SM 15050-xE-GB-2

SM 15050-upE-GB-2
Service Manual
HYDRAULIC
MINING PC5500-6 E
SHOVEL
SERIAL NUMBER 15050 and up
WARNING
Unsafe use of this machine may cause serious
injury or death. Operators and maintenance
personnel must read this manual before
operating or maintaining this machine. This
manual should be kept near the machine for ref-
erence and must be periodically reviewed by all
personnel who will come into contact with it.
NOTICE
CAUTION
Komatsu has Operation and Maintenance
Manuals written in some other languages. If a
foreign language manual is necessary, contact
your local distributor for availability.
COPYRIGHT
This material is property of Komatsu Mining Germany GmbH and is not to be reproduced, used, or
disclosed except in accordance with the written authorization of Komatsu Mining Germany GmbH.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve
the right to make changes or add improvements at any time without incurring any obligation to
install such changes on products sold previously.
Due to this continuous program of research and development, periodic revisions may be made to
this publication. It is recommended that the customer contact their distributor for information on the
latest revision.
Contents and 00_Foreworda15028.doc 04.01.07
CONTENTS
TABLE OF CONTENTS
00 Safety - Foreword
01 Technical DATA (Leaflet)
02 Assembly PROCEDURE (Brochure)
Section
1. Main assembly groups
2. Drive.
3. Hydraulic oil tank.
4. Hydraulic oil cooling.
5. Controlling.
6. Components
7. Main hydraulic pumps and pump regulation.
8. Operating hydraulic.
9. Hydraulic track tensioning system.
10. Hydraulic operated access ladder
11. Cable weel
12. Hints for the hydraulic circuit diagram
13. Hints for the electric circuit diagram
14. ECS-T
15. Lubrication Systems
APPENDIX
) • Each section includes a detailed table of contents.

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

SAFETY
19
SAFETY CONTENTS
CONTENTS
CONTENTS ...................................................................................................................................... 20
Overview .......................................................................................................................................... 21
NORMAL OPERATIONS ..................................................................................................... 21
REGULAR MAINTENANCE ................................................................................................ 21
TROUBLESHOOTING, ADJUSTMENTS AND REPAIR ..................................................... 21
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR ......................... 22

PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR .................... 22
PREPARATIONS FOR SAFE OPERATION ....................................................................... 22
FIRE PREVENTION ............................................................................................................ 24
PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE ....................................... 26
BURN PREVENTION .......................................................................................................... 27
PRECAUTIONS WHEN CLEANING CAB GLASS .............................................................. 27
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES ......................................... 28
PRECAUTIONS AT JOBSITE ............................................................................................. 29
STARTING ENGINE ............................................................................................................ 35
OPERATION ....................................................................................................................... 36
PRECAUTION FOR MAINTENANCE .............................................................................................. 42

PRECAUTIONS FOR INSPECTION AND MAINTENANCE ............................................... 48
ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS ....... 54
SPECIAL SAFETY EQUIPMENT ..................................................................................................... 56
20
OVERVIEW SAFETY
OVERVIEW
The appropriate safety information for specific working modes on the excavator can be found in the following:-
NORMAL OPERATIONS
z For normal operating procedures, refer to the OPERATION section of the Operation and Maintenance Manual.
z For operational safety information, refer to GENERAL PRECAUTIONS COMMON TO OPERATION in this
chapter on page 22.
z For on site safety information, refer to PRECAUTIONS AT JOBSITE in this chapter on page 29.
REGULAR MAINTENANCE
z For information on regular maintenance, including maintenance intervals, refer to the MAINTENANCE section
of the Operation and Maintenance Manual.
z For maintenance safety information, refer to the PRECAUTIONS FOR MAINTENANCE section in this chapter
on page 42.
TROUBLESHOOTING, ADJUSTMENTS AND REPAIR

z Additional safety information for troubleshooting and adjustments can be found in this chapter on page 54.
z For maintenance solutions, refer to the separate manuals TROUBLESHOOTING manual. Available through
Komatsu Mining Germany.
z For servicing information and adjustments, refer to the separate SERVICE MANUAL. Available through
Komatsu Mining Germany.
ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING,

DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR
z Prior to starting assembling, disassembling and transportation of the excavator read and follow the additional
safety precautions given in the Assembly Procedure Manual.
21
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR
GENERAL PRECAUTIONS COMMON TO OPERATION ON

THE EXCAVATOR
Mistakes in operation, inspection, or maintenance may result in personal injury or death. Before carrying out oper-
ation, inspection, or maintenance, always read this manual and the safety labels on the machine carefully and
obey the warnings.
PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR
ENSURING SAFE OPERATION
z Only trained and authorized personnel can operate and maintain the machine.
z During operations, personnel are not allowed outside of the operator’s cabin.
z Follow all safety rules, precautions and instructions when operating or performing inspection or maintenance
on the machine.
z If you are not feeling well, or are under the influence of alcohol or medication, your ability to safely operate or
repair your machine may be severly impaired putting yourself and everyone else on your jobsite in danger.
z When working with another operator or with a person on worksite traffic duty, discuss the content of the opera-
tion beforehand and use the determined signals when carrying out this operation.
UNDERSTANDING THE MACHINE
Before operating the machine, read this manual thoroughly. If there are any places in this manual that you do not
understand, ask the person in charge of safety to give an explanation.
PREPARATIONS FOR SAFE OPERATION
PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT
z Be sure that all guards, covers and mirrors are in their proper positions. Have guards and covers repaired
immediately if they are damaged.
z Understand the method of use of safety features and use them properly.
z Never remove any safety features. Always keep them in good operating condition.
INSPECTING THE MACHINE
Check the machine before starting operations. If any abnormality is found, do not operate the machine until repairs
of the problem location have been completed.
22
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR SAFETY
WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT
Illustration (Z 25966)
z Do not wear loose clothing and accessories. If these

catch on the control levers or moving parts, there is a
danger that it may cause the machine to move unex-
pectedly.
z Always wear a hard hat and safety shoes when work-

ing on the machine outside of the cabin. If the nature of
the work requires it, wear safety glasses, mask, gloves,
ear plugs and a safety belt when operating or maintain-
ing the machine.
z If you have long hair and it hangs out from your hard
hat, there is a hazard that it may get caught up in the
machine, so tie your hair up and be careful not to let it
get caught.
z Check that all protective equipment functions properly

before using it.
KEEP MACHINE CLEAN
z If you get on or off the machine or carry out inspection

or maintenance when the machine is dirty with mud or
oil, there is a hazard that you will slip and fall. Wipe off
any mud or oil from the machine. Always keep the
machines clean.
z If water gets into the electrical system, there is a haz-

ard that it will cause malfunctions or a misoperation. If
there is any misoperation, there is a danger that the
machine may move unexpectedly and cause serious
personal injury or death. When washing the machine
with water or steam, do not allow the water or steam to
come into direct contact with electrical components.
PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT
z When entering the operator’s compartment, always remove all mud and oil from your shoes. If you operate the
pedal with mud or oil affixed to your shoes, you may slip and this may cause a serious accident.
z Do not leave tools or machine parts lying around inside the operator’s compartment. If tools or parts get into
the control devices, they may obstruct operation and cause the machine to move unexpectedly, resulting in
serious personal injury or death.
z Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.
z Do not use a cell phone when driving or operating the machine. This may lead to mistakes in operation, which
could cause serious personal injury or death.
z Never bring any dangerous objects such as flammable or explosive items into the operator’s compartment.
23
PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT
Always follow the precautions below to prepare for action if

any injury or fire should occur.
z Be sure that fire extinguishers have been provided and

read the labels to ensure that you know how to use
them in emergencies.
z Carry out periodic inspection and maintenance to

ensure that the fire extinguisher can always be used.
z Provide a first aid kit. Carry out periodic checks and

add to the contents if necessary.
IF A PROBLEM IS FOUND
If you find any problems in the machine during operation

and maintenance (noise, vibration, smell, incorrect gauges,
smoke, oil, leakage, etc., or any abnormal display on the
warning devices or monitor), report to the person in charge
and have the necessary action taken. Do not operate the
machine until the problem has been corrected.
FIRE PREVENTION
ACTION IF FIRE OCCURS
z Activate the STOP switch to stop the engine.
z Use the access ladders and steps to get off the

machine.
z If it is impossible to escape from the rear of the cab,

use the rope ladder provided for emergency escape to
escape from the side of the cab (Z 25975).
z After escaping with the emergency escape ladder, acti-

vate the engine stop chains (1 on illustration Z 25976)
to shut down the engine if they are equipped on your
shovel.
24
PRECAUTIONS TO PREVENT FIRE
z Fire caused by fuel, oil, antifreeze, or window washer fluid.
Do not bring any flame or fire close to flammable sub-

stances such as fuel, oil, antifreeze, or window washer
fluid. There is a danger they may catch fire. To prevent
fire, always observe the following:
z Do not smoke or use any flame near fuel or other

flammable substances.
z Stop the engines before adding fuel.
z Do not leave the machine while adding fuel or oil.
z Tighten all fuel and oil caps securely.
z Be careful not to spill fuel on overheated surfaces

or on parts of the electrical system.
z After adding fuel or oil, wipe up any spillage.
z Put greasy rags and other flammable materials into a safe container to maintain safety in the workplace.
z When washing parts with oil, use a non-flammable oil. Do not use diesel oil or gasoline. There is a danger
that they may catch fire.
z Do not weld or use a cutting torch to cut any pipe or tubes that contain flammable liquids.
z Determine well ventilated areas for storing oil and fuel. Keep the oil and fuel in the determined place and
do not allow unauthorised persons to enter.
Before carrying out grinding or welding work on the machine, remove any flammable materials.
z Fire caused by accumulation of flammable material.
Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or
affixed around the engins, exhaust manifold, muffler or battery, or inside the undercovers.
z Fire coming from electrical wiring
Short circuits in the electrical system can cause fire. To prevent fire, always observe the following:
z Keep all electrical connections clean and securely tightened.
z Check the wiring every day for looseness or damage. Tighten any loose connectors or wiring clamps.
Repair or replace any damaged wiring.
z Fire coming from piping
Check that all hose and tube clamps, guards, and cushions are securely fixed in position.
If they are loose, they may vibrate during operation and rub against other parts. There is a danger that this
may lead to damage to the hoses and cause high pressure oil to spurt out, leading to fire, personal injury, or
death.
z Explosion caused by lighting equipment
z When checking fuel, oil, battery electrolyte, or coolant, always use lighting with anti-explosion specifica-
tions.
z When taking the electrical power for the lighting from the machine itself, follow the instructions of this man-
ual.
25
PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE
USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE
To prevent personal injury caused by slipping or falling off

the machine, always do as follows.
z Always use the handrails and steps when getting on or

off the machine.
z To ensure safety, always face the machine and main-

tain three-point contact (both feet and one hand, or
both hands and one foot - see illustration Z 25971).
with the handrails and steps to ensure that you support
yourself.
z When walking around the machine, where possible,

move only in areas that have non-slip padded walk-
ways and non-slip gratings. Extra care is to be taken
when moving around outside of these areas.
z Before getting on or off the machine, check the handrails and steps. If there is any oil, grease, or mud on the
handrails or steps, wipe it off immediately. Always keep these parts clean. Repair any damage and tighten any
loose bolts.
NO JUMPING ON OR OFF THE MACHINE
z Never jump on or off the machine. Never get on or off a moving machine.
z If the machine starts to move when there is no operator on the machine, do not jump onto the machine and try
to stop it.
NO PEOPLE ON THE ATTACHMENT
Never let any person mount the boom, arm, bucket, or other attachment without appropriate safety equipment.
There is danger of falling and suffering serious personal injury. Refer to “SPECIAL SAFETY EQUIPMENT” on
page 56 for further information.
WORKING IN HIGH PLACES

When working in high places, use safety harness and fall absorber to ensure that the work can be carried out
safely. Refer to “SPECIAL SAFETY EQUIPMENT” on page 56 for further information.
LEAVING OPERATOR’S SEAT WITH LOCK
Before standing up from the operator's seat in order to

adjust the seat, always lower the work equipment to the
ground, turn off the engine, relieve the pressure in the
hydraulic system and set lock lever to LOCK position (L). If
the lock is not applied, there is danger of serious personal
injury if the work equipment control levers are touched by
mistake and the machine moves suddenly. For information
on relieving the pressure in the hydraulic system, refer to
chapter ’Relieving The Pressure In The Hydraulic System’
in the ’Operation’ part of this manual.
26
LEAVING THE MACHINE
When leaving the machine, always lower the work equip-

ment completely to the ground, turn off the engine, relieve
the pressure in the hydraulic system and set lock lever (1)
securely to the LOCK position (L), then stop the engine.
Use the key to lock all the equipment. Always remove the
key, take it with you, and keep it in the specified place (Z
25970). For information on relieving the pressure in the
hydraulic system, refer to chapter ’Relieving The Pressure
In The Hydraulic System’ in the ’Operation’ part of this
manual.
BURN PREVENTION
Hot coolant, illustration (Z 25972)
z To prevent burns from hot water or steam spurting out

when checking or draining the coolant, wait for the
water to cool to a temperature where it is possible to
touch the radiator cap by hand before starting the oper-
ation. Even when the coolant has cooled down, loosen
the cap slowly to relieve the pressure inside the radia-
tor before removing the cap.
Hot oil, illustration (Z 25973)
z To prevent burns from hot oil spurting out when check-

ing or draining the oil, wait for the oil to cool to a tem-
perature where it is possible to touch the cap or plug by
hand before starting the operation. Even when the oil
has cooled down, loosen the cap or plug slowly to
relieve the internal pressure before removing the cap
or plug.
PRECAUTIONS WHEN CLEANING CAB

GLASS
Always keep the cab glass clean to ensure good visibility
when operating.
Use an ethyl alcohol based washer liquid. Methyl alcohol

base washer liquid may irritate your eyes, so do not use it.
27
If the cab glass on the work equipment side is broken,

there is a hazard that the intruding objects may contact the
operator's body directly. Stop operation immediately and
replace the glass.
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES

On jobsites where there is a hazard that falling objects
(Z 25978), flying objects (Z 25977), or intruding objects
may hit or enter the operator's cab, consider the operating
conditions and install the necessary guards to protect the
operator.
z When carrying out operations in mines or quarries

where there is danger of falling or flying rocks, order/
use the optionally available front guard.
z When carrying out the above operations, always

ensure that bystanders are a safe distance away and
are not in hazard from falling or flying objects.
z The above recommendations assume that the condi-

tions are for standard operations, but it may be neces-
sary to add additional guards according to the
operating conditions on the jobsite. Always contact
your Komatsu distributor for advice.
UNAUTHORIZED MODIFICATION
z Komatsu will not be responsible for any injuries, acci-

dents, product failures or other property damage result-
ing in modifications made without authorisation from
Komatsu.
z Any modifications made without authorisation from

Komatsu can create hazards. Before making a modifi-
cation, consult your komatsu distributor.
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS
z Any injuries, accidents, or product failures resulting from the use of unauthorized attachments or parts will not
be the responsibility of Komatsu.
28
PRECAUTIONS AT JOBSITE
INVESTIGATE AND CONFIRM JOBSITE CONDITIONS
On the jobsite, there are various hidden dangers that may lead to personal injury or death. Before starting opera-
tions, always check the following to confirm there are no dangers on the jobsite.
z When carrying out operations near combustible materials, there is a hazard of fire, so be careful when operat-
ing.
z Check the terrain and condition of the ground at the worksite, and determine the safest method of operation.
Do not operate where there is a hazard of landslides or falling rocks.
z If water lines, gas lines, or high-voltage electrical lines

may be buried under the worksite, contact each utility
and identify their locations. Be careful not to sever or
damage any of these lines (Z 25979).
z Take necessary measures to prevent any unauthorized

person from entering the operating area.
z If there is a fire near the machine, there is danger of

sparks being sucked in and causing a fire on the
machine.
z When travelling or operating in shallow water or on soft

ground, check the shape and condition of the bedrock,
and the depth and speed of flow of the water before
starting operations.
z Maintain the travel path on the jobsite so that there is

no obstruction to travel operations.
WORKING ON LOOSE GROUND
z Avoid travelling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The
ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine,
there is a hazard that the machine may fall or tip over. Remember that the soil after heavy rain or blasting or
after earthquakes is weak in these areas.
z When working on embankments or near excavated ditches, there is a hazard that the weight and vibration of
the machine will cause the soil to collapse. Before starting operations, take steps to ensure that the ground is
safe and to prevent the machine from rolling over or falling.
29
DO NOT GO CLOSE TO HIGH VOLTAGE CABLES
WARNING
Do not travel or operate the machine near electric cables. There is a hazard of electric shock, which may
cause serious injury or property damage. Even going close to high-voltage cables can cause an electric
shock, which may cause serious burns or even death.
On jobsites where the machine may go close to electric

cables, always do as follows.
z Before starting work near electric cables, inform the

local power company of the work to be performed, and
ask them to take the necessary action.
z Always maintain a safe distance (see the table on the

right) between the machine and the electric cable.
Check with the local power company about safe oper-
ating procedure before starting operations.
z To prepare for any possible emergencies, wear rubber

shoes and gloves. Lay a rubber sheet on top of the
seat, and be careful not to touch the chassis with any
exposed part of your body.
z Use a signalman to give warning if the machine

approaches too close to the electric cables.
z When carrying out operations near high voltage cables,

do not let anyone near the machine.
.
z If the machine should come too close or touch the elec-
tric cable, to prevent electric shock, the operator should Voltage of Cables Safety Distance
not leave the operator's compartment until it has been 100 V - 200 V Over 2 m (7 ft)
confirmed that the electricity has been shut off. Also,
6,600 V Over 2 m (7 ft)
do not let anyone near the machine.
22,000 V Over 3 m (10 ft)
66,000 V Over 4 m (14 ft)
154,000 V Over 5 m (17 ft)
187,000 V Over 6 m (20 ft)
275,000 V Over 7 m (23 ft)
500,000 V Over 11 m (36 ft)
30
CONTINUE READING ON THE FOLLOWING PAGE
31
VISIBILITY FROM OPERATOR’S SEAT
32
The illustration Z 26495 shows an example of general blind areas of large Komatsu hydraulic mining shovels.
The grey shaded areas (A) show the areas where the view is blocked when the operator is sitting in the operator’s
seat, and the shovel is equipped with standard mirrors. The boundary line (B) shows the distance of 1 meter from
outside surface of the shovel. Please be fully aware that there are places that can not seen when operating the
machine.
REMARK
The blind areas (A) differ depending on the machine type, attachment and position of attachment.
NOTICE
The International Standard ISO 5006 defines criteria for Operator’s visibility. This standard is not met and
does not apply to large hydraulic mining shovels.
CAUTION
Make sure the job site is organized in such a way, that the safety of man and equipment is always ensured.
Camera System with Monitors
Komatsu Mining Germany offers optionally camera systems and monitors to improve the overall visibility. See lat-
est version of the OMM for typical arrangement of cameras and monitors.
The camera system can be installed ex works and can also be retrofitted in the field. If you need more information,
please contact your local Komatsu distributor.
ENSURE GOOD VISIBILITY
When operating or travelling in places with poor visibility, if it is impossible to confirm the condition of the job side
or obstacle is in the area around the machine, there is danger that the machine may suffer damage or the operator
may suffer serious personal injury. When operating or travelling in places with poor visibility, always observe the
following items strictly.
z If the visibility cannot be sufficiently assured, position a flagman if necessary. The operator should pay careful
attention to the signs and follow the instructions of the flagman.
z The signals should be given only by one flagman.
z When working in dark places, turn on the working lamps and front lamps of the machine, and if necessary, set
up additional lighting in the area.
z Stop operations if there is poor visibility, such as in fog, snow, rain, or sand storms.
z Check the mirrors on the machine before starting operations every day. Clean off any dirt and adjust the view
to ensure good visibility.
z In areas where it is impossible to confirm the area around the machine and observation cameras have been
set up, clean off any dirt from the lens and make sure that the cameras give a clear view of the working area of
the machine.
CHECKING SIGNS AND SIGNALMAN’S SIGNALS
z Set up signs to inform of road shoulders or soft ground. If the visibility is not good, position a signalman if nec-
essary. Operators should pay careful attention to the signs and follow the instructions from the signalman.
z Only one signalman should give signals.
z Make sure that all workers understand the meaning of all signals and signs before starting work.
33
GAS, DUST, STEAM AND SMOKE
z Operate internal combustion engines and fuel operated heating systems only on adequately ventilated prem-
ises. Before starting the machine on enclosed premises, make sure that there is sufficient ventilation.
Observe the regulations in force at the respective site.
WARNING
Carry out welding, flame-cutting and grinding work on the machine only if this has been expressly autho-
rized, as there may be a risk of explosion and fire which may result in serious injury or death.
z Special care must be taken before welding, flame-cutting and grinding operations are carried out on the coun-
terweight. The filling of the counterweight chambers can create explosive gases which will accumulate in the
chambers of the counterweight.
WARNING
These gases must be expelled before welding, flame-cutting and grinding operations are carried out on
the counterweightas there is a danger of explosion which may result in serious injury or death.
z Follow the instructions given in PARTS & SERVICE NEWS No. AH04518 for expelling the gases from the
counterweight chambers. (See Volume 2 binder)
WARNING
Before carrying out welding, flame-cutting and grinding operations, clean the machine and its surround-
ings from dust and other inflammable substances and make sure that the premises are adequately venti-
lated as there is a risk of explosion which may result in serious injury or death.
VENTILATION OF ENCLOSED AREAS
z If it is necessary to start the engine within an enclosed

area, or when handling fuel, flushing oil, or paint, open
the doors and windows to ensure that adequate venti-
lation is provided to prevent gas poisoning.
WARNING
Unventilated areas where poisonous fumes can accumulate can kill. Always ensure adequate ventilation.
EMERGENCY EXIT FROM OPERATOR’S CAB
If the cab door does not open, use the sliding window for an emergency escape. On machines without a sliding
window, use the emergency escape hammer to break the window glass and use the window as an emergency
escape.
34
STARTING ENGINE
WARNING TAG
If there is a "DANGER DO NOT OPERATE!" warning tag

displayed, it means that someone is carrying out inspection
and maintenance on the machine (illustration Z 25982). If
the warning sign is ignored and the machine is operated,
there is a danger that the person carrying out the inspec-
tion or maintenance may be caught in the rotating parts or
moving parts and suffer personal injury or death. Do not
start the engine or touch the levers.
CHECKS BEFORE STARTING ENGINE
Carry out the following checks before starting the engine at the beginning of the day's work to ensure that there is
no problem with the operation of the machine. If this inspection is not carried out properly, problems may occur
with the operation of the machine, and there is the danger that this could lead to serious personal injury or death.
z Remove all dirt from the surface of the window glass to

ensure a good view.
z Completely remove all flammable materials accumu-

lated around the engine and battery, and remove any
dirt from the windows, mirrors, handrails, access ladder
and steps.
z Check the coolant levels, fuel levels, and oil levels, and
check for damage to the electric wiring.
z Adjust the operator's seat to a position where it is easy

to carry out operations, check the camera system func-
tions and check that there is no damage or wear to the
seat belt or mounting clamps.
z Check the operation of the instruments and gauges,

check the angle of the mirror, and check that the con-
trol levers are all at the Neutral position.
z Before starting the engine, check that lock lever

(Z 25969) is in LOCK position (L).
z Adjust the mirrors so that the rear of the machine can

be seen clearly from the operator's seat.
z Check that there are no persons or obstacles above,

below, or in the area around the machine.
35
PRECAUTION WHEN STARTING ENGINE
z Start and operate the machine only while seated.
z Do not short circuit the starting motor circuit to start the engine. Short circuiting can cause fire.
z When starting the engine, sound the horn as a warning.
z Do not let any person on the machine other than the operator and the operator's assistant (1 person). For
demonstration purposes or during training, more than two people can be present in the operator’s cabin at the
same time. All personnel within the cabin at such times must secure good hand-holds and be aware of sudden
movements. All appropriate relevant safety measures are to be observed.
PRECAUTION IN COLD AREAS
z Carry out the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the control
levers or control pedals are operated, the reaction of the machine will be slow or the machine may move in a
way not expected by the operator. Particularly in cold weather, be sure to carry out the warming-up operation
thoroughly.
z If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.
There is a hazard that this will ignite the battery and cause the battery to explode.
z Before charging or starting the engine with a different power source, melt the battery electrolyte and check that
there is no leakage of electrolyte before starting.
OPERATION
CHECKS BEFORE OPERATION
If the checks before starting are not carried out properly, the machine will be unable to display its full performance,
and there is also danger that it may lead to serious personal injury or death.
When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate
slowly. Do not allow anyone near the machine.
z Always fasten your seat belt.
z Check that the movement of the machine matches the display on the control pattern label in the cabin. If it
does not match, replace it immediately with the correct control pattern label.
z Check the operation of the gauges and equipment, and check the operation of the bucket, arm, boom, travel
system and swing system.
z Check for any problem in the sound of the machine, vibration, heat, smell, or gauges; check also that there is
no leakage of oil or fuel.
z If any problem is found, carry out repairs immediately.
36
PRECAUTIONS WHEN TRAVELLING IN FOR-

WARD OR REVERSE
z Before travelling, set the machine so that sprocket (1)

is behind the operator's seat (Z 25983).
z If sprocket (1) is in front of the operator's cab, the

machine moves in the opposite direction from the oper-
ation of the pedals (front and rear travel is reversed, left
and right steering is reversed). Be extremely careful
when operating the machine in this situation.
z Before travelling, check again that there is no one in

the surrounding area, and that there are no obstacles
(Z 25984).
z Before travelling, sound the horn to warn people in the

area.
z Always operate the machine only when seated.
z Do not allow anyone apart from the operator to ride on

the machine.
z Check that the travel alarm works properly.
z Secure the cab door when it is both open and closed.
z Always keep the cab door closed when operating the

machine.
z If there is an area to the rear of the machine which can-

not be seen, position a signal person. Take special
care not to hit other machines, objects or people when
turning or swinging the machine (Z 25985.)
Always be sure to carry out the above precautions even

when the machine is equipped with mirrors or camera sys-
tems.
37
PRECAUTIONS WHEN travelling
z When travelling on flat ground, keep the work equip-

ment 100 to 150 cm (39 to 59 in) high above the
ground (Z 25986).
z If the view to the right side is poor, raise the boom to

ensure better visibility.
z When travelling on rough ground, travel at low speed

and do not operate the steering suddenly. There is
danger that the machine may turn over. The work
equipment may hit the ground surface and cause the
machine to lose its balance, or may damage the
machine or structures in the area.
z Avoid travelling over obstacles when possible. If the

machine has to travel over an obstacle, keep the work
equipment close to the ground and travel at low speed.
Never travel over obstacles which make the machine
tilt strongly to one side (Z 25987).
z When travelling or carrying out operations, always

keep a safe distance from people, structures or other
machines to avoid coming into contact with them.
TRAVELLING ON SLOPES
Illustrations (Z 25988 )
To prevent the machine from tipping over or slipping to the

side, always do as follows.
z Keep the work equipment 100 - 150 cm (39 - 59 in)

above the ground surface so that the work equipment
can be lowered to the ground immediately to stop the
machine in emergencies.
z When travel up slopes, set the operator's cab facing

uphill, when travel down slopes, set the operator's cab
facing downhill. Always be aware and informed about
the firmness and bearing capacity of the ground under
the machine when travelling. Cavaties and under-
ground mines may cause the ground beneath the exca-
vator to collapse.
38
z When travelling up a steep slope, extend the work

equipment to the front to improve the balance, keep the
work equipment approximately 100 to 150 cm (39 to
59 in) above the ground, and travel at low speed
(Z 25990).
z When travelling downhill, keep the travel pedals close

to the neutral position, and travel at low speed.
z Always travel straight up or down a slope. travelling at

an angle or across the slope is extremely dangerous.
z Do not turn on slopes or travel across slopes. Always

go down to a flat place to change the position of the
machine, then travel on to the slope again (Z 25991).
z Travel on slippery ground with low speed. Even with

slight slopes there is a hazard that the machine may
slip.
OPERATIONS ON SLOPES
z When working on slopes, there is a hazard that the

machine may lose its balance and turn over when the
swing or work equipment are operated. This may lead
to serious injury or property damage, so always provide
a stable place when carrying out these operations, and
operate carefully.
z Do not swing the work equipment from the uphill side to

the downhill side when the bucket is loaded. This oper-
ation is dangerous, and may cause the machine to tip
over.
z If the machine has to be used on a slope, pile the soil

to make a platform (A illustration Z 25992) that will
keep the machine as horizontal as possible.
39
PROHIBITED OPERATIONS
z Never dig the work face under an overhang. There is a

hazard that rocks may fall or that the overhang may
collapse and fall on top of the machine (Z 25993).
z Do not excavate too deeply under the front of the

machine. The ground under the machine may collapse
and cause the machine to fall (Z 25994).
z To make it easier to escape if there is any problem, set

the tracks at right angles to the road shoulder or cliff
with the sprocket at the rear when carrying out opera-
tions (Z 25995).
z Generally speaking, the machine is more liable to over-

turn when the work equipment is at the side than when
it is at the front or rear.
z Do not suddenly lower, swing, or stop the work

equipment.
z Do not suddenly extend or retract the boom cylin-

der. There is a hazard that impact will cause the
machine to tip over.
z Do not pass the bucket over the head of other workers

or over the operator's seat of dump trucks or other
hauling equipment. The load may spill or the bucket
may hit the dump truck and cause serious injury or
property damage.
TRAVELLING ON FROZEN OR SNOW COVERED SURFACES
z Snow-covered or frozen surfaces are slippery, so be extremely careful when travelling or operating the
machine, and do not operate the pedals suddenly. Even a slight slope may cause the machine to slip, so be
particularly careful when working on slopes.
z With frozen ground surfaces, the ground becomes soft when the temperature rises, and this may cause the
machine to tip over.
z If the machine enters deep snow, there is a hazard that it may tip over or become buried in the snow. Be care-
ful not to leave the road shoulder or to get trapped in a snow drift.
40
z When clearing snow, the road shoulder and objects placed beside the road are buried in the snow and cannot
be seen. There is a hazard of the machine tipping over or hitting covered objects, so always carry out opera-
tions carefully.
PARKING THE MACHINE
z Park the machine on firm, level ground. Select a place

where there is no hazard of falling rocks or landslides,
or of flooding if the land is low.
z Lower the work equipment completely to the ground.
z When leaving the machine, set lock lever (1) to the

LOCK position (L), then stop the engine (Z 25969).
z Always close the operator's cab door, and use the key
to lock all the equipment in order to prevent any unau-
thorized person from moving the machine. Always
remove the key, take it with you, and leave it in the
specified place.
z If it is necessary to park the machine on a slope,

always set the bucket on the downhill side, then dig it
into the ground.
TRANSPORTATION
This machine must be disassembled for transportation. When transporting the machine, please consult your
Komatsu distributor.
Use only appropriate means of transport and lifting gear of adequate capacity.
The recommissioning procedure must be strictly in accordance with the General Assembly Procedure Manual.
41
SAFETY PRECAUTION FOR MAINTENANCE
PRECAUTION FOR MAINTENANCE

z Observe the adjusting, maintenance and inspection activities and intervals set out in the Operation,- Lubrica-
tion and Maintenance Manual, including information on the replacement of parts and equipment. These activi-
ties may be executed by skilled personnel only.
z Brief operating personnel before beginning special operations and maintenance work, and appoint a person to
supervise the activities.
z In any work concerning the operation, conversion or adjustment of the machine and its safety-oriented devices
or any work related to maintenance, inspection and repair, always observe the start-up and shut-down proce-
dures set out in the Operation,- Lubrication and Maintenance Manual and the information on maintenance
work.
z Ensure that the maintenance area is adequately secured.
z If the machine is completely shut down for maintenance and repair work, it must be secured against inadver-
tent starting by:
z locking the principal control elements and removing the ignition key and/or
z attaching a warning tag to the main switch or control levers.
z setting the maintenance safety switch to the 0 position and securing it with a padlock
z Carry out maintenance and repair work only if the machine is positioned on stable and level ground and has
been secured against inadvertent movement and buckling.
z To avoid the risk of accidents, individual parts and large assemblies being moved for replacement purposes
should be carefully attached to lifting tackle and secured. Use only suitable and technically perfect lifting gear
and suspension systems with adequate lifting capacity. Never work or stand under suspended loads.
z The fastening of loads and the instructing of crane operators should be entrusted to experienced persons only.
The marshaller giving the instructions must be within sight or sound of the operator.
z For carrying out overhead assembly work always use specially designed or otherwise safety-oriented ladders
and working platforms. Never use machine parts as a climbing aid. Wear a safety harness when carrying out
maintenance work at greater heights.
Keep all handles, steps, handrails, platforms, landings and ladders free from dirt, snow and ice.
z Always tighten any screwed connections that have been loosened during maintenance and repair.
z Any safety devices removed for set-up, maintenance or repair purposes must be refitted and checked immedi-
ately upon completion of the maintenance and repair work.
z Ensure that all consumables and replaced parts are disposed of safely and with minimum environmental
impact.
z Before starting any lubrication or maintenance work read the Fundamental Safety Instructions on page 19.
z Park the Excavator at a safe place on level ground. Proceed according to the instructions ”Parking the
Shovel”. Lower the attachment flat onto the ground. Move all control levers to neutral position.
z Stop the engines and move all control levers through their shift positions to relieve the pressure in the hydrau-
lic system. Refer to ”Stopping the Engines” for detailed description of the stopping procedure.
z Before any maintenance work is started, set the maintenance safety switch to 0 position. Refer to page 44 for
location of the maintenance safety switch. In the 0 position the engines can not be started. Secure this position
by inserting a padlock into the holes of the switch. Up to ten padlocks can be attached to the holes provided.
42
PRECAUTION FOR MAINTENANCE SAFETY
z A warning plate ”Caution Machine Maintenance” must be fixed in the Operator’s cab before any lubrication or
maintenance work is started.
z Block the machine to prevent machine movement
z Always use safety devices to block hydraulic cylinders. Never rely on the machine hydraulic system to hold
when working on the loader attachment. A hydraulic line or cylinder could fail or someone could accidently
strike the control levers causing the loader to fall.
z Relieve all pressure in the hydraulic system before servicing the hydraulic system.For information on relieving
the pressure in the hydraulic system, refer to chapter ’Relieving The Pressure In The Hydraulic System’ in the
’Operation’ part of this manual.
z Oily cloth and inflammable material must be removed from the machine. Clean the excavator before starting
maintenance work.
z Switch-off battery main switch and remove key, before working on the electrical system.
z Wear safety clothing, goggles, respirator and other safety devices, whenever working conditions make this
necessary. Observe the local safety rules.
z Never allow unauthorized persons access to the machine during lubrication and maintenance work.
z After servicing, remove oily cloth, inflammable material and all tools from the machine.
z Clean the Excavator with a steam jet, especially after servicing the hydraulic system and fuel system.
WARNING
When using a steam cleaner, wear safety glasses and protective clothing. Hot steam can cause serious personal
injury.
NOTICE
z For cleaning the Excavator and its components use only fresh water with a salt content of less than
0.05%.
z DO NOT use steam jet, high pressure cleaning device or strong water jet for cleaning headlights, sole-
noid valves, sensors, cable connections and bearings.
z Be sure to reinstall safety devices, guards or shields after adjusting and/or servicing the machine.
STOP ENGINE FOR MAINTENANCE
z Stop the machine on firm, level ground.
z Select a place where there is no hazard of falling rocks

or landslides, or of flooding if the land is low.
z Lower the work equipment completely to the ground

and stop the engine.
z Turn the main key switch to the ON position. Operate

the work equipment control lever back and forth, left
and right at the full stroke 2 to 3 times to eliminate the
remaining internal pressure in the hydraulic circuit, and
then push up lock lever (1) to the LOCK position
(Z 25969).
43
Check that the battery main switch is off and main power is not conducted. (Wait for approx. one minute after acti-
vating the engine STOP switch and press the horn switch. If the horn does not sound, it is not activated.)
WARNING TAG
z Always attach the “DO NOT OPERATE“ warning tag to

the work equipment control lever in the operator's cab
to alert others that you are performing service or main-
tenance on the machine. Attach additional warning
tags around the machine if necessary.
z Keep this warning tag in the tool box while it is not

used. If there is not the tool box, keep the tag in the
operation manual pocket.
z If any other person starts the engine, or touches or

operates the control levers or control pedals while you
are performing service or maintenance, you may suffer
serious injury.
z Before entering the machinery house, switch off main-

tenance safety switch (Z 27736)
z The maintenance safety switch is located in the

machinery house, next to the entrance door (Pos. 1 on
ill. Z 25999).
z Before beginning maintenance operations, set the

safety switch to "0" to prevent a starting of the engines.
Secure this position by inserting a padlock into the
holes of the safety switch. Up to ten padlocks can be
attached.
44
KEEP WORKPLACE CLEAN AND TIDY
z Do not leave hammers or other tools lying around in the work place. Wipe up all grease, oil, or other sub-
stances that will cause you to slip. Always keep the work place clean and tidy to enable you to carry out oper-
ations safely.
WARNING
If the work place is not kept clean and tidy, there is the danger that you will trip, slip, or fall over and injure
yourself.
APPOINT LEADER WHEN WORKING WITH OTHERS
When repairing the machine or when removing and installing the work equipment, appoint a leader and follow his
instructions during the operation.
TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING
To prevent injury, do not carry out maintenance or adjust-

ments with the engine running. If work must be carried out
with the engine running, carry out the operation with at
least two workers and do as follows:
z One worker must always sit in the operator's seat and

be ready to stop the engine at any time. All workers
must maintain contact with the other workers and be
fully aware of all relevant safety measures.
z For safety information when working with oil under high

pressure on the hydraulic system, refer to “SPECIAL
SAFETY EQUIPMENT” on page 56
z When carrying out operations near the fan, fan belt, or

other rotating parts, there is a hazard of being caught in
the parts, so be careful not to come close (Z 26052).
z Do not touch any control levers or control pedals. If any

control levers or control pedals must be operated,
always give a signal to the other workers to warn them
to move to a safe place.
z Never drop or insert tools or other objects into the fan

or fan belt. Parts may break or be sent flying.
INSTALLING, REMOVING OR STORING ATTACHMENTS
z Appoint a leader before starting removal or installation

operations for attachments.
z Place attachments that have been removed from the

machine in a stable condition so that they do not fall
(Z 26055). And take steps to prevent unauthorized per-
sons from entering the storage area.
45
PRECAUTIONS WHEN WORKING UNDER

THE MACHINE OR EQUIPMENT
z If it is necessary to go under the work equipment or the

machine to carry out service and maintenance (Illustra-
tion Z 26056), support the work equipment and
machine securely with blocks and stands strong
enough to support the weight of the work equipment
and machine.
z It is extremely dangerous to work under the machine if

the track shoes are lifted off the ground and the
machine is supported only with the work equipment. If
any of the control levers are touched by accident, or
there is damage to the hydraulic piping, the work
equipment or the machine will suddenly drop. This is
extremely dangerous. Never work under the work
equipment or the machine.
NOISE
When carrying out maintenance of the engine and you are

exposed to noise for long periods of time, wear ear covers
or ear plugs while working. If the noise from the machine is
too loud, it may cause temporary or permanent hearing
problems.
WHEN USING A HAMMER
When using a hammer, pins may fly out or metal particles

may be scattered. This may lead to serious injury. Always
do as follows.
z If hard metal parts such as pins, bucket teeth, cutting

edges, or bearings are hit with a hammer, there is a
hazard that pieces might be scattered and cause injury.
Always wear safety glasses and gloves (Z 26057).
z When hitting pins or bucket teeth, there is a hazard that

broken pieces might be sent flying and injure people in
the surrounding area. Always check that there is no
one in the surrounding area.
There is a hazard that the pin hit with strong force may fly out and injure people in the surrounding area.
46
PROPER TOOLS
Illustration ( 26053)
Use only tools suited to the task and be sure to use the
tools correctly. Using damaged, low quality, faulty, make-
shift tools or improper use of the tools could cause serious
personal injury.
ACCUMULATOR
The accumulator is charged with high-pressure nitrogen

gas. When handling the accumulator, careless procedure
may cause an explosion which could lead to serious injury
or property damage. For this reason, always observe the
following precautions.
z Do not disassemble the accumulator.
z Do not bring it near flame or dispose of it in fire.
z Do not make holes in it, weld it, or use a cutting torch.
z Do not hit or roll the accumulator, or subject it to any

impact.
z When disposing of the accumulator, the gas must be

released. Please contact your Komatsu distributor to
have this work performed.
PERSONNEL
Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the area.
If necessary, employ an observer.
47
PRECAUTIONS FOR INSPECTION AND MAINTENANCE
PRECAUTION WHEN WELDING
Welding operations must always be carried out by a qualified welder and in a place equipped with proper equip-
ment. There is a hazard of gas, fire, or electrocution when carrying out welding, so never allow any unqualified
personnel to carry out welding.
BATTERY HANDLING
WARNING
Battery electrolyte contains sulphuric acid, and batter-
ies generate flammable hydrogen gas, which may
explode. Wrong handling can lead to serious injury or
fire. For this reason, always observe the following pre-
cautions.
z Do not use or charge the battery if the battery electro-

lyte level is below the LOWER LEVEL line. This may
cause an explosion. Check the battery electrolyte level
periodically and add distilled water to bring the electro-
lyte level to the UPPER LEVEL line.
z When working with batteries, always wear safety

glasses and rubber gloves.
z Never smoke or use any flame near the battery

(Z 25996).
z If you spill acid on your clothes or skin, immediately

flush the area with large amount of water.
z If acid gets into your eyes (Z 25997), flush them imme-

diately with large amount of water and seek medical
attention.
z Before working with batteries, activate the STOP

switch and remove battery main switch key.
As there is a hazard that sparks will be generated, always do as follows.
z Do not let tools or other metal objects make any contact between the battery terminals. Do not leave tools or
other metal objects lying around near the battery.
z When disconnecting the battery terminals, wait for approx. one minute after activating the engine STOP switch
and be sure to disconnect the grounding terminal
(negative (-) terminal) first. Conversely, when connecting them, begin with the positive (+) terminal and then
the grounding (-) terminal. Make sure that all the terminals are connected securely.
z Attach the battery terminal securely.
z Flammable hydrogen gas is generated when the battery is charged, so remove the battery from the chassis,
take it to a well-ventilated place, and remove the battery caps before charging it.
z Tighten the battery caps securely.
z Install the battery securely to the determined place.
48
PRECAUTIONS WITH HIGH PRESSURE OIL
WARNING
The hydraulic system is always under internal pressure. When inspecting or replacing piping or hoses,
always check that the pressure in the hydraulic circuit has been released. If the circuit is still under pres-
sure, it will lead to serious injury, so always do as follows.
z For details of the method of releasing the pressure, see the latest version of the Operation and Maintenance
Manual. If the circuit is still under pressure, do not carry out any inspection or replacement operation.
z If there is any leakage from the piping or hoses, the

surrounding area will be wet, so check for cracks in the
piping and hoses and for swelling in the hoses.
z When carrying out inspections, wear full-face protec-

tion and penetration resistant clothing and gloves
(leather).
z There is a hazard that high-pressure oil leaking from

small holes may penetrate your skin or cause blind-
ness if it contacts your eyes directly (Z 26060). If you
are hit by a jet of high-pressure oil and suffer injury to
your skin or eyes, wash the place with clean water, and
consult a doctor immediately for medical attention.
PRECAUTIONS WITH HIGH FUEL PRESSURE
High pressure is generated inside the engine fuel piping

when the engine is running. When carrying out inspection
or maintenance of the fuel piping system, wait for at least
30 seconds after stopping the engine to let the internal
pressure go down before starting inspection or mainte-
nance.
HANDLING HIGH PRESSURES HOSES OR PIPES
z If oil or fuel leaks from high-pressure hoses, it may cause fire or defective operation, which may lead to serious
injury. If any loose bolts are found, stop work and tighten to the specified torque. If any damaged hoses are
found, stop operations immediately and contact your Komatsu distributor.
Replace the hose if any of the following problems are found.
z Damaged or leaking hydraulic fitting.
z Frayed or cut covering or exposed reinforcement wire layer.
z Covering swollen in places.
z Twisted or crushed movable portion.
z Foreign material embedded in covering.
REPLACEMENT OF HOSE LINES
Hydraulic hoses are subjected to natural aging. Hence, their usable lifetime is limited to maximum 6 years.
49
NOTICE
Hose lines considered as Safety Critical Parts have to be replaced earlier. Refer to the chapter "Lubrica-
tion and Maintenance Schedule" in the MAINTENANCE section of the Operation and Maintenance Manual
for further information.
CAUTION
The maximum permissible storage time of hydraulic hoses must be observed. This storage period is part
of the usable lifetime and must be considered when installing a new hose line. If, for example, a hose line
with a one year storage time is to be installed, the remaining service life of the hose line must be consid-
ered. All hose lines are marked with the date of production.
All hydraulic hoses of the Shovel have to be replaced when their service life has expired, even if there is no visible
damage. Refer to the chapter "Lubrication and Maintenance Schedule" in the MAINTENANCE section of the
Operation and Maintenance Manual for further information.
WARNING
Repairs on hydraulic hoses are not allowed. Use ONLY GENUINE Komatsu Mining Germany replacement
hose lines.
INSPECTION OF HOSE LINES
WARNING
Great care is to be taken when inspecting the hose lines. Hydraulic fluid escaping under pressure can
cause serious injuries. Oil leaks can also cause fires. Ensure that there is no pressure in the system when
performing the inspection. Refer to chapter ’Relieving The Pressure In The Hydraulic System’ in the
"Operation" part of the Operation and Maintenance Manual.
Inspect all hoses, hose lines and fittings carefully during the course of the daily walk-around inspection. Check for
leaks and damages. Beware of pinhole leakages. Replace damaged parts without delay.
Some examples of faults on hydraulic hoses requiring replacement of the concerned part:
z Damage to the outer layer (e.g. chafed spots, cuts or scratches).
z Brittle top layers. Flaws on the hose material
z Distortion of the hose line (strong deviation from the original shape) under pressurized and pressureless con-
ditions or when kinked or crushed, e.g. disintegration of hose layers or blistering.
z Leaks.
z Detachment of hose and fitting. Damaged hose fitting.
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
To ensure safety at all times when operating the machine, the user of the machine must always carry out periodic
maintenance. In addition, to further improve safety, the user should also carry out periodic replacement of the parts
given in the table. These parts are particularly closely connected to safety and fire prevention.
50
With these parts, the material changes as time passes, or they easily wear or deteriorate. However, it is difficult to
judge the condition of the parts simply by periodic maintenance, so they should always be replaced after a fixed
time has passed, regardless of their condition. This is necessary to ensure that they always maintain their function
completely.
However, if these parts show any abnormality before the replacement interval has passed, they should be repaired
or replaced immediately.
If the hose clamps show any deterioration, such as deformation or cracking, replace the clamps at the same time
as the hoses.
When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time.
z Ask your Komatsu distributor to replace safety critical parts.
51
PRECAUTIONS FOR HIGH VOLTAGE
z When the engine is running and immediately after it is stopped, high voltage is generated inside the engine
controller and the engine injector.
WARNING
Danger of electrocution. Never touch the inside of the controller or the engine injector portion.
z The headlights also operates using high voltage. Never perform maintenance on the headlights.
z If it is necessary to touch the inside of the controller or the engine injector portion, or the headlight electrics
please contact your Komatsu distributor.
z The cab base contains high voltage electrical appliances. Access to the cab base for authorized service staff
only.
SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES
z Any work on and with the machine must be executed by reliable personnel only. Statutory minimum age limits
must be observed.
z Employ only trained or instructed staff and set out clearly the individual responsibilities of the personnel for
operation, set-up, maintenance and repair.
z All personnel must be aware of the appropriate safety measures when working on or around the machine.
z Make sure that only authorized personnel works on or with the machine.
z Define the machine operator’s responsibilities - also with regard to observing traffic regulations - giving the
operator the authority to refuse instruction by third parties that are contrary to safety.
z Do not allow persons to be trained or instructed or persons taking part in a general training course on or with
the machine without being permanently supervised by an experienced person.
z Work on the electrical system and equipment of the machine must be carried out only by skilled electricians or
by persons instructed under the supervision and guidance of a skilled electrician and in accordance with elec-
trical engineering rules and regulations.
z Work on the chassis, brake and steering systems must be performed only by skilled personnel who have been
specifically trained for such work.
z Work on the hydraulic system must be carried out only by personnel with special knowledge and experience of
hydraulic equipment.
WASTE MATERIALS
Operation
z 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.
z 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.
52
z 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
z Preserve our environment. To prevent environmental pollution, pay careful attention to the method of dispos-
ing waste materials.
z 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.
z Dispose of harmful material, such as oil, fuel, coolant, solvent, filters and batteries in accordance with local
environmental regulations and laws.
AIR CONDITIONING MAINTENANCE
WARNING
If air conditioner refrigerant gets into your eyes, it may cause blindness; if it touches your skin, it may cause frost-
bite. Never touch refrigerant.
COMPRESSED AIR
WARNING
When carrying out cleaning with compressed air, there is a hazard of serious injury caused by flying parti-
cles.
z When using compressed air to clean elements or the radiator, always wear safety glasses, dust mask, gloves,
and other protective equipment.
z Never drop or insert tools or other objects into the fan or fan belt. Parts may break or be sent flying.
53
SAFETY ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS
ADDITIONAL SAFETY INFORMATION FOR TROUBLE-

SHOOTING AND ADJUSTMENTS
INSPECTION OF THE HYDRAULIC SYSTEM
A hands-on approach to inspecting the hoses and pipes of the hydraulic system can only be made when the exca-
vator is shut down and there is no oil pressure in the hydraulic system.
WARNING
Do not use your hands during inspection or move in the vicinity of the hydraulic system’s piping or tubing
when the engine is running before checking for leaks, as hydraulic fluid escaping under pressure can
cause serious injuries.
z Additional to the general personal protective clothing as described on page 23, full face protection and pene-
tration resistant clothing and gloves must be worn.
z Troubleshooting and adjustments may only be performed by personnel trained by Komatsu Mining Germany in
safe and correct hydraulic handling procedures.
z Before troubleshooting or adjustments, the inspection of areas of potential dangers for damages, leaks or
loose connections on the pressure lines and hydraulic components must be carried out visually only when the
engine is shutdown and when there is no hydraulic pressure in the system.
z When the machine is running, the areas of potential danger can only be entered when no leakages or other
irregularities have been noticed when the high pressure oil circulation has been brought up to maximum pres-
sure from a safe distance (operator’s cab, machinery house roof, ladder platform).
TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS
To prevent injury, do not carry out adjustments with the engine running. If work must be carried out with the engine
running, perform the task with, at maximum, two maintenance workers and an operator and do as follows.
z An operator that has been trained on the machine he is

operating, must always sit in the operator's seat and be
ready to stop the engine at any time. All workers must
maintain contact with the other workers and be fully
aware of all relevant safety measures.
z When carrying out operations near the fan, fan belt, or

other rotating parts, there is a hazard of being caught in
the parts, so be careful not to come close (Z 26052).
z Do not touch any control levers or control pedals. If any

control levers or control pedals must be operated,
always give a signal to the other workers to warn them
to move to a safe place.
54
ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS SAFETY
AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR
General safety rules for working on the excavator
z Only trained personnel who are aware of all dangers are allowed to work on the hydraulic system
z Visually inspect all potential danger areas for leakages before pressure build up.
z Do not remain on or around the excavator for longer than is absolutely necessary in order to perform your
tasks.
55
SAFETY SPECIAL SAFETY EQUIPMENT
SPECIAL SAFETY EQUIPMENT
56
SPECIAL SAFETY EQUIPMENT SAFETY
FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB
The Shovel must be equipped with a front guard protective structure ”OPG Front Guard” if it is used for applica-
tions where there is a risk of hitting objects from the front.
OBJECT HANDLING
Object handling operations are not allowed.
LIGHTING
The Shovel must only be operated when the operator has sufficient visibility in relation to the work area.
Disturbing shady areas or dazzling effects must be avoided.
If necessary, the Shovel must be retrofitted with additional lighting equipment (working lights) in order to ensure
sufficient visibility conditions.
WARNING BEACON
The Shovel can be retrofitted with a warning beacon which is fitted on the cab roof by means of a magnetic
bracket.
NOTICE
The above-mentioned special safety devices can be ordered as accessories together with the Shovel.
They are also available as a field package for installation through our service organization.
SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)
The safety harness should only be used together with connectors according to
EN 354, and fall arrest according to EN 355, or fall protection devices according to EN 360.
See the following pages for further information.
57
SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)
58
WARNING
Always use a Safety Harness (1) in conjunction with a strap type Fall Absorber (2), illust. (Z 25898) before board-
ing the loader attachment or other unsecured areas on the Shovel.
NOTICE
z The Safety Harness is located in the Cabinet in the Operator’s Cab.
z The illustration (Z 25898) shows the standard use of the safety harness with a strap type fall absorber.
Legend for illustration Z 25898
(1) Safety Harness according to EN 361
(2) Strap-Type Fall Absorber according to DIN EN 355
(3) Railings (attachment points)
(4) Walkway on the boom
(A) Shoulder Strap
(B) Back Plate
(C) Catching Hook
(D) Shoulder-Strap Fixing
(E) Belly Strap
(F) Holding Hook
(G) Hold-Back Hook
(H) Pelvis Strap

(J) Leg Strap
59
60
INSTRUCTIONS FOR USE
Open the lock, lift the harness by the catch hook (C), ensuring the leg straps hang below (J). Pull the harness over
the shoulders as you would a jacket. Insert the end of the belly strap (E) through the buckle and tighten securely,
as shown in the illustration (Z 25898).
Prevent the shoulder straps from slipping by fastening the breast strap. Pull the leg straps (J) between the legs
and securely buckle them at the front as illustrated. Adjust the harness so that it snugly fits the body ensuring that
the catching hook (C) is in the center of the back.
The safety harness is a personal accessory and should only belong to its owner.
The safety harness should only be used together with connectors acc. to EN 354, and fall arrest acc. to EN 355, or
fall protection devices acc. to EN 360.
The attachment point for the safety harness should be above the wearer, and the carrying capacity of the attach-
ment point should be sufficient to correspond with the minimum carrying capacity acc. to EN 795.
61
62
PRIOR TO USING THE HARNESS (1), THE WEARER SHALL
z Carry out a visual check of the system or component; correct functioning and perfect working order have to be
assured.
z Make sure that the recommendations for use with other components of the system be observed in conformity
with the instructions for use.
The system or component must no longer be used, if there are any doubts in respect of its safe condition. The
equipment has to be inspected by the manufacturer or by a qualified person.
It is essential for safety reasons that a fall protection system or system component which has already been sub-
jected to fall be removed from service and sent back to the manufacturer or an authorized qualified repair shop for
maintenance and renewed testing.
Fall protection systems have to be treated with care and to be kept clean and ready for use. It has to be warned
against bringing the systems into contact with acids or other caustic liquids and gases, oils, detergents, or sharp-
edged objects.
Should the harness have become wet during use or cleaning, do not dry near a fire or other sources of heat, but
rather in a natural way in not too warm rooms. Keep the harness freely suspended or loosely rolled up.
When using the fall protection systems, the pertaining safety regulations in force and the "Rules for Use of Per-
sonal Fall Arrest Systems" have to be observed for protection against danger.
At least every 12 months, the safety harness and its components have to be inspected by a competent person
authorized by the manufacturer and maintained, if the manufacturer considers it necessary.
RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS

OF THE SAFETY HARNESS (1),
During the holding function, the connectors may only be placed around a mast or other construction between the
two holding hooks, so that free fall is limited to max. 0.5 m.
It should be strictly seen to it that the connector be not slung around constructions with too small diameter or sharp
edges.
With the lateral holding hooks, work may only be carried out on horizontal or almost horizontal surfaces (roofs).
The connectors have to be adjusted in such a way that the area, where danger of falling down prevails, cannot be
reached.
63
64
INSTRUCTIONS FOR USE
Strap-Type Fall Absorber acc. to DIN EN 355 (Type E.K.N.-BFD)
Use
Within a fall-arrest system, the strap-type fall absorber (2) has to be used in conjunction with a safety harness (1)
acc. to DIN EN 361. The maximum length including the safety rope must not exceed 2.0 m. For longer ropes, a
rope-shortening device has to be applied in addition.
Fix the rope to the attachment point and attach the strap-type fall absorber to the catching hook in the back of the
safety harness. The attachment point should be above the wearer and its minimum carrying capacity should be 10
KN, acc. to DIN EN 795.
The strap-type fall absorber and the safety rope must not be damaged, e.g. never pull
them over sharp edges nor get them burnt by welding sparks.
Storing and maintenance
The strap-type fall absorber has to be kept dry in an airy and shady room. It must not be ex-posed to acids, caustic
chemicals, nor to an aggressive atmosphere, and contact with oils has to be avoided. If the strap-type fall absorber
is dirty, it may be cleaned with a little water and a light-duty detergent. Dry it in a shady place (nowhere near fire or
other sources of heat). Protect it from sharp-edged objects.
Inspection
Prior to use, all parts have to be inspected for safe condition and damages. At least once a year, the strap-type fall
absorber has to be tested by a competent person. A damaged or used strap-type fall absorber has to be removed
from service immediately. The strap-type fall absorber must not be changed in any way.
65
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.
00-3
ENVIRONMENT PROTECTION Environment NOTICE
FOREWORD
GENERAL
With this SERVICE MANUAL KOMATSU provides you with the

description of the construction and the function of the major systems of the
Hydraulic Excavator PC5500-E.
We describe for you all functions and how to carry out the inspections and
adjustments.
How do you find "your" desired information?
In the table of CONTENT all the functions and components are shown in
their sequence of the description.
If after reading this SERVICE MANUAL you can give us suggestions and
comments for improvements - please do not hesitate to contact us.
Komatsu Mining Germany GmbH

- Service Training -
Postfach 180361
40570 Düsseldorf
Tel.:0211 / 7109 - 206

Fax.:0211 / 74 33 07
The editorial staff will be pleased about your co-operation.
- FROM THE PRACTICE - FOR THE PRACTICE -
) • This service manual corresponds to the state of development of the

machine at the time the manual was produced.
Variations based on special customers request and special equipment
are not included in this manual
00-4
FOREWORD HOISTING INSTRUCTIONS
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 10,0 11,2 12,5 14,0 16,0 18,0 20,0 22,4 30,0 40,0 50,0 60,0
[mm]
Allowable 1,0 1,4 1,6 2,2 2,8 3,6 4,4 5,6 10,0 18,0 28,0 40,0
load [tons]
) • 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 HOISTING INSTRUCTIONS
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 Wrench Tightening torque

dia. size [mm] [Nm]
Quality grades
8.8 10.9 12.9

M 8 13 6 21 31 36
M 10 17 8 43 63 73
M 12 19 10 74 108 127
M 14 22 12 118 173 202
M 16 24 14 179 265 310
M 18 27 14 255 360 425
M 20 30 17 360 510 600
M 22 32 17 485 690 810
M 24 36 19 620 880 1030
M 27 41 19 920 1310 1530
M 30 46 22 1250 1770 2080
M 33 50 24 1690 2400 2800
M 36 55 27 2170 3100 3600
M 39 60 2800 4000 4700
M 42 65 32 3500 4950 5800
M 45 70 4350 6200 7200
M 48 75 35 5200 7500 8700
M 52 80 6700 9600 11200
M 56 85 41 8400 12000 14000
M 60 90 10400 14800 17400
M 64 95 46 12600 17900 20900
M 68 100 15200 21600 25500
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
00-9
00-10
00-11
00-12
Basic Values in Ohm according to DIN 43 76

For Measuring Resistor PT100
°C -0 -1 -2 -3 -4 -5 -6 -7 -8 -9
-50 80,31 79,91 79,51 79,11 78,72 78,32 77,92 77,52 77,13 76,73
-40 84,27 83,88 83,48 83,08 82,69 82,29 81,89 81,50 81,10 80,70
-30 88,22 87,83 87,43 87,04 86,64 86,25 85,85 85,46 85,06 84,67
-20 92,16 91,77 91,37 90,98 90,59 90,19 89,80 89,40 89,01 88,62
-10 96,09 95,69 95,30 94,91 94,52 94,12 93,73 93,34 92,95 92,55
0 100,00 99,61 99,22 98,83 98,44 98,04 97,65 97,26 96,87 96,48
°C 0 1 2 3 4 5 6 7 8 9
0 100,00 100,39 100,78 101,17 101,56 101,95 102,34 102,73 103,12 103,51
10 103,90 104,29 104,68 105,07 105,46 105,85 106,24 106,63 107,02 107,40
20 107,79 108,18 108,57 108,96 109,35 109,73 110,12 110,51 110,90 111,28
30 111,67 112,06 112,45 112,83 113,22 113,61 113,99 114,38 114,77 115,15
40 115,54 115,93 116,31 116,70 117,08 117,47 117,85 118,24 118,62 119,01
50 119,40 119,78 120,16 120,55 120,93 121,32 121,70 122,09 122,47 122,86
60 123,24 123,62 124,01, 124,39 124,77 125,16 125,54 125,92 126,31 126,69
70 127,07 127,45 127,84 128,22 128,60 128,98 129,37 129,75 130,13 130,51
80 130,89 131,27 131,66 132,04 132,42 132,80 133,18 133,56 133,94 134,32
90 134,70 135,08 135,46 135,84 136,22 136,60 136,98 137,36 137,47 138,12
100 138,50 138,88 139,26 139,64 140,02 140,39 140,77 141,15 141,53 141,91
110 142,29 142,66 143,04 143,42 143,80 144,17 144,55 144,93 145,31 145,68
120 146,06 146,44 146,81 147,19 147,57 147,94 148,32 148,70 149,07 149,45
130 149,82 150,20 150,57 150,95 151,33 151,70 152,08 152,45 152,83 153,20
140 153,58 153,95 154,32 154,70 155,07 155,45 155,82 156,19 156,57 156,94
150 157,31 157,69 158,06 158,43 158,81 159,18 159,55 159,93 160,30 16067
00-13
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 Page
1.0 Main assembly groups
General lay out 2
1.1 Superstructure 3
1.1.1 Machine house 4
1.1.2 Hydraulic Oil Reservoir 5
1.1.3 Hydraulic Oil Cooler 6
1.1.4 High tension switch cabinet 7
1.1.5 Counter weight 8
1.1.6 Cab support 9
1.1.7 Operators cab 10
1.1.8 Control Blocks 11
1.1.9 Swing gears 12
1.2 Under carriage 13
1.3 Attachment
1.3.1. Backhoe Attachment (BHA) 14
1.3.2. Front Shovel Attachment (FSA) 15
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1.0
2
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Page 2
1. General lay out
Legend for illustration (Z 22387):

(1) Superstructure
(2) Under carriage
(3) Front Shovel Attachment (FSA)
(4) Backhoe Attachment (BHA)
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1.0
3
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Page 3
1.1 Superstructure

(1) Operators Cab with integrated FOPS
(2) Cable drum
(3)
(4) Cab support (contains the low tension electric switch board)
(5) Swing ring connection
(6) Switch cabinet, middle tension (main electric supply )
(7) Hydraulic ladder
(8) Counter weight
(9) Hydraulic oil cooler with hydraulic driven fans
(10) Hydraulic oil reservoir
(11) Batteries
(12) Swing Gear
(13) Grease pump of the Central Lubrication System (CLS)
(14) Grease pump of the Swing gear pinion Lubrication System (SLS)
(15) Main Control blocks with high pressure filters
(16) Main electric motor 1

(17) Flexible coupling
(18) PTO gear with hydraulic pumps
(19) Main hydraulic pumps 1, 2 and 3
(20) Capacitor motor 1
(21) Main electric motor 2

(22) Flexible coupling
(23) PTO gear with hydraulic pumps
(24) Main hydraulic pumps 4, 5 and 6
(25) Capacitor motor 2
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1.0
4
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Page 4
1.1 Superstructure
1.1.1 Machine house
Legend for illustration (Z 22390a):
A View from the back of machinery house without counter weight

B View from the right side of machinery house
C Top view
(1) Motor coolant air outlet

(2) Main motor supply cable
(3) Capacitor
(4) Hydraulic control and filter panel
(5) PTO gear box
(6) Main hydraulic pumps
(7) Auxiliary pumps, installed at the drive through shaft of the main
hydraulic pumps (piggyback pumps)
(8) Hydraulic pump for radiator fan drive
(9) Hydraulic pump for the hydraulic oil cooler fan drive
(10) Suction oil reservoir
(11) Flexible coupling, oil filled
(12) Batteries
(13) Engine 1
(14) Engine 2
(15) Hydraulic motor for the radiator fan drive
(16) Radiator for the engine cooling system
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1.0
5
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Page 5
1.1 Superstructure
1.1.2 Hydraulic Oil Reservoir

(1) Breather filter
(2) Temperature controlled back pressure valve
(3) Drain coupling of the hydraulic oil reservoir
(4) Return oil filter
(5) Case drain (leak oil) filter
(6) Main shut-off valve (Gate valve) with compensator
(7) Return oil collector tube
(8) Drain coupling of the Return oil collector tube
(9) Back pressure valves for swing motors
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Page 6
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Page 6
1.1 Superstructure
1.1.3 Hydraulic Oil Cooler

(1) Cooler frame with swing out facility
(2) Hydraulic motor of upper fan
(3) Upper fan
(4) Fan guard
(5) Outer part of the upper radiator set
(6) Inner part of the upper radiator set
(7) Hydraulic motor of lower fan
(8) Lower fan
(9) Fan guard
(10) Outer part of the lower radiator set
(11) Inner part of the lower radiator
(12) Swing out doors
(13) Locking bars to secure the swing out doors
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1.0
7
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Page 7
1.1 Superstructure
1.1.4 High tension switch cabinet
A Left side view

B Front side view
C Top view
X High tension switch cabinet
(1) Main fuses, high tension

(2) Main supply switch, manual controlled
(3) Main motor switches, remote controlled
(4) Current transformer
(5) Main transformer
(6) Air condition for switch cabinet
(7) Access stair
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1.0
8
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Page 8
1.1 Superstructure
1.1.5 Counter weight

(1) Counter weight
Total weight
~40000 kg
(2) Mounting bolts

Quantity Bolt size Grade SW* Tightening
(mm) (mm) torque (Nm)
16 M 48 x 380 10.9 75 7500
* SW = Wrench size
(3) Lifting points
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1.0
9
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Page 9
1.1 Superstructure
1.1.6 Cab support

(1) Cab support (Location of electrical switch board “X2”)
(2) Mounting bolts
6 M 36 x 320 10.9 55 3100
* SW = Wrench size
(3) Mounting bolts

6 M 36 x 160 10.9 55 3100
* SW = Wrench size
(4) Door
(5) Gasket
(6) Door handle (adjustable)
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1.0
10
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Page 10
1.1 Superstructure
1.1.7 Operators cab
(1) Monitor panel

(2) Switch panel
(3) Operators seat
(E19) Control lever
– EURO Control
– KMG Control
(E20) Control lever

– EURO Control
– KMG Control
(E21a) Control pedal A - forward

Left track
B - reverse
(E21b) Control pedal A - forward

Right track
B - reverse
(E22) Control pedal - Swing brake
(E23) Control pedal (left) Clam closing
(E24) Control pedal (right) Clam opening
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1.0
11
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Page 11
1.1 Superstructure
1.1.8 Control blocks

(1) Control block carrier
(2) Remote control valves
(3) Main control blocks
(4) High pressure filter
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1.0
12
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Page 12
1.1 Superstructure
1.1.9 Swing gears

(1) Swing gear box
(2) Swing parking brake – Spring loaded multi disk brake
(Released by oil pressure)
(3) Parking brake Control port (X)
(4) Oil level gauge - gear box
(5) Breather – gear box
(6) Oil filling plug – gear box
(7) Oil level gauge – motor adapter housing
(8) Breather – motor adapter housing
(9) Oil drain plug – motor adapter housing
(10) Oil drain plug - gear box
(20.1 + 20.2) Swing motor
(49.1 + 49.2) Swing brake valve block
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1.0
13
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Page 13
1.2 Under carriage

(1) Undercarriage center body
(2) Crawler carrier R.H.-side
(3) Crawler carrier L.H.-side
(4) Connecting pins, center body to crawler carriers
(5) Crawler tracks
(6) Rotary distributor
(7) Brake valves
(8) Travel motors
(9) Parking brakes, spring loaded disk type brakes
(10) Travel gear
(11) Sprocket
(12) Track rollers
(13) Carrier rollers
(14) Guide wheel (Idler)
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1.0
14
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Page 14
1.3 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
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1.0
15
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Page 15
1.3 Attachment
1.3.2 Front Shovel Attachment (FSA)

(1) Boom
(2) Boom Cylinders
(3) Stick
(4) Stick Cylinders
(5) Bucket backwall
(6) Bucket Cylinders
(7) Clam
(8) Bucket Clam cylinders
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Drive Section 2.0
Page 1
Section Page
2.0 Prime drive assembly
General 2
2.1 Coupling 3
2.2 Pump-spline lubrication 4
2.3 PTO Lubrication and cooling 5-6
2.4 Hydraulic pumps – location, drive speed and flow rates 7
2.0
2
Drive Section 2.0
Page 2
2.0 Prime drive assembly

(1) Cooling air intake
(2) Cooling air exhaust
(3) Electric Motor
(4) Alignment shims
(5) Alignment supports
(6) Motor frame
(7) Coupling
(8) Pump distributor gear (PTO)
General
The two electric motors are solid bolted to the motor frame (6).
The alignment shims (4) thickness must be determined due the alignment
procedure. The alignment must be done in accordance to the Parts & Service
News AH01523, last edition.
) • The alignment shims thickness must be also determined when

replacing the electric motor! Never use the existing shims without
determination.
2.0
3
Drive Section 2.0
Page 3
2.1 Coupling

(1) Input drive hub
(2) Output drive flange
(3) Outside rubber support ring
(4) Rubber element
(5) Motor drive shaft
(6) Gearbox input flange
(7) Hub looking washer
(8) Coupling ring
) • Repair and replacement have to be done accordingly to Parts &

Service News AH01523, last edition.
Design:
VULASTIC-L – coupling type are provided with one flexible rubber element
(4). The flexible ring connect the input drive hub (1) via the coupling ring (8)
with the output drive flange (2) of the coupling.
Function:
The high flexible VLULASTIC–L coupling transfers the torque without any
rotational gap. They are wear-resisting and maintenance free. Because of
symmetrical arrangement of the flexible rings, there are no returning forces
either by the torque transfer or the centrifugal forces.
VULASTIC-L couplings dampen rotating vibrations, reducing same by
partial storing of the shock energy and damp noises.
The coupling allows in an acceptable range axial, radial and angular
misalignment of the shafts.
Replacement and alignment refer to Parts & Service News AH01523, last
edition.
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4
Drive Section 2.0
Page 4
2.2 Pump-spline 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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5
Drive Section 2.0
Page 5
2.3 PTO Lubrication and cooling

Legend for illustration (Z 22410e):
The machine is equipped with two motors and gearboxes. The motor close to
the counter weight is called motor 1 and the motor to the front is called motor
2. The extension of the component designation shows the mounted position.
Example: Pressure filter (69.1) is the pressure filter for the PTO lubrication of
motor 1 and (69.2) of motor 2.
(1) Line to the cooler (hot oil)
(2) Return line from the cooler (cooled oil)
(3) Return line from valve
(4) Suction line from PTO oil pan to the pump
(P) Pressure port
(8.1)(8.4) Gear pump PTO-gearbox lubrication
(69.1)(69.2) Pressure filter - PTO gear lubrication
(74.1)(74.2) Pressure relief valve, 7,5 bar
(78.14)(78.15) Solenoid valve (Y53-x), (reduction of relief valve pressure)
(105.3+105.4) Oil cooler, part of hydraulic oil cooler motor 1
(105.1+105.2) Oil cooler, part of hydraulic oil cooler motor 2
(M1-1)(M1-2) Pressure check point
(B17-1)(B17-2) Pressure switch, 0,5 bar
(B27-1)(B27-2) Maintenance switch, 5 bar
(B49-1) Temperature sensor
Function:
Pump (8.1)/(8.4) forces the gear oil from the gear oil pan through filter
(69.1)/(69.2)) to pressure relief valve (74.1/74.2). This pressure relief valve
acts as a back pressure valve causing that most of the oil passes through the
gear oil coolers (105.3+105.4)/(105.1+105.2).
The gear oil coolers are a small part of the hydraulic oil coolers, thus the gear
oil gets cooled by the same air stream as the hydraulic oil. From the coolers
the oil flows to the port (P) of the gear and internally via a system of pipes to
the several spray nozzles. The spray nozzles in the gear case ensure proper
and adequate distribution of the lube oil. The circuit is monitored by the
pressure switches (B17-1). At too low lube oil pressure (0.5 bar), a fault
message will be displayed on the monitor at the dash board.
The gear oil temperature is monitored by the sensor unit (B49-1) (B49-2). At too
high oil temperature a fault message will be displayed on the monitor at the dash
board.
If the oil temperature is to low, solenoid valve (Y53-1) (Y53-2) energised and
opened port X of the pressure relive valve (74.1) (74.2). This reduced the relieve
valve pressure setting. The main gear oil flow direct back to the PTO to quick
warm up of the gear oil.
continued
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6
Drive Section 2.0
Page 6
Cont`d.
2.3 PTO Lubrication and cooling

(1) Pilot operated relief valve (8) Valve spring
(2) Plug screw (9) Seal rings
(3) Valve piston (B27-x) Maintenance switch
(4) Port for pressure switch B17-1 (74.x) Pressure relief valve
(6) Port for pressure check stud (A) Pressure port
(7) Jet bore (T) Return from valve
Adjustments:
• The adjustment of the maximum permissible PTO lube pressure, has
to be carried out with cold oil to avoid serious damages to the coolers.
• The check for a sufficient PTO lube pressure has to be carried out
with warm oil to avoid serious damages gearbox.
Setting the pressure relief valve (74.x) at cold oil.

1. Connect a pressure gauge to check point (M1.x).
2. Disconnect plug of solenoid valve Y53-1/ Y53-2
3. Start the respective motor
4. Required pressure: 7,5 bar.
If adjustment is required:
5. Remove protection cap (1a).
6. Loosen lock nut (1b).
7. Set the pressure with set screw (1c).
8. Tighten lock nut (1b) and re-install protection cap (1a)
9. Reconnect plug of Y53-1/ Y53-2
) • If the pressure of 7,5 bar cannot be adj. 100 %, adj. to the maximum
visible pressure.
Checking the PTO lube pressure at operating temperature (warm oil)

1. Connect a pressure gauge to check point (M1.x).
2. Start the motor and let it run with max. speed.
3. Required pressure: 2-7,5 bar.
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Drive Section 2.0
Page 7
2.4 Hydraulic pumps – location, drive speed and flow rates
Legend for illustration (Z 22415b):

(1 - 6) Axial piston pump (swash plate type)
pump volume Vg = 500 cm³/rev
theoretical flow rate, each Qmax = 700 Liter/min
Drive speed* n = 1409 min-1
for all working motions pmax = 310 bar
(10.1), (10.2) Axial piston pump

pump volume Vg = 80 cm³
theoretical flow rate Qmax = 142 Liter/min
for oil cooler fan drive pmax = 180 bar
(8.1), (8.4) Gear pump

pump volume Vg = 58.7 cm³/rev
theoretical flow rate Qmax = 82,2 Liter/min
for PTO gear lubrication pmax = 7,5 bar
(8.2), (8.5) Gear pump

for hydraulic oil circulation pmax = 15 bar
(7.1), (7.2) Gear pump

for pilot pressure supply pmax = 60 bar
) • * at 1500 min-1 (50Hz) or 1800 min-1 (60Hz) input drive speed

Hydraulic Oil Reservoir Section 3.0
Page 1
Section Page
3.0 Hydraulic oil reservoir
General lay out 2
3.1 Main oil tank, location of switches, sensors etc. 3

3.2 Suction oil tank with strainers 4
3.3 Return oil collector tube with strainer 5
3.4 Back pressure valve 6
3.5 Transfer Pump (Optional Equipment) 7
3.6 Return and Leak Oil Filter 8
3.7 Breather Filter 9
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3. General lay out

(1) Filter cover retainer
(2) Filter cover
(3) (A) – Return oil filter – 10 µm (4x)
(B) – Case drain filter – 3 µm (1x)
(4) Man hole cover
(5) Hydraulic oil filler plug
(6) Differential pressure switch, screen filter monitoring
(7) Test port, back pressure 8 bar
(8) Test port, back pressure swing motor 15 bar
(24) Pressure switch B24 – monitors item (132.1+132.2)
(39) Hydraulic oil level gauge
(41) Main oil reservoir
(114) Return oil collector tube with pressure check point M10
(115) Back pressure valve
(118) Oil drain, quick release coupling
(128) Shut off valve (Gate valve) with monitoring switch S31
(129) Compensator
(132.1 + 132.2) Breather filter
(178) Oil cooler filter (screen filter)
The hydraulic oil tank is a welded sheet-metal construction.

The filling capacity is about 3800 litres. The tank contains four return oil
filters (3-A) and one case drain filter (3-B).
The breather filter (132.1 + 132.2) cleans the air that streams into the tank.
The back pressure valve (115) and the pressure check point (M10) are located
at the collector tube (114) for return oil.
The connection to the suction tank can be closed with the shut- off valve (118)
to prevent oil flow during repairs on the hydraulic pumps. This unit is
controlled by the switch S31, to prevent a motor start with closed shut-off
valve. Fault message ”Start blocked because of main Shut-Off (gate) valve” is
displayed at the operators dash board.
The screen filter (178) protect the oil cooler for internal contamination, the
filter is monitored by differential pressure switch (178).
The back pressure valves (8) increase the circulation pump pressure to 15 bar
for cavitation protection of the swing motors.
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3.1 Main oil tank, location of switches, sensors etc.

(B4) Oil level sensor “Hydraulic oil level too low”
(B15) Hydraulic oil temperature probe
“Hydraulic oil temperature below: too hot”
(B24) Breather filter pressure switch
(B25) Pressure switch – Pressure leak oil chamber
(B26) Pressure switch – Pressure return oil chamber
(B32) Hydraulic oil temperature probe “Temp. gauge cabin”
(B42) Oil level sensor “Oil level maximum”
(B50) Oil level sensor “Hydraulic oil refill level”
(Y101) Solenoid valve “Back pressure reduction”
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3.2 Suction oil tank with strainers

(1) Suction oil reservoir
(2) Drain coupling
(3) Bolt
(4) Gaskets
(5) Main suction oil strainer
(6) Gaskets
(7) Intermediate pipe
(8) Nut
(9) Bolt
(10) Compensator
(11) Suction strainer – one for each main pump
(12) Suction hose connection pipe
The suction oil tank (1) is a welded sheet-metal construction.

The capacity is 187 liters.
The suction lines of all hydraulic pumps are connected to the suction tank.
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3.3 Return oil collector tube with strainer

(1) Return oil collector tube - Part 1 -
(4) Strainer
(5) Bolt
(6) Self locking nut
(7) Gasket
(8) Differential pressure switch B165
Task:
The strainer is installed to prevent the hydraulic oil coolers from getting
clogged up in case of contamination in the main return oil circuit.
Excessive increase of the hydraulic oil temperature can be an indication for a
restricted strainer, i.e. bad cooling performance due to insufficient oil flow
through the coolers.
In case that main components such as cylinders or motors are internal
fragmentary damaged, the strainer should be inspected for metal chips.
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3.4 Back pressure valve

(1) Back pressure valve assembly
(2) Solenoid valve (Y101)
Task:
The back pressure valve has to fulfill two functions in the hydraulic system:
1. To ensure a sufficient pressure within the return oil circuit, i.e. to supply
oil via the anticavitaton valves to the low pressure side of cylinders,
respectively motors.
2. To force the return oil through the coolers depending on the present
hydraulic oil temperature, controlled by solenoid valve Y101.
- Low temperature ⇒ low volume through the coolers
- High temperature ⇒ high volume through the coolers
) • Further information about the function principle and adjustments,

refer to Section 4.0 this Manual.
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3.5 Transfer pump (Optional Equipment)

1 Electric switch to start the transfer pump
2 Evacuation of the return oil collector pipes and cooler circuit
3 Evacuation of the back-pressure valve pipe
4 Evacuation of the suction oil reservoir
5 Main gate valve, hydraulic oil reservoir shut off unit
6 Transfer pump, electric propelled gear pump
7 Hydraulic oil reservoir
8 Breather filter of the hydraulic oil reservoir
9 Return oil filter
10 Leak oil filter
General
With the transfer pump it is possible to evacuate the suction oil reservoir, the oil
cooler and the return oil line as well as the back-pressure valve pipe. This is
required if the respective line must be opened for servicing or maintenance. It is
the tool to protect from oil spilling or to prevent oil draining.
The transfer pump is an electric driven (24 V board net power) gear pump. The
transfer pump can be used only with switch (1) when the main motor / engine is
stopped.
Evacuated oil is pumped through the return oil filter into the main oil reservoir
(7).
) • Evacuate only one area at the same time to prevent overfilling of the
main hydraulic reservoir.
Operational area of the Transfer Pump:
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Valves of the transfer pump
Position Function General Cock handling
Evacuation of the return

1 oil collector pipes and To open the selected valve turn the cock 90o counter-
cooler circuit clockwise (from the position marked with ’C’ = ’Closed’
to the position marked with ’O’ = ’Open’). To close the
Evacuation of the back pipe turn the cock 90o clockwise (from the position
2
pressure valve pipe marked with ’O’ = ’Open’ to the position marked with ’C’
= ’Closed’).
Evacuation of the suction
3
oil reservoir
Tab. Cock handling
) • Open only one suction area at the same time because of limited
transfer volume in the hydraulic reservoir. Observe the hydraulic oil
volume to prevent oil overfilling.
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3.5.1 Evacuation of the suction oil reservoir
1 Stop main motor / engine.
2 Close main gate valve (5) by spinning the valve wheel cw. to final stop.
3 Vent return and leak oil filter chamber by slightly opening the return oil cover (9). This
step prevents a closed connection between suction line and filter chamber via the oil
cooler.
) • If the return oil chamber is not aerated it will not be possible to

evacuate the return oil pipes or oil cooler.
4 Open the transfer pump valve to suction oil reservoir (4). See illustration Z 27706 position
"O" or Tab. ‘Cock handling’ for further information about cock opening/closing.
5 Start transfer pump with switch (1) right of the pump at the motor housing wall.
6 Open bleeder plugs (B) of the main pump suction line. Refer to illustration Z 26481.
To prevent overfilling of the main hydraulic oil reservoir observe the sight
glass. Do not leave pump unattended in operation. Stop transfer pump if
there is any oil spilling at the breather filter (6) of the oil reservoir.
7 Stop transfer pump when the suction reservoir is empty and the pump aspirates air. It is
indicated by a different noise from the pump. The suction reservoir is now empty and can
be opened for servicing or repair.
Put hydraulic system back into service:

8 Close suction valve (4) of the transfer pump. All transfer pump suction valves must be
closed. See illustration Z 27706 position "C" or Tab. ‘Cock handling’ for further
information about cock opening/closing.
9 Return oil cover (9) on top of the main oil reservoir.

10 To put suction tank back into service close bleeder plucks (B) of the main pump suction
line. Refer to illustration Z 26481.
11 Open main gate valve by spinning the valve wheel ccw. up to final stop. Check for oil
leakage. Refer to AH06519 for further venting instructions.
12 Open bleeder plugs at the main pumps, fan pump and control oil pump suction line until
bubble free oil comes out. Use adequate receptacle to collect out flowing oil.
13 Bleed all main pumps, fan pump and control oil pump by opening the leak oil drain line
and bleeder nipples or open the main pressure line of the respective pump until oil comes
out.
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14 Lower park attachment to the ground in a position as shown on the oil level plate. Stop
motor / engine and check oil level. If required correct oil level.
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3.5.2 Evacuation of the return oil collector pipes and cooler circuit
cooler.

3 Open the transfer pump valve (2) to the return oil pipes and oil cooler. See illustration Z
27706 position "O" or Tab. ‘Cock handling’ for further information about cock
opening/closing.
5 Stop transfer pump when the return oil pipes including the oil cooler are empty and the
pump aspirates air. It is indicated by a different noise from the pump. The return oil pipes
and cooler now empty in this area can be opened for servicing or repair.
7 To put the return oil line and oil cooler back into service close return oil cover (9) on top
of the main oil reservoir.
8 Start motor / engine, the return oil line, oil cooler and filter chamber refill automatically,
there is no bleeding required.
9 Check for oil leakage.
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3.5.3 Evacuation of the back-pressure valve pipe
cooler.

3 Open the transfer pump valve (3) to the return oil pipes and oil cooler. See illustration Z
27706 position "O" or Tab. ‘Cock handling’ for further information about cock
opening/closing.
5 Stop transfer pump when the return oil pipes including the oil cooler are empty and the
pump aspirates air. It is indicated by a different noise from the pump. The return oil pipes
and cooler now empty this area can be opened for servicing or repair.
7 To put the return oil line and oil cooler back into service close return oil cover (9) on top
8 Start motor / engine, the return oil line, oil cooler and filter chamber refill automatically,
there is no bleeding required.
9 Check for oil leakage.
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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
(8) Safety filter element (200 micron strainer)
(9) By pass-valve, 2.3bar
(9.1) Valve cone
(9.2) Valve spring
(9.3) O-ring
(10) Profile gasket
(11) Seal ring
Function:
The returning oil flows into the filter chamber (A) of the hydraulic tank. (The
sketch shows one section only).
The chamber is split into two sections; one sections with 4 filters for the return oil
and one for the leak oil. But the five filters are all the same. The hydraulic oil
enters the filter at the top and passes then on its way to the entire tank the filter-
element (7). "Inside to outside filtration."
The filter element condition is monitored by a pressure switch (B25, 0.5 bar for
the leak oil filter) and (B26, 2 bar for the return oil filter).
As soon as the pressure inside the filter chamber reaches the set pressure of those
switches due to the restriction of the filter-element which is caused by foreign
matters, the fault message ”Return oil filter restricted" or ”Leak oil filter
restricted” is displayed at the operator's dash board The filter elements must be
replaced. For safety pre-cautions the filter is equipped with a by-pass valve. As
the filter chamber pressure increases the by-pass valve opens at 2.3 bar and
protects the element from bursting.
But the oil flows not totally unfiltered into the tank because it must flow through
the strainer (8).
•
)
The switch point of the pressure switch for the leak oil has been
chosen so low with best intention to protect first of all the radial seal
rings of the hydraulic motors.
Because the filter is oversized for this purpose, the message ”Leak
oil filter restricted” is displayed very seldom under normal
circumstances.
• Maintenance see MAINTENANCE MANUAL
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3.7 Breather filter

(1) Nut
(2) Cover
(3) Filter element
(4) Filter pot
A breather filter is installed to clean the air that streams into the tank any time
the oil level decreases while extending attachment cylinders
The filter element condition is monitored by a vacuum type pressure switch
(B24, 80mbar).
Maintenance see MAINTENANCE MANUAL
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Hydraulic Oil Cooling Section 4.0
Page 1
Section Page
4.0 Hydraulic oil cooling
4.1 General 2
4.2 Function of the hydraulic oil cooling circuit 3
4.3 Adjustment of the Back Pressure Valve 4
4.4 Fan drive (Two stage cooler fan RPM control) 5+6
4.5 Pressure relief valves and solenoid valve 7+8
4.6 Fixed Displacement Pump, with variable setting 9
4.7 Radiator fan drive speed adjustment 10 –
12
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2
Page 2
4.1 General
The hydraulic oil cooling system maintains the hydraulic oil at a normal
operating temperature.
Legend for illustration (Z 21594)

(1) Noise shield
(1) Cooler (Radiator)
(2) Cooler frame
(3) Fan
(4) Fan motor (Axial piston motor)
(5) Bolt
(6) Bolt
(7) Drive shaft
(8) Shaft protecting Sleeve
(9) Drive shaft seal
(10) Ball bearings
(11) Seeger clip ring
(12) Bearing group carrier
(13) Oil level plug
(14) Breather filter
Design:
There are four hydraulic oil coolers in front of the hydraulic tank on the R.H.
side of the platform.
They are in pairs mounted in one frame, one above the other. The air stream
needed for the cooling is produced by hydraulic driven fans. The air flows
from inside to outside through the coolers.
For a better cleaning, the coolers can be moved to the side. (“Swing out
cooler”)
The bearing group carrier is filled with oil to lubricate the bearings.
4.0
3
Page 3
4.2 Function of the hydraulic oil cooling circuit
Legend for illustration (Z 22419aa)

(107.1-107.4) Restrictor, shock absorbers for the hydraulic oil cooler
(106.1-106.4) Hydraulic oil cooler
(115) Back pressure valve
(L6 + L7) Return line from control blocks
(C1 + C2) Supply line for the anticavitation circuit of the swing
motors
(M10) Pressure check point
(C1 + C2) Supply line for the anticavitation circuit of the swing
motors
(Y101) Solenoid valve – 4/2-directional control valve
(H) Lines to cooler (hot oil)
(C) Lines to tank (cold oil)
Function:
The returning oil from the system flows via the lines (L6 - L7) into the
collector tube (114). On the top of it is the Back Pressure Valve (115)
installed.
The back pressure valve (115) causes a back pressure which forces most of
the relative hot oil through the lines (H) to the cooler (106.1-106.4).
On its flow through the cooler the hydraulic oil gets cooled and flows than
through the restrictors (107.1-107.4) and the lines (C) into the filter chamber
of the main oil reservoir (41).
The restrictors are acting like shock absorbers to prevent cooler cracking at
pressure peaks.
Besides the back pressure valve acts as an oil flow control valve as far as the
oil temperature has not reached its steady temperature.
During the warm up period (1/2 Qmax) the back pressure valve (115) is wide
open, because solenoid valve Y101 is energized, which results in less oil
flows through the cooler which causes that the oil gets quicker its optimum
With increasing oil temperature the oil gets thinner, so that the main pumps
can be shifted to Qmax position and simultaneously solenoid valve Y101 will
be de-energized, so that the valve piston will be more closed by the force of
the spring thus that more oil passes the cooler.
4.0
4
Page 4
4.3 Adjustment of the Back Pressure Valve
Checks and settings only at normal operating temperature of the hydraulic oil,
main pumps in maximum flow position and "Idle Time" control eliminated
(service switch S151 actuated)!
1. Connect a pressure gauge to check point (M10).

2. Disconnect plug connector (13) of solenoid valve Y101.
3. Actuate service switch S151 ().
4. Start both both the motors..
5. Required pressure: 8 ±0,5 bar
a) Take off protective cap (12).
b) Loosen lock nut (5).
c) Adjust the pressure with the set screw (6).
d) Tighten lock nut (5) and refit protective cap (12).
6. Disconnect the pressure gauge, reconnect solenoid valve Y101 and
switch back service switch S151.
Legend for illustration (Z 21596c):

(1) Control oil port
(2) "Y"- port (external return to tank)
(2a) "X"- port (external return to tank via solenoid valve Y101)
(3) Poppet
(4) Valve spring
(5) Lock nut
(6) Set screw
(7) Jet bore (large)
(8) Valve spring
(9) Valve piston
(10) Jet bore (small)
(11) Plug screw
(12) Protective cap
(13) Plug connector
(A) Return to tank (Filter chamber)
(Z) Pressure oil to valve
4.0
5
Page 5
4.4 Fan drive (Two stage cooler fan RPM control)
Legend for illustration (Z 22420aa)

(10.2) Axial piston pump Motor 1 (fixed displacement pump, with
variable setting)
(10.4) Axial piston pump Motor 2 (fixed displacement pump, with
variable setting)
(22.1) Fan motor (Axial piston motor)
(22.2) Fan motor (Axial piston motor)
(168.1) Pressure relief valve – Motor 1 radiator fan drive
(168.2) Pressure relief valve – Motor 2 radiator fan drive
(68.1) Pressure filter with pressure differential switch B28-1 (Motor 1)
(68.2) Pressure filter with pressure differential switch B28-2 (Motor 2)
(103.1) Check valve– (Anti cavitation valve for fan drive motor)
(103.2) Check valve– (Anti cavitation valve for fan drive motor)
(148.11) 4/3 direction flow valve – Motor 1 radiator fan speed (stop, low and
high speed), solenoid Y6A-1 + Y6B-1
(148.12) 4/3 direction flow valve – Motor 2 radiator fan speed (stop, low and
high speed), solenoid Y6A-2 + Y6B-2
(169.1) pressure reduction valve (low fan speed adjusting) motor 1
(169.2) pressure reduction valve (low fan speed adjusting) motor 2
(L) Leak oil (case drain) to tank
(P) Pressure to motor
(R) Return oil to tank
Mot1 Mot1 PVG PVG of Motor 1
Mot2 Mot2 PVG PVG of Motor 2
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Page 6
Function:
From pump (10.x) flows the oil through the filter (68.x) to the fan motor (22.x) and
then back to the tank.
The check valve (103.x) act as an anti cavitation valve and is installed, because the
fan motor -driven by inertial force- is running for a short period after the oil flow is
interrupted by solenoid valve (Y6A-x/Y6B-x) or if the motor has been switched off.
The hydraulic circuit "Fan drive" is secured by the pilot controlled pressure relief
valves (168.x) and (169.x).
These valves are working together with the solenoid valve (Y6A-x/Y6B-x),
controlled by the PLC, depending on the hydraulic oil temperature:
• With de-energized solenoids Y6A-x and Y6B-x the relief valve (168.x) is
functioning and the fans are running with max. adjusted speed (1300 RPM)
• With solenoid Y6A-x energized the relief valve (168.x) is not functioning and
the fans are running with a very low speed caused by the flow resistance only.
• With solenoid Y6b energized the relief valve (169.x) is controlling the relief
valve (168.x) and the fans are running with 1000 RPM RPM only.
(See also description on next page)
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4.5 Pressure relief valves and solenoid valves

Pressure relief valves (168.x)
Legend for illustration (Z 21598b)

(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 changed (Remote controlled) by means of the
port "X" and the function of the solenoid valve Y6A-x / Y6B-x and pressure
reduction valve 169.x. .( Function see next page)
continued
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Page 8
Cont’d.
4.5 Pressure relief valves and solenoid valve, illustration (Z 21599c)
Function:
With de-energized solenoids (Y6A-x and Y6B-x), the spool (3) of the 4/3
direction flow valve 148.x keeps the "X" connection of valve (168.x) and port
“B“ to port “P“ closed. The pressure relief valve (168.x) operates normal with
the max. adjusted pressure. The fan turn with maximum speed.
The energized solenoid Y6B, operate the spool (3) of the 4/3 direction flow
valve 148.x and a connection is made between port “P“ , port “B“ and port "X"
of valve (168.x)
The system pressure now opens main piston (7) of valve (168.x), because via
solenoid Y6B (P to B) the oil from the rear side of piston (7) flows from the
"X"-port to the “P“ port of valve (169.x). This valve (169.x) reduce now the
max. adjusted pressure of valve (168.x) to a lower value. The fan turn with
reduced speed.
The energized solenoid Y6A, operate the spool (3) of the 4/3 direction flow
valve (148.x) and a connection is made between port “P“ and port “A” and port
"X" of relief valve (168.x).
The system pressure now opens the main piston (7) of valve (168.x) because
via the "X"-port the oil from the rear side of piston (7) flows to tank. The
normal relief valve function is eliminated. The fan turn with minimum speed,
nearly stand still.
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4.6 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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4.7 Oil cooler Radiator fan drive speed adjustment
Basic Adjustment

(1) Dust cap
(2) Lock nut
(3) Set screw
(P) Axial piston pump (fixed displacement pump, with variable
setting)
(6) Qmin stop bolt
(6.1) Lock nut
(7) Qmax stop bolt
(7.1) Lock nut
(10) Positioning pin (mover)
(168.1) Pressure relief valve – bottom oil cooler fan (Motor 1)
(168.4) Pressure relief valve – top oil cooler fan (Motor 2)
(169.1) pressure reduction valve – bottom oil cooler fan (Motor 1)
(169.2) pressure reduction valve – top oil cooler fan (Motor 2)
(Y6A-1 /Y6B-1) 4/3 direction flow valve – Motor 1
(Y6A-2 /Y6B-2) 4/3 direction flow valve – Motor 2
(L1) Measurement of Qmin stop bolt
(L2) Measurement of Qmax stop bolt
(M5-1) Pressure check points - Motor 1 oil cooler fan drive operating
pressure
(M5-2) Pressure check points - Motor 2 oil cooler fan drive operating
pressure
) • A blocked cooler, restricted air flow, defect cooler seal or bend fan
influence the fan RPM and air flow.
• Basic adjustment has to be carried out whenever one of the following
components has been replaced:
- pump
- relief valve
- hydraulic motor
continued
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Page 11
Cont'd
4.7 Oil cooler fan drive speed adjustment Radiator fan drive speed
adjustment
Basic Adjustment max fan speed
1. Reduce the output flow of the respective pump (P),by adjusting the
minimum possible swivel angle, to avoid over speeding the fan:
To do this, loosen both lock nuts (6.1 + 7.1) and turn out bolt (6)and
turn in bolt (7) up to final stop.
This is necessary to avoid a loose positioning pin (10), resulting in
oscillating of the cylinder barrel.
Tighten the lock nuts.
2. Remove protection cap (1) from relief valve (168.x), loosen lock nut
(2) and turn set screw (3) fully clockwise and then a half turn
counter clockwise.
3. Disconnect the plug connectors (Y6A-x and Y6B-x) of the 4/3
direction flow valve, to ensure that the full flow of pump P will be
delivered to the fan motor. The valve is in neutral position and all
ports are blocked.
4. Connect a pressure gauge to check point (M5-x).
5. Start the respective motor. and let it run in high idle.
6. Check the fan speed with a non-contact rev counter
Required fan speed: 1300250 RPM
• Be careful not to get caught in the fan or other rotating parts
7. Increase the output flow of pump P ,by adjusting the swivel angle, until
the fan speed is 20 RPM higher than required:
To do this, loosen both lock nuts (6.1 + 7.1) and turn in bolt (6) and
turn out bolt (7) the same length.
This is necessary to avoid a loose positioning pin (10), resulting in
oscillating of the cylinder barrel.
Tighten the lock nuts (6.1 + 7.1).
• Do not exceed the maximum permissible operating pressure of
230 bar
) • Note down the lengths ”L1” and ”L2” as reference measurements.
continued
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Page 12
Cont'd
8. Loosen lock nut (2) of the relief valve (168.x), and decrease the
pressure with set screw (3) until the correct fan speed is obtained.
9. Tighten lock nut (2) and fix protection cap (3).
Basic Adjustment middle fan speed

10. Activate the 4/3 direction flow valve (Y6B-x), by connecting the
solenoid plug (Y6B-x ) to permanent 24 V. Use a the 24V socket
(close to the motor house light switch or emergency switch.at the
PTO *) or activate the fan via PLC control ( digital output, key
switch required).
11. Check the fan speed with a non-contact rev counter Required fan
speed: 1000 RPM
12. If adjustment is necessary loosen lock nut (5) of the relief valve
(169.x), and decrease the pressure with set screw (4) until the correct
fan speed is obtained.
13. Stop motor and reconnect the plugs to the correct positions.
14. Disconnect the pressure gauge from check point (M5-x).
Fan speed check

If the maximum fan speed is out of adjustment, increase or decrease first the
pressure at relief valve (168.x), to change the speed.
• Do not exceed the maximum permissible operating pressure of 230 bar
If the speed can not be raised by increasing the pressure then increase the
output flow of pump (10.x).
*) Prepare a test wire with a plug ET-No. 891 039 40, and a plug
ET-No. 440 305 99. Connect terminal 1 to positive (+)
(center off plug 440 305 99) and terminal 2 to ground (-).
Controlling Section 5.0
Page 1
Section Page
5.0 Controlling
General lay out 2
5.1 Control and filter panel location of components 3

(valves, switches, sensors etc.)
5.2 Pilot Pressure Supply and Adjustments 4–7
5.3 Remote control valves arrangement 8
5.4 Function principle of the 9 + 10
Electro-Hydraulic- Proportional Control
5.5 Potentiometer Control (Lever, Joy Stick) 11
5.6 Potentiometer Control (Pedal) 12
5.7 Proportional amplifier module, Type A 13
(for swing brake only)
5.8 Proportional amplifier module, Type B 14
(for Boom, Stick, Bucket, Swing and Travel)
5.9 Ramp Time Module 15
(Analogue command value module for Boom,
Stick, Travel and Swing function)
5.10 Adjustments of Amplifier Modules (General) 16
5.11 Adjusting the Amplifiers Type B 17 + 18
5.12 Adjusting the Amplifiers Type A 19 + 20
5.13 Adjusting the Ramp Time Module 21 + 23
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2
X4 - pump support
pressure X3 – remote control
pressure (1/2Qmax; Qmin)
X2
pump regulation
pilot pressure
X1 - pump regulation
pressure
to (45.2); (45.3) and (43) Z 22429
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Page 2
5.0 General lay out

(7.1 / (7.2) Pumps for pilot pressure and pump regulation system
(84.1 / 84.2) Check valve (for combined operation)
(68.1) Filter
(70.1) Pressure relief valve (X4 – pressure)
(70.2) Pressure relief valve (X2 – pressure)
(85) Pressure accumulator (10 Liter, 10 bar pre-charge
pressure)
(91) Check valve
(45.1; 45.2 ;45.3, 43) Remote control valves
(14; 15; 16; 13)) Control blocks
General
The controlling includes the pilot pressure system and the pump regulation
system.
The pumps (7.1 / 7.2) forcing the oil through the filter (68.1) 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 relive 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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5.1 Control and filter panel location of components Legend for illustration (Z 22497):
Solenoid valves
Motor 1 Motor 2
(Y5) Swing gear house brake (swing parking brake)
(Y6A-1) (Y6B-1) Oil cooler fan RPM control
(Y6A-2) (Y6B-2) Oil cooler fan RPM control
(Y14A-1) (Y14A-2) Radiator fan RPM control, low speed (only diesel drive)
(Y14B-1) (Y14B-2) Radiator fan RPM control, middle speed (only diesel drive)
(Y16) Travel gear house brake (travel parking brake)
(Y17) Idle time control (Qmin)
(Y17a) ½ Q-max (reduced oil flow at cold oil)
(Y127) Swing service brake control
(Y61.1) (Y61.2) „XLR“ pressure, pumps 1 - 3, „XLR“ pressure, pumps 4 - 6
(Y102.1) (Y102.2) „X4“ pressure, pumps 1 - 3, „X4“ pressure, pumps 4 - 6
(Y124A/B) Refilling arm – up and down (only with diesel engines)
(Y124c) Refilling arm lock (only with diesel engines)
(Y48) Swing motor power/ speed control
(Y120) Emergency swing service brake control
(Y123A/B) ladder up and down
(Y125) ladder speed control
Pressure switches:
(B16) Pilot pressure for Swing gear house brake (24 bar)
(B21.1) (B21.2) Radiator fan drive filter differential switch (filters 68.3+5) (only diesel)
(B22) Differential pressure switch, pilot pressure system filter
(B27.1) (B27.2) Differential pressure switch, PTO gear oil filter
(B28.1) (B28.2) Pressure switch, cooler fan drive filter
(B48) Pilot pressure for travel gear house brake (24 bar)
(B97.1) (B97.2) „X4.1“ pressure, pumps 1 - 3, „X4.2“ pressure, pumps 4 - 6
(B85.1) (B85.2) “X1.1” pressure, pumps 1+2; “X1.2” pressure pumps 4 - 6
(B86) X2 pressure sensor
Pressure check points:
(M1.1) (M1.2) Pressure PTO gear lubrication
(M2) X4 - pressure
(M3) X2 - pressure
(M5.1) (M5.2) Cooler fan drive pressure
(M6) Pressure travel gear house brake
(M7) Pressure Swing gear house brake
(M11) Pressure swing brake (safety circuit )
(M18) Pressure for hydraulic pump regulation (electronic out)
(M19.1) (M19.2) Radiator fan drive pressure (only with diesel engines)
(M20.1) (M20.2) X1 pressure pumps 1, 2, 4, 5, 6
(M30) X3 pressure for pumps at ½ flow position
(M32) X3 pressure for pumps at ½ flow position
(M40) Pilot pressure, X-2
Filter:
(68.1) Pilot pressure and pump regulation
(68.2) (68.4) Oil cooler fan drive
(68.3) (68.5) Engine radiator fan drive (only with diesel engines)
(69.1) (69.2) PTO gear lubrication
continued
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5.0
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5.2 Pilot Pressure Supply and Adjustments
Pilot Pressure Circuit

The pilot pressure oil is used for the following functions.
To move the control block spools, to supply the main pump 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 Lincoln
Lubrication pumps, to move the hydraulic operated ladder, to move the
hydraulic operated refilling arm and to supply the hydraulic track tensioning
system.

(7.1 / 7.2) Pilot pressure pumps
(84.1 / 84.2) Check valve (for combined operation)
(68.1) Filter
(70.1) Pressure relief valve 60 bar
(70.2) Pressure relief valve 35 bar
(85) Pressure accumulator
(43 + 45.x) Remote control valves
(M2) 60 bar pressure check point (X4-Pressure)
(M3) 35 bar pressure check point (X2-Pressure)
(M40) 35 bar pres. check point (X2-Pressure in front of accumulator)
Function:
Study together with the hydraulic circuit diagram
The pumps (7.1 and 7.2) are delivering the oil through the filter (68.1) to port A
of the pressure relief valve (70.1) and the pressure relief valve (70.2) port A.
The pressure relief valve (70.1) maintains the adjusted pressure of 60 bar it is
called X4-pressure.
X4 - pressure: Pump support pressure
Pump bearing lubrication
Actuation of refilling arm and ladder
Lubrication system
Track tensioning system
continued
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Cont’d.:
The pressure relief valve (70.2) maintains the adjusted pressure of 35 bar it is
the X2-pressure.
X2 – pressure: Pilot pressure system

Pump regulation system
Capacity regulation swing motors
Travel- and Swing gear house brakes (spring loaded multi -
disk brakes)
The pressure accumulator (85) holds an amount of oil under pressure to ensure
sufficient pilot pressure during normal operations and a limited number of
operations without motor power.
The check valves (91) prevents return flow of the pilot pressure oil.
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6
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Cont'd:
Pilot Pressure Circuit

(91) Check valve
(85) Bladder Accumulator – 10 liter, 10 bar (located behind the filter and
valve panel of motor 2 on top of the PTO)
(PX2) Pilot pressure line
(LX2) Leak / return oil line from the remote control blocks
Function:
The pilot pressure oil flows via line (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 see “5.3 Remote control
valves arrangement” in this section.
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Checks and Adjustment of Pilot Pressure

(85) Bladder Accumulator – 10 liter, 10 bar pre-charge pressure
(located underneath the catwalk in front of the PTO)
(70.1) Pressure relief valve for pump support pressure X4 (60 bar)
(70.2) Pressure relief valve for pilot pressure X2 (35 bar)
(M2) Pressure check point X4, pump support pressure (60 bar)
(M3) Pressure check point X2 pressure, pilot pressure (35 bar)
(M40) Pressure check point for accumulator (If not factory installed, fit a
T-union with test connector as shown in illustration Z 21635a)
) • Since the “X2” and the “X4” pressure are influencing each other it is
always necessary to adjust both valves 70.1+70.2 alternately.
60 bar pressure „X4“, valve 70.1:
1. Connect pressure gauge to check point (M2)
2. Start both motors
3. Read pressure, required = 60 -2 bar
If readjustment is required *:
35 bar pressure „X2“, valve 70.2:
1. Connect pressure gauge to check point (M3)
2. Start both motors
3. Read pressure, required = 35+3 bar
If readjustment is required *:
* Valve adjustment:
a Remove dust cap (1).
b. Loosen lock nut (2).
c. Set pressure with set screw (3).
d. Tighten lock nut (2) and re-fit dust cap (1).
Checking of Accumulator Function

1. Connect pressure gauge to check point (M40).
2. Start one motor.
3. After build-up of pressure stop the 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 leakage’s.

• To check the accumulator charging pressure refer to SERVICE
BULLETIN AH01531a latest edition.
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5.3 Remote control valves arrangement
No. Solenoid Proportional Function

valve valve FSA BHA
Y20a Y20 L.H. Crawler forward

Y20b L.H. Crawler reverse
Y21a Y21 Stick extending
45.1 Y21b Stick retracting
Y22a Y22 Bucket filling (curl)
Y22b Bucket emptying (dump)
Y23a Y23 Boom raising
Y23b Boom lowering
Y24a Y24 Clam closing Bucket filling (curl)

X24b Clam opening Bucket emptying (dump)
Y25a Y25 Bucket filling (curl) Boom raising
45.2 Y25b Bucket emptying (dump) Boom lowering
Y26a Y26 Boom raising Reserved
Y26b Boom lowering Reserved
Y27a Y27 Stick extending Stick extending
Y27b Stick retracting Stick retracting
Y28a Y28 R.H. Crawler reverse

Y28b R.H. Crawler forward
Y29a Y29 Boom raising
45.3 Y29b Boom lowering
Y30a Y30 Bucket filling (curl)
Y30b Bucket emptying (dump)
Y31a Y31 Stick extending
Y31b Stick retracting
43 Y32a Y32 R.H. Swing

Y32b L.H. Swing
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5.4 Function principle of the Electro-Hydraulic- Proportional Control

(1) Pump
(2) Filter
(3) Pressure relief valve
(4) Check valve
(5) Pressure Accumulator
(6) Directional Solenoid valve, a side
(7) Directional Solenoid valve, b side
(8) Proportional Solenoid valve
(9) Control valve block
(10) Battery
(11) Electronic units with amplifiers etc.
(12) Control lever
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 motors 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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Page 10
Cont'd:
5.4 Function principle of the Electro-Hydraulic- Proportional Control
(Exemplary illustration of the function of two axis with one Amplifier only)
Legend for illustration (Z 21638a)
(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 for the internal electronics 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 „X-
axis“ (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 35 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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5.5 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 Potentiometer Control (Pedal)

(1) Potentiometer Control Unit
(2) Pedal
(3) Standard cable
(4) Connection cable for combined operation
Application for:
(A) Swing foot brake
(B) Clam Opening/closing, (only face shovel attachment)
(C) Travelling
The Potentiometer Control (inductive linear 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.
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5.7 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 is snapped onto mounting rails inside the X2-box.
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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5.8 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 is snapped onto mounting rails inside the X2-box.
The amplifier module contains the necessary electronics for the control of
two proportional solenoids and two directional solenoids. The 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 80 ms 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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5.9 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" ⇒ Actual ramp time
"w" ⇒ 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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5.10 Adjustments of Amplifier Modules (General)

(1) Potentiometer control
(2) Terminal with a separating possibility
(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,- Travel,- and Swing Function.
B. Without ramp time module,
i.e. Bucket and Clam Function.
The ramp time modules (3) and the amplifiers (4) are adjustable.
Adjustments are required:
Ramp time modules Amplifiers
• When commissioning the machine • When replacing a solenoid valve
• When replacing a module • 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" "b" "c" "d"

a) A multimeter, good readable for
mA VDC
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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5.11 Adjusting the Amplifiers Type B, illustration (Z 21642a)
Procedure applicable for all amplifiers except the one for the swing
brake:
(Do not start the motors leave 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 electric circuit diagram (see page adjustments of amplifier and
time ramp modul) e.g. 330 mA. (The first step (10 %) value)
If necessary correct the value with potentiometer (10%).
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. 570 mA. (The second step (90 %) value).
If necessary correct the value with potentiometer (J2).
* 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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Cont'd:
5.11 Adjusting the Amplifiers Type B, illustration (Z 21642)
10. Repeat settings of item 8 and 9 until both mA values are stabilized, because
the 10% and J2 adjustment influence each other.
11. 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 ice
versa.
Attantion! The adjustment values can be different betwin the directions (poitiv A
or negative B) and the single amplifier. Use the respective electric diagram of
your machine (page: adjustments of amplifier and time ramp modul)
12. Repeat the setting as described under item 7 to 10.
13. Remove multimeter, test wire, close* the terminals and reconnect the wire to
terminal 5 of the amplifier module.
Adjusting the Ramp Time

In the amplifier module is a ramp time function integrated which is active
when there is no additional ramp time module in the respective control
circuit.
1. Turn potentiometer (time) 30 revolutions counter clockwise to guarantee the
correct start position at the complete left side.
2. Turn potentiometer (time) so many revolutions clockwise as shown in the
table below (part of the electrical circuit diagram).

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.
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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)
If necessary correct the value with potentiometer (R1).

continued
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Cont'd:
9. 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).
If necessary correct the value with potentiometer (R2).
) • It is important that the pilot pressure for the pressure increasing valve
is 19± 1 bar.
For more information refer to section 8.2 „Swing Circuit“
10. Repeat settings of item 8 and 9 until both mA values are stabilized, because
R1 and R2 influence each other.
11. 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

(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 motors turn only the key switch in ON – position.
Basic Adjustment:
1. Connect 0 VDC 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 Z" a value of 0 VDC measured at terminal 7.
Disconnect the test lead after the setting is done.
2. Connect +10 VDC 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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Cont'd:
5.13 Adjusting the Ramp Time Module

(1) Control lever (joystick)
(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 24 Volt 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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Cont'd:
5.13 Adjusting the Ramp Time Module (values as a example only)
E48 Stick
24 Volt at Joy stick Signal Pot Value to be measured at socket "t"
Terminal 9 Neutral ⇒ Stick out 0V to +10V t1 0,10 Volt = 1000 ms
Terminal 10 Stick out ⇒ Neutral +10V to 0V t2 0,10 Volt = 1000 ms
Terminal 11 Neutral ⇒ Stick in 0V to -10V t3 0,10 Volt = 1000 ms
Terminal 12 Stick in ⇒ Neutral -10V to 0V t4 0,10 Volt = 1000 ms
E49 Boom
Terminal 9 Neutral ⇒ Lower 0V to +10V t1 0,10 Volt = 1000 ms
Terminal 10 Lower ⇒ Neutral +10V to 0V t2 5,00 Volt = 20 ms
Terminal 11 Neutral ⇒ Lift 0V to -10V t3 0,10 Volt = 1000 ms
Terminal 12 Lift ⇒ Neutral -10V to 0V t4 5,00 Volt = 20 ms
E50 Swing
Terminal 9 Neutral ⇒ Swing R 0V to +10V t1 0,20 Volt = 500 ms
Terminal 10 Swing R ⇒ Neutral +10V to 0V t2 0,10 Volt = 1000 ms
Terminal 11 Neutral ⇒ Swing L 0V to -10V t3 0,20 Volt = 500 ms
Terminal 12 Swing L ⇒ Neutral -10V to 0V t4 0,10 Volt = 1000 ms
E50B Swing brake

Terminal 9 Neutral ⇒ counter 0V to +10V t1 0,10 Volt = 1000 ms
swing right
Terminal 10 Counter swing right +10V to 0V t2 0,500 Volt = 20 ms
⇒ Neutral
Terminal 11 Neutral ⇒ counter 0V to -10V t3 0,10 Volt = 1000 ms
swing left
Terminal 12 Counter swing left -10V to 0V t4 0,500 Volt = 20 ms
⇒ Neutral
continued
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E51 Left crawler

Terminal 9 Neutral ⇒ Forward 0V to +10V t1 0,500 Volt = 20 ms
Terminal 10 Forward ⇒ Neutral +10V to 0V t2 0,500 Volt = 20 ms
Terminal 11 Neutral ⇒ 0V to -10V t3 0,500 Volt = 20 ms
Backward
Terminal 12 Backward ⇒ -10V to 0V t4 0,500 Volt = 20 ms
Neutral
E52 Right crawler

Terminal 9 Neutral ⇒ 0V to +10V t1 0,500 Volt = 20 ms
Backward
Terminal 10 Backward ⇒ +10V to 0V t2 0,500 Volt = 20 ms
Neutral
Terminal 11 Neutral ⇒ Forward 0V to -10V t3 0,500 Volt = 20 ms
Terminal 12 Forward ⇒ Neutral -10V to 0V t4 0,500 Volt = 20 ms
E59 Bucket (only BHA)

Terminal 9 Neutral ⇒ Fill 0V to +10V t1 0,05 Volt = 2000 ms
Terminal 10 Fill ⇒ Neutral +10V to 0V t2 0,10 Volt = 1000 ms
Terminal 11 Neutral ⇒ Dump 0V to -10V t3 0,10 Volt = 1000 ms
Terminal 12 Dump ⇒ Neutral -10V to 0V t4 0,10 Volt = 1000 ms
04.01.07 PC5500-6-E_Sec_5-0_rev3.doc
Components Section 6.0
Page 1
Section Page
6.0 Components
6.1 Hydraulic
6.1.1 Main Control Blocks and High Pressure Filter FSA 2-3
6.1.2 Main Control Blocks and High Pressure Filter BHA 4-5
6.1.3 Distributor Manifold – Restrictor blocks FSA 6
6.1.4 Distributor Manifold – Restrictor blocks BHA 7
6.1.5 Restrictor Block with Pressure Relief Valve 8
6.1.6 Anti Cavitation Valve Block 9
6.1.7 Remote Control Valves 10
6.1.8 Directional Solenoid Valves (4 way / 3 positions) 11
6.1.9 Proportional Solenoid Valves 12
6.1.10 High Pressure Filter 13
6.1.11 Control Blocks and Valves 14-17
6.1.12 Load Holding Valve 18
6.1.13 Travel Brake Valve 19
6.1.14 Pressure Reducing Valve 20
6.1.15 Directional Solenoid Valves (2 positions / 4-ways) 21
6.1.16 Pressure Increasing Valve 22
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6.1.1 Main Control Blocks and High Pressure Filter

Front Shovel Attachment FSA

Pump circuit No. I
(14 / I ) Control block I (L.H. Travel, Stick, Bucket, Boom,)
(46.1) High pressure filter, Pump 2 and 5
(31.01) SRV Travel motors left backward
(32.01) ACV Travel motors left backward
(31.02) SRV Travel motors left forward
(32.02) ACV Travel motors left forward
(33.1) SRV Stick cylinder piston side
(32.3) ACV Stick cylinder piston side
(32.4) ACV Stick cylinder rod side
(32.5) ACV Bucket cylinder rod side
(33.2) SRV Bucket cylinder rod side
(32.6) ACV Bucket cylinder piston side
(32.7) ACV Boom cylinder rod side
(32.8) ACV Boom cylinder piston side
Pump circuit No. II

(15 / II) Control block II (Bucket, Boom, Reserved, Stick)
(44.2) High pressure filter, Pump4
(32.10) ACV Bucket piston side
(30) SRV Clam cylinder piston side
(191) SRV (pressure increasing valve) Stick cylinder rod side
continue
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Pump circuit No. III

(176 / III) Control block (R. H. Travel, Boom, Bucket, Stick)
(31.03) SRV Travel motors right forward
(32.17) ACV Travel motors right forward
(31.04) SRV Travel motors right backward
(32.18) ACV Travel motors right backward
Pump circuit No. IV

(13 / IV) Control block IV (Single spool for swing)
(44.1) High pressure filter, Pump 3
) • There is one MRV in each control block.
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6.1.2 Main Control Blocks and High Pressure Filter

Backhoe Attachment

Pump circuit No. I
(175 / I ) Control block I (L.H. Travel, Stick, Bucket, Boom,)
(31.01) SRV Travel motors left backward
(32.01) ACV Travel motors left backward
(31.02) SRV Travel motors left forward
(32.02) ACV Travel motors left forward
Pump circuit No. II

(15 / II) Control block II (Bucket, Boom, Reserved, Stick)
(44.2) High pressure filter, Pump4
(32.15) ACV Bucket piston side
(33.06) SRV Boom cylinder rod side
continue
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Cont’d
Main Control Blocks and High Pressure Filter BHA
Pump circuit No. III

(176 / III) Control block (R. H. Travel, Boom, Bucket, Stick)
(31.03) SRV Travel motors right backward
(32.17) ACV Travel motors right backward
(31.04) SRV Travel motors right forward
(32.18) ACV Travel motors right forward
Pump circuit No. IV

(13 / IV) Control block IV (Single spool for swing)
(44.1) High pressure filter, Pump 3
) • There is one MRV in each control block.
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6.1.3 Distributor Manifold - Location of restrictor blocks and anti cavitation

valves
Front Shovel Attachment (FSA)

(1) Distributor manifold
(2) Synchronization (Equalization) lines
(4) Anti Cavitation Valve Block (ACV)
(5) Restrictor Block (Throttle valve)
(6) Restrictor Block (Throttle valve)
(7) Service-line Relief Valve
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6.1.4 Distributor Manifold - Location of restrictor blocks and anti cavitation

valves
Backhoe Attachment

(4) ACV Block Section A ,Boom cylinder rod side
Pressure check point
(7) Restrictor blocks
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6.1.5 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) Adjustment spindle

(2 + 3) O-ring with back-up ring
(4) Retainer
(5 + 6) O-ring with back-up ring
(7) Spring
(8) Spring cup
(9) Throttle sleeve
(10) O-ring
(11 Housing
(12) Return line port, T
(13) Pressure relief valve
(14) Allen bolt
(15) Clip ring
(16) Lock nut
A+B Line ports
M Pressure check point
Y 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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6.1.6 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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6.1.7 Remote control valves
) • Remote control valves are part of the electric-hydraulic control system

(1) Pilot pressure supply port (marked with P)
(2) Pilot pressure return port to tank (marked with L)
(3) Pilot pressure output lines to the control block
(marked with A1/B1, A2/B2, . . . . )
(4) Directional solenoid valve, 3 position / 4 ports
(5) Proportional solenoid valve, (0 – 700 mA, 0 – 35 bar).
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 (5) and one
of the directional solenoid valves (3 either Ax or Bx) 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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6.1.8 Directional Solenoid Valves

(4/3 direction flow valve = 4 way / 3 positions)
) • This solenoid operated directional spool valves are installed to control

the start, stop and direction of an oil flow.

(1) Housing
(2) Solenoids
(3) Control spool
(4) Reset springs
(5) Plunger
(6) 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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6.1.9 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) Proportional solenoid (5) Pressure measuring spool
(2) Control piston (6) Connection plug
(3) Valve housing (7) Return spring
(4) Pressure measuring spool (8) Bleed screw
Function:
In un-operated 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.
W
• 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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6.1.10 High Pressure Filter
) • There is one filter in each pump line installed.

(1) Filter head
(2) Drain plug
(3) Filter case
(4) Hexagon
(5) Filter element
(6) Seal
(7) O-ring
(8) Back-up ring
(9) O-ring
(10) Spring
(11) Differential pressure switch
P1 Input pressure
P2 Output pressure
a Electrical connection
b REED contact
c Permanent magnet piston
d Spring
e Plug screw
Function:
High-pressure in-line filters prevent contamination from entering the
hydraulic circuits. The high pressure filters are installed between the main
hydraulic pumps and main 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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6.1.12 Control Blocks and Valves
) • This is a principle drawing, showing valve block I, II and III.

(1) Control block housing
(2) Cab ("A side)
(3) Cap ("B" side)
(4) Solid spool
(5) "B" side service line ports
(6) Centering springs
(7) MRV, main relief valve
(8) Port A, to cylinder/motor
(9) Port B, to cylinder / motor
(10) Fine controlling grooves
(11) Port P, from pumps
(12) Port T, to tank
(13) Load holding valves
(14) Spin look spool extension (only block I and II)
(15) Spin look balls (only block I and II)
(16) Spin look cab extension
Control blocks with "Open Center and Closed Ports".

Control blocks I, II and III are 4 spool blocks and IV is a 1 spool block.
See hydraulic circuit diagram for spool details.
Each spool is provided with "Fine Controlling Grooves" and ring grooves for
hydraulically centering of the spool.
Between 8 and 19 bar pilot pressure the spools are moved in their fine control
range.
Spool number 4 of block I, 2 of block II and 4 of block III are special designed,
to keep the pressure channel connected to the center channel during the floating
function is activated, so that pump flow is available for other functions. This
spools are marked in the hydraulic diagram with (#) symbol.
The Load Holding Valves are installed inside of the spool, for each port to the
cylinder or motor one valve. The hydraulic diagram shows only one.
The MRV is a pilot operated pressure relief valve.
Control block I, II and III are equipped with a spool spin look system (item 14,
15, 16) to prevent spool spinning because of high oil flow during lowering
function.
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(1) Main relief valve (MRV)Control block housing
(2) Load holding valve
(3) Anti cavitation valve (ACV)
(4) 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) 4 valve block

E.g. the spools moves up when pilot pressure is build up in the control pipe
line a1. (Imagine the lower symbol box moves to the center position.)
Now pump oil flows through holding 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.
E.g. the spool (4) moves up when pilot pressure is build up in the control pipe
A4. Now the user port A4 is connected to the pump pressure line and the free
circulation to the tank. There is no high pressure build up only 8 bar from the
back pressure valve and line resistance. Via port B4 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 holding valve (2) which secures
the hydraulic pump from extreme pressure peaks.
The holding 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.
(B) single valve block
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(1) Spool
(2) Reset springs
Function:
Reset springs (2) moves the spool (1) in neutral position.
Fine control grooves 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 (1) is inter connecting the entire groove to the
user channel.
In neutral position of spool (1) the pump oil is flowing back via port PU to the
tank.
Lower picture:
Example. The spool is moved by pilot pressure on the left spool side to right
position: Port PU is closed and the connection through the holding valve (3)
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).
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(01) Service -Line Relief Valve (9) Set screw
(02) Anti Cavitation Valve (10 Lock nut
(03) Main Relief Valve (11) Spring, pilot part
(04) Closing plate (12) Poppet
(5) Plug screw (13) + 16) Jet bore
(6) Spring (14) Spring, main cone
(7) Valve cone (15) Main valve cone
(8) Dust cap (17) 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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6.1.12 Load Holding Valve

(1) Spool
(2) Reset springs
Control Blocks I to IV (4 spool blocks and single spool block)

Two load holding valves are fitted into each spool of the control blocks, one
valve for each port (A and B).
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 and allows the oil to flow from the
pump through the spool centre to the port.
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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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
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).
Holding 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.
For more information and adjustment see section 8.3.
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6.1.14 Pressure Reducing Valve
) • Pressure reducing valves are installed to reduce the common 35 bar

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

(1) Set screw
(2) Spool
(3) Compression spring
(4) Threaded sleeve
(5) Non return valve
(6) Boring
(7) Spring chamber
(8) 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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6.1.15 Directional Solenoid Valves (2 positions / 4-ways)
) • This solenoid operated directional spool valves are installed to control

the start, stop or direction of an oil flow.

(1) Housing
(2) Solenoid
(3) Control spool
(4) Return spring
(5) Plunger
(6) 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 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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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) Pilot valve with valve seat
(2) Valve poppet
(4) Main valve with sleeve
(5) Main piston
(6) Closing spring
(7+8) Set screws
(9) Piston
(10) Pin
(11+12) Jet bore
(13+14) Lock nut
Function:
The valve poppet (2) is connected via the jet bores (11) and (12) with the
pressure port (P).
If static pressure increase above the set pressure value, the valve poppet (2)
opens and allows oil to flow freely via port (T1) to tank. This out flowing oil
generates a pressure drop in the spring chamber of the main spool (5). The
closing force of the spring (6) is now lower as the oil pressure from the
pressure port (P) and the main piston (5) opens to release pressurized oil to the
tank via port (T2).
Damped opening and closing is obtained by the throttled volumetric change.
By applying external pressure of Pst max = 35 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 maximal possible pressure (P) adjustment is 440 bar with max. control
pressure at port X.
The lower setting is fixed by means of the setting screw (7) and lock nut (13);
1 turn of setting screw reduce or increase the pressure about ~150 bar.
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Main Hydraulic Pumps Section 7.0
and Page 1
Pump Regulation System
Section Page
7.0 Main hydraulic pumps and pump regulation system
General 2–5
7.1 Main Pumps
7.1.1 Location of Pumps 6
7.1.2 Pump bearing flushing / lubrication 7
7.1.3 Operating Principles 8 - 15
7.1.4 Checks and Adjustments 16 - 20
7.2 Electronic Pump Regulation System
7.2.1 Electronic load limiting control - General 21
7.2.2 Electronic Power Module EPM 22
7.2.3 Electronic Signal Rectifier ESR 23 - 24
7.2.4 Microcontroller MC7 25
7.2.5 Checks and adjustments - General 26
Method A - With 24V supply to terminals
- X1- pressure adjustment 27
- Demanded power adjustment 28 - 29
- PID – Factor adjustment 30
Method B - With the electronic service tool BB-3
- Language selection 31 - 32
- Adjustment mode SET1 and SET2 33
- Number of motor selection 34
- X1-pressure (max. current) adjust. 35
- Demanded power adjustment 36
- Storage new settings 38
Method C - With a laptop and BODEM software
- Starting the program 39 - 40
- Language selection 41
- Entering of the password 42
- Number of Motor selection 43
- X1-pressure (max. current) adjust. 44
- Demanded power adjustment 45 - 47
7.3 Hydraulic Constant Regulation System
7.3.1 General 49
7.3.2 X1-pressure adjustment (constant-pressure) 50
7.0
2
and Page 2
Pump regulation system general

(1 - 6) Main hydraulic pumps
(7.1) Pilot pressure pumps, motor 1
(7.2) Pilot pressure pumps, motor 2
(68.1) Pilot pressure filter unit
(70.1) 60 bar pressure relief valve
(70.2) 35 bar pressure relief 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" ½ Q-max flow reduction
for all main pumps (low hydraulic oil temperature)
(Y102-1) Solenoid valve: "Pump regulation support pressure and pump bearing
lubrication"
(Y102-2) Solenoid valve:
"Pump regulation support pressure and pump bearing lubrication"
(81.1) Pressure reducing valve: "Remote control pressure" ½ Q-max flow re-
duction for the warming-up period
(81.2) 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, motor 1" (Standard operation mode)
pump regulation, motor 1" (Standard operation mode)
(79.1) Change over valve: "Electronic or Hydraulic pump regulation", motor 1
(79.2) Change over valve: "Electronic or Hydraulic pump regulation", motor 2
7.0
3
and Page 3
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 of the load of
the motor. (Electronic pump regulation with micro-controller MC7)
• For additional functions, such as rotating dependent or temperature-dependent flow
reduction.
Function:
X1 – pump regulation pressure (0 – 24 bar):

The power controller of the main pumps can be remotely controlled by applying an ex-
ternal 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 (35 bar):

Constant pilot pressure to regulate the main pumps at special circumstances, e.g. to fix
pump # 3 in Q-max position (pump for swinging.)
X3 – remote control pressure (0 / 16 / 35bar):

Basic setting Q-min (0 bar), the flow rate increases with the
pilot pressure X3 at port Pst, up to Q-max (35 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
½ Q-max.: X3 = 16 bar
Q-max.: X3 = 35 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.
7.0
4
and Page 4
Function:
Solenoid valve Y17: (33/7)*

If de-energized pumps #1-6 are in Q-min position. It gets energized as soon as one of
the control levers/pedals has been operated and de-energized when ever all controls
are in neutral position for more than 20 seconds.
Solenoid valve Y17a: (33/5)*

The solenoid is de-energized as long the hydraulic oil temperature is below the val-
ues of temperature range „T2“ (depending on the filled in hydraulic oil) shown in the
table. ( pumps #1-6 are in ½ Q-max. position)
Note: * Electric circuit diagram page / column (based on Id # 897 899 40)
7.0
5
and Page 5
Function:
Proportional Solenoid valve Y61-1 and Y61-2: (40/2)*

This valves, connected to the MC7 micro-controller E32 (electronic pump regula-
tion), creates a X1-pressure depending on the load of the motor.
This X1-pressure is the information to reduce pump delivery, in order to keep the
motor at rated power.
Pressure reducing valve 81.1:

"Remote control pressure" (X3)
- ½ Q-max flow reduction during the warming-up period for all pumps by the
function of solenoid valve Y17a.
- ½ Q-max flow reduction only for pump #1 while swinging with max. speed by
the function of solenoid valve Y126.
Pressure reducing valve 81.2:

Pump regulation pressure X1 at "hydraulic pump regulation" (Hydraulic constant
regulation mode) by the function of change over valve (79.1 / 79.2). One valve for
both motors. This valve create a constant X1 pressure, the pressure can be change for
different pump regulation checks and adjustments.
Change over valve 79.1 and 79.2:

Change over three way cock valve to select "Electronic or constant regulation
mode", one for each motor.
Note: * Electric circuit diagram page / column (based on Id # 897 878 40)
7.0
6
and Page 6
7.1 Main Pumps
7.1.1. Location of Pumps

(1 - 6) Axial piston pump (swash plate type)
theoretical flow rate, each Qmax = 700 Liter/min
for all working motions pmax = 310 bar
(10.2), (10.4) Axial piston pump

for oil cooler fan drive pmax = 180 bar
(8.1), (8.4) Gear pump

for PTO gear lubrication pmax = 7,5 bar
(8.2), (8.5) Gear pump

for hydraulic oil circulation pmax = 15 bar
(7.1), (7.2) Gear pump

for pilot pressure supply pmax = 60 bar
) • * at 1500 min-1 input drive with electric motor speed

7.0
7
and Page 7
7.1 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 throt-
tle 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
(147.1-147.6) Orifice (one for each main pump)
(33) Filter for pilot pressure
(P) Ports for X4-pressure (pump support pressure)
(U) Port for the pump bearing flushing / lubrication
7.0
8
and Page 8
7.1 Main Pumps
7.1.3 Operating Principles

Main hydraulic pump A4VSO 500 LR3DN / 30L
Type code explanation:
A4VSO 500 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
Max displacement in cm3 at one (1) revolution
Axial piston pump series 4, variable displacement ,swash plate design for open circuits
Function and characteristics:

• The A4VSO 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. Combina-
tions with gear pumps are also possible.

The lower illustration shows only a principle pump construction
(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) Cylindrical roller bearing
(10) Splints for the through drive coupling (Aux. pump drive)
(11) Swivel cradle
(12) Q-min stop bolt
(13) Power control valve
(14) Pressure balance valve
(15) Power curve correction
(16) Pressure cut off valve
(17) Q-max. stop bolt
(18) Remote control valve
continued
7.0
9
and Page 9
7.1 Main Pumps

Cont'd:
Symbol of main hydraulic pump A4VSO 500 LR3DN / 30L
(1) Main pump (swash plate pump, variable displacement)
(2) Pump bearing group
(3) Drive shaft
(4) Non return valves
(5.1) Mechanical stroke limitation*
(5.2) Remote pressure (PST) operated piston for item 6
(5.3) Mechanical stroke limitation*
(6) Spool valve (pressure balance valve)
(7) Nozzle
(9) Nozzle
(10) Pressure cut-off valve
(11) Auxiliary pump (Gear pump, fixed displacement
(13) Slipper pad piston
(14) Lever
(15) Cam
(16) Through drive shaft
)
• * Factory side adjusted, no field adjustment required
B/B1 Pressure port

S Oil intake (suction port)
MB Operating pressure check point
Mst Control pressure check point
R(L) Filler and bleeder port
T, K1, K2 Connection port for chip indicator
P Pump support pressure (”X4”-pressure)
Pst Remote control pressure port (”X3”-pressure)
U Bearing flushing port
XLR Regulating pressure port (”X1”-pressure)
continued
7.0
10
and Page 10
7.1 Main Pumps

Cont'd:
Sectional drawing of Power Controller LR3DN / 30L

(5.1) Mechanical stroke limitation
(5.2) Remote pressure (PST) operated piston for item 6
(5.3) Mechanical stroke limitation
(6) Spool valve (pressure balance valve)
(13) Slipper pad piston
(14) Lever
) • Refer also to illustration Z 22447 on the previous page.

7.0
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and Page 11
7.1 Main Pumps
7.1.3 Operating Principles, illustration (Z 21552a)

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 low operating temperature
C: Motor running and service switch S150 activated
Example C with the following conditions:

• Motor running
• Pump pressure lower as X4 = 60 bar (pump support pressure)
• X1 = 24 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 (S150 activated)
for pumps #1, #2 #4, #5, #6 and #3 except during swinging than the pump
is out of regulation and keeps in Qmax.
• X4 = 60 bar (pump support pressure)
Pump support pressure is present at valve #6, the slipper pad of
piston #13 and the small area side of the positioning piston #12
Response of pump control mechanism:

Valve #6 moves to position "b" because the X4-pressure will overcome the spring
force, since the oil behind nozzle (7) flows through valve #5 (which is in position
"a", due to the missing remote control pressure X3) back to tank.
Pump support pressure X4 passes valve #6 position "b" and flows via power control
valve #8 position "a" to the large area side of positioning piston #12.
Because the large area side of positioning piston #12 is approximately three times larger
as the small area side, the pump support pressure X4 of 60 bar present on both sides, re-
sulting in stronger force at the large area side, keeps the pump in Q-min position.
The pump remains in Q-min position

continued
7.0
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and Page 12
7.1 Main Pumps

Cont'd:
Q-max position: (remember Q means volume)

When does the pumps move into Q-max position?
Motor running
and hydraulic oil at normal operating temperature (> T2)
and the controls frequently used within 20 sec.
(or Service switch S151 activated)
and 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 #13 and the small area side of the positioning piston #12
• X1 = 24 bar (pump regulation pressure)
• X3 = 35 bar (remote control pressure); Y17 and Y17a energized
for all six pumps.
• X4 = 60 bar (pump support pressure), present at valve #6.

Valve #6 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 #5 (which is in position
"b", due to the 35 bar remote control pressure X3).
The large area side of positioning piston #12 is connected, via power control valve
(8) position "a" and pressure balance valve (6) 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 #12.
The pump moves into Q-max position
continued
7.0
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and Page 13
7.1 Main Pumps

Cont'd:
½ Q-max position: (remember Q means volume)

When does the pumps move into half Q-max position?
Motor running
and hydraulic oil below normal operating temperature (< T2)
and the controls frequently used within 20 sec.
(or Service switch S151 activated)
and 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
• X1 = 24 bar (pump regulation pressure)
• X3 = 16 bar (remote control pressure); Y17 energized and Y17a de-
energized
for all six pumps.

Valve #6 moves to an intermediate position (in-between "a" and "b"), since a certain
amount of oil behind nozzle (7) flows through valve #5 (which is also in an interme-
diate position, due to the 16 bar remote control pressure X3) back to tank.
The large area side of positioning piston #12 is connected, via power control valve
(8) position "a" and pressure balance valve (6), to the return oil line.
The pump moves into ½ Q-max position, because the return oil flow through pres-
sure balance valve (6) is restricted (due to its intermediate position), resulting in a
pressure at the large area side of the positioning piston (12).
The pump moves into ½ Q-max position
continued
7.0
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and Page 14
7.1 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 S150 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 ≈ 150 bar (Hydraulic constant regulation)
(Constant X1-pressure of approximately 8 bar)

• Motor running
• Pump pressure 260 bar adjustable at main relief valve, present at the slipper
pad of piston #13 and the small area side of the positioning piston #12
• X1 = 12 bar (constant regulation pressure adjustable at pressure reducing
valve 81.2) Change over valve (79.1 / 73.2) switched to hydraulic mode
• X3 = 35 bar (remote control pressure); Y17 energized and Y17a energized

Valve #6 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 #5 (which is in position
"b", due to the 35 bar remote control pressure X3).
The operating pressure (with the value for start of de-stroking) at the slipper pad of
piston #13 moves the power control valve (8) 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 pis-
ton #12.
Because the large area side of positioning piston #12 is approximately three 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 #12 are balanced
continued
7.0
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and Page 15
7.1 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
X1 = 24 bar (pump regulation pressure)
X3 = 35 bar (remote control pressure)
X4 = 60 bar (pump support pressure)

Independent of the position of power control valve #8 the pressure cut-off valve #10
causes the pump to de-stroke to the pre-adjusted Q-min position.
The operating pressure moves the pressure cut-off valve #10 (at set pressure) into
position "b" and flows to the large area side of positioning piston #12.
Because the large area side of positioning piston #12 is approximately three 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 position.
The pump moves into Q-min position

7.0
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and Page 16
7.1 Main Pumps
7.1.4 Checks / Adjustments
Location of Adjustments
Legend for , illustration (Z21557)
(2) Q-min. stop bolt
(3) Pressure balance valve
(4) Start of destroking
(5) Power curve correction
(7) Q-max. stop bolt
(8) Angle indicator
The average length of the measurement "L" is: set screws (bolts)
location Length “L” (mm)

1 13.4
2 21.9
3 7,6
4 8.1
5 ----
6 6.0
7 27.6
) • The measurement "L" is an orientation only if the adjustment is to-

tally 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

7.0
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and Page 17
7.1 Main Pumps
Pressure balance valve (Δ P 20bar), illustration (Z21558)
Pressure balance valve, illustration (Z 21558b)
• The pressure balance valve is bench adjusted. There is no field set-

ting with a sufficient result possible.
continued
7.0
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and Page 18
7.1 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 150 bar with a pump regulation pressure X1 of 0 bar.
1. Connect a 400 bar pressure gauge to the pressure check point at the respective
high pressure filter for the pumps being checked.
2. Connect a 25 bar pressure gauge to respective pressure check point M20-1 or
M20-2 at the control and filter panel (X1-pressure).
3. Change over the respective three way cock to electronic regulation.
4. Unplug the respective proportional valve Y61.1 / Y61.2.
5. Insert an Allen key into the angle indicator bolt (see illustration) for better visi-
bility of the start of.
6. Start the respective motor. The X1-pressure should be 0 bar.
7. Stall the hydraulic for the pump to be checked and alter the operating pressure
with the MRV between 140 and 160 bar.
Start of de-stroking should be at an operating pressure of 150 bar, shown at the
gauge connected to the high pressure filter.
If readjustment is required proceed as follow:

a) Adjust with the MRV an operating pressure of 150 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 de-stroking.
d) Tighten lock nut #6.
8. Re-adjust the operating pressure at the MRV to 310+10 bar and plug on the
Y61.1 resp. Y61.2
(For exact values refer to the final test report.)
9. Remove Allen key and gauges.
continued
7.0
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and Page 19
7.1 Main Pumps
7.1.4 Checks and Adjustments

Cont'd:
Pressure cut-off valve (DR control valve), illustration (Z21560)
The sense of this check is to make sure that the pump is in Q-min. position at an op-
erating pressure between 300 bar and 310 bar.
1. Connect a 400 bar pressure gauge to the pressure check point at the respec-
tive high pressure filter for the pumps being checked.
2. Insert an Allen key into the angle indicator bolt (see illustration) for better
visibility of the start of de-stroking.
3. Start the respective motor, stall the hydraulic only for the pump to be
checked and alter the operating pressure with the respective MRV between
280 and 310 bar.
• Stall only one pump per motor to prevent an influence of the regula-
tion system..
Recommendation to stall the respective pump with FSA:

Pump 1 and 6: a) Unplug solenoid valve Y16 (park brake travel motor active)
b) Activate carefully the left travel motor with full pressed
pedal in one direction
Pump 3 and 4: a) Activate carefully the clam open function and keep it in final
position
Pump 2 and 5 a) Unplug solenoid valve Y16 (park brake travel motor active)
b) Activate carefully the right travel motor with fully pressed
pedal in one direction and keep it in this position.
4. The angle indicator must indicate Q-min. position at a pressure of 300 bar
shown at the gauge connected to the high pressure filter.
If readjustment is required proceed as follow:
a) Loosen lock nut #8.
b) Turn set bolt #9, so that the pump is in Q-min. 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, gauges and plug in the unplugged plugs.
continued
7.0
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and Page 20
7.1 Main Pumps

7.1.4 Checks and Adjustments
Cont'd:
Q-max. and Q-min. stop bolt, illustration (Z21561)
1. Unscrew box nut (10 or 14).

2. Loosen the lock nut (11 or 13)
3. Turn the stop (12 or 15) in or out until required length
Length "X" or "Y"
5. Tighten the lock nut and screw on box nut (12).
• 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 direc-
tion: (suction line becomes pressure line and pressure line becomes
suction line)
7.0
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and Page 21
7.2.1 Electronic load limiting control - General, illustration (Z 22448)
The drive train of the excavator consists of two electric motors, 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 Z22407a shows the principle of the electronic load limiting control.
The MC7 (E32-1) processes the following input signals:
• Voltage (Pin 47) from electronic signal rectifier (A32)
• Current motor 1 (Pin 45) from electronic signal rectifier (A33-1)
• Current motor 2 (Pin 46) from electronic signal rectifier (A33-2)
The MC7 (E32-1) processes the following output signals:

• Signal value to control the proportional solenoid valve Y61-1 (Pin 28) Motor 1
• Signal value to control the proportional solenoid valve Y61-2 (Pin 30) Motor 2
• Switch signals (Pin 32 and 33), diagnostic of the MC7 (E32-1)
Each electric motor drives three variable displacement pumps by means of a PTO-
gearbox. Each pump is equipped with a hydraulic power controller (HPC).
This controller limits the input torque of the pump to an adjusted command value (X1-
pressure, for start of destroking).
The command value (X1-pressure) is present via proportional solenoid valves Y61-1 re-
spectively Y61-2 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 volt-
age, into a proportional DC Voltage and transfers it into the MC7 (E32-1).
The ESR-Module (A33-1 + A33-2) transforms an AC Voltage, which is proportional to the
respective motor current, into a proportional DC Voltage and transfers it also into the MC7
(E32-1).
These input signals are the information about the actual load to the motors and serves the
MC7 (E32-1)
The control algorithm of the load limiting control (MC7) always compares the actual re-
quired 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.
7.0
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and Page 22
7.2.2 Electronic Power Module EPM, illustration (Z 22624b)
The power – Module A31a transforms the 24 VDC battery voltage into posi-
tive/negative 15 VDC and the power Module A31b into positive 5 VDC which is the
supply voltage for the ESR Modules.
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 Power
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 Power
Modules 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 ei-
ther 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 Power
Module, the Module is defect.
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and Page 23
7.2.3 Electronic Signal Rectifier ESR – Modules, illustration (Z 22625a)

Function:
The ESR-Module transforms an AC signal-voltage, which is proportional to the net-
work voltage respectively the motor current, into a proportional DC Voltage and trans-
fers it into the MC7.
Testing the ESR-Module, A32 + A33.1 + A33.2
Testing the ESR input/output voltage

For a transformer function test the AC-Input Voltage and the
DC-Output Voltage must be measured and compared.
• The potentiometer settings are under no circumstances

allowed to be altered, because the setting is possible only with a HF-
Generator 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

________ = 1/4 = 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
7.0
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and Page 24
7.2.3 Electronic Signal Rectifier ESR – Modules, illustration (Z 22626a)

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.
EXAMPLE FOR ESR 1:

U 6570 V
ESR1 ----------------- --------------- = 2,488 VDC Voltage
T1 x T2 x T3 66 x 10 x 4
EXAMPLE FOR ESR 2:

I 80 A
ESR2 ----------------- ----------------- = 1,333 VDC Current Motor 1
T1 x T2 x T3 30 x 0.5 x 4
EXAMPLE FOR ESR 3:

I 75 A
ESR3 ----------------- ----------------- = 1,25 VDC Current Motor 2
T1 x T2 x T3 30 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 80
ESR2 ----------- ----------- = 5,333 VDC
T1 x T2 30 x 0.5
7.0
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and Page 25
7.2.4 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 over-voltage 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 con-
nected 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
7.0
26
and Page 26
7.2.5 Checks and adjustments General

Microcontroller MC7, illustration (Z 21714c)
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 inter-
face X13-1 (located in the operators cab)
or
C. With a laptop, running the BODEM software, connected to the serial inter-
face X13-1 (located in the operators cab)
) • Procedure B and C should only be carried out by authorized person-

nel. [ 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 de-
partment.
7.0
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and Page 27
7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22628)

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 valves (79.1 – motor 1 respectively 79.2– motor 2) are in
position “Electronic Pump Regulation”
2. Connect a pressure gauge to the respective check points (M20.1 or M20.2), 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 applying terminal for propor-
tional solenoid valve Y61-1 or Y61-2 as follows:
Motor1 →Y 61-1 → No connection to 24V required.
Motor2 →Y 61-2 → Connect permanent 24V to terminal 53, using a test lead.
5. Adjusting the X1-pressure:
Start the respective motor.
Read the pressure, required = 24± 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
7.0
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and Page 28
7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22629a)

Cont'd:
Method A - Demanded power adjustment
) • The adjustment has to be carried out separately for each motor
1. Connect pressure gauges to check points M12.1, M12.2, M12.3 and M12.4 at the
high pressure filters.
2. Connect pressure gauges to the X1 pressure check points M20.1 and M20.2.
3. Unplug solenoid valves Y6a-1, Y6b-1 and Y6a-2, Y6b-2 to ensure that the hy-
draulic oil cooler fans are running with maximum speed.
4. Start main motor of the circuit to be adjusted.
5. Set the MRV individually to approx. 120 bar *, to prevent the motors from over-
loading during the adjustment.
6. Shift the three way cock valves (79.1 and 79.2) to position “Hydraulic (con-
stant) Regulation Mode”.
7. Set the X1-pressure at pressure reducing valve (81.2) > 25 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 final stop
position and keep it fully under load), and increase the pressure at all 4 MRV’s *
equally to 212 bar.
Expected motor current at 3 times 212 bar ≅ 88 Ampere (reading of text display)
(peak point).
Record this current for other tests.
)
• If the motor current is lower respectively the operating pressure is
higher 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
7.0
29
and Page 29

Cont'd:
Method A - Demanded power adjustment

1. 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 of Motor 1:
Connect 24V, simultaneously to terminal 50 and 52 permanent.
c) Select the demanded power adjusting mode of Motor 2:
Connect 24V, simultaneously to terminal 50, 52 and 53 permanent.
d) Stall the hydraulic with the values of item 8 (Peak point)
3 times ≅ 212 bar => ≅ 88 Ampere (each motor) (all pumps Q-max position
and cooler fans with max. speed).
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 de-

manded power
2. Re-set the X1-pressure at pressure reducing valves (81.2) as recorded**.
3. Shift the three way cock valves (79.1 and 79.2) to position “Electronic Regulation
Mode”
4. Reset the MRV’s to 310 bar+5bar , and remove the gauges.
5. After the adjustments are finished, remove the test leads and pressure gauges, stop
the motors and turn the main key switch in OFF position to deactivate the adjusting
mode.


continued
7.0
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and Page 30

7.2.5 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 differen-
) tial 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:

Connect 24V, simultaneously to terminal 54 and 55 for 10 seconds, using
two test leads and disconnect the voltage thereafter.
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:
Connect 24V, simultaneously to terminal 54 and 55 for 10 seconds, using
two test leads and disconnect the voltage thereafter.
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 connect-
ing 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 ad-
justing mode.
7.0
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and Page 31

Method B -
With the electronic service tool (EST) BB-3 connected to the serial interface X13
(located in the operators cab)
1. Make sure the respective change over valve is in position “Electronic Pump Regu-
lation”
2. Connect a pressure gauge to check point (respective M20-1, M20-2 ), using a
long pressure gauge hose to be able reading the pressure inside the operators
cab.
3. Connect the electronic service tool (BB-3) to the data link adapter X13,
with key switch (S1) in OFF position.
4. Turn key switch (S1) 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 Config/Cal.
F2 Diagnostic
PROC Status
TE ACH Storage
Language selection
To change the language press simultaneously The language selection menu appears
the buttons ALT + Clear
F1 Config/Cal.
ALT + CLEAR F2 Diagnostic
PROC Status
TE ACH Storage
continued
7.0
32
and Page 32
Cont'd:
Method B Language selection
Press button 2 The language will change to English

and the display show the main menu
1. Deutsch
2 2. English
3. - - -
4. - - -
One of the four main menu items can be selected using the given keys.
7.0
33
and Page 33
Method B - A: 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 Main display SET 2

Standard after start up Only with password
F1 Config/Cal. F1’ Config/Cal.

F2 Diagnostic F2 Diagnostic
PROC Status PROC Status
TE ACH Storage TE ACH Storage
Change from SET 1 to SET 2:
SET 1 F1 Config/Cal.
Press F1 Config/Cal F2 Diagnostic
PROC Status
TE ACH Storage
1 Demand Power
Press ALT + in the same time 2 Max current
3 PID - Factor
4 Error Lamp
A password will be requested
Enter password (5 7 0 8 7 5)
?: _
1 ... 9
SET 2 1 Configuration
Press MENU to go back to the main menue 2 PID Control
3 Low Voltage
4 –––
F1’ Config/Cal.
F2 Diagnostic
PROC Status
TE ACH Storage
To switch back to SET 1 repeat this procedure
or switch off and on the MC7.
continued
7.0
34
and Page 34
Method B - Number of motor selection:
Activate adjustment mode SET 2 as

described on page 65
F1’ Config/Cal.
Press F1 Config/Cal F2
PROC
Diagnostic
Status
TE ACH Storage
1 Configuration
Press
1 Configuration 2
3
PID Control
Low Voltage
4 –––
1 No of valves
Press 2 No of motors 2
3
No of motors
––
4 ––
Select desired number of motors 2 No of motors
use or 1 motor
2 No of motors
Press ENTER Acceptation
2 motors
1 No valves
Press. 2 x MENU Return to sub menu. 2 No motors
3 ––
4 ––
F1’ Config/Cal.
F2 Diagnostic
PROC Status
TE ACH Storage
Save setting to the EEPROM of the MC7 as described at page 75.
continued
7.0
35
and Page 35
7.2.5 Checks and adjustments Micro-controller MC7, illustration (Z 22357a)
Method B
X1-Pressure (maximum current) Adjustment:
Press F1 Config/Cal F1
F2
Config/Cal.
Diagnostic
PROC Status
If sub menu SET 2 is displayed change to
TE ACH Storage
sub menu SET 2 as described on page 65.
1 Demand Power
Press
2 Max current 2
3
Max current
PID - Factor
4 Error Lamp
Select desired valve
1 Valve 1 Mot. 1
Press 1 Valve 1, Motor1
2 Valve 2 Mot. 1
or 3 Valve 1 Mot. 2
Press Valve 1, Motor2
3 4 Valve 2 Mot. 2
Example Motor 1, Valve1 1 Valve 1 Mot. 1

0 – 100±1
71
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:
1 Valve 1 E1
0 – 100±1
pressing or 78
1 Valve 1 Mot. 1
Press ENTER Accept tion 2 Valve 2 Mot. 1
3 Valve 1 Mot. 2
4 Valve 2 Mot. 2
F1 Config/Cal.
Press. 2 x MENU Return to main menu F2 Diagnostic
PROC Status
TE ACH Storage

continued
7.0
36
and Page 36
7.2.5 Checks and adjustments Microcontroller MC7, illustration (Z 22357)a
Method B -
Demanded power adjustment:
Cont'd:
F1 Config/Cal.
Press F1 Config/Cal F2 Diagnostic
PROC Status
If sub menu SET 2 is displayed change to TE ACH Storage
1 Demand Power
2 Max current
Press 1 Configuration
3 PID-Factor
4 Error Lamp
Select desired demand power adjustment

SET 1 1 Set demand m. 1
Press 1 demand power Motor1 2 Set demand m. 2
or 3 Demand power 1
Press demand power Motor2 4 Demand power 2
2
1 Set demand m. 1
Example Motor 1 0–0±1
0
and
Load respective Motor with max power
Start?
––> <ENTER>
Press ENTER Selection
Cancel?
––> <ENTER>
Press ENTER Starting Function ended

Saved
Press <ENTER>
Press ENTER Confirm

F1 Config/Cal.
F2 Diagnostic
Press. 2 x MENU Return to main menu PROC Status
TE ACH Storage

continued
7.0
37
and Page 37
Method B
Cont'd:
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.
F1 Config/Cal.
Press F1 Config/Cal
F2 Diagnostic
PROC Status
If sub menu SET 2 is displayed change to TE ACH Storage
SET 1 1 Demand Power

Press 3 PID-Factor. 2
3
Max current
PID-Factor
4 Error Lamp
1 PID-Factor
Press
1 PID-Factor. 2
3
–––
–––
4 –––
Adjust the PID-Factor

1 PID-Factor
by pressing . 80–120±1%
or 100
1 PID-Factor
2 –––
Press ENTER Acception 3 –––
4 –––
and check the machine movement again
if necessary repeat PID-Factor adjustment
F1 Config/Cal.
Press. 2 x MENU Return to main menu. F2 Diagnostic
PROC Status
TEACH Storage

continued
7.0
38
and Page 38
Method B
Cont'd:
Storage all new settings to the MC7:
This menu item permits storage of all edited parameters to the EEPROM
of the MC electronics
.
F1 Config/Cal.
Press TEACH Activate storage menu F2 Diagnostic
PROC Status
TE ACH Storage
1 Save Params
Press 1 Save Params 2
3
Default Rarams
Get EEPROM
4 Send EEPROM
Teach?
Press ENTER Store parameters ––> <ENTER>
Cancel?
––> <ENTER>
1 Save Params
Press. MENU Return to main menu. 2 Default Rarams
3 Get EEPROM
4 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 gauge.
7.0
39
and Page 39
Method C - With a laptop computer and BODEM software connected to the

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

4. Start the computer.
5. Click on the Bottom - icon to start the program.
continued
7.0
40
and Page 40
Method C, Starting the program

Cont'd:
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 hard-
ware and software information.
7.0
41
and Page 41
Method C
Language selection
Open menu FILE → Language , select the required language and confirm with OK .
7.0
42
and Page 42
Method C
Entering of the password:
) • The password is only required to adjust the number of valves or en-

gines 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 and con-
firm with OK. (Password 570875)
) • After entering a correct password and confirming with OK the BODEM

software start a new upload from the MC7 memory to the PC.
7.0
43
and Page 43
Method C
Cont'd:
Number of Motor selection:
Pre condition: The correct password was entered as described on page 83.
Open Parameters and select Display / Edit Parameters. Then select in the left window
Configuration. Now on the right side there two pull down menus.
Example: select for PC 5500 1 valve per motor and 2 Motors.
Write new setting permanent to the MC7 EEPROM with Apply and confirm with OK.
7.0
44
and 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 the respective check point (M20-x), 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 respective 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 respective slide bar. (Valve 1 Mot. 1 is the X1-1 pressure and
Valve 1 Mot. 2 the X1-2 pressure).
Write new setting permanent to the MC7 EEPROM with Apply and confirm with OK.
7.0
45
and Page 45
Method C
Demand power adjustment:
Pre-conditions: Normal operating temperature, correct pilot pressure setting and the sys-
tem must be free of air.
Open menu Parameters and in the pull down window the menu point Display / Edit Pa-
rameters.... Now the window with the demand power adjustment will be on screen.
Screen with password Screen without password.

The demand power adjustment is possible both modes.
continued
7.0
46
and Page 46

Cont'd:
Method C
Demand power adjustment:
1. Connect pressure gauges to the high pressure check points at the high pres-
sure filters. (M12.1, M12.2, M12.3 and M12.4)
2. Connect pressure gauges to the X1 pressure check points (M20.1 and M20.2).
3. Unplug fan control solenoid valves (Y6a-1, Y6b-1 and Y6a-2, Y6b-2) to ensure
that the hydraulic oil cooler fans are running with maximum speed.
4. Shift the three way cock valves (79.1 and 79.2) to position “Hydraulic (constant)
Regulation Mode”.
5. Start one motor.
6. Set the X1-pressure at pressure reducing valve (81.2) > 25 bar **, to ensure that
the pumps remain in Q-max. flow position during the adjustment.
7. Apply max. load to all pumps (e.g. extend the bucket cylinders to the stop posi-
tion until the hydraulic system stalls), and increase the pressure at all 4 MRV’s *
equally to the demand power pressure written in the final test report (PC5500,
S/N 15016 = 212 bar). Check the current drawn of the respective motor at this
stage (reading of text display)
Expected approx. ~ 88 Ampere. Record this values for other tests.


continued
7.0
47
and Page 47

Cont'd:
Method C Demand power adjustment:
8. Select Execute... of menu point Set demand m. 1 for motor 1 or

Set demand m. 2 for motor 2.
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.
9. Stop motor and repeat from item 5 for the second motor.
7.0
48
and Page 48

Cont'd:
PID Factor adjustment: Method C

to obtain the most efficient pump regulation characteristic.
• With the PID-Factor adjustment (proportional, integral and differen-
) tial 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 possi-
ble to the boarder line)
2. Now reduce the PID-Factor in short steps until the system works smoothly
again.
7.0
49
and Page 49
7.3.1 General
The pilot pressure pumps ( 7.1 and 7.2) deliver the oil through the pressure filter
(68.1) to port A of the pressure relief valve (70.1) for limiting the pump support
pressure X4 to 60 bar. By the function of pressure reducing valve (70.2), the X4
pressure of 60 bar is reduced to the pilot pressure X2 of 35 bar. The common X2
pressure will be reduced by the function of pressure reducing valves ( 81.2 ) to the
necessary constant X1 pressure, to prevent the motors 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 - 3) Main hydraulic pumps (driven by Motor 1)
(4 - 6) Main hydraulic pumps (driven by Motor 2)
(7.1) Pilot pressure pump (driven by Motor 1)
(7.2) Pilot pressure pump (driven by Motor 2)
(68.1) Pilot pressure filter unit
(70.1) Pressure relief valve 60 bar (X4)
(70.2) Pressure reducing valve 35 bar (X2)
(81.1) Pressure reducing valve: "½ Qmax , remote control X3 pressure”
(81.2) Pressure reducing valve: "Pump regulation pressure X1 at hydraulic
constant regulation mode "
operation mode" (Standard mode Motor 1)
operation mode" (Standard mode Motor 2)
(79.1) Change over valve: "Electr. or Hydr. pump regulation" Motor 1
(79.1) Change over valve: "Electr. or Hydr. pump regulation" Motor 2
7.0
50
and Page 50
7.3.2 X1-pressure adjustment (constant-pressure), illustration (Z 22639a)

1. Connect pressure gauges to check points M12.1, M12.2, M12.3 and M12.4 at
the high pressure filters.
2. Connect pressure gauges to the X1 pressure check points M20.1 and M20.2.
3. Unplug solenoid valves Y6a-1, Y6b-1 and Y6a-2, Y6b-2 to ensure that the hy-
draulic oil cooler fans are running with maximum speed.
4. Shift the three way cock valves (79.1 and 79.2) to position “Hydraulic (constant)
Regulation Mode”.
5. Start motor 1.
6. Set the X1-pressure at pressure reducing valve (81.2) to approx. 3 bar **
7. 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 MRV’s *
equally to 260bar.
8. Check the current drawn of motor 1 at this stage (reading of text display)
Expected approx. .. ≅ 70±5 Ampere. If necessary adjust the X1-pressure at pres-
sure reducing valve (81.2) . Record this values for other tests.
9. Stop motor 1 and start motor 2 .
10. Apply max. load to all pumps (e.g. extend the bucket cylinders to the stop position
until the hydraulic system stalls), and set the pressure at all 4 MRV’s * equally to
260 bar.
11. Check the current drawn of motor 2 at this stage (reading of text display)
The current of motor 1 should be approx. ≅ 70±5 Ampere depend on the setting
of motor 1. There is only one valve (81.2) for both motors.
12. Shift the three way cock valves (253.1 and 254.1) to position “Electronic regulation“.
13. Plug on the unplugged solenoid valve.
14. Reset the MRV’s * to 310 bar+5bar , and remove the gauges.


− Remove dust cap (d).
04.01.07 rev.2 PC5500-6-E_Sec_7-0_15016E_rev2.doc

04.01.07 rev.2 PC5500-6-E_Sec_7-0_15016E_rev2.doc
Operating Hydraulic Section 8.0
Page 1

Section Page
8.0 Operating Hydraulic
General 2
8.0.1 Floating function of boom and stick cylinders 3+4
8.1 Hydraulic for the attachment cylinder FSA and BHA
8.2 Hydraulic for the swing circuit
8.3 Hydraulic for the travel circuit
01.04.03 PC5500-6_Sec_8-0_rev1.doc
8.0
&2
01.04.03 PC5500-6_Sec_8-0_rev1.doc
Page 2
8.0 General
Overall view of the Hydraulic system, illustration (Z 21955):
(1 – 6) Main pumps
(7) High pressure filters
(8) Main control blocks
(10) Attachment cylinders
(11) Swing motors
(12) Rotary joint
(13) Travel motors
General information
The control blocks, the piping to the distributor manifold and the connecting
hoses to the attachment are in some points 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:
F •
•
Study together with the circuit diagram.
The following numbering refers to the hydraulic circuit diagram.
Each main pump (1 to 6) delivers oil trough the high pressure filter (44.1,
44.2, 46.1 and 46.2) to port P of the main control blocks (FSA – 14, 15, 16
and 13) (BHA - 175, 15,176 and 13). The single valve block IV (13) is in line
to valve block II (15) connected.
This results in three main circuits.
If all spools of the control blocks (1 to 6) are in neutral position, the oil leaves
the block at port T and returns via return oil pipes, return oil collector
manifold (35), return oil pipes (L6 and L7), return oil collector tube (114),
back pressure valve (115) and the return oil filters (117.1-117.4) into the tank
(41).
The function of back pressure valve (115) ensures:
- sufficient oil supply for all anti-cavitation 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
01.04.03 PC5500-6_Sec_8-0_rev1.doc
8.0
&3
01.04.03 PC5500-6_Sec_8-0_rev1.doc
8.0
&4
8.0 General
Cont'd:
8.0.1 Floating function of boom and stick cylinders FSA:

illustration (Z 22568):
The Excavator (only front shovel attachment) 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:
There are different main valve spools in the three main valve blocks (14, 15 and
16) for boom and stick installed. Only by lowering of the boom or retracting of the
stick is the floating function active if the button on the lever is not pushed. The
piston and rod side of the respective cylinders are in floating position direct
connect to the return line (tank). The pressure free pump circulation is still active
there is no pump pressure to the respective cylinders. By external force the
cylinder can move up or down with negligible hydraulically resistance.
In floating position of the boom only valve spool 4 of main valve block I and 2 of
block III active.
In floating position of the stick only valve spool 2 of Main valve block I and 4 of
block III active.
To push down the boom or retract the stick by hydraulically force the respective
button on the lever must by activated.
S98 for the Stick cylinders
S95 for the Boom cylinders
In normal operation mode (i.e. float position) the piston side, the rod side and the
tank are connected together when lowering the boom or retracting the stick.
If a pressurised lowering of the boom or retracting of the stick cylinders is
required the connection of piston side, rod side and tank must be disconnected and
the rod side must be connected to the pump pressure. This is done by
disconnecting the respective special floating valve spool and activating the
respective standard valve spool. Now pressurised pump oil can flow to the
cylinder rod side.
01.04.03 PC5500-6_Sec_8-0_rev1.doc
8.0
&4
01.04.03 PC5500-6_Sec_8-0_rev1.doc
Page 4
Boom:
S95 ON K160 ON Float position deactivated
A10 deactivated Floating spool block I section 4 off

A10A activated Standard spool block II section 3 ON
S95 OFF K160 OFF Float position activated
A10 activated Floating spool block I section 4 ON

A10A deactivated Standard spool block II section can be on or off
Stick:
S98 ON K170 ON Float position deactivated
A8B deactivated Floating spool block III section 4 off

A8A activated Standard spool block II section 4 ON
S98 OFF K170 OFF Float position activated
A8B activated Floating spool block III section 4 ON

A8A deactivated Standard spool block II section can be on or off
F
• 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
01.04.03 PC5500-6_Sec_8-0_rev1.doc
01.04.03 PC5500-6_Sec_8-0_rev1.doc
Hydraulic for the Section 8.1
Attachment Cylinders Page 1

Section Page
8.1 Hydraulic for the attachment cylinder FSA and BHA
8.1.1 Electric / Hydraulic Flowchart Boom raising 2+3
8.1.2 Electric / Hydraulic Flowchart Boom lowering 4+6
8.1.3 Electric / Hydraulic Flowchart Stick extending 7+8
8.1.4 Electric / Hydraulic Flowchart Stick retracting 9 + 11
8.1.5 Electric / Hydraulic Flowchart Bucket filling (curl) 12 + 13
8.1.6 Electric / Hydraulic Flowchart Bucket emptying 14 + 15
8.1.8 Electric / Hydraulic Flowchart Clam opening 17
8.1.9 Electric / Hydraulic Flowchart Clam closing 18
8.1.10 Checks and adjustments of the 19 + 20
Main Relief Valves (Primary valves)
8.1.11 Checks and adjustments of the
Service Line Relief Valves (Secondary valves)
Boom cylinder piston side FSA + BHA 21 + 22
Boom cylinder piston rod side FSA + BHA 23 + 24
Stick cylinder piston side FSA 25 + 26
Stick cylinder piston side BHA 27 + 28
Stick cylinder piston rod side FSA 29 + 31
Stick cylinder piston rod side BHA 32 + 33
Bucket cylinder piston side FSA 34 + 35
Bucket cylinder piston side BHA 36 + 37
Bucket cylinder piston rod side FSA 38 + 39
Bucket cylinder piston rod side BHA 40 + 41
Clam cylinder piston rod side FSA 42
Clam cylinder piston side FSA 43
8.1.12 Checks and adjustments for the lowering speed. 44

General: Flow Restrictors
Boom cylinder FSA (Float position activated / deactivated) 44 + 46
Boom cylinder BHA 47
Stick cylinder FSA (Float position activated / deactivated) 48 + 49
Stick cylinder BHA 50
Bucket cylinder FSA 51
Bucket cylinder BHA 52
Clam cylinder 53
8.1.13 Checks for the valve control logic. 54
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
2
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1.1 Electric / Hydraulic flowchart “ Boom raising ” FSA

(E19) Control lever (Joy stick)
(D32) Time relay – Pilot control: Neutral position monitoring
(Y-) Direction (axis) of joy stick
(-10V) Signal voltage (Maximum)
(gn) Color code of signal voltage cable ( Joy stick)
(X2...) Terminal rail with number
(E49) Ramp time module
(A10) Amplifier module – Boom
(A10A) Amplifier module – Boom
(A10B) Amplifier module – Boom
(K79) Relay – pilot control:
Contacts 8 / 12 only closed while lifting the boom.
(K160) Relay – Floating control:
Contacts 2 / 10 closed auto floating active .
Contacts 2 / 10 open while bucket filling (priority function).
(K76A) Relay – pilot control:
Contacts 2 / 10 open while stick extending (priority
function).
(45.1 – 45.3) Remote control valves
(Y23, Y26, Y29) Proportional solenoid valve
(Y23a, Y26a, Y29a) Directional solenoid valve
(I – III) Main control blocks I – III
Electrical signal flow (EURO control).

Signal voltage of joy stick (E19) arrives via ramp time module (E49) and the
relay contacts (K79, K160) at terminal 5 of the three amplifier modules (A10,
A10a and A10b) and further to the proportional and directional solenoid valves
of the remote control blocks (45.1, 45.2, and 45.3).
Hydraulic signal flow. (pilot pressure)
When the respective 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 the distributor manifold at the hydraulic cylinders.
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
3
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1.1 Electric / Hydraulic flowchart “ Boom raising ” BHA

(D32) Time relay – Pilot control: Neutral position
monitoring
(YD) Direction (axis) of joy stick
(A10a) Amplifier module – Boom
(A10b) Amplifier module – Boom
(Y23, 25 + Y29) Proportional solenoid valve
(175, 15, 176) Main control blocks I – IV

Signal voltage of joy stick (E19) arrives via ramp time module (E49) at
terminal 5 of the amplifier modules (A10 to A10b) and further to the
proportional and directional solenoid valves of the remote control blocks (45.1,
45.2, 45.3).
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 III)
and arrives via distributor manifold at the hydraulic cylinders piston side.
The piston extend and the boom move up.
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
4
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1.2 Electric / Hydraulic flowchart “ Boom lowering ” FSA, Auto Float off

(+Y) Direction (axis) of joy stick
(+10V) Signal voltage (Maximum)
Contacts 6 / 10 open while extending the stick.
Contacts 6 / 10 open while filling the bucket.
Contacts 8 / 12 closed while moving the boom up.
Contacts 2 / 10 closed and 5 / 9 open while auto floating on.
(K207C) Relay – pilot control:
Contacts 5 / 9 closed while warming up hydraulic oil (S205).
(Y23b, Y26b, Y29b) Directional solenoid valve
(I – III) Main control blocks I – IV

The auto float button in the right lever E19 is still engaged this will energize
relay K160. Signal voltage of joy stick (E19) arrives via ramp time module
(E49) only at terminal 5 of the amplifier modules (A10a and A10b) and further
to the proportional and directional solenoid valve of the remote control blocks
(45.2 and 45.3).
When the proportional and directional solenoid valves are energized pilot pressure
oil flows to the pilot pressure ports of the respective main control blocks.
Hydraulic oil flow
Only the oil of main pump 3 and 4 flows through the main control blocks (II)
and arrives via the distributor manifold at the boom hydraulic cylinders piston
rod side. Through main valve block III for boom lowering is no pressure oil
flow depend on a different valve spool with closed pressure port.
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
5
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1.2 Electric / Hydraulic flowchart “ Boom lowering ” FSA, Auto Float on

Contacts 6 / 10 open while extending the stick.
Contacts 6 / 10 open while filling the bucket.
Contacts 8 / 12 closed while moving the boom up.
Contacts 2 / 10 closed and 5 / 9 open while auto floating on.
Contacts 5 / 9 closed while warming up hydraulic oil (S205).

The auto float button in the right lever E19 is disengaged and relay K160 is de-
energized. Signal voltage of joy stick (E19) arrives via ramp time module
(E49) only at terminal 5 of the amplifier modules (A10 and A10b) and further
to the proportional and directional solenoid valve of the remote control blocks
(45.1 and 45.3).
Hydraulic oil flow
Now the pump oil flow still back to the return line. Both pressure lines at valve
block I section 3 (A3 and B3) are connected to the same back pressure charged
return line. Valve spool 2 of main valve block III connect only port B2 to the
return line. The return line, the piston side and the piston rod side of the boom
cylinders now connected together. The boom can moved up and down by external
force.
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6
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1.2 Electric / Hydraulic flowchart “ Boom lowering ” BHA

(A10a) Amplifier module – Boom
(A10b) Amplifier module – Boom
(Y23, 25 + Y29) Proportional solenoid valve
(175, 15, 176) Main control blocks I – IV

Signal voltage of joy stick (E19) arrives via ramp time module (E49) at terminal 5
of the amplifier modules (A10, A10a and A10b) and further to the proportional
and directional solenoid valves of the remote control blocks (45.1 – 45.3).
oil flows to the pilot pressure ports of the main control blocks.
Hydraulic oil flow
and arrives via distributor manifold at the hydraulic cylinders piston rod side.
The piston retract extend and the boom move down..
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8.1.3 Electric / Hydraulic flowchart “ Stick extending ” FSA

monitoring
(YC) Direction (axis) of joy stick
(A8) Amplifier module – Stick
(A8a) Amplifier module – Stick
(A8b) Amplifier module – Stick
Contacts 7 / 11 and 8 / 12 closed while extending the stick.
Contacts 1 / 9 open while bucket filling.
Contacts 5 / 9 closed and 7 / 11 opened while floating
system active.
(45.1, 45.2, 45.3) Remote control valves
(I, II + III) Main control blocks I – III

of the amplifier modules (A8, A8a and A8b) and further to the proportional and
directional solenoid valves of the remote control blocks (45.1, 45.2 and 45.3).
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, III)
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8
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8.1.3 Electric / Hydraulic flowchart “ Stick extending ” BHA

(Y+) Direction (axis) of joy stick
(45.1-45.3) Remote control valves
(Y21a, Y27a, Y27b) Directional solenoid valve
(I, II, III) Main control blocks I, II III

directional solenoid valves of the remote control blocks (45.1, 45.2, and 45.3).
Hydraulic oil flow
and arrives via distributor manifold at the hydraulic cylinders.
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9
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8.1.4 Electric / Hydraulic flowchart “ Stick retracting ” FSA Auto Float off

monitoring
(YD) Direction (axis) of joy stick
Contacts 7 /11 and 8 / 12 open while retracting the stick.
Contacts 1 / 9 only open while bucket moving.
Contacts 1 / 9 closed and 3 / 11 open while auto floating
off.
Contacts 5 / 9 closed while warming up hydraulic oil
(S205).
(45.1, 45.2, 45.3) Remote control valves
(I + III) Main control blocks I + III

of the amplifier modules (A8, A8a) and further to the proportional and directional
solenoid valves of the remote control blocks (45.1 and 45.2).
oil flows to the pilot pressure ports of the control blocks ( I and II ).
Hydraulic oil flow
Only the oil of main pump 3 and 4 flows through the main control block (II)
and arrives via the distributor manifold at the stick hydraulic cylinders piston
side. Through main valve block I for stick retracting is no pressure oil flow
depend on a different valve spool with closed pressure port.
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8.1.3 Electric / Hydraulic flowchart “ Stick retracting ” FSA, Auto Float active

(-Y) Direction (axis) of joy stick
(Y21a, Y27a, Y27b) Directional solenoid valve
(I, II, III) Main control blocks I, II III

The auto float button in the left lever E20 is disengaged relay K170 is de-
energized. Signal voltage of joy stick (E20) arrives via ramp time module
(E48) at terminal 5 of the amplifier modules (A8, A8a and A8b) and further to
the proportional and directional solenoid valve of the remote control blocks
(45.1 and 45.3). Amplifier module A8a disengaged with open K80 if bucket
filling is actuated..
Hydraulic oil flow
Both pressure lines at valve block III section 4 (A4 and B4) are connected to the
same back pressure charged return line. Valve spool 4 of main valve block I
connect only port B2 to the return line. The return line, the piston side and the
piston rod side of the stick cylinders now connected together. The stick can move
forward and backward by external force.
If only the stick retracting function is active section 4 of main valve block II
opened additional port A4 and B4 to extend the max. oil flow for max. stick
speed.
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8.1.4 Electric / Hydraulic flowchart “ Stick retracting ” BHA

monitoring
(Y-) Direction (axis) of joy stick
(Y21b, Y27b, Y31a) Directional solenoid valve
(I, II, III) Main control blocks I, II, III

directional solenoid valves of the remote control blocks (45.1, 45.2 and 45.3).
Hydraulic oil flow
and arrives via distributor manifold at the hydraulic cylinders.
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12
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1.5 Electric / Hydraulic flowchart “ Bucket filling ” FSA

monitoring
(-X) Direction (axis) of joy stick
(ws / gn) Color code of signal voltage cable ( Joy stick)
(A9) Amplifier module – Bucket
(A9a) Amplifier module – Bucket
(A9b) Amplifier module – Bucket
(K50) Relay – pilot control: Bucket cut-off
Contacts 6 / 10 only closed if the hydraulic oil is in normal
Contacts 1 / 9 only open while bucket dump.
Contacts 1 / 9 only open while lifting the boom.
(45., 45.2, 45.3) Remote control valves
(Y22A, Y24A, Y30A) Directional solenoid valve

Signal voltage of joy stick (E19) arrives via relay contacts K50 at terminal 5 of
the amplifier modules (A9, A9a, A9b) and further to the proportional and
directional solenoid valves of the remote control blocks (45.1, 45.2, 45.3).
Hydraulic oil flow
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8.1
13
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1.5 Electric / Hydraulic flowchart “ Bucket filling ” BHA

monitoring
(XB) Direction (axis) of joy stick
Contacts 6 / 10 only closed if the hydraulic oil is
overheated.
(I, II, III) Main control blocks I, II, III

Signal voltage of joy stick (E19) arrives terminal 5 of the amplifier modules (A9,
A9a, A9b) and further to the proportional and directional solenoid valves of the
remote control blocks (45.,45.2 and 45.3).
Hydraulic oil flow
and arrives via distributor the manifold at the hydraulic cylinders.
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14
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8.1.6 Electric / Hydraulic flowchart “ Bucket dump ” FSA

monitoring
(+X) Direction (axis) of joy stick
Contacts 6 / 10 only closed if the hydraulic oil is in normal
Contacts 1 / 9 only open while bucket dump.
Contacts 1 / 9 only open while lifting the boom.
Contacts 1 / 3 only open while S205 activated (hydraulic
oil warming up)
(45., 45.2, 45.3) Remote control valves
(Y22A, Y24A, Y30A) Directional solenoid valve

the ELB modules. From ELB modules the signal voltage arrives at terminal 5 of
directional solenoid valves of the remote control blocks (45.1, 45.2, 45.3). Only
while bucket dump together with boom up K78 and K79 opened the contacts 1 / 9
and deactivate amplifier module A9 (priority to the boom).
Hydraulic oil flow
and arrives via the distributor manifold at the hydraulic cylinders. There is no oil
flow through main control block I to the bucket cylinder if bucket dump and boom
up is activated.
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8.1
15
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1.6 Electric / Hydraulic flowchart “ Bucket dump ” BHA

(+X) Direction (axis) of joy stick
Contacts 6 / 10 only closed if the hydraulic oil is overheated.
(14.1 + 14.3) Remote control valves
(Y64) Proportional solenoid valve
(Y71 + Y75) Proportional solenoid valve
(Y23 + Y45) Directional solenoid valve
(Y37) Directional solenoid valve
(II, III + IV) Main control blocks II, III + IV
Electrical signal flow (EURO control)

directional solenoid valves of the remote control blocks (45.1, 45,2 and 45.3).
Hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (II, III, IV)
and arrives via distributor manifold (42) at the hydraulic cylinders.
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06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1.8 Electric / Hydraulic flowchart “ Clam opening ” FSA

(E24) Control pedal
(rs) Color code of signal voltage cable ( Joy stick)
(A11) Amplifier module – Clam
Contacts 7 / 11 only closed while traveling the left crawler.
(II) Main control block II

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.
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18
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8.1.9 Electric / Hydraulic flowchart “ Clam closing ” FSA

(E23) Control pedal
(rs) Color code of signal voltage cable ( Joy stick)
(A11) Amplifier module – Clam
Contacts 7 / 11 only closed while traveling the left crawler.
(II) Main control block II

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.
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8.1.10 Checks and adjustments of the Main Relief Valves (MRV),

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).
MRV Check
Functions FSA
block point
Pump circuit
I M12.1 travel stick bucket boom
I
Pump circuit
II M12.3 clam bucket Boom stick
II
Pump circuit
III M12.4 travel boom bucket stick
III
Pump circuit
IV M12.2 Swing, (if no swing active circuit II)
IV
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 M12.1 - M12.4.
2. Start both motors.
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.
) • When using the single function “bucket fill”, (gray shadow), all MRV
can be adjusted, because all four pump circuits are engaged.
Adjusting:
1. Remove protective cap (a).
2. Loosen lock nut (b).
3. Turn set screw (c) -clockwise to increase pressure, Counter-clock
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.
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8.1
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06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1.10 Checks and adjustments of the Main Relief Valves (MRV),

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).
MRV in Check Functions BHA

control block point
Pump circuit I I M12.1 Travel Stick Bucket Boom
Pump circuit II II M12.3 Bucket Boom - Stick
Pump circuit III III M12.4 Travel Boom Bucket Stick
Pump circuit IV IV M12.2 Swing, (if no swing active circuit II)
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 M12.1 – M12.4.
2. Start both motors..
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.
) • When using the single function “bucket fill”, (gray shadow), all MRV
can be adjusted, because all four pump circuits are engaged.
Adjusting:
1. Remove protective cap (a).
2. Loosen lock nut (b).
3. Turn set screw (c) -clockwise to increase pressure, Counter-
clock wise to decrease pressure.
5. Tighten lock nut (b) and install cap (a).

) are firmly tightened (with 300 Nm).
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8.1.11 Checks and adjustments of the Service Line Relief Valves (SRV),
Boom cylinder “piston side” FSA + BHA
There are three service line relief valves (secondary valves) installed, all three
at the distributor manifold, to limit the maximum possible pressure peaks in
the service line.
Since the opening pressure of the SRV’s is higher than the setting of the Main
Relief Valves (MRV’s) it is necessary to increase the main relief pressure for
testing and adjusting purposes.
SRV FSA SRV BHA Press. check point Location

141.1 138.1 M23 Manifold section B
141.2 138.2. M29.1 Manifold section N
141.3 138.3 M29.2 Manifold section N
MRV I M12.1 (at HP filter) Double HP filter R.H.
MRV II M12.3 (at HP filter) Single HP filter, block II
MRV III M12.4 (at HP filter) Double HP L.H..
MRV IV M12.2 (at HP filter) Single HP filter, block IV
1. Connect gauges to all above listed check points (min. 400 bar).
3. Extend the boom cylinder to the stop position until the hydraulic
system stalls.
4. Increase slowly the pump supply line pressure, by turning in set screws (3)
of the MRV’s in control block I, II, III 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
SRV’s, 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 SRV’s open during checks and adjustments
it is necessary to further increase the setting of both MRV’s.
5. Remove protective cap (1) of MRV.

6. Loosen lock nut (2).
7. Turn set screw (3) of the MRV’s ½ turn further in, the gauge
pointers will remain at the value shown at item #4 (350 bar + 5 bar).
8. Tighten lock nut (2).
continued
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8.1
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06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Cont'd:
illustration (Z 22482a):
Boom cylinder “piston side” FSA +BHA

9. Adjust all three SRV’s equally, until all gauges show a pressure of
360 bar.
Adjust in steps of ¼ turn of set screw (3) in the following sequence:
141.1 þ 141.2 þ 141.3
Remove protective cap (1) of SRV’s.
Loosen lock nut (2).
Turn set screw (3) -clockwise to increase pressure, Counter-clock
Tighten lock nut (2) and install cap (1).
10. Reduce the pressure, at SRV- 141.1 to a value below the required value,
and then increase up to the required pressure (350 bar), while
observing all gauges.
) • Now all gauges will show the same value of 350 bar,
but only SRV-143.1 has the correct setting.
11. Proceed with the other valves in the same manner in the following
sequence:
141.2 þ 141.3
• Strong pulsation of the return line hoses, indicates deviation in

opening pressure of SRV’s and must be avoided.
Repeat the adjusting procedure until the oil returns well-balanced
via all six service line relief valves.
12. Reset the MRV’s to 310 bar + 5 bar after the check / adjustment is finished,
as follows:
Remove protective cap (1).

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06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
illustration (Z 22483b):
Boom cylinder “piston rod side” FSA +BHA
There is one service line relief valve (secondary valve) installed in the main
control block II, to limit the maximum possible pressure peaks in the service
line. Since the opening pressure of the SRV is higher than the setting of the
Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure
for testing and adjusting purposes.
Valve Press. check point Location

SRV 33.4 FSA M12.3 (High pressure filter) Control block II, section A3 FSA
SRV 33.6 BHA section A2 BHA
MRV circuit II M12.3 (High pressure filter) Single high pressure filter,
control block II
MRV circuit IV M12.2 (High pressure filter) Single high pressure filter,
control block IV
1. Connect gauges to all above listed check points.

3. Press floating system button S95 at the lever with the boom function
and retract the boom cylinder to the stop position until the hydraulic
system stalls.
4. Increase slowly the pump supply line pressure, by turning in set
screws (3) of the MRV in control blocks II, while observing the
If there is a setting required follow
5. Turn set screw (3) of the MRV ¼ turn further in, the gauge pointers
will remain at the value shown at item #4 .
)
• To ensure that only the SRV open during checks and adjustments it
is necessary to further increase the setting of MRV control block II..
continued
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
24
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
illustration (Z 22483b):
Cont'd:
7. Adjust the SRV until the gauges show a pressure of 350 bar.
9. Reset the MRV to 310 bar + 5 bar after the check / adjustment is finished
11. Stop engine.
12. Install all protective cups (1).

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8.1
25
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Stick cylinder “piston side” FSA
the service line.

SRV 142.5 Manifold section F
SRV 142.6 M27.1 Manifold section F
SRV 142.7 Manifold section J
MRV circuit I M12.1 (High pressure filter) Double high pressure filter R.H.
MRV circuit II M12.3 (High pressure filter) Single HP filter, control block II
MRV circuit III M12.4 (High pressure filter) Double high pressure filter L.H..
MRV circuit IV M12.2 (High pressure filter) Single HP filter, control block IV

3. 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.
Stop as soon the pressure does not raise any further.
)
• Since the piston side of the stick cylinders are protected by several
lowest setting.
it is necessary to further increase the setting of the MRV’s.

7. Turn set screw (3) of the MRV ½ turn further in, the gauge
8. Tighten lock nut (2) and install cap (1).
continued
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
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06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Cont'd:
Stick cylinder “piston side” FSA

9. Adjust all three SRV’s equally, until all gauges show a pressure of 360
bar.
142.5 þ 142.6 þ 142.7
Turn set screw (3) -clockwise to increase, Counter-clock wise to
decrease the setting.
10. Reduce the pressure at SRV 142.5 to a value below the required value,
and increase up to the required pressure (350 bar), while observing all
gauges.
sequence: 142.6 þ 142.7

via all three service line relief valves.
12. Reset the MRV to 310 bar + 5 bar (320 bar block IV) after the check /
adjustment is finished, as follows:

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06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Stick cylinder “piston side” BHA
There are two service line relief valves (secondary valves) installed, in main
control blocks I and II, to limit the maximum possible pressure peaks in the
service line.

SRV 33.1 M12.1 (High pressure filter) Control block I, section A2
SRV 33.5 M12.3 (High pressure filter) Control block II, section A42
MRV circuit I M12.1 (High pressure filter) Control block I
MRV circuit II M12.3 (High pressure filter) Control block II
MRV circuit IV M12.2 (High pressure filter) Control block IV

3. Extend the stick cylinder (stick retracting) to the stop position until
the hydraulic system stalls.
of the MRV’s in the control blocks, while observing the pressure gauges.
)
• Since the piston side of the stick cylinders are protected by several
lowest setting.

7. Turn set screw (3) of the MRV’s ½ turn further in, the gauge
continued
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06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Cont'd:
Stick cylinder “piston side” BHA

9. Adjust all two SRV’s equally, until all gauges show a pressure of
360 bar.
33.1 þ 33.5
sequence: 33.1 þ 33.5

12. Reset the MRV to 310 bar + 5 bar after the check / adjustment is finished,
as follows:

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06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Stick cylinder “piston rod side” FSA
There are two service line relief valves (secondary valves) installed, in main
control blocks I and II, to limit the maximum possible pressure peaks in the
service line.

SRV 33.1 M12.1 (High pressure filter) Double high pressure filter R.H.
SRV 33.5 M12.3 (High pressure filter) Single HP filter, control block II

5. Retract the stick cylinder to the stop position until the hydraulic
system stalls.
of MRV’s in all above listed control blocks I, II, IV, while observing the
respective pressure gauges. Stop as soon the pressure does not raise any
further. The gauge pointers should remain at 350 bar + 5 bar.
a) Remove protective cap (1).

c) Turn set screw (3) -clockwise to increase pressure, Counter-
clock wise to decrease pressure.
d) Tighten lock nut (2).
continued
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
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06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Cont'd:
)
• Since the piston rod side of the stick cylinders are protected by
several SRV’s, the pressure gauges show the pressure of that valve
with the lowest setting.
one valves have a higher setting
7. Turn set screw (3) of both MRV’s ½ turn further in, the gauge pointers
will remain at the value shown at item #6 (350 bar + 5 bar).
8. Adjust the SRV’s equally, until all gauges show a pressure of 360 bar.
Adjust in steps of ¼ turn of set screw (1) (SRV’s) in the following
sequence : 33.1 þ 33.5
9. Turn set screw (3)-clockwise to increase pressure, Counter-clockwise to
decrease pressure.
Adjust pressure at SRV 33.1 to ~360 bar if the pressure don’t increase
turn set screw from the last setting max. ¼ turn in (c.w.).
10. Adjust pressure at the SRV 33.5 to ~350 bar.
11. Reduce the pressure, at SRV 33.1 to a value below the required value and
then increase up to the required pressure (350 bar), while observing all
gauges.
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06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Cont'd:

via all service line relief valves.
14. Reset the MRV’s to 310 bar + 5 bar after the check / adjustment is finished
15. Stop engine.
16. Install all protective cups (1).

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Stick cylinder “Piston rod side” BHA

There are three service line relief valves (secondary valves) installed at the
distributor manifold, to limit the maximum possible pressure peaks in the
service line.

SRV 142.5 M27.1 Manifold (42) section G
SRV 142.6 M27.2 Manifold (42) section J
SRV 142.7 M28 Manifold (42) section J
MRV circuit II M12.3 (High pressure filter) Single high pressure filter,
control block II
MRV circuit IV M12.2 (High pressure filter) Single high pressure filter,
control block IV

3. Retract the stick cylinder (extend the stick) to the stop position until
of MRV’s in the control blocks, 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 rod side of the stick cylinders are protected by

7. Turn set screw (3) of both MRV’s ½ turn further in, the gauge
continued
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
33
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Cont'd:
Stick cylinder “Piston rod side” BHA

9. Adjust all SRV’s equally, until all gauges show a pressure of
360 bar.
142.5 þ 142.6þ 142.7
and then increase up to the required pressure (350 bar), while observing
all gauges.
sequence: 142.6þ 142.7

as follows:
Turn set screw (3) -clockwise to increase pressure, Counter-clock wise
to decrease pressure.
• It is important that the valve body of MRV and the SRV are firmly
) tightened (with 300 Nm).
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
34
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Bucket cylinder “Piston side” FSA
the service line.

SRV 142.1 M24.1 Manifold (42) section C
SRV 142.2 M24.2 Manifold (42) section C
SRV 142.3 M25 Manifold (42) section D
MRV circuit I M12.1 (High pressure filter) Double high pressure (HP) filter R.H.
MRV circuit III M12.4 (High pressure filter) Double HP filter L.H..
1. Connect gauges to check points M12.1.to M12.4 and M24.1.

3. Extend the Bucket cylinder to the stop position until the hydraulic
system stalls.
of all four MRV’s in control block I to IV, while observing the
)
• Since the piston side of the bucket cylinders are protected by several
lowest setting.

continued
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
35
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Cont'd:
Bucket cylinder “Piston rod side” FSA

360 bar.
142.1 þ 142.2 þ 142.3
sequence:
142.2 þ 142.3

via all six service line relief valves.
as follows:
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
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36
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Bucket cylinder “Piston side” BHA
distributor manifold, to limit the maximum possible pressure peaks in the service
line.
Since the opening pressure of the SRV’s is higher than the setting of the Main Relief
Valves (MRV’s) it is necessary to increase the main relief pressure for testing and
adjusting purposes.

SRV 142.1 M24.1 Manifold section C
SRV 142.2 M24.2 Manifold section C
SRV 142.3 M25 Manifold section D
MRV circuit II M12.3 (High pressure filter) Single high pressure filter, block II
MRV circuit IV M12.2 (High pressure filter) Singe high pressure filter, block IV

2. Start both engines and let them run with max. speed.
3. Extend the bucket cylinder (Bucket filling) to the stop position until
of MRV in control block I, II, III 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 bucket cylinders are protected by several
lowest setting.

continued
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
37
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Cont'd:
Bucket cylinder “Piston side” BHA

360 bar.
142.1 þ 142.2 þ 142.3
sequence: 142.2 þ 142.3 þ 142.

as follows:

06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
38
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Bucket cylinder “Rod side” FSA

There are two service line relief valves (secondary valves) installed, one in
main control block I section 3 and one in block II section 2, to limit the
maximum possible pressure peaks in the service line.

MRV circuit IV M12.2 (High pressure filter) Single high pressure filter, block IV

3. Stall the system with full retracted bucket cylinder in final stop position.
of MRV’s in the control blocks, while observing the pressure gauges.
)
• Since the piston rod side of the bucket cylinders are protected by

continued
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
39
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Cont'd:
Bucket cylinder “Rod side” FSA

9. Adjust both SRV’s equally, until all gauges show a pressure of
360 bar.
33,2 þ 33.6
all gauges.
11. Proceed with the other valve in the same manner.

as follows:
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
40
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Bucket cylinder “Piston rod side” BHA
distributor manifold, to limit the maximum possible pressure peaks in the
service line.

SRV 142.8 M34.1 Manifold section L
SRV 142.9 M34.2 Manifold section L
SRV 142.10 M34.3 Manifold section M
MRV circuit IV M12.2 (High pressure filter) Single high pressure filter, block IV
2. Start both engines and let it run with max. speed.
3. Retract the Bucket cylinder (Bucket dump) to the stop position until
of MRV’s in control block I, I, III and IV, while observing the pressure
gauges. Stop as soon the pressure does not raise any further.
)
• Since the piston rod side of the bucket cylinders are protected by
it is necessary to further increase the setting of the MRV.

continued
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
41
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Cont'd:
Bucket cylinder “Piston rod side” BHA

9. Adjust all SRV’s equally, until all gauges show a pressure of 360 bar.
142.8 þ 142.9 þ 142.10
Turn set screw (3) -clockwise to increase pressure, Counter-clock wise
to decrease pressure.
10. Reduce the pressure, at SRV- 142.8 to a value below the required value
all gauges.
sequence: 142.9 þ 142.10

as follows:

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42
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Page 42
Attachment Cylinders
Clam cylinder “Rod side” (clam opening) FSA
There is one service line relief valve (secondary valve) installed at the distributor
manifold section E, to limit the maximum possible pressure peaks in the service line.
Since the opening pressure of the SRV is higher than the setting of the Main Relief
Valves (MRV’s) it is necessary to increase the main relief pressure for testing and
adjusting purposes.

SRV 142.4 M26 Manifold (42) section E
MRV circuit II M12.3 (High pressure filter) Control block II
MRV circuit IV M12.2 (High pressure filter) Control block IV
1. Connect gauges to the above listed check points.

2. Start engine 2 and let it run in high idle.
3. Retract the clam cylinder (open the bucket) to the stop position until the
hydraulic system stalls.
4. Increase slowly the pump supply line pressure, by turning in set screws (3) of
MRV in control block II and IV, while observing the pressure gauges.
If necessary correct the adjustment as follows:
7. Turn set screw (3) of the MRV ½ turn further in, the gauge pointers will
remain at the value shown at item #4 (350 bar + 5 bar).
9. Reduce the pressure, at SRV 142.4 to a value below the required value, and
then increase up to the required pressure (350 bar), while observing all auges.
10. 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.
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
43
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Clam cylinder “Piston side” (clam closing) FSA
There are three service line relief valves (secondary valves) installed, two at
distributor manifold section K and one at main control block II section 1, to
limit the maximum possible pressure in the service line when closing the
bucket.
To avoid damages at the clam shell, due to wrong operation, the SRV’s
should be adjusted in a way that the pressure is just sufficient to close the
clam with horizontal back wall.

SRV 144 (1) M22 Manifold section K
SRV 144 (2) M22 Manifold section K
SRV 32.10 MM12.3 (High pressure filter) Control block II

2. Start engine 2 and let them run in high idle.
3. Raise the attachment and bring the back wall of the bucket in a
horizontal position (bucket dump).
4. Press carefully pedal “bucket closing”. The clam should close complete
and must stay closed after pedal in neutral position.
Adjust the SRV’s as follows:
Turn set screw (3) -clockwise to increase pressure,
Counter-clock wise to decrease pressure while
depressed pedal “clam closing”.
Adjust all three SRV’s equally, until the gauges show a pressure of 220 bar.
Now reduce the pressure at one SRV in steps of 5 bar until the bucket opens
by gravity (check with released pedal).
Now read the pressure and adjust 10% plus the reading 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.
• Because of different wear packages the pressure can be between 150
bar and more as 200 bar.
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
44
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1.12 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 flow restrictors (throttle valves) at the distributor manifold section B,
throttle valve 141.1 and section N, throttle valve 141.3.
II. Float position deactivated the lowering speed has to be adjusted by
altering the flow restrictor (throttle valve) at the distributor manifold
section N, throttle valve 141.2.
On excavators equipped with Backhoe Attachment (BHA) the lowering speed has
to be adjusted at all flow restrictors on distributor manifold section B and N,
throttle valves 141.1, 141.2 and 141.3.
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 engines
and allow pressure equalizing by moving the lever several times.
• Loosen the lock nut (1) and turn the bolt (2) cw for more restriction and ccw
for less restriction. 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 newest Service Bulletin
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
45
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc

Boom cylinder FSA
Due to the two different operation modes for lowering the boom, the lowering
speed must be adjusted twice:
I. Float position activated
II. Float position deactivated
Maximum permissible lowering speed for both operation modes:
Cylinder retracting time/meter (s /m) Total time(s)

Boom FSA 1,4 4,3
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 both engines 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 throttle valves
141.1 (section B) and 141.3 (section N, pointing to the attachment).
Adjust as follows:
To decrease the lowering speed loosen lock nut (1) and turn the bolt (2) cw.
To increase the lowering speed loosen lock nut (1) and turn the bolt (2) ccw.
Since there are several valves throttling the return oil flow the valves
must be set synchronously. The adjusting screws have to be turned in
by the same amount of revolutions.
O.K.
6. Check lowering speed again and repeat the adjustment if necessary.

7. If the adjustment is finished tighten lock nut (1).
continued
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
46
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Cont'd:
Boom cylinder FSA

II. Float position deactivated (with push button S95):

1. Adjust the throttle adjustment bold of throttle valve 141.2 to the same amount
of revolutions as the valve 141.1 and 141.3.
4. Shift the engines to high idle speed.
5. 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
watch) and hold it until the final position (B) is reached.(stop the stop watch).
6. The lowering speed will be the same as with floating position. 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 throttle valve 141.1, 141.2 and
synchronous 141.3 at the distributor manifold section B and N.
Adjust as follows:
To decrease the lowering speed loosen lock nut (1) and turn the bolt (2) cw. To
increase the lowering speed loosen lock nut (1) and turn the bolt (2) ccw.
The adjusting screws have to be turned in by the same amount of
revolutions.
O.K.

06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
47
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc

Boom cylinder BHA
Maximum permissible lowering speed:
Cylinder retracting time/meter Total time

(s /m) (s)
Boom BHA 1,4 5,0
3. Shift the engines to high idle speed.
4. Rapidly move the control lever (E19) to the front end position (start the stop
watch).
141.1, 141.2 and 141.3 at the distributor manifold.
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.
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.

If the adjustment is finished tighten lock nut (1).
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
48
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1.12 Checks and adjustments of the lowering speed, illustration (Z 22490):

Stick cylinder FSA
Due to the two different operation modes for lowering the stick, the lowering
speed must be adjusted twice:
I. Float position activated
II. Float position deactivated
Maximum permissible lowering speed for both operation modes:

(s /m) (s)
Stick FSA 0,9 2,4
I. Float position activated:

3. Rapidly move the control lever (E20) to the rear end position (start the stop
watch until the stick start moving) and hold it until close to the final position
(B) is reached.(stop the stop watch).
142.5 and 142.7 at the distributor manifold.
Adjust as follows:
To decrease the lowering speed loosen lock nut (1) and turn the bolt (2) cw. To
increase the lowering speed loosen lock nut (1) and turn the bolt (2) ccw.
Since there are several valves throttling the return oil flow of the stick
O.K.

If the adjustment is finished tighten lock nut (1).
continued
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
49
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Cont'd:
8.1.12 Checks and adjustments of the lowering speed, illustration (Z 22490):
Stick cylinder FSA

II. Float position deactivated (with push button S95a):

1. Adjust the throttle adjustment bold of throttle valve 142.6 to the same amount
of revolutions as the valve 142.5 and 142.7.
3. Start both engines and let it run in high idle.
5. 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).
6. The lowering speed will be the same as with floating position. 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 throttle valve 142.5, 142.6 and
synchronous 142.7 at the distributor manifold section F and J.
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.

06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
50
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc

Stick cylinder BHA
Cylinder extending time/meter Total time

(s /m) (s)
Stick BHA 0,6 1,5
4. Rapidly move the control lever (E20) to the rear end position (start the stop
watch) and hold it until close to the final position (B) is reached.(stop the
stop watch).
142.5, 142.6 and 142.7 at the distributor manifold.
Adjust as follows:
(2) ccw.
Since there are several valves throttling the return oil flow of the stick
O.K.

06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
51
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc

Bucket cylinder FSA

(s /m) (s)
Bucket FSA 1,1 3,0
4. Rapidly move the control lever (E19) to the r.h. end position (start the stop
watch).
142.1, 142.2 and 142,3 at the distributor manifold section C and D.
Adjust as follows:
Since there are several valves throttling the return oil flow of the
bucket cylinder the valves must be set synchronously. The
adjusting screws have to be turned in by the same amount of
revolutions.
O.K.

06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
52
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc

Bucket cylinder BHA

(s /m) (s)
Bucket BHA 0,5 1,1
4. Rapidly move the control lever (E19) to the r.h. end position (start the stop
watch).
142.1, 142.2, 142.3, 142.8, 142.9 and 142.10 at the distributor manifold.
Adjust as follows:
(2) ccw.
Since there are several valves throttling the return oil flow of the bucket
O.K.

06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
53
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc

Clam cylinder FSA


3. Open the clam of the empty bucket to the maximum 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 nearly reached.(stop the stop
watch).
5. If the lowering speed is too high, i.e. the speed is uncomfortable, the speed
must be reduced by altering the throttle valve 142.4 at the distributor
manifold section E.
Adjust as follows:
7. If the adjustment is finished tighten lock nut (1) and write down the adjusted
running time for later checks.
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1
54
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
8.1.13 Checks for the valve control logic

(1) Main pump condition Ö P = pressurized outlet
(2) Main pump condition Ö (-) = free flow to reservoir
(3) Pilot ports a = outlet ports a
(4) Pilot ports b = outlet ports b
(5) Port condition Ö (-) = closed port
(6) Port condition Ö O = open port
(7) Respective function
(8) Single control valve block for swing
(9) control valve block number
(10) Swing parking brake switch S29
General:
For harmonic attachment motion and well working floating function the valve
spools must be activated with different priorities. The whole valve control logic is
a arrangement of electric relay controlling and the main hydraulic control valve
sequence.
The correct function of the valve control logic can be checked by pressure gauges
(0 -50bar) connected to the pressure test ports at the control valve cabs.
Checks:
a) Connect the pressure gauges (0-50 bar) to all test ports at the pilot control
cabs (26 gauges necessary *) and (0-400 bar) to the high pressure filter
test ports M44.1, 44.2, 46.1, 46.2
b) Mark the control cab with the respective function and port designation.
c) Use the Check list for the Valve Logic in the appendix in this binder.
d) Unplug solenoid valve Y16 (travel parking brake closed) and activate the
swing brake with the switch at the dash board. The ladder and the
refilling arm are in high position (working position) the operator sits on
the operators seat. Make sure that the machine can move hazardless all
functions
e) Start one motor.
f) The operator activate carefully step for step the respective lever or pedal
as shown in the check list. Compare each step with the pressure condition
of the control cabs and main pressure to the check list.
If there is a wrong result, check the respective electric circuit and hydraulic
pilot circuit.
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
06.10.05 PC5500-6-D_Sec_8-1_rev3.doc
Hydraulic for the Swing Circuit Section 8.2
Page 1
Section Page
8.2 Hydraulic for the swing circuit
8.2.1 Swing Circuit (Brief description) 2+3
8.2.2 Swing Motor 4-7
8.2.3 Swing Gear Box 8
8.2.4 Swing Parking Brake (Gear house Brake) 9
8.2.5 Swing Brake Valve 10+12
8.2.6 Electric / Hydraulic flowchart “Swing Left” 13
8.2.7 Electric / Hydraulic flowchart “Swing Right” 14
8.2.8 Swing Monitoring System 15 + 16
8.2.9 Adjustments for the swing circuit 17 - 19
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
8.2
2
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
Page 2
8.2.1 Swing Circuit (Brief description)
(I - VI) Main pumps

(13) Single control block IV
(48) Manifold
(20.1+ 20.2) Swing motors
(71.1+ 71.2) Manifold at the control and filter panel
(25.2) Double check valve
(49.1 + 49.2) Pressure increasing valve (swing brake valve)
(Y48) Swing motors power control valve
(Y120) Solenoid valve
(43) Remote control valve block
(Y32) Proportional valve of the remote control block
(Y32a/b) Directional solenoid valve of the remote control block
(20) Control lever left hand
(50) Ramp module
(A7) Amplifier module
Brief description (Control circuits)

(Study together with the for the machine valid hydraulic and electric circuit
diagram).
When the lever (E20) is moved out of its neutral position, proportional
solenoid valves Y32 are energized. Simultaneously the directional solenoid
valves Y32a (R.H.-swing) or Y32b (L.H.-swing) are energized.
By the function of the remote control valve (43) pilot pressure oil is sent to
one side of the control block (13/IV) when operating the control lever for
"Swinging". At the same time by the function of the proportional valve
(Y127) pilot pressure (proportional to the lever deflection) is present at port
„X“ pressure increasing valve (PIV)of each brake valve block (49.1+ 49.2)
thus a internal pressure built up (higher as 150 bar) in the service lines is
possible.
continued
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
8.2
3
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
Page 3
Cont'd.:
8.2.1 Functional description:
Illustration (Z 22501b):
Brief description (Service circuits)
(Study together with the for the machine valid hydraulic and electric circuit
diagram).
The swing motors (20.1 + 20.2) are feed by the main pump (III). This pump is
at port XLR permanent with 35 bar X2- pressure fix adjusted to Qmax.
The oil flows from the pumps through check valve (47.3) and filter (153.3) to
the single control block (13 / IV).
In neutral position of the spool oil flows via port C into control block II for
additional oil volume from pump 3 to valve circuit II. If no function of
control block II is activated the oil flow via port T in to the collector tube (35)
and further via the return oil lines (L6 + L7) into the tank.
On its way to tank the oil must flow through the back pressure valve (115)
and the return oil filter (117.2 - 117.5). (Back pressure valve function see
chapt. 4.)
When operating the control lever for "Swinging" the pump line is connected
in the control block (33/IV) with the corresponding service line (A1 or B1) to
the swing motors (20.1 + 20.2).
The oil flows from the control block through each one of the swing brake
valves (49.1 + 49.2; description see page 6 and 7) and the swing motors (20.1
+ 20.2).
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 (L11 + L12) and the leak oil
filter (108) back to tank.
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
8.2
4
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
Swing motor A6VM Section 8.2
Page 4
8.2.2 Swing Motor Axial Piston Motor A6VM355 HD1D

(1) Check valve
(2) Check valve
(3) Governor valve
(5) Boost pressure valve
(6) Flushing valve (16l/min)
(7) Flow control valve
(8) Constant pressure control valve (adjusted: 280 bar)
General:
A6VM355 HD1D is a variable displacement motor with an axial piston rotary
group of bent axis design for hydrostatic drives.
Its control range allows the variable displacement motor to meet both, high speed
and torque requirements. The output speed is proportional to its displacement.
The output speed increases with decreased displacement trough lower
operating pressure.
The output torque increases with increased displacement trough higher
operating pressure.
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
8.2
5
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
Page 5
8.2.1 Swing Motor Axial Piston Motor A6VM355 HD1D
Hydraulic control, illustration Z22430

By switching pilot pressure to port X at the motor (0 bar or 35 bar) the displacement is
fixed in Vg max or variable.
Without pilot pressure at port X (0 bar) the displacement is fixed to Vg max .
With pilot pressure at port X (35 bar) the displacement is variable from
Vg min (175 cm3/rpm) to Vg max (355 cm3/rpm).
With a swing speed of 0 up to 120 impulses per minute (measured by a proximity
switch located at the swing gear) the motors are in maximum displacement position,
i.e. min. speed and max. torque available.
With a swing speed of more as 120 imp./min. pilot pressure is directed via a solenoid
valve to port X at the motors, to actuate governor valve (3). Now the output speed is
variable depending on the operating pressure, controlled by the function of control
valve (8).
As a result of decreasing operating pressure the motors are reducing their
displacement so that the swing speed will increase.
If the operating pressure rises as a result of load torque, to the setting of the constant
pressure control valve (280 bar), the motors are swiveled out to a greater angel (higher
displacement) and the swing speed will decrease.
Function Speed X- Operating Torque Motor

indicator pressure pressure displacement
imp/min bar bar
Start swing 0-120 0 310 à ~280 Max. Vg max
Standstill to low speed
Swing movement 120-max. 35 280 à ~75 Reduced Vg max à Vg min
Low speed to Max. speed variable
Swing movement Max. 35 ~75 Reduced Vg min
Max. speed
Swing down path 120-0 0 ~170 à 0 Max. Vg max
Control lever in neutral
Counter Swing (braking) 120-0 0 330 à 0 Max. Vg max
Control lever moved to the
opposite side of swing direction
Continued
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6
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Page 6
8.2.2 Hydraulic Motor Axial Piston Motor A6VM355 HD1D
Hydraulic control, illustration Z22431b

Cont'd:
A Flow from A to B without „X-pressure“ (slow swing speed) :

The operating pressure opens check valve (1) and closes the opposite valve (2). The
same pressure is present at the control port of pressure control valve (8) and inside
the small area side of the positioning piston (4). The large area side is connected via
the governor valve (3) to tank (port T2).
The motor remains in Vgmax position. = max. torque by low speed.
B Flow from A to B, with „X-pressure“ (higher swing speed),

operating pressure 0 –280 bar:
Operating pressure opens check valve (1) and closes the opposite valve (2). The
same pressure is present at the control port of pressure control valve (8) and inside
the small area side of the positioning piston (4).
Because of the „X“ pressure at the control port of governor valve (3) a connection
is made from the operating pressure to the large area side of positioning piston (4).
Same pressure on both sides but different areas causes a greater force at the piston
side moving the motor into the Vgmin position.
The motor is in regulation mode due to 35 bar “X-pressure”
Motor displacement to Vgmin position (<280bar).
C Flow from A to B, with „X-pressure“ (higher swing speed),

operating pressure 280-310 bar:
Depending on the system pressure (more as 280 bar), valve (8) connect the large
area side of the positioning piston (4) with the pressure less return line (T2). Low
pressure at the large side cause a greater force at the pressurized small area side of
the positioning piston (4) moving the motor into the Vgmax position.
The motor is in regulation mode due to high operating pressure (>280bar) :
Motor displacement to Vgmax position (>280bar).
As a result of decreasing operating pressure the motors are reducing their

displacement so that the swing speed will increase.
If the operating pressure rises as a result of load torque, to the setting of the constant
pressure control valve (280 bar), the motors are swiveled out to a greater angel (higher
displacement) and the swing speed will decrease.
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
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PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
Page 7
8.2.2 Checks and Adjustments, illustration Z22432

Preconditions before starting checks and adjustments:
1. Main pump 3 must be in full flow position (X1-pressure = 35 bar), no action
required because stabilized X1 pressure is automatic activated during swinging
2. MRV’s and SRV’s (pressure increasing valves) correctly adjusted.
Checking the Q-max. and Q-min. stop bolt setting.

Q-max : The average outer length of 25.1 mm must not be altered because the
max. possible swivel angle is used.
Q-min : The Qmin. adjustment depends on the max. permissible swing speed (with
reduced swivel angle). The average outer length is 36.1 mm
) • It is important that the adjustment is equal on both motors!
How to check the Q-min. adjustment.

1. Lift the extended attachment to horizontal position.
2. Measure the time for 5 revolutions after swinging one turn as an approach swing.
The time should be t5rev = 90+5 sec .
3. If a adjustment is required:
Turn off box nut (1) and loosen lock nut (3)
Turn bolt (2) further in for less speed or further out for higher speed.
One turn of the Qmin bolt (2) cause a change of approx. ∆t5rev = 4.6 sec.
4. Re-check speed and tighten lock nut and re-fit box nut (1) after setting is finished.
How to check / adjust the start of regulation.

1. Activate manually relay K153 to energize Y48 to pressurized swing motor port
X with X2-pressur.
2. Connect a pressure gauge (0-400 bar) to check point M12.2 at high pressure
filter of single control block IV.
3. Measure and note outer length (L) of Qmax stop bolt (2) (for resetting later on)
Loosen lock nut (3) approx. ½ turn without turning the stop bolt..
4. Start engine 1 and let it run in high idle.
5. Apply the swing parking brake.
6. Operate carefully the control lever for swing in one direction and keep it in end
position. The resulting operating pressure should be 320 bar.
7. Loosen look nut of MRV at single control block IV.
8. Decrease / increase alternately the operating pressure between 300 bar and 260 bar
at MRV set screw. Check by turning the Qmax stop bolt (2) by hand, if the motor
control lens touches the Qmax stop bolt:
The lens must touch the stop bolt with a pressure higher than 280 bar.
The lens must not touch the stop bolt with a pressure lower than 280 bar
9. Correct the start of regulation with valve (8) if necessary.
10. Reset MRV. Stop engine and deactivate K153
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
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8
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
Page 8
8.2.3 Swing Gear Box
Legend for illustration (Z 25305), manufacturer: Siebenhaar

(1) Drive housing (11) Bearing ring
(2) Drive shaft (12) Cartridge
(3) Sun gear shaft (13) Spherical roller bearing
(4) Multi disc brake, spring (14) Oil drain plug, gear box
loaded pilot pressure released (15) Cylindrical roller bearing
(5) Breather filter motor adapter (16) Oil level gauge (dipstick)
housing for gear box
(6) Oil level gauge (dipstick) (17) First planetary stage
for drive shaft housing (18) Drive shaft to second stage
(7) Disk brake housing (19) Second planetary stage
(8) Cylindrical roller bearing (20) Radial seal ring
(9) Internal ring gear (21) Drive pinion
(10) Cylindrical roller bearing (22) Grease line port
(23) Centering circle
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.
A grease nipple is via a hose connected to the bearing lubrication port (22).
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
8.2
9
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Page 9
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) Clip ring (circlip)
(2) Thrust washer
(3) Outer discs
(4) Inner discs
(5) Piston
(6) Quad ring with back up ring
(7) Quad ring with back up ring
(8) Springs
(9) Piston back up ring and seal retainer
(10) O ring
(11) Clip ring (circlip)
(12) Oil pressure port
Function:
Brake applied:
The outer disks (3) engaged to the housing by serration and the inner disks (4) in
serrated connection with drive shaft are pressed together by the springs (8). This
results in a fixed connection between housing and drive shaft.
Brake released:
Oil pressure via port (12) reaches the bottom of the piston (5) and forces the
piston upwards against the thrust washer (2).
This function eliminates the spring force to the disc (3) and (4) thus the brake is
released.
The releasing pressure is 12 - 20 bar, the maximum permissible pressure
60 bar.
This is a so named "Wet Brake" because the brake housing is filled with oil.
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
8.2
10
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
Page 10
8.2.5 Swing Brake Valve

(1) Pressure increasing valve (7) Spring of main piston
(items 6 - 13) (8) Jet bore
(2) Check valve circuit A (9) Valve poppet
(3) Check valve circuit B (10) Spring
(4) Anti-cavitation valve circuit B (11) Intermediate piston
(5) Anti-cavitation valve circuit A (12) Pilot pressure piston
(6) Jet bore, of main piston plug (13) Main piston
Ports:
(Y) Leak oil
(T) Return oil
(A) Service line from control block
(A1) Service line to the motor
(B) Service line from control block
(B1) Service line to the motor
Pressure check points:

(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
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
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11
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Page 11
Cont'd.:
8.2.5 Swing Brake Valve
If after a swing motion the joy stick is released 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.
Both service line’s (pump line and tank line) are blocked at the control
valve block. In this period the service line (previously pump line) acts now
as suction line and the return line (previously return line) acts now as
output line. Because of the closed service ports at the control block all oil
from the swing motor must pass the brake valve block. The pressure
increasing valve in the brake valve block acts now as a back pressure
valve. This variable back pressure is the brake force.
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 pre-
tensioning 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.
continued
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
8.2
12
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
Page 12
Cont'd.:
8.2.5 Swing Brake Valves

Anti cavitation prevention. Illustration Z 22672a
(2) Main back pressure valve
(3) Gear pump (8.2 + 8.5)..
(4) Swing motor back pressure valve blocks (195.1 + 195.2)
(5) Swing brake valve blocks (49.1 + 49.2).
(6) Swing motor (20.1 + 20.2)
(7) Pressure relieve valve (swing motor back pressure)
(8) Check valve
(9) Pressure check point M35.1 and M35.2
(10) Valve drain connection
A Input from gear pump
B Output to swing brake block
T Tank connection to return oil collector tube
During the swing down phases the swing motors (6) are working as “pumps”.
It means that the pressure side change to a suction side and the suction side
change to a pressure side. To prevent cavitation in the swing motors during
this change there are two back pressure valves (4) fitted. The valves (4)
together with the gear pumps (3) increase the main back pressure up to 15
bar. Port B is direct connected to the tank port (return line) of the swing brake
valve block (5).
Adjustments - Measurements -Settings

Setting of the swing circuit back pressure valves (3)
1. Connect pressure gauge (0 – 25 bar) to check points M35.1 and M35.2

at the valve blocks (195.1 +195.2). The valve blocks fitted at the return
oil collector tube in front of the hydraulic tank.
2. Start both engines and let them run in high idle.
3. The pressure at the gauges should be 15 bar if the gauges shows a
different value the pressure relieve valves in the back pressure valve
must be adjusted.
a) Loosen look nut

b) Turn in or out set screw to increase or decrease the pressure.
c) Tighten look nut
4. Stop engines
5. Disconnect the gauges.
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13
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
Page 13
8.2.6 Electric / Hydraulic flowchart “Swing Left”

(13) Main control block IV
(20.1 + 20.2) Swing motors
(48) Distribution block
(49.1 + 49.2) Swing brake valve blocks
(A7) Amplifier module – Swing (Y32 + Y32a/b – Block IV)
(A16) Amplifier module – Swing brake
(E50B) Ramp time module – Swing brake
(K165) Relay counter lock (option)
(K253) Relay controlled by swing brake (foot brake)
(ws/gn) Colour code of signal voltage cable ( Joy stick)
(-X) Direction (axis) of joy stick (minus x = left)
(X2F...) Terminal rail with number
(Y32a + Y32b) Directional solenoid valve
(Y127) Proportional valve, controlling pressure increasing valve
The electrical signal.

terminal 5 of the amplifier module (A7) and further via relay K165 (if
equipped) to the proportional and directional solenoid valves of the remote
control blocks (43). In the same time signal voltage of joy stick arrives via
K253 and ramp time module E50B to terminal 5 of the amplifier module A16.
Relay contact 2 / 10 of relay K165 (if equipped) opened if the excavator
superstructure swing in a different direction as the lever direction (counter
look). Relay K253 energized if the swing brake pedal is activated this
eliminate the ramp time function of E50B.
The hydraulic signal. (pilot pressure)
pressure oil flows to the pressure ports of the main control blocks.
Proportional valve Y127 increase proportional to the lever deflection the pilot
pressure to the pressure increasing valves.
The hydraulic oil flow
Now the oil of the main pump 3 flows through the main control block (IV) and
arrives via swing brake valves (49.1 + 49.2) at the swing motors (20.1 + 20.2).
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
8.2
14
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
Page 14
8.2.7 Electric / Hydraulic flowchart “Swing Right”

(13) Main control block IV
(20.1 + 20.2) Swing motors
(48) Distribution block
(49.1 + 49.2) Swing brake valve blocks
(A7) Amplifier module – Swing (Y32 + Y32a/b – Block IV)
(A16) Amplifier module – Swing brake
(E50B) Ramp time module – Swing brake
(K165) Relay counter lock (option)
(K253) Relay controlled by swing brake (foot brake)
(ws/gn) Colour code of signal voltage cable ( Joy stick)
(+X) Direction (axis) of joy stick (plus x = right)
(X2F...) Terminal rail with number
(Y32a + Y32b) Directional solenoid valve
(Y127) Proportional valve, controlling pressure increasing valve
The electrical signal.

terminal 5 of the amplifier module (A7) and further via relay K165 K165 (if
equipped) to the proportional and directional solenoid valves of the remote
control blocks (43). In the same time signal voltage of joy stick arrives via
K253 and ramp time module E50B to terminal 5 of the amplifier module A16.
Relay contact 2 / 10 of relay K165 (option) opened if the excavator
superstructure swing in a different direction as the lever direction (counter
look). Relay K253 energized if the swing brake pedal is activated this
eliminate the ramp time function of E50B.
The hydraulic signal. (pilot pressure)
pressure oil flows to the pressure ports of the main control blocks.
Proportional valve Y127 increase proportional to the lever deflection the pilot
pressure to the pressure increasing valves.
The hydraulic oil flow

Now the oil of the main pump 3 flows through the main control block (IV) and
arrives via swing brake valves (49.1 + 49.2) at the swing motors (20.1 + 20.2).
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
8.2
15
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
Page 15
8.2.8 Swing Monitoring System, illustration (Z 21947a)

There are two reasons why the swing monitoring system is installed:
a) ⇒ To prevent adverse effects of a counter action.
b) ⇒ To increase the swing speed, by reducing the swivel angel of the
swing motor (lowering the required oil volume per motor rotation)
Function of the swing monitoring system:

The two sensors B98 and B99, (Proximity switches mounted into a housing
near the ring-gear) sensing the direction of rotation.
How?
Because the distance from sensor to sensor (B) is less than the distance of two
teeth (A), one of the sensors recognizes first a swing action.
The signals of both sensors are used as input signals for the module (E42)
which monitors the swing direction.
The same signals from sensor B99 are send to the module E43 for sensing the
swing speed.
Proximity switch B99 together with module E43 monitors the swing speed to
control via relay K154 and K153 solenoid valve (Y48).
• Activated solenoid valve Y48 allows full X2 pressure to swing motors
(20.1 + 20.2) port X = if the working pressure is less then 280 bar
increasing of swing speed is possible.
• De activated solenoid valve Y48 causes no X2 pressure to swing motor
(20.1 + 20.2) port X = the motors are fixed in maximum swivel angel
(max. volume = max. torque and min. speed)
⇒ Acceleration
During the first acceleration phase the maximum torque by minimum speed is
required, the motors must be in maximum swivel angel (x-port 0 bar). E43
detect the swing speed, if the speed is below 120 Imp./min. relays K154 and
K153 are still de energized and further solenoid valve Y48 de-energized (x-
port = 0 bar = max. motor swivel angel = max torque). After this first
acceleration the required torque and hydraulic pressure droops and the swing
speed increase. E43 detect more as 120 Imp./min and energize relay K154. If
the lever direction and the swing direction is the same K153 energized and
further D153 energized solenoid valve Y48 (x-port = 35 bar = variable motor
swivel angel is possible).
⇒ “ Braking ” with counter position of the lever
If the operator release the lever or move the lever to counter position relay
K153 opened contact 5 / 9 it de energize time relay D153. After the time is
elapsed (one second) solenoid valve Y48 de energize and change over in
neutral position so that pilot line L18 release the pressure to the tank (port X =
0 bar). The swing motors move to maximum swivel angel. Now a maximum
breaking torque is available.
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8.2
16
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
Page 16
8.2.8 Swing Monitoring System, illustration (Z 21947a)
(Study together with the valid hydraulic and electric circuit diagram for the
machine)
Adjustments - Measurements -Settings
a) Distance between Swing ring teeth and the switches B98 and B99
The sensors B98 and B99 are inductive switches with own electronic.
Sensor B98 switches 24V via cable “Sig” to terminal 4 of E42 and
Sensor B99 switches 24V via cable “Sig” to terminal 11 of E42 if a
tooth comes close to the sensor head.
Simultaneously these signal arrives at E43 terminal 4.
Adjust the distance “C” of the sensors B98 and B99 to 5±1 mm.
b) E42 for monitoring the slew direction

E42 is an programmable module which is factory programmed with the
parameters are shown in the electric diagram. Therefore no adjustments
or settings are required.
The indication light (In1 from B98 / In2 from B99) lights/pulses if a
input signal comes up. The indication light (Out1 for swing left / Out2
for swing right) lights if the module indicates a swing direction.
c) E43 for monitoring the slew direction

E43 is an programmable module which is factory programmed with the
parameters are shown in the electric diagram below.
Settings:
E43 (speed monitor) “counter prevention”
No Function nominal setting
1 Setting the start up delay Not used set to “0”
2 Fine setting of the preset value (pulses / min.) 12 imp/min (i.e.120)
3 Setting the hysteresis Not used set to “0”
4 LED: lights when the output relay is energised ---
5 Setting the switching function Set to “III”
6 Coarse setting of the preset value (pulses / min) X x 10 imp/min
If necessary increase or decrease the imp/min with set screw no. 2

until a smooth slew operation is possible.
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
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17
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
Page 17
8.2.9 Checks and adjustments for the swing circuit
) • It is important that the complete MRV-valve and the Pressure

Increasing Valve is firmly (with 300 Nm) tightened.
Otherwise, the internal sealing sealed not properly which results in:
difficulty setting, loud flow noises and abnormal temperatures.
• Whenever pressure checks are carried out, they must be carried out
for both, r.h. and l.h. swing, to make sure the check valves in the brake
valve are in good shape.
• 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 the gauge (0-400 bar) to check point M12.2 at the high
pressure filter units (153.3) of single control block IV.
2. Release the pilot pressure by several movements of the lever with
motor / engine stand still. The key switch S1 must be on the ladder and
service arm must be in up position. Disconnect carefully the pilot
pressure lines from the pressure increasing valves and close the lines
with a suitable plug.
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 engine and let it run with max. speed.
5. Lower attachment to ground and apply house brake (swing parking
brake).
6. Actuate either l.h. or r.h. rotation until the hydraulic system stalls and
increase slowly the MRV-pressure while observing the pressure gauge.
Gauge value must remain at 330 -5 bar. Increase MRV setting
additional 1/8 turn cw..
7. If the gauge shows a lower or higher value the pressure increasing
valves must be adjusted.
continue
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
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18
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Page 18
Cont'd:
High pressure check / adjustment
Pressure Increasing Valve (PIV) high pressure adjustment
Procedure:
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 don’t
increase turn set crew from the last setting max. ¼ turn in (c.w.).
c) Secure by tightening lock nut (1).
d) Loosen lock nut (1) of the second PIV.
e) Adjust pressure with set screw (2) to 330 –5 bar.
f) Secure adjusted set screw (2) by tightening lock nut (1)
g) Loosen lock nut (1) of the first PIV.
h) Adjust pressure with set screw (2) of the first PIV to 330 –5 bar
(lower pressure c.c.w. just as the pressure gauge show a reaction)
i) Secure adjusted set screw (2) by tightening lock nut (1)
j) Re-check pressure setting.
k) Re-set MRV to 310 + 5 bar after the check / adjustment is finished.
Low pressure check / adjustment (Swinging down path (drifting)

(with still disconnected pilot pressure line )
8. Actuate either l.h. or r.h. rotation until the hydraulic system stalls.
a) loosen lock nut (3) at the first PIV and turn out set screw (4)
until 150 +5 bar is reached.
b) Tighten lock nut (3).
c) Loosen lock nut (3) at the second PIV and turn out set screw
(4) until the gauge start lowering the pressure.
d) Re-check pressure setting.
9. Re-connect the pilot pressure line. Proceed like item 2.
) • For later one pressure checks the steps 2 + 3 must not be done.
• The Swinging down path may be extended, means the low pressure
may be decreased a little; e.g. for greater operating radius such as at
strip Mining. But a little only otherwise disturbance due Swinging will
occur.
• The Swinging down path may be shortened, means the low pressure
may be increased approx. 20 bar; but not more because that means
greater shocks in the systems which will shorten the life time of the
components.
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
8.2
19
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Page 19
Cont'd:
Brake pilot pressure - check / adjustment

1. Connect the gauge to the check point M4.
2. Start engine and let it run with max. speed.
3. Depress fully the foot brake pedal and read the pressure.
The pressure must be 19 +3 bar.

Alter the position of the potentiometer R2 of the amplifier A16 as long as the
pressure is 19 +3 bar.
Basic adjustment for A16 see section 5
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
PC5500-6-D_Sec_8-2_rev4.doc 06.10.05
Hydraulic for the travel circuit Section 8.3
Page 1
Section Page
8.3 Travel System
8.3.1 Travel Circuit (Brief description) 2+3
8.3.2 Rotary Distributor 4+5
8.3.3 Side Frame Components 6
8.3.4 Travel Gear and Parking Brake 7
8.3.5 Parking Brake 8
8.3.6 Electric / Hydraulic Flow Chart 9
8.3.7 Adjustment / Checks 10 + 12
PC5500-6-D_Sec_8-3_rev2.doc 06.10.05
8.3
2
PC5500-6-D_Sec_8-3_rev2.doc 06.10.05
Travel System Section 8.3
Page 2
Travel Circuit
(1; 2; 5; 6) Main pumps

(14 / I) L.H. Control block
(16 / III) R.H. Control block
(21.1- 21.4) Travel motors (A2FM 355)
(28.1+28.2) Travel motors valve blocks
(34) Rotary distributor
(40) Suction tank
(46.1+46.2) Double filter
(52.1 + 52.4) Travel gear house brakes
(M12.1 + M12.4) High pressure check points
(M33.1, M33.2) High pressure check points left travel motors
(M33.3, M33.4) High pressure check points right travel motors
Brief description
(Study together with the machine valid hydraulic and electric circuit dia-
gram).
Control circuits, not shown

By the function of the remote control valve (45.1 + 45.3) pilot pressure oil is
sent to one side of each control block (14/I + 16/III) when operating the foot
pedal for travelling "Forward or Reverse“.
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3
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Page 3
8.3.1 Service circuits ( Z22521)
(Study together with the valid hydraulic and electric circuit diagram for the
machine).
The travel motors (21.1 - 21.4) are driven by the pumps (1; 2; 5; 6).
The oil flows from the pumps through check valves and the filters (46.1 + 46.2)
to the control blocks (14 / I + 16 / III).
In neutral position of the spools the oil flows via the return oil lines into the col-
lector tube (35, not shown). From the collector tube (35) flows the oil via the re-
turn oil lines (L6 + L7, not shown) into the collector tube (114) and further to
the tank. On its way to tank the oil must flow through the back pressure valve
(115) or the oil coolers (106.1 – 106.4) and the return oil filter (117.1 - 117.4).
(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 (34) and the valve blocks (175 + 176) to the travel motors (21.1 -
21.4).
The oil flows from the travel motors via the rotary distributor back to the control
blocks and further to tank.
Each travel gear includes two spring loaded multi disk brakes (House brakes)
(52.1 - 52.4). They are used as parking brakes, automatically applied (by the
function of Y16) whenever both motors stoped. The brake release pressure is
monitored by the pressure switch (B48).
The leak oil (case drain) flows through the line (L) and the leak oil filter (108)
back to tank.
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8.3.2 Rotary Distributor
Task:
The rotary distributor (joint) permits a hydraulic connection between the su-
perstructure and the undercarriage, that means between the rotating and the
stationary part.
(1) Rotor
(2) Rotary distributor housing
(3) Cover
(4) Thrust washer
(6) Sealing plunger
(8+9) Seal ring and O-ring
(10) PTFE Sealing
(11) V – Sealing
(12) Rotor guide rings
(13) O-ring
Translations:
Schnitt = Cross section
Versetzt gezeichnet = Offset drawn
Verschlußschraube mit Loctite gesichert = Plug screw sealed with Loctite
mit Körnerschlag gesichert = sealed with punch mark
Kammer mit Fett gefüllt = Chamber grease filled
Ports:
A-D Service lines
L Leak oil
ST Control oil „Travel break“
X Control oil (travel motor flushing)
K1 Track tensioning
K2 Track tensioning
continued
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Page 5
Cont’d.
Function (Z 22522):
During operation superstructure and under carriage rotate towards each other.
The travel oil motors must be supplied with hydraulic oil in every position in
which the superstructure is turned in regard to the undercarriage. Oil is di-
rected 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
and the housing (stator) is fixed by the upper structure. The sealing of the ring
grooves among one another is done by seal rings (8) and o-rings (9).
The hydraulic connection for the travel motor case drain and the travel motor
house brake is done via the ports (L) and (St).
The rotor (1) is at the top and bottom section guided in the housing by the
guide rings (12).
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6
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8.3.3 Side Frame Components, Cross Sections

A Under carriage view from the back side

B Final drive with
C Side frame with top and bottom roller
D Track tensioning cylinder
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7
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8.3.4 Travel Gear and Parking Brake
Function principle ( illustration Z22524a):

The spur gear stage (B) is driven by two hydraulic motors via two drive
shafts (A). This in turn causes that by the shaft (C) the first planetary stage
(D) is driven; opposite the input drive direction.
The planetary gears of the second planetary stage are connected to the hollow
shaft (G).
The drive sprocket is mounted to the hollow shaft (G).
For maintenance see MAINTENANCE MANUAL

For more details see PARTS BOOK.
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8
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Page 8
8.3.5 Parking Brake

The Spring Loaded Multi-disk Brake is used as a safety brake (parking
brake); applied by spring force and released by oil pressure.
Legend:
(1) Disk housing
(2) Piston
(3) Back-up ring with radial seal rings (15)
(4) Bach-up ring
(5) Coupler
(6) Inner disks (lamellas)
(7) Outer disks
(8 + 9) Springs
(10 - 12) O-ring
(13) Clip ring
(14) Clip ring
(16) Release pressure port
(17) Quad-Ring with back-up rings (18)
(19) Quad-Ring with back-up rings (20)
(21 + 22) Plug screw with seal ring
Function:
Brake applied:
The outer disks (7) engaged to the housing by serration and the inner disks (6) in
serration connection with the coupler, are pressed together by the springs (8 +
9). This results in a fixed connection between housing and coupler.
Brake released:
Oil pressure via port (16) reaches the left side of the piston (2) and forces the
piston towards the back-up ring (4), as shown.
This function eliminates the spring force onto the disks thus the brake is re-
leased.
The releasing pressure is 18 bar, the maximum permissible pressure 60 bar.
This brake named "Wet Brake" because the brake housing is filled with gear oil.
For maintenance see MAINTENANCE MANUAL
For more details see PARTS BOOK
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9
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Page 9
Electric / Hydraulic Flow Charts
On the following pages are shown the electric / hydraulic flow charts for the
travel circuit.
The electrical signal created by the foot pedals (E21a and E21b) reach first
of all the ramp modules (E51 and E52) and further the amplifier modules
(A12 and A13). It is a voltage signal from –10 up to +10 Volt dependent to
the pedal deflection and direction. The amplifier modules changes this signal
in a current signal from 0 to 1000 mA and a directional signal (0 or 24 V).
The current signal activate the proportional valve and the directional signal
the directional solenoid valve of the remote control block (45.1 and 45.3).
The valves in case activate the pilot pressure to the main control valve blocks.
This hydraulic signal (pilot pressure) from the remote control valves flow to
the main control blocks (175 and 176) to the pilot pressure ports a1 or b1
which in case push the main control valve spool to control the main hydraulic
oil flow from the main pump.
The main hydraulic oil flows now from the main control blocks via the ro-
tary distributor (34) to the hydraulic motors (21.1 - 21.4).
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10
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Page 10
Adjustments / Checks
) • It is important that the complete MRV-valve is firmly (with 300 Nm)

tightened.
Otherwise, the internal sealing sealed not properly which results in:
difficulty setting, loud flow noises and abnormal temperatures.
High pressure check / adjustment (illustration Z 22528)

1. Connect the gauge (0-400 bar) to the check points M12.1. and M12.4
at the double high pressure filters.
2. Unplug solenoid valve Y16 (Z 22529, filter and valve panel motor 2) to
keep the parking brake applied.
4. Engage carefully desired travel motion and hold foot pedal in final po-
sition to built up max. pressure.
5. Increase * slowly the MRV-pressure while observing the pressure
gauge. Gauge value must remain at 310 +5 bar.
Motor 2
continued
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11
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Cont’d.
If the gauge shows a lower or higher value and to be sure both SRVs are correct
adjusted the SRVs (main valve block and brake valve block) must be adjusted.
) • A faulty anti cavitation valve (32.1; 32.2; 32.13; 32.14) can influence
the SRV pressure reading / setting. In a doubt inspect the valve. Re-
pair or replace faulty valve if necessary.
• A faulty rotary distributor or motor gives the same problems.
Repair or replace faulty part.
Procedure:
6. Set MRV of main valve block I and III to a higher setting (~ 340 bar,
for adjustment use the function “stick extending”
7. Engage carefully desired travel motion and hold foot pedal in final po-
sition to built up max. pressure
8. Adjust* the respective SRV to a higher setting (~330 bar)
9. Connect pressure gauge to check points M33.1, M33.2, M33.3 and
M33.4 at the travel valve block in the car body. The respective high
pressure check point is on the other side diagonal to the SRV.
10. Adjust* the SRV at the desired travel function to 310 bar.
11. Reset the respective SRV at the main valve block to 310 bar, increase
the setting from a lower pressure just to the point when the gauge stop
increasing it should be 310 bar (provided setting from the SRV at the
brake valve is correct).
12. Create max. pump pressure with “stick extending” to the max. position
and re-set MRV to 310 + 5 bar after the check / adjustment is finished
and re-plug solenoid valve Y16
13. Stop enignes.
*
a) Remove dust cap of the SRV (1)
c) Adjust pressure with set screw (3).
d) Secure adjustment by tightening lock nut (2).
e) Re-fit dust cap (1).
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Page 13
Function Check of the Travel Gear House Brake
1. Connect pressure gauge to check point (M6) at the filter and valve
panel motor 2.
3. Read the pressure. Gauge must show common pilot pressure (norm.
35 + 1 bar). If not check the pilot pressure. If the pressure is below
24 bar, the text display must show „Travel gear house brake ON“.
4. Operate the travel foot pedals, the machine must travel.
In case the machine doesn’t travel the text display must show
„Travel gear house brake ON“
5. Unplug solenoid (Y16) and operate the travel foot pedals, the ma-
chine must not travel.
The text display must show „Travel gear house brake ON“
) • In a case of malfunctioning check the electrical controlling and the

solenoid valve Y16.
Function check of the pressure switch (B48)

1. Connect pressure gauge to check point (M6).
2. Start one motor. The gauge must show common pilot pressure (norm.
35 + 1 bar).
3. Set pilot pressure relief valve (70.2) to 22 bar X2 pressure.
4. Unplug solenoid valve Y16 to allow pressure release from the pres-
sure line of the house brake.
5. Reconnect solenoid valve Y16.
The text display must show „Travel gear house brake ON“
6. Increase the pilot pressure up to 26 bar
„Travel gear house brake ON“ must disappear
If not check the pressure switch B48 and exchange it if it is out of
the range.
7. Reset pilot pressure to 35 bar
PC5500-6-D_Sec_8-3_rev2.doc 06.10.05
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Hydraulic Track Tensioning System Section 9.0
Page 1
Section Page
9.0 Hydraulic Track Tensioning System
General 2
9.1 Functional description 3+4

9.2 Pressure Increasing Valve 5
9.3 Tensioning Cylinder 6
9.4 Adjustments / Checks 7–9
9.5 Functional test 9
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2
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Page 2
9.0 General:

(62.1 – 62.4) Track tensioning cylinders
(M15.3 + M15.4) Bleeder and hydraulic pressure check points at the
R.H.- tensioning cylinders.
(M15.1 + M15.2) Bleeder and hydraulic pressure check points at the
L.H.- tensioning cylinders.
(M15.5) Bleeder and hydraulic pressure check point at the bladder
accumulator (59.1) for the L.H.-side.
accumulator (59.2) for the R.H.-side.
(60.1 + 60.2) Membrane accumulator, 1,3 liter (pre-charge pressure 31bar)
(54.2) Service shut-off cock for the L.H.-side
(54.3) Service shut-off cock for the R.H.-side
* "O" = open - "C" = closed
(59.1 + 59.2) Bladder accumulator, 5 liter (pre-charge pressure 150bar)
(34) Rotary joint
L3 (St) Supply line from solenoid valve Y16 over rotary joint port St
The hydraulic track tensioning system ensures automatically the correct track
tension.
The pilot pressure pumps (7.1+7.2, see hydraulic diagram page 02) will supply
oil to all four tensioning cylinders (62.1-62.4).
The maximum pressure is limited by the pressure increasing valve (182), one
for both sides.
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 (60.1 + 60.2, first stage) and (59.1 + 59.2, 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 22454:
) Under normal operating condition the shut-off cock (54.1) located on

the valve block (181) in the car body are closed. The shut-off cock
(184) located on the valve block (181) in the car body and (54.2 and
54.3) located inside the side frames are open.
The oil flow of the pilot pressure pumps (7.1 + 7.2), filtered by pressure filter
(68.1) enters port "P" of the solenoid valves Y16 via hydraulic line L3 and
the rotary joint to the track tensioning valve block (181) in the car body.
If solenoid valves Y16 is actuated (i.e. pressure at sensor B48), the oil flows
(X2-pressure with 35 bar) via the pressure relive valve (83), rotary joint (34), the
shut-off cock (184) and check valves (180.1+180.2) into the tensioning cylinders
(62.1 - 62.4).
The resulting force moves the guide wheels toward the front, until the correct
track tension is obtained.
Simultaneously the system is connected to the pressure increasing valve (182).
External forces acting at the guide wheels will be absorbed through the pressure
accumulators (60.1 + 60.2, first stage) and (59.1 + 59.2, second stage).
Purpose of the pressure increasing valve

The two system pressures
• 35 bar with motors stopped
• 315 bar with motors running
are controlled by the pressure increasing valve as follows.
With stopped motors and switched off ignition there is no pilot pressure (X2) at
the pressure increasing valve (182) and only the lowest adjusted pressure of 35
bar remains in the system.
As soon as one motor has been started, the pilot pressure (X2) of 35 bar act
on the pressure increasing valve. As a result the system pressure can rise to
the adjusted pressure of 315 bar.
continued
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9.0
4
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Page 4
Cont'd.:
9.1 Functional description:
Illustration (Z 22454):
Cushioning Function
When the tensioning cylinders (62.1 - 62.4) are moved in by external forces,
the none return valves (179.1 + 179.2) 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, is taken up by the side frame
accumulators (60.1.1 + 60.2).
Second stage: at a pressure higher than 150 bar, is taken up by the center section
accumulators (59.1 + 59.2).
The system pressure can rise up to 315 bar pressure increasing valve (182)
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 (X2), as soon as the pressure in the
lines to the tensioning cylinder is lower than 35 bar.
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9.0
5
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Page 5
9.2 Pressure Increasing Valve
) The pressure increasing valve is a remote controlled pressure relief

valve.

(1) Pilot valve with valve seat
(2) Valve poppet
(4) Main valve with sleeve
(5) Main piston
(6) Closing spring
(7) Set screw - low pressure 35 bar
(8) Set screw - high pressure 310bar
(9) Piston
(10) Pin
(11+12) Jet bore
(13+14) 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); one
turn of the screw ~ 150 bar. The possible max. pressure setting with the set
screw (8) on block is about 440 bar.
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9.0
6
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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
(6) O-ring
(7) Scraper
(8) Retracting device
(M) Bleeder port
(P) Oil supply
• Maximum permissible piston stroke 350mm!

During bench test an external stroke limitation must be used!
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9.0
7
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Page 7
9.4 Adjustments / Checks

(182) Pressure increasing valve
(54.3) Service shut-off cock for the R.H.-side
(54.2) Service shut-off cock for the L.H.-side (not illustrated)
(59.2) Bladder accumulator 150 bar
(60.2) Accumulator 31 bar
(MRV) Main relief valve – Operating pressure of main control
block I
(M12.4) Pressure check point – Operating pressure of main control
block I
accumulator (59.2) for the R.H.-side.
accumulator (59.1) for the L.H.-side (not illustrated).
(M15.3) Pressure check point - track tensioning system
operating pressure – R.H.
(62.3+62.4) Track tensioning cylinder R.H.
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. Connect a pressure gauge (min.400 bar) to check point M12.4.
2. Start one motor.
3. Increase the MRV-setting (Block I), ~ 330 to 340 bar.
4. Switch OFF the motor, open cock valve (54.1) to allow pressure
relieve of the R.H. track, and close it again.
continued
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9.0
8
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Page 8
Cont'd.:
5. Move the pressure gauge from M12.4 to M15.3

6. Connect pressure check point M12.4 with pressure check point M16.1,
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 (182) and close the hose (P) ith a plug.
8. Loosen lock nut (4) of the pressure increasing valve and screw in set
sleeve (5) until piston (1) comes to stop. (substitution of X2 pressure)
9. Start one motor.
10. Stall the hydraulic with the bucket filling function (bucket cylinders
completely extended) and observe pressure at check point M15.3.
A pressure of 315 + 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 58.2)
a) Loosen lock nut (2).
b) Adjust pressure with set screw (3).
c) Secure adjustment by tightening lock nut (2).
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 58.2)
a) Stall the hydraulic with the bucket filling function (bucket
cylinders completely extended) and observe pressure at check
point M15.3.
b) loosen lock nut (4) and turn set screw (5) ccw until gauge at
check-point M15.8 shows 35 bar.
c) Tighten lock nut (4).
continued
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9.0
9
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Page 9
Cont'd.:
12. Switch OFF the motor and open cock (54.1) to allow pressure relieve.
13. Re-connect the pilot pressure line to port X of the pressure increasing
valve (182).
13. Remove the pressure gauge hose between pressure check point M12.4
and pressure check point M16.1.
15. Close the cock (54.1).
16. Re-set MRV to 310 + 5 bar after the check / adjustment is finished.
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 (M15.3).
d) Start both motors.
e) Travel approx. 10 m with the shovel. The pressure should be rise to a
higher value.
f) Stop the motors.
g) The pressure must drop to 35 bar.
If the pressure remains at a higher or lower pressure*, re-adjust the low

pressure setting at the pressure increasing valve (182) is necessary.
) * The pressure may drop below 35 bar after a longer time, this is o.k.
because of internal leakage.
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Access ladder Section 10.0
Page 1
hydraulically operated
Section Page
10.0 Access ladder hydraulic operated
10.0 General 2
10.1 Function of hydraulic operated access ladder 3+4
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10.0
2
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Page 2
10. Access ladder hydraulic operated

General
legend for Illustration Z22494

(A) Access ladder in lowered position
(B) Access ladder way to upper position
(C) Stop bar
(Z) Hydraulic cylinder
(S84) Ladder control switch “up”
(S84B) Ladder control switch “down”
(S84A) safety switch operated from ground level for lowering (pull switch)
(S22) Control sensor : Cut off the pilot control system and actuation of the
slew brake with ladder in lowered position.
(S91) Monitor and control sensor: It monitors the ladder position and
controls the moving speed of the ladder. In case the sensor (S22)
fails, the sensor (S91) prevents unintended movement of the ladder .
The access ladder is hydraulic driven by the hydraulic cylinder (Z) via the 60
bar X4 pressure. S84 is the control switch to move the ladder up and down.
The additional pull switch S84A move the ladder only down from the ground.
To lower the ladder the motor can run or stand still. Only to move the ladder
up the motor must running.
) If the ladder is out of the upper position the pilot control system
switches off (all machine movements stoped) and the solenoid valve
Y120 activates the service swing brake. The text display in the cab
shows a message.
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10.0
3
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Access ladder Section 10
Page 3
10.1 Function of hydraulic operated access ladder

Legend:
(7.1+7.2) Pumps
(84.1+84.2) Check valves
(68.1) Filter with filter monitoring switch B22
(70.1) Pressure relieve valve (60 bar)
(70.2) Pressure relieve valve (35 bar)
(162.3 – 5) Check valves
(171) Pressure relieve valve (70 bar)
(174) Ladder cylinder
(172) Orifice
Y125 Solenoid valve: lower speed limit
Y123A Solenoid valve: ladder up
Y123B Solenoid valve: ladder down
The motor is running

Additional to the hydraulic diagram Z22495 use the electric diagram on next
page
The pumps (7.1) and (7.2) are delivering oil through filter (68.1) to port P of the
solenoid valve Y123A/B and the pressure relief valve (70.1) port A. The pressure
relief valve (70.1) maintains the adjusted pressure of maximum 60 bar.
Solenoid valve Y123A/B lead pump oil to the cylinder if one of the solenoids is
energised. Depend on the activated solenoid valve the ladder move up or down.
The pressure relief valve (171) limits the pressure of the ladder cylinder to max.
70 bar.
Return oil from the cylinder flows back via solenoid valve Y123A/B to the
solenoid valve Y125. With energised solenoid this valve lead back oil unhindered
to the oil tank It is energised when both approximately switch S22 and S91 are not
activated (ladder between upper and lower end position). A short way before the
ladder reached one of the end positions one sensor (S 22 – in up position; S 91 –
in down position) switch on and de energise Y125. Now back oil must pass the
orifice (172). By the flow resistance of the orifice the ladder motion will be
slowed down.
If the ladder is in the “Up – position” the activated sensor S22 de-energised Y125
and energised Y123A, now the still connected pump pressure to the cylinder
piston side keep the ladder in the final up position.
If switch S84 is in neutral position and the ladder in “down – position” sensor S91
de-energise all solenoids (Y125; Y123 A+B) and the ladder is “blocked”.
continued
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10.0
4
17.01.07 PC5500-6-E_Sec_10-0_rev0.doc
9 Page 4
Cont'd:
The motor is out and the ladder is in the “Up – position”
With activated switch S84 to position 2 (ladder down) solenoid valve Y123B
and relay K132 are active. Y123B opened the piston side of the cylinder to
the tank and K132 activate Y125 that the oil can flow without resistance to
the tank. Now the ladder can move down only by its own mass (gravity). The
operator have 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 (162.3).
It is no key contact necessary this function is direct supplied to the battery via
fuse F17.
There is an additional pull switch S84A below the ladder support. With this
switch 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 can be the result.
17.01.07 PC5500-6-E_Sec_10-0_rev0.doc
17.01.07 PC5500-6-E_Sec_10-0_rev0.doc
Section 11.0
Cable drum
Page 1
Section Page
11.0 Cable drum
11.0 General 2
11.1 Components 3
11.2 Function
11.2.1 Controlling of the drive motor 4
11.2.2 Travel motion control 5
11.3 Checks and Adjustments 6
11.4 Description and operating instruction for cam switch 5S4 and 5S6 7
PC5500-6-E_Sec_11-0_rev0.doc 17.01.07
11.0
2
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Section 11.0
Cable drum
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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Section 11.0
Cable drum
Page 3
11.1 Components
(5M6) Brake motor
(5S1) Service switch for manual actuation of cable drum.
(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 de-energizes K178).
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).
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 limit switch 5S7* stops forward travelling by de-energizing K177 as soon as the safety
cable length on the drum gets unwinded.
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
PC5500-6-E_Sec_11-0_rev0.doc 17.01.07
11.0
4
PC5500-6-E_Sec_11-0_rev0.doc 17.01.07
Section 11.0
Cable drum
Page 4
11.2 Function
(5M6) Brake motor
(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: ½Max. – Max. => 5K10 ON + 5K11 ON => max. torque
Cable length on drum: Min. – ½Max. => 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.
PC5500-6-E_Sec_11-0_rev0.doc 17.01.07
11.0
5
PC5500-6-E_Sec_11-0_rev0.doc 17.01.07
Section 11.0
Cable drum
Page 5
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 Travel response
Solenoid valves
Switch / contacts
1. Too tight 5S6 / 11–12 K177 Y20b + Y28b crawler left + crawler right
forward motion stopped
2. Too slack 5S6 / 21–22 K178 Y20a + Y28a crawler left + crawler right
reverse motion stopped
3. Too strong deflection to the left 5S8 / br–sw K179 Y20a crawler left
4. Too strong deflection to the right 5S9 / br–sw K180 Y28a crawler right
5. Maximum permissible cable 5S4 / 31–32 K178 Y20a + Y28a crawler left + crawler right
length on the drum
6. Safety cable winding unwinded 5S4 / 11–12 K177 Y20b + Y28b crawler left + crawler right
forward motion stopped
7. Ground contact 5S10 and/or 5S11 K178 Y20a + Y28a crawler left + crawler right
) 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.
PC5500-6-E_Sec_11-0_rev0.doc 17.01.07
11.0
6
PC5500-6-E_Sec_11-0_rev0.doc 17.01.07
Section 11.0
Cable drum
Page 6
11.3 Checks and Adjustments

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.
(5S7)
(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.
(F79) Motor temperature control unit with monitoring LED’s.
(R) – red LED on => motor temperature to high.
(G) – green LED on => permissible temperature range.
Hysteresis:
Rcold ≤ 1kΩ, Rswitch point ≥ 3kΩ (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
PC5500-6-E_Sec_11-0_rev0.doc 17.01.07
11.0
7
PC5500-6-E_Sec_11-0_rev0.doc 17.01.07
Section 11.0
Cable drum
Page 7
11.4 Description and operating instruction for cam switch 5S4
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.
PC5500-6-E_Sec_11-0_rev0.doc 17.01.07
PC5500-6-E_Sec_11-0_rev0.doc 17.01.07
Hints for reading the Section 12.0
Page 1
Hydraulic Circuit Diagram
Section Page
12.0 Hints for reading the hydraulic circuit diagram
General 2
12.1 Symbols 5
12.1.1 Lines, unions 5-6
12.1.2 Components, valves 7
12.1.3 Sensors 8
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
04.01.07 PC5500-6_Sec_12-0_rev3.doc
12.0
2
04.01.07 PC5500-6_Sec_12-0_rev3.doc
Page 3
12.0 General:
Legend for Illustration Z22987
) •
•
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.
Item Description Number / Code Explanation
A Diagram No. and Type of the 897 895 40 a Diagram No. only for the
respective machine PC8000-E respective machine
B Respective Serial No. 12041
C Sheet-No. / Quantity of sheets 01 / 04 1st of four sheets
D Co-ordinates to describe the 1 C 10 Page 1 on co-ordinate C vertical
location of a component and 10 horizontal Remote control
valve 102.1
E Component-No. 127 127 Main control block I
F Line-No. with cross hint, L37/3B9 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
04.01.07 PC5500-6_Sec_12-0_rev3.doc
12.0
4
04.01.07 PC5500-6_Sec_12-0_rev3.doc
Page 5
12.1 Symbols
12.1.1 Lines, unions
Symbol Description Used as / at / on
1 Oil supply line, can be a Suction line or pressurized
hose or a pipe. line of main hydraulic circuit
or pilot pressure circuit or
auxiliary circuits (e.g. fan
drive).
2 Return oil line, can be a Return lines, connected to
hose or a pipe. the return oil filter chamber
3 Case drain (leak) oil line, Return lines, connected to

can be a hose or a pipe. the case drain (leak) oil filter
chamber of the main oil
reservoir.
4 Control oil line, can be a Pilot control line, pump
hose or a pipe. regulation line and parking
brake control lines.
5 Crossed lines Pipes or hoses not

connected
6 Connection point, is a Connection between

connection of hydraulic several lines
lines without definite
position
7 Component connection Connection to components
point, is a connection with like, valve blocks, tanks,
a definite position at a pumps, ...
component
8 Plugged connection point, Not used connection
can be plugged with any points.
kind of plugs.
9 Plugged line inside of a Not used connection

manifold, can be plugged points.
with different kind of plugs.
04.01.07 PC5500-6_Sec_12-0_rev3.doc
12.0
6
12.1 Symbols
12.1.1 Line, union

10 Compensator, Oil tank outlet to the
Compensate line length pumps
differences depend on
vibration and temperature.
11 Quick coupling, Tank drain couplings, often
is a special union with removed lines (e.g. at grease
integrated check valve systems with removable
barrels).
12 Blind, Orifice, e.g. Oil cooler inlet,
not adjustable with
orifice diameter in mm
13 Pressure check point HP Filter, Fan valve

With a special quick block....at all important
coupling. circuits
14 Distributor block Connection of lines with

the same destination e.g.
return lines to tank
04.01.07 PC5500-6_Sec_12-0_rev3.doc
Page 7
12.1 Symbols
12.1.2 Components, valves

15 Accumulator, Input line to the remote
is filled with nitrogen gas control valves, return oil
with for the respective collecting tube, track
accumulator specified tensioning system
pressure
16 Screen filter, Installed in suction lines to
the screen size is 1.0 mm the pumps, oil tank outlet,
return oil collecting tube
17 Oil cooler, Hydraulic oil cooler,

PTO oil cooler
18 Breather filter, On top of PTO or

hydraulic tank
19 Spray nozzles, Gearbox (PTO) cooling

inside of a case for and lubricating system
cooling and lubricating
continued
04.01.07 PC5500-6_Sec_12-0_rev3.doc
12.0
8
12.1 Symbols
12.1.3 Sensors
20 Pressure switch / sensor e.g. return / leak oil
Input = pressure chamber (digital), high
Output = electrical signal pressure filter (analogue)
analogue or digital
21 Pressure switch e.g. swing or travel

Input = pressure detection PC3000,
Output = digital electrical
The switch point is 24 bar
22 Temperature sensor, e.g. hydraulic tank

Input = temperature
Output = electric signal
proportional to the
temperature
23 Level sensor, Hydraulic tank, fuel tank

Input = fluid level
Output = electrical signal
analogue or digital
24 Chip sensor, Main pumps

Input = contaminate oil
Output = electrical digital
signal
04.01.07 PC5500-6_Sec_12-0_rev3.doc
Page 9
12.1 Symbols
12.1.4 Valves, valve components

25 Manuel operated unit Valve in track tensioning
Lever system,
26 Electric / magnetic Solenoid valve

operated unit
Solenoid
27 Pilot pressure Pressure relief valve, disc

controlled unit brake, ...
28 Spring, Solenoid valves,

with fixed force
29 Spring adjustable Pressure relieve valves,....

spring force is adjustable
30 Check valve e.g. main pump outlet,

In drawn pos.: from right swing brake valve block,
to left free flow, from left anti cavitation valves at
to right blocked flow. main control blocks or
distribution manifold
31 Check valve spring By pass of the return oil
loaded filter, by pass of
Opened in flow direction secondary filter
only against spring force
= pressure
32 Double check valve, Swing brake control,
in drawn pos.: opened
only from the left to the
bottom or from the right
to bottom
04.01.07 PC5500-6_Sec_12-0_rev3.doc
12.0
10
12.1 Symbols
12.1.4 Valves, valve components

33 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 Track tensioning system

manual operated,
2/2 cock valve
35 3/2 control valve Change over valve from

manual operated, electronically pump
3/2 cock valve regulation to emergency
mode (hydraulically
pump regulation)
36 4/2 directional control valve e.g. swing parking brake,
as solenoid valve travel parking brake,
4/2 way solenoid valve, ladder controlling,,
electrically controlled.
Neutral position:
P-A and B-T connected.
37 Variable throttle valve Travel brake valve,
hydraulically controlled located in the car body
pilot control port pressure
less = maximum restriction
38 3/2 directional control Service arm controlling
solenoid valve, seat
design = leak oil free
3/2 way solenoid valve,
neutral = port P-A open
39 4/3 directional control Ladder controlling,
solenoid valve service arm controlling
4/2 way solenoid valve,
in neutral all ports closed
40 External pilot PC 3000 and PC4000
controlled proportional with floating system
floating valve
04.01.07 PC5500-6_Sec_12-0_rev3.doc
Page 11
12.1 Symbols
12.1.4 Valves and valve components

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 Control valve for pressure

“pressure less lowering” less lowering. Used to assist
Neutral position: open pump the floating function of boom
flow (P-PU), control port and stick,
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
43 Main control valve “floating Control valve with floating
function” function in position a,
Neutral position: open pump e.g. floating valve for boom
flow (P-PU), control port or stick, .
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
44 Pressure reducing valve, Emergency mode
assembly pressure (X3-pressure),
Variable inlet pressure at port pilot oil pressure
B and constant lower output
pressure at port A, output
pressure is adjustable.
04.01.07 PC5500-6_Sec_12-0_rev3.doc
12.0
12
12.1 Symbols
12.1.4 Valves and valve components

45 Pressure relief valve, e.g. ladder controlling,
direct controlled and service arm controlling ..
adjustable
46 Pressure relief valve Secondary relieve valve

with anti cavitation at main control blocks
valve (check valve)
Assembly, external drain
at port Y
47 Pressure increasing valve Swing brake block, track

pressure relieve valve with tensioning system.
variable setting, pilot
pressure controlled via port
X. Low pilot pressure = low
relieve pressure
48 Proportional pressure Remote control valves to

valve, reduce the control the main control
pressure in port A blocks,
proportional to the
solenoid current.
49 4 port proportional Pump regulation, only
pressure relief valve, output port A is used for
direct operated by a our systems
proportional solenoids.
50 Pressure relief valve, Radiator and oil cooler

mechanical and fan drive
hydraulically via pilot
port X adjustable, oil
drain port Y
51 Throttle check valve Distribution manifold
with secondary relieve normally in the line to the
valve, throttle and cylinder piston side.
secondary valve
mechanical adjustable,
external drain at port Y.
04.01.07 PC5500-6_Sec_12-0_rev3.doc
Page 13
12.1 Symbols
12.1.5 Pump, motor, cylinder

52 Single acting Cylinder, Track tensioning system
pressurised moving only
in one direction, return by
external force
53 Double acting Cylinder, Attachment i.e. boom,

Cylinder in which the fluid stick, bucket or clam
pressure operates alternately cylinder
in both directions (forward
A B and backward strokes)
A = Piston side
B = Rod side
54 Drive shaft of a motor Main pumps, swing
or pump with one motor, fan drive, travel
direction drive
55 Hydraulic pump with fix Fan pump, circulation

volume per revolution pump, pilot pump, PTO
suction port S and pressure lubrication pump
outlet P
56 Hydraulic pump with Main pumps

variable output volume
per revolution
with external case drain
57 Hydraulic pump Main pumps

assembly
with pump bearing
lubrication, one direction
and external case drain
04.01.07 PC5500-6_Sec_12-0_rev3.doc
12.0
14
12.1 Symbols
12.1.5 Pump, motor, cylinder

58 Variable hydraulic Main pump
pump with charge
pump
and external drive shaft
bearing lubrication
59 Hydraulic motor Fan motor

can be used in both
direction, with external
case drain L
60 Motor with disc brake Travel motor

disc brake is spring
loaded it means:
pressure less pilot line =
maximal brake torque
61 Variable swing motor Swing motor PC5500

with integrated control
valves and flushing
valves
04.01.07 PC5500-6_Sec_12-0_rev3.doc
Page 15
12.1 Symbols
12.1.6 Assembly and main components

62 Lubricant pump drive Lubricant pump station
differential cylinder with for central lubrication
integrated control valves system and swing ring
to propel the grease pump lubrication system
63 Swing brake valve Swing brake system.

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..
64 Rotary joint Hydraulical connection

Upper part with between superstructure
connections drawn to and car body
the top, lower part with
connections drawn to
the bottom
65 Travel brake valve block mounted in the supply

with secondary pressure line to the travel motors,
relieve valve is located in the car body
is connected in the line to
the travel motors. The
return oil flow is restricted
according to the pressure
inlet.
04.01.07 PC5500-6_Sec_12-0_rev3.doc
12.0
16
12.1 Symbols
12.1.6 Assembly and main components

66 Remote control lever to Control lever in the
control the main control operators cabin
blocks
67 Remote control pedal to Control lever in the

control the main control operators cabin
blocks
68 Hydraulic oil tank with Main hydraulic tank

leak and return oil filter,
back pressure valve and
sensors
04.01.07 PC5500-6_Sec_12-0_rev3.doc
Page 17
04.01.07 PC5500-6_Sec_12-0_rev3.doc
Page 1
Electric Circuit Diagram
Section Page
13.0 Hints for reading the electric circuit diagram
13.1 Designation of electrical devices 2

13.2 Symbols 3+4
13.3 General information 5+6
13.4 Reading a circuit diagram 7+8
13.0
2
Page 2
13.1 Designation of electrical devices
Indicating letter Kind of component

A System, subassembly, parts group, trigger boxes, control units
B Transducer for conversion of non-electrical variables to electrical
variables, and vice versa.
Speed sensors, pressure sensors, pressure switches, oil-pressure
switches, temperature sensors
C Condenser, capacitor, Condensers and capacitors, general
D Elements with time lag, memory elements, binary elements
E Various devices and equipment
F Protection device
Fuses, current protection circuits
G Power supply, generator
Batteries, generators, alternators
H Monitor, alarm, signaling device
Indicator lights, signal lights, headlights, warning buzzers, horn
K Relay, contactors
L Inductor
Coils, windings
M Motor
N Regulators, amplifiers
P Measuring instrument
Q High voltage switching units
R Resistors, heating devices
S Switches, selectors
T Transformer
U Modulator, converter from one electrical in an other electrical value
V Semiconductor, electron tubes, diodes, rectifiers, zener diodes
W Transmission path, conductor, antenna
X Terminal, Plug, Plug and socket connection
Y Electrically actuated mechanical device
Solenoid-operated valves
Z Compensating units, filters, limiters cable connection
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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 2) Maintained 3) Single pole

contact contact two way contact
break before make
4) Normally 5) Push-button 6) Limit switch
closed contact switch NO contact
NC contact
7) Manual operated 8) Foot-operated 9) Pressure
switch isolator, push-button operated switch
disconnect switch switch
10) NO contact with 11) Multi-position 12) Indicating
time lag switch selector instrument
(general) symbol
13) Contacts with 14) Resistor 15) Ammeter
time lag general
16) Battery 17) Tapped 18) Voltmeter

resistor
19) Inductive 20) Continuously 21) Recording

resistance adjustable, instrument
general
22) With iron core 23) Adjustable in 24) Signal lamps

steps pilot lights
25) Continuously 26) Potentiometer 27) Operating coil

adjustable rhesostat solenoid
28) Transformer 29) Capacitor 30) Rectifier, semi

general, conductor
continuously
adjustable
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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 44) Generator (G)- 45) Terminal

phase Motor (M)
46) Thermal over- ground, 47) 3-phase-motor 48) Earthing, general

load protection
49) Magnetic over- socket 50) 3-phase squirrel cage

current protection
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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13.3 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 = X2-Board, terminal group “S” Y136 = Plug connector to solenoid

45 = Terminal No 45 .1 = Terminal 1 of connector
All circuits are shown currentless and all relays and switches are in neutral position.
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13.3 General information
Explanation of the Drawing Concept
(1) Drawing number

(2) Sheet number / quantity of sheets
(3) Designation of drawing
(4) Designation of component or assembly
(5) Column (vertical sections)
(6) Lines (horizontal sections)
(7) Component symbol
(8) Neutral wire / machine ground
(9) Designation of phase
(10) Phase strip
(11) Terminal strip and terminal
(12) Cable plug and pin number
(13) Relay coil
(14) Relay contacts, partially with detailed information
(15) Cross reference for the continuation, Page / Column
(16) 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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13.4 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:

1 9
08.5 5 opens on sheet 8 section 5 when relay is energized
2 10
: 6 Not used
3 11
: 7 Not used
4 12
: 8 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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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 = Circuit breaker (24V power supply)
b. F11 / 10.5 = Power line F11, comes from circuit breaker F11, sheet
08 section 8 and continues on sheet 10 section 5.
c. S27 / 20.7 = Line S27, comes from switch S27, sheet 08 section 1
and continues on sheet 20 section 7.
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.
Electronic Control System Section 14.0
ECS Page 1

Section Page
14.0 Electronic Control System ECS
14.1 General Design of the ECS-T System 2

14.1.1 Input and outputs of the PLC 3
14.1.2 Task 3
14.1.3 PLC DIGSY plus ® 4
14.1.4 Definitions; Symbols and Abbreviations 5 + 6 +7
14.2 How to Proceed due Maintenance and Installation 8+9

14.2.1 Meaning of the Status LED’s 10 + 11
14.2.2 Short Circuit Marker -LED “MK” 12
14.2.3 Diagnostic for Temperature-Module “ANM” 13
14.3 Front Connector Arrangement 14

14.3.1 Front Connector Arrangement BIM-Module 14 + 15
14.3.2 Front Connector Arrangement, ANM-Module 16 + 17
14.3.3 Ground connection of the Control Unit 18
14.3.4 Interface-Connection COM SP /SK 19
14.4 Power supply 20

14.4.1 Operation Voltages +24 V 20
14.4.2 Safety Precautions for Faultfinding 21
14.4.3 CPU Voltage Range 22
14.4.4 Electric Classification 22
14.4.5 Fuse 22
14.5 Function explanations with electrical diagram 23

14.5.1 General 23
14.5.2 Pressure Measuring 24
14.5.3 Temperature Measuring 25 + 26
14.5.4 Temperature – Resistance Chart PT100 27
14.6 Hints for reading the functional flow charts 28

14.6.1 General 28
14.6.2 Example 29
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14.1 General Design of the ECS System
ECS Electronic Control System
Legend: Illust. Z 21407a
(1) PLC Programmable Logic Control (DIGSY plus ®)

(2) Text display
(3) Keys for function control and pre-adjustments
(4) Outlet “X27” for data transfer
(5) Field computer system (like MODULAR MINING)
(6) Printer
(7) Memory card unit
(8) Laptop
I/ O 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
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3
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14.1.1 Input and Output of the PLC, Illust. Z 21408
PLC = Programmable Logic Control

(Programmable Logic Control = Control system with a write-reading-
memory, 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.
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4
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14.1.3 PLC DIGSY plus ® (circuit diagram code E6)
Legend for illustration Z 21409b

1. Central Processing Unit (CPU) board.
2. Binary Module (BIM) board.
3. Analogues Module (ANM) board.
4. MK Output short circuit marker LED red
5. Input state-LED green, Inputs E1.1 - E1.8 up to E14.1-E14.8
6. Input or Output State-LED red (A2/ E9, Af/E10, A6/E11,
A8/E12, A14/E21) Can be used as Inputs or Outputs
7. Output state-LED red, Output A1.1 - A1.8 up to A13.1-E13.8
8. Diagnostic-LED (DIAG), (green flashing = OK.)
5Volt Voltage-LED (+5V), (green = OK.)
9. Diagnostic LED for ANM
10. COM SP Interface (COM SP) (Text display connection)
11. COM SK Interface (COM SK) (PC-Connection)
12. Binary Module BIM-plug-in location (slots) (X1-X5)
13. Analogous Module ANM-plug-in location (slots) (X6-X8)
14. 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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14.1.4 Definitions; Symbols and Abbreviations

≡ Sign used for “corresponds to”
≠ Sign used for “not equal to”
Bit 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 metal-

oxide 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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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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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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14.2 How to Proceed due Maintenance and Installation
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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14.2 How to Proceed due Maintenance and Installation

Cont’d.:
• 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
m • 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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14.2.1 Meaning of the Status LED’s, Illust. Z 21431b
The DIGSY plus performs by the function of the Status LED’s (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 Remedy
5 V-LED Voltage
green o.k.
5 V-LED CPU not working Supply Check the
red (RESET) < 4,65V +24 V Supply
DIAG-LED red if not o.k. *)
5 V-LED CPU not working Supply Check the
OFF (except the is missing +24 Volt
LED is defect)
Fuse S1 Replace the **
defect Fuse F1
LED defect *)
(if DIAG
LED is ON)
others *)
5 V-LED
flashing
red/green cyclically Watchdog *)

new starts in operation
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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11
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14.2.1 Meaning of the Status LED’s, Illust. Z 21431b

Cont’d.:
Table: State of the DIAG-LED and their meaning
LED Effect Cause Remedy
DIAG-LED Program Communication via Check the cable
green in operation Interface COM-SP connection and the
not active Interface port
(interrupted)
COM-SP<╪> Text
display
DIAG-LED Program- Temperature External cooling
orange state inside housing
unchanged too high
+24 VCPU < 14 V Increase the voltage
Accumulator voltage Replace the
too low accumulator module
Fixed operands Check the
deleted accumulator
connections
SPS in start loop wait
after voltage ON
programming in Stop the
operation programming *1)
DIAG-LED Program EEPROM not Initialize
RED not running (stopped) Initialized EEPROM *1)
EEPROM- or Initialize
RAM- fault EEPROM *1)
if the fault is
still present *2)
DIAG-LED Program Program Start program *1)
OFF not running stopped
(except LED
defect) No Program Load program *1)
otherwise LED
defect *2)
DIAG Program- Communication via
flashing state Interface COM-SP
unchanged or COM-SK active
Color State COM-SP⇔ Text
depending Display
COM-SK⇔ (PC)
*1) Function of the Programming Software PROSYD
*2) = Return PLC to manufacturer
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14.2.2 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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14.2.3 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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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 Symbol Operand Definition

1 Input 1.1 E 1.1 Input 1 of the input group. 1
2 Input 1.2 E 1.2 Input 2 of the input group. 1
3 Input 1.3 E 1.3 Input 3 of the input group 1
9 Input 9.1 E 9.1 Input 1 of the output group 2
17 0 V (GND) Ground
18 Input 2.2 E2.2 Input 2 of the input group 2
continued
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14.3.1 Front Connector Arrangement, BIM Module (Digital Input / Output)
Cont’d.:
Pin Symbol Operand Definition
22 Output 1.1 A 1.1 Output 1 of the output group 1
29 Output 1.8 A1.8 Output 8 of the output group 1
30 UE/A Under Load Voltage UE/A =
31 UE/A Under Load Voltage Voltage.
32 UE/A Under Load Voltage Input / Output
33 UCPU DIGSY (plus)- Operation Voltage
41 Output1.4 A 1.4 Output 4 of the output group 1
42 Output1.5 A 1.5 Output 5 of the output group 1
45 Output 1.8 A1.8 Output 8 of the output group 1
46 UE/A Under Load Voltage
49 UCPU DIGSY (plus)- Operation Voltage.
50 0 V (GND) Ground / GND
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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14.3.2 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 EA-
Configuration chart (EA-Belegungsliste) see Appendix and the
respective electric diagram.
PIN PIN-NAME OPERAND COMMENTARY

1 KR Relay contact
2 KG Relay contact
3 KA Relay contact
4 GND/ANA Analogous GND
8 A1I AW Z.1 Current output 1
9 A1U AW Z.1 Tension output 1
16 A4G GND – Output 4
19 GND/ANA Analogues - GND
22 E8G GND – input 8
• All pins are internal connected
continued
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14.3.2 Front Connector Arrangement, ANM-Module (Analogues Input)
Cont’d.:
PIN PIN-NAME OPERAND COMMENTARY
26 A1G GND - Output 1
27 4U+E4G GND - Input 4
29 E3G GND - Input 3
34 GND/ANA Analogues – GND
35 E8 EW Z+1.4 Input (U/I) 8
37 E7 EW Z +1.3 Input (U/I) 7
39 E6 EW Z +1.3 Input (U/I) 6
41 E5 EW Z +1.3 Input (U/I) 5
43 E4 EW Z.4 Input (U/I) 4
• All pins are internal connected
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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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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 X27 to Laptop
VL4 X27 to Memory Card System
VL5 24V Power supply to Memory Card System
VL6 X27 to Portable Printer
VL7 24V Power supply to Portable Printer
VL8 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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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: Pin 33 and 49

GND: Pin 17 and 50
+ 24 V I/O-Supply: 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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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)
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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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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 de-
energized relay or normal open switch contact) thus the ECS recognize a fault
after switching ON the system.
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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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14.5.3 Temperature Measuring and trouble shooting Illustration Z22803a
General: (study with the respective circuit diagram)

The signal of the PT100 temperature probe can’t 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- it’s 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 Ω.
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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14.5.3 Temperature Measuring and trouble shooting, illustration Z22803a
Cont’d.:
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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14.5.4 Temperature – Resistance Chart PT100
Basic Values in Ohm according to DIN 43 76
For Measuring Resistor PT100
°C -0 -1 -2 -3 -4 -5 -6 -7 -8 -9
-50 80,31 79,91 79,51 79,11 78,72 78,32 77,92 77,52 77,13 76,73
-40 84,27 83,88 83,48 83,08 82,69 82,29 81,89 81,50 81,10 80,70
-30 88,22 87,83 87,43 87,04 86,64 86,25 85,85 85,46 85,06 84,67
-20 92,16 91,77 91,37 90,98 90,59 90,19 89,80 89,40 89,01 88,62
-10 96,09 95,69 95,30 94,91 94,52 94,12 93,73 93,34 92,95 92,55
0 100,00 99,61 99,22 98,83 98,44 98,04 97,65 97,26 96,87 96,48
°C 0 1 2 3 4 5 6 7 8 9
0 100,00 100,39 100,78 101,17 101,56 101,95 102,34 102,73 103,12 103,51
10 103,90 104,29 104,68 105,07 105,46 105,85 106,24 106,63 107,02 107,40
20 107,79 108,18 108,57 108,96 109,35 109,73 110,12 110,51 110,90 111,28
30 111,67 112,06 112,45 112,83 113,22 113,61 113,99 114,38 114,77 115,15
40 115,54 115,93 116,31 116,70 117,08 117,47 117,85 118,24 118,62 119,01
50 119,40 119,78 120,16 120,55 120,93 121,32 121,70 122,09 122,47 122,86
60 123,24 123,62 124,01, 124,39 124,77 125,16 125,54 125,92 126,31 126,69
70 127,07 127,45 127,84 128,22 128,60 128,98 129,37 129,75 130,13 130,51
80 130,89 131,27 131,66 132,04 132,42 132,80 133,18 133,56 133,94 134,32
90 134,70 135,08 135,46 135,84 136,22 136,60 136,98 137,36 137,47 138,12
100 138,50 138,88 139,26 139,64 140,02 140,39 140,77 141,15 141,53 141,91
110 142,29 142,66 143,04 143,42 143,80 144,17 144,55 144,93 145,31 145,68
120 146,06 146,44 146,81 147,19 147,57 147,94 148,32 148,70 149,07 149,45
130 149,82 150,20 150,57 150,95 151,33 151,70 152,08 152,45 152,83 153,20
140 153,58 153,95 154,32 154,70 155,07 155,45 155,82 156,19 156,57 156,94
150 157,31 157,69 158,06 158,43 158,81 159,18 159,55 159,93 160,30 16067
Example: 84 ° C Ì 80° + 4° = 132,42 Ω

124,4 Ω Ì 124,4 ≈ 124,39 = 60° + 3° = 63 °C
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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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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 query Yes No

1) Sensor or cable B85-X : 5 sec. < --6bar B85-X : 5 sec. : Voltage
defect? 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
⇓
Fault message No 1190
2) _running_motor-x Motor X is running for Motor X is not running
> 15 sec ? more than 15 seconds
3) X1-pressure to B85-X : 2 sec. > 40bar B85-X : 5 sec. : Voltage
high? i.e. > 6,5V at EW13.3 below 6,5V at EW13.3
⇓
Fault message No 962
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Section 15.0
Lubrication System
Page 1
Table of contents
Page
General Function 3
Oscillation Cylinder and Control Block 9
Adjustments 11
One line system 13
Electrical function 17
Capacitive analog sensor for lubricant level monitoring 21
Adjustments
End Line pressure switch 23
Injectors 25
Function Pinion type (dummy wheel) system 27
Electrical Function (dummy wheel) system 31
Capacitive analog sensor for lubricant level monitoring 35
Adjustments
End-Of-Line Switch setting 37
Injectors 39
Components
Hydraulically driven lube pump 41
Injectors 45
End-Line Switch 51
In line Filter 53
Vent valve (Solenoid valve) 55
04.01.07 rev.6 PC5500-6-D_Sec_15-0_rev1.doc

15.0
2 Lubrication System
Section 15.0
Lubrication System
Page 3
General Function
Legend: illustration Z 24042a

(1) Lubricant pump drive (Hydraulic cylinder)
(2) Solenoid valve (Oil pressure supply)
(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

15.0
Cont'd.
X-axis Time
Y-axis Lubricant supply line pressure
PI Pressure Increasing
S+ Switch point ON of the end of line pressure switch
PH Pressure Holding
S- Switch point OFF of the end of line pressure switch
PR Pressure Relieve
PT Pause Time
Section 15.0
Lubrication System
Page 5
Function of a lubrication cycle 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 shuttle’s the grease cylinder at 18
– 20 double strokes per minute and delivering 612 – 680 cm³ (37.3 – 41.5 in³) 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 Vent valve 7 end-of-line switch

Y7, CLS Y7a, CLS (1) 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
15.0
Cont'd.
X-axis Time
Y-axis Lubricant supply line pressure
PI Pressure Increasing
S+ Switch point ON of the end of line pressure switch
PH Pressure Holding
S- Switch point OFF of the end of line pressure switch
PR Pressure Relieve
PT Pause Time
Section 15.0
Lubrication System
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.

15.0
Section 15.0
Lubrication System
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.

15.0
Section 15.0
Lubrication System
Page 11
Adjustments (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 engine and run at high idle.
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 engine and run at high idle.
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 can’t be adjusted, check adjustment of the 60

) bar pilot pressure valve (X-4 pressure) at the filter and control panel in
the machinery house.

15.0
Section 15.0
Lubrication System
Page 13
One line system

Legend: illustr. Z 21176
(2) Solenoid valve (Oil pressure supply)
(7) Vent valve (Solenoid valve, de-energized open to barrel)
(9) Lubricant level indication (capacitively analog sensor)
(11) Pump mechanism
(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

15.0
Section 15.0
Lubrication System
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 re-
initiated 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
W • 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

15.0
Section 15.0
Lubrication System
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 engine must run in high idle.
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

15.0
Section 15.0
Lubrication System
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

15.0
Section 15.0
Lubrication System
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.

15.0
Section 15.0
Lubrication System
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. Start engine.
3. Start a lube cycle with the dashboard switch S24.
+
4. 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

15.0
Section 15.0
Lubrication System
Page 25
Cont'd:
Injectors, illustr. 21181:
Series SL-1 injector:

Lubricant output adjustable from 0.13 up to 1.3 cm³ 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 cm³ 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

15.0
Section 15.0
Lubrication System
Page 27
Function Pinion type (dummy wheel) system.
Legend: Z 21183a
(2) Solenoid valve Y9 (Oil pressure supply)
(7) Vent valve Y9A (Solenoid valve, de-energized open)
(9) Lubricant level indication
(11) Pump mechanism
(16) Breather
(17) 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

15.0
Section 15.0
Lubrication System
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

15.0
Section 15.0
Lubrication System
Page 31
Electrical function. 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

15.0
Section 15.0
Lubrication System
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

15.0
Section 15.0
Lubrication System
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. If there is a new calibration required refer to Service News
AH 04503

15.0
Section 15.0
Lubrication System
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. Block the swing function with the swing ring parking, use the switch at
the dash board.
3. Start engine.
4. Start a lube cycle with the dashboard switch S26 and activate for a short
time the swing function to the left or right.
+
5. 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. Screw out screw (1) and take off cover (2).

7. Alter the spring tension with adjustment screw (3) that the switch
operates at 180 bar.
8. Install cover (2) and screw (1).
continued

15.0
Section 15.0
Lubrication System
Page 39
Cont'd:
Injectors, illustr. 21181:

Lubricant output adjustable from 0.13 up to 1.3 cm³ 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 cm³ 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

15.0
Section 15.0
Lubrication System
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) Pressure reducing valve
(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.
B 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

15.0
Section 15.0
Lubrication System
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.

15.0
Section 15.0
Lubrication System
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) Design: (model SL11)

(01+02) Metering valve, assy. (01) Metering valve, assy.
(03+04) Injector bar (02) Adjusting screw
(05) Adjusting screw (03) Nut
(06) Nut (04) Plug screw
(07) Plug screw (05) O-ring
(08) Seal ring (06) Disk
(09) Disk (07) Seal ring
(10) Seal ring (08) Disk
(11) Bolt with nut (09) Guide
(12) Disk (10) Indicator pin
(13) Seal ring (11) Seal ring
(14) Piston (12) Piston
(15) Compression spring (13) Seal ring
(16) Spring retainer (14) Pin
(17) Seal ring (15) Compression spring
(18) Disk (16) Spring retainer
(19) Seal ring (17) Bolt with piston
(20) Disk (18) Seal ring
(21) Piston (19) Valve housing
(22) Seal (20) Union
(23) Adapter bolt
(24) Valve housing
(25) Union
continued

15.0
Section 15.0
Lubrication System
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

15.0
Section 15.0
Lubrication System
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.

15.0
Section 15.0
Lubrication System
Page 51
End-line switch
TASK:
The pressure control unit is monitoring and controlling the centralized lube
system.
Design: illustr. Z 21190

(1) Piston
(2) Disk
(3) Switch contact
(4) Spring
(5) Pressure switch
(6) Adjustment sleeve
(7) Connection to pressure circuit
(8) 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.

15.0
Section 15.0
Lubrication System
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

15.0
Section 15.0
Lubrication System
Page 55
Vent valve, illustr. Z 21192
TASK:
By the function of the vent valve the lubricant supply line gets pressure-
relieved, 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).

15.0

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) • Each section includes a detailed table of contents.

• IMPORTANT SAFETY NOTICE

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

WARNING - Serious personal injury or extensive property damage can

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

) NOTE - Refers to special information

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR ......................... 22

PRECAUTION FOR MAINTENANCE .............................................................................................. 42

ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS ....... 54

SPECIAL SAFETY EQUIPMENT ..................................................................................................... 56

TROUBLESHOOTING, ADJUSTMENTS AND REPAIR

ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING,

GENERAL PRECAUTIONS COMMON TO OPERATION ON

PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR

ENSURING SAFE OPERATION

UNDERSTANDING THE MACHINE

PREPARATIONS FOR SAFE OPERATION

PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT

INSPECTING THE MACHINE

WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT

z Do not wear loose clothing and accessories. If these

z Always wear a hard hat and safety shoes when work-

z Check that all protective equipment functions properly

KEEP MACHINE CLEAN

z If you get on or off the machine or carry out inspection

z If water gets into the electrical system, there is a haz-

PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT

PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT

Always follow the precautions below to prepare for action if

z Be sure that fire extinguishers have been provided and

z Carry out periodic inspection and maintenance to

z Provide a first aid kit. Carry out periodic checks and

If you find any problems in the machine during operation

ACTION IF FIRE OCCURS

z Activate the STOP switch to stop the engine.

z Use the access ladders and steps to get off the

z If it is impossible to escape from the rear of the cab,

z After escaping with the emergency escape ladder, acti-

PRECAUTIONS TO PREVENT FIRE

z Fire caused by fuel, oil, antifreeze, or window washer fluid.

Do not bring any flame or fire close to flammable sub-

z Do not smoke or use any flame near fuel or other

z Stop the engines before adding fuel.

z Do not leave the machine while adding fuel or oil.

z Tighten all fuel and oil caps securely.

z Be careful not to spill fuel on overheated surfaces

z After adding fuel or oil, wipe up any spillage.

z Fire caused by accumulation of flammable material.

z Fire coming from electrical wiring

z Keep all electrical connections clean and securely tightened.

z Fire coming from piping

z Explosion caused by lighting equipment

PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE

USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE

To prevent personal injury caused by slipping or falling off

z Always use the handrails and steps when getting on or

z To ensure safety, always face the machine and main-

z When walking around the machine, where possible,

NO JUMPING ON OR OFF THE MACHINE

NO PEOPLE ON THE ATTACHMENT

WORKING IN HIGH PLACES

LEAVING OPERATOR’S SEAT WITH LOCK

Before standing up from the operator's seat in order to