or
ENTER Acceptation
Press. 2 x MENU Return to sub menu.
F1
F2
PROC
TE ACH
Config/Cal.
Diagnostic
Status
Storage
Save setting to the EEPROM of the MC7 as described at page 38.
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and
7.2
Section 7.0
Page 35
7.2.3 Checks and adjustments Micro-controller MC7, illustration (Z 22357f)

Method B
X1-Pressure (maximum current) Adjustment:
F1
Press
Config/Cal
If sub menu SET 2 is displayed change to

sub menu SET 2 as described on page 33.
Press
Max current
F1
F2
PROC
TE ACH
Config/Cal.
Diagnostic
Status
Storage
1
2
3
4
Demand Power
Max current
PID - Factor
Error Lamp
1
2
3
4
Valve
Valve
Valve
Valve
Select desired valve

Press
or
Press
Valve 1, Motor1
Valve 1, Motor2
Example Motor 1, Valve1

Start the respective motor. Do not load the motor.
Check the X1-pressure with a pressure gauge and set
it to the desired value by:
pressing
Press
or
ENTER
Press. 2 x
Acceptation
MENU
Return to main menu
1
2
1
2
Mot.
Mot.
Mot.
Mot.
1
1
2
2
1 Valve 1 Mot. 1
0 1001
71
1 Valve 1 E1
0 1001
78
1
2
3
4
Valve
Valve
Valve
Valve
F1
F2
PROC
TE ACH
1
2
1
2
Mot.
Mot.
Mot.
Mot.
1
1
2
2
Config/Cal.
Diagnostic
Status
Storage
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36
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and
7.2
Section 7.0
Page 36

Method B
Demanded power adjustment:
Press
F1
Config/Cal

Press
Configuration
1
2
3
4
Demand Power
Max current
PID-Factor
Error Lamp
1
2
3
4
Set demand m.
Set demand m.
Demand power
Demand power
Select desired demand power adjustment

Press
or
Press
SET 1
demand power Motor1
demand power Motor2
1
2
1
2
1 Set demand m. 1
001
0
Example Motor 1
and
Load respective Motor with max power
Press ENTER
Selection
Start?
> <ENTER>
Cancel?
> <ENTER>
Press ENTER
Starting
Function ended
Saved
Press <ENTER>
Press ENTER Confirm

Press. 2 x
MENU
Return to main menu
F1
F2
PROC
TE ACH
Config/Cal.
Diagnostic
Status
Storage
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37
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and
7.2
Section 7.0
Page 37
7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22636a)

Method B
PID-Factor adjustment:
Jerky movements while lifting with full bucket and swinging at the same time:
Reduce jerking Reduce the PID-Factor in short steps.
To obtain the most efficient pump regulation characteristic adjust to the PID-Factor until
the system jerks as close as possible to the boarder line.
Press
F1
F1
F2
PROC
TE ACH
Config/Cal

SET 1
Press
PID-Factor.
Press
PID-Factor.
Adjust the PID-Factor

by pressing .
or
Press
ENTER
Acceptation
and check the machine movement again

if necessary repeat PID-Factor adjustment
Press. 2 x
MENU
Return to main menu.
Config/Cal.
Diagnostic
Status
Storage
1
2
3
4
Demand Power
Max current
PID-Factor
Error Lamp
1
2
3
4
PID-Factor
1 PID-Factor
801201%
100
1
2
3
4
PID-Factor
F1
F2
PROC
TEACH
Config/Cal.
Diagnostic
Status
Storage
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38
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and
7.2
Section 7.0
Page 38

Method B
Storage all new settings to the MC7:
This menu item permits storage of all edited parameters to the EEPROM
of the MC electronics
Activate storage menu
F1
F2
PROC
TE ACH
Save Params
1
2
3
4
Press ENTER
Store parameters
Teach?
> <ENTER>
Cancel?
> <ENTER>
Press. MENU
Return to main menu.
1
2
3
4
Press TEACH
Press
Config/Cal.
Diagnostic
Status
Storage
Save Params
Default Rarams
Get EEPROM
Send EEPROM
Save Params
Default Rarams
Get EEPROM
Send EEPROM
If all adjustments are correct and stored in the MC7, proceed as follow:
Stop the motors and turn key switch (S1) in OFF position
Disconnect the electronic service tool (BB-3) and the pressure gauges.
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39
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and
7.2
Section 7.0
Page 39

Method C -
With a laptop computer and BODEM software connected to the

serial interface X13 (located in the operators cab)
Pre-conditions: Normal operating temperature, correct pilot pressure
setting and the system must be free of air.
Starting the program
1. Connect the laptop computer to the data link adapter X13,
with key switch (1S1) in OFF position.
2. Make sure that the dongle is connected to the laptop computer. If not
3. Turn key switch (1S1) in ON position.

4. Start the computer.
5. Click on the Bodem - icon to start the program.
continued
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40
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and
7.2
Section 7.0
Page 40

Method C
Cont'd:
Starting the program
6. The program starts (only) the first time with the Demo Version.
7. Open menu FILE INTERFACE , select the required interface connection

(Standard COM1), confirm with OK and leave the program.
8. Start the program again. Now the computer is connected to the Microcontroller.
During uploading of the MC7 data to the PC a window opened and shows some
hardware and software information.
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41
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and
7.2
Section 7.0
Page 41

Method C
Language selection
Open menu FILE Language , select the required language and confirm with OK .
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42
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and
7.2
Section 7.0
Page 42

Method C
Entering of the password:
The password is only required to adjust the number of valves or

engines and for fine tuning of special regulation parameters. All other
adjustments are possible without the password.
Open menu Parameters and select Enter password. Write the correct password (570875)
and confirm with OK.
After entering a correct password and confirming with OK the

BODEM software start a new upload from the MC7 memory to the PC.
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43
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and
7.2
Section 7.0
Page 43

Method C
Number of Motor selection:
Pre condition: The correct password was entered as described on page 42.
Open Parameters and select Display / Edit Parameters. Then select in the left window
Configuration. Now on the right side there are two pull down menus.
Example: select for PC 8000 1 valve per motor and 2 Motors.
Write new setting permanent to the MC7 EEPROM with Apply and confirm with OK.
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44
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and
7.2
Section 7.0
Page 44

Method C
X1-Pressure (maximum current) Adjustment:
Make sure the change over valve is in position Electronic Pump Regulation
Connect a pressure gauge to check point M5.1, using a long pressure gauge hose to be able
reading the pressure inside the operators cab.
Open menu Parameters select Display/Edit parameters and Max current,
start the motor without load and wait 30 sec. The X1-pressure will raise to the max. adjusted
value. If necessary adjust the required pressure (according to the final test report or hydraulic
diagram) with the slide bar. (Valve 1 Mot. 1 is the X1 pressure).
Write new setting permanent to the MC7 EEPROM with Apply and confirm with OK.
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45
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and
7.2
Section 7.0
Page 45

Method C
Demand power adjustment:
The adjustment has to be carried out separately for each motor
Pre-conditions: Normal operating temperature, correct pilot pressure setting and the
system must be free of air.
Open menu Parameters and in the pull down window the menu point Display / Edit
Parameters. Now the window with the demand power adjustment will be on screen.
Screen with password

Screen without password.
The demand power adjustment is possible in both modes.
continued
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46
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and
7.2
Section 7.0
Page 46

Method C
Cont'd:
Pre-conditions: Normal operating temperature, correct pilot pressure setting and the system
must be free of air.
1.
2.
3.
4.
5.
6.
7.
8.
Connect pressure gauges to check points M11, M12, M13 and M14 at the
high pressure filters.
Connect a pressure gauge to the X1 pressure check point M5.1.
Unplug solenoid valves Y6a and Y6b to ensure that the hydraulic oil cooler
fans are running with maximum speed.
Shift the three way cock valve (253.1) to position Hydraulic (constant)
Regulation Mode.
Start the motor.
Set the MRVs of main valve block I, II, III and IV individually to approx. 120
bar *, to prevent the motor from overloading during the test.
Set the X1-pressure at pressure reducing valve (253.2) > 34 bar **, to ensure
that the pumps remain in Q-max. flow position during the adjustment.
Apply max. load to all pumps (e.g. extend the bucket cylinders to the stop
position until the hydraulic system stalls), and increase the pressure at all 4
MRVs * equally to the demand power pressure written in the final test report
e.g. PC4000, S/N 08165 = 172 bar. Check the current drawn of the respective
motor at this stage (reading of text display)
Expected: approx. ~ 128 Ampere. Record this values for other tests.
continued
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47
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and
Section 7.0
Page 47
7.2 Electronic Pump Regulation System

Method C
Cont'd:
9.
Select Execute of menu point Set demand m. 1 for motor 1 .

Select Start to set the actual power as demand power. Confirm with OK. The
new actual demand power will be only shown after a new upload of the MC7
settings. Exit the BODEM software and start again.
10. Stop the motor.
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48
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and
7.2
Section 7.0
Page 48

7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22636b)
Method C
PID Factor adjustment:
This adjustment is required to obtain the most efficient pump regulation characteristic.
Pre-conditions: Normal operating temperature, correct pilot pressure setting and the
system must be free of air.
With the PID-Factor adjustment (proportional, integral and
differential factors) it is possible to influence the regulation dynamics.
This factor is multiplied with all PID parameters.
Only one factor / adjustment for both motors
Open Parameters and select Display / Edit Parameters. Select in the left window PID
control. Adjust now the PID-Factor with the slide bar or write direct the requested
value to the window with the % value. Write new adjustment permanent to the MC7
EEPROM with Apply and confirm with OK.
Jerky movements while lifting and swinging at the same time: Reduce the PID-Factor in
short steps until the system works smoothly. (As close as possible to the boarder line)
No Jerky movements:
1. Increase the PID-Factor in short steps until the system jerks. (As close as possible to the
boarder line)
2. Now reduce the PID-Factor in short steps until the system works smoothly again.
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49
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and
7.3
Section 7.0
Page 49

7.3.1. General
The pilot pressure pump (8.1) delivers the oil through the pressure filter (33)
to port A of the pressure relief valve (252.2) for limiting the pump support
pressure X4 to 60 bar. By the function of pressure reducing valve (252.1), the
X4 pressure of 60 bar is reduced to the pilot pressure X2 of 45 bar. The
common X2 pressure will be reduced by the function of pressure reducing
valves (253.2) to the necessary constant X1 pressure, to prevent the motor from
overloading.
For testing purposes the pump regulation system can be changed to

the hydraulic operation mode. In case of a failure in the electronic
regulation system the hydraulic operation mode can also be used for
emergency operation.
The standard operation mode of the pump regulation system is the
Electronic Operation Mode.

(1 - 4) Main hydraulic pumps
(8.1)
Pilot pressure pumps
(33)
Pilot pressure filter unit
(252.2) 60 bar pressure relief valve
(252.1) 45 bar pressure reducing valve
(253.1) Change over valve: "Electronic or Hydraulic pump regulation"
(253.2) Pressure reducing valve: " Pump regulation pressure X1 at hydraulic
pump regulation" (Hydraulic constant regulation mode)
(Y61-1) Proportional solenoid valve: "Pump regulation pressure X1 at electronic
pump regulation " (Standard operation mode)
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50
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and
7.3
Section 7.0
Page 50

7.3.2. X1-pressure adjustment (constant-pressure), illustration (Z 22639f)
Connect pressure gauges to check points M11, M12, M13 and M14 at the
high pressure filters.
2. Connect a pressure gauge to the X1 pressure check point M5.1 .
3. Unplug solenoid valves Y6a and Y6b to ensure that the hydraulic oil cooler
fans are running with maximum speed.
4. Shift the three way cock valves (253.1) to position Hydraulic (constant)
Regulation Mode.
5. Start the motor.
6. Set the MRVs of main valve block I, II, III and IV individually to approx. 120
bar *, to prevent the motor from overloading during the test.
7. Set the X1-pressure at pressure reducing valve (253.2) to approx. 11 bar **
8. Apply max. load to all pumps (e.g. extend the bucket cylinders to the stop
position until the hydraulic system stalls), and increase the pressure at all 4
MRVs * equally to 260 bar.
Check the current drawn of the motor at this stage (reading of text display)
Expected approx. 120 Ampere. Record this values for other tests.
9. Shift the three way cock valves (253.1) to position Electronic regulation.
10. Reset the MRVs * to 310 bar+5bar , stop the motor and remove the gauges.
1.

Remove dust cap (d).
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Operating Hydraulic
Section 8.0
Page 1

Section
8.0
Page
Operating Hydraulic
General
8.1
Hydraulic for the attachment cylinder FSA and BHA
8.2
Hydraulic for the swing circuit
8.3
Hydraulic for the travel circuit
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8.0
2
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Operating Hydraulic
8.0
Section 8.0
Page 2
General
Overall view of the Hydraulic system, illustration (Z 21955):
(1 4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Main pumps
High pressure filters
Main control blocks
Attachment cylinders
Swing motors
Rotary joint
Travel motors
General information
The control blocks, the piping to the distributor manifold and the connecting
hoses to the attachment are different between the Backhoe Attachment (BHA)
and the Front Shovel Attachment (FSA). If a conversion is required, contact
the service department for further information.
Function:
Study together with the circuit diagram.

The following numbering refers to the hydraulic circuit diagram.
Each main pump (1 to 4) delivers oil trough the high pressure filter (13.1 to
13.4) to port P of the main control blocks (I to IV).
This results in four main circuits.
If all spools of the control blocks (I to IV) are in neutral position, the oil
leaves the block at port T and returns via return oil pipes, return oil collector
manifold (107), return oil pipes (L6 and L7), return oil collector tube (54),
back pressure valve (55) and the return oil filters (49.1 - 49.4) into the tank.
The function of back pressure valve (55) ensures:
- sufficient oil supply for all anticavitation valves
- and that sufficient oil is forced through the oil coolers.
If a control lever or pedal is actuated, pilot pressure oil moves the spools of the
control blocks, directing the oil flow from the main pumps to one side of the
user (either cylinders or motors). From the opposite side of the user the oil
returns to the control block and from there via the return oil circuit back into
the tank.
Each circuit is provided with one MRV (also called primary valve, at least one
SRV (also called secondary valve) and at least one flow restrictor.
continued
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8.0
3
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Operating Hydraulic
8.0
Section 8.0
Page 3
General
Cont'd:
Floating function of boom and stick cylinders FSA:
illustration (Z 22005):
The Excavator operates automatically with the float position for boom and stick
activated.
That means the lowering movement of boom and stick is always done in the float
position.
For deactivation of the float position, two push buttons are installed:
a) S95 in the right joy stick (E19) for the Boom function
b) S95a in the left joy stick (E20) for the Stick function
Press the respective button and keep it depressed as long as the float position shall
be deactivated.
When releasing the button the float position is activated again.
Function:
The additionally installed single control blocks (Y132, Y133,Y134 and Y135)
connect the piston side of the cylinders with the rod side and also with the tank:
Y132, Y133 and Y134 for the Stick cylinders
Y135 for the Boom cylinders
In normal operation mode (i.e. float position) the pilot pressure oil is directed via
Y132a, Y133a and Y135a to the single control blocks when lowering the boom
or stick.
If a pressurised lowering of the cylinders is required the pilot pressure oil is
directed via Y132a, Y133a and Y135a to the main control blocks.
The solenoid valves Y132a, Y133a and Y135a (4/2-directional control valves) are
controlled by push button S95 and S95a.
Boom: S95 ON Y135a ON
Float position deactivated

S95 OFF Y135a OFF
Float position activated

S95a ON Y132a + Y133a ON
S95a OFF Y132a + Y133a OFF
Stick:

Due to the two different operation modes for lowering, the lowering
speed of boom and stick cylinder must be adjusted twice:
A. Float position deactivated
B. Float position activated
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Hydraulic for the

Attachment Cylinders
Section 8.1
Page 1

Section
8.1
Page
Hydraulic for the attachment cylinder FSA and BHA
8.1.1 Electric / Hydraulic Flowchart Boom raising
8.1.2 Electric / Hydraulic Flowchart Boom lowering
8.1.3 Electric / Hydraulic Flowchart Stick extending
8.1.4 Electric / Hydraulic Flowchart Stick retracting
8.1.5 Electric / Hydraulic Flowchart Bucket filling (curl)
8.1.6 Electric / Hydraulic Flowchart Bucket emptying
8.1.7 Electric / Hydraulic Flowchart Clam opening
8.1.8 Electric / Hydraulic Flowchart Clam closing
8.1.9 Checks and adjustments of the
Main Relief Valves (Primary valves)
8.1.10 Checks and adjustments of the
Service Line Relief Valves (Secondary valves)
Boom cylinder piston side FSA + BHA
Boom cylinder piston rod side FSA + BHA
Stick cylinder piston side FSA
Stick cylinder piston side BHA
Stick cylinder piston rod side FSA
Stick cylinder piston rod side BHA
Bucket cylinder piston side FSA
Bucket cylinder piston side BHA
Bucket cylinder piston rod side FSA
Bucket cylinder piston rod side BHA
Clam cylinder piston rod side FSA
Clam cylinder piston side FSA
8.1.11 Checks and adjustments for the lowering speed.
General: Flow Restrictors and single control blocks
Boom cylinder FSA (Float position activated / deactivated)
Boom cylinder BHA
Stick cylinder FSA (Float position activated / deactivated)
Stick cylinder BHA
Bucket cylinder FSA
Bucket cylinder BHA
Clam cylinder
PC4000-6-E_#08165_Sec_8-1_rev0.doc
2+3
4+5
6+7
8+9
10 + 11
12 + 13
14
15
16 + 17
18 + 19
20 + 21
22 + 23
24 + 25
26 + 27
28 + 29
30 + 31
32 + 33
34 + 35
36 + 37
38
39
40
41 + 42
43
44 + 45
46
47
48
49
02.03.05
8.1
2
E19
D32
gn
YD
X2
482
X2
481
E49
Bucket
(boom up)
10
K58
-10V
K76
K78
12
(left crawler)
6
10
(right crawler)
A10b
A10
A10a
A10c
7-8
7-8
7-8
7-8 3
X2
235
X2
234
207
206
X2
226
X2
225
251
250
15
14.2
Y73
b1
b2
b3
b1
b2
b3
b4
I B1 B2
B3
II B1
B2
B3
B4
A1
A2
A3
A4
a1
a2
a3
a4
Y69
A1
a1
A2
a2
Y33
95
1
A3
a3
14.3
14.1
Y40
Y63
b1
b2
III B1 B2
A1
A2
a1
G
a2
L
Y76
Y20
Y46
b3
b1
b2
b3
b4
B3
IVB1
B2
B3
B4
A3
A1
A2
A3
A4
a1
a2
a3
a4
a3
M
42
Z 21956
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Hydraulic for the

Section 8.1
Page 2
8.1.1 Electric / Hydraulic flowchart Boom raising FSA

(E19)
Control lever (Joy stick)
(D32)
Time relay Pilot control: Neutral position monitoring
(YD)
Direction (axis) of joy stick
(-10V)
Signal voltage (Maximum)
(gn)
Colour code of signal voltage cable ( Joy stick)
(X2...)
Terminal rail with number
(E49)
Ramp time module
(A10)
Amplifier module Boom
(A10a)
(A10b)
Amplifier module Boom up or Bucket when not raising
the boom.
(A10c)
(K58)
Relay pilot control:
Contacts 6 / 10 only closed while lifting the boom.
(K76)
Contacts 8 / 12 only closed while traveling the left crawler.
(K78)
Contacts 6 / 10 only closed while traveling the right crawler.
(14.1 14.3)
(15)
(95)
(Y63 + Y69)
Proportional solenoid valve
(Y73 + Y76)
(Y20 + Y40)
(Y33 + Y46)
(I IV)
Main control blocks I IV
(42)
Electrical signal flow.
Signal voltage of joy stick (E19) arrives via ramp time module (E49) at
terminal 5 of the amplifier modules (A10 to A10c) and further to the
proportional and directional solenoid valves of the remote control blocks (14.1,
14.2, 14.3, and 15).
Hydraulic signal flow. (pilot pressure)
When the proportional and directional solenoid valves are energized pilot
pressure oil flows to the pilot pressure ports of the main control blocks.
Hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (I to IV)
and arrives via distributor manifold (42) at the hydraulic cylinders.
PC4000-6-E_#08165_Sec_8-1_rev0.doc
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8.1
3
PC4000-6-E_#08165_Sec_8-1_rev0.doc
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Hydraulic for the

Section 8.1
Page 3
8.1.1 Electric / Hydraulic flowchart Boom raising BHA

(E19)
(YD)
(-10V)
(gn)
(X2...)
(E49 E49c)
Ramp time module
(A10)
(A10a)
(A10b)
(A10c)
(K76)
(K78)
(14.1 14.3)
(15)
(Y63 + Y69)
(Y73 + Y76)
(Y40)
(Y33 + Y46)
(I IV)
(42)
Signal voltage of joy stick (E19) arrives via ramp time modules (E49 to E49c)
at terminal 5 of the amplifier modules (A10 to A10c) and further to the
14.2, 14.3, and 15).
Hydraulic oil flow
PC4000-6-E_#08165_Sec_8-1_rev0.doc
02.03.05
8.1
4
YC
+10V
E19
D32
gn
X2
482
X2
481
E49
Bucket
K58
K76
10
(boom up)
K78
12
(left crawler)
6
10
(right crawler)
A10b
A10
A10a
A10c
7-8 9
7-8 9
7-8 9
7-8
X2 207 215
X2 226 227
X2F
X2 251 256
15
14.2
Y73
1
95
1
14.3
14.1
Y41
Y63
Y76
Y21
Y47
Y135a
b1
b2
b3
I B1 B2
B3
A1
a1
A2
a2
b1
b2
b3
b4
II B1 B2
B3
B4
A3
a3
b1
A1
A2
A3
A4
a1
a2
a3
a4
b2
III B1 B2
A1
A2
a1
G
a2
L
b1
b3
B3
A3
a3
M
b2
b3
b4
IVB1 B2
B3
B4
A1
A2
A3
A4
a1
a2
a3
a4
42
Y135
P
T B
PC4000-6-E_#08165_Sec_8-1_rev0.doc
Z 21958
02.03.05
Hydraulic for the

Section 8.1
Page 4
8.1.2 Electric / Hydraulic flowchart Boom lowering FSA

(E19)
(D32)
(YC)
(+10V)
(gn)
(X2...)
(E49)
Ramp time module
(A10)
(A10a)
(A10b)
Amplifier module Boom up or Bucket
(A10c)
(K58)
(K76)
(K78)
(14.1 14.3)
(15)
(95)
(Y63)
(Y73 + Y76)
(Y21 + Y41)
(Y47)
(Y135a)
(Y135)
Single control block
(I IV)
(42)
Signal voltage of joy stick (E19) arrives via ramp time module (E49) at terminal 5
of the amplifier modules (A10, A10a and A10c) and further to the proportional
and directional solenoid valves of the remote control blocks (14.1, 14.3, and 15).
When the proportional and directional solenoid valves are energized pilot pressure
oil flows to the pilot pressure ports of the main control blocks and single control
block (Y135).
Hydraulic oil flow
Now piston and piston rod side of the boom cylinders are connected, so that the
boom lowers only by gravity. The excess oil flows via distributor manifold (42)
through the main control blocks (II and III) and single control block (Y135) back
to tank.
PC4000-6-E_#08165_Sec_8-1_rev0.doc
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8.1
5
PC4000-6-E_#08165_Sec_8-1_rev0.doc
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Hydraulic for the

Section 8.1
Page 5
8.1.2 Electric / Hydraulic flowchart Boom lowering BHA

(E19)
(YC)
(+10V)
(gn)
(X2...)
(E49 E49c)
Ramp time module
(A10)
(A10a)
(A10b)
Amplifier module Boom up or Bucket
(A10c)
(K76)
(K78)
(14.1 14.3)
(15)
(Y63 + Y69)
(Y73 + Y76)
(Y21 + Y41)
(Y32 + Y47)
(I IV)
(42)
Signal voltage of joy stick (E19) arrives via ramp time modules (E49 to E49c)
at terminal 5 of the amplifier modules (A10 to A10c) and further to the
14.2, 14.3, and 15).
Hydraulic oil flow
PC4000-6-E_#08165_Sec_8-1_rev0.doc
02.03.05
8.1
6
YC
+10V
E20
D32
gn
X2
480
X2
479
E48
5
7
Bucket fill
K74
(Stick out)
K78
K76
7-8 9
5
A9
X2 237 236
X2 254 253
7-8 9
X2 210 203
14.2
Y68
A8a
10
14.3
15
Y30
Y71
Y74
b3
b1
b2
b3
b4
I B1 B2
B3
II B1
B2
B3
B4
A1
A2
A3
A4
A1
a1
a2
a3
a4
a1
A1
a1
A2
a2
A3
a3
b1
Y42
Y37
b2
b1
12
(left crawler)
(right crawler)
A8
7-8
b2
b3
b4
IVB1 B2
B3
B4
A2
A3
A4
a2
a3
a4
42
Y132
P
T B
Y133
Y134
T B
T B
Z 21960
PC4000-6-E_#08165_Sec_8-1_rev0.doc
02.03.05
Hydraulic for the

Section 8.1
Page 6
8.1.3 Electric / Hydraulic flowchart Stick extending FSA

(E20)
(D32)
(YC)
(+10V)
(gn)
(X2...)
(E48)
Ramp time module
(A8)
Amplifier module Stick
(A8a)
(A9)
Amplifier module Stick extend or Bucket fill
(K74)
Contacts 5 / 9 only closed while extending the stick.
(K76)
(K78)
(14.2 + 14.3)
(15)
(Y68)
(Y71 + Y74)
(Y30 + Y37)
(Y42)
(Y132 Y134)
Single control blocks (closed ports while extending the stick)
(I, II + IV)
(42)
of the amplifier modules (A8, A8a and A9) and further to the proportional and
directional solenoid valves of the remote control blocks (14.2, 14.3, and 15).
oil flows to the pilot pressure ports of the main control blocks .
Hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (I, II, IV)
PC4000-6-E_#08165_Sec_8-1_rev0.doc
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8.1
7
PC4000-6-E_#08165_Sec_8-1_rev0.doc
02.03.05
Hydraulic for the

Section 8.1
Page 7
8.1.3 Electric / Hydraulic flowchart Stick extending BHA

(E20)
(YC)
(+10V)
(gn)
(X2...)
(E48)
Ramp time module
(A8)
(A8a)
(A11)
(K76)
(K78)
(14.2 + 14.3)
(15)
(Y68)
(Y72 + Y74)
(Y30 + Y38)
(Y42)
(I, II + IV)
Main control blocks I, II + IV
(42)
Hydraulic oil flow
PC4000-6-E_#08165_Sec_8-1_rev0.doc
02.03.05
8.1
8
E20
D32
gn
YD
X2
480
X2
479
E48
-10V
5
7
Bucket fill
K74
(Stick out)
K78
K76
A8a
10
7-8 3
A9
14
X2F 51
7-8 9
14.2
Y68
Y31
Y74
Y132a
b3
I B1 B2
B3
A2
a2
Y43
Y133a
b1 b2
a1
52
14.3
A1
12
(left crawler)
X2F 10
(right crawler)
A8
7-8
99.5
A3
a3
b1
b2
b3
b4
IVB1
B2
B3
B4
A1
A2
A3
A4
a1
a2
a3
a4
42
Y132
P
T B
PC4000-6-E_#08165_Sec_8-1_rev0.doc
Y133
Y134
T B
T B
02.03.05
Z 21962
Hydraulic for the

Section 8.1
Page 8
8.1.4 Electric / Hydraulic flowchart Stick retracting FSA

(E20)
(D32)
(YD)
(-10V)
(gn)
(X2...)
(E48)
Ramp time module
(A8)
(A8a)
(A9)
Amplifier module Stick extend or Bucket fill
(K74)
(K76)
(K78)
(14.2 + 14.3)
(99.5)
Check valve (necessary for combined operation of travel
right and retracting the stick)
(Y68 + Y74)
(Y31 + Y43)
(Y132a + Y132a) Directional solenoid valve
(Y42)
(Y132 Y134)
Single control blocks (ports A-B-T connected while
retracting the stick)
(I + IV)
Main control blocks I + IV
(42)
of the amplifier modules (A8, A8a) and further to the proportional and directional
solenoid valves of the remote control blocks (14.2 and 14.3).
oil flows to the pilot pressure ports of the single control blocks (Y132, Y133 and
Y134).
Hydraulic oil flow
Now piston and piston rod side of the stick cylinders are connected, so that
the stick lowers only by gravity. The excess oil flows via distributor manifold
(42) through the single control blocks (Y132, Y133 and Y134) back to tank.
PC4000-6-E_#08165_Sec_8-1_rev0.doc
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8.1
9
PC4000-6-E_#08165_Sec_8-1_rev0.doc
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Hydraulic for the

Section 8.1
Page 9
8.1.4 Electric / Hydraulic flowchart Stick retracting BHA

(E20)
(YD)
(-10V)
(gn)
(X2...)
(E48)
Ramp time module
(A8)
(A8a)
(A11)
(K76)
(K78)
(14.2 + 14.3)
(15)
(Y68)
(Y72 + Y74)
(Y31 + Y39)
(Y43)
(I, II + IV)
Main control blocks I, II + IV
(42)
Hydraulic oil flow
PC4000-6-E_#08165_Sec_8-1_rev0.doc
02.03.05
8.1
10
E19
XB -10V
ws/gn
D32
X2
477
X2
476
10
K50
(Hydr. oil
not overheat )
K58
(Boom up )
10
K71
(Bucket fill )
K74
K58
K76
(Boom up )
(Bucket fill )
(Stick out )
K78
10
(left crawler)
10
K71
7
11
(right crawler)
A10b
A9
A9a
A9b
7-8 3
7-8 3
7-8 3
7-8 3
X2 235 230
X2 210 205
X2 224 220
X2 252 249
15
14.2
Y69
Y32
b1
b2
b3
b1
b2
b3
b4
I B1 B2
B3
II B1
B2
B3
B4
A1
A2
A3
A4
a1
a2
a3
a4
A1
a1
A2
a2
Y71
A3
a3
Y36
Y64
b1
b2
III B1 B2
A1
A2
a1
G
14.3
14.1
a2
L
Y22
Y75
Y44
b3
b1
b2
b3
b4
B3
IVB1
B2
B3
B4
A3
A1
A2
A3
A4
a1
a2
a3
a4
a3
M
42
PC4000-6-E_#08165_Sec_8-1_rev0.doc
02.03.05
Z 21965
Hydraulic for the

Section 8.1
Page 10
8.1.5 Electric / Hydraulic flowchart Bucket filling FSA

(E19)
(D32)
(XB)
(-10V)
(ws / gn)
(X2...)
(A9)
Amplifier module Bucket
(A9a)
(A9b)
(A10b)
Amplifier module Boom up or Bucket when not raising
the boom.
(K50)
Relay pilot control: Bucket cut-off
Contacts 6 / 10 only closed if the hydraulic oil is overheated.
(K58)
Contacts 6 / 10 and 5 / 9 only closed while lifting the boom.
(K71)
Contacts 6 / 10 and 5 / 9 only closed while filling the bucket.
(K74)
(K76)
(K78)
(14.1 14.3)
(15)
(Y63 + Y64)
(Y71 + Y75)
(Y22 + Y32)
(Y36 + Y44)
(I IV)
(42)
Signal voltage of joy stick (E19) arrives via relay contacts at terminal 5 of the
amplifier modules (A9, A9a, A9b and A10b) and further to the proportional and
directional solenoid valves of the remote control blocks (14.1, 14.2, 14.3, and 15).
Hydraulic oil flow
PC4000-6-E_#08165_Sec_8-1_rev0.doc
02.03.05
8.1
11
PC4000-6-E_#08165_Sec_8-1_rev0.doc
02.03.05
Hydraulic for the

Section 8.1
Page 11
8.1.5 Electric / Hydraulic flowchart Bucket filling BHA

(E19)
(XB)
(-10V)
(ws / gn)
(X2...)
(A9)
(A9a)
(A9b)
(K50)
(K76)
(K78)
(14.1 + 14.3)
(15)
(Y64)
(Y71 + Y75)
(Y22 + Y44)
(Y36)
(II, III + IV)
Main control blocks II, III + IV
(42)
amplifier modules (A9, A9a, A9b) and further to the proportional and directional
solenoid valves of the remote control blocks (14.1, 14.3, and 15).
Hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (II, III, IV)
PC4000-6-E_#08165_Sec_8-1_rev0.doc
02.03.05
8.1
12
E19
XA +10V
ws/gn
X2
477
X2
476
D32
10
K50
(Hydr. oil
not overheat )
K58
(Boom up )
K71
(Bucket fill )
K78
7
11
(right crawler)
A9a
A9b
7-8
7-8 9
X2 252 247
X2 224 218
14.3
14.1
1
Y64
b1 b2
A2
a1
A
Y23
b1
b3
III B1 B2
A1
a2
L
B3
b2
IVB1 B2
A3
a3
M
Y75
Y45
b3
b4
B3
B4
A1
A2
A3
A4
a1
a2
a3
a4
42
PC4000-6-E_#08165_Sec_8-1_rev0.doc
02.03.05
Z 21967
Hydraulic for the

Section 8.1
Page 12
8.1.6 Electric / Hydraulic flowchart Bucket emptying FSA

(E19)
(D32)
(XA)
(+10V)
(ws / gn)
(X2...)
(A9a)
(A9b)
(K50)
(K58)
(K71)
Contacts 5 / 9 only closed while filling the bucket.
(K78)
(14.1 + 14.3)
(Y64 + Y75)
(Y23 + Y45)
(III + IV)
Main control blocks III + IV
(42)
amplifier modules (A9a and A9b) and further to the proportional and directional
solenoid valves of the remote control blocks (14.1 and 14.3).
Hydraulic oil flow
PC4000-6-E_#08165_Sec_8-1_rev0.doc
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8.1
13
PC4000-6-E_#08165_Sec_8-1_rev0.doc
02.03.05
Hydraulic for the

Section 8.1
Page 13
8.1.6 Electric / Hydraulic flowchart Bucket emptying BHA

(E19)
(XA)
(+10V)
(ws / gn)
(X2...)
(A9)
(A9a)
(A9b)
(K50)
(K76)
(K78)
(14.1 + 14.3)
(15)
(Y64)
(Y71 + Y75)
(Y23 + Y45)
(Y37)
(II, III + IV)
Main control blocks II, III + IV
(42)
amplifier modules (A9, A9a, A9b) and further to the proportional and directional
solenoid valves of the remote control blocks (14.1, 14.3, and 15).
Hydraulic oil flow
PC4000-6-E_#08165_Sec_8-1_rev0.doc
02.03.05
8.1
14
E24
D32
-10V
rs
X2 484
K76
7
11
(left crawler)
A11
7-8
X2
209 214
15
Y72
b1
b2
II B1 B2
b3
b4
B3
B4
A1
A2
A3
A4
a1
a2
a3
a4
Y39
42
Z 21970
PC4000-6-E_#08165_Sec_8-1_rev0.doc
02.03.05
Hydraulic for the

Section 8.1
Page 14
8.1.7 Electric / Hydraulic flowchart Clam opening FSA

(E24)
Control pedal
(D32)
(-10V)
(rs)
(X2...)
(A11)
Amplifier module Clam
(K76)
(15)
(Y72)
(Y39)
(II)
Main control block II
(42)
Signal voltage of control pedal (E24) arrives via relay contact at terminal 5 of the
amplifier module (A11) and further to the proportional and directional solenoid
valves of the remote control block (15).
oil flows to the pilot pressure port of the main control block .
Hydraulic oil flow
Now the oil of the main pump flows through the main control block (II) and
arrives via distributor manifold (42) at the hydraulic cylinders.
PC4000-6-E_#08165_Sec_8-1_rev0.doc
02.03.05
8.1
15
E23
D32
+ 10V
rs
X2 484
K76
7
11
(left crawler)
A11
7-8 9
X2
209 208
15
Y72
b1
b2
II B1 B2
A1
a1
A
A2
a2
D
b3
b4
B3
B4
A3
A4
a3
E
Y38
a4
F
42
Z 21971
PC4000-6-E_#08165_Sec_8-1_rev0.doc
02.03.05
Hydraulic for the

Section 8.1
Page 15
8.1.8 Electric / Hydraulic flowchart Clam closing FSA

(E23)
Control pedal
(D32)
(+10V)
(rs)
(X2...)
(A11)
Amplifier module Clam
(K76)
(15)
(Y72)
(Y38)
(II)
Main control block II
(42)
Signal voltage of control pedal (E23) arrives via relay contact at terminal 5 of the
amplifier module (A11) and further to the proportional and directional solenoid
valves of the remote control block (15).
oil flows to the pilot pressure port of the main control block .
Hydraulic oil flow
Now the oil of the main pump flows through the main control block (II) and
arrives via distributor manifold (42) at the hydraulic cylinders.
PC4000-6-E_#08165_Sec_8-1_rev0.doc
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8.1
16
PC4000-6-E_#08165_Sec_8-1_rev0.doc
02.03.05
Hydraulic for the

Section 8.1
Page 16
8.1.9 Checks and adjustments of the Main Relief Valves (MRV), illustration (Z 21972):
There are four main relief valves (primary valves) installed, one in each main
control block, to limit the maximum pump supply line pressure (operating
pressure).
Pump circuit I
MRV in
control block
I
Check
point
M14
Pump circuit II
II
M12
Boom
Pump circuit III

Pump circuit IV
III
IV
M11
M13
Swing
Boom Bucket
Functions FSA
Swing
Clam
Bucket filling
Boom raise
Bucket filling
Stick extending
Bucket
Stick
Stick
Travel
Boom
Travel
Each Pump circuit can be checked or adjusted individually by selecting one

function of the required pump circuit.
Checking:
1.
Connect the gauge to the required check point M11 - M14.
2.
Start engine and let it run with max. speed.
3.
Extend or retract the cylinder to the stop position for the valve being
tested until the hydraulic system stalls.
4.
Read the pressure. Required: 310 + 5 bar
If the pressure is not correct, carry out a comparative measurement with an
other function, in order to avoid wrong measuring results caused by
wrongly adjusted SRV or other defects in the system.
Adjusting:
1.
Remove protective cap (a).
2.
3.
Turn set screw (c) -clockwise to increase pressure, Counterclock wise to decrease pressure.
4.
Tighten lock nut (b) and install cap (a).
It is important that the valve body of MRV-valve and the SRV-valve

are firmly tightened (with 300 Nm).
Otherwise, the internal sealing is not properly which results in loud
flow noises and wrong adjustments.
PC4000-6-E_#08165_Sec_8-1_rev0.doc
02.03.05
8.1
17
PC4000-6-E_#08165_Sec_8-1_rev0.doc
02.03.05
Section 8.1
Page 17
Hydraulic for the

8.1.9 Checks and adjustments of the Main Relief Valves (MRV), illustration (Z 21972):
There are four main relief valves (primary valves) installed, one in each main
control block, to limit the maximum pump supply line pressure (operating
pressure).
Pump circuit I
Pump circuit II
Pump circuit III
Pump circuit IV
MRV in
control block
I
II
III
IV
Check
point
M14
M12
M11
M13
Functions BHA
Swing
Boom
Stick
Swing
Boom Bucket
Boom
Bucket
Bucket
Stick
Stick
Travel
Boom
Travel
Each Pump circuit can be checked or adjusted individually by selecting one

function of the required pump circuit.
Checking:
1.
Connect the gauge to the required check point M11 - M14.
2.
3.
Extend or retract the cylinder to the stop position for the valve being
tested until the hydraulic system stalls.
4.
Read the pressure. Required: 310 + 5 bar
If the pressure is not correct, carry out a comparative measurement with an
other function, in order to avoid wrong measuring results caused by
wrongly adjusted SRV or other defects in the system.
Adjusting:
1.
Remove protective cap (a).
2.
3.
Turn set screw (c) -clockwise to increase pressure, Counterclock wise to decrease pressure.
5.
Tighten lock nut (b) and install cap (a).

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18
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Checks and adjustments of the Service Line Relief Valves (SRV),

Boom cylinder Piston side FSA + BHA
There are six service line relief valves (secondary valves) installed, four at
the distributor manifold (42), one in main control block II and one in block
IV, to limit the maximum possible pressure peaks in the service line.
Since the opening pressure of the SRVs is higher than the setting of the Main
Relief Valves (MRVs) it is necessary to increase the main relief pressure for
testing and adjusting purposes.
Valve
SRV 66.5
SRV 66.7
SRV 65.4
SRV 70.13
SRV 70.2
SRV 70.1
MRV circuit II
MRV circuit IV
1.
2.
3.
4.
Press. check point

M12 (High pressure filter)
M26.2
M26.1
M16.2
M16.1
Location
Control block II, section A1
Control block IV, section A1
Manifold (42) section O
Manifold (42) section O
Manifold (42) section B
Manifold (42) section B
Control block II
Control block IV
Connect gauges to all above listed check points.

Extend the boom cylinder to the stop position until the hydraulic
system stalls.
Increase slowly the pump supply line pressure, by turning in set screws (3)
of both MRVs in control block II and IV, while observing the
pressure gauges. Stop as soon the pressure does not raise any further.
The gauge pointers should remain at 350 bar + 5 bar.
Since the piston side of the boom cylinders are protected by several
SRVs, the pressure gauges show the pressure of that valve with the
lowest setting.
Even when the gauges show the required pressure it is possible that
one or more valves have a higher setting.
To ensure that only the SRVs open during checks and adjustments
it is necessary to further increase the setting of both MRVs.
5.
6.
7.
8.
PC4000-6-E_#08165_Sec_8-1_rev0.doc
Remove protective cap (1) of MRV.

Loosen lock nut (2).
Turn set screw (3) of both MRVs turn further in, the gauge
pointers will remain at the value shown at item #4 (350 bar + 5 bar).
Tighten lock nut (2) and install cap (1).
continued
02.03.05
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19
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Section 8.1
Page 19

Cont'd:
Boom cylinder Piston side FSA +BHA
9.
Adjust all six SRVs equally, until all gauges show a pressure of
360 bar.
Adjust in steps of turn of set screw (3) in the following sequence:
70.1 70.2 70.13 65.4 66.5 66.7
Remove protective cap (1) of SRVs.
Turn set screw (3) -clockwise to increase pressure, Counter-clock
wise to decrease pressure.
10.
Reduce the pressure, at SRV- 70.1 to a value below the required value,
and then increase up to the required pressure (350 bar), while
observing
all gauges.
)
11.
12.
Now all gauges will show the same value of 350 bar,
but only SRV-70.1 has the correct setting.
Proceed with the other valves in the same manner in the following
sequence:
70.2 70.13 65.4 66.5 66.7
Strong pulsation of the return line hoses, indicates deviation in

opening pressure of SRVs and must be avoided.
Repeat the adjusting procedure until the oil returns well-balanced
via all six service line relief valves.
Reset the MRVs to 310 bar + 5 bar after the check / adjustment is finished,
as follows:
Remove protective cap (1).
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Boom cylinder Piston rod side FSA +BHA
There are service line relief valves (secondary valves) installed in the main
control blocks, to limit the maximum possible pressure peaks in the service line.
Valve
SRV 66.3
SRV 66.8
MRV circuit III
MRV circuit IV
1.
2.
3.
4.
Press. check point

Location
Control block III, section B3
Control block IV, section B1
Control block III
Control block IV

Retract the boom cylinder to the stop position until the hydraulic
system stalls.
of MRVs in the control blocks, while observing the pressure gauges.
Stop as soon the pressure does not raise any further.
If the piston rod side of the boom cylinders are protected by several
lowest setting.
5.
6.
7.
8.

continued
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21
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Section 8.1
Page 21

Cont'd:
Boom cylinder Piston rod side FSA +BHA
9.
Adjust all SRVs equally, until all gauges show a pressure of 360 bar.
Adjust in steps of turn of set screw (3).
10.
observing
all gauges.
)
11.
12.
Proceed with the other valves in the same manner.

via all service line relief valves.
as follows:
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Stick cylinder Piston side FSA
There are four service line relief valves (secondary valves) installed, three at
the distributor manifold (42) and one in main control block IV, to limit the
maximum possible pressure peaks in the service line.
Valve
SRV 66.11
SRV 65.2
SRV 70.8
SRV 70.9
MRV circuit IV
1.
2.
3.
4.
Press. check point

M20
M21.1
M21.2
Location
Manifold (42) section G
Manifold (42) section J
Control block IV

Extend the stick cylinder to the stop position until the hydraulic
system stalls.
of the MRV in control block IV, while observing the pressure gauges.
Since the piston side of the stick cylinders are protected by several
lowest setting.
it is necessary to further increase the setting of the MRVs.
5.
6.
7.
8.
PC4000-6-E_#08165_Sec_8-1_rev0.doc

Turn set screw (3) of the MRV turn further in, the gauge
continued
02.03.05
8.1
23
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Section 8.1
Page 23

Cont'd:
Stick cylinder Piston side FSA
9.
Adjust all four SRVs equally, until all gauges show a pressure of
360 bar.
65,2 70.8 70.9 66.11
10.
observing
all gauges.
)
11.
12.
sequence:
70.8 70.9 66.11

via all four service line relief valves.
Reset the MRV to 310 bar + 5 bar after the check / adjustment is finished,
as follows:
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24
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Page 24

Stick cylinder Piston side BHA
There are three service line relief valves (secondary valves) installed, in main
control blocks I, II and IV, to limit the maximum possible pressure peaks in
the service line.
Valve
SRV 66.4
SRV 66.6
SRV 66.12
MRV circuit I
MRV circuit II
MRV circuit IV
1.
2.
3.
4.
Press. check point

Location
Control block I, section B3
Control block II, section B2
Control block I
Control block II
Control block IV

Retract the stick cylinder to the stop position until the hydraulic
system stalls.
of the MRVs in the control blocks, while observing the pressure gauges.
Since the piston side of the stick cylinders are protected by several
lowest setting.
5.
6.
7.
8.
PC4000-6-E_#08165_Sec_8-1_rev0.doc

Turn set screw (3) of the MRVs turn further in, the gauge
continued
02.03.05
8.1
25
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Section 8.1
Page 25

Cont'd:
Stick cylinder Piston side BHA
9.
Adjust all three SRVs equally, until all gauges show a pressure of
360 bar.
66,4 66.6 66.12
10.
observing
all gauges.
)
11.
12.
sequence:
66.6 66.12

via all three service line relief valves.
Reset the MRV to 310 bar + 5 bar after the check / adjustment is finished,
as follows:
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26
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Section 8.1
Page 26

Stick cylinder Piston rod side FSA
There are two service line relief valves (secondary valves) installed, in main
control blocks I and IV, to limit the maximum possible pressure peaks in the
service line.
Valve
SRV 66.4
SRV 66.12
MRV circuit I
MRV circuit IV
1.
2.
3.
4.
Press. check point

Location
Control block I, section B3
Control block I
Control block IV

system stalls.
Since the piston rod side of the stick cylinders are protected by
several SRVs, the pressure gauges show the pressure of that valve
with the lowest setting.
5.
6.
7.
8.

continued
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27
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Section 8.1
Page 27

Cont'd:
Stick cylinder Piston rod side FSA
9.
Adjust both SRVs equally, until all gauges show a pressure of
360 bar.
66,4 66.12
10.
and then increase up to the required pressure (350 bar), while observing
all gauges.
)
11.
12.
Proceed with the other valves in the same manner.

as follows:
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28
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Page 28

illustration (Z 21980a):
Stick cylinder Piston rod side BHA
There are three service line relief valves (secondary valves) installed at the
distributor manifold (42), to limit the maximum possible pressure peaks in the
service line.
Valve
SRV 70.8
SRV 70.9
SRV 70.10
MRV circuit I
1.
2.
3.
4.
Press. check point

M21.1
M21.2
M22
Location
Manifold (42) section K
Control block I

system stalls.
Since the piston rod side of the stick cylinders are protected by
5.
6.
7.
8.

continued
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29
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Section 8.1
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illustration (Z 21980a):
Cont'd:
Stick cylinder Piston rod side BHA
9.
Adjust all SRVs equally, until all gauges show a pressure of
360 bar.
70.8 70.9 70.10
10.
all gauges.
)
11.
12.
sequence:
70.9 70.10

as follows:
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30
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Page 30

Bucket cylinder Piston side FSA
There are six service line relief valves (secondary valves) installed, four at
the distributor manifold (42), one in main control block III and one in block
IV, to limit the maximum possible pressure peaks in the service line.
Valve
SRV 66.1
SRV 66.9
SRV 65.1
SRV 70.4
SRV 70.12
SRV 65.3
MRV circuit III
MRV circuit IV
1.
2.
3.
4.
Press. check point

M17.1
M17.2
M24
M25
Location
Control block III, section A2
Manifold (42) section C
Manifold (42) section M
Manifold (42) section N
Control block III
Control block IV

Extend the Bucket cylinder to the stop position until the hydraulic
system stalls.
of both MRVs in control block III and IV, while observing the
pressure gauges. Stop as soon the pressure does not raise any further.
Since the piston side of the bucket cylinders are protected by several
lowest setting.
5.
6.
7.
8.
PC4000-6-E_#08165_Sec_8-1_rev0.doc

continued
02.03.05
8.1
31
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8.1.10
Section 8.1
Page 31

Cont'd:
Bucket cylinder Piston side FSA
9.
Adjust all six SRVs equally, until all gauges show a pressure of
360 bar.
65.1 70.4 70.12 65.3 66.1 66.9
10.
observing
all gauges.
)
11.
12.
sequence:
70.4 70.12 65.3 66.1 66.9

via all six service line relief valves.
as follows:
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32
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Section 8.1
Page 32

Bucket cylinder Piston side BHA
service line.
Valve
SRV 70.3
SRV 70.4
SRV 70.12
MRV circuit III
1.
2.
3.
4.
Press. check point

M17.1
M17.2
M24
Location
Manifold (42) section M
Control block III

system stalls.
of MRV in control block III, while observing the pressure gauges.
Since the piston side of the bucket cylinders are protected by several
lowest setting.
5.
6.
7.
8.
PC4000-6-E_#08165_Sec_8-1_rev0.doc

continued
02.03.05
8.1
33
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8.1.10
Section 8.1
Page 33

Cont'd:
Bucket cylinder Piston side BHA
9.
360 bar.
70.3 70.4 70.12
10.
observing
all gauges.
)
11.
12.
sequence:
70.4 70.12

as follows:
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34
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Section 8.1
Page 34

Bucket cylinder Piston rod side FSA
There are two service line relief valves (secondary valves) installed, one in
main control block III and one in block IV, to limit the maximum possible
pressure peaks in the service line.
Valve
SRV 66.2
SRV 66.10
MRV circuit III
MRV circuit IV
1.
2.
3.
4.
Press. check point

Location
Control block III, section B2
Control block III
Control block IV

Retract the bucket cylinder to the stop position until the hydraulic
system stalls.
Since the piston rod side of the bucket cylinders are protected by
5.
6.
7.
8.

continued
PC4000-6-E_#08165_Sec_8-1_rev0.doc
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35
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8.1.10
Section 8.1
Page 35

Cont'd:
Bucket cylinder Piston rod side FSA
9.
Adjust both SRVs equally, until all gauges show a pressure of
360 bar.
66,2 66.10
10.
all gauges.
)
11.
12.
Proceed with the other valve in the same manner.

as follows:
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36
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8.1.10
Section 8.1
Page 36

Bucket cylinder Piston rod side BHA
service line.
Valve
SRV 70.5
SRV 70.7
SRV 70.11
MRV circuit III
1.
2.
3.
4.
Press. check point

M18
M20
M23
Location
Manifold (42) section D
Manifold (42) section G
Manifold (42) section L
Control block III

system stalls.
of MRV in control block III, while observing the pressure gauges.
Since the piston rod side of the bucket cylinders are protected by
it is necessary to further increase the setting of the MRV.
5.
6.
7.
8.
PC4000-6-E_#08165_Sec_8-1_rev0.doc

continued
02.03.05
8.1
37
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8.1.10
Section 8.1
Page 37

Cont'd:
Bucket cylinder Piston rod side BHA
9.
360 bar.
70.5 70.7 70.11
10.
observing
all gauges.
)
11.
12.
sequence:
70.7 70.11

as follows:
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38
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Clam cylinder Piston rod side FSA
There is one service line relief valve (secondary valve) installed at the
service line.
Since the opening pressure of the SRV is higher than the setting of the Main
Valve
SRV 70.6
MRV circuit II
1.
2.
3.
Connect gauges to the above listed check points.

Retract the clam cylinder (open the bucket) to the stop position until the
hydraulic system stalls.
of MRV in control block II, while observing the pressure gauges.
If necessary correct the adjustment as follows:
Turn set screw (3) of the MRV turn further in, the gauge pointers will
remain at the value shown at item #4 (350 bar + 5 bar).
Reduce the pressure, at SRV- 70.6 to a value below the required value, and
then increase up to the required pressure (350 bar), while observing all
gauges.
Reset the MRV to 310 bar + 5 bar after adjustment is finished, as follows:
Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to
decrease pressure.
4.
5.
6.
7.
8.
9.
10.
Press. check point

Location
M19
Manifold (42) section E
M12 (High pressure filter) Control block II

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Clam cylinder Piston side FSA
There are two service line relief valves (secondary valves) installed, one at
distributor manifold (42) and one in main control block II, to limit the
maximum possible pressure in the service line when closing the bucket.
To avoid damages at the clam shell, due to improper operation, the SRVs
should be adjusted in a way that the pressure is just sufficient to keep the
bucket closed.
Valve
SRV 18
SRV 45
1.
2.
3.
Press. check point

Location
M18
Manifold (42) section K
M12 (High pressure filter) Control block II

Raise the attachment and bring the back wall of the bucket in a
horizontal position.
Depress pedal bucket closing until the hydraulic system stalls.
Release the pedal back to neutral position.
The bucket must stay closed. That means the clam-cylinders must
not be retracted by the force (weight) of the clam shell.
Adjust the SRVs as follows:
4.
Turn set screw (3) -clockwise to increase pressure,

Counter-clock wise to decrease pressure.
Adjust both SRVs equally, until the gauges show a pressure of 220 bar.
Now reduce the pressure at both SRVs equally in steps of 5 bar until the
bucket opens by gravity.
Read the pressure and increase the setting with 10%, to compensate the
weight of material stuck at the clam shell.
Since the piston side of the clam cylinders are protected by several
lowest setting.
For standard buckets the pressure is 150 bar, reinforced or with heavy
wear package attached, the pressure maybe raised up to 200 bar.
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40
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Section 8.1
Page 40
Checks and adjustments of the lowering speed,

General
On excavators equipped with Face Shovel Attachment (FSA) there are two
different operation modes for lowering the boom and stick:
I.
Float position activated the lowering speed has to be adjusted by

altering the stroke limiters (4) of the single control blocks (3).
II.
Float position deactivated the lowering speed has to be adjusted by

altering the flow restrictors (throttle valves) at the distributor
manifold (42).
On excavators equipped with Backhoe Attachment (BHA) the lowering

speed has to be adjusted at the flow restrictors only.
Purpose of the Flow Restrictors:

To avoid an interruption of the pump delivery.
To provide an uniform and smooth cylinder travel.
To limit the return oil flow through the control block to the maximum
permissible volume.
Checks and Adjustments:
Activate service switch S151 (located in the cab base) during the checks and
adjustments, to ensure that the main pumps are in Qmax position.
Standard test method is measuring the total cylinder running time by using a
stop watch.
If it is impossible to move the cylinder over the whole way, mark a distance of
one meter with permanent pen P/N 621 566 40 on the piston rod and measure
the time for only one meter movement.
Adjust the Restrictor as follows:
- For easy turning of set screw (2) lower the attachment to ground, stop motor
and allow pressure equalising by moving the joy sticks several times.
- Loosen the lock nut (1) and turn the bolt (2) cw for more restriction and ccw
for less restricton. If more than one restrictor is used for one movement
make sure all set screws are equally adjusted.
During commissioning, a throttle adjustment has to be carried out on all
machines. For safety reasons, the throttle valves are completely screwed in
before each machine is leaving the factory.
For more information refer to the respective Parts & Service News
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41
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Section 8.1
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Boom cylinder FSA
Due to the two different operation modes for lowering the boom, the lowering
speed must be adjusted twice:
I.
II.
Maximum permissible lowering speed:
Boom FSA
Cylinder retracting time/meter

(s /m)
1,8
Total time
(s)
5,0
Adjustments / Checks:
I. Float position activated:
1. Use a stop watch to measure the cylinder running time.
2. Raise the fully extended attachment with empty bucket to the maximum height
position (A).
3. Shift the engine to high idle speed.
4. Rapidly move the control lever (E19) to the front end position (start the stop
watch) and hold it until the final position (B) is reached.(stop the stop watch).
Lower the boom so, that the bucket stops just above the ground.
5. If the lowering speed is too high, i.e. the measured time is less than the
permissible time, the speed must be reduced by altering the stroke limiter of
the single control block (Y135).
Adjust as follows:
To decrease the lowering speed loosen the lock nut (1) and turn the bolt (2) cw.
To increase the lowering speed loosen the lock nut (1) and turn the bolt (2) ccw.
6. Check lowering speed again and repeat the adjustment if necessary.
7. If the adjustment is finished tighten lock nut (1).
continued
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42
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8.1.11
Section 8.1
Page 42

Cont'd:
Boom cylinder FSA
Boom FSA

(s /m)
1,8
Total time
(s)
5,0
II. Float position deactivated (with push button S95):
position (A).
4. Press push button S95 and keep it depressed while lowering the attachment.
Rapidly move the control lever (E19) to the front end position (start the stop
permissible time, the speed must be reduced by altering the throttle valves 70.1
70.2 and 70.13 at the distributor manifold (42).
Adjust as follows:
Since there are several valves throttling the return oil flow of the
boom cylinder the valves must be set synchronously. The adjusting
screws have to be turned in by the same amount of revolutions.
O.K.

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8.1.11
Section 8.1
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Boom cylinder BHA
Boom BHA

(s /m)
1,4
Total time
(s)
5,0
position (A).
4. Rapidly move the control lever (E19) to the front end position (start the stop
permissible time, the speed must be reduced by altering the throttle valves
70.1, 70.2 , 70.13 and 70.14 at the distributor manifold (42).
Adjust as follows:
boom cylinder the valves must be set synchronously. The adjusting
O.K.

If the adjustment is finished tighten lock nut (1).
PC4000-6-E_#08165_Sec_8-1_rev0.doc
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8.1
44
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Hydraulic for the

8.1.11
Section 8.1
Page 44

Stick cylinder FSA
Due to the two different operation modes for lowering the stick, the lowering
speed must be adjusted twice:
I.
II.
Stick FSA

(s /m)
2,3
Total time
(s)
5,5
I. Float position activated:
position (A).
4. Rapidly move the control lever (E20) to the rear end position (start the stop
permissible time, the speed must be reduced by altering the stroke limiters of
the single control blocks (Y132, Y133 and Y134).
Adjust as follows:
Since there are several single control blocks used for the stick movement,
make sure that all stroke limiter are equally adjusted.
O.K.

Continued
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45
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Hydraulic for the

8.1.11
Section 8.1
Page 45

Cont'd:
Stick cylinder FSA
Stick FSA

(s /m)
2,3
Total time
(s)
5,5
II. Float position deactivated (with push button S95a):
position (A).
4. Press push button S95a and keep it depressed while lowering the stick. Rapidly
move the control lever (E20) to the rear end position (start the stop watch) and
hold it until the final position (B) is reached.(stop the stop watch).
and 70.9 at the distributor manifold (42).
Adjust as follows:
Since there are several valves throttling the return oil flow of the stick
cylinder the valves must be set synchronously. The adjusting screws
have to be turned in by the same amount of revolutions.
O.K.

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46
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Hydraulic for the

8.1.11
Section 8.1
Page 46

Stick cylinder BHA
Stick BHA

(s /m)
2,6
Total time
(s)
5,3
position (A).
4. Rapidly move the control lever (E20) to the rear end position (start the stop
70.8, 70.9 and 70.10 at the distributor manifold (42).
Adjust as follows:
Since there are several valves throttling the return oil flow of the stick
cylinder the valves must be set synchronously. The adjusting screws
have to be turned in by the same amount of revolutions.
O.K.

If the adjustment is finished tighten lock nut (1).
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47
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Hydraulic for the

8.1.11
Section 8.1
Page 47

Bucket cylinder FSA
Bucket FSA

(s /m)
2,1
Total time
(s)
5,0
position (A).
4. Rapidly move the control lever (E19) to the r.h. end position (start the stop
and 70.12 at the distributor manifold (42).
Adjust as follows:
bucket cylinder the valves must be set synchronously. The adjusting
O.K.

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48
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Hydraulic for the

8.1.11
Section 8.1
Page 48

Bucket cylinder BHA
Bucket BHA

(s /m)
2,4
Total time
(s)
5,2
position (A).
4. Rapidly move the control lever (E19) to the r.h. end position (start the stop
70.3, 70.4 and 70.12 at the distributor manifold (42).
Adjust as follows:
bucket cylinder the valves must be set synchronously. The adjusting
O.K.

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49
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8.1.11
Section 8.1
Page 49

Clam cylinder BHA
Clam

(s /m)
-----
Total time
(s)
5,0
2. Open the clam of the empty bucket to the maximum height position (A).
4. Rapidly push the control pedal (E23) to the end position (start the stop watch)
and hold it until the final position (B) is reached.(stop the stop watch).
permissible time, the speed must be reduced by altering the throttle valve 70.6
at the distributor manifold (42).
Adjust as follows:
PC4000-6-E_#08165_Sec_8-1_rev0.doc
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Hydraulic for the Swing Circuit
Section 8.2
Page 1

Section
8.2
Page
8.2.1
Swing Circuit (Brief description)
2+3
8.2.2
Swing Motor
4+5
8.2.3
Swing Gear Box
8.2.4
Swing Parking Brake (Gear house Brake)
8.2.5
Swing Brake Valve
8+9
8.2.6
Electric / Hydraulic flowchart Swing Left
10
8.2.7
Electric / Hydraulic flowchart Swing Right
11
8.2.8
Checks and adjustments for the swing circuit
12 + 13 +14
8.2.9
Function check for the hydraulic swing brake
15
8.2.10
Function check for the swing parking brake
16
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2
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Section 8.2
Page 2
8.2.1 Swing Circuit

(1 + 3)
(9 / III)
(10 / I)
(16.1 + 16.2)
(60.1+ 60.2)
Main pumps
Control block
Control block
Manifold
Swing motors
Brief description (Service circuits)

The machine is equipped with a two speed swing system.
(Study together with the for the machine valid hydraulic and electric circuit
diagram).
The swing motors (60.1 + 60.2) are driven by the pumps (1 + 3).
The oil flows from the pumps through high pressure filters to the control
block (9/III) and (10/I).
With the spools in neutral position oil flows via the return oil line into the
collector tube (107) and further via the return oil lines (L6 + L7) into the
collector tube (54) and further to the tank.
On its way to tank the oil must flow through the back pressure valve (55) and
the return oil filter (59.1 - 59.4). (Back pressure valve function see section 4.)
When operating the control lever for "Swinging" the pump line is connected
in the control blocks (9/III and 10/I) with the corresponding service line (A1
or B1) to the swing motors (60.1 + 60.2).
The oil flows from the control block through each one of the swing brake
valves (61.1 + 61.2; description see page 8 and 9) and the swing motors (60.1
+ 60.2).
Each swing gear includes one spring loaded multi disk brake (House brake)
for locking the superstructure.
The leak oil (case drain) flows through the line (L18 + L19) and the leak oil
filter (53) back to tank.
continued
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8.2
3
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Section 8.2
Page 3
Cont'd.:
8.2.1 Swing Circuit:
(1 + 3)
(9 / III)
(10 / I)
(14.1)
(16.1 + 16.2)
(60.1+ 60.2)
(95)
Y24 + Y25
Y26 + Y27
Y65 + Y66
Y120 + Y126
Y127
Y130 + Y131
Main pumps
Control block
Control block
Remote control valve block
Manifold
Swing motors
directional solenoid valves
directional solenoid valves
proportional solenoid valves
directional solenoid valve
proportional solenoid valve (foot brake pedal)
directional solenoid valve
Brief description (Control circuits)

When the lever (E19) is moved out of its neutral position, proportional solenoid
valve Y65 and solenoid valve Y131 (pump #3 fixed in Qmax position) are
energized. Simultaneously the directional solenoid valves Y24 (R.H.-swing) or
Y25 (L.H.-swing) are energized.
At the same time, by the function of proportional
solenoid valve Y127, pilot pressure is present at
port X of each brake valve block thus a
pressure built up in the service lines is possible.
i.e. Swing speed low = Only oil flow of pump #3
If swing speed switch S154 is activated, also

proportional solenoid valve Y66 and depending
on the swing direction directional solenoid valves
Y26 (R.H.-swing) or Y27 (L.H.-swing) are
energized. Simultaneously solenoid valves Y130
and Y126 (pump #1 fixed in Qmax position) are
energized, so that only a reduced of oil flow from
pump #1 will be added to increase the swing.
i.e. Swing speed fast = oil flow of pump #3 + reduced oil flow of pump #1
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4
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Section 8.2
Page 4
8.2.2 Swing Motor

Axial piston motor A2FLM (with SL-bearing)
The axial piston units of product group A2FM with fixed displacement can
operate as a hydraulic motor only.
The drive speed is proportional to the consumption capacity.
The output torque increases with the pressure drop between high and low
pressure side.
The motor converts hydrostatic energy into mechanical energy.
(1)
(2)
(3)
(4)
(5)
(5a)
(6a)
(6b)
(7)
(8)
Drive shaft
Housing
Case drain port
Retaining plate
Piston
Pivot (center) pin
Upper dead point
Lower dead point
Cylinder
Control lens
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
End plate
Centering spring
Taper roller bearing
Spring
Slipper pads
Thrust washer
Roller bearing
Circlip
Sealing flange
Radial seal ring
Description of the SL-bearing (SL = slipper bearing)

The main part of the axial forces is supported by the slipper pads (13) which
are installed on the driving circular side of the drive shaft.
Each piston is allocated to one slipper pad.
These slipper pads are located in the cylinder chamber and get pressurized via
piston borings (5). The slipper pads support themselves on the thrust washer
(14) and discharge axially the tapered roller bearing (11).
Without pressure the slipper pads are kept on the thrust washer by means of
spring (12).
continued
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8.2
5
PC4000-6-E_#08165_Sec_8-2_rev0.doc
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Section 8.2
Page 5
Cont'd.:
8.2.2 Swing Motor, illustration (Z 21936)
Axial piston motor A2FLM (with SL-bearing)
Function:
The pressure oil inlet (A or B) and consequent oil outlet (B or A) determine
the output drive direction of the drive shaft (1).
Direction of rotation:
"Clockwise"
= Direction of flow A to B
"Counter-Clockwise" = Direction of flow B to A
with view onto drive shaft!
Via the control lens (8) the oil is directed to the cylinder bores.
The piston (5) is moved from the lower (6b) to the upper dead point (6a) by
means of the force acting on it and causes the drive shaft to rotate. On further
rotation of the drive shaft (additional pistons are pressurized) this piston is
moved towards the lower dead point again and oil of the cylinder chamber is
forced out through the kidney formed openings of the control lens. This oil is
fed back to the tank via the return line.
If the supply and return line is changed it changes the output drive direction
of the drive shaft.
By means of the angled arrangement of the cylinder (7) (bent axis design), a
certain piston stroke is produced which results in a fixed displacement per
revolution of the drive shaft. According to the size of the applied flow this
produces a specific output speed.
The output torque at the drive shaft is dependent on the size of the motor and
the required operating pressure.
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6
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Section 8.2
Page 6
8.2.3 Swing Gear Box

(1) Drive housing
(2) Drive shaft
(3) Sun gear shaft
(4) House brake
(Multi disk brake)
(5) Breather filter
Drive shaft housing
(6) Oil level gauge (dipstick)
Drive shaft housing
(7) Disk brake housing
(8) Cylindrical roller bearing
(9) Internal ring gear
(10) Cylindrical roller bearing
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
Bearing ring
Cartridge
Spherical roller bearing
Oil drain plug, gear box
Oil level gauge (dipstick)
Gear box
First planetary stage
Drive shaft to second stage
Second planetary stage
Radial seal ring
Drive pinion
Grease line port
The swing gear is of compact design with a two stage planetary gear including a
multi disk house brake.
The gear is bolted to the superstructure and fits firmly due to the machined
diameter (A) and the bolt torque.
The torque loaded on the hydraulic motor is transmitted by drive shafts (2)
and sun gear shaft (3) to the first planetary stage (17).
The sun shaft (17) of the first planetary stage transmits the torque into the
second planetary stage (19). By the planetary gears the output drive shaft is
rotated and transmits the torque to the pinion (21).
The drive housing, and the gearbox are filled with gear oil.
Aeration is done by breather filters.
To lubricate the pinion bearing port (22) is connected to the central
lubrication system.
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7
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Section 8.2
Page 7
8.2.4 Swing Parking Brake (Gear house Brake)

The Spring Loaded Multi-disk Brake is a safety brake; applied by
spring force and released by oil pressure.
(1)
Disk housing
(2)
Thrust washer
(3)
Inner disks (lamellas)
(4)
Outer disks (lamellas)
(5)
Sinus (spacing) ring
(6)
Piston
(7)
Quad-Rings with back- up rings
(8)
Quad-Rings with back- up rings
(9)
Springs
(10)
Thrust washer
(11)
Circlip
(12)
Drive shaft
(13)
Oil pressure port
Function:
Brake applied:
The outer disks (4) engaged to the housing by serration and the inner disks (3) in
serrated connection with drive shaft (12) are pressed together by the springs (9).
This results in a fixed connection between housing and drive shaft.
Brake released:
Oil pressure via port (13) reaches the bottom of the piston (6) and forces the
piston upwards against the thrust washer (10).
This function eliminates the spring force onto the disks so that the sinus
(spacing) rings can keep the outer disks (4) apart, thus the brake is released.
The releasing pressure is 19 - 20 bar, the maximum permissible pressure
60 bar.
This is a so named "Wet Brake" because the brake housing is splash lubricated
by gear oil.
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8
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Section 8.2
Page 8
8.2.5 Swing Brake Valve

(1) Pressure increasing valve
(items 6 - 13)
(2) Check valve circuit A
(3) Check valve circuit B
(4) Anti-cavitation valve circuit B
(5) Anti-cavitation valve circuit A
(6) Jet bore, of main piston plug
Ports:
(Y)
(T)
(A)
(A1)
(B)
(B1)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Spring of main piston

Jet bore
Valve poppet
Spring
Intermediate piston
Pilot pressure piston
Main piston
Leak oil
Return oil
Service line from control block
Service line to the motor
Service line from control block
Service line to the motor

(MA) Circuit A
(MB) Circuit B
Explanation of the function by the symbol:
When ever a swing motion is carried out or the foot brake is used, pilot
pressure arrives the pressure increasing valve (1) at port "X".
The pilot pressure pre-loads these valves.
The oil for the hydraulic motor from the control block arrives the service line
port A or B, depending if a R.H. or a L.H. swing motion is carried out.
The ports A and B are internally connected to the ports A1 and B1 and these
ports in turn with the hydraulic motor.
The operating pressure, at either port A or B closes the anti-cavitation valves
(4 or 5) and opens the check valves (2 or 3).
That means by the check valves (2 or 3) the service lines are connected to the
pressure increasing valve.
When ever the pressure is higher than the setting of the pressure increasing
valve, this valves opens and dumps the oil into the return line (T) to tank.
The pressure can be checked at the check points MA or MB.
continued
PC4000-6-E_#08165_Sec_8-2_rev0.doc
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8.2
9
PC4000-6-E_#08165_Sec_8-2_rev0.doc
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Section 8.2
Page 9
Cont'd.:
8.2.5 Swing Brake Valve, illustration (Z 21935)
If after a swing motion the joy stick is put into neutral position without
using the foot brake, the superstructure is turned by inertial force and the
hydraulic motor acts as a pump because it is driven by the swing gear.
In this period the pressure in the service line is lower than the pressure in
the return line, because there is a back pressure valve at the tank, and oil is
forced through the anti-cavitation valves into the service line.
Function of the pressure increasing valve.
When ever a swing motion is carried out or the foot brake is used, pilot
pressure arrives the pressure increasing valve (1) at port "X". The pilot
pressure pre-loads these valves.
By applying pilot pressure via the external port X to piston (12), the pretensioning of the pressure spring (10) is increased by the amount of the piston
stroke "S", which results in the actual valve setting.
The system pressure is in front of the main piston (13) and via the jet bore (6)
also in the chamber of the spring (7) and via the jet bore (8) at the pressure
relief valve poppet (9).
Due to the force balance the piston (13) is kept in its position supported by
the spring (7).
Overcomes the system pressure the setting of the valve (9), this valve opens a
channel to the dump line port (Y). Due to the drop of force the piston (13) is
moved to the right.
The pressure line gets connected with the return line (T).
Damped opening and closing are obtained by the throttled volumetric change
that is caused by the jet bores.
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10
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Section 8.2
Page 10
8.2.6 Electric / Hydraulic flowchart Swing Left

(E19)
(E22)
Control pedal swing brake
(-X)
(-10V)
(ws/gn)
Colour code of signal voltage cable ( Joy stick) white/green
(br gn)
Colour code of voltage cable ( brake pedal) brown green
(X2...)
(E50, E50a, E50b) Ramp time modules
(A7)
Amplifier module Swing (Y65 + Y24/25 Block III)
(A7a)
Amplifier module Swing (Y66 + Y26/27 Block I)
(A16)
Amplifier module Swing brake
(K80)
Relay Contacts 7 / 11 only closed while rotating with swing
speed switch S154 activated.
(K190)
Relay Swing brake without ramp time Contacts 5 / 9
and 6 / 10 only closed while using the brake pedal.
(14.1)
(95)
(Y65 + Y66)
(Y24 + Y26)
(Y127)
(I + III)
Main control blocks I +III
(16.2)
(61.1 + 61.2)
Swing brake valve blocks
(PIV)
Pressure increasing valve
(60.1 + 60.2)
Swing motors
Illustration Z21945 shows:
The electrical signal.
Signal voltage of joy stick (E19) arrives via ramp time modules (E50,-a) at
terminal 5 of the amplifier modules (A7 + A7a) and further to the proportional
and directional solenoid valves of the remote control blocks (14.1+ 95).
Simultaneously signal voltage arrives via ramp time modules (E50b) at terminal 5
of the amplifier modules (A16) and further to the proportional valve (Y127)
The hydraulic signal. (pilot pressure)
oil flows to the pressure ports of the main control blocks and to the pressure
increasing valves (PIV).
The hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (I + III)
and arrives via swing brake valves (61.1 + 61.2) at the swing motors (60.1 +
60.2).
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11
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Section 8.2
Page 11
8.2.7 Electric / Hydraulic flowchart Swing Right

(E19)
(E22)
Control pedal swing brake
(+X)
(+10V)
(ws/gn)
Colour code of signal voltage cable ( Joy stick) white/green
(br gn)
Colour code of voltage cable ( brake pedal) brown green
(X2...)
(E50, E50a, E50b) Ramp time modules
(A7)
Amplifier module Swing (Y65 + Y24/25 Block III)
(A7a)
Amplifier module Swing (Y66 + Y26/27 Block I)
(A16)
Amplifier module Swing brake
(K80)
Relay Contacts 7 / 11 only closed while rotating with swing
speed switch S154 activated.
(K190)
Relay Swing brake without ramp time Contacts 5 / 9
and 6 / 10 only closed while using the brake pedal.
(14.1)
(95)
(Y65 + Y66)
(Y24 + Y26)
(Y127)
(I + III)
Main control blocks I +III
(16.1)
(61.1 + 61.2)
Swing brake valve blocks
(PIV)
(60.1 + 60.2)
Swing motors
Illustration Z21945 shows:
The electrical signal.
Signal voltage of joy stick (E19) arrives via ramp time modules (E50,-a) at
terminal 5 of the amplifier modules (A7 + A7a) and further to the proportional
and directional solenoid valves of the remote control blocks (14.1+ 95).
Simultaneously signal voltage arrives via ramp time modules (E50b) at terminal 5
of the amplifier modules (A16) and further to the proportional valve (Y127)
The hydraulic signal. (pilot pressure)
oil flows to the pressure ports of the main control blocks and to the pressure
increasing valves (PIV).
The hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (I + III)
and arrives via swing brake valves (61.1 + 61.2) at the swing motors (60.1 +
60.2).
PC4000-6-E_#08165_Sec_8-2_rev0.doc
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12
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Section 8.2
Page 12
8.2.8 Checks and adjustments for the swing circuit

Maximum permissible swing speed
Flow reduction for pump No 1 with pressure reducing valve 255.4
(Q reduced while swinging with high speed)
(M33)
pressure to pressure increasing valves
(M41)
X1 pressure - Fixed pump No 3 (X1= 45 bar)
(M42)
X1 pressure - Fixed pump No 1 (X1= 45 bar)
(M32)
Reduced X3 pressure to pump No 1
(255.4) Pressure reducing valve reduced X3 pressure ( Qmax)
(Y126) Solenoid valve flow reduction (Pump 1)
(Y130) Solenoid valve Fixed pump (Pump 1)
(Y131) Solenoid valve Fixed pump (Pump 3)
1.
2.
3.
4.
Connect a pressure gauges to check points M33, M41

and M42.
Start the engine and let it run with max. speed.
Move the control lever(E19) to the end position (L.H.
or R.H.) with activated and deactivated swing speed
switch (S154), swing one turn as an approach swing
and start counting the number of revolutions in one
minute.
Read pressure while swinging.
Required values:
S154 = OFF (normal)
S154 = ON (max.)
M33 = 15 bar
M33 = 45 bar
M41 = 45 bar
M41 = 45 bar
M42 = 45 bar
M42 = 34 bar
RPM = 4 0,3
RPM = 2,75 0,3
Do not exceed the maximum permissible swing speed of 4 0,3 RPM
Note down the pressures and speeds as reference values.
If adjustment is necessary:
5. Loosen lock nut (e)
6. Adjust the pressure with set screw (f)
7.
Tighten lock nut and remove the gauges.
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13
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Section 8.2
Page 13
8.2.8 Checks and adjustments for the swing circuit, illu. (Z 21948b)
It is important that the complete MRV-valve and the Pressure

Increasing Valve is firmly (with 300 Nm) tightened.
Otherwise, internal leaks could occur which result in:
problems of correct adjustment, loud flow noises and high
temperatures.
Whenever pressure checks are carried out, they must be carried out
for both, R.H. and L.H. Swing, to make sure the double check valves in
the control lines and the check valves in the brake valve blocks are in
good condition.
Because the Swing motors are working hydraulically in combined
operation, the pressure gauge shows the pressure of the pressure
increasing valve with the lowest setting.
Even when the gauge shows the required pressure it is possible that
one valve has a higher setting.
Therefore lower the pressure on one valve below the required pressure
and then increase up to required pressure.
Proceed with next valve in the same manner.
High pressure check / adjustment

1. Connect gauges to check point M11 and M14 at the high pressure filter units.
2. Disconnect the pilot pressure lines from the T-unions and close the lines with a
suitable plug (P).
3. Loosen lock nut (3) of both pressure increasing valves (PIV) and screw in set
screw (4) until piston (5) comes to stop.
4. Start the engine and let it run with max. speed.
5. Lower attachment to ground and apply house brake with switch S29.
6. Adjust the MRV-pressure to ~350 bar.
7. Actuate either L.H. or R.H. rotation (S154 ON) until the hydraulic system stalls.
Read the pressure, required = 330 5 bar.
8. If the gauge shows a smaller or greater value the pressure increasing valve must
be adjusted:
a) Loosen lock nut (1) of the first pressure increasing valve PIV.
b) Adjust pressure with set screw (2) to ~340 bar.
If the pressure wont increase, turn set crew (2) of the second PIV a turn
further in (c.w.).
c) Secure by tightening lock nut (1).
d) Loosen lock nut (1) of the second PIV.
e) Reduce the pressure with set screw (2) to a value of about 320 bar, and then
increase up to the required pressure of 330 bar.
f) Secure adjusted set screw (2) by tightening lock nut (1)
g) Reduce the pressure with set screw (2) of the first to a value of about 320 bar,
and then increase up to the required pressure of 330 bar.
h) Secure adjusted set screw (2) by tightening lock nut (1)
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8.2
14
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Section 8.2
Page 14
8.2.8 Checks and adjustments for the swing circuit, illu. (Z 21948b)
Low pressure check / adjustment (Swinging down path (drifting)
(with still disconnected pilot pressure line )
9.
Actuate either L.H. or R.H. rotation (S154 ON) until the hydraulic system stalls.
a) Loosen lock nut (3) of both (PIVs) and reduce the pressure equally with set
screws (4) to a value of about 130 bar, secure setting with lock nut (3)
b) Loosen lock nut (3) of the first PIV.
c) Reduce the pressure with set screw (4) of the first PIV to a value of about 110
bar, and then increase up to the required pressure of 120 bar.
d) Secure adjusted set screw (4) by tightening lock nut (3)
e) Loosen lock nut (3) of the second PIV.
f) Reduce the pressure with set screw (4) of the second PIV to a value of about
110 bar, and then increase up to the required pressure of 120 bar.
g) Secure adjusted set screw (4) by tightening lock nut (3)
10. Re-connect the pilot pressure line.
11. Re-set MRV-pressure and remove the gauges after the check / adjustment is
finished

opening pressure of PIVs and must be avoided.
via all three pressure increasing valves.
Brake pilot pressure - check / adjustment

1.
Connect the gauge to the check point M27.
2.
3.
Depress fully the foot brake pedal (E22) and read the pressure.
The pressure must be 24 +1 bar.
Alter the position of the potentiometer R2 of the amplifier A16 until the
pressure is 24 +1 bar.
Basic adjustment for A16 see section 5
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15
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Section 8.2
Page 15
8.2.9 Function check for hydraulic swing brake

(M39) Pressure check point (Pressure to pressure increasing valve)
(S22) Switch Position of access ladder
(S28) Switch Operators seat
(Y120) Solenoid valve hydraulic swing brake ON - OFF
(Y127) Proportional solenoid valve hydraulic swing brake
Safety circuit (automatic actuation)
The hydraulic swing brake will be applied automatically when the access
ladder and/or the service arm of the central refilling system is not in its
completely lifted position and/or if the operators seat is not occupied.
Brake apply pressure
1. Connect gauge to check point (M39).
2. Start the motors.
3. Lift the access ladder to the end position.
4. Check the pressure at check point(M39) under the following conditons:
a) Seat is occupied and access ladder complete up.
0 bar=> released.
No message should appear on the text display
b) Seat is occupied and access ladder down.
The message Pilot control cut out should appear
45 bar=> applied.
c) Seat is not occupied and access ladder complete up.

The message Pilot control cut out should appear
45 bar=> applied.
Operation circuit (manual actuation through joystick or brake pedal)

To shorten the braking angle of the superstructure either the brake pedal must
be actuated or the a counter action of the joystick is required.
As a result, proportional valve Y127 will vary the pilot pressure at the
pressure increasing valves (PIV) in relation to the lever deflection.
Brake apply pressure
5. Apply the parking brake. Therefore move toggle switch (S29) in position 1
6. Actuate either the joystick (L.H. or R.H.) or the swing brake pedal and read the
pressure.
Required: 0 <=> 24 bar. (variable i.e. proportional to the lever deflection)
7. Disconnect the pressure gauge.
In case of malfunction check the electrical control system and the

function of solenoid valve Y120 and/or Y127.
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8.2
16
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Section 8.2
Page 16
8.2.10 Function check for the swing parking brake

(M1.2) Pressure check point (X2 - pilot pressure)
(M10) Pressure check point (Pressure to swing parking brake)
(B16) Pressure switch
(Y5)
Solenoid valve swing parking brake ON - OFF
(252.1) Pressure reducing valve
Parking Brake Release Pressure. (House Brake Pressure)
1. Connect gauge to check point (M1.2).
2. Start the motor and read the pressure. Required = 45 3 bar.
If not, correct the pilot pressure adjustment. (refer to Section 5).
3. Apply the parking brake. Therefore move toggle switch (S29) in
position 1, now the following message should appear:
Swing gear house brake ON
4. Actuate either L.H. or R.H. rotation, the machine should not turn.
If the machine turns the parking brake must be repaired.
5. Release the parking brake. Therefore move toggle switch (S29) in
position 0, now the swing function must be possible again and
the monitor returns to standard display.
In case of malfunction check the electrical control system

and the function of solenoid valve Y5.
Function Check of pressure switch B16

1. Connect pressure gauge to check point (M10).
2. Start the motor. Gauge must show normal pilot pressure X2 = 45 3 bar.
3. Move toggle switch (S29) in position 0
4. Set pilot pressure reducing valve (252.1) to 22 bar.
5. Unplug and reconnect solenoid valve Y5 to allow pressure relieve from
pilot pressure line to house brake.
The text display must show Swing gear house brake ON
6. Increase the pilot pressure up to 26 bar.
Swing gear house brake ON must disappear.
7. Reset pilot pressure X2 to 45 3 bar.
Pressure at B16 <24 bar => Brake applied (ON)

Pressure at B16 >24 bar => Brake released (OFF)
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Hydraulic for the Travel Circuit
Section 8.3
Page 1

Section
8.3
Page
8.3.1 Travel Circuit (Brief description)
2+3
8.3.2 Travel Motor
8.3.3 Rotary distributor
8.3.4 Travel Gear Box
8.3.5 Travel Parking Brake (Gear house Brake)
8.3.7 Electric / Hydraulic flowchart Travel forward
8.3.8 Electric / Hydraulic flowchart Travel backward
10
8.3.9 Checks and adjustments for the travel circuit
11
8.3.10 Function check for the travel parking brake
12
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8.3
2
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Section 8.3
Page 2
8.3.1 Travel Circuit

(2 + 4)
(II)
(IV)
(14.2)
(15)
(19)
(21.1+ 21.2)
(41)
(55)
(56.1+ 56.2)
(57.1+ 57.2)
(B48)
(M4)
(Y16)
(L9)
(ST)
Main pumps
Control block
Control block
Rotary distributor
Travel motors
Main oil reservoir
Back pressure valve
Travel brake valves
Travel parking (house) brakes
Pressure switch, parking brake release pressure
Pressure check point for parking brake release pressure
Solenoid valve for travel parking brake
Case drain (leak oil) line
Pilot pressure line to the travel parking brake
Brief description (Control circuits)

(Study together with the hydraulic and electric circuit diagram).
When the pedals E21a and E21b are moved out of there neutral
position, proportional solenoid valves Y67 and Y70 and simultaneously
the directional solenoid valves Y28 or Y29 (L.H.-crawler) and Y34 or
Y35 (R.H.- crawler) are energized.
(E21a) Control pedal
A forward => Y70 +Y35
Left track
B reverse => Y70 +Y34
(E21b) Control pedal

A forward => Y67 +Y28
Right track
B reverse => Y67 +Y29
continued
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8.3
3
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Section 8.3
Page 3
Cont'd.:
8.3.1 Travel Circuit
Illustration (Z 22506a):
Brief description (Service circuits)
(Study together with the hydraulic and electric circuit diagram).
The travel motors (21.1 + 21.2) are driven by the pumps (2 + 4).
The oil flows from the pumps through the high pressure filters to the control
blocks (II + IV).
In neutral position of the spools the oil flows via the return oil lines into the
collector tube (107) and further via the return oil lines (L6 + L7) into the tank
collector tube (54) and further to the tank.
On its way to tank the oil must flow through the back pressure valve (55) and
the return oil filter (59.1 - 59.4). (Back pressure valve function see section 4.)
When operating the foot pedal for "Travelling" the pump line of each control
block is connected with the corresponding service line (A1 or B1) via the
rotary distributor (19) and travel brake valves (56.1 + 56.2) to the travel
motors (21.1 + 21.2).
The travel brake valve acts as a flow control valve in order to avoid the travel
motors picking up speed when travelling downhill.
Each travel gear includes a spring loaded multi disk brakes (House brakes 57.1 57.2). They are used as parking brakes, automatically applied by the function of
Y16 whenever the engine is switched OFF.
The brake release pressure is monitored by the pressure switch (B48).
The leak oil (case drain) flows through the line (L9) and the leak oil filter (53)
back to tank.
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4
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Section 8.3
Page 4
8.3.2 Travel Motor

Axial piston motor A2FLM
The axial piston units of product group A2FM with fixed displacement can
operate as a hydraulic motor only.
The drive speed is proportional to the consumption capacity.
The output torque increases with the pressure drop between high and low
pressure side.
The motor converts hydrostatic energy into mechanical energy.
(1)
(2)
(3)
(4)
(5)
(5a)
(6a)
(6b)
(7)
Drive shaft
Housing
Case drain port
Retaining plate
Piston
Pivot (center) pin
Upper dead point
Lower dead point
Cylinder
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
Control lens
End plate
Taper roller bearing
Roller bearing
Thrust washer
Circlip
Circlip
Sealing flange
Radial seal ring
Function:
The pressure oil inlet (A or B) and consequent oil outlet (B or A) determine
the output drive direction of the drive shaft (1).
Direction of rotation:
"Clockwise"
= Direction of flow A to B
"Counter-Clockwise" = Direction of flow B to A
with view onto drive shaft!
Via the control lens (8) the oil is directed to the cylinder bores.
The piston (5) is moved from the lower (6b) to the upper dead point (6a) by
means of the force acting on it and causes the drive shaft to rotate. On further
rotation of the drive shaft (additional pistons are pressurized) this piston is
moved towards the lower dead point again and oil of the cylinder chamber is
forced out through the kidney formed openings of the control lens. This oil is
fed back to the tank via the return line.
If the supply and return line is changed it changes the output drive direction
of the drive shaft.
By means of the angled arrangement of the cylinder (7) (bent axis design), a
certain piston stroke is produced which results in a fixed displacement per
revolution of the drive shaft. According to the size of the applied flow this
produces a specific output speed.
The output torque at the drive shaft is dependent on the size of the motor and
the required operating pressure.
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8.3
5
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Section 8.3
Page 5
8.3.3 Rotary Distributor

Task:
The rotary distributor (joint) permits a hydraulic connection between the
superstructure and the undercarriage, that means between the rotating and the
stationary part.
(1)
(2)
(3)
(4)
(5)
Rotor
Rotary distributor housing
Cover
Bearing ring (splitted)
Sealing element
(6)
(7)
(8)
(9)
(10)
Seal
Rotor guide rings
O-ring
Plug screws
Mover
Ports:
A-D
Service lines
K1 / K2
Control oil track tensioning
L
Leak oil
ST
Control oil
T
Return oil to tank
The letters punch marked, beside the ports are marked as they are used in the
hydraulic diagram.
Function:
During operation superstructure and under carriage constantly rotate towards
each other. Nevertheless, the travel oil motors must be supplied with
hydraulic oil in every position in which the superstructure is moved in regard
to the undercarriage. Oil is directed by the control blocks to the ports (A-D)
of the housing (2).
The oil flows to the outlet ports (A-D), of the rotor (1), via ring grooves as
well as longitudinal and cross holes. The rotor is bolted to the under carriage.
The sealing of the ring grooves among one another is done by sealing
elements (5).
The hydraulic connection for case drain, house brake and the track tensioning
cylinders is done via the ports (L), (St), (K1) and (K2).
The entering of dirt gets blocked by the seal ring (6) and the collar of the
cover (3). The rotor (1) is at the top and bottom section guided in the housing
by the guide rings (7).
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6
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Operating Hydraulic
Section 8.3
Page 6
8.3.4 Travel gear

The travel gear consists of one spur gear set and two planetary stages.
The travel gearbox is fitted to the side frame with bolts.
(1)
Input drive shaft
(2)
Spur gear
(3)
Sun gear first stage
(4)
Planetary ring gear first stage
(5)
Planetary carrier first stage
(6)
Planetary ring gear second stage
(7)
Sun gear second stage
(8)
Planetary carrier second stage
(9)
Side frame mounting flange
(10)
Motor adapter and brake housing
(11)
Multi disk house brake
Function:
Spur gear (2) is driven by a hydraulic motor and input drive shaft (1).
The planetary carrier first stage (5) is driven by sun gear (3) which is connected
to spur gear (2).
The planetary gears are revolving in the planetary ring gear of the housing. As a
result of the fixed housing the planetary carrier will be turned.
The planetary carrier second stage (8) is turned by sun gear (7) which is
connected to the sprocket drive shaft.
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7
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Section 8.3
Page 7
8.3.5 Travel parking brake (Gear house brake)

The Spring Loaded Multi-disk Brake is a safety brake; applied by spring
force and released by oil pressure.
(1)
Radial seal rings
(2)
Retainer
(3)
Springs
(4)
O-ring
(5)
Piston
(6)
Plug screw
(7+8)
Quad-Ring with
back-up rings
(9)
Release pressure port
(10+11) Quad-Ring with
back-up rings
(12)
O-ring
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
Intermediate ring
Outer disks (lamellas)
Inner disks
Outer disk carrier
O-ring
Seeger clip ring
Bolt
Retainer
O-ring
Seeger clip ring
Inner disk carrier
Radial seal ring
Function:
Brake applied:
The outer disks (14) engaged to the housing by serration and the
inner disks (15) in serration connection with the disk carrier, are pressed
together by the springs (3). This results in a fixed connection between
housing and inner disk carrier (23).
Brake released:
Oil pressure via port (9) forces the piston (5) against the springs (3) towards
the retainer (2).
This function eliminates the spring force onto the disks thus the brake is
released.
The minimum releasing pressure is 21 - 23 bar, the maximum permissible
pressure 100 bar.
This is a so named "Wet Brake" because the brake housing is filled with oil.
For more information refer to the OPERATION AND

MAINTENANCE MANUAL, PARTS BOOK and REPAIR MANUAL
of the corresponding machine.
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8.3
8
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Section 8.3
Page 8

Task:
Travel brake valves control the oil flow from the hydraulic motor to the tank
depending on operating pressure. This braking action prevents the motors from
over speeding.
Function:
Spring force keeps the spool in the lowest flow position. with increasing
operating pressure the opening for the return oil flow becomes larger.
On its way to the hydraulic motor the oil flows from A to A1 respectively from
B to B1 depending on the selected travel motion.
Example:
Operating pressure at port A moves spool (1) against the force of the spring (2)
and opens the way for the return oil (B1 to B).
Check valve (3) prevents a direct oil flow from B1 to B.
If the operating pressure decreases to such an extend that the spring force
overcomes the pressure, the flow to the tank becomes restricted, resulting in
braking of the machine.
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9
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Section 8.3
Page 9
8.3.7 Electric / Hydraulic flowchart Traveling forward

(E21a)
Foot pedal left crawler
(E21b)
Foot pedal right crawler
(+10V)
(rs)
Colour code of signal voltage cable ( footpedal)
(X2...)
(E51)
Ramp time module
(E52)
Ramp time module
(A12)
Amplifier module left crawler
(A13)
Amplifier module right crawler
(K177)
Relay Controlled by cable drum switches 5S6 and 5S7.
Contacts 5/9 and 6/10 closed in normal operating condition.
(14.2)
(15)
(Y67 + Y70)
(Y28 + Y35)
(II IV)
Main control blocks
(19)
Rotary distributor
(21.1 21.2)
Hydraulic motors
(56.1 56.2)
Travel brake valves
Signal voltage of foot pedals (E21a + E21b) arrives via ramp time module (E51
+ E52) at terminal 5 of the amplifier modules (A12 and A13) and further to the
proportional and directional solenoid valves of the remote control blocks (14.2
and 15).
Hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (II and IV)
and arrives via Rotary distributor (19) and travel brake valves (56.1 56.2) at the
hydraulic travel motors.
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8.3
10
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Section 8.3
Page 10
8.3.8 Electric / Hydraulic flowchart Traveling backward

(E21a)
Foot pedal left crawler
(E21b)
Foot pedal right crawler
(D32)
(-10V)
(rs)
Colour code of signal voltage cable ( footpedal)
(X2...)
(E51)
Ramp time module
(E52)
Ramp time module
(A12)
Amplifier module left crawler
(A13)
Amplifier module right crawler
(K178)
Relay Controlled by cable drum switches 5S6 and 5S4.
Contacts 5/9 and 6/10 closed in normal operating condition.
(K179)
Relay Controlled by cable drum switches 5S8.
Contacts 5/9 closed in normal operating condition.
(K180)
Relay Controlled by cable drum switches 5S9.
Contacts 6/10 closed in normal operating condition.
(14.2)
(15)
(Y67 + Y70)
(Y29 + Y34)
(II IV)
Main control blocks
(19)
Rotary distributor
(21.1 21.2)
Hydraulic motors
(56.1 56.2)
Travel brake valves
Signal voltage of foot pedals (E21a + E21b) arrives via ramp time module (E51
+ E52) at terminal 5 of the amplifier modules (A12 and A13) and further to the
proportional and directional solenoid valves of the remote control blocks (14.2
and 15).
Hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (II and IV)
and arrives via Rotary distributor (19) and travel brake valves (56.1 56.2) at the
hydraulic travel motors.
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8.3
11
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8.3.9 Checks and adjustments for the travel circuit

(1) Protective cap
(56.1 + 56.2)
(2) Locknut
(68.3 + 68.4)
(3) Set screw
(68.3 + 68.4)
(19) Rotary distributor
(M12 M28.4)
Section 8.3
Page 11
Travel brake valves

Anti cavitation valves L.H.
Anti cavitation valves R.H
Pressure check points
Pressure check of the Service Line Relief Valves (SRV)

1. Connect pressure gauge to the required check points :
L.H. track
R.H. track
M12 = Operating pressure for the L.H.-motor M13 = Operating pressure for the R.H.-motor
M28.1 = SRV- pressure L.H.-travel forward
M28.3 = SRV- pressure R.H.-travel forward
M28.2 = SRV- pressure L.H.-travel backward M28.4 = SRV- pressure R.H.-travel backward
2. Unplug solenoid valve Y16 (located at the control and filter panel) to keep
the parking brake applied.
3. Start engine and let it run with max. speed
4. Engage carefully the desired travel motion and keep the pedal in final
position to built up max. pressure.
5. Increase slowly the MRV-pressure while observing the pressure gauge.
Gauge value must remain at 310bar + 5bar.
If the gauge shows a smaller or greater value the SRV must be adjusted
A faulty Anti-cavitation Valve (68.3 + 68.4, 68.6 + 68.7) or a leaking

seal of the rotary joint (19) can influence the SRV pressure reading /
setting. Repair or replace faulty parts if necessary
Adjusting the SRVs :

+
1. Set MRVs to 320 bar 10 bar (using an attachment cylinders)
2. Engage carefully the desired travel motion and keep the pedal in final position
to built up max. pressure.
3. Lower the pressure at the required SRV to 290 bar and then increase up to the
required pressure of 310bar. Proceed with next valves in the same manner.
+
4. Re-set MRVs to 310 bar 5 bar (using an attachment cylinders) and replug the solenoid valve Y16.
How to adjust MRVs and SRVs:
a) Remove protective cap (1) and loosen lock nut (2).
b) Adjust pressure with set screw (3).
c) Secure adjustment by tightening lock nut (2) and replace cap (1).
d) Re-check pressure setting.
It is important that the complete MRV-valve and SRV-valve is firmly

(with 300 Nm) tightened.
Otherwise, internal leaks could occur which result in:
problems of correct adjustment, loud flow noises and high temperatures.
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12
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8.3.10 Function check for the travel parking brake

(252.1) Pressure reducing valve
(M1.2)
(B48) Pressure switch
(M4)
(E35) Text display
(Y16)
Section 8.3
Page 12

Solenoid valve
Parking Brake Release Pressure. (House Brake Pressure)

1. Connect gauge to check point (M1.2).
2. Start the motor and read the pressure. Required = 45 3 bar.
If not, the X-2 pilot pressure adjustment must be corrected. (refer to Section 5).
3. Disconnect plug connection from solenoid valve Y16, now the following message
should appear:
Travel gear house brake ON
4. Operate the travel pedals, the machine should not travel.
If the machine moves the parking brake must be repaired.
5. Reconnect plug connection to solenoid valve Y16, now the travel function must
be possible again and the monitor returns to standard display.
In case of malfunction check the electrical control system and the

function of solenoid valve Y16.
Function Check of pressure switch B48

1.
Connect pressure gauge to check point (M4).
2.
Start the motor. Gauge must show reduced pilot pressure X2 = 35 +2 bar.
3.
Set pilot pressure relief valve (252.1) to 22 bar.
4.
Unplug and reconnect solenoid valve Y16 to allow pressure relieve
from pilot pressure line to house brake.
The text display must show Travel gear house brake ON
5.
Increase the pilot pressure up to 26 bar.
Travel gear house brake ON must disappear.
6.
Reset pilot pressure X2 to 45 3 bar.
Pressure at B48 <24 bar => real time monitor 0 => Brake applied (ON)
Pressure at B48 >24 bar => real time monitor 1 => Brake released (OFF)
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Hydraulic Track Tensioning System Section 9.0

Page 1

Section
9.0
Page
Hydraulic Track Tensioning System
General
9.1
Functional description
3+4
9.2
9.3
Tensioning Cylinder
9.4
Adjustments / Checks
7 + 8 + 9 + 10
9.5
Functional test
10
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9.0
2
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Page 2
9.0
General:
(59)
Rotary distributor (joint).
(ST)
Supply line, pilot pressure from travel parking brake circuit
(118.1)
Supply line shut-off cock.
"O" = open
(118.2 + 118.3) Service shut-off cocks.
"C" = closed
(118.4)
Main shut-off cocks.
(119.1 + 119.2) Membrane accumulator, 1,3 liter (pre-charge pressure 31bar)
(120.1 120.4)
Bladder accumulator, 5 liter (pre-charge pressure 150bar)
(121.1 + 121.2) Check valves (prevents feedback pressure to pilot pressure)
(124.1 124.4)
Track tensioning cylinders
(125.1 + 125.2) Check valves (prevents a cross-over flow)
(141)
Pressure increasing valve.
The hydraulic track tensioning system ensures automatically the correct track
tension.
The pilot pressure pumps (9.1 and 9.3) will supply oil to all four tensioning
cylinders (124.1 124.4).
The maximum pressure is limited by pressure increasing valves (141).
The pressure in the tensioning cylinders transmits the required force to move
the guide wheels to the front, until the correct track tension is obtained.
External forces acting at the guide wheels will be absorbed through the
pressure accumulators (119.1 + 119.2, first stage) and (120.1 120.4, second
stage).
For information about the preventative track inspection, refer to the

Operation and Maintenance Manual.
Functional description on next page
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3
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Page 3
9.1
Functional description:
Illustration Z 22756 and Z 22757 (on next page):
Under normal operating condition shut-off cock (118.4) located on the

valve block (140) in the car body is closed. The shut-off cock (118.1)
located on the valve block (140) in the car body and (118.2 and 118.3)
located inside the side frames are open.
The oil flow of the pilot pressure pumps (9.1 + 9.3), filtered by pressure filters
(68.1 + 68.7) enters port "P" of solenoid valve Y16, via the common pilot
pressure supply line (45 bar) of the central control and filter panel (36).
If solenoid valve Y16 is actuated (i.e. pressure at sensor B48), the oil for the
travel parking brake (reduced to 35 bar by the function of valve 147), flows via
rotary joint (59), shut-off cock (118.1), the orifice, the two check valves (121.1 +
121.2) and the shut-off cocks (118.2 + 118.3) the into the tensioning cylinders
(124.1 124.4).
The resulting force moves the guide wheels toward the front, until the correct
track tension is obtained.
Simultaneously the system is via check valves (125.1 + 125.2) connected to the
pressure increasing valve (141).
External forces acting at the guide wheels will be absorbed through the pressure
accumulators (119.1 + 119.2, first stage) and (120.1 120.4, second stage).
Purpose of the pressure increasing valve
The two system pressures
35 bar with engine stopped

310 bar with engine running
are controlled by the pressure increasing valve as follows.
With stopped motor and switched off ignition there is no pilot pressure (L39) at
pressure increasing valve (141) and only the lowest adjusted pressure of 35 bar
remains in the system.
As soon as the motor has been started, the pilot pressure acts on the pressure
increasing valve. As a result the system pressure can rise to the adjusted pressure
of 310 bar.
continued
02.03.05
9.0
4
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Page 4
9.1
Functional description:
Cont'd.:
Illustration (Z 22757):
Cushioning Function
When the tensioning cylinders (124.1 124.4) are moved in by external
forces, the none return valves (121.1 + 121.2) will be closed.
A certain amount from the displaced oil of the tensioning cylinders is taken
up by the pressure accumulators.
First stage:
at a pressure higher than 31 bar, oil is taken up by the side frame

accumulators (119.1 + 119.2).
Second stage: at a pressure higher than 150 bar, oil is taken up by the center
section accumulators (120.1 120.4).
The system pressure can rise up to 310 bar pressure increasing valve (141)
setting.
With reduction of external forces, the oil is pushed back by the accumulator
pressure into the tensioning cylinders.
If the displaced oil volume was higher than the accumulators could take up,
oil is added from the pilot pressure circuit, as soon as the pressure in the lines
to the tensioning cylinder is lower than 35 bar.
To avoid serious damages to the pilot pressure system in case of a faulty
check valve, pressure relief valve (257.1) with a 55 bar setting is installed.
For information about the preventative track inspection, refer to the

Operation and Maintenance Manual.
To check the accumulator charging pressure refer to PARTS &
SERVICE NEWS AH01531a latest edition.
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5
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Page 5
9.2
The pressure increasing valve is a remote controlled pressure relief

valve.

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11+12)
(13+14)
Pilot valve with valve seat

Valve poppet
Compression spring
Main valve with sleeve
Main piston
Closing spring
Set screw - low pressure 35 bar
Set screw - high pressure 310bar
Piston
Pin
Jet bore
Lock nut
Function:
The valve poppet (2) is connected via the jet bores (11) and (12) with the P
port.
If static pressure increases above the set pressure value, the valve poppet (2)
opens and allows oil to flow freely to tank (T1). This oil generates a pressure
drop in the spring chamber of the main spool, the closing force of the spring
(6) is cancelled, and the main piston (5) opens to allow the pump flow to flow
to tank (T2).
Damped opening and closing is obtained by the throttled volumetric change.
By applying external pressure of Pst max = 60 bar to the main spool (9) via
port X, the pre-tensioning of the pressure spring (3) is increased by the amount
of the piston stroke "S" and system pressure is increased correspondingly.
The setting is fixed by means of the setting screw (7) and lock nut (13); 1 turn
of the screw ~ 150 bar.
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Page 6
9.3
Tensioning cylinder:
(1)
Cylinder tube
(2)
Piston
(3)
Piston guide ring
(4)
Piston guide strap
(5)
Seal ring (light)
(6)
O-ring
(7)
Scraper
(8)
Retracting device
(9)
Seal ring (dark)
(M) Bleeder port

(P)
Oil supply
Maximum permissible piston stroke 360mm!

During bench test an external stroke limitation must be used!
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Page 7
9.4
(1+3+5) Lock nut
(2+4+6) Set screw
(147)
Pressure reducing valve Track tensioning system (35 bar)
(252.1)
(252.2)
Pressure relief valve for pump support pressure X4 (60bar)
(257.1)
Pressure relief valve Safety valve for Travel brake / Track
tensioning system (55 bar)
(M1.1)
Check point X4 pressure (60 bar)
(M1.2)
Check point X2 pressure (45 bar)
(M9.1)
Check point Travel parking brake / Track tensioning safety
pressure (55 bar)
(M9.2)
Check point Track tensioning operating pressure (35 bar)
(Y16)
Solenoid valve travel parking brake
Checking / Setting the 55 bar pressure relief valve (257.1) safety valve
1.
Connect pressure gauges to check point M1.1 + M1.2 + M9.1
2.
Start the both motors.
3.
Check the X4-pressure at M1.1, required 60 bar.
If necessary correct the setting by the function of valve 252.1 as follow:
4.
Unplug solenoid valve Y16.
5.
Increase the pilot pressure X2 by the function of valve 252.2 to ~ 60 bar.
6.
Check the Safety-pressure at M9.1, required 55bar.
If necessary correct the setting by the function of valve 257.1 as follow:
7.
Re-connect solenoid valve Y16.
8.
Re-set the X2-pressure to 45 bar by the function of valve 252.2
Checking / Setting the 35 bar pressure reducing valve (147) supply pressure
1.
Connect a pressure gauge to check point M9.2.
2.
Start the both motors.
3.
Read pressure, required = 35+2 bar
If readjustment is required proceed as follow
a) remove dust cap (a) and loosen lock nut (b).
b) Set pressure with set screw (c).
c) Tighten lock nut (b) and re-install cap (a).
continued
02.03.05
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8
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Page 8
9.4
(1)
Piston
(2)
Lock nut
(3)
Set screw - high pressure
(4)
Lock nut
(5)
Set screw - low pressure
(P)
Plug
(X)
Pilot pressure port
(141)
(118.1)
(118.3)
(118.4)
(119.2)
(120.3 / .4)
(124.3 / .4)
(M11.5)
(M29.2)
(M29.4)
(MRV)
Cont'd.:
310bar
35 bar

Service shut-off cock supply line
Service shut-off cock in the side frame (or the L.H.-side)
Main shut-off cock
Membrane accumulator 31 bar
Bladder accumulators 150 bar
Track tensioning cylinders
Pressure check point (Main control block IV) pump 5
Pressure check point at the track tensioning cylinders L.H.-side
Pressure check point at the bladder accumulators L.H.-side
Main relief valve Operating pressure of main control block IV
Checking / Setting the pressure increasing valve

Pre-conditions: Correct MRV, SRV and pilot pressure setting and the system
must be free of air.
The description is only for the R.H. track. The same procedure applies also
for the L.H. side.
Basic Adjustment:
1.
2.
3.
4.
Connect a pressure gauge to check point M11.5

Start the motors.
Increase the MRV-setting (Block IV), to ~ 330 to 340 bar.
Switch OFF the motors, open cock valve (118.4) to allow pressure
relieve of track cylinders, and close it again.
continued
02.03.05
9.0
9
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Page 9
9.4
Cont'd.:
5.
Move the pressure gauge from M11.5 to M29.4
6.
Connect pressure check point M11.5 with pressure check point M29.2,
using a long pressure gauge hose. (required for the oil supply)
7.
Disconnect the pilot pressure line at port X of the pressure increasing
valve (141) and close the hose with a plug (P).
8.
Loosen lock nut (4) of the pressure increasing valve and screw in set
sleeve (5) until piston (1) comes to stop. (substitution of 35bar pilot
pressure)
9.
Start the motors
10. Stall the hydraulic with the clam opening function (clam cylinders
completely retracted) and observe pressure at check point M29.4.
A pressure of 310 + 5 bar must reached within a time period of 10 15
minutes and must remain at this value.
The maximum pressure will be shown only after the accumulators are
completely filled with oil.
When the pressure reaches the pre-charge gas pressure ( 31 bar and
150 bar) the gauge pointer moves slower depending on the gas
compression.
If the gauge shows a lower or higher value the pressure increasing valve
must be adjusted.
Setting procedure, high pressure stage (Valve 141)
a)
b)
Adjust pressure with set screw (3).
c)
Secure adjustment by tightening lock nut (2).
d)
Re-check pressure setting.
11.
The low pressure setting of the pressure increasing valve must now be
reset (with the pilot pressure line at port X still disconnected):
Setting procedure, low pressure stage (Valve 141)
a)
Stall the hydraulic with the clam opening function (clam cylinders
completely retracted) and observe pressure at check point M29.4.
b)
loosen lock nut (4) and turn set screw (5) ccw until gauge at
check-point M29.8 shows 35 bar.
c)
Tighten lock nut (4).
d)
Re-check pressure setting.
continued
02.03.05
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10
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Page 10
9.4
Cont'd.:
12.
13.
Switch OFF the motors and open cock (118.4) to allow pressure relieve.
Re-connect the pilot pressure line to port X of the pressure increasing
valve (141).
Remove the pressure gauge hose between pressure check point M11.5
and pressure check point M29.2.
Close the cock (118.4).
Re-set MRV (Block IV)to 310 + 5 bar after the check / adjustment is
finished.
13.
15.
16.
9.5
Functional Test
After all adjustments are finished, do the following:
a)
Bleed all air from the system
b)
Place shutoff and pressure relief cocks into correct operating position.
c)
Connect pressure gauge to check point (M29.4).
d)
Start motors.
e)
Travel approx. 10 m with the shovel.
f)
Stop the motors.
g)
The pressure must drop to 35 bar.
If the pressure remains the at a higher or lower pressure*, re-adjust the low
pressure setting at the pressure increasing valve (141).
The pressure may drop below 35 bar after a longer time, this is o.k.
because of internal leakage.
02.03.05
Access ladder
hydraulically operated
Section 10.0
Page 1

Section
10.0
Page
Access ladder hydraulically operated
10.0 General
10.1
Function of hydraulically operated access ladder
3+4
10.2
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2
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Access ladder
Section 10.0
Page 2
10.0 Access ladder hydraulically operated

General
Legend for illustration Z22813a
(A)
Access ladder in lowered position
(B)
Access ladder in upper position (Working position)
(C)
Stop bar
(D)
Inner pivot bracket of the access ladder
(E)
Pull chain for emergency lowering of the access ladder
(Z)
Hydraulic cylinder
(36)
Central control and filter panel
(S84) Ladder control switch for lowering the Ladder
(S84B) Ladder control switch for lifting the Ladder
(S84A) Safety switch for emergency lowering of the access ladder. When the
chain (E) is being pulled down with the motor running the pilot control
system is made inoperative preventing further movement of the shovel.
(S22) Safety sensor, located on ladder pivot bracket
Function of sensor (S22):
Cut out of the pilot control system and actuation of the hydraulic
swing brake with the ladder in lowered position.
(S91) Monitor and control sensor
This sensor monitors the ladder position and controls the moving speed
of the ladder. In case the sensor (S22) fails to function properly, the
sensor (S91) prevents unintended movement of the ladder.
The access ladder is hydraulically operated by the hydraulic cylinder (Z) with
the pilot pressure X2 of 45 bar. The movement of the ladder is controlled by
the function of switch:
S84:
=> Lowering the ladder
S84B
=> Lifting the ladder
Lifting the ladder is only possible with the motor running. The lowering
movement is possible by hydraulic force with the motor running or by the
force of gravity with the motor at stand sill.
If the ladder is not in the final upper position the pilot control is
switched off and solenoid valve Y120 activates the hydraulic swing
brake. The display in the operators cab shows a message.
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3
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Access ladder
Section 10
Page 3
10.1 Function of hydraulically operated access ladder

(2)
Main pump
(8.1)
Pilot pump
(33)
Filter with filter monitoring switch B22
(115)
Hydraulic cylinder
(157)
Solenoid valve Y123a/b
(252.1)
Pressure reducing valve (45 bar) X2-pressure
(252.2)
Pressure relieve valve (60 bar) X4-pressure
(258.1)
Solenoid valve Y125
(258.3)
Pressure relieve valve (safety valve 70 bar)
(258.4)
Shuttle valve
(258.5 + 258.6) Check valves
(258.7)
Orifice
Y125
Solenoid valve: lowering speed control (OFF => reduced speed)
Y123A
Solenoid valve: ON => ladder up
Y123B
Solenoid valve: ON => ladder down
Prime drive is running
Study together with illustration Z22814a and the electric diagram on the next
page.
The pump (8.1) delivers the oil through filter (33) to port A of pressure relief
valve (252.2).
The pressure relief valve (252.2) maintains the adjusted pressure of 60 bar, called
X4-pressure.
By the function of pressure reducing valve (252.1) the X4-pressure will be
reduced to 45 bar (called X2-pressure) and is present at port P of solenoid
valve Y123A/B. If solenoid valve Y123 A or B is energized the oil flows to the
cylinder and the ladder will move up or down. By the function of shuttle valve
(258.4) both service lines are connected to safety valve (258.3), which limits the
pressure to 70 bar.
Return oil from cylinder (115) flows back via solenoid valve Y123A/B to
solenoid valve Y125.
Y125 = ON => Maximum cylinder speed, return oil flow not restricted when
both proximity switches S22 and S91 are not activated (ladder
between top and bottom end position)
Y125 = OFF => Reduced cylinder speed, return oil flow is restricted by orifice
(258.7) when one of the proximity switches S22 (ladder up) or
S91 (ladder down) is activated i.e. cushioning function just
before the final upper or lower end position is reached.
If the ladder is in the top position the activated sensor S22 de-energizes Y125
and energizes Y123A, with the result that the cylinder of the ladder is always
charged with pressure in this position.
If switch S84 is in neutral position and the ladder in bottom position sensor
S91 de-energise all solenoids (Y125; Y123 A+B) and the ladder is blocked.
continued
PC4000-6-E_#08165_Sec_10-0_rev0.doc
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10.0
4
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Access ladder
Section 10.0
Page 4
10.1 Function of hydraulically operated access ladder

Cont'd:
Prime drive is not running and the ladder is in the final upper position
With switch S84 activated in position 2 (ladder down) solenoid valve Y123B
and relay K132 are active. Y123B connects the piston side of the cylinder to
the return line and K132 activates Y125, so that the oil can return without
resistance to the tank. Now the ladder can move down only by its own mass
(due to the force of gravity). The operator has to push the ladder slightly until
it starts moving down by its own weight.
The rod site of the cylinder receives oil via anti-cavitation valve (258.5).
It is not necessary to activate the key switch, because the involved
components are directly battery supplied via fuse F17.
There is an additional pull switch S84A below the ladder support. With this
switch activated the ladder can moved down from the ground.
Make sure that there are no obstacles in the moving range of the
ladder. Stop raising the ladder by releasing the control switch (S84) if
there are any obstacles in the moving range.
Mount the ladder only in completely lowered position.
Do not lift persons or objects (tools) with the hydraulic access ladder.
Serious injury or death could occur.
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5
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Access ladder
Section 10.0
Page 5
10.2 Adjustments / Checks

(1 + 3 + 5) Lock nut
(2 + 4 + 6) Set screw
(252.1)
Pressure reducing valve (45 bar) X2-pressure
(252.2)
Pressure relieve valve (60 bar) X4-pressure
(258.3)
Pressure relieve valve (safety valve 70 bar)
(A)
Access ladder in lowered position
(B)
Access ladder in upper position (Working position)
(C)
Stop bar
(D)
Inner pivot bracket of the access ladder
(E)
Pull chain for emergency lowering of the access ladder
(S84) Ladder control switch for lowering the Ladder
(S84B) Ladder control switch for lifting the Ladder
(S84A) Safety switch for emergency lowering of the access ladder. When the
chain (E) is being pulled down with the motor running the pilot control
system is made inoperative preventing further movement of the shovel.
(S22) Safety sensor, located on ladder pivot bracket
Cut out of the pilot control system and actuation of the hydraulic
swing brake with the ladder in lowered position.
(S91) Monitor and control sensor
This sensor monitors the ladder position and controls the moving speed
of the ladder. In case the sensor (S22) fails to function properly, the
sensor (S91) prevents unintended movement of the ladder.
Checking / Setting the 70 bar pressure relief valve (258.3) safety valve
1.
Connect pressure gauges to check point M1.1; M1.2 and M37.1.
2.
Start the motor.
3.
Lift the ladder to the final upper (working) position, using switch (S84B)
4.
Increase the X4-pressure to 80 bar, by turning in set screws (2) of
pressure relieve valve (252.2).
5.
Increase the X2-pressure to 75 bar, by turning in set screws (4) of
pressure deducing valve (252.1).
6.
Check the setting of pressure relieve valve (258.3) at check point M37.1.
Required 70 bar. If necessary correct the setting as follow:
a) Reduce the pressure with set screw (6) at valve (258.3) to 60 bar
b) Set the pressure to 70 bar 2 bar.
7.
Reset valve (252.2) to 60 bar, valve (252.1) to 45 bar and tighten lock nuts
(1 + 3), adjustment is finished.
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Cable drum
Section 11.0
Page 1

Section
11.0
Cable drum
11.0 General
11.1
Components
11.2
Function
Page
2
3
11.2.1 Controlling of the drive motor
11.2.2 Travel motion control
11.3
Checks and Adjustments
11.4
Description and operating instruction for cam switch 5S4 and 5S6
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11.0
2
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Cable drum
Section 11.0
Page 2
11.0 Cable drum

General
Legend for Illustration Z 22831a
(5M6)
Brake motor
(5S3)
Rotation direction indicator (switch)
(5R1)
Resistor for brake motor torque adjustment
(5S4)
Gear type cam switch for resistor controlling and for
monitoring of the two last cable windings.
(5S6)
Pendulum control cam switch, to detect slack or tight cable
(5S8, 5S9)
Proximity switch to detect cable deflection to right or left
(5S10, 5S11)
Proximity switch for ground contact protection.
Task:
The cable drum, driven by a brake motor with slip ring rotor, is installed to
wind up or unwind the power supply cable automatically.
1. To considerably improve the mobility of the excavator.
2. To make the operation safer (Material and personnel) i.e. less risk to
damage the cable when travelling backwards and less danger of injury
because the cable must not manual moved.
3. To increase the lifetime of the cable, because the cable is not dragging on
the ground.
For the optimal use of the cable drum it is necessary that the operator
understands the system very well.
Regular maintenance is essential
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11.0
3
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Cable drum
Section 11.0
Page 3
11.1 Components
(5M6)
Brake motor
(5S1)
Service switch for manual actuation of cable drum.
(5S3)
(5R1)
(5S4)
Gear type cam switch for resistor controlling and for
monitoring of the two last cable.
(5S6)
Pendulum control cam switch, to detect slack or tight cable.
(5S8, 5S9)
Proximity switch to detect cable deflection to right or left
(5S10, 5S11)
Proximity switch to detect ground contact
(5K7, 5K8, 5K12, 5K13) Relay for brake motor direction controlling
(5K10, 5K11)
Relay for brake motor torque controlling
(5F13)
Circuit breakers
(5B79)
Brake motor temperature probe
(F79)
Motor temperature control unit
(X8)
Terminal box
The resistor 5R1 serves as a series resistor for a three- phase motor with a slip ring
rotor (stand still, sliding rotor-brake motor)
It is a resistor with one or more taps (as a function of drum design), to make a selection
of different star bridges possible. The taps serve to regulate the motor and brake torque
during winding up and unwinding.
With service switch 5S1 is it possible to control the cable drum manually in both
directions (windup, unwind, stop and automatic)
The terminal box X8 contains the terminal rails , the relays 5K7, 5K8, 5K10, 5K11,
circuit breakers 5F13 + 5F14 and motor temperature control unit F79.
Direction of rotation monitoring switch 5S3 opens its contact and de-energizes 5K10
and 5K11 while unwinding (traveling forward) and eliminates the resistor which
controls the star bridge. (Lowest tensioning force)
Gear type cam switch 5S4* reduces the tensioning as soon as half of the cable is
unwinded (contact 21/22 opens and de-energizes 5K11) or stops reverse travelling as
soon as the max. length of the cable is winded up (contact 31/32 opens and deenergizes K178) or stops forward travelling as soon as the safety cable length on the
drum gets unwinded (contact 11/12 opens and de-energizes relay K177).
The proximity switch 5S8 stops L.H. crawler reverse travelling at too much deflection
of the power supply cable to the left (contact br/sw opens and de-energizes K179).
The proximity switch 5S9 stops R.H. crawler reverse travelling at too much deflection
of the power supply cable to the right (contact br/sw opens and de-energizes K180).
The proximity switch 5S10 and 5S11 stops reverse travelling with ground contact.
Pendulum control cam switch 5S6* stops forward travelling at too tight power supply
cable (contact 11/12 opens and de-energizes K177) or reverse travelling at too much
slack of power supply cable (contact 21/22 opens and de-energizes K178).
The motor temperature control unit F79 interrupts all travel motions as soon as drive
motor 5M6 reaches a critical temperature (monitored by sensor 5B79).
*Refer to page 7 for adjustment procedure
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11.0
4
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Cable drum
Section 11.0
Page 4
11.2 Function
(5M6)
Brake motor
(5S3)
(5R1)
(5S4)
Gear type cam switch for resistor controlling
(5K7, 5K8)
Relay for brake motor direction controlling
(5K10, 5K11) Relay for brake motor torque controlling
(5F13)
Circuit breakers
(F79)
Motor temperature control unit
(X2 + X8)
Terminal board
D53
Time relay at the X2 board
11.2.1 Controlling of the drive motor
General:
In the automatic mode of control switch 5S1, the power supply to drive motor
5M6 is controlled by the function of the travel control system, which controls
relay 5K7, i.e. while traveling the contacts of 5K7 are closed and kept closed for
further 10 seconds after stopping the travelling motion (controlled by time relay
D53), before the power supply will be interrupted and the motor brake is active.
The torque of drive motor 5M6 is controlled by the function of the relay 5K10 and
5K11; which changes the resistance at the star bridge (5R1). Both relay are
simultaneously controlled by switch 5S3 (Direction of rotation monitoring
switch), to ensure the lowest tensioning force while unwinding (i.e. traveling
forward)
Winding up (automatic mode of control switch 5S1):
While winding up the NC-contact of switch 5S3 remains closed which allows
voltage to the relay 5K10 and (if the contact 21/22 of switch 5S4 is closed) also to
5K11.
Example travelling reverse:
Cable length on drum: Max. Max. => 5K10 ON + 5K11 ON => max. torque
Cable length on drum: Min. Max. => 5K10 ON + 5K11 OFF => reduced torque
Unwinding (automatic mode of control switch 5S1):
The NC-contact of switch 5S3 opens while traveling forward and de-energizes
simultaneously 5K10 and 5K11, with the result that there is just enough torque to
hold the cable tight.
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5
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Section 11.0
Page 5
Cable drum
11.2 Function
11.2.2 Travel motion control, illustration Z 22835
General:
The cable drum is equipped with safety switches for the protection of the power
supply cable during travelling and turning operations. Movements which could
damage the power cable are automatically switched off.
Cable condition
Monitored by
Travel shut off relay
Directional
Solenoid valves
Travel response
K177
Y20b + Y28b
crawler left + crawler right
Switch / contacts
1. Too tight
5S6 / 1112
forward motion stopped

2. Too slack
5S6 / 2122
K178
Y20a + Y28a

reverse motion stopped
3. Too strong deflection to the left
5S8 / brsw
K179
Y20a
crawler left
4. Too strong deflection to the right
5S9 / brsw
K180
Y28a
crawler right
5. Maximum permissible cable

length on the drum
5S4 / 3132
6. Safety cable winding unwinded
5S4 / 1112
K178
Y20a + Y28a

K177
Y20b + Y28b

forward motion stopped
7. Ground contact
5S10 and/or 5S11
K178
Y20a + Y28a

)
)
If the reverse motion stopped because of a activated ground contact

switch 5S10 or 5S11 it is possible to activate the reverse motion manually
via activation of horn switch at the left control lever in the cab.
Refer to section 8.3 in this Manual for further information.
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02.03.05
11.0
6
PC4000-6-E_#08165_Sec_11-0_rev0.doc
02.03.05
Cable drum
Section 11.0
Page 6
11.3 Checks and Adjustments

(5S3)
No adjustment required. Check the function of contact 2/P.
The built-in switch must open while unwinding.
(5S4)
Gear type cam switch for resistor controlling and safety switch
to detect full cable drum and the last two safety cable windings.
The contact 31/32 must open as soon as the maximum
permissible cable length is on the drum, travel reverse will stop
by deactivated relay K178.
As soon as the last second winding comes up contact 11/12
opens and travel forward will stop by deactivated relay K177.
Adjusting procedure see section 11.4 on next page and check the
function under operating conditions.
(5S6)
Pendulum control cam switch, to detect slack or tight cable.

Adjust the switch in such a way that contact 11/12 opens at
too tight cable and contact 21/22 opens at too slack cable.
Check the function under operating conditions. Make sure
that the shock absorber at the pendulum will work in its
permissible range.
Adjusting procedure see section 11.4 on next page.
(5S8, 5S9)
Proximity switch to detect cable deflection to right or left.

Adjust the distance between switch and metal bar to 7mm.
Check the function under operating conditions.
(5S10, 5S11)
Proximity switch to detect ground contact.

Adjust the distance between switch and metal bar to 7mm.
(F79)
Motor temperature control unit with monitoring LEDs.

(R) red LED on => motor temperature to high.
(G) green LED on => permissible temperature range.
Hysteresis:
Rcold 1k, Rswitch point 3k (Sensor between P1 and P2)
Check the function with potentiometer.
(D53)
Time relay for power cut off after 10 seconds without travelling.
Check adjustment, refer to service Bulletin 21-584 for more
information.
(X2 + X8)
Terminal board
PC4000-6-E_#08165_Sec_11-0_rev0.doc
02.03.05
11.0
7
PC4000-6-E_#08165_Sec_11-0_rev0.doc
02.03.05
Cable drum
Section 11.0
Page 7
11.4 Description and operating instruction for cam switch 5S4 and 5S6
Legend for Illustration Z 22837
(1) Micro switch housing
(2) Actuator (Roller lever)
(3) Cam disc
(4) Adjusting spanner
(5) Cup spring
(6) Tension nut
The cam discs (3), arranged in pairs on the centering discs, can be adjusted
individually and continuously by means of a adjusting spanner (4) The centering
discs can be reversed and are fixed to the square shaft without clearance.
Adjustment can be performed in any position without having to turn the control
shaft. The cam discs, separated from each other by the guard plate, slide past each
other without touching during adjustment. The cam ring next to the cam ring to be
adjusted will not shift and remains in the set position.
Hollow-type rivets prevent accidental shifting of the cam discs.
By selecting the appropriate contact - either make or brake - any angle between 0
and 350 can be set without changing the cam rings.
When the cam hits the actuator (2), the latter will operate the micro switch (1).
Adjustment of the switch mechanism.
1. Loosen the tensioning nut (6) with the handle of the adjusting spanner (4).
2. Bring the adjusting spanner (4) in the position shown on illustration Z22837.
3. Set the cam discs (3) to the required position.
4. Adjust all other cam discs, following this procedure.
5. When all cam discs have been adjusted, tighten the tensioning nut.
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PC4000-6-E_#08165_Sec_11-0_rev0.doc
02.03.05
Hints for reading the

Hydraulic Circuit Diagram
Section 12.0
Page 1

Section
12.0
Page
Hints for reading the hydraulic circuit diagram
General
12.1
12.2
02.03.05
Symbols
12.1.1
Lines, unions
5-6
12.1.2
Components, valves
12.1.3
Sensors
12.1.4
Valves, valve components
9-12
12.1.5
Pumps, motors, cylinders
13-14
12.1.6
Assemblies and main components
15-16
Legend for the circuit diagram (929 663 40)
17-24
PC4000-6-E_#08165_Sec_12-0_rev0.doc
12.0
2
02.03.05
PC4000-6-E_#08165_Sec_12-0_rev0.doc

Section 12.0
Page 3
12.0 General:
Legend for Illustration Z22987
)
Item
02.03.05
The illustrations are used for exemplary explanations only.

Use original circuit diagram for detailed reading
There are more symbols on the following pages shown as in the
diagrams drawn. Some symbols of the diagrams not shown in the
following pages.
Description
Number / Code
Explanation
Diagram No. and Type of the 897 895 40 a

respective machine
PC8000-E
Diagram No. only for the

respective machine
Respective Serial No.
Sheet-No. / Quantity of sheets 01 / 04
1st of four sheets
Co-ordinates to describe the

location of a component
Page 1 on co-ordinate C vertical

and 10 horizontal Remote control
valve 102.1
Component-No. 127
Line-No. with cross hint,
12041
1 C 10
127
L37/3B9
Main control block I

Case drain line (Line No.37)
comes from / goes to sheet 2
coordinate E7
All the components drawn in neutral and pressure less position.

Full wide continues black line shows a main component or assembly. (Ex.: Valve
and Filter panel, Main pump, Hydraulic tank, ...)
Continues black line shows a main hydraulic line. This lines are temporary or
continues load with high or pilot pressure.
Broken line shows a return, drain or control oil line.
Black dot shows a connection point. The position of this connection is not definitely
fixed.
White dot shows a connection or port of a component with a fix definitely position
or port number.
Page 1 shows the high pressure main hydraulic circuits with all pilot control valves,
control blocks, distributor manifold and cylinders or motors.
Page 2 shows all main pumps and pilot pressure pumps with the main pump control
system and the other auxiliary pilot pressure circuits as lubrication system and
ladder.
Page 3 shows the main pump control arrangement, the auxiliary circuits with oil
cooling system and the hydraulic tank.
Page 4 shows the car body hydraulic with travel brakes, travel motors and track
PC4000-6-E_#08165_Sec_12-0_rev0.doc
12.0
4
02.03.05
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12.1
Section 12.0
Page 5
Symbols
12.1.1 Lines, unions
Symbol
Description
Used as / at / on
Oil supply line, can be a

hose or a pipe.
Return oil line, can be a

hose or a pipe.
Case drain (leak) oil line,

can be a hose or a pipe.
Control oil line, can be a

hose or a pipe.
Crossed lines
Pipes or hoses not

connected
Connection point, is a
connection of hydraulic
lines without definite
position
Component connection
point, is a connection with
a definite position at a
component
Plugged connection point,
can be plugged with any
kind of plugs.
Connection between
several lines
02.03.05
Plugged line inside of a

manifold, can be plugged
with different kind of plugs.
Suction line or pressurized

line of main hydraulic circuit
or pilot pressure circuit or
auxiliary circuits (e.g. fan
drive).
Return lines, connected to
the return oil filter chamber
of the main oil reservoir.
Return lines, connected to
the case drain (leak) oil filter
chamber of the main oil
reservoir.
Pilot control line, pump
regulation line and parking
brake control lines.
Connection to components
like, valve blocks, tanks,
pumps, ...
Not used connection
points.
Not used connection
points.
PC4000-6-E_#08165_Sec_12-0_rev0.doc
12.0
6
12.1
Symbols
12.1.1 Line, union
Symbol
10
Description
Used as / at / on
Compensator,
Compensate line length
differences depend on
vibration and temperature.
Quick coupling,
is a special union with
integrated check valve
Oil tank outlet to the

pumps
12
Blind, Orifice,
not adjustable with
orifice diameter in mm
e.g. Oil cooler inlet,
13

With a special quick
coupling.
HP Filter, Fan valve

block....at all important
circuits
14
Distributor block
Connection of lines with

the same destination e.g.
return lines to tank
11
02.03.05
Tank drain couplings, often

removed lines (e.g. at grease
systems with removable
barrels).
PC4000-6-E_#08165_Sec_12-0_rev0.doc

12.1
Section 12.0
Page 7
Symbols
12.1.2 Components, valves
Symbol
Description
Used as / at / on
Accumulator,
is filled with nitrogen gas
with for the respective
accumulator specified
pressure
Screen filter,
the screen size is 1.0 mm
Input line to the remote

control valves, return oil
collecting tube, track
tensioning system
17
Oil cooler,
Hydraulic oil cooler,

PTO oil cooler
18
Breather filter,
On top of PTO or
hydraulic tank
19
Spray nozzles,
inside of a case for
cooling and lubricating
Gearbox (PTO) cooling

and lubricating system
15
16
Installed in suction lines to

the pumps, oil tank outlet,
return oil collecting tube
continued
02.03.05
PC4000-6-E_#08165_Sec_12-0_rev0.doc
12.0
8
12.1
Symbols
12.1.3 Sensors
Symbol
Description
Used as / at / on
20
Pressure switch / sensor

Input = pressure
Output = electrical signal
analogue or digital
e.g. return / leak oil

chamber (digital), high
pressure filter (analogue)
21
Pressure switch
Input = pressure
Output = digital electrical
The switch point is 24 bar
e.g. swing or travel

detection PC3000,
22
Temperature sensor,
Input = temperature
Output = electric signal
proportional to the
temperature
e.g. hydraulic tank
23
Level sensor,
Input = fluid level
Output = electrical signal
analogue or digital
Hydraulic tank, fuel tank
24
Chip sensor,
Input = contaminate oil
Output = electrical digital
signal
Main pumps
02.03.05
PC4000-6-E_#08165_Sec_12-0_rev0.doc

12.1
Section 12.0
Page 9
Symbols
12.1.4 Valves, valve components
Symbol
Description
Used as / at / on
25
Manuel operated unit

Lever
Valve in track tensioning

system,
26
Electric / magnetic
operated unit
Solenoid
Solenoid valve
27
Pilot pressure
controlled unit
Pressure relief valve, disc

brake, ...
28
Spring,
with fixed force
Solenoid valves,
29
Spring adjustable
spring force is adjustable
Pressure relieve valves,....
30
Check valve
In drawn pos.: from right
to left free flow, from left
to right blocked flow.
31
Check valve spring

loaded
Opened in flow direction
only against spring force
= pressure
Double check valve,
in drawn pos.: opened
only from the left to the
bottom or from the right
to bottom
e.g. main pump outlet,

swing brake valve block,
anti cavitation valves at
main control blocks or
distribution manifold
By pass of the return oil
filter, by pass of
secondary filter
32
02.03.05
Swing brake control,
PC4000-6-E_#08165_Sec_12-0_rev0.doc
12.0
10
12.1
Symbols
Symbol
33
12.1.4 Valves, valve components

Description
Used as / at / on
Shut-off Valve with
Gate valve between main oil
monitoring switch,
reservoir and suction tank
the adjustable switch
monitors the valve position
34
2/2 control valve

manual operated,
2/2 cock valve
Track tensioning system
35
3/2 control valve

manual operated,
3/2 cock valve
Change over valve from

electronically pump
regulation to emergency
mode (hydraulically
pump regulation)
36
4/2 directional control valve

as solenoid valve
4/2 way solenoid valve,
electrically controlled.
Neutral position:
P-A and B-T connected.
Variable throttle valve
hydraulically controlled
pilot control port pressure
less = maximum restriction
3/2 directional control
solenoid valve, seat
design = leak oil free
neutral = port P-A open
4/3 directional control
solenoid valve
in neutral all ports closed
External pilot
controlled proportional
floating valve
e.g. swing parking brake,

travel parking brake,
ladder controlling,,
37
38
39
40
02.03.05
Travel brake valve,

located in the car body
Service arm controlling
Ladder controlling,
service arm controlling
PC 3000 and PC4000

with floating system
PC4000-6-E_#08165_Sec_12-0_rev0.doc

12.1
Section 12.0
Page 11
Symbols
12.1.4 Valves and valve components
Symbol
Description
Used as / at / on
41
Main control valve

Standard control valve for
standard function
two directions of cylinder or
In neutral position:
motor.
open pump flow (P-PU) and
control port flushing (T a, T
b), in position a or b closed
circulation port (P- PU)
42
Main control valve

pressure less lowering
Neutral position: open pump
flow (P-PU), control port
flushing (T a, T b)
Position b: closed circulation
port (P-PU), normal function
P B and B - T,
Position a: open circulation
port P PU, only port B T
connected
Main control valve floating
function
Neutral position: open pump
flow (P-PU), control port
flushing (T a, T b),
Position b: closed circulation
port (P-PU), normal function
P B and B - T,
Position a: open circulation
port (P PU) = A, B, T, P
connected together via tank
Pressure reducing valve,
assembly
Variable inlet pressure at port
B and constant lower output
pressure at port A, output
pressure is adjustable.
43
44
02.03.05
Control valve for pressure

less lowering. Used to assist
the floating function of boom
and stick,
Control valve with floating

function in position a,
e.g. floating valve for boom
or stick, .
Emergency mode
pressure (X3-pressure),
pilot oil pressure
PC4000-6-E_#08165_Sec_12-0_rev0.doc
12.0
12
12.1
Symbols
12.1.4 Valves and valve components
Symbol
Description
Used as / at / on
45
Pressure relief valve,

direct controlled and
adjustable
e.g. ladder controlling,

service arm controlling ..
46

with anti cavitation
valve (check valve)
Assembly, external drain
at port Y
Secondary relieve valve

at main control blocks
47

pressure relieve valve with
variable setting, pilot
pressure controlled via port
X. Low pilot pressure = low
relieve pressure
Swing brake block, track

tensioning system.
48
Proportional pressure
valve, reduce the
pressure in port A
proportional to the
solenoid current.
4 port proportional
pressure relief valve,
direct operated by a
proportional solenoids.
Remote control valves to

control the main control
blocks,
50
Pressure relief valve,

mechanical and
hydraulically via pilot
port X adjustable, oil
drain port Y
Radiator and oil cooler

fan drive
51
Throttle check valve

with secondary relieve
valve, throttle and
secondary valve
mechanical adjustable,
external drain at port Y.
Distribution manifold
normally in the line to the
cylinder piston side.
49
02.03.05
Pump regulation, only

output port A is used for
our systems
PC4000-6-E_#08165_Sec_12-0_rev0.doc

12.1
Section 12.0
Page 13
Symbols
12.1.5 Pump, motor, cylinder
Symbol
Description
Used as / at / on
52
Single acting Cylinder,

pressurised moving only
in one direction, return by
external force
Track tensioning system
53
Double acting Cylinder,

Cylinder in which the fluid
pressure operates alternately
in both directions (forward
and backward strokes)
A = Piston side
B = Rod side
Attachment i.e. boom,

stick, bucket or clam
cylinder
54
Drive shaft of a motor

or pump with one
direction
Main pumps, swing

motor, fan drive, travel
drive
55
Hydraulic pump with fix

volume per revolution
suction port S and pressure
outlet P
Fan pump, circulation

pump, pilot pump, PTO
lubrication pump
56
Hydraulic pump with

variable output volume
per revolution
with external case drain
Main pumps
57
Hydraulic pump
assembly
with pump bearing
lubrication, one direction
and external case drain
Main pumps
02.03.05
PC4000-6-E_#08165_Sec_12-0_rev0.doc
12.0
14
12.1
Symbols
12.1.5 Pump, motor, cylinder
Symbol
Description
Used as / at / on
58
Variable hydraulic
pump with charge
pump
and external drive shaft
bearing lubrication
Main pump
59
Hydraulic motor
can be used in both
direction, with external
case drain L
Fan motor
60
Motor with disc brake

disc brake is spring
loaded it means:
pressure less pilot line =
maximal brake torque
Travel motor
61
Variable swing motor

with integrated control
valves and flushing
valves
Swing motor PC5500
02.03.05
PC4000-6-E_#08165_Sec_12-0_rev0.doc

12.1
Section 12.0
Page 15
Symbols
12.1.6 Assembly and main components
Symbol
Description
Used as / at / on
62
Lubricant pump drive

differential cylinder with
integrated control valves
to propel the grease pump
Lubricant pump station

for central lubrication
system and swing ring
lubrication system
63
Swing brake valve

assembly,
act as a hydraulical back
pressure system parallel
to a motor with variable
pressure setting and
independent pressure
side. Input port A or B
and outlet on the opposite
connection to the motor..
Swing brake system.
64
Rotary joint
Upper part with
connections drawn to
the top, lower part with
connections drawn to
the bottom
Hydraulical connection
between superstructure
and car body
65
Travel brake valve block

with secondary pressure
relieve valve
is connected in the line to
the travel motors. The
return oil flow is restricted
according to the pressure
inlet.
mounted in the supply

line to the travel motors,
is located in the car body
02.03.05
PC4000-6-E_#08165_Sec_12-0_rev0.doc
12.0
16
12.1
Symbols
12.1.6 Assembly and main components
Symbol
Description
Used as / at / on
66
Remote control lever to

blocks
Control lever in the

operators cabin
67
Remote control pedal to

blocks
Control lever in the

operators cabin
68
Remote control valve to

direct the pilot pressure
proportional to the lever
deflection to the A or
B-side of the main control
blocks.
P=
Pilot pressure line
L=
Return line
1 + 2 = Controlled output
Electric-hydraulic control
system. Electrical signals
from the joysticks or
pedals are used to operate
the remote control valves.
69
Hydraulic oil tank with

leak and return oil filter,
back pressure valve and
sensors
Main hydraulic tank
02.03.05
PC4000-6-E_#08165_Sec_12-0_rev0.doc

Section 12.0
Page 17
12.2 Legend for the circuit diagram (929 663 40):

(1) - (4)
(5.1)
(5.2)
(6)
(7)
(8.1)
(8.2)
(9)
(10)
(11)
(12)
(13.1)
(13.2)
(13.3)
(13.4)
(14.1)
(14.2)
(14.3)
(15)
(16.1 + 16.2)
(17.1)
(17.2)
(18)
(19)
(20.1)
(20.2)
(20.3)
(20.4)
02.03.05
Main hydraulic pumps A4VSLO 750 LR3DN / 30L Axial

piston pump (swash plate type)
Fan drive pump Hydraulic oil cooler A7FO 63RNZB01
Axial piston pump (fixed displacement with, variable setting)
Not used
Not used
Oil intake pipe with bleeder screw (Gear pump 8.2)
Gear pump R1A5100C3A1A Pilot pressure - Pump
regulation - Pump bearing lubrication
Gear pump R1A5100C3A1A PTO-gearbox lubrication
Control block III MO-3469-00 / 3MO-40
Special spool for lowering the boom (without pump pressure)
Control block I
MO-3468-00 / 3MO-40
Control block II
MO-3455-00 / 4MO-40
Special spool for lowering the boom (without pump pressure)
Control block IV MO-3454-00 / 4MO-40
High pressure filter at Control block III
High pressure filter at Control block I
High pressure filter at Control block II
High pressure filter at Control block IV
Manifold
Grease pump (Hydraulic Cylinder)Lincoln Power Master
Central Lubrication System
Grease pump (Hydraulic Cylinder)Lincoln Power Master
Slew ring Lubrication System
Service line relief valve (SRV) Clam closing 150 bar
Rotary distributor
Orifice - bearing lubrication Main pump I
Orifice - bearing lubrication Main pump II
Orifice - bearing lubrication Main pump III
Orifice - bearing lubrication Main pump IV
PC4000-6-E_#08165_Sec_12-0_rev0.doc
12.0
18
(21.1)
(21.2)
(22)
(23)
(24)
(25)
(26)
(27.1 27.11)
(28.1 28.16)
(29)
(30)
(31.1)
(31.2)
(32.1 32.4)
(33)
(34.1)
(34.2)
(35)
(36)
(37.1)
(37.2)
(38)
(39.1 + 39.2)
(40)
(41)
(42)
(43.1)
(43.5)
(44.1 + 44.2)
02.03.05
Travel gear drive L.H.

Axial piston motor A2FM 500 /60W-VZH-01
Travel gear drive R.H.
Axial piston motor A2FM 500 /60W-VZH-01
Not used
Not used
Pressure switch B24 monitors item (92.1) (92.2)
Not used
Not used
Base plate for solenoid valves
Solenoid valves 4/2-directional control valve
Pressure relief valve PTO gear lubrication
Hydraulic oil level gauge
Pressure relief valve - Hydraulic oil cooler fan drive, with
solenoid valve Y6a / Y6b for fan RPM control
Not used
Restrictor, shock absorbers for the hydraulic oil cooler
Pressure filter (B22) pilot pressure, pump regulation, pump
bearing lubrication, track tensioning, grease pumps
Pressure filter (B28) Hydraulic oil cooler fan drive
Not used
Pressure filter (B27) - PTO gear lubrication
Axial piston motor A2FM 63 /61W-PAB-03
Axial piston motor A2FM 63 /61W-PAB-03
Check valve - ACV for hydraulic oil cooler fan drive
Hydraulic oil cooler
Suction oil tank
Main oil reservoir
Temperature transmitter B49-1 PTO gear oil temp.
Temperature transmitter B15 Hydraulic oil temp.
Adapter
PC4000-6-E_#08165_Sec_12-0_rev0.doc

Section 12.0
Page 19

(45)
(46.1 + 46.2)
(47)
(48.1 + 48.2)
(49)
(50)
(51.1 + 51.2)
(52)
(53)
(54)
(55)
(56.1 + 56.2)
(57.1 + 57.2)
(58)
(59.1 59.4)
(60.1)
(60.2)
(61.1 + 61.2)
(62.1 62.3)
(63)
(64.1 64.9)
(65.1 65.4)
(66.1 66.12)
(67.1 67.4)
(68.1 68.7)
(69.1 69.23)
(70.1 70.13)
(71)
(72)
(73)
(74)
02.03.05
Service line relief valve (SRV) Clam closing 150 bar the
main control block II
Block
Pressure reducing valve Track tensioning system
Swing parking brakes Spring loaded multi disk brake
Not used
Not used
PTO gear oil cooler
Not used
Case drain filter
Back pressure valve
Travel brake valve block
Travel parking brakes Spring loaded multi disk brake
Not used
Return oil filter
Slew gear drive L.H.
Axial piston motor A2FLM 355 /60W-VZH-01
Slew gear drive R.H.
Axial piston motor A2FLM 355 /60W-VZH-01
Swing brake valve block
Shut-off valve Truck tensioning system
2/2-directional control valve (manual operated)
Pressure switch B17 Min. PTO gear lubrication pressure
Anti cavitation valves (ACV) at the distributor manifold (42)
Restrictor block with service line relief valve (SRV) at the
distributor manifold (42)
Service line relief valve (SRV) at the main control blocks
Dust cap for item (77.1 77.4)
Check valve Anti cavitation valve at the main control blocks
Cover plate at the main control blocks
Restrictor block with service line relief valve (SRV) at the
distributor manifold (42)
Not used
Not used
Not used
Not used
PC4000-6-E_#08165_Sec_12-0_rev0.doc
12.0
20
(75.1)
(75.2)
(76)
(77.1 77.4)
(78)
(79)
(80)
(81)
(82.1 + 82.2)
(83.1 83.4)
(84)
(85)
Pressure transducer B164 Case drain filter camber

Pressure transducer B163 Return oil filter camber
Not used
Not used
Not used
Proportional pressure reducing valve Y61 Pump regulation
Not used
Bladder Accumulator 5 liter, 150 bar
Track tensioning cylinder
B32
Bladder Accumulator 10 liter, 10 bar
(86.1)
(86.2)
(87)
(88)
(89.1 + 89.2)
(90)
(90.1)
(90.2)
Level switch B4 Minimum hydraulic oil level

Level switch B50 Hydraulic oil refilling indication
Shut off valve with S31 (Gate valve)
Compensator
Membrane accumulator 1,3 liter, 31 bar
Strainer
Pressure switch B48 travel parking brake operating pressure
Pressure switch B16 Swing parking brake operating
pressure
Not used
Breather filter
Not used
Not used
Not used
Solenoid valves 4/3-directional control valve
Not used
Check valve
Not used
Hydraulic cylinder access ladder
Not used
Not used
Not used
(91)
(92.1 + 92.2)
(93)
(94)
(95)
(96)
(97.3)
(98)
(99.5)
(100)
(101)
(102)
(103)
(104)
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Section 12.0
Page 21

(105)
(106)
(107)
(108)
(109)
(110)
(111)
(112)
(113.1 + 113.2)
(114)
(115)
Not used
Pulsation damper, accumulator 0,65 liter, 1 bar
Not used
Junction block
Oil intake pipe with bleeder screw (Gear pump 8.1)
Not used
Pressure transducer (B85-1 & B86)
Not used
Not used
(116)
(117)
(118)
(119.1 119.4)
(120.1 + 120.2)
(121)
(122)
(123)
(124)
(125)
(126.3)
(126.4)
(127)
(128.1 128.4)
(129.1 129.4)
(130)
(131)
(132.1 + 132.2)
(133 135)
(136)
(137.1 + 137.2)
(138.1 + 138.2)
(140)
(141)
Not used
Not used
Strainer return oil collector tube
Strainer suction line of main pumps
Adapter
Not used
Not used
Not used
Pressure relief valve Medium speed cooler fan
Not used
Pressure transducer Back pressure valve (B166)
Pressure transducer pressure Hydraulic oil cooler (B165)
Pressure transducer Hydraulic oil level (B105)
Pressure transducer main pumps (B87a/ B87b/ B87c/ B87d)
Floating valves (single control blocks) used
Valve block (Track tensioning system)
Pressure transducer suction oil tank (B162)
Block
Block
Junction block
Check valves
Check valves
Pressure increasing valve (track tensioning system)
Shut-off valve Truck tensioning system
02.03.05
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12.0
22
(247)
(248.1)
Option: fast motion for travel not used

Solenoid valve 4/2-directional control valve (swing brake)
(248.2)
(249)
(250)
(251)
(252.1)
(252.2)
(253.1)
Solenoid valve 4/2-directional control valve (swing parking brake)

Solenoid valves 4/3-directional control valve (ladder)
Cartridge valve block (complete)
Manifold of cartridge valve block
Pressure relief valve for pump support pressure X4 (60bar)
Change over valve Electronic pump regulation or hydraulic
constant regulation
(253.2)
Pressure reducing valve hydraulic constant regulation
(253.3)
Orifice
(255.1)
Solenoid valves 3/2-directional control valve (Y126)
(255.2)
(255.3)
Solenoid valves 3/2-directional control valve (Y17a)
(255.4)
Pressure reducing valve Qmax
(256.3)
Proportional pressure reducing valve Y127 Swing brake
(256.4)
Double check valve (shuttle valve)
(256.5) + (256.6) Check valves
(257.1)
Pressure relief valve (55 bar) safety valve to protect the
travel parking brakes in case of a defect rotary distributor
(257.2)
(257.3)
Check valve
(257.4)
Not used
(258.1)
Solenoid valve (Y125)
(258.3)
Pressure relief valve access ladder
(258.4)
Double check valve
(258.5 + 258.6) Check valve
(258.7)
Orifice
02.03.05
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Section 12.0
Page 23

M1.1
M1.2
M2
M3
M3-1
M4
M5-1
M6
M7
M8
M9
M9
M10
M10
M11
M12
M13
M14
M16.1 + M16.2
M17.1 + M17.2
M19
M20
M21.1 + M21.2
M22
M24 + M25
M26.1 + M26.2
M27
02.03.05

PTO gear lubrication pressure
X1 pressure, hydraulic constant regulation only
Release pressure for travel parking brake and operating
pressure of the track tensioning system
X1 pressure general (electronic or hydraulic constant
regulation general)
Hydraulic oil cooler fan drive operating pressure
Back pressure inside return oil filter chamber
Travel parking brake safety pressure (55 bar)
Back pressure inside case drain filter chamber
Back pressure for hydraulic oil cooling system
Swing parking brake operating pressure (45 bar)
Operating pressure, Pump 3
Boom cylinder piston side
Bucket cylinder piston side
Clam cylinder rod end
Stick cylinder piston side
Stick cylinder piston side
Clam cylinder piston side
Bucket cylinder piston side
Boom cylinder piston side
Pilot pressure / swing operation brake
PC4000-6-E_#08165_Sec_12-0_rev0.doc
12.0
24
M28.1
M28.2
M28.3
M28.4
M29.1 + M29.2
M29.5 + M29.6
M29.3 + M29.4
M30-1
M33
M34
Operating pressure, track tensioning system

Reduced X3 pressure to pump No 1 Qmax (~ 15 bar)
Option operating pressure: fast motion for travel not used
M36
M36.1 + M37.2
M36.2 + M37.1
M37.1
M37.2
M39
M40
M41
M42
X3 pressure pumps No 2 + No 3 + No 4
Operating pressure, L.H. swing
Operating pressure, R.H. swing
Hydraulic cylinder access ladder piston side
Hydraulic cylinder access ladder rod side
Proportional pressure to hydraulic swing brake
02.03.05
Operation pressure L.H.-crawler forward

Operation pressure L.H.-crawler backwards
Operation pressure R.H.-crawler backwards
Operation pressure R.H.-crawler forward
Bleeder and pressure check point, track tensioning cylinder
PC4000-6-E_#08165_Sec_12-0_rev0.doc

Electric Circuit Diagram
Section 13.0
Page 1

Section
13.0
Page
Hints for reading the electric circuit diagram
13.1
Designation of electrical devices
13.2
Symbols
3+4
13.3
General information
5+6
13.4
Reading a circuit diagram
7+8
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Section 13.0
Page 2
13.1 Designation of electrical devices

Indicating letter
A
B
C
D
E
F
G
H
K
L
M
N
P
Q
R
S
T
U
V
W
X
Y
Z
PC4000-6-E_#08165_Sec_13_0_rev0.doc
Kind of component
System, subassembly, parts group, trigger boxes, control units
Transducer for conversion of non-electrical variables to electrical
variables, and vice versa.
Speed sensors, pressure sensors, pressure switches, oil-pressure
switches, temperature sensors
Condenser, capacitor, Condensers and capacitors, general
Elements with time lag, memory elements, binary elements
Various devices and equipment
Protection device
Fuses, current protection circuits
Power supply, generator
Batteries, generators, alternators
Monitor, alarm, signaling device
Indicator lights, signal lights, headlights, warning buzzers, horn
Relay, contactors
Inductor
Coils, windings
Motor
Regulators, amplifiers
Measuring instrument
High voltage switching units
Resistors, heating devices
Switches, selectors
Transformer
Modulator, converter from one electrical in an other electrical value
Semiconductor, electron tubes, diodes, rectifiers, zener diodes
Transmission path, conductor, antenna
Terminal, Plug, Plug and socket connection
Electrically actuated mechanical device
Solenoid-operated valves
Compensating units, filters, limiters cable connection
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13.0
3
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Section 13.0
Page 3
13.2 Symbols
Our common used symbols in accordance to VDE/IEC (Association of
German Electrical Engineers DIN 40710 - 40716 and the International
Electrical Commission) differ for the most part from the symbols in
accordance to JIC/ASA (Joint Industrial Concil and American Standard
Association) USA and Canada JIC EMP-1-1967 and ASA 2 32-3).
For this reason the following comparative chart.
1) Normally open
contact
2) Maintained
contact
4) Normally
closed contact
5)
7) Manual operated
switch isolator,
disconnect switch
10) NC contact with
time lag
8) Foot-operated
push-button
switch
11) Multi-position
switch selector
13) Contacts with

time lag
14) Resistor
general
16) Battery
17) Tapped
resistor
18) Voltmeter
19) Inductive
resistance
20) Continuously
adjustable,
general
21) Recording
instrument
22) With iron core
23) Adjustable in
steps
24) Signal lamps

pilot lights
25) Continuously
adjustable
26) Potentiometer
rhesostat
27) Operating coil

solenoid
28) Transformer
29) Capacitor
general,
continuously
adjustable
30) Rectifier, semi

conductor
PC4000-6-E_#08165_Sec_13_0_rev0.doc
Push-button
switch
3) Single pole
two way contact
break before make
6) Limit switch
NO contact
NC contact
9) Pressure
operated switch
12) Indicating
instrument
(general) symbol
15) Ammeter
02.03.05
13.0
4
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Section 13.0
Page 4
13.2 Symbols
31) Rectifier bridge
32) Thermal over load limit
33) Phase, 4-wire system
34) Current transformer
35) Undervoltage relay
36) Junction of conductors
37) Voltage transformer
38) Temperature relay
39) Junction
40) Circuit interrupter
41) Contactor
42) Terminal
43) Circuit breaker, three

phase
44) Generator (G)Motor (M)
45) Terminal
46) Thermal over- ground,

load protection
47) 3-phase-motor
48) Earthing, general
49) Magnetic over- socket

current protection
50) 3-phase squirrel cage
51) Plug and
52) Slipring motor
53) Fuse with bolted contacts 54) 3-phase squirrel cage

induction motor in
Star-delta starting
55) Thermal overload relay 55) Two speed motor
(tapped windings)
(for ex. 8 to 4 poles)
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13.0
5
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02.03.05

Section 13.0
Page 5
13.3 General information

Komatsu circuit diagrams
Each sheet has the following information in the bottom right hand corner:
Diagram Number
example: 897 844 40
Machine Type
example: PC4000-6
Sheet Number and Total Number of sheets 01/63 - 02/ . etc.
Each sheet is numbered from 8 (at the left corner) to 1 (at the right corner) along the
top and bottom lines, and lettered down from F (at the top) to A (at the bottom)
along the left and right side lines.
This coordinate system enables you to find components easily.
On the table of contents, page one, the individual circuits are listed up with the
respective page number.
Example: The circuit for the superstructure lighting is shown on page 39.
Pages number two, three and four are cross reference lists of component codes
related to page numbers.
Example: The relay with the component code K1-1 is shown on page 8.
On page five is a list of answers to frequently asked questions (FAQ) concerning
abbreviations, function of components (e.g. time relays) mathematical symbols etc.
used in the diagram.
All electrical components are connected via cable harnesses to the main switch
board X2. There is only one Plug connector in between, which is always located
close to the respective component like sensors, solenoids etc.
All 24 volt wires are blue and have a printed code (every 10 cm) at each end of the
wire. (see illustration)
The first part of the code shows the required connection and the second part gives
the information what is connected at the other side of the wire.
Example:
going to
coming from
coming from
going to
X2S
45
= X2-Board, terminal group S

= Terminal No 45
Y136 = Plug connector to solenoid

.1 = Terminal 1 of connector
All circuits are shown currentless and all relays and switches are in neutral position.
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13.0
6
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02.03.05

Section 13.0
Page 6
13.3 General information

Explanation of the Drawing Concept
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
Drawing number
Sheet number / quantity of sheets
Designation of drawing
Designation of component or assembly
Column (vertical sections)
Lines (horizontal sections)
Component symbol
Neutral wire / machine ground
Designation of phase
Phase strip
Terminal strip and terminal
Cable plug and pin number
Relay coil
Relay contacts, partially with detailed information
Cross reference for the continuation, Page / Column
Indication where the relay contact opens or closes
Location of the Main Terminal Boxes

(X1)
Dashboard inside the cabin
(X2)
Main switch board inside the cab base
(3E14-1) Electronic control module (ECM- Quantum) left bank of the engine
(3E54-1) Electronic control module (ECM- Cense) flywheel end of the engine
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13.0
7
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02.03.05

Section 13.0
Page 7
13.4 Reading a Circuit Diagram.

Examples are shown by sectional drawings out of the electric circuit

diagram 897 844 40 page 08.
(1)
Section F8 / sheet 08
The hint F11/06.1 indicates that the wire from F11 is continued on
sheet 06 column 1.
(2)
Section C4 / sheet 08
Shown is the relay coil K51-1 only and not its contacts.
The contacts are shown somewhere else in the diagram.
Switching and contact positions are shown below at the foot of that
particular circuit in row C-C as shown below.
Example for K51-1:

08.5
:
:
:
1
5
2
6
3
7
4
8
9
10
11
12
opens on sheet 8 section 5 when relay is energized

Not used
Not used
Not used
When diodes are fitted to a relay, they are fitted to allow a current flow in one
direction only. An LED* (Light Emitting Diode) indicates a current flow if it
lights up.
When diodes ** are fitted anti-parallel to a relay coil, they absorb the high
induced voltage caused by making and breaking the current flow through the
coil.
This occurs each time we operate a switch supplying current to the coil. The
diode effect allows the induced current to circulate within the coil windings and
decay when the energy to the coil is cut.
*
**
LED between A1 and coil

Diode between A1 and A2.
(3)
Section F7 / sheet 08
Connectors and Terminals are identified by a letter and number
code. X2 o 23-28 = Terminal box X2 Terminals 23 to 28 are linked
with a metal bridge.
continued
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13.0
8
PC4000-6-E_#08165_Sec_13_0_rev0.doc
02.03.05

Section 13.0
Page 8
Cont.:
13.4 Reading a Circuit Diagram.
(4)
Section E 1 sheet 08
The components have a letter and a number prefix, and these are
explained below in rows A and B.
Components are depicted in a system unique to VDE/IEC
(Association of German Electrical Engineers DIN 40710-40716 and
the International Electrical Commission) or to KMG standard.
S27 = Toggle switch (with non-automatic return)
a.
F11
b.
F11 / 10.5 =
c.
S27 / 20.7 = Line S27, comes from switch S27, sheet 08 section 1
and continues on sheet 20 section 7.
Circuit breaker (24V power supply)

Power line F11, comes from circuit breaker F11, sheet
08 section 8 and continues on sheet 10 section 5.
Function:
If switch S27 is actuated, terminal A and B are connected and 24VDC will
energize the coils of K121 and K121a on page 08 and simultaneously via line
S27 a digital input to the PLC on sheet 20 section 7.
Now the machine can be operated in emergency mode and a warning text
appears on the display.
PC4000-6-E_#08165_Sec_13_0_rev0.doc
02.03.05
Electronic Control System

ECS
Section 14.0
Page 1

Section
14.0
Page
Electronic Control System ECS
14.1
14.2
14.3
14.4
14.5
14.6
General Design of the ECS-T System
14.1.1
Input and outputs of the PLC
14.1.2
14.1.3
14.1.4
Task
PLC DIGSY plus
Definitions; Symbols and Abbreviations
3
4
5 + 6 +7
How to Proceed due Maintenance and Installation
8+9
14.2.1
14.2.2
14.2.3
10 + 11
12
13
Meaning of the Status LEDs

Short Circuit Marker -LED MK
Diagnostic for Temperature-Module ANM
Front Connector Arrangement
14
14.3.1
14.3.2
14.3.3
14.3.4
14 + 15
16 + 17
18
19
Front Connector Arrangement BIM-Module

Front Connector Arrangement, ANM-Module
Ground connection of the Control Unit
Interface-Connection COM SP /SK
Power supply
20
14.4.1
14.4.2
14.4.3
14.4.4
14.4.5
20
21
22
22
22
Operation Voltages +24 V

Safety Precautions for Faultfinding
CPU Voltage Range
Electric Classification
Fuse
Function explanations with electrical diagram
23
14.5.1
14.5.2
14.5.3
14.5.4
23
24
25 + 26
27
General
Pressure Measuring
Temperature Measuring
Temperature Resistance Chart PT100
Hints for reading the functional flow charts
28
14.6.1
14.6.2
28
29
PC4000-6-E_#08165_Sec_14-0_rev0.doc
General
Example
02.03.05
14.0
2
PC4000-6-E_#08165_Sec_14-0_rev0.doc
02.03.05

ECS
Section 14.0
Page 2
14.1 General Design of the ECS System

ECS
Legend:
Illust. Z 21407a
(1)
PLC Programmable Logic Control (DIGSY plus )
(2)
(3)
(4)
(5)
(6)
(7)
(8)
I/ O
Text display
Keys for function control and pre-adjustments
Outlet X27 for data transfer
Field computer system (like MODULAR MINING)
Printer
Memory card unit
Laptop
Input / Output data transfer
Items 5 to 8 are optional equipment
Meaning of the PLC front cover codes
BIM
Binary Module
ANM
Analogous Module
MK
Short Circuit Memory
A
Digital Output
E
Digital Input
DIAG
Diagnostic
More in detail see page 4
PC4000-6-E_#08165_Sec_14-0_rev0.doc
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14.0
3
PC4000-6-E_#08165_Sec_14-0_rev0.doc
02.03.05

ECS
14.1.1
Section 14.0
Page 3
Input and Output of the PLC, Illust. Z 21408

PLC = Programmable Logic Control
(Programmable Logic Control = Control system with a write-readingmemory, whose content can be altered (via an serial interface) by a PC and
the resp. Software.
No mechanical action necessary.)
14.1.2
Task
The PLC receives from the monitored excavator components the actual
values and does an evaluation.
The evaluation results in a control and display function.
See I / O connection table (chapter 10) and electric circuit diagram for I / O
levels and ports.
The picture shows as an example the application for a two motor

version.
PC4000-6-E_#08165_Sec_14-0_rev0.doc
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14.0
4
PC4000-6-E_#08165_Sec_14-0_rev0.doc
02.03.05

ECS
14.1.3
Section 14.0
Page 4
PLC DIGSY plus (circuit diagram code E6)

Legend for illustration Z 21409b
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Central Processing Unit (CPU) board.

Binary Module (BIM) board.
Analogues Module (ANM) board.
MK Output short circuit marker LED red
Input state-LED green, Inputs E1.1 - E1.8 up to E14.1-E14.8
Input or Output State-LED red (A2/ E9, Af/E10, A6/E11,
A8/E12, A14/E21) Can be used as Inputs or Outputs
Output state-LED red, Output A1.1 - A1.8 up to A13.1-E13.8
Diagnostic-LED (DIAG), (green flashing = OK.)
5Volt Voltage-LED (+5V), (green = OK.)
Diagnostic LED for ANM
COM SP Interface (COM SP) (Text display connection)
COM SK Interface (COM SK) (PC-Connection)
Binary Module BIM-plug-in location (slots) (X1-X5)
Analogous Module ANM-plug-in location (slots) (X6-X8)
Ground Connection (GND)
The quantity and configuration of the BIM and ANM Module can be
vary, depend on the excavator typ and additional options.
MK-LED, The short circuit marker are used to indicate an external short to GND
MK1, MK3, MK5, MK7 & MK9- LED for outputs A1.1 - A1.8
A3.1 - A3.8, A5.1 - A5.8, A7.1 - A7.8 & A13.1 A13.8
MK2, MK4 , MK6, MK8 and MK10 if there groups as outputs used
A MK-marker is placed, if an output (e.g. A1.1) gets from the program an output signal
and at the same output happens an external short. The red MK 1-LED lights ON
If there is a short all outputs of the resp. Output group i.e.. A1.1 - A1.8)
are switched Off
The short circuit marker remains until the control system gets switched
Off/ON (after eliminating the short).
State-LED Input lights up with a present 24 Volt signal.

State-LED Output lights up with a switched On output.
5V-LED, indicate specified operation states by different colors and duration of
lightning (Continuos On or flashing). For detail information see Section 4.
DIAG-LED, indicate specified operation states by different colors and duration of
lightning (Continuos On or flashing). For detail information see Section 4.
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ECS
14.1.4
Section 14.0
Page 5
Bit
Sign used for corresponds to

Sign used for not equal to
A bit is the smallest unit for information. It can assume only two
conditions: logical 0 or logical 1 ( also referred to as logical L-Level and
logical H-Level).
Boolean algebra Mathematical rules for binary variables and conditions. For Boolean
equations the following signs are used:
Logical AND operation (AND or &)
Logical OR operation (OR or >=1)
Logical Negation (NOT or 0)
Byte
Unit for Information unit comprised of 8 bits. A byte can assume a value
between 0 and 255.
Word
Memory unit comprised of 2 byte or 16 bit. A word covers the numeric

range from 32767 to +32767.
Clock
Signal pulse
VWP
VerWaltungProgramm: (management program) A control program

created by the user.
AWP
AnWender Program: (Application program, user program) A control

program created by the user.
AWL
AnWeisungsListe: (instruction sequence) Representation of a program

using alphanumeric signs and symbols as defined in DIN 19239.
Programming in AWL (selection logic) is the at present widely applied
method of programming.
CMOS
Complementary Metal-Oxide Semiconductor: Complementary metaloxide semiconductor technology with very low-level closed circuit
current. These semiconductors are used above all for accumulator and
battery buffering.
RAM
Random Access Memory: Read-write memory in which each memory cell

can be addressed in order to read, write or delete at any time. RAM losses
all of its information when the computer is turned off which is why it is
often buffered by accumulators or batteries.
EPROM
Erasable Programmable Read Only Memory: Read-only memory erasable

by ultraviolet light and electrically programmable. With this memory type,
the contents remain intact in the event of a power failure. In the case of
DIGSY plus this memory contains the management program (firmware).
continued
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02.03.05

ECS
14.1.4
Section 14.0
Page 6
Cont'd:
EEPROM
Electrically Erasable Programmable Read-Only Memory (also called

E2PROM):Electrically erasable and programmable memory. In the event
of a power failure, the contents of this type of memory remain intact. The
DIGSY plus application program (AWP) is loaded into this type of
memory.
COMPILER A program that translates the instructions of a programming language

(e.g. instruction sequence [AWL]) into machine code (processor
instructions).
EDITOR
Utility program for the creation and changing of programs.
Loop
Program loop.
Off-Line
Operational method of a programming device without attached

automation device.
On-Line
Operational method of a programming device (PC) is connected to the

automation device thereby enabling data and programs to be read or
changed.
PC
Personal Computer: Programmable unit for the DIGSY plus .
Watch-Dog: Internal supervisory unit in computers and automation devices used to

recognize system and memory errors.
CPU
Central Processing Unit: Control and central unit in an automation

device usually based on a microprocessor. It can read the application
program code and run the instructions contained therein.
Cycle Time
Time required for the application program to run through once.

continued
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ECS
14.1.4
Section 14.0
Page 7
Cont'd:
Coding Types and Number Systems
ASCII
American Standard Code for Information Interchange: A standardized

information processing code developed in the USA based on
7 bits = 0 127 (7-bit code), (extended ASCII-code of 8-bit = 0 - 255)
Digital
(Eng. Digit) is the representation of a continuos value or a physical

quantity (e.g. voltage) in several levels as a numeric value.
With regard to automation devices one also refers to word processing
in which case a word is a number (e.g. 573).
Analogue
is the representation of a continuos physical quantity (e.g. current or

voltage) which corresponds to the value of a proportional condition
(e.g. rotational speed, routing, temperature, etc.)
For an automation device this physical value converted into 1024 levels,
for example (10-bit analogues-digital conversion). The digitalized value
thus acts within a defined range (e.g. 0 0 volts to 1024 10 volts) in
proportion to a certain input quantity (e.g. voltage). Conversely, by using
a digital-analog conversion, a digitalized value can be converted into a
continuous output signal (current, voltage).
Numeral
A value expressed in one digit: from 0 to 9 in the decimal system and 0-F
in the hexadecimal system.
Number
Value consisting of one or more numeric characters.
Baud
Unit used in serial transmission of data: bits per second (bit/s).
Baud Rate
Modulation rate or transmission speed of serial transmission of binary

numbers. The DIGSY plus uses a baud rate of 2400 baud for
communication and down-loading.
Binary
Numbers, data and information which are exclusively expressed using

the two values 0 and 1 are bivalent = binary dates and information,
exclusive with the use of digits 0 and 1 (e.g. 1 = current 0 = no current).
Dual(Binary) Number (Dual = 2) is the simplest binary numeric expression. Each

position is arranged according to increasing powers of 2.
Example: 13463dec. = 0011 0100 1001 0111dual
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ECS
14.2
Section 14.0
Page 8
Keep in mind
- BE CAREFUL
- BE ALERT
- THINK ABOUT WHAT YOU ARE DOING
Any PERSON doing any work in or around the machine must be familiar
with the local SAFETY INSTRUCTIONS and with the specific SAFETY
INSTRUCTIONS REGARDING TO HIS OCCUPATION.
Serious damage may happen at unqualified actions at the System or
Unit or when not paying attention to the hints given in this manual or
on labels at the units
Qualified persons in sense of the safety relevant hints in this manual or on the
product, are persons which are
either as project engaged person familiar with the safety concept for
automatic control systems;
or as operating personal for the use of an automatic control system being
instructed;
or having the authorization and occupation to put such systems into operation
or doing repair work as well as having the authorization and occupation to put
such systems/units into operation regarding the power
circuits and there safety standards and, to earth and to mark it.
continued
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ECS
14.2
Section 14.0
Page 9
Contd.:
Serious damage may happen at irrelevant opening and improper repair.
Open always the resp. circuit breaker before opening a unit.
I/O cables may only be connect or disconnect in a powerless state.
A BIM module will be damaged while supplying an external power
of 24VDC to the inputs and/ or outputs. If it is necessary for
faultfinding or external unit checks the connection to the PLC has to be
interrupted.
Without power interruption the interface cable are only allowed to be
disconnect or connect when following preconditions are given:
1. The cable must be shielded and the shield must be connected to the
cover of the plug-in connector.
2. A potential balance must be made by connecting the GND
potential parts of the plug connector parts before connecting
the cables.
Replace the fuses only by fuses which matches the values given in the
technical dates
Do not through batteries into open flame and do not solder at their cell
body, explosion can occur (max. Temperature 100 C). Do not open and
do not recharge batteries that contain lithium or mercury. Replace
them by same type only!
Dispose batteries and accumulators as special waste.
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ECS
14.2.1
Section 14.0
Page 10
Meaning of the Status LEDs, Illust. Z 21431b

The DIGSY plus performs by the function of the Status LEDs (5V and DIAG) and
the so named Diagnostic Words* (DW1 up to DW256) many data and statuses.
With a PC and the Program- and Diagnostic Software the. Diagnostic Words are
visible on a monitor.
The following sections explain the diagnostic possibilities more in detail.
* Can be called-up by PC assistance only.
Table: Statuses of the +5 V-LED and their meaning
LED
Effect
Cause
5 V-LED
Voltage
green
o.k.
5 V-LED
CPU not working
Supply
red
(RESET)
< 4,65V
DIAG-LED red
5 V-LED
CPU not working
Supply
OFF
(except the
is missing
LED is defect)
Fuse S1
defect
Remedy
Check the
+24 V Supply
if not o.k. *)
Check the
+24 Volt
Replace the **
Fuse F1
LED defect
(if DIAG
LED is ON)
*)
others
*)
Watchdog
in operation
*)
5 V-LED
flashing
red/green
cyclically
new starts
red/
orange
Continuos Reset
Component fault
*)
** Replacement only after co-ordination with Komatsu Mining Germany, Dept. 8124.1
*) = Return PLC to manufacturer
continued
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ECS
Section 14.0
Page 11
14.2.1
Meaning of the Status LEDs, Illust. Z 21431b
Contd.:
Table: State of the DIAG-LED and their meaning
LED
Effect
Cause
DIAG-LED
Program
Communication via
green
in operation
Interface COM-SP
not active
(interrupted)
COM-SP<> Text
display
DIAG-LED
ProgramTemperature
orange
state
inside housing
unchanged
too high
+24 VCPU < 14 V
Increase the voltage
Accumulator voltage
too low
Replace the
accumulator module
Fixed operands
deleted
Check the
accumulator
connections
SPS in start loop

after voltage ON
wait
programming in
operation
EEPROM not
Initialized
Stop the
programming *1)
Initialize
EEPROM *1)
EEPROM- or
RAM- fault
Initialize
EEPROM *1)
if the fault is
still present *2)
Start program *1)
DIAG-LED
RED
DIAG-LED
OFF
Program
not running (stopped)
Program
not running
(except LED
defect)
Program
stopped
No Program
otherwise LED
defect
DIAG
ProgramCommunication via
flashing
state
Interface COM-SP
or COM-SK active
unchanged
Color State
COM-SP Text
depending
Display
COM-SK (PC)
*1) Function of the Programming Software PROSYD
*2) = Return PLC to manufacturer
PC4000-6-E_#08165_Sec_14-0_rev0.doc
Remedy
Check the cable
connection and the
Interface port
External cooling
Load program *1)

*2)
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12
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ECS
14.2.2
Section 14.0
Page 12
Short Circuit Marker -LED MK

The short circuit markers are used to indicate a short of the outputs at an external
short to GND.
A MK marker will be initialized if by the user-program an output signal is
given and at the same output is an external short present.
The MK marker remains until (after short elimination) the control system is
switched OFF and ON.
See also Section 14.1.3 page 4
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ECS
14.2.3
Section 14.0
Page 13
Diagnostic for Temperature-Module ANM

For the function control a two-color LED is used, visible at the front cover.
The diagnostic - LED indicates following states:
- LED red:
System in reset mode or range overflow of
one or more analogous outputs.
- LED green:
Ordinary operation, no range overflow.
- LED red/green flashing (2Hz) Watch-dog timer response or cyclically

overflow of one ore more analogous outputs.
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ECS
Section 14.0
Page 14
14.3 Front Connector Arrangement

14.3.1
Front Connector Arrangement, BIM Module (Digital Input / Output)
.This is an example for the first Slot. Additional BIM Modules can
be vary depend on configuration of the variable input/output port
A2/E9/ A4E10, A6/E11, A8/E12 or A14/E21.
The configuration for the respective excavator is written in the
EA-Configuration chart (EA-Belegungsliste) see Apendix.
Pin
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Symbol
Input 1.1
Input 1.2
Input 1.3
Input 1.4
Input 1.5
Input 1.6
Input 1.7
Input 1.8
Input 9.1
Input 9.2
Input 9.3
Input 9.4
Input 9.5
Input 9.6
Input 9.7
Input 9.8
0 V (GND)
Input 2.2
Input 2.4
Input 2.6
Input 2.8
Operand
E 1.1
E 1.2
E 1.3
E 1.4
E 1.5
E 1.6
E 1.7
E 1.8
E 9.1
E 9.2
E 9.3
E 9.4
E 9.5
E 9.6
E 9.7
E 9.8
E2.2
E2.4
E2.6
E2.8
Definition
Input 1 of the input group. 1
Input 2 of the input group. 1
Input 3 of the input group 1
Input 1 of the output group 2
Ground
continued
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ECS
Section 14.0
Page 15

14.3.1
Front Connector Arrangement, BIM Module (Digital Input / Output)
Contd.:
Pin
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
Symbol
Output 1.1
Output 1.2
Output 1.3
Output 1.4
Output 1.5
Output 1.6
Output 1.7
Output 1.8
UE/A
UE/A
UE/A
UCPU
Input 2.1
Input 2.3
Input 2.5
Input 2.7
Output 1.1
Output 1.2
Output 1.3
Output1.4
Output1.5
Output 1.6
Output 1.7
Output 1.8
UE/A
UE/A
UE/A
UCPU
0 V (GND)
Operand
A 1.1
A 1.2
A 1.3
A 1.4
A 1.5
A 1.6
A 1.7
A1.8
E 2.1
E 2.3
E 2.5
E 2.7
A 1.1
A 1.2
A 1.3
A 1.4
A 1.5
A 1.6
A 1.7
A1.8
Definition
Output 1 of the output group 1
Under Load Voltage
Under Load Voltage
Under Load Voltage
DIGSY (plus)- Operation Voltage
Under Load Voltage
Under Load Voltage
Under Load Voltage
DIGSY (plus)- Operation Voltage.
Ground / GND
UE/A =
Voltage.
Input / Output
There are two pins (two channels) parallel connected only for output A1.1
A1.8 (the same for additional boards A3, A5, A7, A13).
E1, E2,...E7, E13 and E14 input port fix configured.

A2/E9, A4/E10, A6/E11, A8/E12 and A14/E21 variable input or output
ports depend on software programming.
A1/A9, A3/A10, A5/A11, A7/A12 and A13/A21 output ports fix
configured.
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ECS
Section 14.0
Page 16

14.3.2
PIN
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Front Connector Arrangement, ANM-Module (Analogues Input)

.This is an example for the first ANM slot. Additional ANM modules
configuration can be vary depend on configuration (temperature or
pressure).
The configuration for the respective excavator is written in the EAConfiguration chart (EA-Belegungsliste) see Appendix and the
respective electric diagram.
PIN-NAME
KR
KG
KA
GND/ANA
GND/ANA
GND/ANA
GND/ANA
A1I
A1U
A2I
A2U
A3I
A3U
A4I
A4U
A4G
A3G
A2G
GND/ANA
GND/ANA
GND/ANA
E8G
E7G
E6G
E5G
OPERAND
AW Z.1
AW Z.1
AW Z.2
AW Z.2
AW Z.3
AW Z.3
AW Z.4
AW Z.4
COMMENTARY
Relay contact
Relay contact
Relay contact
Analogous GND
Analogous GND
Analogous GND
Analogous GND
Current output 1
Tension output 1
Current output 2
Tension output 2
Current output 3
Tension output 3
Current output 4
Tension output 4
GND Output 4
GND Output 3
GND Output 2
Analogues - GND
Analogues - GND
Analogues - GND
GND input 8
GND input 7
GND input 6
GND input 5
All pins are internal connected

continued
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ECS
Section 14.0
Page 17

14.3.2
Front Connector Arrangement, ANM-Module (Analogues Input)
Contd.:
PIN
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
PIN-NAME
A1G
4U+E4G
A2G
E3G
A3G
E2G
A4G
E1G
GND/ANA
E8
GND/ANA
E7
GND/ANA
E6
GND/ANA
E5
A1G
E4
E4
E3
E3
E2
E2
E1
E1
OPERAND
EW Z+1.4
EW Z +1.3
EW Z +1.3
EW Z +1.3
EW Z.4
EW Z.4
EW Z.3
EW Z.3
EW Z.2
EW Z.2
EW Z.1
EW Z.1
COMMENTARY
GND - Output 1
GND - Input 4
GND - Output 2
GND - Input 3
GND - Output 3
GND - Input 2
GND - Output 4
GND - Input 1
Analogues GND
Input (U/I) 8
Analogues GND
Input (U/I) 7
Analogues GND
Input (U/I) 6
Analogues GND
Input (U/I) 5
GND Output 1
Input (U/I) 4
Input (U/I) 4
Input (U/I) 3
Input (U/I) 3
Input (U/I) 2
Input (U/I) 2
Input (U/I) 1
Input (U/I) 1
All pins are internal connected
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ECS
Section 14.0
Page 18

14.3.3
Ground connection of the Control Unit

Attention: The complete shield of the analogous cable must be connected to the
ground (GND) bolt of the PLC housing. This bolt must be connected to the
X2 frame / machine ground by a cable (as short as possible) with 2,5 mm2
cross section.
When using plug connectors with metal boxes and connected shield the
additional complete shielding of the analogous cable with the ground bolt
is not necessary. But attention must be played that the metal box is
connected by screws with the PLC housing.
The twisted signal lines are pair wise shielded and already via the 50-pol
female part of the connector connected to ground. The single shielding at
the free end of the cable must not be connected with earth.
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19
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ECS
Section 14.0
Page 19

14.3.4
Interface-connection COM SK / SP
Legend for illustration Z 21425a (Exemplary picture about what possible)

(1)
Text display
(2)
PLC
(3)
Plug socket X27
(4)
Laptop computer
(5)
Memory card system
(6)
Portable printer
(7)
Field dispatch system
Cables:
VL3
VL4
VL5
VL6
VL7
VL8
X27 to Laptop
X27 to Memory Card System
24V Power supply to Memory Card System
X27 to Portable Printer
24V Power supply to Portable Printer
X27 to Field Computer System
Communication interface:
COM-SK => Programming interface (Baud rate 19200)
COM-SP => Communication with text display (Baud rate 9600)
Data cables and/or communication systems are optional equipment.

For more detailed information see OPERATION MANUAL of the
shovel
and the Software Program for the individual Communication System
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20
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ECS
Section 14.0
Page 20
14.4 Power supply

14.4.1
Operation Voltages +24 V, Illust. Z 21426
Study together with the relevant circuit diagram
50-pin SUB Connector:
+ 24 V CPU-Supply:
GND:
+ 24 V I/O-Supply:
Pin 33 and 49
Pin 17 and 50
Pin 30 - 32, 46 48
This supply voltage is the operating voltage for the module outputs. It must
be strong enough to carry the load current of all outputs.
It is provided with a LOAD-DUMP protection to protect (for short times)
wrong polarity and over voltage peaks.
Wrong polarity causes destroying of the module!
External 24 V supply to the outputs causes destroying of the module!
See next page for more information
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21
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ECS
Section 14.0
Page 21
14.4 Power supply

14.4.2
Safety Precautions for Faultfinding, Illust. Z21427
As already mentioned no external 24 V supply is allowed to the

outputs of the BIM modules of the PLC.
If it is necessary while tracing faults, the cable to the PLC must be
disconnected subsequent to a component check, thus as relays,
solenoids or others by the PLC controlled components.
Procedure: Study together with the relevant circuit diagram
1.
Find the terminal between the component and the PLC.
2.
Example terminal 8X2-280 for the solenoid valve 8Y6.1.
3.
Disconnect the wire on one side of the terminal.
4.
Now supply 24 V to the solenoid and check function of it.
5.
Finally re-connect the wire to the terminal
Binary Outputs A
2A-Short circuit proof
Each single Output of the Output group can withstand a load of 2A, but the
total load must not exceed 10 A. The Output group will be switched OFF if
one of the Output becomes overloaded (> 2 A), the short circuit marker will
be set and the MK- LED comes ON.
(A1 MK1, A3 MK3, A5 MK5)
PC4000-6-E_#08165_Sec_14-0_rev0.doc
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ECS
Section 14.0
Page 22
14.4 Power supply

14.4.3
CPU Voltage Range
Electrical requirements +24 supply volt
14 V up to 36 V without any restrictions regarding the max. current
consumption of 4 amps out of the +5 V logic voltage.
At voltage drops below 18 V the 2amps-outputs switched OFF due to
safety reasons. The short circuit markers initiated.
The +24 V CPU is monitored on the CPU plus
DB16.1
After the diagnostic bit Under-voltage UCPU DB16.1 has been set, all
access to the EEPROM memory of the CPU plus is blocked
A drop below 9V results in a reset.
During and after voltage drops according to DIN 40839 part 2 operates the
CPU plus normally.
14.4.4
Electric classification
The voltage supply meets the requirements according to:
ISO 7637-2 Automotive Technique 24V
DIN 0871-B
IEC 801-4 step 4, VDE 0843-4.
DIN/VDE 0470 part1 (old DIN 40050)
14.4.5
Fuse
TR5 / 2.5AT IEC 127-3 Manufacturer Wickmann,
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ECS
Section 14.0
Page 23
14.5 Function explanations with electrical diagram

14.5.1
General
Signal Status
Voltage level:
1 = 24 V* between E (Input) and GND
0 =
0 V** between E (Input) and GND
* 13 V up to actual supply voltage

** 0V up to 5 V
The left half of the picture shows so named PULL-DOWN resistors and the
right half PULL-UP resistors. The resistors are installed to get a low ohmical
input. A system with contacts only leads to a (high ohmical) input if dust or
moisture bridges the contacts.
PULL-DOWN resistors are installed with a normal NC contact (means with a
de-energized relay or normal closed switch contact) thus the ECS recognize a
fault after switching ON the system.
PULL-UP resistors are installed with a normal NO contact (means with a deenergized relay or normal open switch contact) thus the ECS recognize a fault
after switching ON the system.
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24
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ECS
Section 14.0
Page 24

14.5.2
Pressure Measuring (Hydraulic System), Illustration Z 22805

(study with the respective circuit diagram)
(Program run see Flowchart)
Analogous Inputs:
EW 14.1 for pressure sensor B87A (0 up to 500 bar)
Measuring channel: 0......10 V
Function:
- Voltage supply for the pressure sensor: 24 V
- Output voltages Ua (OUT+, pin 2) of the pressure sensors:
Sensor 0 0,4 bar
K= 25 V / bar
Sensor 0 60 bar
K= 0,1667 V / bar
Sensor 0 500 bar
K= 0,02 V / bar
(Pressure sensors with +1 V Offset)
Possible voltage checks:
24 V Supply between supply line 15 (start at circuit breaker) and GND.
Output voltage OUT (pin 2) of the sensor
between GND. Use respective circuit diagram for terminal numbers.
* How to calculate the Output voltage Ua:
Ua = output voltage proportional to the pressure input.
P = input pressure
K = calculation factor for the respective pressure sensor.
Ua = (P x K) + 1 V
Example for 200 bar and a 0 500 bar sensor:
Ua = (200 x 0,02) + 1 V = 5 V
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ECS
Section 14.0
Page 25
14.5.3 Temperature Measuring and trouble shooting Illustration Z22803a

General:
(study with the respective circuit diagram)
The signal of the PT100 temperature probe cant connect direct to the ANM
Module (Analog input of the PLC). A temperature transducer module change
the PT100 signal (Ohm) into a suitable current (mA) signal for the ANM
Module. The temperature probe is connected with a four wire technique to
compensate the line resistance of the long wire between the X2 switch board
and the temperature probe.
Analogous Inputs (eg.: Hydraulic oil temperature sensor B15)
The temperature probe B15 is with 4-wire technology (distorting compensation)
connected to the transducer U15 terminal 1, 4, 2, and 3 (measuring range: -50
C......+150 C). The output terminal 5 and 6 of the transducer is connected to the
ECS analogues input EW 2.1 (input range 4 20 mA). The transducer need 24
V power supply via terminal 7 and 8 (+24V, ground).
Function:
The temperature transducer convert the
measured values from the PT100 temperature
probe into electrically standardized analog
signals. With the four wire technique the length
and the cross section of the wires are not
important; because the electrical resistance of the
two current lines gets compensated. The sensor
is supplied with a low electrical current from the
temperature transducer (I+ and I-). Additional to
the temperature probe (PT100) resistance the
line resistance influence the current flow what
falsified the PT100 measurement. To
compensate the line resistance there are two
additional lines (U+ and U-) close to the PT100
connected. Via this lines the transducer measure
exact a tension drop between in- and output of
the PT100 probe witch is only created by the
PT100 resistance. Because there is no current flow through this lines witch
are influenced by the line resistance (compared to hydraulic system- its like
a test hose with a pressure gauge). The module convert this tension drop into
a current signal (4-20mA) which is proportional to the temperature.
In the interest of proper function must the line resistance not exceed 50 .
Additional the lines must be shielded according to the standards. The picture
shows the wiring of a PT100 probe to a temperature transducer in four wire
technique.
continued
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26
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ECS
14.5.3
Section 14.0
Page 26
Temperature Measuring and trouble shooting, illustration Z22803a

Contd.:
Possible measurements PT100:
Disconnect the wires at the resistor and measure the resistance across the
resistor.
Compare the measured resistance with the values given in the table on next
page.
If the value correspond to the temperature measured with an other temperature
gauge the PT100 resistor is OK.; otherwise replace resistor.
Wiring:
Disconnect the wires at the resistor and inside X2-box at the temperature
transducer terminal 1, 2, 3, and 4.
Measure the line resistance to the ground.
All single wire resistance must be the same.
Transducer:
Connect a Ampere-meter in line between terminal 5 of the transducer and the
disconnected wire to the ECS. Select mA range and check the current. The value
must compare to the PT100 resistance with the following calculation:
I = [( 50 + t ) x 0,08 ] + 4
t = temperature [C]
(Check temperature via PT100 resistance and temperature chart next page)
I = current [mA] to the ECS
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Section 14.0
Page 27
ECS
14.5.4
Temperature Resistance Chart PT100

Basic Values in Ohm according to DIN 43 76
For Measuring Resistor PT100
-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
100,00
99,61
99,22
98,83
98,44
98,04
97,65
97,26
96,87
96,48
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
Example:
84 C
80 + 4 = 132,42
124,4
124,4 124,39 = 60 + 3 = 63 C
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ECS
Section 14.0
Page 28
14.6 Hints for reading the functional flow charts

14.6.1
General
Probably the best aid for trouble shooting is the confidence of knowing
the system and how to use the ECS. Every component has a purpose in
the system. The construction and operating characteristics of each one
should be understood.
Use always the electric/hydraulic circuit diagram the flowchart and
the operation manual for the specific machine.
1. Select on page 1 of the flow chart, (which contains the table of contents
and the main program) the respective subprogram, for example the
Power-Master lube system.
2. Components in the flow chart, have the same identification code as in the
electric/hydraulic circuit diagram, as shown in cross reference list (page 2-4).
For example: Relay K50 = ?
On page 2 (cross reference list) you find out that relay K50 is shown on
page 43 of the flowchart.
3. On each page of the respective subprogram you will find the functional
description in plain text.
In case of problems concerning reading the program loops, you may find
answers in the frequently asked questions list on page 6 and 7 of the flow
chart.
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ECS
Section 14.0
Page 29
14.6 Hints for reading the functional flow charts

14.6.2
Example: Monitoring the X1-pressure for pump control,

illustration Z25072
Grey shaded fields in the table below shows the normal way , used from the program,
if the excavator is in standard condition.
Item
1)
query
Sensor or cable
defect?
Yes
No
B85-X : 5 sec. < --6bar
B85-X : 5 sec. : Voltage
i.e. <1V at EW13.3
between 1V and 11V at
or
EW13.3
B85-X : 5 sec. > +55,3bar
i.e. > 11V at EW13.3
2)
3)
_running_motor-x
> 15 sec ?
X1-pressure to
high?
Fault message No 1190

Motor X is running for
more than 15 seconds
B85-X : 2 sec. > 40bar
i.e. > 6,5V at EW13.3
Motor X is not running

B85-X : 5 sec. : Voltage
below 6,5V at EW13.3
Fault message No 962
PC4000-6-E_#08165_Sec_14-0_rev0.doc
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Section 15.0
Page 1
Lubrication System
Table of contents
Page
General Function
Oscillation Cylinder and Control Block
Adjustments
One line system
Electrical function
Capacitive analog sensor for lubricant level monitoring
Adjustments
End Line pressure switch
Injectors
Function Pinion type (dummy wheel) system
Electrical Function (dummy wheel) system
Capacitive analog sensor for lubricant level monitoring
Adjustments
End-Of-Line Switch setting
Injectors
Components
Hydraulically driven lube pump
Injectors
End-Line Switch
In line Filter
Vent valve (Solenoid valve)
PC4000-6-E_#08165_Sec_15-0_rev0.doc
3
9
11
13
17
21
23
25
27
31
35
37
39
41
45
51
53
55
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15.0
2
Lubrication System
Section 15.0
Page 3
Lubrication System
General Function
Legend: illustration Z 24042a

(1)
Lubricant pump drive (Hydraulic cylinder)
(2)
Solenoid valve (Oil pressure supply)
(3)
Flow control valve
(4)
Pressure reducing valve
(5)
Hydraulic oil supply line (Pilot pressure)
(6)
Hydraulic oil return line
(7)
Vent valve (Solenoid valve, de-energized open to barrel)
(8)
Grease supply line to injectors
(9)
Lubricant level indication (capacitively analog sensor)
(10)
Lubricant barrel
(11)
Pump mechanism
(12)
Lubricant filter
(13)
Hydraulic pressure test plug (Operating pressure)
(14)
Lubricant pressure gauge (Operating pressure)
(15)
Vent line to barrel
(16)
Breather
(17)
Electrical terminal box
Cylinder pressure must not exceed 650 psi (45 bar)
continued
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15.0
4
Lubrication System
Cont'd.
X-axis
Y-axis
Time
Lubricant supply line pressure
PI
S+
PH
SPR
PT
Pressure Increasing
Switch point ON of the end of line pressure switch
Pressure Holding
Switch point OFF of the end of line pressure switch
Pressure Relieve
Pause Time
Lubrication System
Function of a lubrication cycle
Section 15.0
Page 5
illustration Z24042c and Z22023a
PT-phase
With the pump and controller system in a rest state a pre-set pause time interval
occurs as determined by the PLC.
Diagram position (a):
A 24 VDC signal from the PLC activate solenoid valve (2) that opens and activate
the lubrication pump. (*). As solenoid valve (2) opens hydraulic oil flows through
the pressure reducing valve (4), it lowers the hydraulically pilot oil pressure to the
operating range of the hydraulic driven lube pump. The reduced pilot oil pressure
operates now the grease pump. The oil cylinder shuttles the grease cylinder at 18
20 double strokes per minute and delivering 612 680 cm (37.3 41.5 in) of
lubricant per minute (approx. 550 612 g / 19.64 21.45 oz.)
At the same time a 24 V signal energize release valve (7), it close now the release
line to the lubrication container.
PI-phase
With energized release valve (7) (*) and solenoid valve (2) the pump continues to
cycle until maximum pressure is achieved and the injectors have metered
lubricant to the bearings.
S+ point, diagram position (b)
When the maximum system pressure is reached the end-of-line switch (*) open its
contact. In the normal application is the end-of-line switch adjusted to 185 bar
(2630 psi. ).The pressure increasing phase is now finished.
The open pressure switch (*) signals the controller to stop the pumping cycle and
the controller terminates the signal to the solenoid valves (2) The pilot oil flow to
the pump stops.
Solenoid valve 2
Y7, CLS
Vent valve 7
Y7a, CLS (1)
end-of-line switch
B43, CLS
Y8a, CLS (2)

Y9, SLS
Y9a, SLS
B46, SLS
SLS = Slew Ring Teeth Lubrication System

CLS = Central Lubrication System
(*) check respective circuit diagram
continued
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15.0
6
Lubrication System
Cont'd.
X-axis
Y-axis
Time
Lubricant supply line pressure
PI
S+
PH
SPR
PT
Pressure Increasing
Switch point ON of the end of line pressure switch
Pressure Holding
Switch point OFF of the end of line pressure switch
Pressure Relieve
Pause Time
Lubrication System
Section 15.0
Page 7
Cont'd.
PH-phase
Release valve (7) is still energized to keep the pressure in the lubricant line for a
fix adjusted time (pressure holding time normally 5 min).
Diagram position (c):
With expired pressure holding time vent valve (7) de-energize. It opens the
release line to the lubricant container. The lubricant line pressure drop to zero so
the injectors can recharge for the next lubricant injection. (PR-phase).
PR-phase
In the pressure relieve phase the end of line switch (*) move back to neutral
contact position it signals the PLC that the lube pressure relieve phase is now
active.
PT-phase
The system is now at rest (pause time), ready for another lube cycle and the
sequence repeats itself.
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8
Lubrication System
Lubrication System
Section 15.0
Page 9
Oscillation Cylinder and Control Block, illustration Z 21174
Description:
Oscillation cylinder (6) is auto directional controlled, non pressure related. This
differential cylinder is connected to the pilot pressure suppliy line (P) and a tank
line (T). The speed is contolled by a flow contol valve (3) and the maximum
working pressure is controlled by a pressure reducing valve (2).
Function:
The Oscillatin cylinder (6) starts as soon pilot pressure is send via the connection
(P) to the control block (1). Design related the cylinder (6) retract always first
after start or from any position the piston has stopped before. When the cylinder
reaches the fully retracted position the flow will be redirected automatically and
the cylinders moves in the extending position. If the cylinder comes to an stop in
between the end positions weather the oil supply get stopped or the cylinder is
hold back by a higher work resistance than the supply pressure, the cylinder
changes direction and retracts.
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10
Lubrication System
Lubrication System
Adjustments
Section 15.0
Page 11
(illustration Z21175b):
Stroke speed
For a sufficient lube pump operation 18 20 double strokes / min for the pump
drive cylinder are required. Therefore the flow reducing valve (3) has to be
adjusted accordingly.
Procedure:
1. Remove electrical plug connection form the discharge valve (7), so no
pressure built up will take place during the following test.
2. Start motor.
3. Switch ON the lube system annually and count strokes per minute, visible
on the moving up and down of pipe (1).
a. Loosen lock nut (3.1)
b. Turn adjustment (3) until the right number of strokes is achieved.
turn set screw ccw for more speed and cw to reduce the speed
c. Tighten lock nut (3.1).
Working pressure
The pressure reducing valve (2) mounted in the oscillation control block reduce
the supply pressure internally to maximal allowed 45 bar.
The pressure ration is 6,55 to 1, that means 45 bar supply pressure result in 295 bar
maximum lubricant pressure.
At the end of line pressure switch the pressure should be 180 0,5 bar. With the
lubricant line resistance and different lubricant viscosity the pressure at the
lubricant pump output must be higher as 180 bar. For standard condition adjust the
maximum pump pressure to 220 bar 250 bar, depend on lubricant line resistance
and different lubricant viscosity.
Procedure:
1. Disconnect quick coupling (8), so the pump will be blocked when started.
2. Start motor.
3. Switch ON the lube system manually, the gauge should show 220-250 bar.
a. Loosen lock nut (2.1)
d. Turn adjustment (2) until the right pressure is shown at the gauge.
turn set screw ccw for lower pressure and cw to increase the pressure
b. Tighten lock nut (2.1).
c. Reconnect quick coupling (8).
If the required pressure cant be adjusted, check adjustment of the 60

bar pilot pressure valve (X-4 pressure) at the filter and control panel in
the machinery house.
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12
Lubrication System
Lubrication System
Section 15.0
Page 13
One line system

Legend: illustr. Z 21176
(1)
(2)
Solenoid valve (Oil pressure supply)
(3)
Flow control valve
(4)
(5)
(6)
(7)
Vent valve (Solenoid valve, de-energized open to barrel)
(8)
(9)
Lubricant level indication (capacitively analog sensor)
(10)
Lubricant barrel
(11)
Pump mechanism
(12)
Lubricant filter
(13)
(14)
(15)
Vent line to barrel
(16)
End-of-line switch
(17)
(Pressure check point)
(18)
Injector block
(19)
Lubricant feed line to bearing
Function:
As soon as the adj. "Pause-Time" is finished the solenoid valves
(2) and (7) are energized. The lubricant pump (1) start to pump lubricant in
the lubricant supply line.
By the function of the solenoid valve (7) the port to the vent line (15) (return
line to the lubricant container) is closed, thus a pressure built up is possible.
The high-pressure barrel pump (1) supplies lubricant into the supply line (8). It
continuos through the lubricant filter (12) to the injectors (metering valves) (18).
The picture shows an example only. The hole system includes much
more injectors which are connected via pipes or hoses to the supply
line (8).
In the Injectors the lubricant forced with full pump pressure via the feed lines
(19) to the lube points.
The actual operating pressure can be monitored at the pressure gauge (14)
and checked at the pressure check point (17).
continued
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15.0
14
Lubrication System
Lubrication System
Section 15.0
Page 15
Cont'd.
Illustr. Z 21176
When all injectors pistons have reached there final position no more lubricant
is accepted from the supply line which causes a pressure increase in the
supply line (8).
As soon as the pressure reaches the adjusted value of the end-of-line switch
(16) the solenoid valves (2) de-energized and the lubricant pump switched
Off. Depend on different factory settings vent valve (7) de energize together
with solenoid valve (2) or after a fix adjusted time of max. 5 minutes.
With de-energized solenoid valve (7) the port to vent line (15) ( return line to
the lubricant container ) opened and release the lubricant and lubricant
pressure in to the container.
With the diminishing pressure in the main line the pistons of the injector (18)
are forced by spring force in their initial position and the discharge chambers
are filled with grease for the following lubrication cycle.
The system is now prepared for a new lubrication cycle. The operation is reinitiated after the next "Pause Time" is elapsed.
The proper build-up of the pressure in the supply line (8) is monitored by the
end-of-line switch (16).
If the pressure adjusted at the end-of-line switch will not reached within the
adjusted "Monitoring Time" the fault message Central lubrication system
fault comes up on the text display and the system switch off
Grease qualities to be used:

According to NLGI classes 000, 00, 0 and 1 according to the lowest
ambient temperature in the operation area
1. The content of molybdenum must not exceed 5 %.

2. Only synthetic graphite allowed in graphite contained lubricants
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15.0
16
Lubrication System
Lubrication System
Section 15.0
Page 17
Electrical function. illustr. Z 21177a
It follows an exemplary explanation for a central lubrication system

for machines equipped with PLC System. For details see the circuit
diagram of the respective machine. The Lubrication Systems are
PLC controlled. No relay adjustment necessary.
Central lubrication system controlling :
The PLC from the ECS System controls the whole lubrication systems.
The solenoid valves (Y7, Y7A or Y9, Y9A) on top of the lubrication stations are
direct connected to digital output ports of the PLC.
On a few machines there are additional relays between PLC outputs and the
solenoid valves.
Depend on a PLC input from the end-of-line pressure switch (B43 or B46) and a
PLC internal time counter the grease system start a lubrication cycle.
The lubrication cycle starts.
If the pause time elapsed the PLC energize both solenoid valves (Y7, Y7A or
Y9, Y9A) of the respective lubrication system. The motor must run. The pilot
pump pressure activate now the lubrication pump and the lubrication pressure to
the injectors increase.
If the lubricant pressure reach the adjusted pressure of the end-of-line pressure
switch (B43 or B46) its contact change and the PLC input signal change.
The PLC de energize the respective lubrication pump supply valve (Y7 or Y9) to
stop the pump. For the next 5 min the respective pressure releasing valve (Y7A
or Y9A) are continued energized to keep the lubricant pressure still on a high
level to be able all injectors inject the hole adjusted amount of lubricant.
After the 5 min. pressure holding time the PLC de energize the respective
pressure releasing valve (Y7A or5 Y9A) The lubricant pressure drops and the
injectors move by spring load back in its initial position. A PLC internal counter
is still counting a additional decreasing time to monitor the end-of-line pressure
switch (B43 or B46) position. The PLC internal time counter is still counting up
to the next lubrication cycle.
The lubrication cycle is finished.
continued
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Lubrication System
Lubrication System
Section 15.0
Page 19
Cont'd:
Illustr. Z 21177a
The next lubrication cycle starts after the decreasing time and pause time has
expired.
With the switch S24 an additional lubrication can be carried out any time provided
the end of line pressure switch (B43) contact is closed.
Monitoring:
The orderly built-up of the pressure in the lubricant supply line is monitored by
the end-of-line switch (B43 or B46).
If the pressure adjusted at the end-of-line switch is not reached within the adjusted
maximal increasing time the PLC switch off both solenoid (Y7 and Y7A or Y9
and Y9A) valves and send the fault message Central lubrication system fault or
Swing ring lubrication system fault to the text display at the dash board.
If the excavator is still working additional four hours with faulty lubrication
system the PLC stop the bucket function. This function is to prevent trouble
depend on a lack of lubricant.
Continued
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20
Lubrication System
Lubrication System
Section 15.0
Page 21
Capacitive analog sensor for lubricant level monitoring,

Illustration Z 21179f
Task:
A lubricant (L) maximum filling level monitoring is necessary to prevent an
overfilling of the grease barrel (C) via the refilling system (only systems with
refilling arm). The PLC use the analog level signal from the sensor to activate a
lamp at the refilling arm just in the moment when the lubricant container is full.
The sensor (S) is mounted on top of the lubricant container and reaches into the
lubricant.
The refilling level activate only a message at the text display to inform that the
lubricant level must be filled up. The message comes up if the lubricant level
reach 5% (910 mm from the cover plate).
The minimum level stop the respective lubrication pump and release the
lubricant pressure until the lubricant level reach the 0% mark (950 mm from the
cover plate). It is necessary to stop the lubrication system with empty lubricant
container to prevent the lubrication pump from running dry. With empty
lubricant container the bucket motion will be switched off after four hours.
Function:
The capacitively level sensor (S) check continuous the lubricant level (L) and
convert the capacitive signal into a current signal between 4 and 20mA. The
current signal increase with increasing lubricant level.
Use the specific electric circuit diagram and program flow charts.
The capacitively proximity switch used in our machines are

programmed by the supplier and therefor no adjustment or settings
required.
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22
Lubrication System
Lubrication System
Section 15.0
Page 23
Adjustments
End line switch setting. Illustration Z 21180
1.
Connect pressure gauge to check point.
Use an other gauge as for checking hydraulic pressures because the

gauge remains filled with grease after the test
2.
3.
4.
Start motor.
Start a lube cycle with the dashboard switch S24.
+
Watch pressure gauge. At a pressure of 180 10 bar the end-line switch
must react and the lubricants pump must stop.*
If at the same time the pressure shown at the built-in gauge is noted
down, this pressure can be taken for later on checks as a reference
pressure.
180 bar is the normal setting.

Under particular circumstances it may be necessary to increase the
pressure slightly
If re-setting is required:
5.
Screw out screw 1 and take off cover 2.
6.
Alter the spring tension with adjustment screw 3 that the switch
operates at 180 bar.
7.
Install cover 2 and screw 1.
continued
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15.0
24
Lubrication System
Lubrication System
Section 15.0
Page 25
Cont'd:
Injectors, illustr. 21181:
Series SL-1 injector:
Lubricant output adjustable from 0.13 up to 1.3 cm per cycle. Hydraulic type
fitting with screw type cover cap is provided for initial filling of feeder line, and
may also be used for visual check of injector operation.
Series SL-1 injectors incorporate a stainless steel visual indicator.
Lubricant output adjustable from 0.82 up to 8.2 cm per cycle.
Designed for systems where a high amount of lubricant is required.
Principle of operation similar to series SL-1.
Adjusting the lubricant output:
1.
Loosen lock nut (C).
2.
Turn adjusting screw (A) counterclockwise (OUT) for more lubricant
output or clockwise (IN) for less lubricant output.
3.
Tighten lock nut (C).
The max. lubricant output is adjusted if the indicator stem (B) moves
not more further outwards
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26
Lubrication System
Lubrication System
Section 15.0
Page 27
Function Pinion type (dummy wheel) system.

Legend:
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
Z 21183a
Solenoid valve Y9 (Oil pressure supply)
Flow control valve
Vent valve Y9A (Solenoid valve, de-energized open)
Lubricant level indication
Lubricant barrel
Pump mechanism
Lubricant filter
Vent line to barrel
Breather
Electrical terminal box
Principle of operation:
By the lubricant pump, the lubricant is supplied to the centered bore hole (B) of the
lubrication type pinion (R). Bore hole (B) must be perfectly aligned to the center of
the lubrication type pinion (A) to be greased, so that lubricant leaves the tooth flank
always when the gear tooth is in contact. The grease outlet (D) of the lubricating type
pinion is arranged at a different angle for each tooth, so that the lubricant is distributed
in a uniform and perfect manners on the tooth flank of the drive pinion to be
lubricated.
Function:
As soon as the adjusted "Pause-Time" elapse the solenoid valves (2 + 7). energized
and the lubricant pump (1) start to pump lubricant.
By the function of the solenoid valve (8) the port to the vent line (15) (return line to
the lubricant container) closed, thus a pressure built up is possible.
The high-pressure lubricant pump (1) supplies lubricant into the supply line (8). It
continuos through the lubricant filter (12) to the injectors (metering valves) (18).
The picture shows an example with one pinion only. There are also
machines which have more lubrication type pinion (dummy wheel).
By the injectors the lubricant is forced with full pump pressure via the feed line
(19) to the centered bore hole (B) of the lubricating type pinion (R).
continued
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Lubrication System
Lubrication System
Section 15.0
Page 29
Cont'd.
Illustr. Z 21183a
The actual operating pressure can be monitored at the pressure gauge (14)
and checked at the pressure check point (17). When all injector pistons have
reached there final position no more lubricant will accepted from the supply
line (8) which causes a pressure increase in the supply line.
Depend on different factory settings vent valve (7) de energize together with
solenoid valve (2) or after a fix adjusted time of max. 5 minutes.
With de-energized solenoid valve (7) the port to vent line (15) ( return line to
the lubricant container ) opened and release the lubricant and lubricant
pressure in to the container.
With the diminishing pressure in the main line the pistons of the injector (18)
are forced by spring force in their initial position and the discharge chambers
fill up with grease for the following lubrication cycle.
The system is prepared for the next lubrication cycle. The operation is
reinitiated after the next "Pause Time".
The proper build-up of the pressure in the supply line (8) is monitored by the
end-of-line switch (16).
If the pressure adjusted at the end-of-line switch is not reached within the
adjusted "Monitoring Time" the fault message Slew ring gear lubrication
system fault is shown on the text display and the pump switch off.
Grease qualities to be used:

According to NLGI classes 000, 00, 0 and 1 according to the lowest
ambient temperature in the operation area
1. The content of molybdenum must not exceed 5 %.

2. Only synthetic graphite must be contained in graphic lubricants
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Lubrication System
Lubrication System
Electrical function.
Section 15.0
Page 31
Illustration Z 21177b
It follows an exemplary explanation for a Slew Ring Lubrication

System for machines equipped with ECS System. For details see the
circuit diagram of the respective machine. The Lubrication Systems
are controlled through the ECS. No relay adjustment required.
Slew Ring Gear Lubrication (Teeth lubrication) controlling :
The PLC from the ECS System control the whole lubrication systems.
Solenoid valves (Y9, Y9A) on top of the lubrication container are direct
connected to digital output ports of the PLC.
On few machines there are additional relays between PLC and the solenoid
valves.
Depend on a PLC input from the end-of-line pressure switch (B43 or B46) and a
PLC internal time counter the grease system start a lubrication cycle.
The lubrication cycle starts.
If the pause time elapsed and the swing function was activated for a short time
the PLC energize both solenoid valves ( Y9 , Y9A ). To start one swing ring
gear lubrication cycle the swing function must be activated one time.
If the lubricant pressure reach the adjusted pressure of the end of line pressure
switch its contact change the position now the input port of the PLC change.
The PLC de energize the respective lubrication pump supply valve (Y9) to stop
the pump. For the next 5 min the respective pressure releasing valve (Y9A) are
continued energized to keep the lubricant pressure still on a high level to be able
all injectors inject the hole amount of lubricant.
After 5 min. pressure holding time the PLC de energize the respective pressure
releasing valve (Y9A) The lubricant pressure drops and the injectors move by
spring load back in its initial position. A internal counter is still counting a
additional decreasing time to prevent a to early new lubrication cycle with the
risk of not complete reset injectors.
The lubrication cycle is finished.
continued
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Lubrication System
Lubrication System
Section 15.0
Page 33
Cont'd:
Illustr. Z 21177b
The next lubrication cycle starts after the decreasing time and pause time has
expired.
With the switch S26 an additional lubrication can be carried out any time provided
the end of line pressure switch (B46) contact is closed.
Monitoring:
The orderly built-up of the pressure in the lubricant supply line is monitored by
the end-of-line switch (B46).
If the pressure adjusted at the end-of-line switch is not reached within the adjusted
maximal increasing time the PLC switch off both solenoid valves (Y9 and Y9A)
and send the fault message Central lubrication system fault to the text display at
the dash board.
If the excavator was working additional four hours with faulty lubrication system
the PLC stop the bucket function. This function is to prevent trouble depend on a
lack of lubricant.
Continued
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Lubrication System
Lubrication System
Section 15.0
Page 35
Capacitive analog sensor for lubricant level monitoring,

Illustration Z 21179f
Task:
A lubricant (L) maximum filling level monitoring is necessary to prevent an
overfilling of the grease barrel (C) via the refilling system (only systems with
refilling arm). The PLC use the analog level signal from the sensor to activate a
lamp at the refilling arm just in the moment when the lubricant container is full.
The sensor (S) is mounted on top of the lubricant container and reaches into the
lubricant.
The refilling level activate only a message at the text display to inform that the
lubricant level must be filled up. The message comes up if the lubricant level
reach 5% (910 mm from the cover plate).
The minimum level stop the respective lubrication pump and release the
lubricant pressure until the lubricant level reach the 0% mark (950 mm from the
cover plate). It is necessary to stop the lubrication system with empty lubricant
container to prevent the lubrication pump from running dry. With empty
lubricant container the bucket motion will be switched off after four hours.
Function:
The capacitively level sensor (S) check continuous the lubricant level (L) and
convert the capacitive signal into a current signal between 4 and 20mA. The
current signal increase with increasing lubricant level.
Use the specific electric circuit diagram and program flow charts.
The capacitively proximity switch used in our machines are

programmed by the supplier and therefor no adjustment or settings
required.
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Lubrication System
Lubrication System
Section 15.0
Page 37
Adjustments
End of line switch setting, illustration Z 21185
1.
Connect pressure gauge to check point close to the end of line pressure
switch.
Use an other gauge as for checking hydraulic pressures because the

gauge remains filled with grease after the test
2.
3.
4.
5.
Block the swing function with the swing ring parking, use the switch at
the dash board.
Start motor.
Start a lube cycle with the dashboard switch S26 and activate for a short
time the swing function to the left or right.
+
Watch pressure gauge. At a pressure of 180 10 bar the end of line
switch must react and the lubricants pump must be stopped.*
If at the same time the pressure shown at the built-in gauge is noted
down, this pressure can be taken for later on checks as a reference
pressure.
But be careful this pressure is higher than the pressure shown at the test
gauge because of the long distance between pump and end of the
supply line.
180 bar is the normal setting.

Under particular circumstances it may be necessary to increase the
pressure slightly
If re-setting is required:
6.
7.
8.
Screw out screw (1) and take off cover (2).

Alter the spring tension with adjustment screw (3) that the switch
operates at 180 bar.
Install cover (2) and screw (1).
continued
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Lubrication System
Lubrication System
Section 15.0
Page 39
Cont'd:
Injectors, illustr. 21181:
Lubricant output adjustable from 0.13 up to 1.3 cm per cycle. Hydraulic type
fitting with screw type cover cap is provided for initial filling of feeder line, and
may also be used for visual check of injector operation.
Series SL-1 injectors incorporate a stainless steel visual indicator.
Lubricant output adjustable from 0.82 up to 8.2 cm per cycle.
Designed for systems where a high amount of lubricant is required.
Principle of operation similar to series SL-1.
Adjusting the lubricant output:
1.
Loosen lock nut (C).
2.
Turn adjusting screw (A) counterclockwise (OUT) for more lubricant
output or clockwise (IN) for less lubricant output.
3.
Tighten lock nut (C).
The max. lubricant output is adjusted if the indicator stem (B) moves
not more further outwards
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Lubrication System
Lubrication System
Section 15.0
Page 41
Hydraulically driven Power Master III lube pump, illustr. Z 21186

Legend: (more detailed see parts list 90-0781) Fig.: 12
(P)
Hydraulic oil supply
(T)
Hydraulic oil return
(Pr)
(Q)
Flow regulator valve
(1)
Hydr. actuator piston
(2)
Oscillator control block
(3)
Pump tube
(4)
Breather port
(5)
Grease outlet port
(6)
Piston rod
(7)
Breather plug
(8)
Ball, outlet check valve
(9)
Ball and seat, check valve
(10)
Main piston and plunger
(11)
Piston rod set
(12)
Inlet valve
(13)
Scoop piston
(14)
Grease inlet
HINT:
Loss of pressure or to short pump strokes indicates:
A
Foreign material lodged under Piston Ball Checks or between Upper

and Lower Inlet Checks (8 + 9).
To correct this problem the upper lower inlet checks (8 + 9) and inlet
valve (13) should be removed and cleaned thoroughly.
If sealing surfaces between upper and lower inlet checks (8 + 9) are
rough or pitted, replace or resurface if damages are slight.
Shovel rod packing worn or damaged. Before installing new packing,

inspect surface of shovel rod and replace if rough or pitted.
Do not grip shovel rod when disassembling lower pump tube assembly.
continued
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Lubrication System
Lubrication System
Section 15.0
Page 43
Trouble shooting, illustr. Z 21186

If the following procedures do not correct the problem, contact a factory
authorized service center.
PROBLEMS:
CYLINDER PRESSURE GAUGE DOES NOT REGISTER PRESSURE.
A.
Check system pressure to pump.
B.
Check for 24 VDC signal at solenoids.
C.
Pressure reducing valve set too low. Check pressure.
PUMP PRESSURE BUILT UP VERY SLOWLY OR NOT AT ALL.
A.
No oscillation of pump, check oscillation control block (2).
B.
Pressure reducing valve (Pr) may be setting too low.
C.
Grease viscosity may be too high for the actual ambient temperature.
D.
If pressure is not building up at all, solenoid valve (pilot pressure
supply solenoid) may be inoperative.
E.
Pump piston (11) and inlet checks may have foreign matter trapped
causing leakage. Remove, inspect and clean if necessary.
F.
Inspect sealing surface on upper and lower checks (8 + 9). Replace if
rough or pitted.
G.
Replace scoop piston if rough or pitted. Replace rod packing (15) if
it is leaking.
H.
Inspect lubricant supply line for leaks or breaks.
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Lubrication System
Lubrication System
Section 15.0
Page 45
Lubricant Injector (metering valve), illustr. Z 21187
TASK:
A readjusted (at the injector) volume of grease is pushed with the injectors to
the bearings or to the progressive distributors.
Design: (model SL1)
(01+02)
Metering valve, assy.
(03+04)
Injector bar
(05)
Adjusting screw
(06)
Nut
(07)
Plug screw
(08)
Seal ring
(09)
Disk
(10)
Seal ring
(11)
Bolt with nut
(12)
Disk
(13)
Seal ring
(14)
Piston
(15)
Compression spring
(16)
Spring retainer
(17)
Seal ring
(18)
Disk
(19)
Seal ring
(20)
Disk
(21)
Piston
(22)
Seal
(23)
Adapter bolt
(24)
Valve housing
(25)
Union
Design: (model SL11)

(01)
Metering valve, assy.
(02)
Adjusting screw
(03)
Nut
(04)
Plug screw
(05)
O-ring
(06)
Disk
(07)
Seal ring
(08)
Disk
(09)
Guide
(10)
Indicator pin
(11)
Seal ring
(12)
Piston
(13)
Seal ring
(14)
Pin
(15)
Compression spring
(16)
Spring retainer
(17)
Bolt with piston
(18)
Seal ring
(19)
Valve housing
(20)
Union
continued
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Lubrication System
Lubrication System
Section 15.0
Page 47
Cont'd:
Function: illustr. Z 21188
Pos. 1
The injector piston (2) is in its normal or rest position. The discharge
chamber (9) is filled with lubricant from the previous cycle.
Under the pressure of incoming lubricant the slide valve (4) is about
to open the passage (5) leading to the piston.
Pos. 2
When the slide valve (4) uncovers the passage lubricant is admitted to
the top of piston (2) forcing the piston down. The piston force
lubricant from the discharge chamber (9) through the outlet port (10)
to the bearing or progressive distributor.
The lubricant pressure at the bearing or the progressive distributor is
always the same as the pump pressure.
Pos. 3
As the piston completes its stroke, it pushes the slide valve (4) past the
passage, cutting off further admission of lubricant to the passage.
Piston and slide valve remain in this position until lubricant pressure
in the supply line is vented (relieved) at the pump.
This is indicated by the injector stem (8). (fully in)
Pos. 4
After pressure is relieved the compressed spring (3) moves the slide
valve (4) to closed position.
This opens the port from the measuring chamber and permits the
lubricant to be transferred from the top of the piston to the discharge
chamber.
This is also indicated by the injector stem (8) (fully out)
continued
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Lubrication System
Lubrication System
Section 15.0
Page 49
Cont'd:
Connection of one or more injectors, illustr. Z 21189
The injectors are designed so that the lubricant output of two or more
injectors can be combined without the use of tees.
The injector body (1) has two outlets ports (a + b), one above the other.
The connector tube (2) is used to couple the injectors together.
Lubricant from injector No. 1 is directed through the connector tube into the
discharge chamber of injector No. 2 but simply combines with the lubricant
delivery of injector No. 2 to yield double output from the outlet of injector
No. 2.
This does not interfere with the operation of injector No. 2.
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Lubrication System
Lubrication System
Section 15.0
Page 51
End-line switch
TASK:
The pressure control unit is monitoring and controlling the centralized lube
system.
Design:
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
illustr. Z 21190
Piston
Disk
Switch contact
Spring
Pressure switch
Adjustment sleeve
Connection to pressure circuit
Electrical connection
Function:
One pressure control unit is installed in each greasing circuit. The grease
pressure, produced by the pneumatic barrel pump, is with his force also at the
piston (1)
If the grease pressure reaches the tension of the spring (4), the piston (1) is
forced against the disk (2), thus that the contacts of the switch (5) are
operated and a electric impulse is given to the electronic control unit of the
greasing equipment.
Adjusting has to be done with the sleeve (6). Clockwise - higher switch point,
counterclockwise - lower switch point.
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Lubrication System
Lubrication System
Section 15.0
Page 53
In-line filter
Legend: illustr. Z 21191

(1)
Plug screw
(2)
Plug screw gasket
(3)
Filter element
(4)
Filter housing
(5)
Spring guide
(6)
Spring
Before servicing stop the motor and remove ignition key in order to
prevent operation of the system.
A clogged filter element will be moved against the spring force by the
lubricant pressure and unfiltered lubricant reaches the system!
For maintenance proceed as follows:
1.
Remove plug screw (1) using 36 mm width wrench.
2.
Remove plug screw gasket (2).
3.
Take out spring (6), spring guide (5) and filter element (3).
4.
Clean all parts and inspect for damage.
Replace as necessary.
5.
Insert filter element, spring guide (5) and spring.
6.
Install plug screw (1) with gasket (2) and tighten with a wrench.
For service intervals see SERVICE LITERATURE chapter 6.6
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Lubrication System
Lubrication System
Section 15.0
Page 55
Vent valve, illustr. Z 21192

TASK:
By the function of the vent valve the lubricant supply line gets pressurerelieved, after the lubrication cycle is finished. The injector pistons can move
into their initial position.
Legend: (Valve VP1 S-G). Fig. 19
(1)
Solenoid
(2)
Valve assy.
(3)
Solenoid stem
(4)
Lever
(5)
Main valve cone
(6)
Auxiliary valve cone
(7)
Reset spring
Function:
The solenoid gets energized. When the lubrication starts.
The connection from A to B gets closed, thus a pressure build-up is possible.
The solenoid gets de-energized, as soon as the lubrication cycle is finished.
This causes opening of the connection A to B, thus the supply line to the
lubricant barrel is open. The lubricant flows from A to B or vice versa
along the main valve cone (5).
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Lubrication System

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PC4000-6-E_#08165_Contents and 00_Foreword_rev0.

PC4000-6-E_#08165_Contents and 00_Foreword_rev0.doc

PC4000-6-E_#08165_Contents and 00_Foreword_rev0.doc

Main assembly groups

Each section includes a detailed table of contents.

PC4000-6-E_#08165_Contents and 00_Foreword_rev0.doc

Serious personal injury or extensive property damage can

Minor personal injury can result or a part, an assembly, or

Refers to special information

RECOMMENDATIONS FOR ENVIRONMENTALLY FRIENDLY OPERATION

Preserve our environment. To prevent environmental pollution, pay careful attention

This service manual corresponds to the state of development of the

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

10,0 18,0 28,0 40,0

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

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE (1Kgm = 9,806Nm)

Insert all bolts lubricated with MPG, KP2K

Basic Values in Ohm according to DIN 43 76

123,62 124,01, 124,39

Main Assembly Groups

Table of contents section 1.0

Hydraulic Oil Reservoir

Hydraulic Oil Cooler

Backhoe Attachment (BHA)

Front Shovel Attachment (FSA)

Main Assembly Groups

General lay out

Main Assembly Groups

Main Assembly Groups

Legend for illustration (Z 21466):

Main Assembly Groups

Hydraulic Oil Reservoir

Legend for illustration (Z 21467):

Main Assembly Groups

Main Assembly Groups

Hydraulic Oil Cooler

Legend for illustration (Z 21472):

Main Assembly Groups

Fuel tank (Fuel reservoir)

Legend for illustration (Z 21473):

Main Assembly Groups

Legend for illustration (Z 21474):

Main Assembly Groups

Legend for illustration (Z 21475):

Main Assembly Groups

Legend for illustration (Z 21476):

Control pedal Control pedal Control pedal -

Main Assembly Groups

Legend for illustration (Z 21477):

Main Assembly Groups

Legend for illustration (Z 21478a):

Main Assembly Groups

Main Assembly Groups

Backhoe attachment (BHA)

Legend for illustration (Z 21482):

Front Shovel Attachment (FSA)

Legend for illustration (Z 21483):

Table of contents section 2.0

Pump distributor gearbox (PTO)

Pump spline shaft lubrication

PTO Lubrication and cooling - Function

PTO Lubrication and cooling Adjustments