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Hydraulic Mining Shovels Cat® 6060/6060FS 06. Servo System

Dixio Torrez - 2013

Servo System Assembly

Service Training

2

Service Training

Pumps Assembly Swing Pump

Swing Charge Pump

4

Gearbox Cooling Pump

Servo pump 4 Servo pump 3

3

4 Oil Cooling Pumps

8

3

6

7

Main Pumps

Swing Pump

5

Gearbox Cooling Pump

2 Engine Fan Drive Pump

Servo pump 2

Servo pump 1

1

2 Oil Cooling Pumps

4

1

2

3

Main Pumps

1

Swing Charge Pump

3

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)

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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

5

Service Training

Acumulators Servo System (64 Bar.N) Ladder

To servo pilot valve Block LH (50 Bar.N)

To servo pilot valve Block RH (80 Bar.N)

• New arrangement of acumulators for better serviceability and improved hose routing

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Servo System Assembly Pilot Valve Block 2 Servo Pump 2+3

Service Training

Solenoid Valves (SIL)

Pilot Valve Block 1 Servo Pumps 1+4

Proportional Valve Pump Regulation -4Y1

-3Y1

Flushing Valve

Swing Balance Valve

Swing Pressure Proportional Valves Travel Functions

Adjustment Proportional Valve Swing Function 7

Emergency Lowering System

Service Training

-2Y19

22 Bar.N 8

Pump- / Valve- and Sensor – RH/LH – Assembly -4B22 -4B23 -4B24 -4B25

-2Y46

-3B22 -3B23 -3B24 -3B25

Service Training

-2B8

-5B4 -5B?

-3B19 -5B5 -5B?

-2B26 -2B27

-2B24 -2B25

-4B10

-4B18

- 2B8 Hydr. Filter Monitoring - 2B20/21 Main Pump Temp. 1/2 - 2B22/23 Main Pump Temp. 3/4 - 2B24/25 Main Pump Temp. 5/6 - 2B26/27 Main Pump Temp. 7/8 - 3B10 Hydr. Temp. Left - 3B18 Shut-Off Valve Left Hydr. Tank

-2B22 -2B23

-2B20 -2B21

-3B10

-3B18

- 3B19 Shut-Off Valve Center Hydr. Tank - 3B22 Main Pump Pressure 1 - 3B23 Main Pump Pressure 2 - 3B24 Main Pump Pressure 3 - 3B25 Main Pump Pressure 4 - 4B10 Hydr. Temp Right - 4B18 Shut-Off Valve Right Hydr. Tank

- 4B22 Main Pump Pressure 5 - 4B23 Main Pump Pressure 6 - 4B24 Main Pump Pressure 7 - 4B25 Main Pump Pressure 8 - 5B4 Contamination Servo Filter 1 - 5B5 Contamination Servo Filter 2 - 2Y46 Toggle Valve Drive

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Servo System Assembly – Detail – Description

-2Y24

-2Y22

-2Y20

-2Y17

Service Training

-2Y23 -2Y18

-2Y27 -2Y18

-2B39 -2B41

-2Y30 -2Y31

-2B33 -3Y1

-2Y15 -2Y16

-2B32

-4Y1

-3Y3 -4Y3

-3B13

-4B13

v -2B31

-2B7 -2B36

-2Y12

-2Y14

-2Y11

- 2Y11 Prop. V. Drive Right Backward - 2Y12 Prop. V. Drive Right Forward - 2Y13 Prop. V. Drive Left Backward - 2Y14 Prop. V. Drive Left Forward - 2Y15 Prop. V. Swing Left - 2Y16 Prop. V. Swing Right - 2Y17 Switch. V. Drive Brake - 2Y18 Switch. V. Servo On - 2Y20 Switch. V. Track Tension - 2Y22 Switch. V. Travel Stage 2 - 2Y23 Switch. V. Park Brake Swing - 2Y24 Switch. V. Travel Press. Booster - 2Y30 Switch. V. Swing Brake (B.Valve) - 2Y31 Switch. V. Swing Brake (B.Valve) - 3Y1 Prop. V. Control Pressure Left - 3Y3 Prop. V. Cooling Hydr. Oil Left - 4Y1 Prop. V. Control Pressure Right - 4Y3 Prop. V. Cooling Hydr. Oil Right

- 2B7 Servo Control Pressure 35bar - 2B31 Prop. V. Swing Left - 2B32 Prop. V. Swing Right - 2B33 P-Balance Valve - 2B36 Park Brake Swing - 2B39 Swing Brake (Balance V.) Left - 2B41 Swing Brake (Balance V.) Right - 3B13 Control Pressure Left - 4B13 Control Pressure Right

-2Y13

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Servo System – Main Pump Control (PMS)

Service Training

Servo Pump 2+3

-4Y1

Servo Pumps 1+4

-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 Servo Pump 2+3

Service Training

Servo 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 Servo Pump 2+3

Service Training

Servo 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 Servo Pump 2+3

Service Training

Servo 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 Servo Pump 2+3

Service Training

Servo 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 Valve 35 bar

2nd Speed 50 bar

Servo Pump 1+4 Travel Park Brake 30 bar Pump Regulation Swing Park Brake 50 bar

50 bar

Pilot 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 Pilot 50 bar

Service Training

Track Tensioning 80 bar Travel Boost 40 bar

Servo Pump 2+3

80 bar Ladder, Clam Boost Service Arm, 40 bar Grease System

Tank

P-Port Main Pumps -2Y18

Pilot 100 bar

-2Y24 -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 -2Y120 – (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 2 + 8, so that the clam pressure is increased to 320bar + 40bar = 360 bar The clam boost function is only connected if necessary, machines with upgraded clam cylinders do not use this function!

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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Proportional Valves for Attachment Functions

Service Training

T

P - 35 bar

20

-2Y10 Tank Return -2Y9

-2Y8 -2Y4 -2Y2

-2Y5 -2Y7 -2Y3

-2Y2 Tank Return

Tank

-2Y6

-2Y36 -2Y38

-2Y37

Proportional Valves for Attachment Functions - FS

Service Training

-2Y36 -2Y2 -2Y5 -2Y8 -2Y10

Valveblock Pre Heating Bucket Cylinder out (Bucket fill) Boom Cylinder out (Boom up) Stick Cylinder out (Stick out) Clam Cylinder out (Clam close)

-2Y37

Valveblock Pre Heating Stick Float Valve Tank Return (no electrical signal) Stick Cylinder in- Float (Stick float) Boom Cylinder in- Float (Boom float) Boom Float Valve Tank Return (no electrical signal)

-2Y7 -2Y4

-2Y38 -2Y6 -2Y3 -2Y2 -2Y9

Valveblock Pre Heating Stick Cylinder In (Stick power in) Boom Cylinder in (Boom power down) Bucket Cylinder out (Bucket fill) Clam Cylinder in (Clam open)

35 bar

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Proportional Valves for Travel Function

Service Training

22

Proportional Valves for Swing Function

Service Training

23

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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