Hydraulic Mining Excavator

CAT 6060

06. Servo System

Matthias Aust - 2012

Pump Assembly - LH Side Service Training

Gearbox Servo
Cooling Pump Auxiliary
Swing
Pump Servo
Pump
Pump

Engine
Fan Drive
Pump

Swing
Charge
Pump

Oil Cooling
Pumps

Main
Pumps

Main
Pumps

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Servo Pump Service Training

3
Servo Schematic Service Training

Servo Pump Servo Pump

RH LH

Emergency
Boom Down
System

Servo / Pilot
Pressure 50 bar

50

-2Y9 -2Y10 -2Y11 -2Y12 -2Y13 -2Y14 -2Y7 -2Y8

-2Y18 Track Tensioning

-2Y1 -2Y2 -2Y3 -2Y4 -2Y5 -2Y6 -2Y5 -2Y5
Pressure 60 / 80 bar

-2Y20

4
50 bar Servo System Service Training

2nd Speed and Hydraulic Oil

Travel Brake Cooling System
Clam +
at Travel Motors
Travel
Rotary
Travel
Boost
Joint Boost
Main
Main
Pumps
Pumps

not used
30 bar

Auxiliary Servo
Pressure 50 bar

not used not used

Servo
Pressure 50 bar
to Distributor

Swing
Park
Brake

5
Servo Adjustment Service Training

View from Outside on Cabin Module:

P3 P1
Test points P1 , P3 , P4

50 bar

P4
Prop.
Valves

-2Y18

P1: 60/80 bar (Servo Pump Supply)

P3: 50 bar (Servo Pressure)

-2Y20 P4: 60/80 bar (Track Tensioning)

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35 bar Adjustment => Check Point P 2 Service Training

-2Y18

50 bar

-2Y18
-2Y20

Users of 35 bar are: -2Y20

Prop. Valves for Attachment Control Valves

Prop. Valves for Float Valves (Boom/Stick)
Prop. Valves for Travel
Prop. Valves for Swing Balance Valve Displacement
Emergency Accumulator

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50 bar Adjustment => Check Point P 3 Service Training

P3
-2Y18

50 bar

-2Y18
-2Y20

-2Y20 Users of 50 bar are:

Service Lift
Swing Brake Solenoid Valve
Prop. Valves for Main Pump Governing
2nd Speed for Travel System
Travel Pressure Boost
Auto Lube System

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60 bar Adjustment => Check Point P 4 Service Training

Machine Working
(Attachment / Travel / Idle)

-2Y18
50 bar

P4

-2Y18

-2Y20

-2Y20 Users of 60 bar are:

Track Tensioning System

Swing Blocking Valves
P-Port on the Main Pumps

60 bar servo to swing blocking valves and p-port on the main

pumps will only be present if the servo pump on the specific
engine is being driven.

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80 bar Servo Adjustment => Check Point M 1 Service Training

If machine travels for more than 15 sec.:

5 sec after stop travelling,
-2Y20 energized for 5s.
50
bar

-2Y18

-2Y18

-2Y20

-2Y20

Please use the push button to switch

from 60 bar to 80 bar.
Then check / adjust the 80 bar pressure.

Users of 80 bar are:

Track Tensioning System ( 5s after travelling)

Service Ladder Pressure increase
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80 bar Servo Service Training

80 bar servo pressure is only available if the solenoid -2Y20 is energized.

This happens in the following conditions:

1. After travelling for a time longer then 15 sec.:

=> 10 sec. after stop travelling the pressure increases to 80 bar for 5 sec.

2. If the access ladder is not complete lifted:

If the ladder down initiator is not switched, because the ladder is not complete lifted up.
(ladder is to heavy to be lifted with only 60 bar in the system)

Note: If the service lift or ladder are not complete lifted, the swing and travel function is not active! (Safety!!!)

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Proportional Valve Block New Style Electric Side Service Training

Pressure Relief Valve Pressure Relief Valve

Servo Pressure 60bar Servo Pressure 80bar (test point P4)
Pos. 1.11 in hydraulic schematic. Pos. 1.10 in hydraulic schematic.
User: track Tensioning User: Track Tensioning

Switching Safety Valve

Servo Pressure
-2Y18

-2Y18

-2Y1 -2Y2 -2Y3 -2Y4 -2Y5 -2Y6 -2Y16 -2Y15

Travel Direction

Test point P2
35 bar servo pressure.

-2Y9 -2Y10 -2Y11 -2Y12 -2Y13 -2Y14 -2Y7 -2Y8

-2Y20

Pressure Reducing Valve

Servo Pressure 35bar
Switching Valve Pos. 1.20 in hydraulic schematic.
Track Tensioning User: proportional valves servo control.
-2Y20
Pressure Reducing Valve
Auxiliary Pressure 50bar
Pos. 1.30 in hydraulic schematic.
User: tanklift, Main Pump prop. valves -3Y1 and -4Y1,
travel boost, 2nd travel stage, ladder, balance valve.

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Proportional Valve Block Electric Side Service Training

1 2 3 4 5 6 7 8
Bucket BH fill Bucket BH empty Mono BH lower Float Valve Mono Mono BH hoist Stick BH in Swing right BH Swing left BH
Bucket LS fill curl in Bucket LS (curl out) Boom LS lower Float Valve Boom Boom LS hoist Stick LS in Swing right LS Swing left LS
Piston Side BH Rod Side BH Rod Side BH Float Valve BH Piston Side BH Piston Side BH Bal. Valve BH Y1 Bal. Valve BH Y2
Piston Side LS Rod Side LS Rod Side LS Float Valve LS Piston Side LS Rod Side LS Bal. Valve LS Y1 Bal. Valve LS Y2
-2Y1 -2Y2 -2Y3 -2Y4 -2Y5 -2Y6 -2Y16 -2Y15

Attention: -2Y18
-2Y1 -2Y2 -2Y3 -2Y4 -2Y5 -2Y6 -2Y16 -2Y15
On the new style valve block,
the proportional valves are in
the front.

There is only one safety

solenoid (-2Y18) for all
functions.
-2Y9 -2Y10 -2Y11 -2Y12 -2Y13 -2Y14 -2Y7 -2Y8
-2Y20

Travel Direction

1 2 3 4 5 6 7 8
BH no Function BH no Function Travel right backw. Travel right for. Travel left backw. Travel left for. BH no Function Stick BH out
Lip Door LS open Lip Door LS close Travel right backw. Travel right for. Travel left backw. Travel left for. Stick LS Float Valve Stick LS out
BH no Function BH no Function Travel Valve Travel Valve Travel Valve Travel Valve BH no Function Rod Side BH
Rod Side LS Piston Side LS Travel Valve Travel Valve Travel Valve Travel Valve Float Valve LS Piston Side LS.
-2Y9 -2Y10 -2Y11 -2Y12 -2Y13 -2Y14 -2Y7 -2Y8

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Servo Block Connections New Style Hydraulic Side Service Training

Travel Direction View on Hydraulic Side

Face Shovel Version

Swing Swing Stick in Boom Boom Boom Bucket Bucket

Left Right Rod Side Piston Side Float Valve Rod Side Rod Side Piston Side

-2Y15 -2Y16 -2Y6 -2Y5 -2Y4 -2Y3 -2Y2 -2Y1

Stick out Stick Travel Travel Travel Travel Clam Clam

Piston Side Float Valve Left Fwd. Left Rev. Right Fwd. Right Rev. Piston Side Rod Side

-2Y8 -2Y7 -2Y14 -2Y13 -2Y12 -2Y11 -2Y10 -2Y9

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Servo Block Connections New Style Hydraulic Side Service Training

Travel Direction View on Hydraulic Side

Backhoe Version

Swing Swing Stick in Boom Boom Boom Bucket Bucket

Left Right Piston Piston Side Float Valve Rod Side Rod Side Piston Side
Side
-2Y15 -2Y16 -2Y6 -2Y5 -2Y4 -2Y3 -2Y2 -2Y1

Stick out Stick Travel Travel Travel Travel Clam Clam

Rod Side Float Valve Left Fwd. Left Rev. Right Fwd. Right Rev. Piston Side Rod Side

-2Y8 -2Y7 -2Y14 -2Y13 -2Y12 -2Y11 -2Y10 -2Y9

15
Servo Valve Assembly New Layout => #340099 Service Training

Emergency Accumulator Auxiliary Accumulator

Check Point Check Point
for 35 bar Circuit for 50 bar Circuit
35 bar 50 bar
(Nitrogen Charge: 30 bar) (Nitrogen Charge: 40 bar)

-2Y27 Clam Boost -2Y17 Travel Brake

Servo Pressure Proportional Valves for all Controls
Reserve -2Y24 Travel Boost Adjustments Attachment / Travel / Swing
Reserve -2Y22 2nd Speed Track Operator Seat
Tensioning Safety Solenoid
-2X23 Swing Brake Reserve
Solenoid -2Y18
-2Y20
16
Servo Valve Assembly New Layout => #340099 Service Training

Emergency Boom Down Hydraulic Oil Cooling Proportional Valves

Solenoid (not used if thermostatically controlled!)
Swing Safety Valves

Solenoid Valve Blocks

for various Functions
Proportional Valveblock for all -2Y17 Travel Brake -2Y27 Clam Boost
Attachment / Travel / Swing Controls Pressure Reducing
-2Y24 Travel Boost Reserve
Valve 30 bar
Distributor Block only for Travel Brake -2Y22 2nd Speed Reserve
for Tank and 50 bar Connections Reserve -2X23 Swing Brake

17
Solenoid Valve Banks Service Training

Travel park brake (Solenoid -2Y17 (50 bar => reduced to 30 bar)

The travel park brake is spring applied and hydraulically released. The brake is released fully, if we use a pressure of 30 bar.
The solenoid valve -2Y17 is energized and oil flows to the travel park brakes. They are released and held in the released position.
The pressure is reduced to 30 bar to be sure that the brake is open, but 2nd speed should not be active if this valve is energized.

2nd speed travelling (Solenoid -2Y22 50 bar)

When the operator shifts the switch in the cab from 'low speed' (turtle) to 'high speed (rabbit) the pressure in the line to the travel park brake
and travel motor regulator is increased to 50 bar and the regulators are shifted to low displacement.

The 50 bar overcomes the 30 bar at the shuttle valve [47/1] and the 2nd speed is active.

Swing Park Brake (Solenoid -2Y23 - 50 bar)

The swing park brake is spring applied and hydraulically released. In the de-energised position of solenoid -2Y23, the swing brake is connected to tank.
=> Brakes are applied.
When the swing brake is released, -2Y23 is energised and 50 bar is supplied to the swing brakes, overcoming the spring tension => brakes are released.

Note: You cant stop the swing movement by using the swing park brake!!! This will occur heavy demolition on the brake disks!

Travel Boost (Solenoid -2Y24 - 50 bar)

The solenoid valve (-2Y24) operates the pressure cut-off valves of main pumps 3 + 5 / 4 + 6 so that the pressure is increased to 320bar + 50bar = 370 bar.

Clam Boost (Solenoid -2Y27 50 bar)

The solenoid (-2Y27) operates the pressure cut-off valves of the main pumps 2 + 8, so that the clam pressure is increased to 320bar + 50bar = 370 bar.

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50 bar Servo System Service Training

Swing Auto
Balance Greasing
Valve System

Y
XLR - RH Main Pumps

Y
XLR - LH Main Pumps

Y Y

-4Y1
PST - RH Main Pumps

Service Lift

-3Y1
PST - LH Main Pumps

Servo
Pressure 50 bar
from Distributor

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60 / 80 bar System Service Training

Track
Tensioning
System

Track Tensioning Ladder

Pressure 60 / 80 bar

20
80 bar Auxiliary Pressure Service Training

All Main Pumps are

supplied with 80bar
auxiliary pressure as
initial Pressure. LH
Auxiliary
Pump

to Pump No. 3/4

21
Servo Assembly Plate Service Training

22
Pumps for Servo- and Auxiliary Pressure LH Side Service Training

Servo
Pump

Auxiliary
Servo
Pump

23
Pumps for Servo- and Auxiliary Pressure RH Side Service Training

Auxiliary
Servo
Pump

Servo
Pump

24
Main Pump Regulation Service Training

Attention: On the new setup, the prop

valves are combined a different way.
(see picture on further pages)

25
Pump Regulation - LH Side Service Training

26
Pump Regulation - RH Side Service Training

27
Auxiliary Pressure for Main Pumps Service Training

28
Lines to Operators Cab Service Training

29
Lines to Operators Cab Service Training

30
Swing Park Brake Connection Service Training

31
Travel Park Brake and 1st Speed Connection (30bar) Service Training

32
Travel Park Brake and 2nd Speed Connection (50bar) Service Training

33
Travel Park Brake and 1st / 2nd Speed Connection Service Training

34
Travel Park Brake and 1st / 2nd Speed Connection LH Side Service Training

35
Travel Boost for Travel Main Pumps 3/4 and 5/6 Service Training

36
Pressure Boost for Clam Main Pumps 2/8 Service Training

37
Emergency Lowering System Service Training

-2Y19

38
Lines for Automatic Lubrication System Service Training

39
More Information? Service Training

Hey Fellows,

Please find more Information

in the Technical Handbook!
Caterpillar

Chapter 8.5.3: Servo System

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