Hydraulic Mining Shovel

6040AC (e-drive) with CAMP/SIL and BCS4

06. Servo System

Dixio Torrez - 2014

Servo Pumps Service Training

Servo Pump

Servo Pump
Lube System

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Servo Pumps Service Training

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Servo Schematic Service Training

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Emergency
Boom Down
System
90

Auxiliary Servo Pressure 50 bar

50

-2Y161 Track Tensioning

Pressure 60 / 80 bar

-2Y144

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50 bar Users Service Training

PMS Proportional Valve -3Y281

Auxiliary Servo
35 bar
Pressure 50 bar
Swing Balance Valve
+ Swing Safety
Accumulator

Hydraulic Oil Cooling Prop. Valves

Solenoid Valve Bank [26 / 2]

Solenoid Valve Bank [26 / 1]

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Solenoid Functions Service Training

Swing parking brake (Solenoid -2Y131)

Swing brake released:

The solenoid valve is energized and oil flows to the swing parking brakes.
They are hydraulically released and held in the released position.
Valve (-2Y131) is de-energized. The swing brake pistons are connected to the hydraulic tank.
The swing brakes are applied by spring force.

2nd speed travelling (Solenoid -2Y143)

The solenoid valve (-2Y143) operates the 2- stage regulator of the travel motors for 2- speed travelling.
When the operator shifts the switch in the cab from 'low speed' (turtle) to 'high speed’ (rabbit) the pressure in the lines to the travel parking brakes
and travel motor regulators is increased to 50 bar and the regulators are shifted to low displacement.

Travel Pressure Boost (Solenoid -2Y142)

The solenoid valve (-2Y142) operates the pressure cut-off valves of the main pumps which are used for the travel function and operates the
pressure cut-off valve, so that the travel pressure is increased from 320 to 370 bar.

Clam Pressure Boost (Solenoid -2Y111) – Optional Function!!!

The solenoid valve (-2Y111) operates the pressure cut-off valves of the main pump which is in charge of the clam function, so that the clam open
pressure is increased from 320 to 370 bar.
=> The clam pressure boost function should only be used if required! It’s always better to operate the clam with the lowest possible pressure!!!

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Swing Park Brake Service Training

Swing Park Brake -2S3

+ 24V

Servo
Controller

-2Y131
- 24V

50 bar Servo

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Emergency Boom Down Service Training

-2Y101

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35 bar Adjustment Service Training

Users of 35 bar are: 35 bar Check point

• Prop. Valves for Servo Main Control Valves

• Prop. Valves for Float Valves
• Prop. Valves for Travel
• Prop. Valves for Swing Balance Valve Displacement
• Emergency Accumulator

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50 bar Adjustment Service Training

50 bar Check point

Users of 50 bar are:

• Service Lift
• Swing Brake Solenoid Valve
• Prop. Valves for Main Pump Governing
• Prop. Valves for Hydraulic Oil Cooling
• 2nd Speed for Travel System
• Travel Pressure Boost

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60 bar Adjustment Service Training

60 bar Checkpoint is Machine Working

located in the pump (Attachment / Travel / Idle)
compartment, close to
the Servo Pump

Users of 60 bar are:

• Track Tensioning System

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80 bar Adjustment Service Training

80 bar Checkpoint is If machine travels for more than 15 sec.:

located in the pump
5 sec after stop travelling,
compartment, close to
the Servo Pump -2Y144 energized for 5s.

-2Y161

-2Y144

Users of 80 bar are:

• Track Tensioning System ( 5s after travelling)

• Service Ladder Pressure increase

Please use the momentary switch

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

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Servo Pressure Check Points 60/80 bar (at PTO Gearbox) Service Training

90 bar
Grease System
Relief Valve
60 bar
Relief Valve

60 / 80 bar
Check Point

Grease System
60 bar
Check Point

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Proportional Valve Block – Electric Side Service Training

50 bar Check Point 35 bar Check Point and BCS Sensor

2nd Speed -2Y143

Reserve -2Y161

Swing Brake -2Y131 -2Y1 -2Y2 -2Y3 -2Y4 -2Y5 -2Y6 -2Y16 -2Y15

Travel Pressure Boost -2Y142

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

-2Y144

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Proportional Valve Block – 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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Attachment - Servo Valves Service Training

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Travel System - Servo Valves Service Training

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Controller Set Up Service Training

Address
1 2 3

CAN – Bus 2

BCS Screen
Foot Pedal
Address Adjustment
CAN – Bus 1

Servo
Controller

Auxiliary Drive Controller

Controller

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Controller and Signal Overview Service Training

E-Motor
Feedback

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Joystick/Foot Pedal - Functions in BCS Screen Service Training

Demand Value

Active Value

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RH Joystick Service Training

Boom Down
(Float)

Bucket Bucket
Curl Close Curl Open

Boom
(Power)
Horn Down
Boom Up

Spare Truck
Counter

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 LH Joystick Service Training

Stick Out

Swing Swing
Left Right

Stick
(Power)
In Spare

Stick In

Clam Spare
Open/Close

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Pedals Service Training

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More Information? Service Training

Hey Fellows,

Please find more Information

in the Technical Handbook!

Chapter 8.5.3: Servo System

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