Hydraulic Mining Shovels

Cat® 6060/6060FS

07. Travel System

Dixio Torrez - 2013

 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
2
Main Pump Assembly Service Training

P8

P7
P6
P5

P4

P3
P2

P1

3
Filter Block Assembly Service Training

P 1/7
P 2/8
P 3/5

3/5 P 4/6

4/6
1/7

2/8

4
Travel Supply: P1/P7 and P2/P8 (P3/5 and P4/6
Attachment) Service Training

Tank return lines P3/P5

Tank return lines

P4/P6 P1/P7 P3/P5 P4/P6 P2/P8

P1/P7

P2/P8
P1/P7 P2/P8

5
Travel Supply: P1/P7 + P2/P8 Service Training

Main Pump supply

P1/7
To Attachment P3/5
Control -RH- To
only if Toggle Attachment
Valve -2Y46 Control -RH-
switched
to –X- position

Travel
Valve RH

Travel
Valve LH

P2/8
P4/6
To Attachment
To
Control -LH-
Attachment
only if Toggle
Control -LH-
Valve -2Y46
switched to
-X- position

Main Pump supply

6
 Rotary Joint and Main Valves Service Training

Travel Valve

Travel Valve

Retarder
Valve

Retarder
Valve

Anti Cavitation Valves

Rotary Joint

7
Rotary Joint and Main Valves (side view) Service Training

8
Rotary Joint and Main Valves (side views) Service Training

9
Rotary Joint and Main Valves (side views) Service Training

10
Travel Valves Service Training

Stroke: 17mm

Spool

Centering
Springs

11
Rotary Joint Service Training

Track Tensioning in the front

Undercarriage Greasing

Case Drain
+ Leakage Oil Return

Leakage Oil Return

Undercarriage Greasing
Track Tension 50 / 80 bar

Travel Brake 30 bar

+ 2nd Speed 50 bar

Travel Brake
+ 2nd Speed
(Shuttle Valve!)
Travel 0-360 bar

Travel 0-360 bar

(4 times)

Undercarriage
Greasing

12
Travel Main Valves and Proportional Valves Service Training

Travel
Travel Valve Proportional
Valves

Travel Valve

13
Case Drain Lines and Retarder Valve Sensing Lines Service Training

Retarder Valve
Sensing Lines

Retarder Valve
Sensing Lines

14
Travel Supply to Undercarriage Service Training

P1/P7

Case Drain
P2/P8

Travel Brake
and 2nd Speed

Secondary
Relief Valve
370 bar

15
Travel Pressure Boost on Main Pumps Service Training

Travel Boost (Solenoid -2Y24 - 40 bar) “DZ”

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

4 1

7 6

16
Travel Motor Service Training

Operating Pressure = 320 + 40 bar = 360 bar

Displacement Travel Park

Control Piston Brake

45 bar

Flushing Valve
(Cooling)

2nd Speed
Control Valve

1st Speed => 250 cm³ Displacement => High Torque ~1,5 km/h

2nd Speed => 170 cm³ Displacement => Lower Torque ~2,0 km/h
17
Travel Motor Service Training

2nd Speed
Connection

Flushing Valve
(Cooling)

18
Travel Brake Service Training

Seals

Piston
Springs

Discs

30 / 50 bar Brake Release Pressure

19
Travel Motor Service Training

Travel Park
Brakes

Flushing Valve
(Cooling)
ar d
M2: Forw

rse
eve
:R
M1

O il
ak
2nd Speed
Le Connection

se
e lea n
rse Flushing Valve
e R tio e ve
r ak nec 2 :R (Cooling)
B on M
C ar
d
rw
: Fo
M1

20
Pedals Service Training

21
CMS Service Training

LH RH Clam LH RH
Adr.: 0 Adr.: 1 Adr.: 2 Adr.: 3 Adr.: 4

CAN Bus for Operator Controls

Proportional
Valves

CAN Bus to
Drive Controllers
and BCS

22
Pedals Service Training

Address
Adjustment

23
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

24
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

25
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.

26
Servo System – RH Block Service Training

Pilot
50 bar Track
Tensioning 80
Travel Boost bar
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

27
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 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.

28
Travel Schematic Service Training

P1/P7

P3/P5

P4/P6

P2/P8

0 – 360 bar => Travel Pressure Boost

30 / 50 bar (Travel Park Brake and 2nd Speed)
50/80 bar (Track Tensioning)
29
Secondary Relief Valves Service Training

Forward direction. Reverse direction.

RHS cross-over relief valve. LHS cross-over relief valves.
The test point is at the RHS The test point is at the LHS
rear of the block. rear of the block.

Reverse direction. Forward direction.

RHS test point. LHS test point.
The relief valve is at the top The relief valve is at the lower
rear of the block rear of the block.

30
Condition: RH Forward Service Training

Servo Controller

24 Volt 0 – 650mA 0 – 35 bar

31
Condition: RH Forward Service Training

32
1st Speed Forward Service Training

45 bar

0 – 360 bar => Travel Pressure Boost

30 bar Servo Pressure (Travel Park Brake released)

Tank

33
2nd Speed Forward Service Training

0 – 360 bar => Travel Pressure Boost

50 bar Servo Pressure (Travel Park Brake released and 2nd Speed)

Tank

34
Condition: RH Reverse Service Training

Servo Controller

24 Volt 0 – 650mA 0 – 35 bar

35
Condition: RH Reverse Service Training

36
1st Speed Reverse Service Training

45 bar

0 – 360 bar => Travel Pressure Boost

30 bar Servo Pressure (Travel Park Brake released)

Tank

37
2nd Speed Reverse Service Training

0 – 360 bar => Travel Pressure Boost

50 bar Servo Pressure (Travel Park Brake released and 2nd Speed)

Tank

38
Condition: Forward Downhill Service Training

39
Retarder Valves Service Training

HP Oil From Main

Pump 0-340 bar

Low Pressure
Return Oil

Restricted Oil

Retarder OFF Retarder ON

40
Retarder Valves Service Training

Pump Pressure

High Pressure
Pressure reduced due
to Downhill Operation 41
Track Tensioning Service Training

42
Track Tensioning Service Training

50 / 80 bar Supply
Track Tension
Cylinder
Tank Return

Shock Relief Valves (330 bar) Accumulator

Isolation Valve
Pilot Operated
check Valves

70 bar
Switching Valve
43
Status 1: System loaded by Servo Pump (50 bar) Service Training

Servo Pump supplies Track

Tensioning System with 50 bar

A A
Y Y
X X

70 bar B B

Pilot pump 1/4

Servo Pump

100

330 330

50bar

Nitrogen Charge

Tank

44
Status 2: Pressure build-up during Travelling
(<330bar) Service Training

Servo Pump supplies Track

Tensioning System with 50 bar.
Travelling causes Pressure
build-up in the System.
A A
Y Y
X X

70 bar B B

Pilot pump 1/4

Servo Pump

100

330 330

50bar

Up to 330 bar

Nitrogen Charge

Tank

45
Status 3: Pressure Release (80 bar for 5 sec.) Service Training

If machine travels for more than 15 sec.:

5 sec after stop travelling,
-2Y20 energized for 5s.
Pressure more than 80 bar can escape to
A A the tank over the 80 bar relief valve.
Y Y
X X

70 bar B B

Pilot pump 2/3

100
-2Y20
330 330
energized
50bar

Up to 330 bar

Nitrogen Charge

Tank

46
Pilot Operated Check Valve Service Training

47