Hydraulic Mining Excavator

CAT 6040

05. Tank, Main Pumps and PMS

Dixio Torrez - 2012

Excavator - Basic Layout Service Training

Variable
Cylinder Displacement
Pump
Valve
Block

Secondary Secondary
Relief Relief
Valve Valve

Primary Cut-Off
330 Relief
Valve
Valve

360 360 320 bar

10 bar

Tank Return
Pressurizer Valve Bypass
Valve

Return 2 bar
Filter

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Hydraulic Tank Service Training

12 bar Pressuriser Valve

Level Gauge

Breather Filter

H.P. Distribution
Blocks

1.5 bar Pressure

Switch
Isolation Valves

Return Filters Bypass Valves

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Hydraulic Tank – Open System – Basics Service Training

Return Oil

12 bar
Preload Valve

1,5 bar
Bypass Valve

Pump Suction Line

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Main Pumps – LH Side (Example) Service Training

Main Pump Type: A4V-500

(Variable Displacement Axial Piston)
Working Pressure: 300/350 bar
Operating Speed: 1486 RPM at 1800 RPM on Engine
Output: ~ 720 ltr./min

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Main Pump – A4V500HD Service Training

Swash Plate Angle For more information, please click on the pump!

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Minimum or Maximum Output??? Service Training

0° = Minimum Flow

0 - 15° Variable Displacement: Min – 500 ccm

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Main Pump Schematic – AV500HD - B Service Training

X2 X1 (8 bar) XB (+50 bar)

min. max.

P (60 / 80 bar) M
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Pump Management – Basics Service Training

Hand / Foot
Controller
Servo Controller

CAN – Bus 1
CAN – Bus 2

Proportional Drive Controller

Valve

RPM-Signal
0 – 100% Joystick
Deflection
P2
Engine RPM Signal
Engine
Pump Control Current
P1
Pump Control Pressure

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CAN-BUS Overview Service Training

BCS Screen Hand Lever and Foot Pedals

CAN – Bus 2

CAN – Bus 1

Drive Controller Drive Controller

LH RH

Servo
Controller + Auxiliary
ICNV Controller

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Overview Pump Control Service Training

Hydraulic Oil Temperature

Engine Temperature

Acceleration Engine Load (RPM)

0 - 100%

Pump Requirements
Signal via from Servo Controller
CAN-Bus via CAN-Bus

Joysticks and
Foot Pedals Servo Controller Drive Controller

PMS Current 150 – 850 mA

Angle Main Pumps 0 – 15°

50 bar Pressure

5 – 43 bar to Main Pumps

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Proportional Valve -3Y1 (LH) and -4Y1 (RH) Service Training

Pump Control Current:

225 – 850 mA

850 mA

150 mA

5 bar 43 bar
Min Flow Max Flow

50 bar Pressure

X1 Signal:
8 – 43 bar to Main Pumps
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Reduced Pump Flow (Reduced Power Consumption) Service Training

Sensor Hydraulic Oil Temperature

If Hydraulic Oil Temperature exceeds 80°C

Sensor Coolant Temperature OR

If Engine Coolant Temperature exceeds 100°C

Acceleration
0 - 100%

Pump Requirements max. PMS Current

Signal via from Servo Controller 640 mA
CAN-Bus via CAN-Bus

Joysticks and
Foot pedals Servo Controller Drive Controller

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Engine Speed Adjustment – Signal Generation Service Training

2000
Drive Controller
1800

Analog Output Ground 1600

0-20 mA

Engine Speed (rpm)

1400
1200
1000
800
Current 600
1,3 mA - 400
6,2 mA 200
0
0 0.5 1 1.5 2 2.5 3 3.5
Voltage @ Engine

Resistor
Terminal
510 Ohm
(X30 / X40)

Engine

Voltage 0,7- 3,2V

Engine Speed
800 - 1900 rpm

Ground
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RH170B – KTA38 – Engine Speed Signal Service Training

Flywheel Ring Gear

(142 Teeth) Drive Controller

Speed Pick-Up Sinus Signal

Sensor 4496Hz @ 1900 rpm
Engine Speed

The Cummins KTA 38 Engine is not equipped with Can Bus, so the RPM signal is generated by a pickup sensor.

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Main Pump – Proportional Valves Service Training

Initial Pressure
Port “P”
Constant 60/80 bar

Main Pump,
Proportional Valves
Boost Pressure
“XD” (+ 50 bar)

Governing
Pressure “X1”

Servo Pressure 50 bar (60/80bar)

Pump Control Pressure 8-43 bar

Tank Return
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BCS Screen Service Training

1. Push Button Service

a ulic“
n „Hydr
utt o e
. Pu sh B e Pictur
2 or th

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A4VSO – HD-B - minimum Flow Service Training

X2 X1 (8 bar) XB (+50 bar)

min. max.

P (60 / 80 bar) M
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Hydraulic Screen – Pump in Neutral Service Training

1900 1900

35.0 50.0

15.0 15.0 15.0 15.0

150 150

8.0 8.0

25.0 25.0 Both Engines Running

no Function activated.
25.0 25.0

42.3
47.3
- Main Pumps in Neutral -

39.9
49.9

43.7 45.6

Water Cooler Fan Reg 650.0

0.0 650.0
0.0

650.0 650.0 15.0

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A4VSO – HD-B - Pump on Flow Service Training

X2 X1 (5 - 43 bar) XB (+50 bar)

min. max.

P (60 / 80 bar) M
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Hydraulic Screen – Pump in Flow Service Training

1800 1800

35.0 50.0

285 285 285 285

850 850

43.0 43.0

25.0 25.0 Both Engines Running

Boom Up with full Bucket.
25.0 25.0

42.3 - Main Pumps 100% Flow -

39.9

43.7 45.6

Water Cooler Fan Reg 650.0 650.0

650.0 650.0 15.0

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A4VSO – HD-B - Pressure Cut Off (300 /350 bar) Service Training

X2 X1 (43bar) XB (+50 bar)

min. max.

P (60 / 80 bar) M
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Hydraulic Screen – Cut Off Service Training

1900 1900

35.0 50.0

300 300 300 300

850 850

43.0 43.0

25.0 25.0 Both Engines Running

Boom Cylinder fully extended.
25.0 25.0

42.3 - Main Pumps min. Flow -

39.9

43.7 45.6

Water Cooler Fan Reg 650.0 650.0

650.0 650.0 15.0

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More Information? Service Training

Hey Fellows,

Please find more Information

in the Technical Handbook!

Chapter 9.3.6 and 9.3.7:

LH and RH Drive Controller

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