Hydraulic Mining Excavator

CAT 6015

06. Servo System

Matthias Aust - 2011

Servo Pump Service Training

Servo Pump

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Servo System Service Training

45 bar
50 / 100 bar from Travel Foot Pedal
To Track Tensioning
System

45
8 – 43 bar
225-820 mA
from PMS Box

45 bar to P Port
8-43 bar of Main Pumps
To X1 Port of
Main Pumps

45 bar to Seat Contact

Valve Y7 3
Servo Valves Service Training

45 bar to Hand
50 bar Adjustments Lever / Foot Pedal

Then reduced to
35 bar to reduce
Proportional Valve the Joystick
225-820 mA Resistance (Hand
Force)

45 bar Adjustment

Au
P P x. P
o r re s
t o su
n P re
Track Tensioning um to
ps
Pressure Increase
Valve (100 bar) 8-4
3
(only while traveling) Signal for travel Ma bar t
in
indication Pu o X 1
mp
from foot pedal s

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Servo Adjustments Service Training

45 bar 100 bar 50 bar

Adjustment Adjustment Adjustment

50/100 bar

Servo Pump

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Servo Pressures Service Training

These are the servo pressures applicable to the CAT 6015 (RH 40-E)  35 bar, 45 bar, 50 bar and 100 bar.

45 bar System:

The 45 bar servo pressure is supplied from servo gear pump driven from the back of Main Pump 1.
This pump pressure is regulated to 45 bar via a pressure reducing valve, near the pumps. (See photo)

Users of 45 bar are:

- Swing brake solenoid valve.

- Travel brake solenoid valve.
- P Port Main Pumps for startup and initiate pump stroke up.

-The hydraulic joysticks and Foot pedals for attachments, travel and swing are fed from the 45 bar servo system.
 This pressure is reduced to 35 bar in relation to easier movement of joysticks and foot pedals.

50 bar Auxiliary System:

The 50 bar auxiliary pressure is also supplied from the servo pump.
The pressure is regulated by the 50 bar pressure limiting valve. (See photo)

Users of 50 bar are:

- Main Pump Proportional valve.

- Track Tensioning while working (attachment).

100 bar Auxiliary System:

The only user of 100 bar is the track tensioning (while travelling).

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Pressure Switches Service Training

45 bar

Safety Valve Y7

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Servo Valves Service Training

45 bar
Joystick Tank

Emergency
Servo Accumulator

Safety Joystick
Valve

Pedals

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Joystick Service Training

Handpiece

Dust Cover

Locknuts

Actuator Plate
Spool Plungers

T P

Control
Piston
Users

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Joystick Service Training

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Pedal Functions Service Training

Clam and Travel Pedals

The CAT 6015 (RH 40-E) is equipped with foot pedals for both travel and bucket clam functions (face shovel).
These pedals operate on a central pivot, and can be pressed down either forward or backward.

A = Clam Open
B = Clam Closed
C = Left Track Forward
D = Left Track Reverse
E = Right Track Forward
F = Right Track Reverse
N = Neutral Position

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Pressure Switches Service Training

DSF (S 50) – Pressure Switch Travel: Switches (opens) and energizes via relay the travel brake release solenoid
valve.
This valve supplies 45 bar servo pressure to the travel brakes for release. (720 mA, Travelmeter, Brake)

SLS (B11) – Load Sensing Sensor: Is the load sensor and sends a 4-20 mA signal to the PMS box when ever a
servo function is operated. This provides a variable Output from the PMS Box to the variable main pumps.

DSL (S48) – Pressure Switch Load: Switch is located under the cab platform and switches (opens) whenever the
joystick or clam pedal is operated only. A 24 volt signal informs the PMS box that the machine is being operated.

DSS (S94) - Pressure Switch Swing: Switch is located under the cab and closes whenever the operator summons a
swing function. This sends a 24 volt signal to the swing brake solenoid, Y11, and releases the swing brakes with
45 bar servo pressure. (Has not an direct influence on Pump Regulation)

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Servo: Attachment Functions Service Training

Load Sensing
Signal to PMS

To PMS

45 bar

To Main
Control Valve.
Boom Up Spool

Safety Valve Y7

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Servo: Attachment Functions Service Training

Main Control Valves

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Servo: Attachment Functions Service Training

The joysticks have a common 35 bar supply. As the operator moves the joysticks, 0-35 bar servo oil flows through to the
Main Control Valves or Float Valve. (Lever way 0-100%  Pressure 0-35 bar)

The servo pressure is also sensed on the DA sensor, (B11) which sends the load sensing signal to the PMS box to stroke
up the main pumps. The pressure is also switches the DL switch, which sends a 24 volt signal to the PMS box. Note that
each of the function will only be available when the operator is seated.

If the safety valve is not energized, servo oil will not be allowed to pass through to the main control valve.

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Servo: Travel Functions Service Training

Load Sensing
Signal to PMS

to Travel
Valve and Travel Brake
Track Solenoid
Tensioning
Valve

45 bar

Safety Valve Y7

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Servo: Travel Functions Service Training

Travel Valves

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Servo: Travel Functions Service Training

The travel pedals have a common 35 bar supply. As the operator moves the pedals, 0-35 bar servo oil flows
through to the travel valves.
The servo pressure is also sensed on the DA sensor, (B11) which sends the load sensing signal to the PMS box to stroke
up the main pumps (225-720 mA).

It is also sensed at the DSF switch which sends a 24 volt signal to the travel brake solenoid to release the travel brakes.
Note that each of the function will only be available when the operator is seated. If the safety valve is not energized servo
oil will not be allowed to pass through to the travel valve.

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Servo: Swing Functions Service Training

to PMS

Swing Brake
Solenoid Y11

to Swing
Balance Valve 45 bar

Safety Valve Y7

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Solenoid Valves Service Training

Swing Brake (Y11): The swing brakes are spring applied, pressure released. In the de-energised position, the swing brake
is connected to tank, and the brakes are applied. When the swing brake is released, solenoid Y11 is energised and 45 bar
is supplied to the swing brakes, overcoming the spring tension, and releasing the brakes.

Travel Brake (Y12): The travel brakes are also spring applied, pressure released. In the de-energised position, the travel
brakes are connected to tank, and the brakes are applied. When the travel brake is released, solenoid Y12 is energised and
35 bar is supplied to the travel brakes, overcoming the spring tension, and releasing the brakes.

Boom Float Solenoid: The boom float solenoid supplied with 0-35 bar servo oil from the left joystick and is in charge for
lowering the boom without pressure from the main pump. It actuates the boom float valve.

Boom Float (Y10) Swing Brake (Y11) Travel Brake (Y12)

35 bar 45 bar 35 bar

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Joysticks Service Training

Regular checks of the joysticks are required. Check the condition of the universal and replace at regular intervals as they
become fatigued due to operator abuse.

There should be clearance maintained between the actuator plate and the plungers this is adjusted by releasing the locknuts
and turning the actuator plate until the clearance is “minimal” between the plungers and the actuator plate.

The hand piece angle can also be adjusted again by releasing the locknut and turning the hand piece in or out.

Any excessive clearance or loss components should be adjusted or tightened as soon as possible.
Ensure the dust cover is secured into position to prevent dust contaminating seals.
Both joysticks are the same and can be used in either right or left positions.
Hand pieces and universals can be replaced separately.

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Joystick Functions Service Training

Right Joystick

The Boom and Bucket Crowd functions are both controlled with the right hand control lever.
When moved as shown, the following will occur:

A = Boom Down
B = Boom Up
C = Bucket Crowd In
D = Bucket Crowd Up

The boom is raised through hydraulic power, although it is lowered through gravity.

When the control lever is moved to the "boom up" position, this activates the hydraulic pumps, which then supply the power
required to raise it.

But when the control lever is moved to the "boom down" position, it opens the boom control and float valves, and the weight
of the front attachment forces the hydraulic oil back into the tank, causing the boom to lower.

This means that the bucket can only be placed on the ground lightly, or in the "Float" position.

The "Boom Power Down" button overrides the float function. When pressed it activates the hydraulic pumps to power the
boom down past the natural limits.

This function is normally used to raise the tracks off the ground.

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Joystick Functions Service Training

C D
A

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Joystick Functions Service Training

Left Joystick

The Stick and Swing functions are both controlled with the left hand control lever.
When moved as shown, the following will occur:

A = Stick Out
B = Stick In
C = Swing Left
D = Swing Right

Releasing the lever will not brake the swing motion, and the superstructure will swing freely when the lever is in the neutral
position. There is a switch operated holding brake that will keep the superstructure stationary, but this must only be applied
when all swing motion has completely stopped.

The stick is swung out or in through hydraulic power unlike a face shovel configuration which has a stick float function. When
the control lever is moved this activates the hydraulic pumps which then supply the power required to extend and retract the
stick cylinders.

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Joystick Functions Service Training

B A

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Pedal Functions Service Training

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