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Hydraulic Mining Shovels

Cat® 6060/6060FS

05. Tank, Pumps and Drive Controller

Dixio Torrez - 2013


Hydraulic Tank – Open System – Basics Service Training

Pressure Sensor -2B8

Return Oil

12 bar Preload Valve

38mm Orifice
1,5 bar Bypass Valve

Pump Suction Line

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Pressurizer Valve Service Training

12 bar

15 bar ~ 0,8 bar

38mm Orifice => ~ 2 bar at full pump flow.

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Tank Assembly Service Training

2 min. Level Sensors

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Tank Housing and Oil Flow Service Training

2 min. Level Sensors

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Pump Assembly and Servo System Service Training

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Main Pumps and Servo System Service Training

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Main Pump Assembly Service Training

P8

P7
P6
P5

P4

P3
P2

P1

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

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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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Travel System Supply Service Training

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Minimum or Maximum Output??? Service Training

0° = Minimum Flow

Variable Displacement: Min. – 446 ccm

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Pump Layout for RH340B Service Training

Displacement adjusted to 2 X 446 ccm


=> Oil Flow 2 X 647 l/min at 1450 RPM
(Engine Speed = 1800 RPM)

U1 U2
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A20 Pump – Basic Design by Rexroth Service Training

Balance
Valve
XD

XLR

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A20 Pump – System in Neutral Service Training

Boost Pressure

Pump Control
5 bar

Initial Pressure
constant 50 bar

Working Pressure
~ 20 bar

Max. Min.

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Flow on Demand (min. – max.) Service Training

Boost Pressure

Pump Control
5 – 43 bar

Initial Pressure
constant 50 bar

Working Pressure
~ 20 - 320 bar

Max. Min.

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Pressure Cut-Off (320bar) Service Training

Boost Pressure

Pump Control
43 bar

Initial Pressure
constant 50 bar

Working Pressure
320 bar

Max. Min.

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Pressure Cut-Off - Boost Pressure 370 bar Service Training

Boost Pressure
+ 50 bar

Pump Control
43 bar

Initial Pressure
constant 50 bar

Working Pressure
370 bar

Max. Min.

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Pump Layout Service Training

PST Controller Remote Control Valve Pressure Balance Valve Power Controller
(New System: blocked)

Cut-Off Valve

PST Controller

Qmax- Stop

Qmin- Stop
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Pressure Boost or Not ??? Service Training

Backhoe Machines:

P1 / P2 / P7 / P8 => Travel Pressure Boost

Face Shovel Machines:

P1 / P2 / P7 / P8 => Travel Pressure Boost

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PMS: Basics – LH Engine only Example: #340085 Service Training

PMS: ____________________________________________
Voltage 24 V

Can Bus Signal 0 - 100 %

HAND / FOOT Temperature Signal

CONTROLLER 225 – 820 mA Current


CMS Card 8 - 43 bar PMS Pressure

Engine RPM Signal

PST - Proportional Valve

Y71
24 Volts
XLR - Proportional Valve
PMS

Y17 Box

1/min
H.T.
(80)
P3 P4
Engine W.T.
(100)
P1 P2

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CAMP (PMS): Basics – LH Engine Service Training

Voltage 24 V

Can Bus Signal 0 - 100 %

HAND / FOOT Temperature Signal

CONTROLLER (150) 225 – 850 mA Current

Servo Controller 6- 43 bar PMS Pressure

Engine RPM Signal

PST - Proportional Valve

-3Y1
24 Volts

Drive Controller

1/min
H.T. IMT
(80) (80)
P3 P4
Engine W.T.
(100)
P1 P2

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New Servo System and Main Pumps Service Training

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Servo Control Valves on Assembly Plate – New MDG Setup! Service Training

New Assembly Plate


with Servo Controls.
=> Take Care of setup
of Proportional valves!

-4Y1 -3Y1

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Proportional Valves Service Training

No CAMP Machines
820 mA

225 mA

8 bar 43 bar
Min Flow Max. Flow

CAMP controlled Machines

850 mA

50 bar Pressure

250 mA
(150 mA)

X1 Signal: 8 bar 43 bar


to Main Pumps Min Flow Max. Flow

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More Information? Service Training

Hey Fellows,

Please find more Information


in the Technical Handbook!
Caterpillar®
Chapter 8.5: Load Limit Regulation

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