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Hydraulic Mining Excavator

CAT 6060

06. Servo System

Dixio Torrez - 2013


Service Training
Servo System Assembly

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Service Training
Pumps Assembly
Swing Gearbox Servo pump 4
Swing Cooling
Pump
Charge Pump
4 Servo pump 3
Pump

3 8
Oil Cooling
Pumps
6
7
Gearbox
Swing Cooling
Pump Pump Servo
5 Servo
Main pump 1
pump 2
Pumps 2

Engine 1
Fan Drive
Pump

1 4
Oil Cooling
Pumps
2
3

1 Swing
Main
Charge
Pumps
Pump
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Service Training
Servo System Assembly
Servo Pump 3 (100Bar)
Servo Pump 1 (60Bar)

Servo Pump 4
(60Bar)

Servo Pump 2
(100Bar)

(64 Bar.N)
Ladder

(50 Bar.N)
(80 Bar.N) 4
Service Training
Servo System Assembly

On LH side; Servo Pump 1 Filter,


pilot valve Block LH (60Bar)

On RH side; Servo Pump 3 Filter,


pilot valve Block RH (100Bar)

On LH side; Servo Pump 2 Filter,


pilot valve Block RH (100Bar)

On RH side; Servo Pump 4 Filter,


pilot valve Block LH (60Bar)

Main Pump Bearing Flushing Filter

• New arrangement of filter for better serviceability


and improved hose routing

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Servo System Assembly Service Training

Pilot Valve Block 2 Solenoid Valves Pilot Valve Block 1


Servo (SIL) Servo
Pump 2+3 Pumps 1+4

Proportional Valve
Pump Regulation
-4Y1 -3Y1

Swing Balance Valve Flushing Valve

Swing Pressure
Proportional Valves Adjustment
Travel Functions Proportional Valve
Swing Function

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Emergency Lowering System Service Training

-2Y19

22 Bar.N

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Servo System – Main Pump Control (PMS) Service Training

Servo Servo
Pump 2+3 Pumps
1+4

-4Y1 -3Y1

Main Pump Control Proportional Valves (Main Pumps 1-4 -3Y1) (Main Pumps 5-8 -4Y1)

The purpose of the main pump control proportional valves is to regulate the main pump flow in relation to the demand of the operator (Joystick).
The flow is also controlled in relation to the Engine RPM (Engine load) to ensure the engine is not overloaded.
In case of to high temperatures in the hydraulic system (hydraulic oil tank) or the engine (coolant / intake manifold) the pump flow is reduced to 80%.

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Servo System – Travel Proportional Valves Service Training

Servo Servo
Pump 2+3 Pumps
1+4

Travel Proportional Valves

The travel proportional valves are supplied by 35 bar servo pressure. They are controlled by the foot pedal deflection (CanBus).
The servo controller box coverts this signal into a current (70-650mA) which is active on the coil of the valve.
The valve outlets (0-35bar) are connected to the travel main valves and control the position of the valve spool.
Left forward: -2Y14 Left reverse: -2Y13
Right forward: -2Y12 Right reverse: -2Y11

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Servo System – Swing Proportional Valves Service Training

Servo Servo
Pump 2+3 Pumps
1+4

Swing Proportional Valves:

The swing proportional valves (Left -2Y15, Right -2Y16) are supplied by 35 bar servo pressure. They are controlled by the joystick deflection
(CanBus). The servo controller box coverts this signal into a current (70-650mA) which is active on the coil of the valve. The valve outlets (0-22bar) are
connected to the swing balance valve and the variable pressure controls the position of the big spool inside the valve.

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Servo System – Swing System Valves Service Training

Servo Servo
Pump 2+3 Pumps
1+4

Swing Pressure Adjustment

This reducing valve is adjusted to ~ 22 bar. It limits the swing pressure to max 352 bar. (16*22 bar)

Swing Balance Valve

The swing balance valve is supplied by 35 bar pressure and controls the flow direction inside the swing pump in relation to the demand of the joystick
and the pressure in the swing system. The valve has a big spool in the middle and two small spools on the sides. The ratio is 16:1.

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Servo System – Swing System Valves Service Training

Servo Servo
Pump 2+3 Pumps
1+4

Swing Flushing Valve

The valve flushes a controlled amount of oil out of the closed swing circuit.
This allows fresh, cold oil to enter the system over the charge pump.

SIL Solenoid Valves (X1 = -2Y30) (X2 = -2Y31)

The purpose of these solenoids is to switch of the swing pump control pressure (X1 + X2 connected to tank) to induce a brake effect in case of a fault
occurs to the swing system. The swing movement is braked due to the swing pump controller piston moves to the neutral position.

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Servo System – LH Block Service Training

-2Y22
-2Y17
-2Y23
Pilot
60 bar

-2Y18

35 bar Supply
to prop. valves

Tank

Swing
Balance Servo
Valve Pump
2nd Speed 1+4
35 bar
50 bar Travel Park
Brake 30 bar
Pump Regulation
Swing Park Pilot
50 bar
Brake 50 bar 35 bar

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Servo System – LH Block Service Training

Swing Balance Valve Supply - 35 bar

This Valves reduces the 60 bar servo Pressure to 35 bar as supply on the p-port of the swing balance valve.

2nd speed travelling – 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 on the rotary joint and the 2nd speed is active. (Solenoid -2Y22)

Travel Park Brake – 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 enters the travel park brake piston via the rotary joint. They are released and held in the released position.
The pressure is reduced to 30 bar to be sure that the brake is open.

Swing Park Brake - 50 bar

The swing park brake is spring applied and hydraulically released. In the de-energized position of solenoid -2Y23, the swing brake is connected to tank.
=> Brakes are applied.
When the swing brake is released, -2Y23 is energized and 50 bar is supplied to the swing brakes, overcoming the spring tension => brakes are released.
Note: You must not stop the swing movement by using the swing park brake!!! This will occur heavy demolition on the brake disks!

Pump regulation – 50 bar

This valves supplies 50 bar pressure to the pump control proportional valve.

Pilot Pressure 60 bar

This relief valve limits the incoming pressure from Servo Pump 1+4 to 60 bar.

Servo On/Off (Solenoid -2Y18 - 35 bar)

This solenoid is operated by the seat switch and switches the 35 bar Pressure supply to the consumers on or off.

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Servo System – RH Block Service Training

Pilot
50 bar Track Tensioning
80 bar
Travel Boost
Servo
40 bar 80 bar
Pump
2+3 Ladder,
Clam Boost
Service Arm,
40 bar
Grease System

Tank

P-Port
Main
Pumps
-2Y18

Pilot -2Y24
100 bar -2Y20
-2Y27

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Servo System – RH Block Service Training

P-Port on Main Pumps

This outlet is used to supply the main pumps with an initial pressure on the p-Port of each main pump. (X2 Port on older pumps).

Servo On/Off (Solenoid -2Y18 - 50 bar)

This solenoid is operated by the seat switch and switches the 50 bar Pressure supply to the consumers on or off.

Travel Boost (Solenoid -2Y24 - 40 bar)

The solenoid valve (-2Y24) operates the pressure cut-off valves of main pumps 1 + 7 / 2 + 8 so that the pressure is increased to 320bar + 40bar = 360 bar

.
Track Tensioning (Solenoid -2Y20 – (80 bar)

This valve increases the track tensioning pressure from 50bar to 80 bar. This causes a pressure release in the track tensioning system.

Clam Boost (Solenoid -2Y27 – 40 bar)

The solenoid (-2Y27) operates the pressure cut-off valves of the main pumps 4 + 6, so that the clam pressure is increased to 320bar + 40bar = 360 bar

80 bar Outlet Port

This outlet is used to supply the hydraulic ladder, the service arm and the automatic lubrication system.

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Solenoid Valve Banks Service Training

-2Y36 Valveblock Pre Heating


-2Y1 Bucket In
-2Y5 Boom Up
-2Y8 Stick Out
-2Y10 Clam Close

-2Y36

-2Y10
-2Y37 Valveblock Pre Heating

-2Y1

-2Y5

-2Y8
Boom Float Valve Tank Return
-2Y7 Boom Float
-2Y4 Stick Float
Stick Float Valve Tank Return

Tank Return

Tank return
-2Y38 Valveblock Pre Heating
-2Y6 Stick Power In

-2Y37

-2Y7

-2Y4
-2Y3 Boom Power Down
-2Y2 Bucket Fill
-2Y9 Clam Open
-2Y38

-2Y6
-2Y3

-2Y2

-2Y9

Tank 35 bar

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