SM PC4000-6 8152 SMPC40008152

PC4000_Contents and 00_Foreword_rev0.
doc
06.09.02
SMPC40008152
Shop
Manual
PC4000-6
HYDRAULIC MINING SHOVEL
SERIAL NUMBERS
PC4000-6 8152
This material is proprietary to Komatsu Mining Germany GmbH and is not to be reproduced, used, or disclosed except
in accordance with written authorization from Komatsu Mining Germany GmbH.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or 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, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
Copyright 2006 Komatsu

Printed in U.S.A.
Komatsu Mining Germany
June 2006
PC4000_Contents and 00_Foreword_rev0.doc
CONTENTS
TABLE OF CONTENTS
00
01
02
Safety - Foreword
Technical DATA (Leaflet)
Assembly PROCEDURE (Brochure)
Section
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14
15
Main assembly groups

Drive.
Hydraulic oil tank.
Hydraulic oil cooling.
Controlling.
Components
Main hydraulic pumps and pump regulation.
Operating hydraulic.
Hydraulic track tensioning system.
Hydraulic operated excess ladder
Central refilling system
Hints for the hydraulic circuit diagram
Hints for the electric circuit diagram
VHMS / ECS-T / ETM
Lubrication Systems
APPENDIX
Each section includes a detailed table of contents.
06.09.02
SAFETY
SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE

Proper service and repair is extremely important for safe machine operation. The
service and repair techniques recommended by Komatsu and described in this manual
are both effective and safe. Some of these techniques require the use of tools specially
designed by Komatsu for the specific purpose.
The following Symbols are used in this Manual to designate Instructions of
particular Importance.
W
F
WARNING -
Serious personal injury or extensive property damage can

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

the shovel can be damaged if the caution instructions are not
followed.
NOTE -
Refers to special information
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE
MANUAL carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read all the precautions given on the decals
which are fixed to the machine.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons missing.
Always wear safety glasses when hitting parts with a hammer.
Always wear safety glasses when grinding parts with a grinder, etc.
continued
00-1
SAFETY
SAFETY NOTICE
Cont'd:
GENERAL PRECAUTIONS
3. If welding repairs are needed, always have a trained, experienced welder carry out the
work. When carrying out welding work, always wear welding gloves, apron, glasses, cap
and other clothes suited for welding work.
4. When carrying out any operation with two or more workers, always agree on the
operating procedure before starting. Always inform your fellow workers before starting
any step of the operation. Before starting work, hang UNDER REPAIR signs on the
controls in the operator's compartment.
5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the
tools and parts in their correct places. Always keep the work area clean and make sure
that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking.
Never smoke while working.
PREPARATIONS FOR WORK
7. Before adding oil or making repairs, park the machine on hard, level ground, and block
the wheels or tracks to prevent the machine from moving.
8. Before starting work, lower bucket, hammer or any other work equipment to the ground.
If this is not. possible, insert the safety pin or use blocks to prevent the work equipment
from falling. In addition, be sure to lock all the control levers and hang warning signs on
them.
9. When disassembling or assembling, support the machine with blocks, jacks or stands
before starting work.
10. Remove all mud and oil from the steps or other places used to get on and off the machine.
Always use the handrails, ladders or steps when getting on or off the machine. Never
jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a
stand to provide safe footing.
PRECAUTIONS DURING WORK
11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs,
loosen
them
slowly
to
prevent
the
oil
from
spurting
out.
Before disconnecting or removing components of the oil, water or air circuits, first
remove the pressure completely from the circuit.
12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to
get burned.
Wait for the oil and water to cool before carrying out work on the oil or water circuits.
continued
00-2
SAFETY
SAFETY NOTICE
Cont'd:
PRECAUTIONS DURING WORK
13. Before starting work, remove the leads from the battery. ALWAYS remove the lead from
the negative (-) terminal first.
14. When raising heavy components, use a hoist or crane.
Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity.
Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly
to prevent the component from hitting any other part. Do not work with any part still
raised by the hoist or crane.
15. When removing covers which are under internal pressure or under pressure from a spring,
always leave two bolts in position on opposite sides. Slowly release the pressure, then
slowly loosen the bolts to remove.
16. When removing components, be careful not to break or damage the wiring, Damaged
wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to
the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can
even start fires.
18. As a general rule, do not use gasoline to wash parts. In particular, use only the minimum
of gasoline when washing electrical parts.
19. Be sure to assemble all parts again in their original places. Replace any damaged part
with new parts.
When installing hoses and wires, be sure that they will not be damaged by contact with
other parts when the machine is being operated.
20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes
are dangerous, so be extremely careful when installing tubes for high pressure circuits.
Also check that connecting parts are correctly installed.
21. When assembling or installing parts, always use the specified tightening torques. When
installing protective parts such as guards, or parts which vibrate violently or rotate at high
speed, be particularly careful to check that they are installed correctly.
22. When aligning two holes, never insert your fingers or hand. Be careful not to get your
fingers caught in a hole.
23. When measuring hydraulic pressure, check that the measuring tool is correctly assembled
before taking any measurements.
24. Take care when removing or installing the tracks of track-type machines. When removing
the track, the track separates suddenly, so never let anyone stand at either end of the track.
00-3
SAFETY
SAFETY 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 PC4000.
We describe for you all functions and how to carry out the inspections and
adjustments.
How do you find "your" desired information?
In the table of CONTENT all the functions and components are shown in
their sequence of the description.
If after reading this SERVICE MANUAL you can give us suggestions and
comments for improvements - please do not hesitate to contact us.
Komatsu Mining Germany GmbH
- Service Training Postfach 180361
40570 Dsseldorf
Tel.:0211 / 7109 - 206
Fax.:0211 / 74 33 07
The editorial staff will be pleased about your co-operation.
- FROM THE PRACTICE - FOR THE PRACTICE -
This service manual corresponds to the state of development of the

machine at the time the manual was produced.
Variations based on special customers request and special equipment
are not included in this manual
00-4
FOREWORD
HOISTING INSTRUCTIONS
HOISTING
Heavy parts (25 kg or more) must be lifted with a hoist etc.
If a part cannot be smoothly removed from the machine by hoisting,

the following checks should be made:
1. Check for removal of all bolts fastening the part to the relative
parts.
2. Check for existence of another part causing interface with the part
to be removed.
WIRE ROPES
1. Use adequate ropes depending on the weight of parts to be hoisted, referring to
the table below:
Wire ropes
(Standard "Z" or "S" twist ropes without galvanizing)
Rope diameter
[mm]
10,0
11,2 12,5 14,0 16,0 18,0 20,0 22,4 30,0 40,0 50,0 60,0
Allowable
load [tons]
1,0
1,4
1,6
2,2
2,8
3,6
4,4
5,6
10,0 18,0 28,0 40,0
The allowable load value is estimated to be 1/6 or 1/7 of the breaking

strength of the rope used.
2. Sling wire ropes from the middle portion of the hook. Slinging near the edge
of the hook may cause the rope to slip off the hook during hoisting, and a
serious accident can result. Hooks have maximum strength at the middle
portion.
continued
Cont'd:
00-5
FOREWORD
WIRE ROPES
3. Do not sling a heavy load with one rope alone, but sling with two or more
ropes symmetrically wound on to the load.
Slinging with one rope may cause turning of the load during hoisting,
untwisting of the rope, or slipping of the rope from its original
winding position on the load, which can result in a dangerous
accident.
4. Do not sling a heavy load with ropes forming a wide hanging angle from the
hook. When hoisting a load with two or more ropes, the force subjected to
each rope will increase with the hanging angles. The table below shows the
variation of allowable load (kg) when hoisting is made with two ropes, each of
which is allowed to sling up to 1000 kg vertically, at various hanging angles.
When two ropes sling a load vertically, up to 2000 kg of total weight can be
suspended. This weight becomes 1000 kg when two ropes make a 120E
hanging angle. On the other hand, two ropes are subject to an excessive force
as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150.
00-6
FOREWORD
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE (1Kgm = 9,806Nm)

STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS
Bolt
dia.
M 10
M 12
M 14
M 16
M 18
M20
M 22
M 24
M 27
M 30
M 33
M 36
M 39
M 42
Wrench Tightening torque

size [mm]
Quality grades
8.8
10.9
43
63
17
32
47
74
108
19
54.6
80
118
173
22
87
128
179
265
24
132
196
255
360
27
188
265
360
510
30
265
376
485
690
32
358
509
620
880
36
457
649
920
1310
41
679
966
1250
1770
46
922
1305
1690
2400
50
1246
1770
2170
3100
55
1600
2286
2800
4000
60
2065
2950
3500
4950
65
2580
3650
Insert all bolts lubricated with MPG, KP2K
00-7
Nm
lbs.ft.
12.9
73
54
127
94
202
149
310
229
425
313
600
443
810
597
1030
760
1530
1128
2080
1534
2800
2065
3600
2655
4700
3466
5800
4277
FOREWORD
CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE
The Conversion Table in this section is provided to enable simple conversion of
figures. For details of the method of using the Conversion Table, see the example
given below.
EXAMPLE
Method of using the Conversion Table to convert from millimeters to inches.
1. Convert 55 mm into inches.
(a) Locate the number 5 in the vertical column at the left side, take this as (A),
then draw a horizontal line from (A).
(b) Locate the number 5 in the row across the top, take this as (B), then draw a
perpendicular line down from (B).
(c) Take the point where the two lines cross as (C). This point (C) gives the
value
when
converting
from
millimeters
to
inches.
Therefore, 55 millimeters = 2.165 inches.
2. Convert 550 mm into inches.
(a) The number 550 does not appear in the table, so divide by 10 (move the
decimal one place to the left) to convert it to 55 mm.
(b) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(c) The original value (550 mm) was divided by 10, so multiply 2.165 inches
by 10 (move the decimal one place to the right) to return to the original
value. This gives 550 mm = 21.65 inches.
00-8
FOREWORD
00-9
CONVERSION TABLE
FOREWORD
CONVERSION TABLE
00-10
FOREWORD
00-11
CONVERSION TABLE
FOREWORD
CONVERSION TABLE
00-12
FOREWORD
CONVERSION TABLE
Basic Values in Ohm according to DIN 43 76

For Measuring Resistor PT100
-0
-1
-2
-3
-4
-5
-6
-7
-8
-9
-50
80,31
79,91
79,51
79,11
78,72
78,32
77,92
77,52
77,13
76,73
-40
84,27
83,88
83,48
83,08
82,69
82,29
81,89
81,50
81,10
80,70
-30
88,22
87,83
87,43
87,04
86,64
86,25
85,85
85,46
85,06
84,67
-20
92,16
91,77
91,37
90,98
90,59
90,19
89,80
89,40
89,01
88,62
-10
96,09
95,69
95,30
94,91
94,52
94,12
93,73
93,34
92,95
92,55
100,00
99,61
99,22
98,83
98,44
98,04
97,65
97,26
96,87
96,48
100,00
100,39
100,78
101,17
101,56
101,95
102,34
102,73
103,12
103,51
10
103,90
104,29
104,68
105,07
105,46
105,85
106,24
106,63
107,02
107,40
20
107,79
108,18
108,57
108,96
109,35
109,73
110,12
110,51
110,90
111,28
30
111,67
112,06
112,45
112,83
113,22
113,61
113,99
114,38
114,77
115,15
40
115,54
115,93
116,31
116,70
117,08
117,47
117,85
118,24
118,62
119,01
50
119,40
119,78
120,16
120,55
120,93
121,32
121,70
122,09
122,47
122,86
60
123,24
123,62 124,01, 124,39
124,77
125,16
125,54
125,92
126,31
126,69
70
127,07
127,45
127,84
128,22
128,60
128,98
129,37
129,75
130,13
130,51
80
130,89
131,27
131,66
132,04
132,42
132,80
133,18
133,56
133,94
134,32
90
134,70
135,08
135,46
135,84
136,22
136,60
136,98
137,36
137,47
138,12
100
138,50
138,88
139,26
139,64
140,02
140,39
140,77
141,15
141,53
141,91
110
142,29
142,66
143,04
143,42
143,80
144,17
144,55
144,93
145,31
145,68
120
146,06
146,44
146,81
147,19
147,57
147,94
148,32
148,70
149,07
149,45
130
149,82
150,20
150,57
150,95
151,33
151,70
152,08
152,45
152,83
153,20
140
153,58
153,95
154,32
154,70
155,07
155,45
155,82
156,19
156,57
156,94
150
157,31
157,69
158,06
158,43
158,81
159,18
159,55
159,93
160,30
16067
00-13
FOREWORD
CONVERSION TABLE
TEMPERATURE
Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit
temperature reading into a Centigrade temperature reading or vise versa is to enter
the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the
center column as a table of Fahrenheit temperatures and read the corresponding
Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the
center column as a table of Centigrade values, and read the corresponding
Fahrenheit temperature on the right.
00-14
Main Assembly Groups
Section 1.0
Page 1
Table of contents section 1.0

Section
1.0
Page
Main assembly groups
General lay out
1.1
Superstructure
1.1.1
Machine house
1.1.2
Hydraulic Oil Reservoir
1.1.3
Hydraulic Oil Cooler
1.1.4
Fuel Tank
1.1.5
Counter weight
1.1.6
Cab support
1.1.7
Operators cab
10
1.1.8
Control Blocks
11
1.1.9
Swing gears
12
1.2
Under carriage
1.3
Attachment
13
1.3.1.
Backhoe Attachment (BHA)
14
1.3.2.
Front Shovel Attachment (FSA)
15
1.0
&2
1.
General lay out

Legend for illustration (Z 21463):
(1)
Superstructure
(2)
Under carriage
(3)
(4)
Backhoe Attachment (BHA)
Section 1.0
Page 2
1.0
&3
1.1
Superstructure
(1)
Operators Cab with integrated FOP system
(2)
Exhaust
(3)
Air cleaner
(4)
Cab support (contains the electrical switch board)
(5)
Swing ring connection
(6)
Fuel reservoir
(7)
Hydraulic ladder
(8)
Counter weight
(9)
Hydraulic oil cooler with hydraulic driven fans
(10)
Hydraulic oil reservoir
(11)
PTO gear with all hydraulic pumps
(12)
Flexible coupling, oil filled
(13)
Engine
(14)
Batteries
(15)
Radiator for the engine cooling system
(16)
Control blocks with high pressure filters
(17)
Swing gears
(18)
Grease pump of the Central Lubrication System
(19)
Grease pump of the Swing gear pinion Lubrication System
Section 1.0
Page 3
1.0
&4
1.1
Section 1.0
Page 4
Superstructure
1.1.1
Machine house

(1)
Roof mounted exhaust
(2)
Roof mounted air cleaners with restriction switches
(3)
Expansion tank of the radiator for the engine cooling system
(4)
Hydraulic control and filter panel
(5)
PTO gear box
(6)
Main hydraulic pumps
(7)
Auxiliary pumps, installed at the drive through shaft of the main
hydraulic pumps (piggyback pumps)
(8)
Hydraulic pump for radiator fan drive
(9)
Hydraulic pump for the hydraulic oil cooler fan drive
(10)
Suction oil reservoir
(11)
Flexible coupling, oil filled
(12)
Batteries
(13)
Engine
(14)
Hydraulic motor for the radiator fan drive
(15)
Radiator for the engine cooling system
1.0
&5
1.1
Superstructure
1.1.2

(1)
Breather filter
(2)
Temperature controlled back pressure valve
(3)
Drain coupling of the hydraulic oil reservoir
(4)
Return oil filter
(5)
Case drain (leak oil) filter
(6)
Main shut-off valve (Gate valve) with compensator
(7)
Return oil collector tube
(8)
Drain coupling of the Return oil collector tube
Section 1.0
Page 5
Section 1.0
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
Section 1.0
Page 6
1.0
&7
1.1
Superstructure
1.1.4
Fuel tank (Fuel reservoir)

(1)
Fuel tank
(2)
Fuel tank breather valve
(3)
Main shut-off cock
(4)
Drain coupling with protection cap
(5)
Shut-off cock for fuel pressure transducer
(6)
Fuel pressure transducer
Section 1.0
Page 7
1.0
&8
Section 1.0
Page 8
1.1
Superstructure
1.1.5
Counter weight

(1)
Counter weight
Total weight
33000 kg
(2)
Mounting bolts
Quantity
16
Bolt size
(mm)
M 42 x 520
SW = Wrench size
(3)
Lifting points
Grade
SW*
(mm)
10.9
65
Tightening
torque (Nm)
4950
1.0
&9
Section 1.0
Page 9
1.1
Superstructure
1.1.6
Cab support

(1)
Cab support (Location of electrical switch board X2)
(2)
Mounting bolts
Quantity
Bolt size
Grade SW*
Tightening
(mm)
(mm) torque (Nm)
4
M 36 x 240
10.9
55
Grade
SW*
(mm)
10.9
55
3100
*SW = Wrench size

(3)
Mounting bolts
Quantity
Bolt size
(mm)
4
M 36 x 240
*SW = Wrench size

(4)
(5)
(6)
Door
Gasket
Door handle (adjustable)
Tightening
torque (Nm)
3100
1.0
& 10
1.1
Superstructure
1.1.7
Operators cab

(1)
(2)
(3)
(E19)
Monitor panel
Switch panel
Operators seat
Control lever
EURO Control
KMG Control
(E20)
Control lever
EURO Control
KMG Control
(E21a)
Control pedal
A - forward
Left track
B - reverse
(E21b)
Control pedal
A - forward
Right track
B - reverse
(E22)
(E23)
(E24)
Control pedal Control pedal Control pedal -
Swing brake
Bucket closing
Bucket opening
Section 1.0
Page 10
1.0
& 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
Section 1.0
Page 11
1.0
& 12
1.1
Section 1.0
Page 12
Superstructure
1.1.9
Swing gears

(1)
Swing gear box
(2)
Swing parking brake
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(60.1 + 60.2)
(61.1 + 61.2)
Spring loaded multi disk brake

(Released by oil pressure)
Equalizing reservoir - gear box oil
Oil level gauge - gear box
Oil drain plug motor adapter housing
Oil level gauge - motor adapter housing
Breather filter brake housing
Oil level gauge brake housing
Pinion
Oil drain plug - gear box
Swing motor
Swing brake valve block
1.0
& 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)
Section 1.0
Page 13
1.0
& 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
Section 1.0
Page 14
1.0
& 15
1.0
& 15
1.3
Attachment
1.3.2

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

Section
2.0
Page
Prime drive assembly
General lay out
2.1
Engine and PTO mounts
3+4
2.2
Coupling
2.3
Air filter
2.4
Fan drive and radiator assembly
7+8
2.5
Radiator fan drive speed adjustment
9 + 10
2.6
Pump distributor gearbox (PTO)
11
2.7
Pump-spline lubrication
12
2.8
PTO Lubrication and cooling
13 + 14
2.9
Hydraulic pumps location, drive speed and flow rates
15
2.0
&2
Drive
2.0
Section 2.0
Page 2
Prime drive assembly

(1)
Engine
(2)
Torsion type coupling
(3)
Pump distributor gear (PTO)
(4)
Adapter flange
(5)
Power frame
General
The drive unit, consists of the PTO gear and the engine, is bolted to the power
frame.
The connection between engine and PTO gear is a flexible coupling.
2.0
&3
Section 2.0
Page 3
Drive
2.1

(1)
Flexible bearing
(2)
Bolt with self locking nut
Quantity
4 per mount
(3)
10
Grade
SW*
(mm)
10.9
36
43
Bolt size
(mm)
M 24 x400
Tightening
torque (Nm)
snugly
Bolt size
(mm)
M 16x 80
Grade
SW*
(mm)
10.9
24
Grade
SW*
(mm)
10.9
55
Grade
SW*
(mm)
10.9
36
Grade
SW*
(mm)
10.9
30
Grade
SW*
(mm)
10.9
46
Tightening
torque (Nm)
265
Bolt size
(mm)
M 36 x250
Tightening
torque (Nm)
Not specified
Bolt size
(mm)
M 24 x 200
Tightening
torque (Nm)
880
Bolt
Quantity
16
(12)
(13)
17
Nut
Bolt
Quantity
(11)
8.8
Tightening
torque (Nm)
Cup springs, seven per bolt

Stop bolt
Quantity
(9)
(10)
SW*
(mm)
Rubber-bounded metal bar

Self locking nut
Bolt M16 with self locking nut
Quantity
(7)
(8)
M 10 x35
Grade
Tie bolt
Quantity
(4)
(5)
(6)
Bolt size
(mm)
Bolt size
(mm)
M 20 x 120
Tightening
torque (Nm)
510
Resilient sleeve
Bolt
Quantity
4
Bolt size
(mm)
M 30 x 200
(14)
Resilient sleeve
SW = Wrench size
Tightening
torque (Nm)
1770
continued
2.0
&4
Drive
2.1
Section 2.0
Page 4
Cont'd
General
The flexible bearings are installed to take the vibrations and the torsion forces
and they carry the total weight of the engine, the pump distributor gear with
all hydraulic pumps.
Check mounting and security of Diesel engine and pump distributor gear,
illustration (Z 21601)
Check all flexible bearings (1) for engine and pump distributor gear.
Check the flexible bearings for damage and signs of fatigue. Make sure that there
is no contact between the upper and lower metal brackets of the flexible bearings
(1). Replace the bearings if necessary. Use new bolts and self locking nuts (2).
After new flexible bearings have been installed, check distance (B) on both torque
supports.
All flexible bearings (1) and all rubber-bounded metal bars (4) should
be replaced during engine overhaul.
Check distance (B) between torque support and stop bolt (8).
With setting of the flexible engine bearings (1) the distance (B) increases and must
be readjusted. To do this, loosen lock nut (9) and tighten stop bolt (8) until the
correct distance (B) is obtained. Tighten lock nut (9) and recheck distance (B).
If new flexible engine bearings (1) have been installed, replace also cup springs
(7) and adjust distance (B) to 29 mm.
Check tie bolts (3) on front and rear carrier units for looseness.
(four tie bolts)
Check to make sure that the self locking retainer nuts (5) are tight and that there is
no gap between nut and rubber-bounded metal bar (4). If necessary retighten
retainer nuts (5) snugly.
Check rubber-bounded metal bars (4) for signs of fatigue and damage.
Replace as necessary.
Check all bolt connections for correct tightening torque.

Check condition of engine carrier and brackets. If any damages, failures
or wrong condition are found, corrective action must be taken.
For more information, refer to Parts & Service News REF NO AH01521.
2.0
&5
Drive
2.2
Section 2.0
Page 5
Coupling
(1)
Coupling Assy.
(2)
Input drive flange
(3)
Leave spring assy.
(4)
Output drive flange
(5)
Dip stick
(6)
Bleeder plug
(7)
O-Rings
(8)
Spacers
E
Engine side
G
Gearbox side (PTO-side)
Task:
The coupling is the connecting link between the engine and the PTO
Function: "GEISLINGER COUPLING"
The combination of the high elasticity of its leaf springs with complimentary
viscous damping by oil displacement, ensures that the coupling reduces the
intensity of torsional vibrations effectively.
The widest engine speed range free of vibration periods and dangerous
resonances is thus obtained.
The springs (3) together with the inner driving and outer driven member form
chambers A and B which are filled with oil.
If the outer member is displaced in relation to the inner member, the
deflection of the leaf springs displaces oil from one chamber to the next, by
this action the relative movements of the two members of the coupling are
braked and the vibrations are dampened.
The spacers (8) limits the movement of the leaf springs.
2.0
&6
Drive
2.3
Section 2.0
Page 6
Air Filter
(1)
Wing nut
(2)
Washer
(3)
Seal ring
(4)
Main filter element
(5)
Cotter pin
(6)
Wing nut with service indicator
(7)
Safety element
(8)
Maintenance switch
(9)
Flap for pre-separator
(10)
Air intake with pre-separation
The air is filtered by a dry-air-filter with pre-separator for coarse impurities.
One filter housing includes 2 filter sets. Each one consists of a main filter
element (4) and a safety element (7).
The filter condition is monitored by the maintenance switch (8).
A fault message like Engine air filter restricted is displayed at the
operator's dash board as soon as the restriction is too high.
The wing nut (6) incorporates a service indicator.
Green indication = O.K.
Red indication
= safety element (7) needs maintenance.
The indication mark must be re-set by blowing through the nut opposite to the
normal air flow or by sucking at the other end, this can be done with the
mouth.
For service intervals and procedure refer to the OPERATION AND

MAINTENANCE MANUAL of the corresponding machine.
2.0
&7
Drive
2.4
Section 2.0
Page 7

(1)
Radiator
(2)
Fan motor (Axial piston motor)
(3)
Intake air fan
(4)
Bearing group carrier
(5)
Ball bearings
(6)
Breather filter
(7)
Oil level plug
(8)
Check valve (Anti-cavitation valve)
For service intervals and procedure refer to the OPERATION AND

MAINTENANCE MANUAL of the corresponding machine.
continued
2.0
&8
Drive
2.4
Section 2.0
Page 8
Cont'd
(1)
Radiator
(2)
Intake air fan
(5.2)
Axial piston pump (fixed displacement pump, with variable setting)
(23)
(31.2) Pressure relief valve - Engine radiator fan drive
(34.2) Pressure filter with pressure differential switch B21
(41)
Main oil reservoir
(52)
Check valve (Anti cavitation valve for fan drive motor)
(Y136) Proportional solenoid valve - Engine radiator fan speed (infinitely
variable)
(L)
Leak oil (case drain) to tank
(P)
Pressure to motor
(R)
Return oil to tank
Function:
From pump (5.2) flows the oil through the filter (34.2) to the fan motor (23) and
then back to the tank.
The check valve (52) act as an anti cavitation valve and is installed, because the fan
motor -driven by inertial force- is running for a short period after the engine has
been switched off.
The hydraulic circuit "Fan drive" is secured by the pilot controlled pressure relief
valve (31.2). This valve works together with the proportional solenoid valve (Y136).
The proportional solenoid valve(Y136) operates depending on engine coolant
temperature.
The ECM (Electronic Control Module) of the engine controls the proportional
solenoid valve (Y136) by sending variable current signals, depending on the engine
coolant temperature.
Which in turn changes the fan speed.
With a low current signal to the proportional solenoid the relief valve is functioning
and the fans are running with the max. set- speed. With a high current signal to the
proportional solenoid the relief valve is not functioning and the fans are running
with a very low speed, caused by the flow resistance only.
2.0
&9
Drive
2.5
Section 2.0
Page 9

Basic Adjustment
(1)
Dust cap
(2)
Lock nut
(3)
Set screw
(5.2)
(6)
Qmin stop bolt
(6.1)
Lock nut
(7)
Qmax stop bolt
(7.1)
Lock nut
(10)
Positioning pin (mover)
(31.2) Pressure relief valve - Engine radiator fan drive
(Y136) Proportional solenoid valve - Engine radiator fan speed (infinitely variable)
(L1)
Measurement of Qmin stop bolt
(L2)
Measurement of Qmax stop bolt
(M7) Pressure check points - Engine radiator fan drive operating pressure
Basic adjustment has to be carried out whenever one of the following

components has been replaced:
- pump
- relief valve
- hydraulic motor
1. Reduce the output flow of pump (5.2),by adjusting the minimum possible
swivel angle, to avoid over speeding the fan:
To do this, loosen both lock nuts (6.1 + 7.1) and turn out bolt (6)
and turn in bolt (7) the same length.
This is necessary to avoid a loose positioning pin (10), resulting in
oscillating of the cylinder barrel.
Tighten the lock nuts.
2. Remove protection cap (1) from relief valve (31.2), loosen lock nut (2) and
turn set screw (3) fully clockwise and then a half turn counter clockwise.
3. Isolate the function of proportional solenoid valve (Y136), by disconnecting
the plug connector, to ensure that the full flow of pump 5.2 will be
delivered to the fan motor.
4. Connect a pressure gauge to check point (M7).
5. Start the engine and let it run with max. speed.
continued
2.0
& 10
Drive
2.5
Section 2.0
Page 10
Cont'd
Basic Adjustment
6. Check the fan speed with a non-contact rev counter
Required fan speed: 1250 min-1
7.
Be careful not to get caught in the fan or other rotating parts
Increase the output flow of pump (5.2),by adjusting the swivel angle,
until the fan speed will be 20 min-1 higher than required:
To do this, loosen both lock nuts (6.1 + 7.1) and turn in bolt (6)
and turn out bolt (7) the same length.
This is necessary to avoid a loose positioning pin (10), resulting in
oscillating of the cylinder barrel.
Tighten the lock nuts (6.1 + 7.1).
Do not exceed the maximum permissible operating pressure of 230bar.
Note down the lengths L1 and L2 as reference measurements.
8.
Loosen lock nut (2) of the relief valve (31.2), and decrease the pressure
with set screw (3) until the correct fan speed is obtained.
9. Tighten lock nut (2) and fix protection cap (3).
10. Activate the function of proportional solenoid valve (Y136), by connecting
the plug connector. (Fan speed controlled in relation to the engine
temperature)
11. Disconnect the pressure gauge from check point (M7).
Fan speed check
If the fan speed is out of adjustment, increase or decrease first the pressure at
relief valve (31.2), to change the speed.
Do not exceed the maximum permissible operating pressure of 230bar.
If the speed can not be raised by increasing the pressure then increase the
output flow of pump (5.2).
2.0
& 11
Drive
2.6
Section 2.0
Page 11
Pump distributor gearbox (PTO)

(1)
Oil level gauge
(2)
Oil filler plug
(3)
Breather filter
(4)
Oil collector reservoir for auxiliary pump drive shaft housing
(5)
Breather filter with oil level gauge (drive shaft housing)
(6)
Main pump drive shaft housings
(7)
Oil level plug of main pump drive shaft housing
(8)
Oil filler plug with breather pipe of main pump drive shaft housing
(9)
Oil drain plug of main pump drive shaft housing
(10)
Oil drain plug of PTO gear
(11)
Flange for heater studs
(12)
Gear oil temperature probe mounting bore
(13)
Thermostat switch mounting bore cover plate
(14)
Suction line connection for gear oil cooling
(15)
Return line connection from gear oil cooler
(16)
Return line connection from cooling system relief valve
(D)
Drive flange
(M)
Power take off for main pumps
(R)
Power take off for engine radiator fan drive pump
(C)
Power take off for hydraulic oil cooler fan drive pump
Description
The pump distribution gear (PTO gear) is of a spur gear design and driven by
an diesel engine.
The PTO gear runs in antifriction bearings and has been provided with a
splash lubrication system. The oil supply of the bearings and tooth contacts
takes place by an injection. The gearwheels are of case-hardened steel.
The hydraulic pumps are directly attached to the gearbox. O-rings included in
the supply enable the unit to be reliably sealed statically.
The gearbox housing is of one-piece design and made of grey cast iron.
Gearbox design allows a direct attachment to the engine via connection flange.
The gearbox has been provided with connections for a separate cooling system
resp. for heating rods. For more information refer to the REPAIR MANUAL
Description for the lubrication see next pages.
2.0
& 12
Drive
2.7
Section 2.0
Page 12
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.
2.0
& 13
Drive
2.8
Section 2.0
Page 13

(1)
Line to the cooler (hot oil)
(2)
Return line from the cooler (cooled oil)
(3)
Return line from valve
(P)
Pressure port
(8.2)
Gear pump PTO-gearbox lubrication
(36)
Pressure filter - PTO gear lubrication
(B27-1)
Maintenance switch, 5 bar
(29)
Pressure relief valve, 10 bar
(M3)
Pressure check point
(B17-1)
Pressure switch, 0,5 bar
(15.1+15.2) Oil cooler, part of hydraulic oil cooler
(B49-1)
Temperature sensor
Function:
Pump (8.2) forces the gear oil from the gear oil pan through filter (20) to
pressure relief valve (21). This pressure relief valve acts as a back pressure
valve causing that most of the oil passes through the gear oil coolers
(17.1+17.2).
The gear oil coolers are a small part of the hydraulic oil coolers, thus the gear
oil gets cooled by the same air stream as the hydraulic oil. From the coolers
the oil flows to the port (P) of the gear and internally via a system of pipes to
the several spray nozzles.
The spray nozzles in the gear case ensure proper and adequate distribution of the
lube oil.
The circuit is monitored by the pressure switches (B17-1). At too low lube oil
pressure (0.5 bar), a fault message will be displayed on the monitor at the dash
board.
The gear oil temperature is monitored by the sensor unit (B49-1). At too high oil
temperature a fault message will be displayed on the monitor at the dash board.
continued
2.0
& 14
Section 2.0
Page 14
Drive
Cont`d.
2.8

(1)
Pilot operated relief valve
(2)
Plug screw
(3)
Valve piston
(4)
Port for pressure switch
B17-1
(-)
-------(6)
Port for pressure check stud
(7)
(8)
(9)
(B27-1)
(29)
(A)
(T)
Jet bore
Valve spring
Seal rings
Maintenance switch
Pressure relief valve
Pressure port
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 (29) at cold oil.
1.
Connect a pressure gauge to check point (M3).
2.
Start the engine and let it run with max. speed.
3.
Required pressure: 10
1 bar.
If adjustment is required:
4.
Remove protection cap (1a).
5.
Loosen lock nut (1b).
6.
Set the pressure with set screw (1c).
7.
Tighten lock nut (1b) and re-install protection cap (1a)
If the pressure of 10
1 bar cannot be adj. 100 %, adj. to the lowest
visible pressure.
Checking the PTO lube pressure at operating temperature (warm oil)

1.
2.
3.
Required pressure: 10
1 bar.
2.0
& 15
Section 2.0
Page 15
Drive
2.9
Hydraulic pumps location, drive speed and flow rates

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

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

(5.2)
(8.1)
Axial piston pump

Drive speed*
for radiator fan drive
Gear pump
Drive speed*
214 Liter/min
n = 2000 min-1
138 Liter/min
n = 1378 min-1
for pilot pressure supply

(8.2)
Gear pump
Drive speed*
PTO gear lubrication
* at 1800 min-1 input drive speed
138 Liter/min
n = 1378 min-1
Section 3.0
Page 1

Section
3.0
Page
General lay out
3.1
Main oil tank, location of switches, sensors etc.
3.2
Suction oil tank with strainers
3.3
Return oil collector tube with strainer
3.4
Back pressure valve
3.5
Transfer pump (Optional Equipment)
3.6
Return and Leak Oil Filter
3.7
Breather Filter
3.0
&2
3.
Section 3.0
Page 2
General lay out

(1)
Filter cover retainer
(2)
Filter cover
(3)
Filter element
(A) - Return oil filter - 10 m
(B) - Case drain filter - 3 m
(4)
Man hole cover
(24)
Pressure switch B24 monitors item (92.1) (92.2)
(30)
Hydraulic oil level gauge
(41)
Main oil reservoir
(54)
Return oil collector tube with pressure check point M10
(55)
Back pressure valve
(67)
Dust cap for item (77)
(77)
Oil drain, quick release coupling
(87)
Shut off valve with S31 (Gate valve)
(88)
Compensator
(92.1 + 92.2)
Breather filter
The hydraulic oil tank is a welded sheet-metal construction.
The capacity is about 3700 litres. The tank contains four return oil filters (3A) and one case drain filter (3-B).
The breather filter (92.1 + 92.2) cleans the air that streams into the tank.
The back pressure valve (55) and the pressure check point (M10) are located
at the collector tube (54) for return oil.
The connection to the suction tank can be closed with the shut- off valve (87)
to prevent oil flow during repairs on the hydraulic pumps. This unit is
controlled by the switch S31, it makes sure a motor start is not possible with a
closed shut-off valve. Fault message Start blocked because of main Shut-Off
(gate) valve is displayed at the operators dash board
3.0
&3
3.1
Section 3.0
Page 3
Main oil tank, location of switches, sensors etc.

Legend for illustration (Z 21495a):
(B4)
Oil level sensor Hydraulic oil level too low
(B15)
Hydraulic oil temperature probe
Hydraulic oil temperature below: too hot
(B24)
Breather filter pressure switch
(B50)
Oil level sensor Hydraulic oil refill level
(B105)
Pressure transducer Hydraulic oil level
(B163)
Pressure transducer Pressure return oil chamber
(B164)
Pressure transducer Pressure leak oil chamber
(B165)
Pressure transducer Pressure oil cooler
(B166)
Pressure transducer Pressure pre-load (back pressure) valve
3.0
&4
Section 3.0
Page 4
3.2
Suction oil tank with strainers

(1)
Suction oil reservoir
(2)
Drain coupling
(3)
Pressure transducer (B162) Pressure suction oil tank
(4)
Plug
(5)
Bolt
Quantity
8
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
16
SW*
(mm)
8.8
30
Tightening
torque (Nm)
360
Bolt size
(mm)
M 16 x 40
Grade
SW*
(mm)
8.8
24
Grade
SW*
(mm)
10.9
30
Grade
SW*
(mm)
10.9
24
Tightening
torque (Nm)
179
Lock nuts
Bolt
Quantity
8
(16)
(17)
M 20 x 85
Grade
Nut
Gaskets
Main suction oil strainer
Intermediate pipe
Gaskets
Suction strainer one for each main pump
Suction hose connection pipe
Bolt
Quantity
(14)
(15)
Bolt size
(mm)
Bolt size
(mm)
M 20 x 90
Tightening
torque (Nm)
510
Resilient sleeve
Bolt
Quantity
8
Bolt size
(mm)
M 16 x 90
Tightening
torque (Nm)
265
The suction oil tank (40) is a welded sheet-metal construction.

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

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

Gasket
SW = Wrench size
Task:
The strainer is installed to prevent the hydraulic oil coolers from getting
clogged up in case of contamination in the main return circuit oil.
Excessive increase of the hydraulic oil temperature can be an indication for a
restricted strainer, i.e. bad cooling performance due to insufficient oil flow
through the coolers.
In case that main components such as cylinders or motors are internal
fragmentary damaged, the strainer should be inspected for metal chips.
3.0
&6
3.4
Section 3.0
Page 6
Back pressure valve

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

refer to Section 4.0 this Manual.
3.0
&7
3.5
Section 3.0
Page 7
Transfer pump (Optional Equipment)

(113)
Transfer pump unit at the hydraulic tank - (Electric driven
gear pump)
(112.1)
Shut off valve suction oil tank
(112.2
Shut off valve return oil collector tube (Manifold)
(112.3)
Shut off valve return oil collector tube (Hydr. oil cooler)
Functions of the Transfer Pump:

A - Transfusing oil from the suction oil reservoir into the main oil reservoir.
Necessary for evacuation of the suction oil reservoir, when changing the
hydraulic oil. Prior servicing the main hydraulic pumps it is advisable to
empty the suction oil reservoir partially.
B - Transfusing oil from return oil collector tube and back-pressure valve
pipe into main oil reservoir. Necessary when changing the hydraulic oil
and prior to servicing the high pressure filters, the main control valves,
or hydraulic oil cooler (oil return system).
Refer to Section 6.15 of the operation and maintenance manual, for

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

(1)
Filter cover retainer
(2)
Filter cover with o-ring
(3)
Pre-tensioning spring
(4)
Retainer
(5)
Filter assembly
(6)
Filter pot with machined cover
(7)
Main filter element, 10 micron absolute
(8)
Safety filter element (200 micron strainer)
(9)
By pass-valve, 2.3bar
(9.1)
Valve cone
(9.2)
Valve spring
(9.3)
O-ring
(10)
Profile gasket
(11)
Seal ring
(12)
Self locking nut
(13)
Self locking nut
Function:
The returning oil flows into the filter chamber (A) of the hydraulic tank. (The
sketch shows one section only).
The chamber is split into two sections; one sections with 4 filters for the return oil
and one for the leak oil. But the five filters are all the same. The hydraulic oil
enters the filter at the top and passes then on its way to the entire tank the filterelement (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 chapter. 6.5 of MAINTENANCE MANUAL
3.0
&9
3.7
Section 3.0
Page 9
Breather filter
(1)
Nut
(2)
Cover
(3)
Filter element
(4)
Filter pot
A breather filter is installed to clean the air that streams into the tank any time
the oil level decreases while extending attachment cylinders
The filter element condition is monitored by a vacuum type pressure switch
(B24, 80mbar).
Maintenance see chapter 6.5 of MAINTENANCE MANUAL
Hydraulic Oil Cooling
Section 4.0
Page 1

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

(32.1 - 32.4)
Restrictor, shock absorbers for the hydraulic oil cooler
(39.1 + 39.2)
Hydraulic oil cooler
(41)
Main oil reservoir
(54)
(55)
Back pressure valve
(L6 + L7)
Return line from control blocks
(L13 + L14)
Supply line for the anticavitation circuit of the swing motors
(M10)
(Y101)
Solenoid valve 4/2-directional control valve
(H)
Lines to cooler (hot oil)
(C)
Lines to tank (cold oil)
Function:
The returning oil from the system flows via the lines (L6 - L7) into the
collector tube (54). On the top of it is the Back Pressure Valve (55) installed.
The back pressure valve (55) causes a back pressure which forces most of the
relative hot oil through the lines (H) to the cooler (39.1 + 39.2).
On its flow through the cooler the hydraulic oil gets cooled and flows than
through the restrictors (37.1 - 37.4) and the lines (C) into the filter chamber of
the main oil reservoir (41).
The restrictors are acting like shock absorbers to prevent cooler cracking at
pressure peaks.
Besides the back pressure valve acts as an oil flow control valve as far as the
oil temperature has not reached its steady temperature.
During the warm up period (1/2 Qmax) the back pressure valve (55) is wide
open, because solenoid valve Y101 is energized, which results in less oil
flows through the cooler which causes that the oil gets quicker its optimum
operating temperature.
With increasing oil temperature the oil gets thinner, so that the main pumps
can be shifted to Qmax position and simultaneously solenoid valve Y101 will
be de-energized, so that the valve piston will be more closed by the force of
the spring thus that more oil passes the cooler.
(See sectional drawing on next page.)
4.0
&4
4.3
Section 4.0
Page 4
Adjustment of the Back Pressure Valve

Checks and settings only at normal operating temperature of the hydraulic oil,
main pumps in maximum flow position and "Idle Time" control eliminated
(service switch S151 actuated)!
1.
2.
Disconnect plug connector (13) of solenoid valve Y101.
3.
Actuate service switch S151.
4.
Start the engine and let it run with maximum speed.
5.
Required pressure: 10 0,5 bar
a) Take off protective cap (12).
b) Loosen lock nut (5).
c) Alter the pressure with the set screw (6).
d) Tighten lock nut (5) and refit protective cap (12).
6.
Disconnect the pressure gauge, reconnect solenoid valve Y101 and
switch back service switch S151.
(1)
Control oil port
(2)
"Y"- port (external return to tank)
(2a)
"X"- port (external return to tank via solenoid valve Y101)
(3)
Poppet
(4)
Valve spring
(5)
Lock nut
(6)
Set screw
(7)
Jet bore (large)
(8)
Valve spring
(9)
Valve piston
(10)
Jet bore (small)
(11)
Plug screw
(12)
Protective cap
(13)
Plug connector
(A)
Return to tank (Filter chamber)
(Z)
Pressure oil to valve
4.0
&5
4.4
Section 4.0
Page 5
Fan drive (Two stage cooler fan RPM control)

(5.1)
(31.1) Pressure relief valve (maximum fan speed)
(34.1) Pressure filter with pressure differential switch B28
(37.1) Fan motor (Axial piston motor)
(37.2) Fan motor (Axial piston motor)
(38)
Check valve (Anti cavitation valve for fan drive motor)
(124) Pressure relief valve (medium fan speed)
(Y6a/b) Solenoid valve
(M6) Pressure check point
Function:
From pump (5.1) flows the oil through the filter (34.1) to the fan motors (37.1 +
37.2) and then back to the tank.
The check valve (38) act as an anti cavitation valve and is installed, because the fan
motor -driven by inertial force- is running for a short period after the oil flow is
inerrupted by solenoid valve (Y6a/b), or if the engine has been switched off.
The hydraulic circuit "Fan drive" is secured by the pilot controlled pressure relief
valves (31.1) and (124).
These valves are working together with the solenoid valve (Y6a/b), controlled by the
VHMS system, depending on the hydraulic oil temperature:
With de-energized solenoids Y6a and Y6b the relief valve (31.1) is
functioning and the fans are running with max. adjusted speed (1250 RPM)
With solenoid Y6a energized the relief valve (31.1) is not functioning and the
fans are running with a very low speed caused by the flow resistance only.
With solenoid Y6b energized the relief valve (124) is controlling the relief
valve (31.1) and the fans are running with 1000 RPM only.
(See also description on next page)
4.0
&6
4.5
Section 4.0
Page 6
Pressure relief valves and solenoid valve

Pressure relief valve (31.1)
(1)
Valve cartridge
(2)
Spring
(3)
Spring chamber
(4)
"X" port
(5)
Jet bore, Pilot poppet
(6)
Jet bore, Main piston
(7)
Main piston
(8)
Valve housing
(9)
Pilot poppet
(Y)
External leak oil port
(A)
Pressure port
(B)
Return oil port
Function:
Pressure in line A affects the main piston (7). At the same time there is pressure
via the jet bore (6) on the spring-loaded side of the main piston and via jet bore
(5) at the pilot poppet (9) of the relief valve cartridge (1).
If system pressure in line A exceeds the value set at the spring (2), pilot poppet
(9) opens. The signal for this comes from line A via the jet bores (6) and (5).
The oil on the spring-loaded side of the main piston (7) now flows via the jet
bore (5) and poppet (9) into the spring chamber (3).
From here it is fed internally by means of the control line (Y) to tank (port B).
Due to the state of equilibrium at the main piston (7), oil flows from line A to
line B, while the set operating pressure is maintained.
The pressure relief valve can be unloaded (Remote controlled) by means of the
port "X" and the function of the solenoid valve (126).( Function see next page)
continued
4.0
&7
Section 4.0
Page 7
Contd.
4.5
Pressure relief valves and solenoid valve, illustration (Z 21599)
Function:
With de-energized solenoids (Y6a and Y6b), the spool (3) keeps the "X"
connection of valve (31.1) and port B to port P closed. The pressure relief
valve (31.1) operates normal.
The energized solenoid Y6b, operate the spool (3) and a connection is made
between port P and port B and port "X" of valve (31.1)
The system pressure now opens the main piston (7) of valve (31.1), because
via solenoid Y6b (P to B) the oil from the rear side of piston (7) flows from
the "X"-port to the P connection of valve (124). The normal valve function
is now remote controlled by the pressure adjusted at valve (124).
The energized solenoid Y6a, operate the spool (3) and a connection is made
between port P and port A and port "X" of relief valve (31.1).
The system pressure now opens the main piston (7) of valve (31.1) because
via the "X"-port the oil from the rear side of piston (7) flows to tank. The a
normal relief valve function is eliminated.
4.0
&8
4.5
Section 4.0
Page 8
Fixed Displacement Pump, with variable setting

(1)
Drive shaft
(2)
Bearings
(3)
Cylinder with pistons
(4)
Center pin
(5)
Control lens
(6)
Q-min adjustment bolt
(7)
Q-max adjustment bolt
(8)
Pressure port
(9)
Tank port
Description.
Pump type A7F0 is a variable displacement pump, designed to operate in open
circuits. It has an internal case drain return. The rotary group is a robust self
aspirating unit. External forces may be applied to the drive shaft.
Changing the swivel angle of the rotary group is achieved by sliding the
control lens along a cylindrical formed track by means of an adjusting screw.
With an increase in the swivel angel, the pump output increase together
with necessary drive torque.
With an decrease in the swivel angel, the pump output decreases together
with the necessary drive torque.
When increasing to maximum swivel angle, there is a danger of

cavitation and over-speeding the hydraulic motor!
Controlling
Section 5.0
Page 1

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

(valves, switches, sensors etc.)
3+4
5.2
Pilot Pressure Supply and Adjustments
57
5.3
Remote control valves arrangement
5.4
Function principle of the

Electro-Hydraulic- Proportional Control
9 + 10
5.5
Potentiometer Control (Lever, Joy Stick)
11
5.6
Potentiometer Control (Pedal)
12
5.7
Proportional amplifier module, Type A

(for swing brake only)
13
5.8
Proportional amplifier module, Type B

(for Boom, Stick, Bucket, Swing and Travel)
14
5.9
Ramp Time Module

(Analogue command value module for Boom, Stick,
Travel and Swing function)
15
5.10
Adjustments of Amplifier Modules (General)
16
5.11
Adjusting the Amplifiers Type B
17 + 18
5.12
Adjusting the Amplifiers Type A
19 + 20
5.13
Adjusting the Ramp Time Module
21 + 23
5.0
&2
Controlling
5.0
Section 5.0
Page 2
General lay out

(E19) Electro proportional joy stick control
(E21a) Electro proportional pedal control, travel left crawler
(E21b) Electro proportional pedal control, travel right crawler
(E22) Electro proportional pedal control, swing brake
(E23) Electro proportional pedal control, bucket closed
(E24) Electro proportional pedal control, bucket open
X4, Pump bearing lubrication, pump support pressure (60bar)
X2 pressure, pilot pressure (45bar)
(8.1)
Gear pump for Pilot pressure, Pump regulation and Pump bearing
lubrication
(14)
Remote control valve blocks
(33)
Pressure filter with pressure differential switch B22
(35)
Control and filter panel
(41)
Main oil reservoir
(49)
Check valve
(85)
Bladder Accumulator 10 liter, 10bar (located underneath the
catwalk in front of the PTO)
(108.1) Pressure relief valve for pump support pressure X4 (60bar)
(108.1) Pressure relief valve for pilot pressure X2 (45bar)
General
The controlling includes the pilot pressure system and the pump regulation
system.
The pump (8.1) forces the oil through the filter (33) to all involved valves.
The pressure accumulator ensures that under any circumstances enough pilot
pressure oil is available. The accumulator (85) is also functioning as a
hydraulic battery for a certain time when the engine was shut down or to
pressure relive the system for repair works.
When the operator is using his controls an electrical signal causes energising
of the selected solenoid valve of the remote control valves(14).
By the function of the remote control valves pilot pressure oil is send to the
relevant control block spools which in turn allows operating hydraulic oil to
the users.
5.0
&3
Controlling
5.1
Section 5.0
Page 3

Solenoid valves
(Y5)
(Y6a)
(Y6b)
(Y16)
(Y17)
(Y17a)
(Y61)
(Y120)
(Y123a)
(Y123b)
(Y124a)
(Y124b)
(Y124c)
(Y125)
(Y126)
(Y127)
(Y128)
(Y129)
(Y130)
(Y131)
(Y136)
Swing parking brake operating pressure

Cooler fan RPM control minimum speed
Cooler fan RPM control medium speed
Travel parking brake operating pressure
Idle time control, (Pump control system)
Q-max (reduced oil flow at too cold oil)
X1 pressure, pumps 1 - 4
Hydraulic swing brake, operating pressure
Ladder raise
Ladder lower
Refilling arm raise
Refilling arm lower
Refilling arm stop (fix) arm park valve
Ladder fast movement
Flow reduction (Pump 1)
Proportional swing brake pressure
Track tension left crawler
Track tension right crawler
Fixed pump No1 (max. flow, X1= 45 bar)
Fixed pump No3 (max. flow, X1= 45 bar)
Engine radiator fan speed (infinitely variable)
Filter:
(33)
(34.1)
(34.2)
(36)
Pilot pressure and pump regulation

Hydraulic oil cooler fan drive
Engine radiator fan drive
Miscellaneous:
(22)
(26)
(29)
(31.1)
(31.2)
(58.1)
(58.2)
(62.3)
(62.4)
(81.1)
(81.2
(98)
(108.1)
(108.2)
(124)
Change over valve Electronic pump regulation or hydraulic constant regulation

Pressure relief valve safety valve to protect the travel parking brakes in case of
a defect rotary distributor
Pressure relief valve PTO gear lubrication
Pressure relief valve - Hydraulic oil cooler fan drive, with solenoid valve Y6a /
Y6b for fan RPM control
Pressure relief valve - Engine radiator fan drive, with proportional solenoid valve
Y136 for fan RPM control
Pressure increasing valve Track tensioning system L.H.
Pressure increasing valve Track tensioning system R.H.
Shut-off valve Truck tensioning system L.H.
Shut-off valve Truck tensioning system R.H.
Pressure reducing valve Qmax
Pressure reducing valve hydraulic constant regulation
Pressure relief valve climbing ladder
Pressure relief valve for pump support pressure X4 (60bar)
Pressure relief valve for pilot pressure X2 (45bar)
Pressure relief valve Medium speed cooler fan
continued
5.0
&4
Controlling
Cont'd:
5.1

Pressure switches:
(B16)
(B17-1)
(B21)
(B22)
(B27)
(B28)
(B48)
(B85-1)
(B86)
(B100)
(B101)

PTO gear lubrication pressure (lowest permissible pressure)
Engine radiator fan drive - Filter element monitoring
Pilot pressure - Filter element monitoring
PTO gear lubrication - Filter element monitoring
Hydraulic oil cooler fan drive - Filter element monitoring
Pressure transducer X1 pressure
Track tensioning system L.H.
Track tensioning system R.H.
Pressure check points:

(M1)
(M2)
(M3)
(M4)
(M5)
(M6)
(M7)
(M15)
(M29.7)
(M29.8)
(M30)
(M31)
(M32)

PTO gear lubrication pressure
Hydraulic oil cooler fan drive operating pressure
Engine radiator fan drive operating pressure
X1 pressure
Track tensioning system L.H. - operating pressure
Track tensioning system R.H. - operating pressure
X3 pressure to pump No 2, No 3 and No 4
Reduced X3 pressure
Reduced X3 pressure to pump No 1
Section 5.0
Page 4
5.0
&5
Controlling
5.2
Section 5.0
Page 5

Pilot Pressure Circuit
The pilot pressure oil is used for the following functions.
To move the control block spools, to supply the main pump regulation
system, to lubricate the main pump bearings, to release the travel- and swing
gear house brakes (spring loaded multi disk brakes), to drive the Lincoln
Lubrication pumps and to supply the hydraulic track tensioning system.
(E21a) Electro proportional pedal control, travel left crawler
(E21b) Electro proportional pedal control, travel right crawler
(E22) Electro proportional pedal control, swing brake
(E23) Electro proportional pedal control, bucket closed
(E24) Electro proportional pedal control, bucket open
(8.1)
Gear pump for Pilot pressure, Pump regulation and Pump bearing
lubrication
(14)
Remote control valve blocks
(33)
Pressure filter with pressure differential switch B22
(35)
(41)
Main oil reservoir
(49)
Check valve
(85)
Bladder Accumulator 10 liter, 10bar(located underneath the
Function: Study together with the hydraulic circuit diagram
The pump (8.1) delivers the oil through filter (33) to port A of the pressure
relief valve (108.2).
The pressure relief valve (108.2) maintains the adjusted pressure of 45 bar
(X2) for the pilot pressure system, the pump regulation system and the
supply for some auxiliary systems.
The pressure accumulator (85) holds an amount of oil under pressure to
provide sufficient pilot pressure during normal operation and to ensure a
limited number of lowering operations with the main drive motor at standstill.
The check valve (49) prevents return flow of the pilot pressure oil.
continued
5.0
&6
Controlling
5.2
Section 5.0
Page 6
Cont'd:
Pilot Pressure Circuit
(41)
Main oil reservoir
(49)
Check valve
(85)
Bladder Accumulator 10 liter, 10bar (located underneath the
(PX2) Pilot pressure line
(LX2)
Leak / return oil line from the remote control blocks
Function:
The pilot pressure oil flows via line (PX2) to port (P) of each remote control
block and is present via a gallery at all proportional and directional solenoid
valves.
These solenoid valves are energized by the function of the Electro
proportional controls (Joy sticks or pedals) and direct the pilot pressure oil to
the respective spools of the main control blocks with a variable pilot pressure
proportional to the deflection of the controls.
For the location and designation of the proportional and directional

solenoid valves of the remote control blocks refer to page 8 in this
section.
5.0
&7
Controlling
5.2
Section 5.0
Page 7
Checks and Adjustment of Pilot Pressure

(85)
Bladder Accumulator 10 liter, 10bar pre-charge pressure
(located underneath the catwalk in front of the PTO)
(M1) Pressure check point X4, pump support pressure (60bar)
(M2) Pressure check point X2 pressure, pilot pressure (45bar)
(Ma)
Pressure check point for accumulator (If not factory installed, fit a
T-union with test connector as shown in illustration Z 21635)
Since the X2 and the X4 pressure are influencing each other it is
always necessary to adjust both valves 108.1+108.2 alternately.
45 bar pressure X2, valve 108.2:
1.
Connect pressure gauge to check point (M2)
2.
Start the engine at let it run with maximum speed.
3.
Read pressure, required = 45+3 bar
If readjustment is required proceed as follow:
a) Remove dust cap (1).
c) Set pressure with set screw (3).
d) Tighten lock nut (2) and re-fit dust cap (1).
60 bar pressure X4, valve 108.1:
1.
Connect pressure gauge to check point (M1a)
2.
3.
Read pressure, required = 60-2 bar
a) Remove dust cap (1).
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 (Ma).
2.
3.
After build-up of pressure stop the drive motor, but do not turn the
key switch to zero position.
4.
Watch pressure gauge. Pressure should remain constant for at
least 5 minutes.
If the pressure droops the system must be checked for leakages.

To check the accumulator charging pressure refer to SERVICE
BULLETIN 21-426 latest edition.
5.0
&8
Controlling
5.3
Section 5.0
Page 8
Remote control valves arrangement

Remote control unit
Schematic code
(14.1)
Proportional
solenoid
Y20
Y63
Boom raising
Y64
Boom lowering
Bucket filling (curl)
Y65
Bucket emptying
L.H. swing
Y21
Y22
Y23
Y24
Y25
(95)
Y26
R.H. swing
Y66
Y27
Y28
(14.2)
Y29
Y30
Y31
Y32
Y34
Y35
Y36
Y37
Y38
Y39
Y40
Y67
R.H. Crawler forward
Y68
R.H. Crawler reverse

Stick extending
Y69
Stick retracting
Boom raising
Y70
L.H. Crawler reverse
Y71
L.H. Crawler forward

Y72
Stick extending
Clam closing
Y73
Clam opening
Boom raising
Y41
Y42
(14.3)
Y43
Y44
Y45
X46
Y47
R.H. swing
L.H. swing
Y33
(15)
Function
Directional
solenoid
Boom lowering
Y74
Stick extending
Y75
Stick retracting
Y76
Bucket emptying
Boom raising
Boom lowering
5.0
&9
Controlling
5.4
Section 5.0
Page 9
Function principle of the Electro-Hydraulic- Proportional Control

(1)
Pump
(2)
Filter
(3)
(4)
Check valve
(5)
Pressure Accumulator
(6)
Directional Solenoid valve, a side
(7)
Directional Solenoid valve, b side
(8)
Proportional Solenoid valve
(9)
Control valve block
(10)
Battery
(11)
Electronic units with amplifiers etc.
(12)
Control lever (Potentiometer control)
Function:
The electric-hydraulic control system is used to control the direction and
volume of oil flow to the operating cylinders and motors via the control valve
blocks.
Hydraulically:
The oil volume of pump (1) flows through filter (2) into the pilot pressure
system. The pressure is limited by the pressure relief valve (3).
With the pressurized oil stored in accumulator (5), a limited number of spool
movements can be carried out with the main drive motor at standstill.
When a lever (or pedal) is actuated, proportional solenoid valve (8) and one
of the directional solenoid valves (either 6 or 7) are energized, and allows the
pilot pressure oil to flow to the spools of the control blocks.
Electrical
Whenever a lever or a pedal is moved out of its neutral position, an amplifier
will created a current between 0 and 1000 mA. (For detailed information refer
to page 10 in this section)
Depending on the lever direction, simultaneously one of the directional
solenoid valves (either 6 or 7) is energized.
The proportional solenoid valve alters the pilot pressure, proportional to the
lever deflection, this results a spool movement between neutral and full stroke
position.
continued
5.0
& 10
Controlling
5.4
Section 5.0
Page 10
Function principle of the Electro-Hydraulic- Proportional Control
Cont'd:
(Exemplary illustration of the function of two axis with one Amplifier only)
(1)
Control lever (joystick)
(2)
Capacitor-Module
(3)
Ramp time module
(4)
Proportional-Amplifier-Module
(5)
Relay (Supply Voltage)
(6)
Proportional solenoid valve-(Pressure-Reducing Valve)
(7)
Directional solenoid valve
(8)
Control block spool
General Function
Control lever (1) is supplied with 24 VDC battery voltage for the switch contacts
and with 24 VDC capacitor supported to create the signal voltage.
When moving lever (1) out of its neutral position, 24 VDC battery voltage arrives at
relay (5) and energizes the Proportional Amplifier (4) with capacitor supported
24 VDC via terminal 1.
Depending on the function of the control lever, 1 to 4 Amplifiers can be involved
for the Y-axis (forward/ backwards direction) and 1 to 4 Amplifiers for the Xaxis (left/right direction.)
The polarity of the Output Signal from joystick (1), either positive or negative,
between 0 and 10 VDC indicates the direction of the lever movement and is
proportional to the lever deflection. This is the Input Signal to the ramp time
module (3) at terminal 5 which will arrive after the adjusted ramp time delay via
terminal 7 to the proportional amplifier (4) at terminal 5.
This Input Signal (between 0 and 10 VDC) is amplified to an Output Signal
between 0 to 1000 mA and is simultaneously send via terminal 7 (negative) or
terminal 8 (positive) to the Proportional Solenoid valve (6) and to the
Directional solenoid valve (7) via terminal 3 (negative) or terminal 9 (positive) to
the a or b-side.
The proportional Solenoid valve (6) alters the pilot pressure (X2) of 45 bar to a
value proportional to the Current Signal.
This pressure controls the movement of the control block spool (8) between
neutral and full stroke position.
5.0
& 11
Controlling
5.5
Section 5.0
Page 11
Potentiometer Control (Lever, Joy Stick)

(1)
Push button *
(2)
Toggle switch *
(3)
Push pin
(3.1)
Coil
(4)
Switch actuator
Switches for:
(5)
Direction monitoring
(5.1)
Directional contacts
(6)
Neutral position monitoring
(6.1)
Neutral position contacts
(7)
Electronic
* Alternative application
The Potentiometer Control (inductive, linear travel 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 YC and YD
Axis "X", splitted into the half axis XA and XB
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, two switches (5 and 6) are fitted per half axis; which are
actuated by the actuator (4) as soon as the lever gets moved out of its neutral
position.
For the Output Signal generation are used two coils (3.1), in series connected,
for one axis. The push pin motion causes a variation of the induction and this
in turn causes a signal variation at the AC voltage bridge. The AC voltage
gets rectified and becomes the DC-Signal Voltage for the amplifiers.
5.0
& 12
Controlling
5.6
Section 5.0
Page 12
Potentiometer Control (Pedal)

(1)
Potentiometer Control Unit
(2)
Pedal
(3)
Standard cable
(4)
Connection cable for combined operation
Application for:
(A)
Swing foot brake
(B)
Clam Opening/closing
(C)
Travelling
The Potentiometer Control (inductive, linear travel transmitter) contains
both the electronic and mechanical components which converts the pedal
movement into a proportional electrical voltage.
In order to be able to electrically monitor the pedal (2) action a neutral
position switch is fitted.
This switch closes when the pedal is moved out of the rest position.
When using the double unit (B) (combined operation) only the signal output
from one unit is used for the Clam Operation.
Due to the cross lined connection via the connection cable (4) the signal is
once positive and once negative (inverted), depending on the Pedal used.
5.0
& 13
Controlling
5.7
Section 5.0
Page 13
Proportional Amplifier Module, Type A

Type A (for swing brake only)
(LED) LED for Solenoid A or B
(P)
Set Potentiometer
R1 for the lowest current value
R2 for the highest current value
The amplifier module contains the necessary electronics for the control of two
proportional solenoids. Depending on the input polarity, either solenoid A or
solenoid B is operated.
The solenoid current (solenoid A - solenoid B) is measured and compared
with the external input value. Differences between feed-back and input
values, for example caused by changes in solenoid temperature or supply
voltage, are compensated.
The module also generates a direction-dependent voltage signal (solenoid A solenoid B) as soon as the solenoid current reaches the lowest set value.
The lowest and highest values are set externally via the potentiometer R1 + R2.
The brightness of the LED's changes with the current.
This function should not be used for setting.
5.0
& 14
Controlling
5.8
Section 5.0
Page 14
Proportional Amplifier Module, Type B

Type B (for Boom, Stick, Bucket, Clam, Swing and Travel)
(LED)
(P) Set Potentiometer:
AX: Proportional output AX active
- 10% for the lowest current value
AS: Switched output AS active
- J2 for the highest current value
BX: Proportional output BX active (Pt) Set Potentiometer for the Ramp
BS: Switched output BS active
Time
Power: Internal supply voltage
Fault: Fault indication
The amplifier module contains the necessary electronics for the control of two
proportional solenoids and two directional solenoids. The amplifier outputs
for proportional solenoids Ax and Bx and the switched outputs As and Bs are
activated by connecting a minimum of approx. 10% signal voltage at the
amplifier input.
A positive signal voltage controls outputs A, a negative signal voltage
controls output B.
A signal voltage of approx. 10% with respect to +/- 10 V input voltage at the
amplifier, produces a stepped output voltage. The height of this 10% jump
may be set separately for proportional outputs Ax and Bx via external
potentiometer. As the signal voltage rises the solenoid current for the
proportional outputs increases linearly.
A further step in output current occurs at approx. 90% signal voltage.
The maximum current or the 90% jump may be set separately for outputs Ax
and Bx via external potentiometers and hence the gradient of the output curve
may be influenced.
LED`s indicate the current output to each proportional and switched output,
whereby the brightness is approx. proportional to the solenoid current in Ax
and Bx. This function should not be used for setting.
A Ramp Time function is included in the amplifier which may be externally
changed by a set potentiometer. The setting range for the ramp time is approx.
from 80ms to 1s. The time setting applies to both up and down ramps and to
both proportional solenoids.
A fault is indicated by the LED Fault.
5.0
& 15
Controlling
5.9
Section 5.0
Page 15
Ramp Time Module

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

"w"
""
Actual ramp time

Internal adjustment variable
Reference potential / GND
General
The Ramp Time Module is snapped onto mounting rails inside the X2-box.
The electrical connection is done via screw terminals.
The module is operated with 24 VDC. A power supply provides the internally
required positive and negative supply voltages.
As soon as the power supply is in operation the green LED (power) lights up.
Internal command values
The internal command value signal is generated from the external command
value signal which is being applied to the differential input, a called-up signal
and an offset signal (zero point potentiometer "Z").
The external command value signal can, via potentiometer "G", changed from
0% to approx. 110%.
Command value call-ups
The call-up signals w1 to w4 also have an adjustment range of 0% to 110%.
No settings required. (factory set to 100%).
Ramp time call up
If the quadrant recognition is not activated, then each command value call-up
"w1" to "w4" is allocated its own ramp time "t1" to "t4".
As long as there is a signal change, the LED allocated to the actual ramp time
is alight.
5.0
& 16
Section 5.0
Page 16
Controlling
5.10 Adjustments of Amplifier Modules (General)

(1)
Potentiometer control
(2)
Terminal with a separating possibility
(3)
Ramp time module
(4)
Amplifier
(5)
Solenoid valve
(6)
Service module
Introduction:
The illustration shows simplified the route of the signal voltage from
Potentiometer Control (1) to Solenoid-Valve (5):
A.
With ramp time module,
i.e. Boom,- Stick,- Travel,- and Swing Function.
B.
Without ramp time module,
i.e. Bucket,- Clam,- and Swing Brake Function.
The ramp time modules (3) and the amplifiers (4) are adjustable.
Adjustments are required:
Ramp time modules
When commissioning the machine
When replacing a module
Amplifiers
When replacing a solenoid valve
When replacing an amplifier
For Checking and Setting the Signal Current at the Proportional-Amplifier (4),
both separating terminal (2) before and behind the Amplifier (4) must be opened.
For the setting procedure the signal voltage from the potentiometer control (1) can
be simulated with the potentiometer of Service-Module (6),which is installed on
the X2-panel.
Accessories required for the adjustments:
a) A multimeter, good readable for
values between 0 and 1000 mA.
b) More convenient is a second meter
for reading voltage simultaneously.
c) A simple wire, 1m length, or better
a prepared test lead same length
d) Four test leads, 1m length, with
banana type connectors on each end.
"a"
"b"
mA
VDC
"c" "d"
5.0
& 17
Controlling
Section 5.0
Page 17
5.11 Adjusting the Amplifiers Type B, illustration (Z 21642)

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

Push the yellow stud (1) down with a screw driver and turn it 90 to the left to
open or to the right to close the terminal. A spring pushes then the stud
outwards and the contacts are either open or closed.
continued
5.0
& 18
Controlling
Section 5.0
Page 18

Cont'd:
11.
12.
13.
If the setting with either positive or negative potential was successful, turn
the potentiometer (P) of the service module into the opposite direction and
check the settings with the other polarity i.e. if the first setting was done
with positive potential then turn the pot into negative direction; otherwise
vice versa.
Repeat the setting as described under item 7 to 10.
Remove multimeter, test wire, close* the terminals and reconnect the wire to
terminal 5 of the amplifier module.
Adjusting the Ramp Time

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

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

5.0
& 19
Controlling
Section 5.0
Page 19
The amplifiers for the crawler foot pedals are adjustable in the same way as
the amplifiers for the joy sticks.(refer to page 17 and 18 in this section)
The amplifier for the swing foot brake is similar.
Procedure for the swing foot brake:
1.
Open* the respective separating terminal (T1) between the pedal unit and
the amplifier module to be set.
2.
Open* the respective separating terminal (T2) between the amplifier module
to be set and the proportional solenoid valve.
3.
Disconnect the wire from terminal five.
4.
Connect the positive output of the service module with terminal five of the
amplifier module, using test lead (2).
5.
Attach a multimeter for voltage reading to the service module, using test
lead (3).
6.
Attach a multimeter (in series) for Amp reading to the terminal between
amplifier module and solenoid valve, using test lead (3).
7.
Press the pedal fully down ; or manual override the relay which allows 24 V
operating voltage to the amplifier module; thus the amplifier gets 24 V
operating voltage.
8.
Turn the potentiometer (P) of the Service-Module until the multimeter
shows 1 VDC ; the multimeter for the current reading will show a value
which should correspond to the value giving in the circuit diagram e.g. 10
mA. (10 % value)

continued
5.0
& 20
Controlling
Section 5.0
Page 20

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

multimeter shows 10 VDC; the multimeter for the current reading will show
a value which should correspond to the value giving in the circuit diagram
e.g. 500 mA. (100 % value).
It is important that the pilot pressure for the pressure increasing valve
is 19+/- 1 bar.
For more information refer to section 8.2 Swing Circuit
Repeat settings of item 8 and 9 until both mA values are stabilized, because
R1 and R2 influence each other.
Remove multimeter, test wire, close* the terminals and reconnect the wire to
terminal 5 of the amplifier module.

5.0
& 21
Controlling
Section 5.0
Page 21
5.13 Adjusting the Ramp Time Module

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

machine and whenever the Ramp Time Module has been replaced.
Do not start the motor, turn only the key switch in ON position.
Basic Adjustment:
1.
Connect 0VDC with a test lead from the red positive terminal of the service module
(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 +10VDC with a test lead from the red positive terminal of the service
module (6) to terminal 5 of the Ramp Time Module (3) and adjust with "Pot G" a
value of 10 VDC measured at terminal 7. Check the negative voltage as well(- 10
VDC). Disconnect the test lead after the setting is done.
Repeat settings of item 1 and 2 until both values are stabilized, because
"Pot Z" and "Pot G" influence each other.
The factory setting of potentiometer "w1" to "w4" for the command
value call-ups must not be adjusted.
continued
5.0
& 22
Controlling
Section 5.0
Page 22

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

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

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

Cont'd:
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 = 1000ms
Terminal 10
Stick out Neutral
+10V to 0V
t2
5,00 Volt = 20ms
Terminal 11
Neutral Stick in
0V to -10V
t3
0,10 Volt = 1000ms
Terminal 12
Stick in Neutral
-10V to 0V
t4
5,00 Volt = 20ms
Pot
E49 Boom
24 Volt at
Joy stick Signal
Terminal 9
Neutral Lower
0V to +10V
t1
0,10 Volt = 1000ms
Terminal 10
Lower Neutral
+10V to 0V
t2
5,00 Volt = 20ms
Terminal 11
Neutral Lift
0V to -10V
t3
0,10 Volt = 1000ms
Terminal 12
Lift Neutral
-10V to 0V
t4
5,00 Volt = 20ms
Pot
E50 Swing
24 Volt at
Joy stick Signal
Terminal 9
Neutral Swing R
0V to +10V
t1
0,10 Volt = 1000ms
Terminal 10
Swing R Neutral
+10V to 0V
t2
5,00 Volt = 20ms
Terminal 11
Neutral Swing L
0V to -10V
t3
0,10 Volt = 1000ms
Terminal 12
Swing L Neutral
-10V to 0V
t4
5,00 Volt = 20ms
E51 Left crawler

24 Volt at
Pot
Terminal 9
t1
0,10 Volt = 1000ms
Terminal 10
t2
0,10 Volt = 1000ms
Terminal 11
t3
0,10 Volt = 1000ms
Terminal 12
t4
0,10 Volt = 1000ms
E52 Right crawler

24 Volt at
Pot
Terminal 9
t1
0,10 Volt = 1000ms
Terminal 10
t2
0,10 Volt = 1000ms
Terminal 11
t3
0,10 Volt = 1000ms
Terminal 12
t4
0,10 Volt = 1000ms
Components
Section 6.0
Page 1

Section
6.0
Page
Components
6.1
Hydraulic
6.1.1
Main Control Blocks and High Pressure Filter FSA
6.1.2
Main Control Blocks and High Pressure Filter BHA
6.1.3
Distributor Manifold Restrictor blocks FSA
6.1.4
Distributor Manifold Restrictor blocks BHA
6.1.5
Single Control Blocks (Floating) for Stick and Boom
6.1.6
Restrictor Block with Pressure Relief Valve
6.1.7
Anti Cavitation Valve Block
6.1.8
Remote Control Valves
6.1.9
Directional Solenoid Valves (Three positions / 4-ways)
10
6.1.10
Proportional Solenoid Valves
11
6.1.11
High Pressure Filter
12
6.1.12
Control Blocks and Valves
6.1.13
Travel Brake Valve
19
6.1.14
Pressure Reducing Valve
20
6.1.15
Directional Solenoid Valves (Two positions / 4-ways)
21
6.1.16
Pressure Increasing Valve
22
13 - 18
6.0
&2
Components
Section 6.0
Page 2
6.1.1 Main Control Blocks and High Pressure Filter

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

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

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

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

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

SRV Bucket cylinder rod side
Pump circuit No. IV

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

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

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

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

ACV Travel motors
Pump circuit No. III

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

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

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

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

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

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

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

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

(18)
SRV Section K, Clam cylinder piston side

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

(65.3)
SRV Section N, Bucket cylinder piston side

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

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

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

(70.3)

(70.4)

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

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

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

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

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

(64.8)
ACV Block Section M, Bucket cylinder piston side
(70.12)
Restrictor block Section M, Bucket cylinder piston side

(70.13)

(70.14)

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

(Y132)
Single control block - Stick lowering function

Floating position
(Y133)

Floating position
(Y134)

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

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

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

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

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

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

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

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

the start, stop and direction of an oil flow.

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

pressure proportional to the electrical signal output of an amplifier.

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

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

when commissioning:
- Supply pressure to the valve
- Remove plug 8
- When no more air bubbles appear screw in plug 8.
6.0
& 12
Components
Section 6.0
Page 12
6.1.11 High Pressure Filter
There is one filter in each pump line installed.

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

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

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

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

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

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

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

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

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

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

Anti Cavitation Valve
Main Relief Valve
Closing plate
Plug screw
Spring
Valve cone
Dust cap
(9)
(10
(11)
(12)
(13) + 16)
(14)
(15)
(17)
Set screw
Lock nut
Spring, pilot part
Poppet
Jet bore
Spring, main cone
Main valve cone
Pilot oil dump line to tank
MRVs and SRVs are pilot operated relief valves. The MRV limits the max.
Pump supply line pressure. The SRV limits the max. possible pressure peak in
the service-line.
The valves have an opening characteristic. That means, that in case of
contamination after the response procedure no further pressure increasing is
possible and damages are avoided.
Function:
The circuit pressure P forces with the force F1 on the piston surface A of the
main valve cone (15). Because there is via the jet bore (16) the same pressure on
the back side of the main cone, this results together with the spring (14) force in
a force F2 that keeps the main cone closed. Via the jet bore (13) the circuit
pressure is in front of the poppet (12). Exceeds the circuit pressure the setting
value of the spring (11), the poppet opens against the force of the spring (11).
This causes that the force F2 decreases and there is no more balance condition
between F1 and F2. Valve cone (15) is moved upwards by the greater force F1.
That means there is now a direct connection from port P to T (tank).
ACVs serve for compensation possible lack of feed when the SRV at the
opposite port is actuated (see circuit diagram) and for avoiding cavitation
damages. In addition, to supply a user in case it is continuously moved by
acceleration forces at zero position of the control spool.
Function:
The circuit pressure inside the spring chamber closes the valve cone (7).
The back pressure of the return line acts on the surface of the valve cone (7).
Whenever the pressure in the service-line is lower than the springs force the
valve cone opens by the force of the back pressure and hydraulic oil is additional
supplied.
6.0
& 17
Components
Section 6.0
Page 17

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

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

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

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

Valves in valve block I and III.

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

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

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

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

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

the start, stop and direction of an oil flow.

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

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

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

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

and
Pump Regulation System
Section 7.0
Page 1

Section
7.0
Page
Main hydraulic pumps and pump regulation system
General
7.1
7.2
Main Pumps
7.1.1
Location of Pumps
7.1.2
Pump bearing flushing / lubrication
7.1.3
Operating Principles
8 15
7.1.4
Checks and Adjustments
16 20
Electronic Pump Regulation System

7.2.1
Electronic load limiting control - General
21
7.2.2
Microcontroller MC7
22
7.2.3
Checks and adjustments - General
23
Method A -
24
X1-pressure adjustment with 24V

supply to separating terminals at
the X2-switch board.
Method B - With the electronic service tool BB-3

- Language selection
7.3
7.4
PC4000_Sec_7-0_rev1.doc
25
25 + 26
- Excavator Type selection
27 + 28
- X1-pressure (max. current) adjust.
29 + 30
Method C - With a laptop and BODEM software

- Starting the program
31 + 32
- Language selection
33
- Excavator Type selection
34
- X1-pressure (max. current) adjust.
35
Hydraulic Constant Regulation System

7.3.1
General
36
7.3.2
37
X1-pressure adjustment (constant-pressure)
Determination of the Peak point
38
-1-
7.0
&2
-2-

and
7.0
Section 7.0
Page 2

General lay out (Hydraulic only)

(1 - 4) Main hydraulic pumps
(8.1)
Pilot pressure pumps
(33)
Pilot pressure filter unit
(108.1) 60 bar pressure relief valve
(85)
Pressure accumulator
(Y17) Solenoid valve: "Idle time control and low hydraulic oil temperature"
Q-min flow for all main pumps
(Y17a) Solenoid valve: "Remote control pressure"
Q-max flow reduction for all main pumps
(Y126) Solenoid valve: "Remote control pressure"
Q-max flow reduction for pump #1 only
(81.1) Pressure reducing valve: "Remote control pressure" Q-max flow
reduction for the warming-up period and flow reduction for pump #1
(81.2) Pressure reducing valve: " Pump regulation pressure X1 at hydraulic
pump regulation" (Hydraulic constant regulation mode)
(Y61) Proportional solenoid valve: "Pump regulation pressure X1 at electronic
pump regulation " (Standard operation mode)
(Y130) Solenoid valve: " Pump regulation pressure X1 = 45 bar for pump #1"
(fixed pump for swing)
(22)
Change over valve: "Electronic or Hydraulic pump regulation"
(74.1) Double check valve
(41)
-3-
7.0
&3
-4-

and
7.0
Section 7.0
Page 3

Pump regulation system
General
Controlled output flow of the main pumps is necessary:
To utilize the available engine power most efficiently in every operating
mode.
To limit the power consumption of the hydraulic pumps depending of the
load of the engine. (Electronic pump regulation with micro-controller MC7)
For additional functions, such as rotating dependent or temperaturedependent flow reduction.
Function:
X1 pump regulation pressure (0 34 bar):
The power controller of the main pumps can be remotely controlled by
applying an external pilot pressure (X1 ) at port X LR to the spring chamber of
the power control valve. The start of destroking can be varied in proportion to
the applied X1 - pressure.
X2 pilot pressure (45 bar):

Constant pilot pressure to regulate the main pumps at special circumstances,
e.g. to fix pump #1 and # 3 in Q-max position when swinging.
X3 remote control pressure (0 / 15 / 45bar):

Basic setting Q-min (0 bar), the flow rate increases with the
pilot pressure X3 at port Pst, up to Q-max (45 bar).
The hyperbolic power control is superimposed on the pilot pressure
signal and keeps the specified drive power constant. (p x Vg = constant).
The flow rates are:
Q-min.:
X3 = 0 bar
Q-max.: X3 = 15 bar
Q-max.:
X3 = 45 bar
X4 pump support pressure (60 bar):

Constant pilot pressure to support the regulation function at low operating
pressure and to lubricate the main pump bearings.
-5-
7.0
&4
-6-

and
7.0
Section 7.0
Page 4

Pump regulation system general
Function:
Solenoid valve Y17:
(44/2)*
If de-energized pumps #1-4 are in Q-min position. It gets energized as soon as
one of the control levers/pedals has been operated and de-energized when
ever all controls are in neutral position for more than 20 seconds.
Solenoid valve Y17a: (44/4)*
The solenoid is de-energized as long the hydraulic oil temperature is below
the values of temperature range T2 (depending on the filled in hydraulic oil)
shown in the table. ( pumps #1-4 are in Q-max. position)
Solenoid valve Y126: (44/2)*

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

With swing
Y17
Y17a
Y126
(1) = Energized
(0) = De-energized
Note:
* Electric circuit diagram page / column (based on Id # 897 844 40)

-7-
7.0
&5
-8-

and
7.0
Section 7.0
Page 5

Pump regulation system general
Function:
Proportional Solenoid valve Y61-1: (42/2)*
This valve, connected to the MC7 micro-controller (electronic pump
regulation), creates a X1-pressure depending on the load of the engine.
This X1-pressure is the information for the pumps to destroke from Q-max.
into Q-min. position, to keep the engine at rated speed of approx. 1800 RPM.
If energized, pump regulation pressure X1 = 45 bar for pump #1"
If energized, pump regulation pressure X1 = 45 bar for pump #3"
Pressure reducing valve 81.1:
"Remote control pressure" (X3)
-
Q-max flow reduction during the warming-up period for all pumps by the
function of solenoid valve Y17a.
Q-max flow reduction only for pump #1 while swinging with max. speed
by the function of solenoid valve Y126.
Pressure reducing valve 81.2:

Pump regulation pressure X1 at "hydraulic pump regulation" (Hydraulic constant
regulation mode) by the function of change over valve (22).
Change over valve 22:
Change over three way cock valve to select "Electronic or constant regulation
mode".
Note:
* Electric circuit diagram page / column (based on Id # 897 844 40)
-9-
7.0
&6
- 10 -

and
7.1
Section 7.0
Page 6
Main Pumps
7.1.1. Location of Pumps
(1 - 4)
Axial piston pump (swash plate type)
theoretical flow rate, each
1033 Liter/min
Drive speed*
n = 1378 min-1
for all working motions
(5.1)
Axial piston pump

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

(5.2)
Axial piston pump

Drive speed*
214 Liter/min
n = 2000 min-1
for radiator fan drive

(8.1)
Gear pump
Drive speed*
138 Liter/min
n = 1378 min-1
for pilot pressure supply

(8.2)
Gear pump
Drive speed*
138 Liter/min
n = 1378 min-1
F
* at 1800 min-1 input drive speed
- 11 -
7.0
&7
- 12 -

and
7.1
Section 7.0
Page 7
Main Pumps
7.1.2. Pump bearing flushing / lubrication
The installed main pumps are provided with an external cooling and lubrication
system for flushing of drive shaft bearing and shaft seal.
Oil supply is provided from the X4-pressure circuit.
To reach the restricted guidance of the coolant for external bearing flushing, the
throttle screw (located behind the union at port U) must screwed in all the way.
An information sign is fixed at the pump.
(1 4)
Main pumps
(20.1 20.4) Orifice (one for each main pump)
(33)
Filter for pilot pressure
(B E)
Ports for X4-pressure (pump support pressure)
(U)
Port for the pump bearing flushing / lubrication
- 13 -
7.0
&8
- 14 -

and
7.1
Section 7.0
Page 8
Main Pumps
7.1.3 Operating Principles
Main hydraulic pump A4VSLO 750 LR3DN / 30L
Type code explanation:
A4VSLO 750 LR 3 D N / 30 L
Rotation
Series
Basic adjustment for minimum displacement
With pressure control
Hydraulic remote adjustment facility
Constant power with hyperbolic curve
Displacement in cm3 at one (1) revolution
Axial piston pump series 4, variable displacement ,swash plate design for open circuits with charge pump
Function and characteristics:

The A4VSLO variable displacement axial piston pump in swash plate
design is intended for drives in open circuit operation.
The flow volume is proportional to the drive speed and the displacement.
By adjusting the swash plate a infinitely variable flow adjustment is
possible.
Pumps of the same nominal size can be built onto the trough drive.
Combinations with gear pumps are also possible.
(1)
Drive shaft
(2)
Cylindrical roller bearing
(3)
Slipper pad
(4)
Swivel angle indicator
(5)
Positioning piston
(6)
Swivel pin
(7)
Cylinder with pistons
(8)
Final connecting plate
(9)
(10)
Impeller (charging pump)
(11)
Splints for the through drive coupling (Aux. pump drive)
(12)
Swivel cradle
(13)
Q-min stop bolt
(14)
Power control valve
(15)
Pressure balance valve
(16)
Power curve correction
(17)
Pressure cut off valve
(18)
Q-max. stop bolt
(19)
Remote control valve
continued
- 15 -
7.0
&9
- 16 -

and
7.1
Section 7.0
Page 9
Main Pumps
Cont'd:
Symbol of main hydraulic pump A4VSLO 750 LR3DN / 30L
(1)
Main pump (swash plate pump, variable displacement)
(2)
Charging pump (impeller type pump)
(3)
Pump bearing group
(4)
Drive shaft
(5)
Non return valves
(6)
(6.1)
Mechanical stroke limitation*
(6.2)
Remote pressure (PST) operated piston for item 6
(6.3)
Mechanical stroke limitation*
(7)
Spool valve (pressure balance valve)
(8)
Nozzle
(9)
Power control valve
(10)
Nozzle
(11)
Pressure cut-off valve
(12)
Auxiliary pump (Gear pump, fixed displacement
(13)
Positioning piston
(14)
Slipper pad piston
(15)
Lever
(16)
Cam
(17)
Through drive shaft
* Factory side adjusted, no field adjustment required
B/B1
S
MB
ML
MST
R
T
P
PST
U
XLR
Pressure port
Oil intake (suction port)
Operating pressure check point
Charging pressure check point
Control pressure check point
Filler and bleeder port
Connection port for chip indicator
Pump support pressure (X4-pressure)
Remote control pressure port (X3-pressure)
Bearing flushing port
Regulating pressure port (X1-pressure)
continued
- 17 -
7.0
& 10
- 18 -

and
7.1
Section 7.0
Page 10
Main Pumps
Cont'd:
Sectional drawing of Power Controller LR3DN / 30L
(6)
(6.1)
Mechanical stroke limitation
(6.2)
Remote pressure (PST) operated piston for item 6
(6.3)
Mechanical stroke limitation
(7)
Spool valve (pressure balance valve)
(9)
Power control valve
(11)
(13)
Positioning piston
(14)
Slipper pad piston
(15)
Lever
Refer also to illustration Z 21550 on the previous page.
continued
- 19 -
7.0
& 11
- 20 -
7.1
Section 7.0
Page 11
Main Pumps
7.1.3 Operating Principles, illustration (Z 21552)
Cont'd:
Q-min position: (remember Q means volume)
When are the pumps in Q-min position?
A: Engine at standstill
B: Engine running and the controls are not used for 20 sec. or longer
at normal operating temperature
C: Engine running and service switch S150 activated
Example C with the following conditions:
Engine running (high idle)
Pump pressure smaller than X4 = 60 bar (pump support pressure)
X1 = 34 bar (pump regulation pressure), this pressure will not influence
the Q-min position under these conditions.
X3 = 0 bar (remote control pressure); Y17 de-energized (S150 activated)
for pumps #2, #3 and #4.
For pump #1, Y17 and Y126 de-energized
X4 = 60 bar (pump support pressure)
Pump support pressure is present at valve #7, the slipper pad of
piston #14 and the small area side of the positioning piston #13
Response of pump control mechanism:
Valve #7 moves to position "b" because the X4-pressure will overcome the
spring force, since the oil behind nozzle (8) flows through valve #6 (which is
in position "a", due to the missing remote control pressure X3) back to tank.
Pump support pressure X4 passes valve #7 position "b" and flows via power
control valve #9 position "a" to the large area side of positioning piston #13
Because the large area side of positioning piston #13 is approximately three
times larger as the small area side, the pump support pressure X4 of 60 bar
present on both sides, resulting in stronger force at the large area side, keeps
the pump in Q-min position.
The pump remains in Q-min position
continued
- 21 -
7.0
& 12
- 22 -

and
7.1
Section 7.0
Page 12
Main Pumps
Cont'd:
Q-max position: (remember Q means volume)
When does the pumps move into Q-max position?
and
and
and
Engine running
hydraulic oil at normal operating temperature (> T2)
the controls frequently used within 20 sec.
(or Service switch S151 activated)
a pump pressure below start of de-stroking.
Example with the following conditions:

Engine running (> 1800 min-1)
Pump pressure between 60 bar and 300 bar, present at the slipper pad
of piston #14 and the small area side of the positioning piston #13
X1 = 34 bar (pump regulation pressure)
X3 = 45 bar (remote control pressure); Y17 and Y17a energized
For pump #1, Y17 energized and Y126 de-energized
X4 = 60 bar (pump support pressure), present at valve #7.
Valve #7 moves to position "a" because the spring force is supported by the
X4-pressure, since the oil flow back to tank is blocked at valve #6 (which is
in position "b", due to the 45 bar remote control pressure X3).
The large area side of positioning piston #13 is connected, via power control
valve (9) position "a" and pressure balance valve (7) position "a", to the return
oil line.
The pump moves into Q-max position, because the pump pressure acts only at
the small area side of positioning piston #13.
The pump moves into Q-max position

continued
- 23 -
7.0
& 13
- 24 -

and
7.1
Section 7.0
Page 13
Main Pumps
Cont'd:
Q-max position: (remember Q means volume)
When does the pumps move into half Q-max position?
and
and
and
Engine running
hydraulic oil below normal operating temperature (< T2)
the controls frequently used within 20 sec.
(or Service switch S151 activated)
a pump pressure below start of de-stroking.

Pump pressure between 60 bar and 300 bar, present at the slipper pad
of piston #14 and the small area side of the positioning piston #13
X3 = 15 bar (remote control pressure); Y17 energized and Y17a de-energized
For pump #1, Y17 energized and Y126 de-energized or energized
Valve #7 moves to an intermediate position (in-between "a" and "b"), since a
certain amount of oil behind nozzle (8) flows through valve #6 (which is also
in an intermediate position, due to the 15 bar remote control pressure X3)
back to tank.
The large area side of positioning piston #13 is connected, via power control
valve (9) position "a" and pressure balance valve (7), to the return oil line.
The pump moves into Q-max position, because the return oil flow through
pressure balance valve (7) is restricted (due to its intermediate position),
resulting in a pressure at the large area side of the positioning piston (13).
The pump moves into Q-max position

continued
- 25 -
7.0
& 14
- 26 -

and
7.1
Section 7.0
Page 14
Main Pumps
Cont'd:
Destroking: (Pump moves from Q-max. into of Q-min. direction)
When does the pumps start to destroke
Engine running
and hydraulic at normal operating temperature (> T2)
and Service switch S150 deactivated
and The load stalls the engine RPM below 1800 min-1
(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)
Pump pressure 180 bar adjustable at main relief valve, present at the slipper
pad of piston #14 and the small area side of the positioning piston #13
X1 = 13 bar (constant regulation pressure adjustable at pressure reducing
valve 81.2) Change over valve (22) switched to hydraulic mode
X3 = 45 bar (remote control pressure); Y17 energized and Y17a energized
For pump #1, Y17 energized and Y126 de-energized
Valve #7 moves to position "a" because the spring force is supported by the
X4-pressure, since the oil flow back to tank is blocked at valve #6 (which is
in position "b", due to the 45 bar remote control pressure X3).
The operating pressure (with the value for start of de-stroking) at the slipper
pad of piston #14 moves the power control valve (9) into position "b" (against
the spring force supported by the X1-pressure).
This in turn connects the operating pressure to the large area side of
positioning piston #13.
times larger as the small area side, the operating pressure present on both sides,
resulting in stronger force at the large area side, moving the pump in Q-min
direction.
The pump de-strokes until the forces at positioning piston #13 are
balanced
continued
- 27 -
7.0
& 15
- 28 -

and
7.1
Section 7.0
Page 15
Main Pumps
Cont'd:
Pressure cut-off valve: (DR control valve, Pump moves into Q-min. position)
When is the pressure cut-off valve active?
Engine running
and With pump pressure above 300 bar
Pump pressure 300 bar
X3 = 45 bar (remote control pressure)
X4 = 60 bar (pump support pressure)
Independent of the position of power control valve #9 the pressure cut-off
valve #11 causes the pump to de-stroke to the pre-adjusted Q-min position.
The operating pressure moves the pressure cut-off valve #11 (at set pressure)
into position "b" and flows to the large area side of positioning piston #13.
times larger as the small area side, the operating pressure present on both
sides, resulting in stronger force at the large area side, moving the pump in Qmin position.
The pump moves into Q-min position
- 29 -
7.0
& 16
- 30 -

and
7.1
Section 7.0
Page 16
Main Pumps
7.1.4 Checks / Adjustments
Location of Adjustments
Legend for , illustration (Z21557)
(1)
(2)
Q-min. stop bolt
(3)
Pressure balance valve
(4)
Start of destroking
(5)
Power curve correction
(6)
(7)
Q-max. stop bolt
(8)
Angle indicator
The average length of the measurement "L" is: set crews (bolts )
location
1
2
3
4
5
6
7
length (mm)
13.8
26.9
8.0
8.1
---6.0
34.4
The measurement "L" is an orientation only if the adjustment is

totally out of requirements.
They must not be used for final adjustments.
The detail for (5) shows the position of the housing edge and the edge
of the eccentric set bolt. The example shows them in parallel position
which is mostly not the case. The adjustment should never be altered.
Further information see next pages
- 31 -
7.0
& 17
- 32 -

and
7.1
Section 7.0
Page 17
Main Pumps
Pressure balance valve (
P 20bar), illustration (Z21558)
1.
Connect a 60 bar pressure gauge to check point MST.
2.
Eliminate "Idle Time Control" by using the switch S151 of

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

pressure (X3) of approx.15 bar)
4.
5.
Gauge reading at MST must be 40 bar (20bar less than the pump
support pressure of 60bar
Loosen lock nut #4 and adjust with the set bolt #5
6.
Plug-on Y17a
Remove the pressure gauge and set S151 for "Idle Time"
elimination into normal position.
continued
- 33 -
7.0
& 18
- 34 -

and
7.1
Section 7.0
Page 18
Main Pumps
Cont'd:
Start of destroking(LR valve), illustration (Z21559)
The reason of this check is to make sure, the pump starts destroking at an
operating pressure of 180 bar with a pump regulation pressure X1 of 13 bar.
1.
2.
3.
4.
5.
6.
Connect a 400 bar pressure gauge to the pressure check point at the
respective high pressure filter for the pumps being checked.
Connect a 25 bar pressure gauge to pressure check point M15 at
the control and filter panel (X1-pressure).
Move the change over valve into position Hydraulic (constant
regulation mode).
Insert an Allen key into the angle indicator bolt (see illustration)
for better visibility of the start of destroking.
Start the engine, let it run with max. speed and adjust at pressure
reducing valve (81.2) the X1-pressure to 13 bar.
Stall the hydraulic for the pump to be checked and alter the
operating pressure with the MRV between 160 and 200 bar.
Start of destroking should be at an operating pressure of 180 bar,
shown at the gauge connected to the high pressure filter.

a)
Adjust with the MRV an operating pressure of 180 bar.
b)
Loosen lock nut #6 (Power control valve).
c)
Turn set bolt #7, so that the pump is still in Q-max. position,
but just at the beginning of destroking.
d)
Tighten lock nut #6.
7.
Re-adjust the operating pressure at the MRV to 310+10 bar and the
8.
X1-pressure at the pressure reducing valve (81.2) to approx. 4bar.

(For exact values refer to the final test report.)
Remove Allen key and gauges.
continued
- 35 -
7.0
& 19
- 36 -

and
7.1
Section 7.0
Page 19
Main Pumps
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 operating pressure between 300 bar and 310 bar.
1.
2.
3.
4.
Connect a 400 bar pressure gauge to the pressure check point at the
respective high pressure filter for the pumps being checked.
Insert an Allen key into the angle indicator bolt (see illustration) for
better visibility of the start of destroking.
Start the engine, let it run with max. speed, stall the hydraulic for
the pump to be checked and alter the operating pressure with the
MRV between 280 and 310 bar.
The angle indicator must indicate Q-min. position at a pressure of
300 bar shown at the gauge connected to the high pressure filter.

a)
Loosen lock nut #8.
b)
Turn set bolt #9, so that the pump is in Q-min. position at
the required value.
c)
Tighten lock nut #8.
5.
Re-adjust the operating pressure at the MRV to 310+10 bar
6.
Remove Allen key and gauges.
continued
- 37 -
7.0
& 20
- 38 -

and
7.1
Section 7.0
Page 20
Main Pumps
Cont'd:
Q-max. and Q-min. stop bolt, illustration (Z21561)
1.
2.
3.
5.
Unscrew box nut (10 or 14).

Loosen the lock nut (11 or 13)
Turn the stop (12 or 15) in or out until required length
Length "X" or "Y"
Tighten the lock nut and screw on box nut (12).
Turning the Q-min. stop bolt too much out can cause serious damage
to the pump.
The pump moves over 0 (zero) position into the opposite drive
direction: (suction line becomes pressure line and pressure line
becomes suction line)
- 39 -
7.0
& 21
- 40 -

and
7.2
Section 7.0
Page 21
7.2.1 Electronic load limiting control - general, illustration (Z 21713)

The drive train of the excavator consists of a diesel engine, 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
diesel engine.
Illustration Z21713 shows the principle of the electronic load limiting control.
The MC7 (E32-1) processes the following input signals:
Diesel engine speed (Pin 52 and 53) from magnetic pick-up (B64-1)
Switch signal (Pin 35) from engine control (3E14-1), 24V if n > 300 min-1
The MC7 (E32-1) processes the following output signals:
Signal value to control the proportional solenoid valve Y61-1 (Pin 28).
Switch signals (Pin 32 and 33), diagnostic of the MC7 (E32-1)
The diesel engine drives four 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 valve
Y61-1 at the hydraulic power controllers of each pump.
The actual speed of the engine is measured with a speed sensor at the
flywheel.
The auxiliary hydraulic pumps and other consumers can be operated

without being directly affected by the load limiting control.
The control algorithm of the load limiting control always compares the actual
engine speed with the rated load speed.
With increasing load the engine torque will rise and the engine speed will
drop.
For this reason the electronic load limiting control will be initiated when the
load speed falls below 1800 min-1 , i.e. the torque of the main pumps will be
lowered (by reducing the X1-pressure) until the rated speed of 1800 min-1 is
attained again.
- 41 -
7.0
& 22
- 42 -

and
7.2
Section 7.0
Page 22
7.2.2 Microcontroller MC7, illustration (Z 21716)

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

47 micro timer I contacts
MC7 - Block Circuit Diagram
- 43 -
7.0
& 23
- 44 -

and
7.2
Section 7.0
Page 23
7.2.3 Checks and adjustments

Microcontroller MC7, illustration (Z 21714a)
The adjustment of the X1-pressure can be done with three different methods:
A.
With 24V supply to separating terminals at the X2-switch board
or
B.
With the electronic service tool (EST) BB-3 connected to the serial
interface X13-1 (located in the operators cab)
or
C.
With a laptop, running the BODEM software, connected to the serial
interface X13-1 (located in the operators cab)
Procedure B and C should only be carried out by authorized

personnel. [ Dealer or KMG-factory staff ]
Because it is possible to influence the behavior of the pump regulation
system.
On the following pages are only the necessary setups described.
If additional information is required, please contact KMG-Service
department.
- 45 -
7.0
& 24
- 46 -

and
7.2
Section 7.0
Page 24
7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 21717)

Method A - X1-pressure with 24V supply to separating terminals at the X2switch board
Pre-conditions: Normal operating temperature, correct pilot pressure setting
and the system must be free of air.
1. Make sure the change over valve is in position Electronic Pump Regulation
2. Connect a pressure gauge to check point (M15), 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 628 and 629 for 10 seconds, using
two test leads and disconnect the voltage thereafter.
4. Selection of the required proportional solenoid valve:
With the main key switch still in on position, select the output terminal of
proportional solenoid valve Y61-1 as follows:
Connect 24V, simultaneously to terminal 626 and 627 for 2 seconds, using
two test leads and disconnect the voltage thereafter.
5. Adjusting the X1-pressure:
Start the engine, let it run with maximum speed.
Read the pressure, required = 34 0,5 bar
If necessary increase the X1-pressure as follows:
Connect 24V to terminal 628.
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.
6. To decrease the X1-pressure connect 24V to terminal 629 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.
- 47 -
7.0
& 25
- 48 -

and
7.2
Section 7.0
Page 25

With the electronic service tool (EST) BB-3 connected to the
serial interface X13-1 (located in the operators cab)
Pre-conditions: Normal operating temperature, correct pilot pressure setting and the
system must be free of air.
Method B -
2. Connect a pressure gauge to check point (M15), 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 X13-1,
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.
Language selection
To change the language press simultaneously
the buttons ALT + Clear
The language selection menu appears
continued
- 49 -
7.0
& 26
- 50 -

and
7.2
Section 7.0
Page 26

Method B
Cont'd:
Language selection
Press button 2
The language will change to English
One of the four main menu items can be selected using the given keys. (Fig.1)
- 51 -
7.0
& 27
- 52 -

and
7.2
Section 7.0
Page 27

Method B
Excavator Type selection:
Press F1 Config/Cal
Config/Cal.
Press 4 Device List.
Press 1 Device List.
Select the excavator type by pressing

or . PC4000/5500/8000/Default
If Default is selected, the type will be
determined by the wiring.
Press ENTER . Accept value/condition
Press MENU . Return to sub menu.
continued
- 53 -
7.0
& 28
- 54 -

and
7.2
Section 7.0
Page 28

Method B
Cont'd:
Press MENU . Return to main menu.
Press 1 . Save Params. This menu item permits

storageof all edited parameters in the EEPROM
of the MC electronics.
Press TEACH . Activate storage menu.
Press ENTER . Store parameters.
Press MENU .Abort.
- 55 -
7.0
& 29
- 56 -

and
7.2
Section 7.0
Page 29

Method B
X1-Pressure (maximum current) Adjustment:
Press F1 Config/Cal
Config/Cal.
Press 2 Max current
Start the respective diesel engine and let it run

with maximum speed. (high free idle)
Do not load the diesel engine.
Press 1 Valve 1. (Engine 1) or
Press 2 Valve 2 (Engine 2)
Press ENTER . Acceptance of new value
Check the X1-pressure with apressure

gauge and set it to the
desired value by pressing or .
Press MENU . Return to sub menu.
continued
- 57 -
7.0
& 30
- 58 -

and
7.2
Section 7.0
Page 30

Method B
Cont'd:
Press MENU . Return to main menu.
Press 1 . Save Params. This menu item permits

storageof all edited parameters in the EEPROM
of the MC electronics.
Press TEACH . Activate storage menu.
Press ENTER . Store parameters.
Press MENU .Abort.
If all adjustments are correct and stored in the MC7, proceed as follow:
Stop the engine and turn key switch (S1) in OFF position
Disconnect the electronic service tool (BB-3) and the pressure gauge.
- 59 -
7.0
& 31
- 60 -

and
7.2
Section 7.0
Page 31

With a laptop computer and BODEM software connected to the
serial interface X13-1 (located in the operators cab)
Pre-conditions: Normal operating temperature, correct pilot pressure setting and the
system must be free of air.
Method C -
2. Connect a pressure gauge to check point (M15), using a long pressure gauge hose to be
able reading the pressure inside the operators cab.
3. Connect the laptop computer to the data link adapter X13-1,
with key switch (S1) in OFF position.
4. Make sure that the dongle is connected to the laptop computer. If not
5. Turn key switch (S1) in ON position.

6. Start the computer.
7. Click on the Bodem - icon to start the program.
continued
- 61 -
7.0
& 32
- 62 -

and
7.2
Section 7.0
Page 32

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

(Standard COM1), confirm with OK and leave the program.
10. Start the program again. Now the computer is connected to the Microcontroller.
- 63 -
7.0
& 33
- 64 -

and
7.2
Section 7.0
Page 33

Method C
Language selection
Open menu FILE Language , select the required language and confirm with OK .
- 65 -
7.0
& 34
- 66 -

and
7.2
Section 7.0
Page 34

Method C
Open menu
Display/Edit parameters Device list , select the required Excavator type and
confirm with OK .
After confirming the Excavator type, confirm saving the parameters with OK.
- 67 -
7.0
& 35
- 68 -

and
7.2
Section 7.0
Page 35

Method C
Open menu
Display/Edit parameters Max current , adjust the required pressure with the
slide bar and confirm with OK .
After adjusting the pressure, confirm saving the parameters with OK.
- 69 -
7.0
& 36
- 70 -

and
7.3
Section 7.0
Page 36

1.3.1. General
The pilot pressure pump (8.1) delivers the oil through the pressure filter
(33) to port A of the pressure relief valve (108.2) for limiting the pilot
pressure (X2). The 45 bar limited pilot pressure oil flows through the
solenoid manifold to the pressure reducing valve (81.2), which reduces the
X2 pressure to the necessary constant X1 pressure, to prevent the engine from
overloading.
For testing purposes the pump regulation system can be changed to the
hydraulic operation mode. In case of a failure in the electronic
regulation system the hydraulic operation mode can also be used for
emergency operation.
The standard operation mode of the pump regulation system is the
Electronic Operation Mode.

(1 - 4) Main hydraulic pumps
(8.1)
Pilot pressure pumps
(33)
Pilot pressure filter unit
(85)
Pressure accumulator
(81.1) Pressure reducing valve: "Remote control pressure" Q-max flow
reduction for the warming-up period and flow reduction for pump #1
(81.2) Pressure reducing valve: " Pump regulation pressure X1 at hydraulic
pump regulation" (Hydraulic constant regulation mode)
(Y61) Proportional solenoid valve: "Pump regulation pressure X1 at electronic
pump regulation " (Standard operation mode)
(22)
Change over valve: "Electronic or Hydraulic pump regulation"
(41)
- 71 -
7.0
& 37
- 72 -

and
7.3
Section 7.0
Page 37

1.3.2. X1-pressure adjustment (constant-pressure) , illustration (Z 22360)
1.
2.
3.
Connect gauges to check points (M11, M12, M13; M14 and M15).
Check High Idle speed = 1900+35 min-1.
4.
5.
6.
Shift the three way cock valve (22) to position Hydraulic regulation
Set the X1-pressure at pressure reducing valve (81.2) to approx. 4 bar **.
Apply max. load to all pumps (e.g. extend the boom cylinder to the
stop position until the hydraulic system stalls), and increase the
pressure at all 4 MRVs equally to 260 bar*.
Check the engine speed. Required = 1850+10 min-1.
If necessary correct the X1-pressure at pressure reducing valve (81.2)
until the required engine speed is obtained. Record this pressure for other
tests.
Shift the three way cock valve (22) to position Electronic regulation
Reset the MRVs to 310 bar+5bar , and remove the gauges.
7.
8.
*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:
Remove dust cap (d).
Loosen the lock nut (e).
Turning the set screw (f) cw the pressure will increase.
- 73 -
7.0
& 38
- 74 -

and
7.4
Section 7.0
Page 38
Determination of the Peak point (Engine performance) ,illustration (Z 22360)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
F
11.
12.
13.
Connect pressure gauges to check points M11, M12, M13; M14 at the
high pressure filter.
Connect a pressure gauge to the X1 pressure check point M15.
Unplug solenoid valves Y6a and Y6b to ensure that the hydraulic oil
cooler fans are running with maximum speed.
Unplug the solenoid valve Y136 to ensure that the engine radiator fan is
running with maximum speed.
Check High Idle speed = 1900+35 min-1.
Set the MRV individually to approx. 120 bar *, to prevent the engine from
overloading during the test.
Shift the three way cock valve (22) to position Hydraulic regulation.
Set the X1-pressure at pressure reducing valve (81.2) > 34 bar **, to
ensure that the pumps remaining in Q-max. flow position during the test.
Apply max. load to all pumps (e.g. extend the boom cylinder to the stop
position until the hydraulic system stalls), and increase the pressure at
all 4 MRVs *equally until the engine speed is 1800
10 min-1.
Record this pressure for other tests. Required: 4 times 165
5 bar.
If the operating pressure respectively the engine speed is higher than
required there is probably not the full volume available.
If the operating pressure respectively the engine speed is lower than
required there is probably not the full engine power available.
Re-set the X1-pressure at pressure reducing valve (81.2) as recorded**.
Shift the three way cock valve (22) to position Electronic regulation
Reset the MRVs to 310 bar+5bar , and remove the gauges.
*Altering the MRV-Setting:
Remove dust cap (a).
Turning the set screw (c) cw the pressure will increase.
**Altering the X1-Setting:
Remove dust cap (d).
Loosen the lock nut (e).
Turning the set screw (f) cw the pressure will increase.
- 75 -
Operating Hydraulic
Section 8.0
Page 1

Section
8.0
Page
Operating Hydraulic
General
8.1
Hydraulic for the attachment cylinder FSA and BHA
8.2
Hydraulic for the swing circuit
8.3
Hydraulic for the travel circuit
2+3
8.0
&2
Operating Hydraulic
8.0
Section 8.0
Page 2
General
Overall view of the Hydraulic system, illustration (Z 21955):
(1 4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Main pumps
High pressure filters
Main control blocks
Attachment cylinders
Swing motors
Rotary joint
Travel motors
General information
The control blocks, the piping to the distributor manifold and the connecting
hoses to the attachment are different between the Backhoe Attachment (BHA)
and the Front Shovel Attachment (FSA). If a conversion is required, contact
the service department for further information.
Function:
Study together with the circuit diagram.

The following numbering refers to the hydraulic circuit diagram.
Each main pump (1 to 4) delivers oil trough the high pressure filter (13.1 to
13.4) to port P of the main control blocks (9 to 12).
This results in four main circuits.
If all spools of the control blocks (1 to 4) are in neutral position, the oil leaves
the block at port T and returns via return oil pipes, return oil collector
manifold (107), return oil pipes (L6 and L7), return oil collector tube (54),
back pressure valve (55) and the return oil filters (49.1 - 49.4) into the tank.
The function of back pressure valve (55) ensures:
- sufficient oil supply for all anticavitation valves
- and that sufficient oil is forced through the oil coolers.
If a control lever or pedal is actuated, pilot pressure oil moves the spools of the
control blocks, directing the oil flow from the main pumps to one side of the
user (either cylinders or motors). From the opposite side of the user the oil
returns to the control block and from there via the return oil circuit back into
the tank.
Each circuit is provided with one MRV (also called primary valve, at least one
SRV (also called secondary valve) and at least one flow restrictor.
continued
8.0
&3
Operating Hydraulic
8.0
Section 8.0
Page 3
General
Cont'd:
Floating function of boom and stick cylinders FSA:
illustration (Z 22005):
The Excavator operates automatically with the float position for boom and stick
activated.
That means the lowering movement of boom and stick is always done in the float
position.
For deactivation of the float position, two push buttons are installed:
a) S95 in the right joy stick (E19) for the Boom function
b) S95a in the left joy stick (E20) for the Stick function
Press the respective button and keep it depressed as long as the float position shall
be deactivated.
When releasing the button the float position is activated again.
Function:
The additionally installed single control blocks (Y132, Y133,Y134 and Y135)
connect the piston side of the cylinders with the rod side and also with the tank:
Y132, Y133 and Y134 for the Stick cylinders
Y135 for the Boom cylinders
In normal operation mode (i.e. float position) the pilot pressure oil is directed via
Y132a, Y133a and Y135a to the single control blocks when lowering the boom
or stick.
If a pressurised lowering of the cylinders is required the pilot pressure oil is
directed via Y132a, Y133a and Y135a to the main control blocks.
The solenoid valves Y132a, Y133a and Y135a (4/2-directional control valves) are
controlled by push button S95 and S95a.
Boom: S95 ON Y135a ON
Float position deactivated

S95 OFF Y135a OFF
Float position activated

Stick:
S95a ON Y132a + Y133a ON

S95a OFF Y132a + Y133a OFF

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
Hydraulic for the

Attachment Cylinders
Section 8.1
Page 1

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

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

(E19)
Control lever (Joy stick)
(D32)
Time relay Pilot control: Neutral position monitoring
(YD)
Direction (axis) of joy stick
(-10V)
Signal voltage (Maximum)
(gn)
Colour code of signal voltage cable ( Joy stick)
(X2...)
Terminal rail with number
(E49)
Ramp time module
(A10)
Amplifier module Boom
(A10a)
(A10b)
Amplifier module Boom up or Bucket when not raising
the boom.
(A10c)
(K58)
Relay pilot control:
Contacts 6 / 10 only closed while lifting the boom.
(K76)
Contacts 8 / 12 only closed while traveling the left crawler.
(K78)
Contacts 6 / 10 only closed while traveling the right crawler.
(14.1 14.3)
(15)
(95)
(Y63 + Y69)
Proportional solenoid valve
(Y73 + Y76)
(Y20 + Y40)
(Y33 + Y46)
(I IV)
Main control blocks I IV
(42)
Electrical signal flow.
Signal voltage of joy stick (E19) arrives via ramp time module (E49) at
terminal 5 of the amplifier modules (A10 to A10c) and further to the
proportional and directional solenoid valves of the remote control blocks (14.1,
14.2, 14.3, and 15).
Hydraulic signal flow. (pilot pressure)
When the proportional and directional solenoid valves are energized pilot
pressure oil flows to the pilot pressure ports of the main control blocks.
Hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (I to IV)
and arrives via distributor manifold (42) at the hydraulic cylinders.
8.1
&3
E19
D32
gn
YD
X2C
195
X2C
194
E49
-10V
K76
K78
12
10
A10b
A10
A10a
A10c
7-8
7-8
7-8
7-8
X2F
X2F 21
20
X2F 40
X2F 48
39
3
47
15
14.2
Y73
1
b1
b2
b3
I B1 B2
B3
Y69
A1
a1
A2
a2
Y33
95
1
b1
A3
a3
b2
b3
b4
II B1 B2
B3
B4
A1
A2
A3
A4
a1
a2
a3
a4
14.3
14.1
Y40
Y63
b1
b2
III B1 B2
A1
A2
a1
a2
Y76
Y20
Y46
b3
b1
b2
b3
b4
B3
IVB1
B2
B3
B4
A3
A1
A2
A3
A4
a1
a2
a3
a4
a3
42
Z 21957
Hydraulic for the

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

(E19)
(D32)
(YD)
(-10V)
(gn)
(X2...)
(E49)
Ramp time module
(A10)
(A10a)
(A10b)
(A10c)
(K76)
(K78)
(14.1 14.3)
(15)
(95)
(Y63 + Y69)
(Y73 + Y76)
(Y20 + Y40)
(Y33 + Y46)
(I IV)
(42)
14.2, 14.3, and 15).
Hydraulic oil flow
8.1
&4
YC
+10V
E19
D32
gn
X2
482
X2
481
E49
Bucket
6
4
K58
(boom up)
K76
10
K78
12
(left crawler)
10
(right crawler)
A10b
A10
A10a
A10c
7-8 9
7-8 9
7-8 9
7-8 9
X2 207 215
X2 226 227
X2 251 256
X2F
15
14.2
Y73
1
95
1
14.3
14.1
Y41
Y63
Y76
Y21
Y47
Y135a
b1 b2
b3
I B1 B2
B3
A1
a1
A2
a2
b1
A3
a3
b2
b3
b4
II B1 B2
B3
B4
b1
A1
A2
A3
A4
a1
a2
a3
a4
b2
III B1 B2
A1
A2
a1
G
a2
L
b1
b3
B3
A3
a3
M
b2
b3
b4
IVB1 B2
B3
B4
A1
A2
A3
A4
a1
a2
a3
a4
42
Y135
P
T B
Z 21958
Hydraulic for the

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

(E19)
(D32)
(YC)
(+10V)
(gn)
(X2...)
(E49)
Ramp time module
(A10)
(A10a)
(A10b)
Amplifier module Boom up or Bucket
(A10c)
(K58)
(K76)
(K78)
(14.1 14.3)
(15)
(95)
(Y63)
(Y73 + Y76)
(Y21 + Y41)
(Y47)
(Y135a)
(Y135)
Single control block
(I IV)
(42)
Signal voltage of joy stick (E19) arrives via ramp time module (E49) at terminal 5
of the amplifier modules (A10, A10a and A10c) and further to the proportional
and directional solenoid valves of the remote control blocks (14.1, 14.3, and 15).
When the proportional and directional solenoid valves are energized pilot pressure
oil flows to the pilot pressure ports of the main control blocks and single control
block (Y135).
Hydraulic oil flow
Now piston and piston rod side of the boom cylinders are connected, so that the
boom lowers only by gravity. The excess oil flows via distributor manifold (42)
through the main control blocks (II and III) and single control block (Y135) back
to tank.
8.1
&5
YC
+10V
E19
D32
gn
X2C
195
X2C
194
E49
5
7
K76
12
10
K78
5
A10b
A10
A10a
A10c
7-8 9
7-8 9
7-8 9
7-8 9
X2F
X2F 21
29
X2F 40
X2F 48
41
53
15
14.2
Y73
b1
b2
b3
b1
b2
b3
I B1 B2
B3
II B1
B2
B3
B4
A1
A2
A3
A4
a1
a2
a3
a4
Y69
A1
a1
A2
a2
Y32
95
1
A3
a3
Y41
Y63
b4
14.3
14.1
Y47
b3
b1
b2
b3
III B1 B2
B3
IVB1
B2
B3
B4
A1
A2
A3
A4
a1
a2
a3
a4
A1
A2
a1
H
Y21
b2
b1
Y76
a2
L
A3
a3
M
b4
42
Z 21959
Hydraulic for the

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

(E19)
(D32)
(YC)
(+10V)
(gn)
(X2...)
(E49)
Ramp time module
(A10)
(A10a)
(A10b)
Amplifier module Boom up or Bucket
(A10c)
(K76)
(K78)
(14.1 14.3)
(15)
(95)
(Y63 + Y69)
(Y73 + Y76)
(Y21 + Y41)
(Y32 + Y47)
(I IV)
(42)
14.2, 14.3, and 15).
Hydraulic oil flow
.
8.1
&6
YC
+10V
E20
D32
gn
X2
480
X2
479
E48
Bucket fill
(Stick out)
12
(right crawler)
K76
A8
A8a
10
(left crawler)
7-8
K78
K74
7-8
A9
X2 237 236
7-8
X2 210 203
14.2
Y68
14.3
15
Y30
Y71
b1 b2
b3
b1
I B1 B2
B3
II B1
B2
B3
A1
A2
a1
a2
A1
a1
X2 254 253
A2
a2
A3
a3
b2
b3
b4
Y74
Y42
Y37
b1
b2
b3
b4
B4
IVB1
B2
B3
B4
A3
A4
A1
A2
A3
A4
a3
a4
a1
a2
a3
a4
42
Y132
P
T B
Y133
Y134
T B
T B
Z 21960
Hydraulic for the

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

(E20)
(D32)
(YC)
(+10V)
(gn)
(X2...)
(E48)
Ramp time module
(A8)
Amplifier module Stick
(A8a)
(A9)
Amplifier module Stick extend or Bucket fill
(K74)
Contacts 5 / 9 only closed while extending the stick.
(K76)
(K78)
(14.2 + 14.3)
(15)
(Y68)
(Y71 + Y74)
(Y30 + Y37)
(Y42)
(Y132 Y134)
Single control blocks (closed ports while extending the stick)
(I, II + IV)
(42)
of the amplifier modules (A8, A8a and A9) and further to the proportional and
directional solenoid valves of the remote control blocks (14.2, 14.3, and 15).
oil flows to the pilot pressure ports of the main control blocks .
Hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (I, II, IV)
8.1
&7
YC
+10V
E20
D32
gn
X2C
193
X2C
192
E48
K76
K78
11
(left crawler)
12
(right crawler)
A8
A11
A8a
7-8 9
7-8 9
7-8 9
X2F 10
X2F 23
22
X2F 51
50
15
14.2
Y68
Y72
Y30
14.3
Y38
Y74
b1 b2
b3
b1
b2
b3
b4
I B1 B2
B3
II B1
B2
B3
B4
A1
A2
A3
A4
A1
a1
a2
a3
a4
a1
A1
a1
A2
a2
A3
a3
b1
Y42
b2
b3
b4
IVB1 B2
B3
B4
A2
A3
A4
a2
a3
a4
42
Z 21961
Hydraulic for the

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

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

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

(E20)
(D32)
(YD)
(-10V)
(gn)
(X2...)
(E48)
Ramp time module
(A8)
(A8a)
(A9)
Amplifier module Stick extend or Bucket fill
(K74)
(K76)
(K78)
(14.2 + 14.3)
(99.5)
Check valve (necessary for combined operation of travel
right and retracting the stick)
(Y68 + Y74)
(Y31 + Y43)
(Y132a + Y132a) Directional solenoid valve
(Y42)
(Y132 Y134)
Single control blocks (ports A-B-T connected while
retracting the stick)
(I + IV)
Main control blocks I + IV
(42)
of the amplifier modules (A8, A8a) and further to the proportional and directional
solenoid valves of the remote control blocks (14.2 and 14.3).
oil flows to the pilot pressure ports of the single control blocks (Y132, Y133 and
Y134).
Hydraulic oil flow
Now piston and piston rod side of the stick cylinders are connected, so that
the stick lowers only by gravity. The excess oil flows via distributor manifold
(42) through the single control blocks (Y132, Y133 and Y134) back to tank.
8.1
&9
E20
D32
gn
YD
X2C
193
X2C
192
E48
-10V
K76
K78
11
(left crawler)
12
(right crawler)
A8
A11
A8a
7-8 3
7-8 3
7-8
X2F 10
X2F 23
14
28
X2F 51
52
15
14.2
14.3
b1
b2
b3
b1
b2
b3
b4
I B1 B2
B3
II B1
B2
B3
A1
A2
a1
a2
Y68
A1
a1
A2
a2
Y72
Y31
A3
a3
Y39
Y74
Y43
b1
b2
b3
b4
B4
IVB1
B2
B3
B4
A3
A4
A1
A2
A3
A4
a3
a4
a1
a2
a3
a4
42
Z 21963
Hydraulic for the

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

(E20)
(D32)
(YD)
(-10V)
(gn)
(X2...)
(E48)
Ramp time module
(A8)
(A8a)
(A11)
(K76)
(K78)
(14.2 + 14.3)
(15)
(Y68)
(Y72 + Y74)
(Y31 + Y39)
(Y43)
(I, II + IV)
Main control blocks I, II + IV
(42)
Hydraulic oil flow
8.1
& 10
E19
XB -10V
ws/gn
D32
X2
477
X2
476
10
K50
(Hydr. oil
not overheat )
K58
(Boom up )
10
K71
(Bucket fill )
K74
(Bucket fill )
(Stick out )
K58
K71
K76
(Boom up )
10
(left crawler)
10
A10b
A9
7-8
7-8
5
3
X2 210 205
X2 235 230
11
(right crawler)
K78
A9a
A9b
7-8 3
7-8
X2 252 249
X2 224 220
15
14.2
Y69
Y32
b1
b2
b3
I B1 B2
B3
A1
a1
A2
a2
Y71
b1
A3
a3
b2
b3
b4
II B1 B2
B3
B4
A1
A2
A3
A4
a1
a2
a3
a4
Y36
Y64
b1
b2
III B1 B2
A1
A2
a1
G
14.3
14.1
a2
L
Y22
b1
b3
B3
A3
a3
M
Y75
Y44
b2
b3
b4
IVB1 B2
B3
B4
A1
A2
A3
A4
a1
a2
a3
a4
42
Z 21965
Hydraulic for the

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

(E19)
(D32)
(XB)
(-10V)
(ws / gn)
(X2...)
(A9)
Amplifier module Bucket
(A9a)
(A9b)
(A10b)
Amplifier module Boom up or Bucket when not raising
the boom.
(K50)
Relay pilot control: Bucket cut-off
Contacts 6 / 10 only closed if the hydraulic oil is overheated.
(K58)
Contacts 6 / 10 and 5 / 9 only closed while lifting the boom.
(K71)
Contacts 6 / 10 and 5 / 9 only closed while filling the bucket.
(K74)
(K76)
(K78)
(14.1 14.3)
(15)
(Y63 + Y64)
(Y71 + Y75)
(Y22 + Y32)
(Y36 + Y44)
(I IV)
(42)
Signal voltage of joy stick (E19) arrives via relay contacts at terminal 5 of the
amplifier modules (A9, A9a, A9b and A10b) and further to the proportional and
directional solenoid valves of the remote control blocks (14.1, 14.2, 14.3, and 15).
Hydraulic oil flow
8.1
& 11
E19
XB -10V
D32
ws/gn
X2C
190
X2C
189
10
K50
(Hydr. oil
not overheat )
K76
K78
10
(left crawler)
A9
7-8
X2F 24
11
(right crawler)
19
A9a
A9b
7-8
7-8
X2F 38
X2F 49
34
3
46
15
Y71
b1
b2
b3
b4
II B1 B2
B3
B4
A1
A2
A3
A4
a1
a2
a3
a4
Y36
Y64
b1
b2
III B1 B2
A1
A2
a1
G
14.3
14.1
a2
L
Y22
b1
b3
B3
A3
a3
M
Y75
Y44
b2
b3
b4
IVB1 B2
B3
B4
A1
A2
A3
A4
a1
a2
a3
a4
42
Z 21966
Hydraulic for the

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

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

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

(E19)
(D32)
(XA)
(+10V)
(ws / gn)
(X2...)
(A9a)
(A9b)
(K50)
(K58)
(K71)
Contacts 5 / 9 only closed while filling the bucket.
(K78)
(14.1 + 14.3)
(Y64 + Y75)
(Y23 + Y45)
(III + IV)
Main control blocks III + IV
(42)
amplifier modules (A9a and A9b) and further to the proportional and directional
solenoid valves of the remote control blocks (14.1 and 14.3).
Hydraulic oil flow
8.1
& 13
E19
XA +10V
D32
ws/gn
X2C
190
X2C
189
10
K50
(Hydr. oil
not overheat )
K76
K78
10
(left crawler)
11
(right crawler)
A9
A9a
A9b
7-8 9
7-8 9
7-8 9
X2F 24
17
X2F 38
X2F 49
32
44
15
Y71
b1
b2
II B1 B2
b3
B4
A1
A2
A3
A4
a1
a2
a3
a4
Y37
Y64
b1 b2
A1
A2
a1
H
Y23
a2
L
b1
B3
b2
IVB1 B2
A3
a3
M
Y75
b3
III B1 B2
b4
B3
14.3
14.1
Y45
b3
b4
B3
B4
A1
A2
A3
A4
a1
a2
a3
a4
42
Z 21968
Hydraulic for the

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

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

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

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

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

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

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

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

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

are firmly tightened (with 300 Nm).
Otherwise, the internal sealing is not properly which results in loud
flow noises and wrong adjustments.
8.1
& 17
Section 8.1
Page 17
Hydraulic for the

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

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

8.1
& 18
Hydraulic for the

8.1.10
Section 8.1
Page 18
Checks and adjustments of the Service Line Relief Valves (SRV),

Boom cylinder Piston side FSA + BHA
There are six service line relief valves (secondary valves) installed, four at the
distributor manifold (42), one in main control block II and one in block IV, to
limit the maximum possible pressure peaks in the service line.
Since the opening pressure of the SRVs is higher than the setting of the Main
Relief Valves (MRVs) it is necessary to increase the main relief pressure for
testing and adjusting purposes.
Valve
SRV 66.5
SRV 66.7
SRV 65.4
SRV 70.13
SRV 70.2
SRV 70.1
MRV circuit II
MRV circuit IV
1.
2.
3.
4.
F
5.
6.
7.
8.
Press. check point

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

Extend the boom cylinder to the stop position until the hydraulic
system stalls.
Increase slowly the pump supply line pressure, by turning in set screws (3)
of both MRVs in control block II and IV, while observing the
pressure gauges. Stop as soon the pressure does not raise any further.
The gauge pointers should remain at 350 bar + 5 bar.
Since the piston side of the boom cylinders are protected by several
SRVs, the pressure gauges show the pressure of that valve with the
lowest setting.
Even when the gauges show the required pressure it is possible that
one or more valves have a higher setting.
To ensure that only the SRVs open during checks and adjustments
it is necessary to further increase the setting of both MRVs.
Remove protective cap (1) of MRV.
Loosen lock nut (2).
Turn set screw (3) of both MRVs turn further in, the gauge
pointers will remain at the value shown at item #4 (350 bar + 5 bar).
Tighten lock nut (2) and install cap (1).
continued
8.1
& 19
Hydraulic for the

8.1.10
Section 8.1
Page 19

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

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

8.1
& 20
Hydraulic for the

8.1.10
Section 8.1
Page 20

Boom cylinder Piston rod side FSA +BHA
There are service line relief valves (secondary valves) installed in the main
control blocks, to limit the maximum possible pressure peaks in the service line.
Valve
SRV 66.3
SRV 66.8
MRV circuit III
MRV circuit IV
1.
2.
3.
4.
F
5.
6.
7.
8.
Press. check point

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

Retract the boom cylinder to the stop position until the hydraulic
system stalls.
of MRVs in the control blocks, while observing the pressure gauges.
Stop as soon the pressure does not raise any further.
If the piston rod side of the boom cylinders are protected by several
lowest setting.
continued
8.1
& 21
Hydraulic for the

8.1.10
Section 8.1
Page 21

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

all service line relief valves.
as follows:

8.1
& 22
Hydraulic for the

8.1.10
Section 8.1
Page 22

Stick cylinder Piston side FSA
There are four service line relief valves (secondary valves) installed, three at
the distributor manifold (42) and one in main control block IV, to limit the
maximum possible pressure peaks in the service line.
Valve
SRV 66.11
SRV 65.2
SRV 70.8
SRV 70.9
MRV circuit IV
1.
2.
3.
4.
F
5.
6.
7.
8.
Press. check point

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

Extend the stick cylinder to the stop position until the hydraulic
system stalls.
of the MRV in control block IV, while observing the pressure gauges.
Since the piston side of the stick cylinders are protected by several
lowest setting.
it is necessary to further increase the setting of the MRVs.
Turn set screw (3) of the MRV turn further in, the gauge
continued
8.1
& 23
Hydraulic for the

8.1.10
Section 8.1
Page 23

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

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

8.1
& 24
Hydraulic for the

8.1.10
Section 8.1
Page 24

Stick cylinder Piston side BHA
There are three service line relief valves (secondary valves) installed, in main
control blocks I, II and IV, to limit the maximum possible pressure peaks in
the service line.
Valve
SRV 66.4
SRV 66.6
SRV 66.12
MRV circuit I
MRV circuit II
MRV circuit IV
1.
2.
3.
4.
F
5.
6.
7.
8.
Press. check point

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

Retract the stick cylinder to the stop position until the hydraulic
system stalls.
of the MRVs in the control blocks, while observing the pressure gauges.
Since the piston side of the stick cylinders are protected by several
lowest setting.
Turn set screw (3) of the MRVs turn further in, the gauge
continued
8.1
& 25
Hydraulic for the

8.1.10
Section 8.1
Page 25

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

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

8.1
& 26
Hydraulic for the

8.1.10
Section 8.1
Page 26

Stick cylinder Piston rod side FSA
There are two service line relief valves (secondary valves) installed, in main
control blocks I and IV, to limit the maximum possible pressure peaks in the
service line.
Valve
SRV 66.4
SRV 66.12
MRV circuit I
MRV circuit IV
1.
2.
3.
4.
F
5.
6.
7.
8.
Press. check point

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

system stalls.
Since the piston rod side of the stick cylinders are protected by
several SRVs, the pressure gauges show the pressure of that valve
with the lowest setting.
continued
8.1
& 27
Hydraulic for the

8.1.10
Section 8.1
Page 27

Cont'd:
Stick cylinder Piston rod side FSA
9.
Adjust both SRVs equally, until all gauges show a pressure of
360 bar.
66,4 66.12
10.
all gauges.
F
11.
12.
Proceed with the other valves in the same manner.

as follows:

8.1
& 28
Hydraulic for the

8.1.10
Section 8.1
Page 28

Stick cylinder Piston rod side BHA
There are three service line relief valves (secondary valves) installed at the
distributor manifold (42), to limit the maximum possible pressure peaks in the
service line.
Valve
SRV 70.7
SRV 70.8
SRV 70.9
MRV circuit I
1.
2.
3.
4.
F
5.
6.
7.
8.
Press. check point

M20
M21.1
M21.2
Location
Control block I

system stalls.
Since the piston rod side of the stick cylinders are protected by
continued
8.1
& 29
Hydraulic for the

8.1.10
Section 8.1
Page 29

Cont'd:
Stick cylinder Piston rod side BHA
9.
Adjust all SRVs equally, until all gauges show a pressure of
360 bar.
70,7 70.8 70.9
10.
all gauges.
F
11.
12.
sequence:
70.8 70.9

as follows:

8.1
& 30
Hydraulic for the

8.1.10
Section 8.1
Page 30

Bucket cylinder Piston side FSA
There are six service line relief valves (secondary valves) installed, four at the
distributor manifold (42), one in main control block III and one in block IV,
to limit the maximum possible pressure peaks in the service line.
Valve
SRV 66.1
SRV 66.9
SRV 65.1
SRV 70.4
SRV 70.12
SRV 65.3
MRV circuit III
MRV circuit IV
1.
2.
3.
4.
F
5.
6.
7.
8.
Press. check point

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

Extend the Bucket cylinder to the stop position until the hydraulic
system stalls.
of both MRVs in control block III and IV, while observing the
pressure gauges. Stop as soon the pressure does not raise any further.
Since the piston side of the bucket cylinders are protected by several
lowest setting.
continued
8.1
& 31
Hydraulic for the

8.1.10
Section 8.1
Page 31

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

all six service line relief valves.
as follows:

8.1
& 32
Hydraulic for the

8.1.10
Section 8.1
Page 32

Bucket cylinder Piston side BHA
service line.
Valve
SRV 70.3
SRV 70.4
SRV 70.12
MRV circuit III
1.
2.
3.
4.
F
5.
6.
7.
8.
Press. check point

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

system stalls.
of MRV in control block III, while observing the pressure gauges.
Since the piston side of the bucket cylinders are protected by several
lowest setting.
continued
8.1
& 33
Hydraulic for the

8.1.10
Section 8.1
Page 33

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

as follows:

8.1
& 34
Hydraulic for the

8.1.10
Section 8.1
Page 34

Bucket cylinder Piston rod side FSA
There are two service line relief valves (secondary valves) installed, one in
main control block III and one in block IV, to limit the maximum possible
pressure peaks in the service line.
Valve
SRV 66.2
SRV 66.10
MRV circuit III
MRV circuit IV
1.
2.
3.
4.
F
5.
6.
7.
8.
Press. check point

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

Retract the bucket cylinder to the stop position until the hydraulic
system stalls.
Since the piston rod side of the bucket cylinders are protected by
continued
8.1
& 35
Hydraulic for the

8.1.10
Section 8.1
Page 35

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

as follows:

8.1
& 36
Hydraulic for the

8.1.10
Section 8.1
Page 36

Bucket cylinder Piston rod side BHA
service line.
Valve
SRV 70.5
SRV 70.7
SRV 70.11
MRV circuit III
1.
2.
3.
4.
F
5.
6.
7.
8.
Press. check point

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

system stalls.
of MRV in control block III, while observing the pressure gauges.
Since the piston rod side of the bucket cylinders are protected by
it is necessary to further increase the setting of the MRV.
continued
8.1
& 37
Hydraulic for the

8.1.10
Section 8.1
Page 37

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

as follows:

8.1
& 38
Hydraulic for the

8.1.10
Section 8.1
Page 38

Clam cylinder Piston rod side FSA
There is one service line relief valve (secondary valve) installed at the distributor
manifold (42), 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
Valve
SRV 70.6
MRV circuit II
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Press. check point

Location
M19
Manifold (42) section E
M12 (High pressure filter) Control block II
Connect gauges to the above listed check points.

Retract the clam cylinder (open the bucket) to the stop position until the
hydraulic system stalls.
of MRV in control block II, while observing the pressure gauges.
If necessary correct the adjustment as follows:
Turn set screw (3) of the MRV turn further in, the gauge pointers will
remain at the value shown at item #4 (350 bar + 5 bar).
Reduce the pressure, at SRV- 70.6 to a value below the required value, and
then increase up to the required pressure (350 bar), while observing all
gauges.
Reset the MRV to 310 bar + 5 bar after adjustment is finished, as follows:
Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to
decrease pressure.
8.1
& 39
Hydraulic for the

8.1.10
Section 8.1
Page 39

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

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

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

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

8.1.11
Section 8.1
Page 40
Checks and adjustments of the lowering speed,

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

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

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

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

To avoid an interruption of the pump delivery.
To provide an uniform and smooth cylinder travel.
To limit the return oil flow through the control block to the maximum
permissible volume.
Checks and Adjustments:
Activate service switch S151 (located in the cab base) during the checks and
adjustments, to ensure that the main pumps are in Qmax position.
Standard test method is measuring the total cylinder running time by using a
stop watch.
If it is impossible to move the cylinder over the whole way, mark a distance of
one meter with permanent pen P/N 621 566 40 on the piston rod and measure
the time for only one meter movement.
Adjust the Restrictor as follows:
-
For easy turning of set screw (2) lower the attachment to ground, stop motor
and allow pressure equalising by moving the joy sticks several times.
Loosen the lock nut (1) and turn the bolt (2) cw for more restriction and ccw
for less restricton. If more than one restrictor is used for one movement
make sure all set screws are equally adjusted.
During commissioning, a throttle adjustment has to be carried out on all

machines. For safety reasons, the throttle valves are completely screwed in
before each machine is leaving the factory.
For more information refer to the respective Parts & Service News
8.1
& 41
Hydraulic for the

8.1.11
Section 8.1
Page 41

Boom cylinder FSA
Due to the two different operation modes for lowering the boom, the lowering
speed must be adjusted twice:
I.
II.
Maximum permissible lowering speed:
Boom FSA
Cylinder retracting time/meter

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

8.1.11
Section 8.1
Page 42

Cont'd:
Boom cylinder FSA
Boom FSA

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

8.1
& 43
Hydraulic for the

8.1.11
Section 8.1
Page 43

Boom cylinder BHA
Boom BHA

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

If the adjustment is finished tighten lock nut (1).
8.1
& 44
Hydraulic for the

8.1.11
Section 8.1
Page 44

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

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

Continued
8.1
& 45
Hydraulic for the

8.1.11
Section 8.1
Page 45

Cont'd:
Stick cylinder FSA
Stick FSA

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

8.1
& 46
Hydraulic for the

8.1.11
Section 8.1
Page 46

Stick cylinder BHA
Stick BHA

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

If the adjustment is finished tighten lock nut (1).
8.1
& 47
Hydraulic for the

8.1.11
Section 8.1
Page 47

Bucket cylinder FSA
Bucket FSA

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

8.1
& 48
Hydraulic for the

8.1.11
Section 8.1
Page 48

Bucket cylinder BHA
Bucket BHA

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

8.1
& 49
Hydraulic for the

8.1.11
Section 8.1
Page 49

Clam cylinder BHA
Clam

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

Section
8.2
Page
8.2.1
Swing Circuit (Brief description)
2+3
8.2.2
Swing Motor
4+5
8.2.3
Swing Gear Box
8.2.4
Swing Parking Brake (Gear house Brake)
8.2.5
Swing Brake Valve
8+9
8.2.6
Electric / Hydraulic flowchart Swing Left
10
8.2.7
Electric / Hydraulic flowchart Swing Right
11
8.2.8
Swing Monitoring System
12 + 13
8.2.9
Checks and adjustments for the swing circuit
14 - 16
8.2.10
Function check for the swing parking brake
17
PC4000_Sec_8-2 _rev1.doc
06.09.02
8.2
&2
06.09.02
Section 8.2
Page 2
8.2.1 Swing Circuit

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

(Study together with the for the machine valid hydraulic and electric circuit
diagram).
The swing motors (60.1 + 60.2) are driven by the pumps (1 + 3).
The oil flows from the pumps through high pressure filters to the control
block (9/III) and (10/I).
With the spools in neutral position oil flows via the return oil line into the
collector tube (107) and further via the return oil lines (L6 + L7) into the tank.
collector tube (54) and further to the tank.
On its way to tank the oil must flow through the back pressure valve (55) and
the return oil filter (59.1 - 59.4). (Back pressure valve function see section 4.)
When operating the control lever for "Swinging" the pump line is connected
in the control blocks (9/III and 10/I) with the corresponding service line (A1
or B1) to the swing motors (60.1 + 60.2).
The oil flows from the control block through each one of the swing brake
valves (61.1 + 61.2; description see page 8 and 9) and the swing motors (60.1
+ 60.2).
Each swing gear includes one spring loaded multi disk brake (House brake)
for locking the superstructure.
The leak oil (case drain) flows through the line (L18 + L19) and the leak oil
filter (53) back to tank.
continued
06.09.02
8.2
&3
06.09.02
Section 8.2
Page 3
Cont'd.:
8.2.1 Swing Circuit:
(1 + 3)
(9 / III)
(10 / I)
(14.1)
(16.1 + 16.2)
(60.1+ 60.2)
(71.1+ 71.2)
(95)
(96.1 96.4)
Y24 + Y25
Y26 + Y27
Y65 + Y66
Y120 + Y126
Y127
Main pumps
Control block
Control block
Remote control valve block
Manifold
Swing motors
Manifold at the control and filter panel
Double check valve (shuttle valves)
directional solenoid valves
directional solenoid valves
proportional solenoid valves
directional solenoid valve
proportional solenoid valve (foot brake pedal)
Brief description (Control circuits)

When the lever (E20) is moved out of its neutral position, proportional solenoid
valves Y65, Y66 and solenoid valve Y131 (pump #3 fixed in Qmax position) are
energized. Simultaneously the directional solenoid valves Y24 (L.H.-swing) or
Y25 (R.H.-swing) are energized.
At the same time by the function of the double
check valves (96.3=> 96.4=> 96.1) pilot pressure
is present at port X of each brake valve block
thus a pressure built up in the service lines is
possible.
i.e. Swing speed low = Only oil flow of pump #3
If swing speed switch S250 is activated, and a
certain speed of the superstructure is obtained oil
flow of pump #1 will be added to increase the
swing speed as follow:
By the function of remote control valve (95) pilot
pressure oil is send to one side of the control
block (10/I), depending on the swing direction via
directional solenoid valves Y26 (L.H.-swing) or
Y27 (R.H.-swing).
i.e. Swing speed fast = oil flow of pump #3 + oil flow of pump #1
06.09.02
8.2
&4
06.09.02
Section 8.2
Page 4
8.2.2 Swing Motor

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

The main part of the axial forces is supported by the slipper pads (13) which
are installed on the driving circular side of the drive shaft.
Each piston is allocated to one slipper pad.
These slipper pads are located in the cylinder chamber and get pressurized via
piston borings (5). The slipper pads support themselves on the thrust washer
(14) and discharge axially the tapered roller bearing (11).
Without pressure the slipper pads are kept on the thrust washer by means of
spring (12).
continued
06.09.02
8.2
&5
06.09.02
Section 8.2
Page 5
Cont'd.:
8.2.2 Swing Motor
Axial piston motor A2FLM (with SL-bearing)
Function:
The pressure oil inlet (A or B) and consequent oil outlet (B or A) determine
the output drive direction of the drive shaft (1).
Direction of rotation:
"Clockwise"
= Direction of flow A to B
"Counter-Clockwise" = Direction of flow B to A
with view onto drive shaft!
Via the control lens (8) the oil is directed to the cylinder bores.
The piston (5) is moved from the lower (6b) to the upper dead point (6a) by
means of the force acting on it and causes the drive shaft to rotate. On further
rotation of the drive shaft (additional pistons are pressurized) this piston is
moved towards the lower dead point again and oil of the cylinder chamber is
forced out through the kidney formed openings of the control lens. This oil is
fed back to the tank via the return line.
If the supply and return line is changed it changes the output drive direction of
the drive shaft.
By means of the angled arrangement of the cylinder (7) (bent axis design), a
certain piston stroke is produced which results in a fixed displacement per
revolution of the drive shaft. According to the size of the applied flow this
produces a specific output speed.
The output torque at the drive shaft is dependent on the size of the motor and
the required operating pressure.
06.09.02
8.2
&6
06.09.02
Section 8.2
Page 6
8.2.3 Swing Gear Box

(1) Drive housing
(2) Drive shaft
(3) House brake (Multi disk brake)
(4) Oil level gauge (dipstick)
Drive shaft housing
(4a) Breather filter
(4b) Oil drain plug
House brake
(5b) Oil drain plug
Gear box
(6b) Oil drain plug
6c)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
Oil filler plug

Adapter flange
Internal ring gear
Bearing ring
Cartridge
Spherical roller bearing
Spherical roller bearing
First planetary stage
Drive shaft to second stage
Second planetary stage
Radial seal ring
Drive pinion
Grease line port
The swing gear is of compact design with a two stage planetary gear including a
multi disk house brake.
The gear is bolted to the superstructure and fits firmly due to the machined
diameter (M) and the bolt torque.
The torque loaded on the hydraulic motor is transmitted by the drive shafts (2)
to the first planetary stage (15).
The sun shaft (16) of the first planetary stage transmits the torque into the
second planetary stage (17). By the planetary gears the output drive shaft is
rotated and transmits the torque to the pinion (19).
The drive housing, and the brake housing of the gearbox are filled with gear
oil.
Aeration is done by breather filters 4a, 5a and 6a.
To lubricate the pinion bearing port (20) is connected to the central
lubrication system.
06.09.02
8.2
&7
06.09.02
Section 8.2
Page 7
8.2.4 Swing Parking Brake (Gear house Brake)

The Spring Loaded Multi-disk Brake is a safety brake; applied by spring
force and released by oil pressure.
(1)
Circlip
(2)
Thrust washer
(3)
Outer disks
(4)
Inner disks (lamellas)
(5)
Piston
(6)
Quad-Rings with back- up rings
(7)
Quad-Rings with back- up rings
(8)
Springs
(9)
Piston back up ring and seal retainer
(10)
O-ring
(11)
Circlip
(12)
Oil pressure port
Function:
Brake applied:
The outer disks (3) engaged to the housing by serration and the inner disks (4)
in serration connection with the carrier are pressed together by the springs (8).
This results in a fixed connection between housing and carrier.
Brake released:
Oil pressure via port (12) reaches the bottom of the piston (5) and forces the
piston upwards against the Piston back up ring and seal retainer (7).
This function eliminates the spring force onto the disks thus the brake is
released.
The releasing pressure is 19 - 20 bar, the maximum permissible pressure
60 bar.
This is a so named "Wet Brake" because the brake housing is partly filled with
gear oil.
F
For service intervals and procedure refer to the

Operation and Maintenance Manual.
06.09.02
8.2
&8
06.09.02
Section 8.2
Page 8
8.2.5 Swing Brake Valve

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

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

(MA) Circuit A
(MB) Circuit B
Explanation of the function by the symbol:
When ever a swing motion is carried out or the foot brake is used, pilot
pressure arrives the pressure increasing valve (1) at port "X".
The pilot pressure pre-loads these valves.
The oil for the hydraulic motor from the control block arrives the service line
port A or B, depending if a R.H. or a L.H. swing motion is carried out.
The ports A and B are internally connected to the ports A1 and B1 and these
ports in turn with the hydraulic motor.
The operating pressure, at either port A or B closes the anti-cavitation valves
(4 or 5) and opens the check valves (2 or 3).
That means by the check valves (2 or 3) the service lines are connected to the
pressure increasing valve.
When ever the pressure is higher than the setting of the pressure increasing
valve, this valves opens and dumps the oil into the return line (T) to tank.
The pressure can be checked at the check points MA or MB.
continued
06.09.02
8.2
&9
06.09.02
Section 8.2
Page 9
Cont'd.:
8.2.5 Swing Brake Valve
If after a swing motion the joy stick is put into neutral position without
using the foot brake, the superstructure is turned by inertial force and the
hydraulic motor acts as a pump because it is driven by the swing gear.
In this period the pressure in the service line is lower than the pressure in
the return line, because there is a back pressure valve at the tank, and oil is
forced through the anti-cavitation valves into the service line.
Function of the pressure increasing valve.
When ever a swing motion is carried out or the foot brake is used, pilot
pressure arrives the pressure increasing valve (1) at port "X". The pilot
pressure pre-loads these valves.
By applying pilot pressure via the external port X to piston (12), the pretensioning of the pressure spring (10) is increased by the amount of the piston
stroke "S", which results in the actual valve setting.
The system pressure is in front of the main piston (13) and via the jet bore (6)
also in the chamber of the spring (7) and via the jet bore (8) at the pressure
relief valve poppet (9).
Due to the force balance the piston (13) is kept in its position supported by the
spring (7).
Overcomes the system pressure the setting of the valve (9), this valve opens a
channel to the dump line port (Y). Due to the drop of force the piston (13) is
moved to the right.
The pressure line gets connected with the return line (T).
Damped opening and closing are obtained by the throttled volumetric change
that is caused by the jet bores.
06.09.02
8.2
& 10
E20
XB
-10V
D32
ws/gn
X2
475
X2
474
E50
K154
10
A7a
A7
7-8 3
7-8 3
X2 223 221
K154a
10
14.1
6
Y65
K153
10
X2 243
b1
b2
A1
95
1
b1
b2
b3
Y24
244
I B1 B2
Y66
b3
Y26
a1
A2
a2
B3
III B1 B2
A3
A1
a3
a1
B3
A2
a2
A3
a3
16.2
61.1
61.2
A
60.2
B
60.1
Z 21945
B
A
06.09.02
Section 8.2
Page 10
8.2.6 Electric / Hydraulic flowchart Swing Left

(E20)
(D32)
(XB)
(-10V)
(ws/gn)
(X2...)
(E50)
Ramp time module
(A7)
Amplifier module Swing (Y65 + Y24/25 Block III)
(A7a)
Amplifier module Swing (Y66 + Y26/27 Block I)
(K153)
Relay
Pump control swing:
Additional oil flow of Pump #1 to the
swing if energized (swing speed dependent)
(K154 + K154a) Relay Counter prevention if energized
(14.1)
(95)
(Y65 + Y66)
(Y24 + Y26)
(I + III)
Main control blocks I +III
(16.1)
(61.1 + 61.2)
Swing brake valve blocks
(60.1 + 60.2)
Swing motors
Illustration Z21945 shows:
The electrical signal.
terminal 5 of the amplifier modules (A7 + A7a) and further to the proportional
and directional solenoid valves of the remote control blocks (14.1+ 95).
The hydraulic signal. (pilot pressure)
pressure oil flows to the pressure ports of the main control blocks.
The hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (I + III)
and arrives via swing brake valves (61.1 + 61.2) at the swing motors (60.1 +
60.2).
06.09.02
8.2
& 11
E20
XA +10V
ws/gn
X2
475
X2
474
E50
D32
K154
10
A7a
A7
7-8
7-8
X2 223 222
K154a
11
14.1
7
K153
Y65
11
b1
X2 243
b2
A1
95
1
b1
b2
b3
Y25
242
I B1 B2
Y66
b3
Y27
a1
A2
a2
B3
III B1 B2
A3
A1
a3
a1
B3
A2
a2
A3
a3
16.1
61.1
61.2
A
60.2
60.1
Z 21946
B
06.09.02
Section 8.2
Page 11
8.2.7 Electric / Hydraulic flowchart Swing Right

(E20)
(D32)
(XA)
(+10V)
(ws/gn)
(X2...)
(E50)
Ramp time module
(A7)
(A7a)
(K153)
Relay
Pump control swing:
Additional oil flow of Pump #1 to the
swing if energized (swing speed dependent)
(K154 + K154a) Relay Counter prevention if energized
(14.1)
(95)
(Y65 + Y66)
(Y25 + Y27)
(I + III)
Main control blocks I +III
(16.1)
(61.1 + 61.2)
Swing brake valve blocks
(60.1 + 60.2)
Swing motors
Illustration Z21945 shows:
The electrical signal.
terminal 5 of the amplifier modules (A7 + A7a) and further to the proportional
and directional solenoid valves of the remote control blocks (14.1+ 95).
The hydraulic signal. (pilot pressure)
pressure oil flows to the pressure ports of the main control blocks.
The hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (I + III)
and arrives via swing brake valves (61.1 + 61.2) at the swing motors (60.1 +
60.2).
06.09.02
8.2
& 12
06.09.02
Section 8.2
Page 12
8.2.8 Swing Monitoring System, illustration (Z 21947)

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 using oil flow of a second pump.
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 are send to the modules E41 and E43 for sensing the swing
speed.
Proximity switch B99 together with module E43 monitors the swing speed to
prevent counter action.
Proximity switch B98 together with module E41 monitors the swing speed to
control solenoid valve (Y126).
Y126 de-energized allows full X2 pressure to pump No 1 = full flow.
Y126 energized causes reduced X2 pressure to pump No 1 = reduced flow.
a) Counter Prevention
Reversing the swing direction is only possible when the swing speed is less
than 120 Imp/min (almost stand still of the Superstructure) monitored from
E43.
b) Increasing the oil flow for the swing circuit, using a second pump
When starting a swing action, only the oil flow of main pump#3 is used as
long as the swing speed is less than 275 Imp/min. monitored from E41.
To obtain an smooth and progressive acceleration to the maximum swing
speed the reduced flow (approx. half capacity) of main pump 1 will be added
as soon as the swing speed is higher then 350 Imp/min.
W
The oil flow of pump No 1 must be reduced in order to prevent

serious damage to swing motors, swing gears and to the swing ring
due to over speed. Therefore a correct adjustment is essential.
06.09.02
8.2
& 13
06.09.02
Section 8.2
Page 13
8.2.8 Swing Monitoring System, illustration (Z 21947)

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 E41 and
Sensor B99 switches 24V via cable Sig to terminal 11 of E43 if a
tooth comes close to the sensor head.
Simultaneously these signals arrives at E42 terminals 4and 11.
Adjust the distance C of the sensors B98 and B99 to 5 mm.
b)
E42 for monitoring the slew direction

E42 is an programmable module which is factory programmed with the
parameters shown in the electric diagram. Therefore no adjustments or
settings are required.
Settings:
c)
E41 (speed monitor) for increasing the oil flow
No
Function
nominal setting
Setting the start up delay
Not used set to 0
Fine setting of the pre-set value (Pulses / min.)
27 imp/min. (i.e.275)
Setting the hysteresis
Not used set to 0
LED: lights when the output relay is energised
---
Setting the switching function
Set to III
Coarse setting of the pre-set value (Pulses / min.)
10 imp/min
If necessary increase or decrease the Imp/min. (depending on the

respective machine), with set screw No 2 until a smooth and progressive
acceleration is possible.
d)
E43 (speed monitor) counter prevention

No
Function
nominal setting
Setting the start up delay
Not used set to 0
Fine setting of the preset value (Pulses / min.)
12 imp/min (i.e.120)
Setting the hysteresis
Not used set to 0
LED: lights when the output relay is energised
---
Setting the switching function
Set to III
If necessary increase or decrease the imp/min with set screw no. 2

until a smooth slew operation is possible.
06.09.02
8.2
& 14
06.09.02
Section 8.2
Page 14
8.2.9 Checks and adjustments for the swing circuit

Flow reduction for pump No 1 with pressure reducing valve 81.1
(Q reduced while swinging)
(M27) pressure to pressure increasing valves
(M30) X3 pressure to pump No 2, No 3 and No 4
(M31) Reduced X3 pressure to pump No 1
(M32) Reduced X3 pressure to pump No 1
(81.1) Pressure reducing valve reduced X3 pressure ( Qmax)
(Y126) Solenoid valve flow reduction (Pump 1)
1.
2.
3.
4.
Connect a pressure gauge to check point M30.

Move the control lever(E20) to the end position (L.H.
or R.H.) with activated swing speed switch (S250),
swing one turn as an approach swing and start
counting the number of revolutions in one minute.
Do not exceed the maximum permissible swing speed of 4 0,3 RPM
Read pressure while swinging, should be about 15 bar.

Note down the pressure as reference value.
If adjustment is necessary:
5. Remove dust cap (d)
6. Loosen lock nut (e)
7. Adjust the pressure with set screw (f)
8. Tighten lock nut and install dust cap
06.09.02
8.2
& 15
06.09.02
Section 8.2
Page 15
It is important that the complete MRV-valve and the Pressure

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

1.
Connect the gauge to the check point M11 and M14 at the high
pressure filter units.
2.
Disconnect the pilot pressure lines from the T-unions and close the lines
with a suitable plug (P).
3.
Loosen lock nut (3) of both pressure increasing valves (PIV) and screw
in set screw (4) until piston (5) comes to stop.
4.
5.
Lower attachment to ground and apply house brake with switch S29.
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.
7.
If the gauge shows a smaller or greater value the pressure increasing
valve must be adjusted.
*
Procedure:
a)
remove dust cap (a) and loosen lock nut (b).
b)
Adjust pressure with set screw (c).
c)
Secure adjustment by tightening lock nut (b) and install dust cap (a).
d)
Re-check pressure setting.
e)
Re-set MRV to 310 + 5 bar after the check / adjustment is finished.
06.09.02
8.2
& 16
06.09.02
Section 8.2
Page 16
Low pressure check / adjustment (Swinging down path (drifting)

(with still disconnected pilot pressure line )
8.
9.
Actuate either L.H. or R.H. rotation until the hydraulic system stalls.
a) loosen lock nut (3) at the pressure increasing valves (PIV) and
turn out set screw (4) until
150 +5 bar is reached.
b) Tighten lock nut (3).
c) Re-check pressure setting.
Re-connect the pilot pressure line.
For later on 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.
Brake pilot pressure - check / adjustment

1.
Connect the gauge to the check point M27.
2.
3.
Depress fully the foot brake pedal (E22) and read the pressure.
The pressure must be 19 +1 bar.
Alter the position of the potentiometer R2 of the amplifier A16 until the
pressure is 19 +1 bar.
Basic adjustment for A16 see section 5
06.09.02
8.2
& 17
06.09.02
Section 8.2
Page 17
8.2.10 Function check for the swing parking brake

(71.1) Manifold
(E47)
CGC color graphic console
(108.2) Pressure relief valve
(M2 M5) Pressure check points
(B16) Pressure switch
(Y5)
Solenoid valve
Parking Brake Release Pressure. (House Brake Pressure)
1. Connect gauge to check point (M2).
2. Start engine and let it run with max. speed and read the pressure.
Required = 45 3 bar.
If not, the pilot pressure adjustment must be corrected. (refer to Section 5).
3. Apply the parking brake. Therefore move toggle switch (S29) in position 1,
now the following message should appear:
Swing gear house brake
Swing gear house brake ON
4. Actuate either L.H. or R.H. rotation, the machine should not turn.
If the machine turns the parking brake must be repaired.
5. Release the parking brake. Therefore move toggle switch (S29) in position 0,
now the swing function must be possible again and the monitor returns to standard
display.
In case of malfunction check the electrical control system and the

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

1.
Connect pressure gauge to check point (M5).
2.
Start the engine. Gauge must show normal pilot pressure X2 = 45 3 bar.
3.
Move toggle switch (S29) in position 0
4.
Set pilot pressure relief valve (108.2) to 22 bar.
5.
Unplug and reconnect solenoid valve Y5 to allow pressure relieve
from pilot pressure line to house brake.
5.
Select the Real Time Monitor Menu at the display and check if the
signal of B16 has changed from 1 to 0.
6.
Increase the pilot pressure up to 26 bar and check if the signal of B16
will change from 0 to 1.
7.
Reset pilot pressure X2 to 45 3 bar.
Pressure at B16 <24 bar => real time monitor 0 => Brake applied (ON)
Pressure at B16 >24 bar => real time monitor 1 => Brake released (OFF)
06.09.02
Hydraulic for the Travel Circuit
Section 8.3
Page 1

Section
8.3
Page
8.3.1 Travel Circuit (Brief description)
2+3
8.3.2 Travel Motor
8.3.3 Rotary distributor
8.3.4 Travel Gear Box
8.3.5 Travel Parking Brake (Gear house Brake)
8.3.7 Electric / Hydraulic flowchart Travel forward
8.3.8 Electric / Hydraulic flowchart Travel backward
10
8.3.9 Checks and adjustments for the travel circuit
11
8.3.10 Function check for the travel parking brake
12
06.09.02
8.3
&2
06.09.02
Section 8.3
Page 2
8.3.1 Travel Circuit

(2 + 4)
(11 / II)
(12 / IV)
(14.2)
(15)
(19)
(21.1+ 21.2)
(41)
(55)
(56.1+ 56.2)
(57.1+ 57.2)
(71.1)
(B48)
(M4)
(Y16)
(L)
(ST)
Main pumps
Control block
Control block
Rotary distributor
Travel motors
Main oil reservoir
Back pressure valve
Travel brake valves
Travel parking (house) brakes
Pressure switch, parking brake release pressure
Pressure check point for parking brake release pressure
Solenoid valve for travel parking brake
Solenoid valve for travel parking brake
Pilot pressure line to the travel parking brake
Brief description (Control circuits)

(Study together with the hydraulic and electric circuit diagram).
When the pedals E21a and E21b are moved out of there neutral
position, proportional solenoid valves Y67 and Y70 and simultaneously
the directional solenoid valves Y28 or Y29 (L.H.-crawler) and Y34 or
Y35 (R.H.- crawler) and (L.H.-swing) or Y25 (R.H.-swing) are
energized.
(E21a) Control pedal
A forward => Y70 +Y35
Left track
B reverse => Y70 +Y34
(E21b) Control pedal

A forward => Y67 +Y28
Right track
B reverse => Y67 +Y29
continued
06.09.02
8.3
&3
06.09.02
Section 8.3
Page 3
Cont'd.:
8.3.1 Travel Circuit
Illustration (Z 22506):
Brief description (Service circuits)
(Study together with the hydraulic and electric circuit diagram).
The travel motors (21.1 + 21.2) are driven by the pumps (2 + 4).
The oil flows from the pumps through the high pressure filters to the control
blocks (11/II + 12/IV).
In neutral position of the spools the oil flows via the return oil lines into the
collector tube (107) and further via the return oil lines (L6 + L7) into the tank
collector tube (54) and further to the tank.
On its way to tank the oil must flow through the back pressure valve (55) and
the return oil filter (59.1 - 59.4). (Back pressure valve function see section 4.)
When operating the foot pedal for "Travelling" the pump line of each control
block is connected with the corresponding service line (A1 or B1) via the
rotary distributor (19) and travel brake valves (56.1 + 56.2) to the travel
motors (21.1 + 21.2).
The travel brake valve acts as a flow control valve in order to avoid the travel
motors picking up speed when travelling downhill.
Each travel gear includes a spring loaded multi disk brakes (House brakes 57.1 57.2). They are used as parking brakes, automatically applied by the function of
Y16 whenever the engine is switched OFF.
The brake release pressure is monitored by the pressure switch (B48).
The leak oil (case drain) flows through the line (L9) and the leak oil filter (53)
back to tank.
06.09.02
8.3
&4
06.09.02
Section 8.3
Page 4
8.3.2 Travel Motor

Axial piston motor A2FLM
The axial piston units of product group A2FM with fixed displacement can
operate as a hydraulic motor only.
The drive speed is proportional to the consumption capacity.
The output torque increases with the pressure drop between high and low
pressure side.
The motor converts hydrostatic energy into mechanical energy.
(1)
(2)
(3)
(4)
(5)
(5a)
(6a)
(6b)
(7)
Drive shaft
Housing
Case drain port
Retaining plate
Piston
Pivot (center) pin
Upper dead point
Lower dead point
Cylinder
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
Control lens
End plate
Taper roller bearing
Roller bearing
Thrust washer
Circlip
Circlip
Sealing flange
Radial seal ring
Function:
The pressure oil inlet (A or B) and consequent oil outlet (B or A) determine
the output drive direction of the drive shaft (1).
Direction of rotation:
"Clockwise"
= Direction of flow A to B
"Counter-Clockwise" = Direction of flow B to A
with view onto drive shaft!
Via the control lens (8) the oil is directed to the cylinder bores.
The piston (5) is moved from the lower (6b) to the upper dead point (6a) by
means of the force acting on it and causes the drive shaft to rotate. On further
rotation of the drive shaft (additional pistons are pressurized) this piston is
moved towards the lower dead point again and oil of the cylinder chamber is
forced out through the kidney formed openings of the control lens. This oil is
fed back to the tank via the return line.
If the supply and return line is changed it changes the output drive direction of
the drive shaft.
By means of the angled arrangement of the cylinder (7) (bent axis design), a
certain piston stroke is produced which results in a fixed displacement per
revolution of the drive shaft. According to the size of the applied flow this
produces a specific output speed.
The output torque at the drive shaft is dependent on the size of the motor and
the required operating pressure.
06.09.02
8.3
&5
06.09.02
Section 8.3
Page 5
8.3.3 Rotary Distributor

Task:
The rotary distributor (joint) permits a hydraulic connection between the
superstructure and the undercarriage, that means between the rotating and the
stationary part.
(1)
(2)
(3)
(4)
(5)
Rotor
Rotary distributor housing
Cover
Bearing ring (splitted)
Sealing element
(6)
(7)
(8)
(9)
(10)
Seal
Rotor guide rings
O-ring
Plug screws
Mover
Ports:
A-D
Service lines
K1 / K2
Control oil track tensioning
L
Leak oil
ST
Control oil
T
Return oil to tank
The letters punch marked, beside the ports are marked as they are used in the
hydraulic diagram.
Function:
During operation superstructure and under carriage constantly rotate towards
each other. Nevertheless, the travel oil motors must be supplied with
hydraulic oil in every position in which the superstructure is moved in regard
to the undercarriage. Oil is directed by the control blocks to the ports (A-D) of
the housing (2).
The oil flows to the outlet ports (A-D), of the rotor (1), via ring grooves as
well as longitudinal and cross holes. The rotor is bolted to the under carriage.
The sealing of the ring grooves among one another is done by sealing
elements (5).
The hydraulic connection for case drain, house brake and the track tensioning
cylinders is done via the ports (L), (St), (K1) and (K2).
The entering of dirt gets blocked by the seal ring (6) and the collar of the
cover (3). The rotor (1) is at the top and bottom section guided in the housing
by the guide rings (7).
06.09.02
8.3
&6
06.09.02
Operating Hydraulic
Section 8.3
Page 6
8.3.4 Travel gear

The travel gear consists of one spur gear set and two planetary stages.
The travel gearbox is fitted to the side frame with bolts.
(1)
Input drive shaft
(2)
Spur gear
(3)
Sun gear first stage
(4)
Planetary ring gear first stage
(5)
Planetary carrier first stage
(6)
Planetary ring gear second stage
(7)
Sun gear second stage
(8)
Planetary carrier second stage
(9)
Side frame mounting flange
(10)
Motor adapter and brake housing
(11)
Multi disk house brake
Function:
Spur gear (2) is driven by a hydraulic motor and input drive shaft (1).
The planetary carrier first stage (5) is driven by sun gear (3) which is connected
to spur gear (2).
The planetary gears are revolving in the planetary ring gear of the housing. As a
result of the fixed housing the planetary carrier will be turned.
The planetary carrier second stage (8) is turned by sun gear (7) which is
connected to the sprocket drive shaft.
06.09.02
8.3
&7
06.09.02
Section 8.3
Page 7
8.3.5 Travel parking brake (Gear house brake)

The Spring Loaded Multi-disk Brake is a safety brake; applied by spring force
and released by oil pressure.
(1)
Radial seal rings
(2)
Retainer
(3)
Springs
(4)
O-ring
(5)
Piston
(6)
Plug screw
(7+8)
Quad-Ring with
back-up rings
(9)
Release pressure port
(10+11) Quad-Ring with
back-up rings
(12)
O-ring
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
Intermediate ring
Outer disks (lamellas)
Inner disks
Outer disk carrier
O-ring
Seeger clip ring
Bolt
Retainer
O-ring
Seeger clip ring
Inner disk carrier
Radial seal ring
Function:
Brake applied:
The outer disks (14) engaged to the housing by serration and the
inner disks (15) in serration connection with the disk carrier, are pressed
together by the springs (3). This results in a fixed connection between
housing and inner disk carrier (23).
Brake released:
Oil pressure via port (9) forces the piston (5) against the springs (3) towards
the retainer (2).
This function eliminates the spring force onto the disks thus the brake is
released.
The minimum releasing pressure is 21 - 23 bar, the maximum permissible
pressure 300 bar.
This is a so named "Wet Brake" because the brake housing is filled with oil.
F
For more information refer to the OPERATION AND

MAINTENANCE MANUAL, PARTS BOOK and REPAIR MANUAL
of the corresponding machine.
06.09.02
8.3
&8
06.09.02
Section 8.3
Page 8

Task:
Travel brake valves control the oil flow from the hydraulic motor to the tank
depending on operating pressure. This braking action prevents the motors from
over speeding.
Function:
Spring force keeps the spool in the lowest flow position. with increasing
operating pressure the opening for the return oil flow becomes larger.
On its way to the hydraulic motor the oil flows from A to A1 respectively from B
to B1 depending on the selected travel motion.
Example:
Operating pressure at port A moves spool (1) against the force of the spring (2)
and opens the way for the return oil (B1 to B).
Check valve (3) prevents a direct oil flow from B1 to B.
If the operating pressure decreases to such an extend that the spring force
overcomes the pressure, the flow to the tank becomes restricted, resulting in
braking of the machine.
06.09.02
8.3
&9
06.09.02
Section 8.3
Page 9
8.3.7 Electric / Hydraulic flowchart Traveling forward

(E21a)
Foot pedal left crawler
(E21b)
Foot pedal right crawler
(D32)
(+10V)
(rs)
Colour code of signal voltage cable ( footpedal)
(X2...)
(E51)
Ramp time module
(E52)
Ramp time module
(A12)
Amplifier module left crawler
(A13)
Amplifier module right crawler
(14.2)
(15)
(Y67 + Y70)
(Y28 + Y35)
(II IV)
Main control blocks
(19)
Rotary distributor
(21.1 21.2)
Hydraulic motors
(56.1 56.2)
Travel brake valves
Signal voltage of foot pedals (E21a + E21b) arrives via ramp time module (E51
+ E52) at terminal 5 of the amplifier modules (A12 and A13) and further to the
proportional and directional solenoid valves of the remote control blocks (14.2
and 15).
Hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (II and IV)
and arrives via Rotary distributor (19) and travel brake valves (56.1 56.2) at the
hydraulic travel motors.
06.09.02
8.3
& 10
06.09.02
Section 8.3
Page 10
8.3.8 Electric / Hydraulic flowchart Traveling backward

(E21a)
Foot pedal left crawler
(E21b)
Foot pedal right crawler
(D32)
(-10V)
(rs)
Colour code of signal voltage cable ( footpedal)
(X2...)
(E51)
Ramp time module
(E52)
Ramp time module
(A12)
Amplifier module left crawler
(A13)
Amplifier module right crawler
(14.2)
(15)
(Y67 + Y70)
(Y29 + Y34)
(II IV)
Main control blocks
(19)
Rotary distributor
(21.1 21.2)
Hydraulic motors
(56.1 56.2)
Travel brake valves
Signal voltage of foot pedals (E21a + E21b) arrives via ramp time module (E51
+ E52) at terminal 5 of the amplifier modules (A12 and A13) and further to the
proportional and directional solenoid valves of the remote control blocks (14.2
and 15).
Hydraulic oil flow
Now the oil of the main pumps flows through the main control blocks (II and IV)
and arrives via Rotary distributor (19) and travel brake valves (56.1 56.2) at the
hydraulic travel motors.
06.09.02
8.3
& 11
06.09.02
Section 8.3
Page 11
8.3.9 Checks and adjustments for the travel circuit

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

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

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

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

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

(with 300 Nm) tightened.
Otherwise, internal leaks could occur which result in:
problems of correct adjustment, loud flow noises and high temperatures.
06.09.02
8.3
& 12
06.09.02
Section 8.3
Page 12
8.3.10 Function check for the travel parking brake

(71.1) Manifold
(E47)
CGC color graphic console
(108.2) Pressure relief valve
(M2 M4) Pressure check points
(B48) Pressure switch
(Y16)
Solenoid valve
Parking Brake Release Pressure. (House Brake Pressure)
1. Connect gauge to check point (M2).
2. Start engine and let it run with max. speed and read the pressure.
Required = 45 3 bar.
If not, the pilot pressure adjustment must be corrected. (refer to Section 5).
3. Disconnect plug connection from solenoid valve Y16, now the following
message should appear:
Trouble travel gear house brake
travel gear house brake OFF (means applied)
Inform service till end of shift and then press
cancel button
4. Operate the travel pedals, the machine should not travel.
If the machine moves the parking brake must be repaired.
5. Reconnect plug connection to solenoid valve Y16, now the travel function must
be possible again and the monitor returns to standard display.
In case of malfunction check the electrical control system and the

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

1.
Connect pressure gauge to check point (M4).
2.
Start the engine. Gauge must show normal pilot pressure X2 = 45 3 bar.
3.
Set pilot pressure relief valve (108.2) to 22 bar.
4.
Unplug and reconnect solenoid valve Y16 to allow pressure relieve
from pilot pressure line to house brake.
5.
Select the Real Time Monitor Menu at the display and check if the
signal of B48 has changed from 1 to 0.
6.
Increase the pilot pressure up to 26 bar and check if the signal of B48
will change from 0 to 1.
7.
Reset pilot pressure X2 to 45 3 bar.
Pressure at B48 <24 bar => real time monitor 0 => Brake applied (ON)
Pressure at B48 >24 bar => real time monitor 1 => Brake released (OFF)
06.09.02
Hydraulic Track Tensioning System Section 9.0

Page 1

Section
9.0
Page
Hydraulic Track Tensioning System
General
9.1
Functional description
3+4
9.2
9.3
Tensioning Cylinder
9.4
Adjustments / Checks
79
9.5
Functional test
9.0
&2

Page 2
9.0
General:
(83.1 83.4)
Track tensioning cylinders
(M29.2 + M29.6) Bleeder and hydraulic pressure check points at the
R.H.- tensioning cylinders.
(M29.1 + M29.5) Bleeder and hydraulic pressure check points at the
L.H.- tensioning cylinders.
(M29.3)
Bleeder and hydraulic pressure check point at the bladder
accumulator (82.1) for the L.H.-side.
(M29.4)
accumulator (82.2) for the R.H.-side.
(89.1 + 89.2)
Membrane accumulator, 1,3 liter (pre-charge pressure 31bar)
(62.2)
Service shut-off cock for the L.H.-side
(62.3)
Service shut-off cock for the R.H.-side
* "O" = open - "C" = closed
(82.1 + 82.2)
Bladder accumulator, 5 liter (pre-charge pressure 150bar)
(19)
Rotary joint
(L16)
Supply line L.H.-side
(L17)
Supply line R.H.-side
The hydraulic track tensioning system ensures automatically the correct track
tension.
The pilot pressure pump (8.1, see diagram on page 4) will supply oil to all four
tensioning cylinders (83.1-83.4).
The maximum pressure is limited by the pressure increasing valves (58.1) for
the L.H.-side and (58.2) for the R.H.-side.
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.
The tension for each crawler ( R.H.-side and L.H.-side) is separately controlled
and adjusted.
External forces acting at the guide wheels will be absorbed through the
pressure accumulators (89.1 + 89.2, first stage) and (82.1 + 82.2, second stage).
For information about the preventative track inspection, refer to the

Operation and Maintenance Manual.
Functional description on next page
9.0
&3

Page 3
9.1
Functional description:
Illustration Z 21927 and Z 21928 (on next page):
Under normal operating condition the shut-off cocks (62.3 and 62.4)
located on the control panel are closed and the shut-off cocks (62.2 and
62.3) located inside the side frames are open.
The oil flow of the pilot pressure pump (8.1), filtered by pressure filter (33)
enters port "P" of the solenoid valves Y128 (L.H.) and Y129 (R.H.) via
orifice (122).
If solenoid valves Y128 / Y129 are actuated (i.e. pressure at sensor B100 / B101
below 30bar), the oil flows via the check valves (80.1 / 80.2), rotary joint (19)
and the shut-off cocks (62.2 / 62.3) into the tensioning cylinders (83.1 - 83.4)
until a pressure of 36 bar is reached. (i.e. pressure at sensor B100 / B101 above
36 bar will deactivate Y128 / Y129)
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 valves (58.1
and 58.2).
External forces acting at the guide wheels will be absorbed through the pressure
accumulators (89.1 + 89.2, first stage) and (82.1 + 82.2, second stage).
Purpose of the pressure increasing valve
The two system pressures
35 bar with engine stopped

310 bar with engine running
are controlled by the pressure increasing valve as follows.
With stopped engine and switched off ignition there is no pilot pressure (X4) at
the pressure increasing valves (58.1 / 58.2) and only the lowest adjusted
pressure of 35 bar remains in the system.
As soon as the engine has been started, the pilot pressure (X4) of 60 bar act
on the pressure increasing valve. As a result the system pressure can rise to
the adjusted pressure of 310 bar.
continued
9.0
&4

Page 4
Cont'd.:
9.1
Functional description:
Illustration (Z 21928a):
Cushioning Function
When the tensioning cylinders (83.1 - 83.4) are moved in by external forces,
the none return valves (80.1 + 80.2) 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 (89.1 + 89.2).
Second stage: at a pressure higher than 150 bar, is taken up by the center section
accumulators (82.1 + 82.2).
The system pressure can rise up to 310 bar pressure increasing valves (58.1 /
58.2) 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 (X4) via the actuated solenoid
valve Y128 (L.H.) respectively Y129 (R.H.), as soon as the pressure in the
lines to the tensioning cylinder is lower than 30 bar.
9.0
&5

Page 5
9.2
The pressure increasing valve is a remote controlled pressure relief

valve.

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

Valve poppet
Compression spring
Main valve with sleeve
Main piston
Closing spring
Set screw - low pressure 35 bar
Set screw - high pressure 310bar
Piston
Pin
Jet bore
Lock nut
Function:
The valve poppet (2) is connected via the jet bores (11) and (12) with the P
port.
If static pressure increases above the set pressure value, the valve poppet (2)
opens and allows oil to flow freely to tank (T1). This oil generates a pressure
drop in the spring chamber of the main spool, the closing force of the spring (6)
is cancelled, and the main piston (5) opens to allow the pump flow to flow to
tank (T2).
Damped opening and closing is obtained by the throttled volumetric change.
By applying external pressure of Pst max = 60 bar to the main spool (9) via
port X, the pre-tensioning of the pressure spring (3) is increased by the amount
of the piston stroke "S" and system pressure is increased correspondingly.
The setting is fixed by means of the setting screw (7) and lock nut (13); 1 turn
of the screw ~ 150 bar.
9.0
&6

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 320mm!

During bench test an external stroke limitation must be used!
9.0
&7

Page 7
9.4
(58.1)
Pressure increasing valve Track tensioning system L.H.
(58.2)
Pressure increasing valve Track tensioning system R.H.
(62.3)
Service shut-off cock for the L.H.-side
(62.4)
Service shut-off cock for the R.H.-side
(MRV)
Main relief valve Operating pressure of main control
block III
(M11)
Pressure check point Operating pressure of main control
block III
(M29.3)
accumulator (82.1) for the L.H.-side.
(M29.4)
accumulator (82.2) for the R.H.-side.
(M29.7)
Pressure check point - track tensioning system
operating pressure - L.H.
(M29.8)
Pressure check point - track tensioning system
operating pressure - R.H.
(Y128)
Solenoid valve Oil supply to the
L.H. - track tensioning system
(Y129)
Solenoid valve Oil supply to the
R.H. - track tensioning system
(1)
(2)
(3)
(4)
(5)
Piston
Lock nut
Set screw - high pressure
Lock nut
Set screw - low pressure
310bar
35 bar
Checking / Setting the pressure increasing valve

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

Increase the MRV-setting (Block III), ~ 330 to 340 bar.
Switch OFF the engine, open cock valve (62.4) to allow pressure
relieve of the R.H. track, and close it again.
continued
9.0
&8

Page 8
Cont'd.:
9.4
5.
6.
7.
8.
9.
10.
Move the pressure gauge from M11 to M29.8

Connect pressure check point M11 with pressure check point M29.4,
using a long pressure gauge hose. (required for the oil supply)
Disconnect the pilot pressure line at port X of the pressure increasing
valve (58.2) and close the hose with a plug (P).
Loosen lock nut (4) of the pressure increasing valve and screw in set
sleeve (5) until piston (1) comes to stop. (substitution of X4 pressure)
Stall the hydraulic with the bucket filling function (bucket cylinders
completely extended) and observe pressure at check point M29.8.
A pressure of 310 + 5 bar must reached within a time period of 10 15
minutes and must remain at this value.
The maximum pressure will be shown only after the accumulators are
completely filled with oil.
When the pressure reaches the pre-charge gas pressure ( 31 bar and
150 bar) the gauge pointer moves slower depending on the gas
compression.
If the gauge shows a lower or higher value the pressure increasing valve
must be adjusted.
Setting procedure, high pressure stage (Valve 58.2)
a)
b)
c)
d)
11.
Adjust pressure with set screw (3).

Secure adjustment by tightening lock nut (2).
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 M29.8.
b)
loosen lock nut (4) and turn set screw (5) ccw until gauge at
check-point M29.8 shows 35 bar.
c)
Tighten lock nut (4).
d)
continued
9.0
&9

Page 9
Cont'd.:
9.4
12.
13.
Switch OFF the engine and open cock (54.1) to allow pressure relieve.
Re-connect the pilot pressure line to port X of the pressure increasing
valve (58.2).
Remove the pressure gauge hose between pressure check point M11 and
pressure check point M29.4.
Close the cock (54.1).
Re-set MRV to 310 + 5 bar after the check / adjustment is finished.
13.
15.
16.
9.5
Functional Test
After all adjustments are finished, do the following:
a)
Bleed all air from the system
b)
Place shutoff and pressure relief cocks into correct operating position.
c)
Connect pressure gauge to check point (M29.8).
d)
e)
Travel approx. 10 m with the shovel.
f)
Stop the engine.
g)
The pressure must drop to 35 bar.
If the pressure remains the at a higher or lower pressure*, re-adjust the low
pressure setting at the pressure increasing valve (58.2) is necessary.
The pressure may drop below 35 bar after a longer time, this is o.k.
because of internal leakage.
Access ladder
hydraulically operated
Section 10.0
Page 1

Section
10.0
11.11.02
Page
Access ladder hydraulic operated
10.0 General
10.1
3+4
Function of hydraulic operated access ladder
10.0
&2
11.11.02
Access ladder
10.
Section 10.0
Page 2
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
(S84A) safety switch 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 engine can run or stand still only to move the ladder
up the engine must running.
11.11.02
If the ladder is out of the upper position the pilot control switch of and
the solenoid valve Y120 activate the hydraulically swing brake. The
ETM in the cab shows a message.
10.0
&3
11.11.02
Access ladder
10.1
Section 10
Page 3
Function of hydraulic operated access ladder

Legend:
(7.1+7.2)
(84.1+84.2)
(68.1)
(70.1)
(70.2)
(162.3 5)
(171)
(174)
(172)
Y125
Y123A
Y123B
Pumps
Check valves
Filter with filter monitoring switch B22
Pressure relieve valve (60 bar)
Check valves
Ladder cylinder
Orifice
Solenoid valve: lower speed limit
Solenoid valve: ladder up
Solenoid valve: ladder down
The engine 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
11.11.02
10.0
&4
11.11.02
Access ladder
Section 10.0
Page 4
Cont'd:
The engine 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.
11.11.02
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.
Hydraulic operated
refilling arm
Section 11.0
Page 1

Section
11.0
11.11.02
Page
Hydraulic operated refilling arm
11.0 General
11.1
Function
11.0
&2
11.11.02
Section 11.0
Page 2
11.0 Hydraulic operated refilling arm

General
Legend for Illustration Z22496

(A)
Refilling arm
(B)
Control switch (pull switch)
(B)
Hydraulic cylinder
(D)
Limit switch S23
(7.1+7.2)
Pilot Pump
(68.1)
Pilot filter with filter monitoring switch B22
(70.1)
(70.2)
(162.1+161.22) Check valves
Y124A
Solenoid valve: refilling arm up
Y124B
Solenoid valve: refilling arm down
Y125C
Solenoid valve: security valve refilling arm locking
(163)
Hydraulic cylinder
The excavator is equipped with a central refilling system for easy service and
maintenance. One part of this system is the movable refilling arm. This arm is
hydraulic driven by the hydraulic cylinder (C) and mounted below the power
frame.
The refilling arm can moved up or down by pull switch S23. For correct
operation of the refilling arm see OPERATION MANUAL:
11.11.02
The pilot control will stop all working functions and the switch the
swing brake on if the refilling arm swing out of the upper position. The
ETM in the cab shows a message.
11.0
&3
11.11.02
10.1
Section 11.0
Page 3
Function of hydraulic operated refilling arm

Legend:
(A)
(B)
(B)
(D)
(7.1+7.2)
(68.1)
(70.1)
(70.2)
(162.1+161.22)
Y124A
Y124B
Y125
(163)
Refilling arm
Control switch (pull switch) S87
Hydraulic cylinder
Limit switch S23
Pilot Pump
Pilot filter with filter monitoring switch B22
Check valves
Solenoid valve: refilling arm up
Solenoid valve: refilling arm down
Solenoid valve: security valve refilling arm locking
hydraulic cylinder
The engine is running

Additional to the hydraulic diagram from illustration Z22496 use the respective
electric diagram.
The pumps (7.1) and (7.2) are delivering oil through filter (68.1) to port P of the
solenoid valve Y124A/B and the pressure relief valve (70.1) port A. The pressure
relief valve (70.1) maintains the adjusted pressure of maximum 60 bar.
If the solenoid valves Y124A together with solenoid valve Y124C is energised
pressurised oil flows to the arm cylinder piston side and the refilling arm will
move up. If the solenoid valves Y124B together with solenoid valve Y124C is
energised pressurised oil flows to the arm cylinder rod side and the refilling arm
will move down.
Solenoid valve Y124C act as a security lock to prevent a uncontrolled down
moving of the refilling arm. This valve is a special 100% leek oil free valve.
All solenoid valves Y124A/B and C are PLC controlled. Control switch B (S87) is
connected to the PLC and act as a remote control. The refilling arm can only
moved down or up with activated key contact (key switch S1 in the cabin). Only
down moving is possible by gravity with engines stand still.
11.11.02
Hints For Reading The Hydraulic

Circuit Diagram
Section 12.0
Page 1
Table of contents section 12

Section
12.0
Page
Hints for reading the hydraulic circuit diagram
General
12.1
Legend for the circuit diagram
12.2
How to read the circuit diagram
2
3-10
11

Circuit Diagram
Section 12.0
Page 2
12.0 General:
Legend for illustration (Z xxxxx):
HINTS FOR READING THE CIRCUIT DIAGRAM FIG.: 1 + 2

The picture is used for exemplary explanations only.
Use original circuit diagram for detailed reading.
Diagram No. and Typ of machine (A)
H455
650 921 40 (KS)
Sheet-No./Quantity of sheets
(B)
01 / 2
1st of two sheets
Coordinates for discr. the

location of a component
(C)
H11 + 7
Boom cylinder
Component-No 34
(D)
E2
Rotary distributor
Line-No. with cross hint, L13/2B8 (E)
F2
Return line comes from

or is continued on sheet 2
coordinate B8
Legend to the circuit diagram: (Pressure check points "M" on page 7 )

Circuit Diagram
12.2
Legend for the circuit diagram:
(1) - (4)
(5.1)
(5.2)
(6)
(7)
(8.1)
(8.2)
(9)
(10)
(11)
(12)
(13.1)
(13.2)
(13.3)
(13.4)
(14.1)
(14.2)
(14.3)
(15)
(16.1 + 16.2)
(17.1)
(17.2)
(18)
(19)
Section 12.0
Page 3
Main hydraulic pumps A4VSLO 750 LR3DN / 30L Axial

piston pump (swash plate type)
Fan drive pump Hydraulic oil cooler A7FO 63RNZB01
Axial piston pump (fixed displacement with, variable setting)
Fan drive pump Radiator Engine A7FO 63RNZB01
Axial piston pump (fixed displacement with, variable setting)
Oil intake pipe with bleeder screw (Gear pump 8.2)
Gear pump R1A5100C3A1A Pilot pressure - Pump
regulation - Pump bearing lubrication
Gear pump R1A5100C3A1A PTO-gearbox lubrication
Control block III
MO-3469-00 / 3MO-40
Special spool for lowering the boom (without pump pressure)
Control block I
MO-3468-00 / 3MO-40
Control block II
MO-3455-00 / 4MO-40
Special spool for lowering the boom (without pump pressure)
Control block IV MO-3454-00 / 4MO-40
High pressure filter at Control block III
High pressure filter at Control block I
High pressure filter at Control block II
High pressure filter at Control block IV
Manifold
Grease pump (Hydraulic Cylinder)Lincoln Power Master
Central Lubrication System
Grease pump (Hydraulic Cylinder)Lincoln Power Master
Slew ring Lubrication System
Rotary distributor
Continued

Circuit Diagram
Section 12.0
Page 4
Cont'd.:
(20.1)
(20.2)
(20.3)
(20.4)
(21.1)
(21.2)
(22)
(23)
(24)
(25.1 + 25.2)
(26)
(27.1 27.10)
(28.1 28.16)
(29)
(30)
(31.1)
(31.2)
(32.1 32.4)
(33)
(34.1)
(34.2)
(35)
(36)
Orifice - bearing lubrication Main pump I

Orifice - bearing lubrication Main pump II
Orifice - bearing lubrication Main pump III
Orifice - bearing lubrication Main pump IV
Travel gear drive L.H.
Axial piston motor A2FM 500 /60W-VZH-01
Travel gear drive R.H.
Axial piston motor A2FM 500 /60W-VZH-01
Change over valve Electronic pump regulation or hydraulic
constant regulation
3/2-directional control valve (manual operated)
Engine radiator fan drive
Axial piston motor A2FM 160 /61W-VAB-02
Pressure switch B24 monitors item (92.1) (92.2)
Check valve
Pressure relief valve safety valve to protect the travel
parking brakes in case of a defect rotary distributor
Base plate for solenoid valves
Solenoid valves 4/2-directional control valve
Pressure relief valve PTO gear lubrication
Hydraulic oil level gauge
Pressure relief valve - Hydraulic oil cooler fan drive, with
solenoid valve Y6a / Y6b for fan RPM control
Pressure relief valve - Engine radiator fan drive, with
proportional solenoid valve Y136 for fan RPM control
Restrictor, shock absorbers for the hydraulic oil cooler
Pressure filter (B22) pilot pressure, pump regulation, pump
bearing lubrication, track tensioning, grease pumps
Pressure filter (B28) Hydraulic oil cooler fan drive
Pressure filter (B21) Engine radiator fan drive
Pressure filter (B27) - PTO gear lubrication
continued

Circuit Diagram
Section 12.0
Page 5
Cont'd.:
(37.1)
(37.2)
(38)
(39.1 + 39.2)
(40)
(41)
(42)
(43.1)
(43.5)
(44.1 + 44.2)
(45)
(46.1 + 46.2)
(47)
(48.1 + 48.2)
(49)
(50)
(51.1 + 51.2)
(52)
(53)
(54)
(55)
(56.1 + 56.2)
(57.1 + 57.2)
(58.1 + 58.2)
(59.1 59.4)
(60.1)
(60.2)
(61.1 + 61.2)

Axial piston motor A2FM 63 /61W-PAB-03
Axial piston motor A2FM 63 /61W-PAB-03
Check valve - ACV for hydraulic oil cooler fan drive
Hydraulic oil cooler
Suction oil tank
Main oil reservoir
Temperature transmitter B49-1 PTO gear oil temp.
Temperature transmitter B15 Hydraulic oil temp.
Adapter
Service line relief valve (SRV) at the main control block II
Block
Not used
Swing parking brakes Spring loaded multi disk brake
Check valve
Not used
PTO gear oil cooler
Check valve - ACV for engine radiator fan drive
Case drain filter
Back pressure valve
Travel brake valve block
Travel parking brakes Spring loaded multi disk brake
Pressure increasing valve Truck tensioning system
Return oil filter
Slew gear drive L.H.
Axial piston motor A2FLM 355 /60W-VZH-01
Slew gear drive R.H.
Axial piston motor A2FLM 355 /60W-VZH-01
Swing brake valve block
continued

Circuit Diagram
Section 12.0
Page 6
Cont'd.:
(62.1 62.4)
(66.1 66.12)
(67.1 67.4)
(68.1 68.7)
(69.1 69.23)
(70.1 70.13)
(71.1 + 71.2)
(72)
(73)
(74.1 + 74.2)
(75.1)
(75.2)
(76.1)
(77.1 77.4)
(78)
(79.1)
(79.2)
(80.1 + 80.2)
(81.1)
Shut-off valve Truck tensioning system

2/2-directional control valve (manual operated)
Pressure switch B17 Min. PTO gear lubrication pressure
Anti cavitation valves (ACV) at the distributor manifold (42)
Restrictor block with service line relief valve (SRV) at the
distributor manifold (42)
Service line relief valve (SRV) at the main control blocks
Dust cap for item (77.1 77.4)
Check valve Anti cavitation valve at the main control blocks
Cover plate at the main control blocks
Cover plate at the main control blocks
Proportional pressure reducing valve Y127 Swing brake
Proportional pressure reducing valve Y61 Pump regulation
Double check valve
Pressure transducer B164 Case drain filter camber
Pressure transducer B163 Return oil filter camber
Orifice
Not used
Pressure switch B100 Truck tensioning system L.H.
Pressure switch B101 Truck tensioning system R.H.
Check valve
Pressure reducing valve Qmax
(81.2)
(82.1 + 82.2)
(83.1 83.4)
(84)
(85)
(86.1)
(86.2)
(87)
Pressure reducing valve hydraulic constant regulation

Bladder Accumulator 5 liter, 150 bar
Truck tensioning cylinder
Not used
Bladder Accumulator 5 liter, 150bar
Level switch B4 Minimum hydraulic oil level
Level switch B50 Hydraulic oil refilling indication
Shut off valve with S31 (Gate valve)
(63)
(64.1 64.9)
(65.1 65.4)
continued

Circuit Diagram
Section 12.0
Page 7
Cont'd.:
(88)
(89.1 + 89.2)
(90)
(91.1)
(91.2)
(92.1 + 92.2)
(93.1 + 93.2)
(94.1 94.4)
(95)
(96.1 + 96.2)
(97.1 97.3)
(98)
(99.1 99.4)
(100)
(101)
(102)
(103)
(104)
(105)
(106)
(107)
(108.1)
(108.2)
(109)
(110)
(111)
(112.1)
(112.2
(112.3)
(113)
(114)
(115)
Compensator
Membrane accumulator 1,3 liter, 31 bar
Strainer
Pressure switch B48 travel parking brake operating pressure
Pressure switch B16 Swing parking brake operating pressure
Breather filter
Orifice
Chip indicators main pumps (B10a.1/B10b.1/B10c.1/B10d.1)
Double check valve
Pressure relief valve climbing ladder
Check valve
Not used
Hydraulic cylinder climbing ladder
Not used
Not used
Not used
Not used
Pulsation damper
Pressure relief valve for pump support pressure X4 (60bar)
Pressure relief valve for pilot pressure X2 (45bar)
Junction block
Oil intake pipe with bleeder screw (Gear pump 8.1)
Shut off valve suction oil tank
Shut off valve return oil collector tube (Manifold)
Shut off valve return oil collector tube (Hydr. oil cooler)
Electric driven gear pump Service-pump at the Hydr. Tank
Not used
Hydraulic cylinder refilling arm
continued

Circuit Diagram
Section 12.0
Page 8
Cont'd.:.
(116)
(117.1 + 117.2)
(118)
(119.1 119.4)
(120.1 + 120.2)
(121)
(122)
(123)
(124.1 124.4)
(125)
(126.1)
(126.2)
(126.3)
(126.4)
(127)
Not used
Cover plate
Strainer return oil collector tube
Strainer suction line of main pumps
Adapter
Not used
Orifice
Pressure transducer main pumps (B87a/ B87b/ B87c/ B87d)
Pressure transducer suction oil tank (B162)
Pressure transducer X1 pressure (B85-1)
Pressure transducer X2 pressure (B86)
Pressure transducer Back pressure valve (B166)
Pressure transducer pressure Hydraulic oil cooler (B165)
Pressure transducer Hydraulic oil level (B105)
continued

Circuit Diagram
Section 12.0
Page 9
Cont'd.:
M1
M2
M3
M4
M5
M6
M7
M8
M9
M10
M11
M12
M13
M14
M15
M16.1 + M16.2
M26.1 + M26.2
M17.1 + M17.2
+ M24 + M25
M20 +
M21.1 + M21.2
M19

PTO gear lubrication pressure
Release pressure for travel parking brake
Release pressure for swing parking brake
Fan drive hydraulic oil cooler
Fan drive engine radiator
Back pressure inside return oil filter chamber
Back pressure inside case drain filter chamber
Back pressure for hydraulic oil cooling system
Operating pressure, Pump 3
X1 pressure for pump regulation
Boom cylinder piston side
M22
M27
M28.1
M28.2
M28.3
M28.4
Clam cylinder piston end

Pilot pressure / swing operation brake
Operation pressure L.H.-crawler forward
Operation pressure L.H.-crawler backwards
Operation pressure R.H.-crawler backwards
Operation pressure R.H.-crawler forward
M29.1 + M29.2
M29.5 + M29.6
M29.3 + M29.4
M29.7 + M29.8
Bleeder and pressure check point, track tensioning cylinder
Bucket cylinder piston side

Stick cylinder piston side
Clam cylinder rod end
Operating pressure, track tensioning system

Operating pressure, track tensioning system
continued

Circuit Diagram
Section 12.0
Page 10
Cont'd.:
M30
M31
X3 pressure (~15bar), flow reduction pump1 while swinging

X3 pressure, for warming up period (1/2 Qmax ~15bar )
M32
M36.1 + M37.2
M36.2 + M37.1
X3, Remote control pressure

Operating pressure, L.H. swing
Operating pressure, R.H. swing

Circuit Diagram
Section 12.0
Page 11
12.2 How to read the circuit diagram

Example: Lifting the boom, Diagram sheet 01
Oil supply.
Co-ordinates B11 - 12, Pump (1 + 6) to the filter (46.2) ports A.
Filter port B to the control block (33/III) in F7 port P.
A
If the spool is in neutral position:
1. From port P via the spools to outlet port T of the control block; to the
return oil collector tube (36) in D7. Beneath the component No. 36 are
two lines with the hint L6/2A5 and L7/2A5, that means:
The continuation or the origin of the lines are to be found on sheet 2A5.
(co-ordinates A5.
2. Sheet 2A5:
From the collector tube (114) to the port A of the back pressure valve
(115) in B5. If the pressure is greater than adjusted, further via the port
B into the filter chamber and through the four return oil filters (117.2 117.5) A7-6 into the tank (41) A5 - A9.
Simultaneously:
From the collector tube in A6 to the oil coolers (106.1 + 106.2) A/B4.
Out of the oil coolers via the restrictors (107.1 - 107.4) to the ports of
the filter chamber, A6.
B
If the spool is moved downwards (circuit diagram):

Port P in E7 via the load holding valve to port B1 in F7,
further via the maifold (48) G3 to the ports B in F2 + G2 of the slew
brake valves (49.1 + 49.2). Further to the port B of the slew motors
(20.1 + 20.2) in G1.
From port A of each motor to the slew brake valves (49.1 + 49.2). From
there via the manifold 48, to port A1 in F7 of the control block (33/III).
Further via the spool to the outlet port T in E5 into the return oil
collector tube (36) in D7.
Now same as described under A2.
If the spool is moved upwards: (circuit diagram):

Now you should be able to find it out yourself.
Hints for reading the

Electric Circuit Diagram
Section 13.0
Page 1

Section
13.0
Page
Hints for reading the electric circuit diagram
13.1
Designation of electrical devices
13.2
Symbols
3+4
13.3
General information
5+6
13.4
Reading a circuit diagram
7+8
13.5
Component list
9 35

Section 13.0
Page 2
13.1 Designation of electrical devices
Indicating letter
A
B
C
D
E
F
G
H
K
L
M
N
P
Q
R
S
T
U
V
W
X
Y
Z
Kind of component
System, subassembly, parts group, trigger boxes, control units
Transducer for conversion of non-electrical variables to electrical
variables, and vice versa.
Speed sensors, pressure sensors, pressure switches, oil-pressure
switches, temperature sensors
Condenser, capacitor, Condensers and capacitors, general
Elements with time lag, memory elements, binary elements
Various devices and equipment
Protection device
Fuses, current protection circuits
Power supply, generator
Batteries, generators, alternators
Monitor, alarm, signaling device
Indicator lights, signal lights, headlights, warning buzzers, horn
Relay, contactors
Inductor
Coils, windings
Motor
Regulators, amplifiers
Measuring instrument
High voltage switching units
Resistors, heating devices
Switches, selectors
Transformer
Modulator, converter from one electrical in an other electrical value
Semiconductor, electron tubes, diodes, rectifiers, zener diodes
Transmission path, conductor, antenna
Terminal, Plug, Plug and socket connection
Electrically actuated mechanical device
Solenoid-operated valves
Compensating units, filters, limiters cable connection
13.0
&3

Section 13.0
Page 3
13.2 Symbols
Our common used symbols in accordance to VDE/IEC (Association of
German Electrical Engineers DIN 40710 - 40716 and the International
Electrical Commission) differ for the most part from the symbols in
accordance to JIC/ASA (Joint Industrial Concil and American Standard
Association) USA and Canada JIC EMP-1-1967 and ASA 2 32-3).
For this reason the following comparative chart.
1) Normally open
contact
2) Maintained
contact
4) Normally
closed contact
5)
7) Manual operated
switch isolator,
disconnect switch
10) NC contact with
time lag
8) Foot-operated
push-button
switch
11) Multi-position
switch selector
13) Contacts with

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

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

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

conductor
Push-button
switch
3) Single pole
two way contact
break before make
6) Limit switch
NO contact
NC contact
9) Pressure
operated switch
12) Indicating
instrument
(general) symbol
15) Ammeter
13.0
&4

Section 13.0
Page 4
13.2 Symbols
31) Rectifier bridge
32) Thermal over load limit
33) Phase, 4-wire system
34) Current transformer
35) Undervoltage relay
36) Junction of conductors
37) Voltage transformer
38) Temperature relay
39) Junction
40) Circuit interrupter
41) Contactor
42) Terminal
43) Circuit breaker, three

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

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

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

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

Section 13.0
Page 5
13.3 General information

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

= Terminal No 45
Y136 = Plug connector to solenoid

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

Section 13.0
Page 6
13.3 General information

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

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

Section 13.0
Page 7
13.4 Reading a Circuit Diagram.

Examples are shown by sectional drawings out of the electric circuit

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

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

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

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

Section 13.0
Page 8
Cont.:
13.4 Reading a Circuit Diagram.
(4)
Section E 1 sheet 08
The components have a letter and a number prefix, and these are
explained below in rows A and B.
Components are depicted in a system unique to VDE/IEC
(Association of German Electrical Engineers DIN 40710-40716 and
the International Electrical Commission) or to KMG standard.
S27 = Toggle switch (with non-automatic return)
a.
F11
b.
F11 / 10.5 =
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.
Circuit breaker (24V power supply)
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.
13.0
&9

Section 13.0
Page 9
10.5
Component list
Legend for the circuit diagram: # 897 844 40
Component Page
Function
Code
A3
46 Service module ESG (-10V......+10V)
A4
48
Capacitor module
A4a
49
Capacitor module
A5a
50
Capacitor module
A6
51
Capacitor module
A7
50
A7a
50
A8
50

Additional flow ( Qmax.) if S250 is activated
Amplifier module Stick (Y68 + Y30/31 Block I)
A8a
50
Amplifier module Stick (Y74 + Y42/43 Block IV)
A9
48
A9a
48
Amplifier module Bucket fill (Y71 + Y36 Block II)

Stick out (Y71 + Y37 Block II)
Amplifier module Bucket (Y64 + Y22/23 Block III)
A9b
48
Amplifier module Bucket (Y75 + Y44/45 Block IV)
A10
49
Amplifier module Boom (Y73 + Y40/41 Block II)
A10a
49
Amplifier module Boom (Y63 + Y20/21 Block III)
A10b
49
A10c
49
Amplifier module Boom up (Y69 + Y33 Block I)

Bucket fill (Y69 + Y32 Block I)
Amplifier module Boom (Y76 + Y46/47 Block IV)
A11
51
Amplifier module Clam (Y72 + Y38/39 Block II)
A12
51
Amplifier module Left crawler (Y70 + Y34/35 Block II)
A13
51
Amplifier module Right crawler (Y67 +Y28/29 Block IV)
A16
46
Amplifier module Swing brake proportional (Y127)
B4
58
B5-1
12
Hydraulic oil level sensor Oil level minimum (E1.1)

Engine shutdown
Differential pressure switch, high pressure filter pump #1
B6-1
12
B7-1
12
B8-1
12
B10a-1
12
Chip indicator pump #1
B10b-1
12
B10c-1
12
B10d-1
12

Continued
13.0
& 10

Cont'd.: 10.5
Section 13.0
Page 10
Component list

Component
Code
Page
Function
B15
27
Temperature sensor temperature hydraulic oil
B16
18
Pressure switch Swing parking brake
B17-1
17
Pressure switch Minimum PTO gear lubrication pressure
B18-1
17
Pressure switch Monitoring the engine air filter
B19-1
17
Pressure switch Monitoring the engine air filter
B21-1
17
Differential pressure switch Filter radiator fan drive
B22
13
Differential pressure switch Filter pilot pressure system
B24
14
Pressure switch Hydraulic tank breather filter
B27-1
17
Differential pressure switch Filter PTO gear lubrication
B28-1
16
Differential pressure switch Filter cooler fan drive
B38
36
Thermostat switch Cab air condition
B43
15
End of line switch
Central Lubrication System (CLS)
B46
15
End of line switch
Swing Lubrication System (SLS)
B48
18
Pressure switch Travel parking brake
B49-1
27
Temperature sensor PTO gear oil temperature
B50
14
Hydraulic oil level sensor Refill level
B63
25
Pressure transducer Fuel level indication system
B64-1
28
Magnetic pick up (MPU) Engine RPM signal
B85-1
25
B86
25
continued
13.0
& 11

Cont'd.: 10.5
Section 13.0
Page 11
Component list

Component
Code
Page
Function
B87a
25
Pressure transducer Operating pressure pump #1
B87b
25
B87c
25
B87d
25
B90
28
Temperature sensor ambient temperature
B98
43
Left proximity switch at swing gear (pump control swing)
B99
43
Right proximity switch at swing gear (pump control swing)
B100
41
Pressure switch Track tension left crawler
B101
41
Pressure switch Track tension right crawler
B103
17
Oil level sensor Engine oil tank empty
B105
26
Pressure transducer Hydraulic oil level
B106-1
25
Pressure transducer Level engine oil tank
B108
27
Pressure transducer Grease level monitoring CLS
B109
27
Pressure transducer Grease level monitoring SLS
B160
26
Pressure transducer Grease operating pressure CLS
B161
26
Pressure transducer Grease operating pressure SLS
B162
26
Pressure transducer Pressure suction tank
B163
26
Pressure transducer Pressure return oil chamber
B164
26
Pressure transducer Pressure leak oil chamber
B165
26
Pressure transducer Pressure oil cooler
B166
26
Pressure transducer Pressure pre-load (back pressure) valve
D32
45
Time relay Pilot control: Power supply, monitoring

arrangement
D37
35
Time relay Windshield wiper wash system
D38
33
Time relay Delay applying the swing parking brake,

when stopping the engine with key switch
D41
41
Time relay Track tension left crawler
D42
41
Time relay Track tension right crawler
D43
35
Time relay Windshield wiper interval

continued
13.0
& 12

Cont'd.: 10.5
Section 13.0
Page 12
Component list

Component
Code
Page
Function
E6
12-30 Programmable logic controller (PLC)
E7
28
Monitoring the charge/discharge current
E8-1
28
RPM-converter (converts rpm-pulses into norm signals)
E13
38
cigarette lighter
E19
46
Joy stick right
E20
46
Joy stick left
E21a
46
Pedal travel left track
E21b
46
Pedal travel right track
E22
46
Pedal swing brake
E23
46
Pedal bucket closing
E24
46
Pedal bucket opening
E25
33
Radio
E26
36
Air-condition
E26a
36
Air-condition operator panel
E32-1
42
Electronic pump control (MC7)
E41
43
Swing speed switch unit
E42
43
Swing direction monitoring unit
E43
43
Swing speed switch unit
E44
34
Refrigerator
E45-1
55
Pump unit Reserve (Automatic engine oil supply system)
E46
30
VHMS controller
E47
32
Colored Graphic Console (CGC)
E48
50
Ramp time module stick function
E49
49
Ramp time module boom function
E50
50
Ramp time module swing function
E51
51
Ramp time module left crawler
E52
51
Ramp time module right crawler
E53-1
10
PWM controller engine radiator fan speed (Y136-1)
E300
37
Engine-independent cab heater
E350
30
ORBComm (Option)
E400
06
Battery charger
Continued
13.0
& 13

Cont'd.: 10.5
Section 13.0
Page 13
Component list

Component Page
Function
Code
F1
07 50 amp. Main circuit breaker
F1a
07
50 amp. Main circuit breaker
F1b
07
F1c
07
F1d
07
F1e
07
F2
34
F5
35
F6
33
F6a
38
F6b
38
F6c
55
F7
39
F7a
39
F8
39
16 amp. circuit breaker

- Rotaflare light (0ption)
- Operator warning system (Option)
- Air compressor for signal horn
- Warning signal travel backwards
- Windshield washer (main windshield and head light
glasses)
- Main windshield wiper and wipers of head light glasses
- Key switch operation
- Interior power house lighting
- Interior cab base lighting
- Interior cab lighting
- Cab: Socket 24V inside (X5), Socket 24V outside (X31),
sink water-pump, cigarette lighter
- Lubrication systems (CLS and SLS)
- Superstructure lighting: Cab roof right
- Superstructure lighting: Cab roof left
- Superstructure lighting: Oil cooler
Continued
13.0
& 14

Cont'd.: 10.5
Section 13.0
Page 14
Component list

Component
Code
Page
Function
F8a
39

- Superstructure lighting: Counterweight
F9
36

- Cabin: Air-condition
F11
08

- Prelube timer 3D30-1
- Voltage regulator for alternator
- Enable engine (emergency shut-down switches and fire
suppression system)
- Engine run, Engine stop, cold start aid
- Emergency operation (PLC-bypass)
- PWM Controller (engine radiator fan speed)
F13
12

- Power supply sensors (PLC)
- Pilot control: power supply, monitoring arrangement
F15
29

- Power supply PLC
F15a
30

- Power supply ORBComm
- Power supply Interface X27b
- Power supply VHMS Controller
- Power supply Colored Graphic Console (CGC)
F17
07
6 amp. circuit breaker (B+ and B-)

- Radio
- Control module of engine-independent cab heater
- Relays and solenoid valves for hydraulic access ladder
- Fire suppression system
F21
24

- Refilling arm enable (Y124c)
- Proximity switches (S91/S22) of hydraulic access ladder
- Timers and solenoid valves of track tensioning system
Continued
13.0
& 15

Cont'd.: 10.5
Section 13.0
Page 15
Component list

F26
36

- Cab blower
F28
48

- Capacitor module A4
- Power supply for switches of lever E20 (L.H. Joystick)
- Proportional Amplifier (A9/A9a/A9b)
- Pilot control supervision Bucket
F28a
49

- Capacitor module A4a
- Ramp time module E49
- Proportional Amplifier (A10/A10a/A10b/A10c)
- Pilot control supervision Boom
F29
50

- Capacitor module A5a
- Power supply for switches of lever E19 (R.H. Joystick)
- Ramp time module E50 and E48
- Proportional Amplifier (A7/A7a/A8/A8a)
- Pilot control supervision Swing / Stick
F29a
51

- Capacitor module A6
- Power supply for switches of pedals E21a/E21b/E23/E24
- Ramp time module E51 and E52
- Proportional Amplifier (A11/A12/A13)
- Pilot control supervision Crawler / Clam
F43
41

- Proximity switch (S23) of refilling arm
- Pump control
- Pilot control: monitoring arrangement
- Power supply for control levers and pedals
- Pilot control: Swing brake and Travel brake
Continued
13.0
& 16

Cont'd.: 10.5
Section 13.0
Page 16
Component list

F59
07 25 amp. circuit breaker
- Stabilized Voltage for PLC and VHMS controller
F61
- Electronic pump control (MC7)
F62
- Refrigerator
F63
- Drivers seat: Seat heating and air compressor
F64
- Cab heater
F65
- Access area lighting: Upper platform (H49/H49a)and
Ladder (H47/H47a)
F66
- Reserve (Automatic engine oil supply system)
F67
- Cabin: Oven (Option)
F68
- Cabin: Coffee-maker (Option)
F70
- Power supply VHMS Controller (E46)
F300
- Engine-independent cab heater
F301
- Preheating Cab base
- Hydraulic oil level sensor (B4)
F400
- Battery charger
Continued
13.0
& 17

Cont'd.: 10.5
Section 13.0
Page 17
Component list

Component
Code
Page
Function
G1
06
Starter battery
G2
06
Starter battery
G3
06
Starter battery
G4
06
Starter battery
G8
06
Battery for stabilized voltage (PLC and VHMS controller)
G9
06
Battery for stabilized voltage (PLC and VHMS controller)
Continued
13.0
& 18

Cont'd.: 10.5
Section 13.0
Page 18
Component list

Component Page
Function
Code
H1-1
10
Operating hour meter (cab base)
H22
31
Buzzer (Acoustic warning signal)
H30
30
H31
30
H37
30
H38
30
H41
38
LED Emergency indication at the PLC

- By-pass switch S27
- All four high pressure filters and chip indicators
- Main shut-off (gate) valve at the hydraulic tank
- Hydraulic oil temperature
Lamp (Pump compartment)
H41a
38
Lamp (Pump compartment)
H43
38
Lamp (Engine compartment)
H43a
38
H43b
38
H43c
38
H44a
38
Lamp (Interior cab lighting)
H44b
38
H44c
38
H44d
38
H44e
38
H44f
38
H45
38
Lamp (Cab: Pantry lighting)
H46
38
Lamp (Cab base lighting)
H47
39
Lamp (Access area lighting at engine compartment)
H47a
39
Lamp (Access area lighting at the cabin)
H48
39
Lamp (Working light: Cab roof right)
H48a
39
Lamp (Working light: Cab roof right)
H48b
39
Lamp (Working light: Cab roof left)
H48c
39
Lamp (Working light: Cab roof left)
H49
39
Lamp (Access area lighting at the upper platform)
H49a
39
Lamp (Access area lighting at the upper platform)

Continued
13.0
& 19

Cont'd.: 10.5
Section 13.0
Page 19
Component list

Component
Code
Page
Function
H50
39
Lamp (Working light: Hydraulic oil cooler)
H50a
39
Lamp (Working light: Hydraulic oil cooler)
H52
24
Indicator lamp Hydraulic oil level (Refilling system)
H63-1
42
LED Indicator
- Electronic Pump regulation module (MC7)
H72
33
Loudspeaker (Cabin - radio)
H73
33
Loudspeaker (Cabin - radio)
H76
24
Indicator lamp Grease barrel CLS (Refilling system)
H78
24
Indicator lamp Grease barrel SLS (Refilling system)
H93a
34
Lamp Warning beacon on cab roof, left (Option)
H93b
34
Lamp Warning beacon on cab roof, right (Option)
H94-1
09
LED Indicator
- Engine, fuel supply or injection trouble
H95-1
09
LED Indicator
- Engine, sensor malfunction
H96-1
09
LED Indicator
- Engine, cooling or lubrication system trouble
H112
30

- Faulty monitor channel engine speed
H116
30

- Emergency shut down switch actuated
H135
30

- Engine shutdown from round man
H137
30

- Hydraulic oil level to low
H138-1
42
LED Indicator
- This light pulses if there is a failure in the electronic
pump regulation module (MC7)
Continued
13.0
& 20

Cont'd.: 10.5
Section 13.0
Page 20
Component list

Component
Code
Page
Function
H139
24
Indicator lamp Fuel level (Refilling system)
H140
34
Acoustic travel alarm
H142
24
Indicator lamp Oil level of engine make up tank

(Refilling system)
H143-1
55
LED Indicator
- This light monitors the automatic engine oil supply
system Reserve
H144
39
Lamp (Working light: Counterweight)
H144a
39
Lamp (Working light: Counterweight)
H145
21
Lamp Engine STOP (Red). This lamp is used to monitor

engine out-of-range condition, in case the VHMS Monitor
fails to function.
H146
21
Lamp Engine WARNING (Yellow). This lamp is used

to monitor engine out-of-range condition, in case the
VHMS Monitor fails to function.
Continued
13.0
& 21

Cont'd.: 10.5
Section 13.0
Page 21
Component list

Component
Code
Page
Function
K1-1
08
Relay Engine start
K3-1
10
Relay which allows further functions only when the

engine runs with n 300RPM
K3c-1
10
Relay which allows further functions only when the

engine runs with n 300RPM
K6-1
08
Relay Engine run (enable)
K16
56
Relay for power supply to fuel solenoid valve Y99
K20
34
Relay Signal horn (Air compressor)
K22-1
10
Relay Cold start aid (Y2-1)
K23
39
Relay Working light: Cab roof, oil cooler, counterweight
K29
23
Relay CLS lubrication pump ON / OFF
K36
23
Relay SLS lubrication pump ON / OFF
K44
33
Relay:
- Power supply, 50amps. After circuit breaker F1
- Power supply, 25amps. After circuit breaker F59
K44b
33
Relay:
- Power supply, pilot control (Energizing the amplifiers
via contacts of K111 / K111)
K44c
33
Relay for cabin equipment:

- Power supply, Plugs (X32/X33/X34), refrigerator (E44)
- Power supply, pilot control (24V to capacitor modules)
K45
21
Relay Engine RPM control (High / Low idle)
K46
21
Relay Pump control, Qmin (Idle time control)
K50
21
Relay Bucket shut off:

- Four operating hours without Lubrication
- Hydraulic oil is overheated
K51-1
08
Relay Engine stop
K58
49
Relay pilot control (Boom up)
K59
35
Relay Windshield wiper motor, low speed
K60
35
Relay Windshield wiper motor, fast speed

Continued
13.0
& 22

Cont'd.: 10.5
Section 13.0
Page 22
Component list

Component
Code
Page
Function
K62
55
Relay Hydraulic oil transfer pump (Option)
K67
36
Relay Cab blower motor (ON if engine n 300RPM)
K71
48
Relay pilot control (Bucket fill)
K74
50
Relay pilot control (Stick out)
K76
51
Relay pilot control (crawler left)
K78
51
Relay pilot control (crawler right)
K79a
22
Relay Hydraulic oil overheating:

- Warning
- Engine derate (reduced engine power)
K80
44
Relay pump control: energized = Y126 and Y130

activated (If swing speed xxx imp/min and S250 = ON)
- Oil flow reduction Pump #1 (Y126)
- X1 pressure = 35bar at Pump #1 (Y130)
K82
21
Relay pump control: energized = Y17a and Y101

activated (warm up period)
- 1/2 Qmax operation (Y17a)
- Reduction pre-load pressure (Y101)
K93-1
21
Relay Engine shutdown
K100
22
Relay PLC self holding

Continued
13.0
& 23

Cont'd.: 10.5
Section 13.0
Page 23
Component list

Component
Code
Page
Function
K111
45
Relay pilot control safety arrangement: Energized = cut

out of Bucket, swing, stick, crawler and clam function if:
- Refilling arm enable switch, ON
- Switch in drivers seat, OFF
- Access ladder not in the upper end position
- Emergency switch activated
- K44c does not work correctly
K111a
45
Relay pilot control safety arrangement: Energized = cut

out of Boom function if:
- Refilling arm enable switch, ON
- Switch in drivers seat, OFF
- Access ladder not in the upper end position
- Emergency switch (S36) activated
- K44c does not work correctly
K121
08
Relay PLC bypass (Emergency operation)
K121a
08
Relay PLC bypass (Emergency operation)
K122
22
Relay Stabilized power supply (PLC control)
K125
45
Relay Neutral contact monitoring (pilot control system)
K126
45
Relay Neutral contact monitoring (pilot control system)
K132
40
Relay Hydraulic access ladder
K134
40
Relay Hydraulic access ladder (ON in up position)
K135
45
Relay Monitoring of K44c / stops pilot control if K44c

doesnt work correctly.
K144
40
Relay Hydraulic access ladder (ON in down position)
K145
41
Relay Refilling arm (ON in up position)

Continued
13.0
& 24

Cont'd.: 10.5
Section 13.0
Page 24
Component list

Component
Code
Page
Function
K151
45
Relay Pilot control monitoring (ON = Attachment active)
K153
43
Relay pump control swing:

- Connects Pump #1 to the swing if energized ( swing
speed dependent)
K154
43

- Counter prevention if energized ( swing speed
dependent)
K154a
43

- Counter prevention if energized ( swing speed
dependent)
K156
24
Relay Refilling arm enable if energized
K157
44
Relay pump control swing : energized = Y131 activated

- X1 pressure = 35bar at Pump #3 while swinging
K160
52
Relay pilot control: energized = Y135a activated

(S95=ON)
- Floating position boom function OFF (Y135a) Block IV
K160a
52
Relay pilot control: energized = Y132a and Y133a

activated (S95a=ON)
- Floating position stick function OFF (Y132a) Block I
-
Floating position stick function OFF (Y133a) Block IV
K161
35
Relay energized = M28 and M28a activated (motors for

wipers of head light glasses)
K163
45
Relay Hydraulic swing brake, de-energized = Y120 deactivated

- Hydraulic swing brake ON (Y120 de-activated
K164
22
Relay energized = Engine oil tank empty
K300
31
Relay Truck counter (S82)
K301
37
Relay Blower motor of engine-independent cab heater
K302
37
Relay Control module of engine-independent cab heater

Continued
13.0
& 25

Cont'd.: 10.5
Section 13.0
Page 25
Component list

Component
Code
Page
Function
L300
30
Ferrite core (Outdoor cable shield termination)
L301
30
L301
31
L301
31
L301
31
L304
30
L304
31
L304
31
L306
30
L307
30
L308
30
M3
34
Electric motor Signal horn compressor
M4
35
Electric motor Main windshield wiper
M8
55
Electric motor Hydraulic oil transfer pump (Option)
M9
36
Electric motor Blower cab heater
M10
36
Electric motor Cab blower (Cab pressurizing)
M25
36
Electric motor Drivers seat air compressor
M26
34
Electric motor Mirror right
M26a
34
Electric motor Mirror left
M27
38
Electric motor Sink, water-pump
M28
35
Electric motor Wiper of head light glasses left
M28a
35
Electric motor Wiper of head light glasses right

Continued
13.0
& 26

Cont'd.: 10.5
Section 13.0
Page 26
Component list

Component
Code
Page
Function
R3
06
Shunt for measuring of charge current
R21 R24
12
Pull-down / Pull-up resistor (PLC, digital inputs)
R25
16
R26
13
R28
17
R30 R33
14
R34 + R36
15
R42 R45
16
R46 R49
17
R50 R54
18
R55 R58
19
R60 R64
20
R65 R67
09
R80 + R81
28
Resistor for PLC analog input: Battery voltage
R85
36
Seat heating
R86
45
R87 R90
12
R91 + R92
18
S1
33
Key switch (dashboard)
S2
06
Battery main switch
S2a
06
Battery main switch
S3
06
Battery charger switch
S4-1
08
Switch Engine Start
S5-1
08
Switch Engine Stop
S6
34
Signal horn button (in L.H. control lever E20)
S7
34
Switch Operator warning system (Option)
S8
34
Switch Operator warning system (Option)
S10
35
Switch Windshield wash system (main windshield and

head light glasses)
Continued
13.0
& 27

Cont'd.: 10.5
Section 13.0
Page 27
Component list

Component
Code
Page
Function
S11
35
Switch Windshield wiper (Interval, slow, fast)
S15
38
Switch Lighting engine compartment
S15a
38
Switch Lighting pump compartment
S16
38
Switch Interior cab lighting (Dashboard)
S17
38
Switch Cab base lighting
S18
39
Switch Access area lighting (Ladder)
S18a
39
Switch Access area lighting (Cabin)
S20
39
Switch Working light (Dashboard)
S21
36
Switch Cab heating blower control (Dashboard)
S22
40
Proximity switch Access ladder position UP
S23
41
Proximity switch Refilling arm position UP
S24
15
Switch Manual lubrication CLS (Dashboard)
S26
15
Switch Manual lubrication SLS (Dashboard)
S27
08
Switch PLC bypass (Cab base)
S28
45
Switch Seat operated switch (in operators seat)
S29
46
Switch Swing parking brake (Dashboard)
S30
20
Switch Engine RPM control - High / Low idle (in R.H.

control lever E19)
S31
14
Proximity switch Gate valve monitoring
S33a
08
Switch Emergency Stop (Ladder)
S33b
08
Switch Emergency Stop (Valve Block)
S33c-1
08
Switch Emergency Stop (Control and filter panel)
S35
55
Switch Hydraulic oil transfer pump (Option)
S36
19
Switch Emergency Stop (Dashboard)
S38
38
Switch Interior cab lighting (Cab door)
S40
36
Switch Cab pressurizing blower (Dashboard)

Continued
13.0
& 28

Cont'd.: 10.5
Section 13.0
Page 28
Component list

Component
Code
Page
Function
S41-1
09
Service switch Engine RPM fixed to 1800 (Cab base)
S42
31
Switch Truck counter number 2 (Dashboard)
S43
20
Push button Lamp test (Refilling arm)
S49
??
Reset button for CGC
S55
34
Switch Warning beacon on cab roof (Dashboard)
S82
31
Push button Truck counter number 1 (in R.H. control

lever E19)
S84
40
Switch Hydraulic access ladder (in front of radiator)
S86
36
Switch Operators seat air compressor (in front of seat)
S87
20
Pull switch Refilling arm operation
S88
34
Switch Mirror adjustment (Dashboard)
S89
36
Switch Seat heating (at backrest of seat)
S91
40
Proximity switch Access ladder position DOWN
S94
45
Switch Refilling arm enable (Dashboard)
S95
52
Switch Floating position boom ON/OFF (in R.H.

control lever E19)
S95a
52
Switch Floating position stick ON/OFF (in L.H. control

lever E20)
S96
34
Switch Mirror heating (Dashboard)
S97
30
Switch Upload of new program to VHMS controller

(Cab base)
S150
44
Service switch Qmin position of main pumps (Cab base)
S151
18
Service switch Neutral contact bypass Qmax position

of main pumps (Cab base)
S152
39
Switch Access area lighting upper platform (at the fuel

tank)
S250
43
Switch Swing speed (in L.H. control lever E20)
S300
37
Control module of engine-independent cab heater

(Dashboard)
S301
37
Thermostat of engine-independent cab heater

Continued
13.0
& 29

Cont'd.: 10.5
Section 13.0
Page 29
Component list

Component
Code
Page
Function
U1
33
DC/DC converter 24V> 12V power supply radio

(inside dashboard)
V13
33
Diode array
V16
33
Diode array
V17
33
Diode array
V18
33
Diode array
V400
06
Bridge rectifier (Cab base)
X5
38
Socket 24V (Cabin inside)
X8
38
Socket 24V (Engine compartment)
X8a
38
Socket 24V (Pump compartment)
X13-1
42
Service Plug Electronic pump control MC7 (dashboard)
X14-1
42
Plug connector Electronic pump control MC7 (Cab base)
X15-1
11
Connector for Modular Mining System service processor

(Cab base X2 panel)
X27a
30
Connector for download of VHMS memory data

(Cabin inside)
X27b
30
Connector for program upload to the VHMS controller

(Cab base X2 panel)
X30
38
Socket 24V (Cab base)
X31
38
Socket 24V (Cabin outside)
X32
34
X33
34
X34
34
X52-1
09
Data link adapter for Electronic Tool connection to the

ECM of the engine (Cabin inside)
X53-1
11
Connector for Modular Mining System (MMS) service

processor (Cab base X2 panel)
Continued
13.0
& 30

Section 13.0
Page 30
Cont'd.: 10.5
Component list
Component Page
Function
Code
Y2-1
08
Solenoid Cold start aid
Y3
35
Pump Windshield wash system
Y3a
35
Pump Head light glasses wash system
Y4
36
Magnetic clutch Air condition compressor
Y5
46
Solenoid valve, swing parking brake
Y6a-1
22
Y6b-1
22
Y7
55
Solenoid valve, hydraulic cooler fan RPM control.

Energized = minimum speed
Solenoid valve, hydraulic cooler fan RPM control.
Energized = medium speed
Solenoid valve, CLS pump ON / OFF
Y7a
55
Solenoid valve, CLS pressure relieve of grease line.
Y9
55
Solenoid valve, SLS pump ON / OFF
Y9a
55
Solenoid valve, SLS pressure relieve of grease line.
Y16
46
Solenoid valve, travel parking brake
Y17
44
Solenoid valve, pump control, Qmin (Idle time control)
Y17a
44
Solenoid valve, pump control, 1/2 Qmax (warm up period)
Y20
53
Directional solenoid valve Boom up (Block III)
Y21
53
Directional solenoid valve Boom down (Block III)
Y22
53
Directional solenoid valve Bucket filling (Block III)
Y23
53
Directional solenoid valve Bucket dump (Block III)
Y24
53
Directional solenoid valve Swing left (Block III)
Y25
53
Directional solenoid valve Swing right (Block III)
Y26
54
Directional solenoid valve Swing left (Block I)
Y27
54
Directional solenoid valve Swing right (Block I)
Y28
54
Y29
54
Y30
54
Directional solenoid valve R.H. Crawler forward

(Block IV)
Directional solenoid valve R.H. Crawler reverse
(Block IV)
Directional solenoid valve Stick extending (Block I)
Y31
54
Directional solenoid valve Stick retracting (Block I)
Y32
54
Directional solenoid valve Bucket filling (Block I)
Y33
54
Directional solenoid valve Boom up (Block I)

Continued
13.0
& 31

Section 13.0
Page 31
Cont'd.: 10.5
Component list
Component
Code
Page
Function
Y34
53
Directional solenoid valve L.H. Crawler reverse

(Block II)
Y35
53
Directional solenoid valve L.H. Crawler forward

(Block II)
Y36
53
Directional solenoid valve Bucket filling (Block II)
Y37
53
Directional solenoid valve Stick extending (Block II)
Y38
53
Directional solenoid valve Clam closing (Block II)
Y39
53
Directional solenoid valve Clam opening (Block II)
Y40
53
Directional solenoid valve Boom up (Block II)
Y41
53
Directional solenoid valve Boom down (Block II)
Y42
54
Directional solenoid valve Stick extending (Block IV)
Y43
54
Directional solenoid valve Stick retracting (Block IV)
Y44
54
Directional solenoid valve Bucket filling (Block IV)
Y45
54
Directional solenoid valve Bucket dump (Block IV)
Y46
54
Directional solenoid valve Boom up (Block IV)
Y47
54
Directional solenoid valve Boom down (Block IV)
Y61-1
42
Proportional solenoid valve Electronic pump regulation
Y63
53
Proportional solenoid valve (remote control unit)
Y64
53
Y65
53
Y66
54
Y67
54
Y68
54
Y69
54
Y70
53
Y71
53
Y72
53
Y73
53
Y74
54
Y75
54
Y76
54

Continued
13.0
& 32

Section 13.0
Page 32
Cont'd.: 10.5
Component list
Component Page
Function
Code
Y99
56
Solenoid valve, shut off valve in fuel supply line
Y101
44
Solenoid valve Reduction pre-load pressure oil cooler
Y120
46
Solenoid valve Hydraulic swing brake
De-energized = Hydraulic swing brake ON
Y123a
40
Solenoid valve Hydraulic access ladder up
Y123b
40
Solenoid valve Hydraulic access ladder down
Y124a
24
Solenoid valve Refilling arm up
Y124b
24
Solenoid valve Refilling arm down
Y124c
24
Solenoid valve Refilling arm enable
Y125
40
Solenoid valve Hydraulic access ladder fast movement
Y126
44
Solenoid valve Oil flow reduction Pump #1
Y127
46
Proportional solenoid valve Hydraulic swing brake
Y128
41
Solenoid valve Track tension left crawler
Y129
41
Solenoid valve Track tension right crawler
Y130
44
Solenoid valve Fixed pump #1 for swing X1 = 35bar
Y131
44
Solenoid valve Fixed pump #3 for swing X1 = 35bar
Y132a
52
Solenoid valve Floating stick function
Y133a
52
Solenoid valve Floating stick function
Y135a
52
Solenoid valve Floating boom function
Y136-1
10
Proportional solenoid valve Engine radiator fan speed
Y300
37
Solenoid valve Fuel pump, engine-independent cab heater
Continued
13.0
& 33
No Illustration
Pre-heating system installed on the job side

Section 13.0
Page 33
Cont'd.:
Component Page
Function
Code
1B1
57
Temperature switch, engine oil Pre heating
1B2
57
Temperature switch, PTO gear oil Pre heating
1B3
58
1B4
58
1B5
59
1B6
59
Temperature switch hydraulic oil, suction tank

Pre heating
Temperature switch engine oil, reserve oil tank
Pre heating
Temperature switch hydraulic oil, main oil tank
Pre heating
Temperature switch heating elements, Pre heating
1B7
59
1B8
59
1B9
59
1B10
59
1B11
59
1D1
60
Time relay Engine coolant, Pre heating
1E1
59
Switch box KIM-Hotstart - Pre heating hydraulic oil
1E2
60
Switch box KIM-Hotstart - Pre heating engine coolant
1F1
57
32 amp. circuit breaker Pre heating
1F2
57
6 amp. circuit breaker, engine oil Pre heating
1F3
57
6 amp. circuit breaker, PTO gear oil Pre heating
1F4
57
6 amp. circuit breaker, battery heater Pre heating
1F5
58
6 amp. circuit breaker, suction tank Pre heating
1F6
58
6 amp. circuit breaker, reserve oil tank Pre heating
1F7
58
20 amp. circuit breaker, cab heater Pre heating
1F8
59
40 amp. circuit breaker Pre heating Hydraulic Oil
1F9
60
40 amp. circuit breaker Pre heating Engine Coolant
1H1
58
Cab heater unit
1K1
58
Relay Cab heater
1K2
59
Relay Heating element hydraulic oil
1K3
59
1K4
59
1K5
59
1K6
59
1K7
59

Continued
13.0
& 34

Section 13.0
Page 34
Cont'd.:
Component
Code
Page
Function
1K8
59
Relay Hydraulic oil level for pre-heating
1K9
58
Relay Hydraulic oil level for pre-heating
1K10
60
Relay Pre heating Engine Coolant
1K11
60
Relay Pre heating Engine Coolant
1Q1
57
Power switch Current supply pre heating
1R1
57
Heating element engine oil (500W)
1R2
57
Heating element PTO gear oil (300W)
1R3
57
Heating element PTO gear oil (300W)
1R4
57
Heating element battery heater engine house (75W)
1R5
57
1R6
57
1R7
57
1R8
57
Heating element battery heater cab support (75W)
1R9
57
Heating element battery heater cab support (75W)
1R10
58
Heating element hydraulic oil suction tank (500W)
1R11
58
Heating element hydraulic oil suction tank (500W)
1R12
58
Heating element engine reserve oil tank (500W)
1R13
59
Heating element main hydraulic oil tank (2000W)
1R14
59
1R15
59
1R16
59
1R17
59
1R18
59
1R19
60
3B 93-1
06
Pressure switch Engine oil pressure
3D 30-1
06
Time relay Engine pre-lube
3E 14-1
09
ECM Engine control module (Quantum)
3E 54-1
11
ECM Engine control module (Cense)
3F 39
06
Fuse 400 amp. (internal part of the cable to starter motors)
3G 5-1
06
Engine alternator (220A)
3K 2a-1
06
Starter relay
3K 2b-1
06
Starter relay
Continued
13.0
& 35

Cont'd.:
Component Page
Function
Code
3M 1-1
06
Engine starter motor
3M 2-1
06
Engine starter motor
3M 6-1
06
Engine pre-lube pump
3N 1-1
06
Voltage regulator for alternator
3X 16-1
09
OEM connector Engine control module
3X17-1
10
OEM connector Engine control module
4B 1
08
Pressure switch fire suppression system
4E 1
56
Central unit fire suppression system
4H 1
56
Horn
4R 1
56
Explosive charge (pressure generator)
4S 3
56
Detection wire
Section 13.0
Page 35
Vehicle Health Monitoring System Section 14.0

Page 1
VHMS
Komatsu Hydraulic Mining Shovel
PC 4000
Vehicle Health
Monitoring System
Section
14.0
Page
2
General
14.1
14.2
Colored Graphic Console (CGC) for PC4000

Specifications for Operators
1 11

Specifications for Servicemen
1 30
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-1
14.0
&2
-2

Page 2
VHMS
14.0 General
V H M S is an on-board electronic monitoring system with off-board
downloading and network capable of performing the following functions:
A. Subsystem and components monitoring for condition-based fault detection
and storage of faults and other events, incl. trend snapshot etc. data.
B. On selected subsystems and components, generation of trending, histogram,
and cumulative data to be used as a predictive maintenance aid.
C. PC-based download data handling tool.
D. Single serial data connection point for all systems on the Excavator.
Operating Principle, illustration (Z 22120)
The Vehicle Health Monitoring System with the Touch on screen buttons on a
Colored Graphic Console (VHMS Graphic Display) allows comfortable
operation and quick access to all information about machine status and
maintenance calls.
All monitoring and control components are connected via a high frequency data
transfer cable (CAN-Bus) for fast communication and easy installation.
The drive engine, a Komatsu SDA 16V 160 (QSK 60), is equipped with two
ECM (Electronic Control Module) controllers, called QUANTUM (Engine
Control system) and CENSE (Engine Monitoring system), with the capability of
working independent from the other controllers.
Condition monitoring on the shovel systems is established by the PLC
(Programmable Logic Controller) a controller with write reading memory
ability which can be altered (via an serial interface) by a PC and the respective
Software.
The PLC receives from the monitored shovel systems the actual values and does
an evaluation, this results in a control function and via the VHMS in a display
function.
All systems are connected via the CAN-Bus to the Vehicle Health Monitor
System controller, where the status reports so as the failure reports are stored in a
continues memory which can be recalled and displayed or frequently
downloaded to a portable PC.
As an optional equipment a controller with monitor is available for connection of
the Modular Mining System.
All components are prepared and interface provided for easy on side installation.
-3

Page 1
VHMS
Section
14.1
Page
Specifications for Operators
14.1.1
Graphic Flow Chart (Screen Overview)
14.1.2
Initialization Screen (No. 0.0)
14.1.3
Operator Information Screen (No. 1.1)
14.1.4
Monitoring Screens
Standard Monitor 1 (No. 1.2)
Expansion monitor 2 (No. 1.3)
14.1.5
Brightness and Contrast Setting Screen (No.

1.2.1)
14.1.6
Fuel Consumption Screen (No. 1.2.2)
14.1.7
Settings for Operator, Screen (No. 1.2.3)

Entry of the Operator identification number
Resetting the Truck Counter
14.1.8
Maintenance Monitor Screen (No. 1.2.4)
8+9
14.1.9
Failure Message Screen (No. 1.2.5)

Failure history for Operator
10
14.1.10
Automatic Messages Screens
11
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14.1
&2
-2-

Page 2
VHMS
14.1.1 Graphic Flow Chart

Operator
Operator Menu
0.0
1.1
1.2
1.3
1.4
1.2.1
1.2.2
1.2.3
1.2.4
1.2.5
Initialization
Information
Machine Conditions:
Monitor1
Standard monitor
Monitor2
Expansion monitor
Monitor3
Expansion monitor
Screen Adjustment
Consumption
Operator ID
Maintenance Monitor
Current Messages
Action of hidden switches

2.0
Input Service ID
Service
Service Menu
Select
If warning or error occurs
Automatic
Messages Monitor
Real Time
Monitor
4.2.1
4.3.1
4.3.2
4.4.1
4.5
4.6
4.7
4.8.1
5.1.1
5.2.1
5.3.1
5.4.1
5.5.1
5.6.1
5.7.1
5.8.1
5.9.1
5.10.1
PM-Clinic
Serial No. setting
(Machine)
Serial No. setting (Engine)
Memory Clear
Maintenance
Failure History
Snapshot Trigger
Data Settings
Engine
Transmission
Hydraulic
Electrical Equipment
Emergency Stop
Manual Switch
Central Lubrication
Open Gear Lubrication
Others
Output Signal
-3-
14.1
&3
0.0
Operator Menu
0.0
1.1
Initialization
Information
1.2
1.3
1.4
1.2.1
1.2.2
1.2.3
1.2.4
1.2.5
Machine Conditiones:
Monitor1
Standard monitor
Monitor2
Expansion monitor
Monitor3
Expansion monitor
Screen Adjustment
Consumption
Operator ID
Maintenance Monitor
Current Messages
Systemtest Running !
(English)
1.1
#Please be Safty Conscious when working!
#Did you check the Operating
Safety of the Excavator ?
#Did you do Maintenance
according to the Service Literature ?
#The routing visual checks, lubrication work
and engine maintenance are not called up.
Monitor 0
Next
1.2
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
Maint Mess Next

Monitor 1
-4-

Page 3
VHMS
14.1.2 Initialization Screen (No. 0.0)
The Monitor of the Vehicle Health Monitoring System VHMS displays the
condition of the machine, the maintenance status, and messages for the
operator and service man, and is also used to input the necessary data. The
surface of the monitor screen is equipped with touch switches to switch the
screen and input the data.
Sequence of Displays
When the main key switch is turned ON, the initialization screen (No. 0.0) is
displayed after 20 seconds for approx. 5 seconds. This screen shows also the
selected system language.
If the ambient temperature of the monitor is below 10C, the screen

remains dark until the internal heater has warmed up the screen to
operating temperature. If the ambient temperatures goes above +60C
the screen becomes dark (back light is turned off to protect the screen).
When the temperature returns to operating range, the display will
appear again, so carry out operations according to the machine
monitor.
The system offers two languages, for example ENGLISH GERMAN,
according to Customer request. Changing of the present language can
be carried out in the main group SETTINGS of the SERVICE MENU.
14.1.3 Operator Information Screen (No. 1.1)

The second display (No. 1.1), is of general information for the operator.
Press the touch switch NEXT on the screen surface for display of the
standard monitor 1, (No. 1.2).
The colored Graphic Flow Chart (Z 21568) attached in the pocket of

the front cover gives an overall view of the menu structure, the menu
availability for the operator and for the service staff, as well as the
automatic functions of the system. The numbering (0.0, 1.1, 1.2 and so
on) of the monitors in this chart is also used on all monitor pictures in
this section. Use this chart for menu control in connection with the
description on the following pages.
-5-
14.1
&4
0.0
1.1
Operator Menu
Initialization
Information
1.2
1.3
1.4
Monitor1 Standard monitor
Monitor2 Expansion monitor
Monitor3 Expansion monitor
1.2.1
1.2.2
1.2.3
1.2.4
1.2.5
Screen Adjustment
Consumption
Operator ID
Maintenance Monitor
Current Messages
-6-

Page 4
VHMS
14.1.4 Monitoring Screens
Standard Monitor 1 (No. 1.2)
See illust. (Z 21571)
Displayed items:
LH column
Date
Time
C = Ambient temperature
h = Operating hours (SMR)
TR1 = Truck counter 1
TR2 = Truck counter 2
1/min = Engine speed (RPM)
Monitor No. 1.
Gauges
Fuel Level
Hydraulic Oil Temperature
Coolant Temperature
Oil Pressure Engine
Color Definition
Blue
= Normal operating range
Yellow = Warning range
Red
= Serious trouble, act immediately.
Engine derate or shutdown may
happen.
When the pointer of a gauge moves into a yellow or red range, there
will be in most cases an automatic message display informing the
operator in plain text about the failure and the necessary action to be
taken. For a typical display see 1.2.5 Automatic Message.
Touch Switches
1
Brightness This button switches to Brightness and Contrast setting screen, for details
see picture No. 1.2.1.
Fuel Consumption This button switches to Fuel consumption screen, for details see
picture No.1.2.2.
Settings Operator This button switches to Settings for Operator, User ID and Truck
counter resetting screen, for details see picture No. 1.2.3.
Maintenance This button switches to the Maintenance Monitor. The color of this switch
changes to yellow when Maintenance is due, for details see Maintenance Monitor No.
1.2.4.
Message This button switches to Failure Message history screen for the operator. The
color of this switch changes to yellow when a current message is available in the Failure
Message history for the operator. The button remains yellow as long as the cause for the
message exists, even if the message was canceled. For details see Failure Message screen
(for Operator) No. 1.2.5.
Monitor selection This button switches to the next Monitor in the following order:
Monitor 1 >2 >3 >1 and so on, see pictures No. 1.2, 1.3 and 1.4.
LH column Same as Standard Monitor 1

Gauges
Engine Oil Temperature
PTO Oil Temperature
Boardnet Voltage
Charging Ampere
LH column Same as Standard Monitor 1

Gauges
Hydraulic Oil Level
Engine Oil Level
Grease Level Central Lubrication System (CLS)
Grease Level Swing ring gear Lube. System (CLS)
-7-
14.1
&5
1.2
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
Maint Mess Next

Monitor 1
1.2
1.3
1.4
Operator Menu
Initialization
Information
Monitor1
Standard monitor
Monitor2
Expansion monitor
Monitor3
Expansion monitor
1.2.1
Screen Adjustment
1.2.2
1.2.3
1.2.4
1.2.5
Consumption
Operator ID
Maintenance Monitor
Current Messages
0.0
1.1
1.3
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
1.2.1
Oil Temp Eng
Oil Temp PTO
Boardnet Volt
Charging AMP
Date Brightness
Oil Level
Level Eng
and Hyd
Contrast Oil
Settings
31.12.00
H
H
Time Brightness
23:59
100
-999.9 C
L
L
99999.9 h
Contrast
Gre Level CLS
Gre Level SLS
Tr1 Tr2
EXIT
H
45
H
999 999
RPM
9999
L
Maint Mess Next

Monitor 3
Monitor 2
Maint Mess Next
1.4
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
RPM
1800
Oil Level Hyd
Oil Level Eng
Gre Level CLS
Gre Level SLS

H
Maint Mess Next

Monitor 3
-8-

Page 5
VHMS
14.1.5 Brightness and Contrast Setting Screen (No. 1.2.1)
When the brightness button is pressed, the screen No. 1.2.1 is displayed. If
this screen is not touched within 5 seconds, it will disappear and the original
screen will be displayed.
(1) Contrast control slide:
To adjust the contrast of the screen, press the desired position on the
slide bar.
(2) Brightness control slide:
To adjust the brightness of the screen, press the desired position on
the slide bar.
-9-
14.1
&6
1.2
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
Maint Mess Next

Monitor 1
1.2
1.3
1.4
1.2.1
Operator Menu
Initialization
Information
Monitor1
Standard monitor
Monitor2
Expansion monitor
Monitor3
Expansion monitor
Screen Adjustment
1.2.2
Consumption
1.2.3
1.2.4
1.2.5
Operator ID
Maintenance Monitor
Current Messages
0.0
1.1
1.3
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
1.2.2
Oil Temp Eng
Oil Temp PTO
Consumption
16:55
L
From
3/Jan/2001 17:02
To
6/Jan/2001 1:39
Boardnet Volt
Charging AMP
FUEL CONSUMPTION
HOURS
L/h
40.9
START
190.9
Maint Mess Next

Monitor 2
Consumption
1.4
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
RPM
1800
From
Oil Level Hyd
Oil Level Eng
16:55
14/Jan/2000 16:55
To
FUEL CONSUMPTION
L
Gre Level CLS
Gre Level SLS
STOP
L/h
HOURS
Maint Mess Next

Monitor 3
- 10 -

Page 6
VHMS
14.1.6 Fuel Consumption Screen (No. 1.2.2)
When the fuel consumption button (2) is pressed, the screen No. 1.2.2 is displayed. The last
data are displayed in each field on the screen. Pushing the START button will erase them
and TO and FUEL CONSUMPTION fields are changed to blank. If you want to start fuel
consumption measurement, push the START button. The Date and local Time will be
inserted into the FROM field. The START button changes to STOP button. Push the
(Go to Monitor) button to go back to the Standard Monitor 1.
When the time period for fuel consumption measurement is over, for example after 4 days,
select the CONSUMPTION Screen from any of the three Monitors No. 1.2, 1.3 or 1.4 by
pushing the fuel consumption button (2). The displayed consumption screen shows the
starting date and time of fuel consumption measurement. Push the STOP button. The
current date and time is inserted into the TO field and the average fuel consumption
calculated during the time period FROM TO is inserted into the FUEL
CONSUMPTION field.
Clock symbol: current time

FROM: date and time when the START button is pushed
TO: date and time when the STOP button is pushed
FUEL CONSUMPTION: Average consumption data between Start and Stop.
Push the (Go to Monitor) button to go back to the Standard Monitor 1.

- 11 -
14.1
&7
1.2
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
Maint Mess Next

Monitor 1
1.2
1.3
1.4
1.2.1
1.2.2
Operator Menu
Initialization
Information
Machine Conditions:
Monitor1
Standard monitor
Monitor2
Expansion monitor
Monitor3
Expansion monitor
Screen Adjustment
Consumption
1.2.3
Operator ID
1.2.4
1.2.5
Maintenance Monitor
Current Messages
0.0
1.1
1.3
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
1.2.3
Oil Temp Eng
Oil Temp PTO
Boardnet Volt
SETTING for Operator
USER ID
12345678901
Reset Truck Counter 1
16
17
Charging AMP
Maint Mess Next

Monitor 2
1.4
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
RPM
1800
Oil Level Hyd
Oil Level Eng
Gre Level CLS
Gre Level SLS

H
Maint Mess Next

Monitor 3
- 12 -

Page 7
VHMS
14.1.7 Settings for Operator, Screen (No. 1.2.3)
When the button -Settings for Operator is pressed, the

screen No. 1.2.3 is displayed.
There are two hidden touch switches on the SETTING for Operator
screen, see (1) and (2) illust. (Z 21576). These switches are used by
service personnel for entering the Service Menu. To enter the Service
Menu, first press the lower button (1) and then the upper button(2).
Entry of the Operator identification number

(USER ID button):
In the selection menu for settings (1.2.3) appears on the
right side of the button USER ID the actual eleven-digit
Operator identification number. The use of the button
USER ID branches into the setting mode for the Operator
identification number, see illust. (Z 21578). Without prior
entry, 0 is predetermined as identification number. To
distinguish Operators, it is possible to enter a eleven-digit
Operator identification number. To this effect, the Clearbutton puts the cursor onto the first position (left side). Data
entry may be started via the number buttons. If eleven
numbers were entered each further entry will be ignored.
Using the Enter-button the identification number will be
taken over and branched back to the selection menu (1.2.3).
Resetting the Truck Counter:
Press the button Reset Truck Counter 1 the display
changes to YES NO decision screen, picture (Z 21577).
When pressing the YES button the counter 1 will be reset
to zero. Truck counter 2 is reset in the same way.
- 13 -
14.1
&8
1.2
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
Maint Mess Next

Monitor 1
1.2
1.3
1.4
1.2.1
1.2.2
1.2.3
Operator Menu
Initialization
Information
Machine Conditions:
Monitor1
Standard monitor
Monitor2
Expansion monitor
Monitor3
Expansion monitor
Screen Adjustment
Consumption
Operator ID
1.2.4
Maintenance Monitor
1.2.5
Current Messages
0.0
1.1
1.3
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
1.2.4
Oil Temp Eng
Oil Temp PTO
MAINTENANCE MONITOR
Boardnet Volt
Charging AMP
Maint Mess Next

Monitor 2
250h Maintenance
250
500h Maintenance
500
1000h Maintenance
1000
2000h Maintenance
2000
3000h Maintenance
3000
STO
P
1.4
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
RPM
1800
Oil Level Hyd
Oil Level Eng
Gre Level CLS
Gre Level SLS

H
Maint Mess Next

Monitor 3
- 14 -

Page 8
VHMS
14.1.8 Maintenance Monitor (No. 1.2.4)
The Maintenance Monitor can be selected from the Standard monitor
1 and from the expansion monitors 2 and 3 by pressing the
Maintenance button (4). The color of this button changes to yellow
when maintenance is due. The color will change to red when
maintenance is overdue.
The maintenance monitor is shown at six different operating hour
readings, see pictures (Z 21579A to F).
Color definition of Periodic Maintenance text:
The five periodic maintenance intervals are listed in text form with a
colored background. The colors have the following significance:
Grey - Maintenance still not due the displayed hours at the right side
of the text are greater than 48 h before the next maintenance is due.
Yellow - Maintenance is due the displayed hours are equal or smaller
than 48 h before the next maintenance or, numbers smaller or equal to
48 h with a minus sign indicating that the maintenance is already
overrun. The total number of hours in the yellow range is 96, divided
in 48 hours with a positive value and 48 hours with a negative value.
Red - Maintenance is overdue hour numbers with a negative value go
further into the minus range indicating that the limit for the periodic
maintenance is exceeded.
Examples of Maintenance Monitor displays:
Illust. Z 21579A: 2050 Operating hours
All five periodic maintenance intervals on the screen are gray. No
maintenance required.
Illust. Z 21579B: 2220 Operating hours
The Periodic 250 h Maintenance field is yellow indicating that this
maintenance has to be carried out. The number of hours displayed is
less than 48. All other maintenance fields having hour numbers
greater than 48 h and are still gray.
Illust. Z 21579C: 2980 Operating hours
The 250 h, 500 h, 1000 h and 3000 h maintenance is due. The 2000 h
maintenance has been carried out at 2000 operating hours and there
are 1020 h left until the next 2000 h maintenance becomes necessary.
- 15 -
14.1
&9
1.2
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
Maint Mess Next

Monitor 1
1.2
1.3
1.4
1.2.1
1.2.2
1.2.3
Operator Menu
Initialization
Information
Machine Conditions:
Monitor1
Standard monitor
Monitor2
Expansion monitor
Monitor3
Expansion monitor
Screen Adjustment
Consumption
Operator ID
1.2.4
Maintenance Monitor
1.2.5
Current Messages
0.0
1.1
1.3
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
1.2.4
Oil Temp Eng
Oil Temp PTO
MAINTENANCE MONITOR
Boardnet Volt
Charging AMP
Maint Mess Next

Monitor 2
250h Maintenance
250
500h Maintenance
500
1000h Maintenance
1000
2000h Maintenance
2000
3000h Maintenance
3000
STO
P
1.4
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
RPM
1800
Oil Level Hyd
Oil Level Eng
Gre Level CLS
Gre Level SLS

H
Maint Mess Next

Monitor 3
- 16 -
Vehicle Health Monitoring System

VHMS
Section 1.0
Page 9
14.1.8 Maintenance Monitor (No. 1.2.4)

(continued)
Illust. Z 21579D: 3050 Operating hours
The 250 h, 500 h, 1000 h and 3000 h maintenance has not been
carried out within the yellow time period so the background color has
changed to red, indicating that the limit for these maintenance items is
exceeded by 50 h.
Inform Service about the present maintenance display.

Maintenance is urgently required.
The 2000 h maintenance has been carried out at 2000 operating hours
and was confirmed in the Service Menu. There are 950 h left until the
next 2000 h maintenance becomes necessary.
Illust. Z 21579E: 3100 Operating hours
The 250 h, 500 h, 1000 h and 3000 h maintenance has been carried
out at 3100 operating hours and was confirmed in the Service Menu.
The background color has changed to gray.
Illust. Z 21579F: 3550 Operating hours
The 250 h, maintenance has been carried out at 3250 and at 3500
operating hours. The periodic 500 h maintenance which was also due
at 3500 operating hours was not carried or not confirmed in the
Service Menu so the background color changed to red. Inform Service
for carrying out the 500 h maintenance. On pressing the key it is
possible to return to the monitor 1.
Peculiarities to be observed:
Higher maintenance also include lower maintenance. (Lower maintenance must also be carried out!)
Exception: On performance of the 3000 h maintenance it is not necessary to also carry out the 2000 h
maintenance. The maintenance cycles are rigidly linked to the running time meter. Maintenance may
be confirmed max. 48 h prior to elapsing the maintenance cycle. Only running time hours are taken
into consideration (No minutes or seconds). On initial start-up any maintenance is indicated with gray.
The routine visual checks and inspections after every 10 and 50

operating hours are not called up on the Maintenance Monitor.
On new machines an INITIAL SERVICING after the first 250 and
1000 operating hours is required, in addition to the periodic
maintenance intervals displayed on the monitor.
Maintenance confirmation through Service Personnel

Maintenance indicated with yellow or red background color should be confirmed through Service
Personnel in the Service Menu subsequent to the execution of the maintenance. With the confirmation
the actual value maintenance number is increased by 1. Thus, the length of the maintenance cycle is
added to the display value and the gray color will appear in the maintenance display. The button in the
Service Menu used for maintenance confirmation then turns gray instead of yellow and is then
without any function. The confirmation of the maintenance generates a corresponding message
present for 1 second and is then stored.
- 17 -
14.1
& 10
1.2
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
Maint Mess Next

Monitor 1
1.2
1.3
1.4
1.2.1
1.2.2
1.2.3
1.2.4
Operator Menu
Initialization
Information
Machine Conditions:
Monitor1
Standard monitor
Monitor2
Expansion monitor
Monitor3
Expansion monitor
Screen Adjustment
Consumption
Operator ID
Maintenance Monitor
1.2.5
Current Messages
0.0
1.1
1.3
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
1.2.5
Oil Temp Eng
Oil Temp PTO
FAILURE Message(for Operator)
1 G00066:
From
L
Total
Trouble hydraulic oil

temperature
01/May/2000 08:20
Boardnet Volt
Charging AMP
2 G00146:
From
3 C00124:
From
Trouble monitoring pump 4

01/May/2000 08:20
High Boost LB
06/ May /2000 10:20
Maint Mess Next

Monitor 2
1.4
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
RPM
1800
Oil Level Hyd
Oil Level Eng
Gre Level CLS
Gre Level SLS

H
Maint Mess Next

Monitor 3
- 18 -

Page 10
VHMS
14.1.9 Failure Message (No. 1.2.5)
(for Operator)
Failure history for Operator
The Failure Message history screen illustration (Z 21580) can be selected from the Standard
monitor 1 and from the expansion monitors 2 and 3 by pressing the Message button. The
color of this button changes to yellow when a current message is available in the failure
message history for the operator.
Legend for illust. (Z 21580)

1
2
3
4
5
Standard monitor display button, switches back to the Monitor previously displayed.
Quick scroll up button, replaces all three messages with three previous messages
Scroll up button, shifts single messages
Scroll down button, shifts single messages
Quick scroll down button, replaces all three messages with three following messages
When the cause for a message listed in the failure history has gone, the message will be
removed from the failure history for operator and the time and date is added to the already
stored message in the memory of the Failure History for Service.
- 19 -
14.1
& 11
Example of a message with red

background color of the top message.
Example of a message with yellow

background color of the top message.
Example of an information message

with green background color of the
top message.
- 20 -

Page 11
VHMS
14.1.10 Automatic Messages
If a failure or an information condition occurs during operation, the present display is automatically
replaced by a message in text. If there are several messages at the same time, the system starts rolling
up of all present messages and the present display. Each message is being displayed a few seconds.
The message text informs the operator about the type of failure and the action to be taken. Carry out
the action given on the screen.
The headings of automatic messages have a background color indicating the severity of the condition
as follows:
Severe - act immediately. See illust. (Z 21581) for a typical message
RED
with red background.
Caution - inform service, work can be continued. See illust. (Z 21582)
YELLOW
for a typical message with yellow background.
Information. See illust. (Z 21583) for a typical message with green
GREEN
background.
All messages available in the system are listed up in the operation

manual.
Legend for illust. (Z 21581) and (Z 21582)

1
2
3
4
6
7
8
9
Top message: Type of failure

Instruction message: Follow the displayed instructions
Message number (Error code): G = excavator generated message C = engine 1 generated
message
Cancel button: When this button is pressed, the displayed current message disappears and is
listed in the failure history for operator. The message will be displayed again when a different
Operator Identification number (ID) is entered.
Pause button (green): When this button is pressed, automatic rolling up of messages is stopped
and the displayed message will be frozen on the screen for two minutes. The button changes to
Restart (red). New message will overwrite the frozen message.
Restart button (red): This button restarts automatic roll up of current messages.
Jump button: This button switches to the last displayed menu, normally the Standard Monitor 1.
After two minutes the display jumps automatically back to the last displayed Automatic
Message and rolling up of messages starts again. If a menu select button was activated during
the two minutes standard Monitor display period, the display will also jump back to Automatic
Message when the two minutes are over. New message will overwrite any menu display and
rolling up of messages starts again.
Order of occurrence of message now being displayed
Total number of existing messages
Legend for illust. (Z 21583)

1
2
3
8
9
Top message: Type of information

Explanation of condition
Message number (Error code): G = excavator generated message C = engine 1 generated
message
Order of occurrence of message now being displayed
Total number of existing messages
- 21 -

Page 1
VHMS
Section
14.2
Page
Colored Graphic Console (CGC)for PC4000
Specifications for Servicemen
14.2.1
Graphic Flow Chart (Screen Overview)
14.2.2
Service ID Setup Screen (No. 2.0)
14.2.3
Service Menu Select Screen (No. 3.1)
14.2.4
Real Time Menu Select Screen (No. 4.1.1)

Real Time Monitor:
Engine (No. 5.1.1 No. 5.1.4)
Transmission (No. 5.2.1)
Hydraulic (No. 5.3.1 No. 5.3.7)
Electrical Equipment (No. 5.4.1 No. 5.4.2)
Emergency Stop (No. 5.5.1 No. 5.5.2)
Manual Switch (No. 5.6.1 No. 5.6.3)
10
Central Lubrication System (No. 5.7.1 No. 5.7.2)
11
Swing Lubrication System (No. 5.8.1 No. 5.8.2)
12
Other Items (No. 5.9.1 No. 5.9.3)
13
Output Signals (No. 5.10.1 No. 5.10.6)
14
14.2.5
PM-Clinic Screen
(No. 4.2.1 + 4.2.2) General
15
(No. 4.2.3 + 4.2.5) Power Check
16
14.2.6
Serial No. Setting
(No. 4.3.1) Machine
17
(No. 4.3.2) Engine
18
14.2.7
Memory Clear
(No. 4.4) Input ID
19
(No. 4.4.1) Memory Clear
20
14.2.8
Maintenance Acknowledgement (No. 4.5 + 4.5.1)
21
14.2.9
Failure History for Service (No. 4.6)
22
14.2.10
Snapshot Trigger (No. 4.7)
23
14.2.11
Settings (No. 4.8.1 No. 4.8.10)

Central Lubrication System CLS
(No. 4.8.1)
24
Swing Lubrication System SLS
(No. 4.8.2)
25
Other Settings 1/2
(No. 4.8.3)
- Language
- Operating
26
Hours
26
- Date
26
- Time
- GMT
27
Ref.
Other Settings 2/2
27
(No. 4.8.4)
- Oil
Viscosity hydraulic
28
- Oil
Viscosity Gear
28
- Message
- PLC-
ON / OFF
29
autom. ON / OFF
Shut-Down ON / OFF
29
(No. 4.8.5 4.8.10)
30
-1-
14.2
&2
-2-

Page 2
VHMS
14.2.1 Graphic Flow Chart

Operator
Operator Menu
0.0
1.1
1.2
1.3
1.4
1.2.1
1.2.2
1.2.3
1.2.4
1.2.5
Initialization
Information
Machine Conditions:
Monitor1
Standard monitor
Monitor2
Expansion monitor
Monitor3
Expansion monitor
Screen Adjustment
Consumption
Operator ID
Maintenance Monitor
Current Messages
Action of hidden switches

2.0
Input Service ID
Service
Service Menu
Select
If warning or error occurs
Automatic
Messages Monitor
Real Time
Monitor
4.2.1
4.3.1
4.3.2
4.4.1
4.5
4.6
4.7
4.8.1
5.1.1
5.2.1
5.3.1
5.4.1
5.5.1
5.6.1
5.7.1
5.8.1
5.9.1
5.10.1
PM-Clinic
Serial No. setting
(Machine)
Serial No. setting (Engine)
Memory Clear
Maintenance
Failure History
Snapshot Trigger
Data Settings
Engine
Transmission
Hydraulic
Emergency Stop
Manual Switch
Central Lubrication
Open Gear Lubrication
Others
Output Signal
-3-
14.2
&3
1.2
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
Maint Mess Next

Monitor 1
Hidden switches (1+2) for Service

Press one switch after the other within
2 seconds (first No1 then No2)
1.2.3
1.3
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
Oil Temp Eng
Oil Temp PTO
Boardnet Volt
USER ID
12345678901
16
17
Charging AMP
Maint Mess Next
Monitor 2
2.0
1.4
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
RPM
1800
Please Input Service ID

Oil Level Hyd
Oil Level Eng
Gre Level CLS
Gre Level SLS

H
0
L
******
Maint Mess Next
Clear Enter
STO
P
Monitor 3
-4-

Page 3
VHMS
14.2.2
Service ID Setup Screen (No. 2.0)
When the button -Settings for Operator is pressed, the

screen No. 1.2.3 is displayed.
There are two hidden touch switches on the SETTING for
Operator screen, see (1) and (2) illust. (Z 21576). These
switches are used by service personnel for entering the
Service Menu. To enter the Service Menu, first press the
lower button (1) and then the upper button(2).
Entry of the Service identification number

The screen for entering the ID number appears which makes
sure that you are service personnel.
The Clear-button puts the cursor onto the first position (left
side). Data entry may be started via the number buttons.
Enter the ID number.
If the check result is correct, the display changes to the
service menu select screen.
2.0
1

******

7
0
Clear Enter
STO
P
Please Input
the correct ID
Clear Enter
STO
P
When you enter the regular service ID, the screen changes.
If the ID is not correct, the display changes to the upper
right screen. Enter the service ID again.
-5-
14.2
&4
1.2
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
1.2.3
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
USER ID
12345678901
16
17
Maint Mess Next
Monitor 1
2.0
1
******
Clear Enter
STO
P
3.1
SERVICE MENU SELECT
Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
-6-

Page 4
VHMS
14.2.3
3.1
Service Menu Select Screen (No. 3.1)

Service Menu Screen
Press a button to be executed from the following screen.
SERVICE MENU SELECT
Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
2
3
4
6
7
8
(1)
Real Time Monitor:

Shifts to the screen for reference the information of the controller.
(2)
PM-Clinic:
Shifts to the screen which displays data required for PM clinic.
(3)
Serial No. Setting:

Registers the serial number of the vehicle chassis and engine.
(4)
Memory Clear:
Clears the record on the VHMS controller.
(5)
Maintenance Monitor:
Shifts to the screen for entering data of the maintenance monitor.
(6)
Failure History:
Allows you to view the error and event history. Shifts to the screen for clearing the
history display.
(7)
Snapshot Trigger:
Allows you to record the vehicle information as a snapshot.
(8)
Setting:
Allows you to enter the local difference information.
-7-
14.2
&5
1.2
1.2.3
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
USER ID
12345678901
16
17
Maint Mess Next
Monitor 1
2.0
1
******
Clear Enter
STO
P
4.1.1
3.1
REAL TIME MENU SELECT (1/2)

Engine
Emergency Stop
Transmission
Manual SW
Hydraulic
Central Lub. Sys
Electrical Equipm.
Open Lub. Sys
SERVICE MENU SELECT

Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
MENU
4.1.2
Other
Output Signals
MENU
-8-

Page 5
VHMS
14.2.4
4.1.1
Engine
Transmission
Hydraulic
Electrical Equipm.
Emergency Stop
Engine
5.1.1
REAL TIME MONITOR (ENGINE) (1/4)
SPEED
E8-1
9999
rpm
SPEED
CENSE
9999
rpm
OIL TEMP
CENSE
999.9
EXHAUST TEMP
CENSE
999.9
COOLANT TEMP
CENSE
9999
Manual SW
Central Lub. Sys
Open Lub. Sys
Reserve 5
EXIT
MENU
5.1.2
GOVERNOR
CENSE
OIL PRESS
CENSE
999.9
bar
BLOWBY PRESS
CENSE
9999
mbar
ATMSPH PRESS
CENSE
9999
mbar
COOLNAT PRESS
CENSE
9999
mbar
OIL LEV (PRESS)
B106
999.9
mbar
EXIT
5.1.3
AIR CLEANER
B18-1
SPEED >300
E14
CENSE DEFECT
E14-1
ENG ENABLE
E14-1
ENG STOP LAMP
E14-1
ENG WARN LAMP
E14-1
EXIT
5.1.4
ENG FLUID LAMP
E14-1
Engine oil tank empty
B103-1
Reserve 4
Reserve 3
Reserve 2
Reserve 1
EXIT
-9-
14.2
&6
1.2
1.2.3
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
USER ID
12345678901
16
17
Maint Mess Next
Monitor 1
2.0
1
******
Clear Enter
STO
P
4.1.1
3.1

Engine
Emergency Stop
Transmission
Manual SW
Hydraulic
Central Lub. Sys
Electrical Equipm.
Open Lub. Sys
SERVICE MENU SELECT

Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
MENU
4.1.2
Other
Output Signals
MENU
- 10 -

Page 6
VHMS
14.2.4
4.1.1
Engine
Transmission
Emergency Stop
Manual SW
Hydraulic
Central Lub. Sys
Electrical Equipm.
Open Lub. Sys
Transmission
5.2.1
REAL TIME MONITOR (TRANSMISSION)
1
PRESSURE
B17-1
FILTER
B27-1
B49-1
999.9
TEMPERATURE
Reserve 3
Reserve 2
MENU
Reserve 1
EXIT
- 11 -
14.2
&7
1.2
1.2.3
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
USER ID
12345678901
16
17
Maint Mess Next
Monitor 1
2.0
1
******
Clear Enter
STO
P
4.1.1
3.1

Engine
Emergency Stop
Transmission
Manual SW
Hydraulic
Central Lub. Sys
Electrical Equipm.
Open Lub. Sys
SERVICE MENU SELECT

Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
MENU
4.1.2
Other
Output Signals
MENU
- 12 -

Page 7
VHMS
14.2.4
4.1.1
Engine
Emergency Stop
Transmission
Hydraulic
Electrical Equipm.
Hydraulic
5.3.1
REAL TIME MONITOR (Hydraulic Pressure) (1/7)
Manual SW
Central Lub. Sys
Open Lub. Sys
PUMP 1
B87a
999.9
bar
PUMP 2
B87b
999.9
bar
PUMP 3
B87c
999.9
bar
PUMP 4
B87d
999.9
bar
X1
B85-1
999.9
bar
B86
999.9
bar
X2
EXIT
MENU
5.3.2
5.3.3
SUCTION OIL
B162
999.9
mbar
Reserve 6
RETURN OIL FILT
B163
9999
bar
Reserve 5
LEAK OIL FILT
B164
9999
bar
Reserve 4
OIL COOLATNT FILT
B165
9999
bar
Reserve 3
COUNTER-BALA.
B166
9999
bar
Reserve 2
Reserve 7
Reserve 1
EXIT
EXIT
5.3.4
5.3.5
REAL TIME MONITOR (Hydraulic-HPF) (4/7)
REAL TIME MONITOR (Hydraulic-Filter) (5/7)
B5-1
FAN COOLANT
B21-1
HPF 2
B6-1
PUMP REGULAT
B22
HPF 3
B7-1
FAN OIL
B28-1
HPF 4
B8-1
GENERATUR UNIT
B60
HPF 1
Reserve 2
Reserve 2
Reserve 1
Reserve 1
EXIT
EXIT
5.3.6
5.3.7
REAL TIME MONITOR (HYDR.-Other Items) (6)
REAL TIME MONITOR (HYDR.-Other Items) (7)
OIL TEMP
B15
999.9
Reserve 6
OIL LEVEL (PRE)
B105
9999
mbar
Reserve 5
SHUT OFF VALVE
S31
Reserve 4
OIL LEVEL
B4
Reserve 3
OIL REFILL INDICAT
B50
Reserve 2
B24
Reserve 1
BREATHER
EXIT
EXIT
- 13 -
14.2
&8
1.2
1.2.3
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
USER ID
12345678901
16
17
Maint Mess Next
Monitor 1
2.0
1
******
Clear Enter
STO
P
4.1.1
3.1

Engine
Emergency Stop
Transmission
Manual SW
Hydraulic
Central Lub. Sys
Electrical Equipm.
Open Lub. Sys
SERVICE MENU SELECT

Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
MENU
4.1.2
Other
Output Signals
MENU
- 14 -

Page 8
VHMS
14.2.4
4.1.1
Engine
Transmission
Emergency Stop
Manual SW
Hydraulic
Central Lub. Sys
Electrical Equipm.
Open Lub. Sys
5.4.1
REAL TIME MONITOR (Electrical Equipment) (1)
BOARDNET VOL
R80
999.9
CHARGING CUR
E7
999.9
F13
CIRC. BREAKER
Reserve 9
Reserve 8
MENU
Reserve 7
EXIT
5.4.2
REAL TIME MONITOR (Electrical Equipment) (2)
Reserve 6
Reserve 5
Reserve 4
Reserve 3
Reserve 2
Reserve 1
EXIT
- 15 -
14.2
&9
1.2
1.2.3
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
USER ID
12345678901
16
17
Maint Mess Next
Monitor 1
2.0
1
******
Clear Enter
STO
P
4.1.1
3.1

Engine
Emergency Stop
Transmission
Manual SW
Hydraulic
Central Lub. Sys
Electrical Equipm.
Open Lub. Sys
SERVICE MENU SELECT

Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
MENU
4.1.2
Other
Output Signals
MENU
- 16 -
Vehicle Health Monitoring System

VHMS
14.2.4
Section 1.0
Page 9
4.1.1
Engine
Emergency Stop
Transmission
Manual SW
Hydraulic
Central Lub. Sys
Emergency Stop
5.5.1
REAL TIME MONITOR (Emergency Stop) (1)
ACCESS LADDER
S33a
VALVE BLOCKS
S33b
MACH-HOUSE
S33c
CAB
S36
Reserve 8
Electrical Equipm.
Open Lub. Sys
MENU
Reserve 7
EXIT
5.5.2
REAL TIME MONITOR (Emergency Stop) (2)
Reserve 6
Reserve 5
Reserve 4
Reserve 3
Reserve 2
Reserve 1
EXIT
- 17 -
14.2
& 10
1.2
1.2.3
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
USER ID
12345678901
16
17
Maint Mess Next
Monitor 1
2.0
1
******
Clear Enter
STO
P
4.1.1
3.1

Engine
Emergency Stop
Transmission
Manual SW
Hydraulic
Central Lub. Sys
Electrical Equipm.
Open Lub. Sys
SERVICE MENU SELECT

Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
MENU
4.1.2
Other
Output Signals
MENU
- 18 -

Page 10
VHMS
14.2.4
4.1.1
Engine
Emergency Stop
Transmission
Manual SW
Hydraulic
Central Lub. Sys
Electrical Equipm.
Open Lub. Sys
Manual Switch
5.6.1
REAL TIME MONITOR (Manual Switch) (1/3)
ENG 1800 RPM
S41-1
ENGINE START
S4-1
ENGINE STOP
S5-1
ENGINE SPEED
S30
KEY SWITCH
S1
SH. DOWN BYPA
S27
EXIT
MENU
5.6.2
GND SH DOWN
S54
EBL BYPASS
S34
OP WARN. SYST.
S7
LAMP TEST
S43
DUMP COUNTER 1
S82
DUMP COUNTER 2
S42
EXIT
5.6.3
SERV ARM SWIT
S87
SERV ARM RELE
S94
Reserve 4
Reserve 3
Reserve 2
Reserve 1
EXIT
- 19 -
14.2
& 11
1.2
1.2.3
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
USER ID
12345678901
16
17
Maint Mess Next
Monitor 1
2.0
1
******
Clear Enter
STO
P
4.1.1
3.1

Engine
Emergency Stop
Transmission
Manual SW
Hydraulic
Central Lub. Sys
Electrical Equipm.
Open Lub. Sys
SERVICE MENU SELECT

Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
MENU
4.1.2
Other
Output Signals
MENU
- 20 -

Page 11
VHMS
14.2.4
4.1.1
Engine
Transmission
Hydraulic
Emergency Stop
Manual SW
Central Lub. Sys
Central Lubrication System

5.7.1
REAL TIME MONITOR (Central Lube Sys.) (1/2)
GREASE LEVEL
B108
9999
mm
GREASE PRESS.
B160
999.9
bar
END LINE SWIT.
B43
MANUAL LUBR.
S24
Reserve 8
Electrical Equipm.
Open Lub. Sys
Reserve 7
EXIT
MENU
5.7.2
REAL TIME MONITOR (Central Lube Sys.) (2/2)
Reserve 6
Reserve 5
Reserve 4
Reserve 3
Reserve 2
Reserve 1
EXIT
- 21 -
14.2
& 12
1.2
1.2.3
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
USER ID
12345678901
16
17
Maint Mess Next
Monitor 1
2.0
1
******
Clear Enter
STO
P
4.1.1
3.1

Engine
Emergency Stop
Transmission
Manual SW
Hydraulic
Central Lub. Sys
Electrical Equipm.
Open Lub. Sys
SERVICE MENU SELECT

Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
MENU
4.1.2
Other
Output Signals
MENU
- 22 -

Page 12
VHMS
14.2.4
4.1.1
Engine
Transmission
Hydraulic
Emergency Stop
Manual SW
Central Lub. Sys
Swing Lubrication System

5.8.1
REAL TIME MONITOR (Slew lube system) (1/2)
GREASE LEVEL
B109
9999
mm
GREASE PRESS.
B161
999.9
bar
END LINE SWI.
B46
MANUAL LUBR.
S26
Reserve 8
Electrical Equipm.
Open Lub. Sys
Reserve 7
EXIT
MENU
5.8.2
REAL TIME MONITOR (Slew lube system) (2/2)
Reserve 6
Reserve 5
Reserve 4
Reserve 3
Reserve 2
Reserve 1
EXIT
- 23 -
14.2
& 13
1.2
1.2.3
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
USER ID
12345678901
16
17
Maint Mess Next
Monitor 1
2.0
1
******
Clear Enter
STO
P
4.1.1
3.1

Engine
Emergency Stop
Transmission
Manual SW
Hydraulic
Central Lub. Sys
Electrical Equipm.
Open Lub. Sys
SERVICE MENU SELECT

Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
MENU
4.1.2
Other
Output Signals
MENU
- 24 -

Page 13
VHMS
14.2.4
4.1.2
Other
Output Signals
Other Items
5.9.1
REAL TIME MONITOR (Other Items) (1/3)
AMBIENT TEMP
B90
999.9
FUEL LEV. (PRES)
B63
9999
mbar
IDLE CONT
K125
IDLE CONT SLEW
K73
SEAT SWITCH
S28
FIRE SUP. SYST.
9K1
EXIT
MENU
5.9.2
PILOT CONTROL
D32
SERV ARM SW.
S23
SLEW BRAKE
B16
TRAV. BRAKE
B48
LOAD LIM FAULT
E32
Reserve 7
EXIT
5.9.3
Reserve 6
Reserve 5
Reserve 4
Reserve 3
Reserve 2
Reserve 1
EXIT
- 25 -
14.2
& 14
1.2
1.2.3
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
USER ID
12345678901
16
17
Maint Mess Next
Monitor 1
2.0
1
******
Clear Enter
STO
P
4.1.1
3.1

Engine
Emergency Stop
Transmission
Manual SW
Hydraulic
Central Lub. Sys
Electrical Equipm.
Open Lub. Sys
SERVICE MENU SELECT

Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
MENU
4.1.2
Other
Output Signals
MENU
- 26 -

Page 14
VHMS
14.2.4
4.1.2
Other
Output Signals
Output Signals
5.10.1
REAL TIME MONITOR (OUTPUT SIGNALS) (1)
ACOUSTIC SIGNAL
H22
CLS PUMP
K29
SLS PUMP
K36
RPM SHIFTING
K45
EXIT
MENU
5.10.2
5.10.3
PUMP Qmin
K46
SELF HOLDING PLC
K100
BUCKET CUT-OFF
K50
STABIL. CURR. SUP.
K122
WARM.-UP (1/2 Qmax)
K82
HYD OIL COOL FAN A1 Y6a-1
ENGINE SHUTDOWN
K93-1
HYD OIL COOL FAN B1 Y6b-1
EXIT
EXIT
5.10.4
5.10.5
HYD OIL TANK FULL
H52
CLS grease full
H76
HYD OIL TEMP HIGH
K79a
SLS grease full
H78
SERVICE ARM UP
Y124a
ENG. OIL TANK FULL
H142
SERVICE ARM DOWN Y124b
VHMS LAMP RED
H145
EXIT
EXIT
5.10.6
VHMS LAMP YELLOW
H76
Engine oil tank empty
H78
Reserve 2
Reserve 1
EXIT
- 27 -
14.2
& 15
1.2
1.2.3
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
USER ID
12345678901
16
17
Maint Mess Next
Monitor 1
2.0
1
******
Clear Enter
STO
P
4.2.1
3.1
PM CLINIC (GENERAL 1)
ENGINE MODEL
QSK60
S/N ENGINE
12345678901
OPERARION HOURS
1257.9
OIL VISCOSITY HYDR.
Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
VG100
HYDRAULIC OIL TEMP
65.5
AMBIENT TEMP.
28.7
MENU
SERVICE MENU SELECT
Power Check
4.2.2
HYDR PRESSURE X2
45.0
bar
PRE LOAD VALVE
10.0
bar
RESERVE
RESERVE
RESERVE
RESERVE
MENU
Power Check
- 28 -

Page 15
VHMS
14.2.5
PM-Clinic (No. 4.2.1 + 4.2.2) General
The PM-Clinic menu provides the following features:

1. General data of machine and operating conditions as displayed on monitors 4.2.1 + 4.2.2.
2. Power Check relevant data can be displayed and also be frozen by actuating:
a) The pause button on the touch screen
or
b) The push button S82 (R.H. control lever), which is normally used as truck counter
3. The frozen data can be stored.
4.2.1
This Monitor appears only if there

are already data stored.
4.2
ENGINE MODEL
QSK60
S/N ENGINE
12345678901
OPERARION HOURS
1257.9
OIL VISCOSITY HYDR.
VG100
HYDRAULIC OIL TEMP
65.5
AMBIENT TEMP.
28.7
MENU
PM-Clinic data
Do you really want to delete

all PM-Clinic data?
Power Check
YES
NO
Make sure PM-Clinic data are

downloaded before deleting.
With Pause Button = Real Time Data
4.2.3
With Reset Button = Frozen Data

4.2.3
PM CLINIC (POWER CHECK) 1/3
1800
rpm
Speed
X1
34.0
bar
P1
150.0
bar
P2
150.0
bar
P3
180.0
bar
P4
160.0
bar
Speed
EXIT
P Average
160.0
bar
PAUSE
1800
rpm
X1
34.0
bar
P1
150.0
bar
P2
150.0
bar
P3
180.0
bar
P4
160.0
bar
SAVE
P Average
160.0
bar
RESET
Pressing the PAUSE button (or S82), will freeze the actual values
and the EXIT and PAUSE buttons will change to RESET and SAVE
buttons.
When pressing the RESET button the actual values are displayed again.
Pressing the SAVE button, will store the frozen values of the presently
displayed monitor.
- 29 -
14.2
& 16
1.2
1.2.3
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
USER ID
12345678901
16
17
Maint Mess Next
Monitor 1
2.0
1
******
Clear Enter
STO
P
4.2.1
3.1
ENGINE MODEL
QSK60
S/N ENGINE
12345678901
OPERARION HOURS
1257.9
OIL VISCOSITY HYDR.
Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
VG100
HYDRAULIC OIL TEMP
65.5
AMBIENT TEMP.
28.7
MENU
SERVICE MENU SELECT
Power Check
4.2.2
HYDR PRESSURE X2
45.0
bar
PRE LOAD VALVE
10.0
bar
RESERVE
RESERVE
RESERVE
RESERVE
MENU
Power Check
- 30 -

Page 16
VHMS
14.2.5
PM-Clinic (No. 4.2.3 4.2.5) Power Check
There are 3 Monitors to freeze data under different conditions.

In order to obtain a complete power check, which consists of three different Monitors, the
save button should only pressed after the third monitor No. 4.2.5 POWER CHECK 3/3 has
been frozen.
4.2.3
Real Time Data
4.2.3
Frozen Data
Speed
1800
rpm
Speed
1800
rpm
X1
34.0
bar
X1
34.0
bar
P1
150.0
bar
P1
150.0
bar
P2
150.0
bar
P2
150.0
bar
P3
180.0
bar
P3
180.0
bar
P4
160.0
bar
P4
160.0
bar
EXIT
P Average
160.0
bar
PAUSE
SAVE
P Average
160.0
bar
RESET
It is possible to store the values of 3 different Power Checks.

To do this Press the uandt buttons to monitor the other Power Check pages.
4.2.4
4.2.4
Speed
1800
rpm
Speed
1800
rpm
X1
34.0
bar
X1
34.0
bar
P1
150.0
bar
P1
150.0
bar
P2
150.0
bar
P2
150.0
bar
P3
180.0
bar
P3
180.0
bar
P4
160.0
bar
P4
160.0
bar
EXIT
P Average
160.0
bar
PAUSE
SAVE
4.2.5
Speed
P1
P2
P3
P4
160.0
bar
RESET
4.2.5
X1
P Average
1800
rpm
Speed
1800
rpm
34.0
bar
X1
34.0
bar
150.0
bar
P1
150.0
bar
150.0
bar
P2
150.0
bar
180.0
bar
P3
180.0
bar
160.0
bar
P4
160.0
bar
EXIT
P Average
160.0
bar
PAUSE
SAVE
P Average
160.0
bar
RESET
4.2.1
PM-Clinic data
Do you really want to record

these PM-Clinic data?
YES
NO
ENGINE MODEL
QSK60
S/N ENGINE
12345678901
OPERARION HOURS
OIL VISCOSITY HYDR.
1257.9
VG100
HYDRAULIC OIL TEMP
65.5
AMBIENT TEMP.
28.7
MENU
Power Check
Monitor 4.2.1 appears again.

- 31 -
14.2
& 17
1.2
1.2.3
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
USER ID
12345678901
16
17
Maint Mess Next
Monitor 1
2.0
1
******
Clear Enter
STO
P
4.3.1
SERIAL NO. SETTING (MACHINE)
MACHINE MODEL
PC4000
Variation Code
BHA
Type
-6
SERIAL No.
12345678901
MENU MACHINE
3.1
SERVICE MENU SELECT
Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
ENGINE
- 32 -

Page 17
VHMS
14.2.6
1
2
3
4
Serial No. Setting (No. 4.3.1) Machine

4.3.1
MACHINE MODEL
PC4000
Variation Code
BHA
Type
-6
SERIAL No.
12345678901
MENU MACHINE
(1)
ENGINE
Machine model setup button:

When you press this button,
the model name selection menu appears.

MACHINE MODEL
PC4000
PC1000
PC6000
Variation Code
PC2000
PC8000
Type
PC3000
BHA
-6
PC10000
SERIAL No.
PC4000
12345678901
MENU MACHINE
ENGINE
(2)
Variation code setup button:

the LBA and BHA selection menu appears.
MACHINE MODEL
Variation Code
LBA
PC4000
BHA
BHA
Type
-6
SERIAL No.
12345678901
MENU MACHINE
ENGINE
(3)
Type setup button:

the type selection menu appears.
MACHINE MODEL
PC4000
Variation Code
-1
-6
BHA
-2 Type-7
-6
-3
SERIAL-8No.
-4
MENU
-5
12345678901
-9
MACHINE
ENGINE
SERIAL No. SETTING
(4)
Serial number setup switch:

Press this switch to set the serial number.
Please input SERIAL No.
12345678901
Clear Enter
EXIT
(5)
Engine serial number setup switch:

Press this switch to change the display to the engine serial number setup screen.
- 33 -
14.2
& 18
1.2
1.2.3
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
USER ID
12345678901
16
17
Maint Mess Next
Monitor 1
2.0
1
******
Clear Enter
STO
P
4.3.1
MACHINE MODEL
PC4000
Variation Code
BHA
Type
-6
SERIAL No.
12345678901
MENU MACHINE
3.1
SERVICE MENU SELECT
Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
ENGINE
- 34 -

Page 18
VHMS
14.2.6
1
2
Serial No. Setting (No. 4.3.2) Machine

4.3.2
SERIAL NO. SETTING (ENGINE)
ENGINE MODEL
QSK60
#1 S/N
12345678901
MENU MACHINE
(1)
ENGINE
Engine model setup button:

selectable engine models are displayed.
Select a desired one.
SERIAL NO. SETTING (ENGINE)

ENGINE MODEL
QSK60
QSK60
#1 S/N
12345678901
MENU MACHINE
(2)
ENGINE
Serial number setup button:

Press this button and then set the serial number in the screen below.
SERIAL No. SETTING
1
Please input SERIAL No.
12345678901
Clear Enter
EXIT
(3)
Machine serial number setup switch:

Press this switch to change the display to the machine serial number setup screen.
- 35 -
14.2
& 19
1.2
1.2.3
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
USER ID
12345678901
16
17
Maint Mess Next
Monitor 1
2.0
1
******
Clear Enter
STO
P
4.4
Please Input Memory Clear ID
1
Clear Enter
******
Please Input Memory

Clear ID
3.1
SERVICE MENU SELECT
Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
MENU
- 36 -

Page 19
VHMS
14.2.7
Memory Clear (No. 4.3.2) Input Memory Clear ID
Entry of the identification number

When the memory clear screen is selected in the service menu selection screen, the display
changes to the ID entry screen to make sure that you are service personnel with the
authorization for memory clear.
Data entry may be started via the number buttons. The Clear-button puts the cursor onto the
first position (left side).
Enter the ID number.
The ID number is a number with up to 10 digits (different from the Service ID). This
number is compared with the number registered in the VHMS.
If the check result is correct, the display changes to the memory clear screen (4.4.1) screen.
4.4
1
0
MENU

******
Please Input Memory

Clear ID
Clear Enter
Please Input
the correct ID
Clear Enter
MENU
If the ID is not correct, the display changes to the upper right screen. Enter the service ID
again.
- 37 -
14.2
& 20
1.2
1.2.3
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
USER ID
12345678901
16
17
Maint Mess Next
Monitor 1
2.0
1
******
Clear Enter
STO
P
4.4
1
******
Please Input Memory

Clear ID
Clear Enter
3.1
SERVICE MENU SELECT
Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
MENU
MEMORY CLEAR
Failure History Data
Load Map Data
Trend Data
PM Clinic
Snap Shot Data

Engine Log
Select buttons.
MENU
- 38 -

Page 20
VHMS
14.2.7
Memory Clear (No. 4.4.1) Memory Clear Screen
MEMORY CLEAR
Load map data clear button
Load Map Data

PM Clinic data clear button
Trend Data
PM Clinic
Failure history data clear button
Snap Shot Data

Engine Log
Trend data clear button
Select buttons.
Snapshot data clear button
MENU
Engine Log data clear button
The Memory Clear screen appears if the ID entry for memory

clear is correct.
Specify the data to be cleared by pressing the corresponding button.
MEMORY CLEAR
MEMORY CLEAR
Load Map Data
Trend Data
PM Clinic
Load Map Data
Trend Data
PM Clinic
Snap Shot Data
Snap Shot Data
Engine Log
Engine Log
In the example at left, the trend data

clear button is pressed. A confirmation
message appears after pressing the
button.
Select buttons.
Select buttons.
The selected item blinks.
MENU
MENU
Select any button to clear data.

When you select a button, it starts blinking.
When you press the blinking button again, the following screen appears.
MEMORY CLEAR
MEMORY CLEAR
Trend Data
Trend Data
Really Clear Trend Data?

YES
STATUS: Executing...
NO
MENU
MENU
A confirmation message appears. Select Yes to clear the data or No to cancel the operation.
MEMORY CLEAR
Load Map Data
Trend Data
PM Clinic
Snap Shot Data

Engine Log
Status: memory clear finished
MENU
- 39 -
14.2
& 21
1.2
1.2.3
Date
31.08.01
Time
23:59
25 C
252.1 h
Tr1 Tr2
12 15
1/min
1800
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
USER ID
12345678901
16
17
Maint Mess Next
Monitor 1
2.0
1
******
Clear Enter
STO
P
4.5
250h Maintenance
-2
500h Maintenance
248
1000h Maintenance
748
2000h Maintenance
1748
3000h Maintenance
2748
MAINTENANCE MONITOR
3.1
SERVICE MENU SELECT
Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
h
h
MENU
- 40 -

Page 21
VHMS
14.2.8
Maintenance Monitor (No. 4.5 4.5.1) Maintenance Acknowledgement
Maintenance confirmation through Service Personnel

Maintenance indicated with yellow or red background color should be confirmed through
Service Personnel in the Service Menu subsequent to the execution of the maintenance. With
the confirmation the actual value maintenance number is increased by 1. Thus, the length of
the maintenance cycle is added to the display value and the gray color will appear in the
maintenance display. The button in the Service Menu used for maintenance confirmation then
turns gray instead of yellow and is then without any function. The confirmation of the
maintenance is then stored.
Example: 250h Maintenance is required (yellow), service meter reading is 252 Hours.
When you select the yellow button,

it changes to blue and starts blinking.
When you press the blinking button again,

the following screen appears.
MAINTENANCE MONITOR
MAINTENANCE MONITOR
250h Maintenance
-2
500h Maintenance
248
1000h Maintenance
748
2000h Maintenance
1748
3000h Maintenance
2748
MENU
MENU
If the display color changes from

yellow to grey, also the "MAINT"
button changes to grey
-2
500h Maintenance
248
1000h Maintenance
748
2000h Maintenance
1748
3000h Maintenance
2748
When you press the YES button, the color

changes back to grey and stops blinking
MAINTENANCE MONITOR
MAINTENANCE MONITOR
250h Maintenance
248
500h Maintenance
248
1000h Maintenance
748
2000h Maintenance
1748
3000h Maintenance
2748
MENU
250h Maintenance
-2
248
Really
Reset 250h Maintenance?
500h Maintenance
1000h Maintenance
748
2000h
Maintenance
YES
NO 1748
3000h Maintenance
2748
MENU
Date
31.08.01
Time
23:59
25 C
252.1 h
Tr1 Tr2
12 15
1/min
1800
250h Maintenance
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
Maint Mess Next

Monitor 1
- 41 -
14.2
& 22
1.2
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
1.2.3
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
USER ID
12345678901
16
17
Maint Mess Next
Monitor 1
2.0
1
******
Clear Enter
STO
P
4.6
3.1
FAILURE HISTORY(for Service)

10 C00655:
31
High Exh Temp #5 RB
11/May/2000 14:55
11 C00618:
Total
to
High Intake Restriction LBF
11/May/2000 14:11
to
11/May/2000 17:19
Communication failure
12 G00417:
PLC <-> VHMS controller
11/May/2000 9:38 to
SERVICE MENU SELECT

Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
MENU
- 42 -

Page 22
VHMS
14.2.9
Failure History for Service (No. 4.6)
Failure history
number
4.6
FAILURE HISTORY(for Service)
10 C00655:
31
Number of failure
history data items
High Exh Temp #5 RB
11/May/2000 14:55
11 C00618:
Total
to
Failure code and

failure contents
High Intake Restriction LBF
11/May/2000 14:11
to
11/May/2000 17:19
Communication failure
PLC <-> VHMS controller
11/May/2000 9:38 to
12 G00417:
Failure detection
start time
Failure detection
end time
MENU
Service menu selector button:

When pressed,
the service menu appears.
Quick scroll up button,

replaces all three messages
with three previous messages
Scroll up button,
shifts single
messages
Scroll down
button, shifts
single messages
Quick scroll down button,

replaces all three messages
with three following messages
This screen (NO. 4.6) appears when you press the Failure History button in the service
menu.
The failure history is displayed in reverse order of occurrence, including the code, contents,
failure detection start time, and failure detection end time. If a failure is not solved, the
failure detection end time is not displayed.
- 43 -
14.2
& 23
1.2
1.2.3
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
USER ID
12345678901
16
17
Maint Mess Next
Monitor 1
2.0
1
******
Clear Enter
STO
P
4.7
3.1
SNAPSHOT TRIGGER
START
Start Snapshot?
SERVICE MENU SELECT

Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
MENU
- 44 -

Page 23
VHMS
14.2.10 Snapshot Trigger (No. 4.7)
4.7
SNAPSHOT TRIGGER
Snapshot start button: When

pressed, the CGC becomes
ready to capture snapshot data.
START
Service menu selector button:

When pressed,
the service menu appears.
Start Snapshot?
MENU
This screen (NO. 4.7) appears when you press the snapshot selector button in the service
menu. It is used for memorize and capture operations of manual snapshot data.
(Usually, data before and after failure occurrence are memorized automatically.)
(Up to 9 snapshot data items can be memorized, 8 for automatic memory and one for
manual memory.)
Snapshot start button:
When pressed, the CGC becomes
ready to capture snapshot data.
SNAPSHOT TRIGGER
Press the Yes button to start

capturing snapshot data.
SNAPSHOT TRIGGER
START
Start Snapshot?
Start Snapshot?
YES
MENU
NO
MENU
When data capturing is started, the

START button disappears and a
message appears.
After approx. 120sec
SNAPSHOT TRIGGER
When data capturing is

completed, the following
screen appears.
SNAPSHOT TRIGGER
CANCEL
START
STATUS: Executing...
MENU
STATUS: Snapshot finished
MENU
To cancel data capturing,

press the CANCEL button.
SNAPSHOT TRIGGER
START
STATUS: Snapshot stopped
MENU
- 45 -
14.2
& 24
1.2
1.2.3
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
USER ID
12345678901
16
17
Maint Mess Next
Monitor 1
2.0
1
******
Clear Enter
STO
P
4.8.1
3.1
CLS SETTINGS
Pause Time
60
min
Monitoring Time
min
Press. Relief Time
10
min
Lub. Cycle Counter
32000
Times
SERVICE MENU SELECT

Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
MENU
- 46 -

Page 24
VHMS
14.2.11 Settings (No. 4.8.1 No. 4.8.10)
Central Lubrication System CLS
Only an integer can be entered as a numerical value.
Decimal numbers cannot be entered.
(No. 4.8.1)
Set CLS Pause Time
CLS SETTINGS
Pause (10 - 60)
60
min
Monitor. (1 20)
min
Relief (10 15)
10
min
Lub. Cycle Counter
32000
Times
MENU
Please input
CLS Pause Time
60
min
Clear Enter
EXIT
Pause Time setting button:
Enter the time depending on the operating conditions.

Only values between 10 and 60 minutes can be entered.
Set CLS Monitoring Time
CLS SETTINGS
Pause (10 - 60)
60
min
Monitor. (1 20)
min
Relief (10 15)
10
min
Lub. Cycle Counter
32000
Times
MENU
Please input
CLS Monitoring Time
3
min
Clear Enter
EXIT
Monitoring Time setting button:

Set CLS Press. Relief Time
CLS SETTINGS
Pause (10 - 60)
60
min
Monitor. (1 20)
min
Relief (10 15)
10
min
Lub. Cycle Counter
32000
Times
MENU
Please input
CLS Press. Relief Time
10
min
Clear Enter
EXIT
Pressure Relief setting button:

Set CLS Lub. Cycle Counter
CLS SETTINGS
Pause (10 - 60)
60
min
Monitor. (1 20)
min
Relief (10 15)
10
min
Lub. Cycle Counter
32000
Times
MENU
Lub. Cycle Counter setting button:
Please input
CLS Lub. Cycle Counter
32000
Times
Clear Enter
EXIT
It is recommendable to keep the counter reading over

the live time of the machine.
If necessary enter the number of the last download.
- 47 -
14.2
& 25
1.2
1.2.3
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
USER ID
12345678901
16
17
Maint Mess Next
Monitor 1
2.0
1
******
Clear Enter
STO
P
4.8.1
3.1
CLS SETTINGS
Pause Time
60
min
Monitoring Time
min
Press. Relief Time
10
min
Lub. Cycle Counter
32000
Times
SERVICE MENU SELECT

Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
MENU
1X
4.8.2
SLS SETTINGS
Pause Time
10
min
Monitoring Time
min
Press. Relief Time
10
min
Lub. Cycle Counter
32000
Times
MENU
- 48 -

Page 25
VHMS
14.2.11 Settings (No. 4.8.1 No. 4.8.10)
Swing Lubrication System SLS
Only an integer can be entered as a numerical value.
Decimal numbers cannot be entered.
(No. 4.8.2)
Set SLS Pause Time
SLS SETTINGS
Pause (10 - 20)
10
min
Monitor. (1 20)
min
Relief (10 15)
10
min
Lub. Cycle Counter
32000
Times
MENU
Please input
SLS Pause Time
10
min
Clear Enter
EXIT
Pause Time setting button:

Set SLS Monitoring Time
SLS SETTINGS
Pause (10 - 20)
10
min
Monitor. (1 20)
min
Relief (10 15)
10
min
Lub. Cycle Counter
32000
Times
MENU
Please input
SLS Monitoring Time
2
min
Clear Enter
EXIT
Monitoring Time setting button:

Set SLS Press. Relief Time
SLS SETTINGS
Pause (10 - 20)
10
min
Monitor. (1 20)
min
Relief (10 15)
10
min
Lub. Cycle Counter
32000
Times
MENU
Please input
SLS Press. Relief Time
10
min
Clear Enter
EXIT
Pressure Relief setting button:

Set SLS Lub. Cycle Counter
SLS SETTINGS
Pause (10 - 20)
10
min
Monitor. (1 20)
min
Relief (10 15)
10
min
Lub. Cycle Counter
32000
Times
MENU
Lub. Cycle Counter setting button:
Please input
SLS Lub. Cycle Counter
32000
Times
Clear Enter
EXIT
It is recommendable to keep the counter reading over

the live time of the machine.
If necessary enter the number of the last download.
- 49 -
14.2
& 26
1.2
1.2.3
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
USER ID
12345678901
16
17
Maint Mess Next
Monitor 1
2.0
1
******
Clear Enter
STO
P
4.8.1
3.1
CLS SETTINGS
Pause Time
60
min
Monitoring Time
min
Press. Relief Time
10
min
Lub. Cycle Counter
32000
Times
SERVICE MENU SELECT

Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
MENU
2X
4.8.3
OTHER SETTINGS (1/2)
Language
English
Operating hours
650.2
Date
2001
Time
16 : 16
GMT Ref.
MENU
19
8.5
Summer
- 50 -

Page 26
VHMS
14.2.11 Settings (No. 4.8.1 No. 4.8.10)
Other Settings 1/2
(No. 4.8.3)
Language
Operating hours
English
650.2
Date
2001
Time
16 : 16
GMT Ref.
19
Operating
German hours
8.5
MENU
English
Language
English
2001
Time
16 : 16
MENU
Summer
19
8.5
GMT Ref.
Language selector button:
650.2
Date
Summer
When the language menu appears,

select a desired language.
The CGC is reset on a software basis. The screen disappears and

then the software is restarted from the opening screen.
Operating Hours SETTING

Language
English
Operating hours
650.2
Date
2001
Time
16 : 16
GMT Ref.
19
8.5
MENU
0
Summer
SMR setting button:
Please input
operating hours
650
.0 hour
Clear Enter
EXIT
Only an integer can be entered as

a numerical value. Decimal numbers
cannot be entered.
Set the service meter only while the engine is stopped.

English
Operating hours
650.2
Date
2001
Time
16 : 16
GMT Ref.
MENU
DATE SETTING
Language
19
8.5
Language
English
Operating hours
650.2
Date
Year
Time
Month
GMT
DayRef.
Summer
MENU
2001
19
16 : 16
8.5
Please input year
2001
0
Summer
Clear Enter
EXIT
For all DATE SETTINGS, i.e. Year Month and Day it is

necessary to confirm the new settings by using the SET button.
Language
English
Operating hours
650.2
Date
2001
Time
16 : 16
19
SET
GMT Ref.
MENU
8.5
Summer
- 51 -
14.2
& 27
1.2
1.2.3
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
USER ID
12345678901
16
17
Maint Mess Next
Monitor 1
2.0
1
******
Clear Enter
STO
P
4.8.1
3.1
CLS SETTINGS
Pause Time
60
min
Monitoring Time
min
Press. Relief Time
10
min
Lub. Cycle Counter
32000
Times
SERVICE MENU SELECT

Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
MENU
2X
4.8.3
Language
English
Operating hours
650.2
Date
2001
Time
16 : 16
GMT Ref.
MENU
19
8.5
Summer
- 52 -

Page 27
VHMS
14.2.11 Settings (No. 4.8.1 No. 4.8.10)
Other Settings 1/2
(No. 4.8.3)
TIME SETTING
Language
English
Language
English
Operating hours
650.2
Operating hours
650.2
Date
2001
Time
16 : 16
GMT Ref.
19
8.5
MENU
Summer
Date
2001
Time
Hour
16 : 16
19
8.5
GMT
Ref.
Minute
MENU
Summer
Please input hour
16
Clear Enter
EXIT
For all TIME SETTINGS, i.e. Hour and Minute it is necessary

to confirm the new settings by using the SET button.
Language
Operating hours
English
650.2
Date
2001
Time
16 : 16
19
SET
GMT Ref.
MENU
Language
English
Operating hours
650.2
Date
2001
Time
16 : 16
19
8.5
MENU
Summer
Time difference entry button:
Please input
GMT Reference
8.5
.5
Clear Enter
To set the local time difference (from the international standard time)
in the VHMS controller, press the GMT Ref.-button and then enter time
with the combination of the numeric keypad and the 0.5h setting.
Language
English
Operating hours
650.2
MENU
EXIT
Date
2001
Time
16 : 16
GMT Ref.
Summer
DATE GMT Reference
GMT Ref.
8.5
Language
19
8.5
Operating hours
Summer time setup switch:
MENU
650.2
Date
2001
Time
17 : 16
GMT Ref.
Summer
English
19
8.5
Summer
When pressed, a check mark appears

and the time increases by 1 hour.
- 53 -
14.2
& 28
1.2
1.2.3
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
USER ID
12345678901
16
17
Maint Mess Next
Monitor 1
2.0
1
******
Clear Enter
STO
P
4.8.1
3.1
CLS SETTINGS
Pause Time
60
min
Monitoring Time
min
Press. Relief Time
10
min
Lub. Cycle Counter
32000
Times
SERVICE MENU SELECT

Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
MENU
3X
4.8.4
Oil viscosity hydraulic
VG46
Oil viscosity gear
CLP150
Message ON/OFF
ON
PLC-autom.ON/OFF
ON
MENU
- 54 -

Page 28
VHMS
14.2.11 Settings (No. 4.8.1 No. 4.8.10)
Other Settings 2/2
(No. 4.8.4)
VG46
OTHER SETTINGS (2)

VG46
VG22
7
13
Oil viscosity gear
VG32
8
14
19
-CLP150
---
Oil viscosity gear
CLP150
Message ON/OFF
ON
Message ON/OFF
VG46
9
15
-- ON
--
ON
VG68
10
16
PLC-autom.ON/OFF
--
--
VG100
PLC-autom.ON/OFF
MENU
MENU6
Hydraulic oil selector button:
ON
11
17
--
--
12
18
--
--
VG46
Oil viscosity gear
CLP150
Message ON/OFF
ON
PLC-autom.ON/OFF
ON
MENU
PTO - gear oil selector button:

Oil
viscosity gear
T32
75W-140
Oil viscosity gear
CLP150
Message ON/OFF
ON
PLC-autom.ON/OFF
ON
The selected hydraulic oil is now

displayed.
OTHER SETTINGS (2)
VG22
MENU
When the selection menu appears,

select the required hydraulic oil.

VG46
CLP150
--
CLP150
Message ON/OFF--
ON
PLC-autom.ON/OFF
ON
MENU
When the selection menu appears,

select the required gear oil.
VG46
Oil viscosity gear
T32
Message ON/OFF
ON
PLC-autom.ON/OFF
ON
MENU
The selected gear oil is now

displayed.
Select the required oil out of the table from the specific flowchart.
- 55 -
14.2
& 29
1.2
1.2.3
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
USER ID
12345678901
16
17
Maint Mess Next
Monitor 1
2.0
1
******
Clear Enter
STO
P
4.8.1
3.1
CLS SETTINGS
Pause Time
60
min
Monitoring Time
min
Press. Relief Time
10
min
Lub. Cycle Counter
32000
Times
SERVICE MENU SELECT

Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
MENU
3X
4.8.4
VG46
Oil viscosity gear
CLP150
Message ON/OFF
ON
PLC-autom.ON/OFF
ON
MENU
- 56 -

Page 29
VHMS
14.2.11 Settings (No. 4.8.1 No. 4.8.10)
Other Settings 2/2
(No. 4.8.4)
VG46
VG46
Oil viscosity gear
CLP150
Oil viscosity gear
CLP150
Message ON/OFF
ON
Message ON/OFF
OFF
PLC-autom.ON/OFF
ON
PLC-autom.ON/OFF
ON
MENU
MENU
Message ON/OFF selector button:
When pressed the display changes from

ON to OFF or vice versa.
Messages ON/OFF
With the button "Messages ON/OFF" is shut down only the automatic display of actual messages for service
purposes. In this case, setting works are not interrupted by accidentally occurred messages and the memory will
not be filled with messages caused by testing operations. Control and monitoring functions remain active.
Each operation of the button "Messages ON/OFF" is saved in the service memory, invisible for the operator.
VG46
VG46
Oil viscosity gear
CLP150
Oil viscosity gear
CLP150
Message ON/OFF
ON
Message ON/OFF
OFF
PLC-autom.ON/OFF
ON
PLC-autom.ON/OFF
ON
MENU
PLC-autom. ON/OFF selector button:
MENU
When pressed the display changes from

PLC-autom. ON/OFF.
With the button "PLC-autom. ON/OFF" it is possible to shut down all control and monitoring functions of the
PLC. The PLC does not evaluate any entry signals and does not change any exit signals.
With the menu pictures 5.10.1 "REAL TIME MONITOR (OUTPUT SIGNALS) (1)" up to 5.10.6 "REAL TIME
MONITOR (OUTPUT SIGNALS) (6)" it is then possible to shut on and off any exit for service purposes without
any interference.
Each operation of the button "PLC-autom. ON/OFF" is saved in the service memory, invisible for the operator.
Example:
5.10.1
ACOUSTIC SIGNAL
H22
0/1
CLS PUMP
K29
0/1
SLS PUMP
K36
0/1
RPM SHIFTING
K45
0/1
Output Signal 0/1 selector button:

When pressed the display changes
from0 to 1 and the Acoustic Signal
is activated.
EXIT

ACOUSTIC SIGNAL
H22
0/1
CLS PUMP
K29
0/1
SLS PUMP
K36
0/1
RPM SHIFTING
K45
0/1
EXIT
With the function PLC-AUTOM. (evaluation)switched OFF all

monitoring and control functions of the PLC are inoperative.
- 57 -
14.2
& 30
1.2
1.2.3
Date
31.08.01
Time
23:59
25 C
2587.9 h
Tr1 Tr2
12 15
1/min
1800
Fuel Level
Hyd Oil Temp
Coolant Eng
Oil Press Eng
USER ID
12345678901
16
17
Maint Mess Next
Monitor 1
2.0
1
******
Clear Enter
STO
P
4.8.1
3.1
CLS SETTINGS
Pause Time
60
min
Monitoring Time
min
Press. Relief Time
10
min
Lub. Cycle Counter
32000
Times
SERVICE MENU SELECT

Real Time Monitor
Failure History
PM-Clinic
Maintenance
Serial No. Setting
Snapshot
Memory Clear
Setting
MENU
4X 9X
4.8.5 - 4.8.10
SHUT-DOWN ON/OFF (1)
Shut-Off (gate) valve
ON
Reserve 11
ON
Reserve 10
ON
Hydraulic oil level
ON
MENU
- 58 -

Page 30
VHMS
14.2.11 Settings (No. 4.8.1 No. 4.8.10)
Shut Down ON / OFF
(No. 4.8.5 - 4.8.10)
For purposes of initial start-up and repair each Shutdown may be closed down individually.
The shutdown remains without any time limit.
With the operation of the button the logical state of the respective Flag in the interface
changes to the PLC.
With the Flag set, the PLC will not activate the shutdown. However, there will result a
shutdown message.
Each operation of the button is saved in the service memory invisible for the operator.
Example:
4.8.5

ON
Reserve 11
ON
Reserve 10
ON
Hydraulic oil level
ON

OFF
Reserve 11
ON
Reserve 10
ON
Hydraulic oil level
ON
Shut-Down ON/OFF selector button:

When pressed the display changes
MENU
MENU
4.8.6
4.8.7
4.8.8
Reserve 9
ON
Monitoring HPF3/Chip3 (Start bl.)
ON
Trouble HPF3/Chip3 (Low idle)
ON
Shut-Off (gate) valve (Start bl.)
ON
ON
ON
ON
ON
Hydr. Oil temp. (Bucket cut off)
ON
ON
ON
Lubrication syst. (Bucket cut off)
ON
MENU
MENU
4.8.9
4.8.10
MENU
MENU
Reserve 8
ON
Reserve 4
ON
Reserve 7
ON
Reserve 3
ON
Reserve 6
ON
Reserve 2
ON
Reserve 5
ON
Reserve 1
ON
MENU
- 59 -

Page 1
VHMS

Section
14.4
Wiring of the main components
Page
2
14.4.1 Wiring of the engine
14.4.2 Wiring of the VHMS Controller
4+5
14.4.3 Wiring of the CGC Monitor
14.4.4 Wiring of the PLC
-1
14.4
&2
-2

Page 2
VHMS
14.4 Wiring of the main components
(Com SK) Interface VHMS controller
(Com SP) Interface (PC-connection)
(E6)
PLC - Programmable Logic Controller
(E46)
VHMS - Controller
(E47)
CGC - Colored Graphic Console
(3E14-1) ECM Quantum - Electronic Control Module
(3E54-1) ECM Cense - Electronic engine monitoring system
(F15A)
(F70)
10 amp. circuit breaker (Power supply from Battery G8 and G9)
- Power supply (stabilized voltage B+) VHMS Controller
(H22)
Buzzer - Acoustic warning signal (Dashboard)
(K300)
Relay contact Truck counter number 1 actuated by push button S82
(R.H. control lever E19)
(R95)
Resistor
(S20)
(S42)
(S49)
Reset button for CGC (Dashboard)
(S97)
Switch Upload of new program to VHMS controller (Cab base)
(X22)
CGC, Power supply and Data link connector
(X29)
CGC, Programming link socket
(X27A)
(X27B)
(X35A)
(X35B)
(X35C)
CAN Bus connector

CAN Bus connector
CAN Bus connector
For better visibility, a bigger size of illustration (Z 22361) is attached

in the pocket of the front cover.
-3
14.4
&3
-4

Page 3
VHMS
14.4.1 Wiring of the engine
CUMMINS - QSK60
KMG PC4000 (1875 @ 1800) OEM WIRING DIAGRAM - REVISION 1.0
CUMMINS
(31 PIN CONNECTOR)
KOMATSU RESPONSIBILITY
26
Engine side
OEM Interface connector
3X16-1
ALTERNATE TORQUE
14
OEM
31 Pin Connector Plug
DEUTSCH P/N:
HD36-24-31SE-059
CUMMINS P/N
3657259
switch open=100%
switch closed =75%
Hydraulic oil temp switch
commands a derate.
Key Switch
24V
Battery (+)
KEY SWITCH INPUT
Emergency
Shutdown
Device (if used)
Fault Lamp 1 (RED)

+
Fault Lamp 2 (YELLOW)

+
Fault Lamp 3 (WHITE)

+
Pin 1: max. 600 mA
16
17
18
12
13
TACH OUTPUT
TACH
USE 12 GAGE WIRE FOR

POWER AND GROUND;
USE 18 GAGE WIRE FOR
EVERYTHING ELSE.
31 - Pin
Centinel Oil level

KMG supply
Cab Base GND
HYD. PUMP ADJUST
Only one switch at

Pin 19 and 21
because the KMG
control panel only
has one lever.
08151: pair of cables
with common shield.
shield ground
at cab base.
IN CAB
9 PIN DATA LINK
CONNECTOR;
DEUTSCH P/N
HD10-9-1939P;
CUMMINS P/N
3616460
ISC1 (THROTTLE)
THROTTLE VALIDATION
from 08152 on:

twisted = 1 Turn/3cm
Tacho: 149 pulses/rev,

rectangular Signal
between 0 and 24V
23
Oil present = GND
20
21
19
Priority: ISC1 over

REMOTE
THROTTLE (Pin 20)
Cab Base GND
A
B
C
E
22
PUBLIC DATA LINK 1 (+)

PUBLIC DATA LINK 1 (-)
UNSWITCHED BATTERY (+)
GROUND
GND for Pin H. PWM-fan control
2
3
24
25
30
SWITCH CLOSED = 1800 rpm

USING REMOTE THROTTLE
Closed = high idle

open = low idle
(closed switch
position is ignored at
start-up. Switch
needs to cycle (open
then close) to obtain
high idle rpm.
GND Required for
pontoon (ship)
applications; Engine
Block ground isolated
from OEM electronics;
Isolated starter required.
HJ 20 Dec 01
PAGE 1
CUMMINS - QSK60
KMG PC4000 (1875 @ 1800) OEM WIRING DIAGRAM - REVISION 1.0
(21 PIN CONNECTOR)
KOMATSU RESPONSIBILITY
Engine side
OEM Interface connector
3X17-1
CUMMINS
24V Battery
+
Main
disconnect
switch
operated with
time delay to
key switch
Max 10A
UNSWITCHED BATTERY
UNSWITCHED BATTERY
G
D
Coolant Level
Shorting Plug
A
B
C
D
GND at Motor-block
DEUTSCH P/N
HD36-24-21SE-059
CUMMINS P/N
3657258
COOLANT LEVEL LOW SIGNAL

COOLANT LEVEL RETURN
COOLANT LEVEL +5 VDC SUPPLY
COOLANT LEVEL HIGH LEVEL
T
V
U
S
21 - Pin
OEM
21 Pin Connector Plug
H
Fan valve magnet
PWM out
Engine torque
(not used)
Electronic Fan
Clutch Signal
max 3 Amp.
inverted:
95% at low temp,
5 % at high temp.
To pin 30 of OEM connector

RELAY
DUAL OUTPUT #2
0V = Engine rpm < 300 rpm
24V = Engine rpm > 300 rpm
Engine Run signal

Used to
disengage the
starter
RELAY
DUAL OUTPUT #1
0V = Engine rpm < 1500 rpm
24V = Engine rpm > 1500 rpm
Not used
HJ 20 Dec 01
PAGE 2
-5
14.4
&4
-6

Page 4
VHMS
Pin layout of connectors, illustration Z22365
CN4-A
14
13
12
11
10
9
8
7
CAN 0-
CN4-B
CAN 0+
6
CAN SHIELD 0 5
4
RS232 TX0
RS232 RX0
RS232 GND
3
2
1
10
9
8
7
6
5
RS232 RX1
GND
RS232 TX1
RS232 RXO
4
3
2
1
CN3-A
18
17
16
15
14
13
12
11
10
9
D_IN0
D_IN1
D_IN3
RS232 GND
RS232 RX2
RS232 TX2
D_IN4
GND
8
7
6
5
4
3
2
1
CN1
20
19
18
17
16
15
14
13
12
11
10
Flash_Write
VB_IN
VB_IN
VBB_IN
VBB_IN
9
8
7
6
D_OUT0
GND
GND
5
4
3
2
1
continued
-7
14.4
&5
-8

Page 5
VHMS
Cont'd:
(E6)
(E47)
(F15A)
(F70)
10 amp. circuit breaker (Power supply from Battery G8 and G9)
- Power supply (stabilized voltage B+) VHMS Controller
(H22)
Buzzer - Acoustic warning signal (Dashboard)
(K300)
Relay contact Truck counter number 1 actuated by push button S82
(R.H. control lever E19)
(R95)
Resistor
(S20)
(S42)
(S49)
(S97)
Switch Upload of new program to VHMS controller (Cab base)
(X22)
(X29)
(X27A)
(X27B)
-9
Section 14.4
Page 6
- 10

Page 6
VHMS
14.4.3 Wiring of the CGC Monitor
(E46)
VHMS - Controller
(E47)
(F15A)
(S49)
(X22)
(X29)
- 11
14.4
&7
- 12

Page 7
VHMS
14.4.4 Wiring of the PLC
(E6)
(E46)
VHMS - Controller
- 13

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PC4000_Contents and 00_Foreword_rev0.

Copyright 2006 Komatsu

PC4000_Contents and 00_Foreword_rev0.doc

Main assembly groups

Each section includes a detailed table of contents.

IMPORTANT SAFETY NOTICE

Serious personal injury or extensive property damage can

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

Refers to special information

This service manual corresponds to the state of development of the

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,

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

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

STANDARD TIGHTENING TORQUE

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

Wrench Tightening torque

Insert all bolts lubricated with MPG, KP2K

Basic Values in Ohm according to DIN 43 76

123,62 124,01, 124,39

Main Assembly Groups

Table of contents section 1.0

Hydraulic Oil Reservoir

Hydraulic Oil Cooler

Backhoe Attachment (BHA)

Front Shovel Attachment (FSA)

Main Assembly Groups

General lay out

Main Assembly Groups

Main Assembly Groups

Legend for illustration (Z 21466):

Main Assembly Groups

Hydraulic Oil Reservoir

Legend for illustration (Z 21467):

Main Assembly Groups

Main Assembly Groups

Hydraulic Oil Cooler

Legend for illustration (Z 21472):

Main Assembly Groups

Fuel tank (Fuel reservoir)

Legend for illustration (Z 21473):

Main Assembly Groups

Legend for illustration (Z 21474):

Main Assembly Groups

Legend for illustration (Z 21475):

*SW = Wrench size

*SW = Wrench size

Main Assembly Groups

Legend for illustration (Z 21476):

Control pedal Control pedal Control pedal -

Main Assembly Groups

Legend for illustration (Z 21477):

Main Assembly Groups

Legend for illustration (Z 21478):

Spring loaded multi disk brake

Main Assembly Groups

Main Assembly Groups

Backhoe attachment (BHA)

Legend for illustration (Z 21482):

Front Shovel Attachment (FSA)

Legend for illustration (Z 21483):

Table of contents section 2.0

Engine and PTO mounts

Fan drive and radiator assembly