Hydraulic Mining Excavator

CAT 6040

05. Tank, Main Pumps and PMS

Matthias Aust - 2013

Hydraulic Tank Service Training

Manual Refill Port

With Magnet Breather
Filter

4 Bypass
Valves
1,5 bar

4x 12 bar
Pre Charge Level Gauge
Valve (2 Level Switches not shown)

7 Return
Filters 10µm

High Pressure
Filter Blocks 100µm

Isolation Pressure
Valves Sensor

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Hydraulic Tank – Return Lines from Oil Cooling System Service Training

2 Bypass
Valves
1,5 bar 2 Return
Filters 10µm

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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

4
Hydraulic Tank – Suction System Service Training

Shut Off Valves

5
Main Pumps – LH Side (Example) Service Training

Main Pump Type: A4V-500

Working Pressure: 300/350 bar
Operating Speed: 1490 RPM
Output: ~ 720 ltr./min

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Basic Hydraulic System Service Training

Power = Flow * Pressure

Example: Deutz Tractor

Engine Power: 40 kW

max. hydraulic Pressure: 200 bar

Flow: 45 ltr./min

Hydr. Power= 200 bar * 45 ltr./min

600
Hydr. Power= 15 kW
45 ltr./min
200 bar

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Excavator - Basic Layout Service Training

Variable
Cylinder Displacement
Pump
Valve
Block

Secondary Secondary
Relief Relief
Valve Valve

Primary Cut-Off
380 Relief
Valve
Valve

360 360 300 bar

12 bar

Tank Return
Pressurizer Valve Bypass
Valve

Return 1,5 bar

Filter

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Cat-6040 – Hydraulic Layout vs. Engine Power Service Training

4 Main Pumps 720 ltr/min 300 bar = 1440 kW

4 Swing Pumps 316 ltr/min 370 bar = 780 kW

2 Swing Charge Pumps 140 ltr/min 30 bar = 12 kW

2 Fan Dive Pumps Engine Cooling 123 ltr/min 280 bar = 115 kW

2 Fan Drive Pumps Hydraulic Cooling 123 ltr/min 280 bar = 115 kW

2 Hydraulic Cooling Circulation Pumps 776 ltr/min 25 bar = 65 kW

2 Servo Pumps 37 ltr/min 80 bar = 10 kW

2 Gearbox Cooling Pumps 8 ltr/min 2 bar = -----

____________________________________________________________________________

Total Hydraulic Power = 2537 kW

Engine Power = ~ 1500 kW

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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 Service Training

Pressure + 50 bar 5-43 bar Control Spool

Cut-Off
Valve

50 bar

n = 1490 RPM
Tank

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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

Address
1 2 3

CAN – Bus 2

BCS Screen

CAN – Bus 1

Servo
Controller

Auxiliary Drive Controller

Drive Controller Controller RH
LH

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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 1 via CAN-Bus 1

Joysticks and
Foot Pedals Servo Controller Drive Controller

PMS Current 225 – 850 mA

(150 mA Standby Current)

Angle Main Pumps 0 – 15°

PMS
Proportional
Valve
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:

150 / 225 – 850 mA

850 mA

150 / 225 mA

5 bar 43 bar
Min Flow Max Flow

50 bar Pressure

X1 Signal:
5– 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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LH Main Pumps – Proportional Valves Service Training

Initial Pressure
Port “P”
Constant 50 bar

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

Governing
Pressure “X1”

Servo Pressure 50 bar

Pump Control Pressure 5-43 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 (5 bar) XB (+50 bar)

min. max.

P (50 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

5.0
8.0 5.0
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 (50 bar) M
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Hydraulic Screen – Pump in Flow Service Training

1800 1800

35.0 50.0

225 225 225 225

225 - 850 225 – 850

5-43 bar 5-43 bar

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 (50 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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Governing Current Service Training

Cat – 6040

Working Pressure Engine Speed Governing Current Governing Pressure

[bar] [RPM] [mA] [bar]

180 1840 850 43

200 1835 850 43

210 1780 813 42

220 1780 757 39

260 1780 717 36

280 1780 660 34

299 1780 620 32

300 Cut-Off 1900 850 43

(Attachment Functions)

350 Cut-Off 1900 850 43

(Travel Function)

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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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