CAT 6060 - Service Training

01.
Introduction
02. Undercarriage
03. Superstructure
Hydraulic Mining Excavator 04. Engine and Pump Drive
05. Pumps , Tank and Drive Controller
CAT 6060 06. Servo System
07. Travel System
08. Attachment Functions
09. Hydraulic Cooling
00. Contents 10. Swing System
11. Pressure Check and Setting
12. Cylinders
13. Central Lube System
Dixio Torrez - 2012 14. E-Schematic
15. Legend Hydraulic Schematic
CAT 6060 - Product Training Service Training
Day 1 Day 2 Day 3 Day 4 Day 5
Engine +
Introduction Travel system Swing System Central Lube System
Pump Drive
Break Break Break Break Break
E-Schematic and
Pumps , Tank and Drive Pressure Check and
Undercarriage Attachment functions Legend Hydraulic
Controller Setting
Schematic
Break Break Break Break Break
Superstructure Servo Systems Hydraulic Oil cooling Cylinders On the machine
2
CAT 6060 - Product Training Service Training
This training material has been designed for training purposes only. It contains general product information with
no guarantee of completeness of e.g. drawings or figures. It is not updated automatically.
Dedicated information is to be found on the following web pages: www.bucyrus-hex.com
The aims are to provide the participant with a level of instruction on the CAT 6060 Excavator to give an
understanding of functionality and complexity.
Participants completing this course will be able to recognize and describe the CAT 6060, its unique components,
and have a formal understanding of its operation and applications.
 Extinguishers, Emergency Escapes

 Smoking Outside
 Course Times
 Lunch Break
 Hotel + Transportation
 WC Location
 Mobile Phones
 Trade Experience?
 How long to do with CAT 60XX - Hydraulic Excavators?
 Hobbies?
 What would you like to learn during this course?
3
Hydraulic Mining Excavator
CAT 6060
01. Introduction
Dixio Torrez - 2012

Face Shovel Version Service Training
2
Backhoe Version Service Training
2240 kW
3000 HP
34 m³
(1:1)
568 t
3
Backhoe Attachment Service Training
Stick
Cylinder
Mono
Boom
Boom
Cylinder
Stick
Bucket
Cylinder
Bucket
4
Face Shovel Version Service Training
34 m³ 2240 kW
(2:1)
3000 HP
kN
2240 kN
567 t
5
Face Shovel Attachment Service Training
Tri
Power
Boom
Stick Boom
Cylinder Cylinder
Stick
Bucket
Cylinder
Clam
Cylinder
Bucket
6
Basic Components Service Training
Attachment
Superstructure
Undercarriage
7
Main Dimensions Service Training
7,955 mm 8,730 mm
7,700 mm 7,000 mm
8,770
7,600 mm mm
6,760
mm
2,500 2,790
mm mm
1,120 mm
1,400
7,090 mm
mm
9,230 mm 7,000 mm
8
Working Diagram Service Training
9
Working Diagram Service Training
10
Undercarriage Service Training
1. Load Roller
2. Carry Roller
3. Track Frame
4. Final Drive / Sprocket / Travel Motors
5. Idler
6. Track Chain
7. Carbody
2 7
5
4
3
11
Superstructure Layout Service Training
1. Engines CAT / CUMMINS 4 4
2. Gearboxes with Hydraulic Pumps

3
3. Engine Radiators
2 1
4. Hydraulic Oil Coolers
5. Hydraulic Tank
6. Swing Boxes
6 8
7. Rotary Distributor (Swivel Drive)
7 5
8. Travel Valves 9
8
9. Batteries
10. Operators Seat

3
11. BCS Column
2 1
12. Auxiliary Seat
11
12
10
12
Working Pressures Service Training
13
CAT 6060
02. Undercarriage
Dixio Torrez - 2012

Undercarriage Service Training
2
Swing Bearing Service Training
3
4
Rollers and Track Pad Service Training
5
Load Roller Service Training
Roller Journal
Duo Cone Seals
Bush & Thrust Washer
End Cap
6
Load Roller Assembly Service Training
7
Carry Roller Service Training
End Cap
Duo Cone
Seal
8
Undercarriage: Manuel Greasing System Service Training
9
Load Rollers with double Lube System Service Training
0,5bar
10
0,5bar
11
Idler Service Training
12
Idler Wheel Service Training
Idler Wheel
Duo Cone Seals
Axle
Slide
13
Idler Service Training
14
Track Tension System Service Training
15
Drive Unit Service Training
16
Final Drive Service Training
Drive
Sprocket
Oil Level /
Drain Plug
17
Final Drive – Type: F 1300 Service Training
Travel Brake
Sight Glass
18
Travel
Motors
Brake
Chambers
19
2nd
3rd
20
Final Drive – Type: GFT 1300 Service Training
Oil Level
Brake Housing Oil Level
(Plug) Main Gearbox
(Plug)
Oil Level
Pre Chamber
(Sight Glass)
21
22
Brake Release Chanel Brake Disks
23
More Information? Service Training
Hey Fellows,
Please find more Information

in the Technical Handbook!
Caterpillar®
Chapter 4: Undercarriage
24
CAT 6060
03. Superstructure
Dixio Torrez - 2012

2
3
Superstructure Frame Service Training
4
Superstructure Frame – Ready to Ship Service Training
5
Hydraulic Oil Cooler Module Service Training
6
Cabin Interior – CAMP System Service Training
Heating
Switch
7
Cabin Interior – CAMP System Service Training
8
Cabin Interior – BCS CAMP System Service Training
9
Superstructure during Assembly in the Field Service Training
10
Fuel Tanks and Service Lift Service Training
11
Engine Cooling Service Training
12
Pump Layout – LH Side Service Training
13
Rotary Joint and Swing Gearboxes Service Training
14
Swing Gearbox Service Training
15
Swing Gearbox Service Training
Grease Point
16
Swing Brake Service Training
17
Swing Motor Service Training
18
Hey Fellows,

Caterpillar®
Chapter 5: Superstructure
19
CAT 6060
04. Engine and Pump Drive – Caterpillar 3512C
Dixio Torrez - 2012

Engine Module – CAT 3512C Service Training
2
Engine Alternatives Service Training
2x CAT 3512 C 2x QSK 45
Total rated net power 2240 kW 2240 kW

acc. to ISO 3046/1 ; SAE J 1349 3000 HP @ 1800 rpm 3000 HP @ 1800 rpm
Peak torque per engine 7130 Nm 6409 Nm

@ 1500 rpm @ 1500 rpm
Max. altitude without power 3048 m a.s.l. 4267 m a.s.l.

reduction
Specific fuel consumption 212 g kW/h 206 g kW/h
@ 1800 rpm @ 1800 rpm
Fuel consumption
at 60% engine utilization 329 l/h 320 l/h
at 70% engine utilization 384 l/h 373 l/h
Emission certification US EPA CARB, US EPA CARB,

TIER 2 TIER 1
Fuel tank capacity 11160 l 11160 l
3
CAT 3512C – Shovel Setup Service Training
4
CAT 3512C Service Training
5
CAT 3512C – Bucyrus Setup Service Training
6
7
CAT 3512C – CAT Setup Service Training
8
9
CAT 3512C - Engine Mounting Service Training
10
CAT 3512C - Fuel System Service Training
11
Air Intake System - CAT Service Training
12
Engine Cooling System - CAT 3512C Service Training
Coolant
13
Coolant
Coolant
14
15
16
Engine Cooling System – ECM Controlled Service Training
Case Drain
Tank
HP 0-280 bar
17
Engine Cooling System – ECM Controlled Service Training
18
Overview Engine cooling Service Training
Engine Coolant
Temperature
via SAE J1939
50 – 650mA
Intake Manifold
Temperature
via SAE J1939 Drive Controller
Angle Engine cooling Pump

0 – 15°
700
Low Speed level Fan
(Engine Coolant 89°C)
600 (Intake Manifold 56°C)
Controller OutputCurrent (mA)
500
Fan Engine Cooler
400
Engine Coolant
Intake Manifold
300
200
High Speed level Fan

100 (Engine Coolant 99°C)
(Intake Manifold 62°C)
0
-100 -50 0 50 100 150 200
Temperature (°C)
19
Engine Cooling System Service Training
Condition: Engine Temperature below 89°C
Thermostats closed.
Oil pressure from the fan drive pump is sensed on ether side of the flow control valve and with the proportional valve receiving
650mA creating a pressure imbalance across either end of the flow control spool. This allows the spool to overcome the spring and
high pressure oil can pass through into the control piston of the fan drive pump.
As the control piston has a larger area that the bias piston the pump is moved into the de-stroked position.
Oil is still supplied to the fan motor but at a reduced flow rated causing a lower fan speed (200 rpm).
Once through the fan motor it can return to tank.
Condition: Engine Temperature above 99°C
Thermostats fully open.
Now with the proportional valve fully closed the pressure across the flow control valve spool is balanced but the adjustment spring now
moves the spool across and opens the fan drive pump control piston to tank. The bias piston now brings the pump onto maximum
output. The increased flow to the fan motor causes the fan speed to increase. (820 rpm)
Condition: Pressure cutoff activated oil pressure reaches 280 bar
Thermostat fully closed.
If the pressure in the circuit reaches 280 bar the pressure is sensed at the pressure cutoff.
At 280 bar the pressure can overcome the pressure cutoff spring setting and the spool lifts.
High pressure oil enters the control piston which has the larger area and can overcome the bias piston which de-strokes the pump
reducing flow but maintaining pressure at 280 bar.
20
Exhaust System - CAT Service Training
Repair any exhaust leaks and replace all covers which have been fitted to the turbochargers
and mufflers. The covers are fitted to reduce the possibility of ignition of atomized oil from
possible leaks. Do not leave these covers off during machine operation.
21
CAT 3512C and Gearbox Service Training
22
Pump Drive Gearbox Service Training
23
24
25
26
Pre Chamber Lubrication Service Training
New: Version with 2 return hoses!!!
Between each of the pumps and the pump

drive gearbox is the drive chamber.
The drive chamber is filled with oil to
lubricate the pump shaft spline and seals.
The Chambers are now are now flood filled
from a reservoir mounted on the firewall
above the gearboxes.
27
Gearbox Oil Cooling - LH Service Training
28
Gearbox Oil Cooling - RH Service Training
29
Gearbox Oil Cooling - Radiators Service Training
30
Engine Module – “Hydraulic Side” Service Training
31
Pump Assembly - LH Side Service Training
32
Pump Assembly Service Training
Bomba Bomba de Bomba servo

Bomba de de giro lubricación y auxiliar
enfriamiento del pto Bomba servo
carga de 4
giro
3 8
Bombas de
enfriamiento
hidraulico 6
7 Bomba de
lubricación y
Bombas de enfriamiento
giro del pto Bomba
5 Bomba
Bombas servo
servo
principales 2 auxiliar
Bomba para el ventilador de

enfriamiento motor diesel 1
1 4
Bombas de
enfriamiento
hidraulico 2
3
Bomba de
1 carga de
Bombas giro
principales
33
Pump Specifications Service Training
Main Pump A20VS0 520 x 8 Cooling Pump 2 x 2 = 4

Variable Displacement Gear Pump
Swash Plate - Double Pumps KP5-250E
Working Pressure 320/360 bar Working Pressure 65 bar
Operating Speed 1457rpm Operating Speed 1950 RPM
Max. Oil Flow 890 l /min Max. Oil Flow 468 L/min
Swing Charge Pump A10 VO 100 x 2

Swing Pump A4V-G-250 2 x 2 = 4 Variable Displacement.
Variable Displacement, Axial Piston
Bi-Directional Axial Piston Operating Speed 1950 RPM
Working Pressure 360 bar Max Oil Flow 187 l / min
Operating Speed 1950 RPM Working Pressure 45 bar
Max. Oil Flow 337 l / min
Fan Drive, Water Cooling x 2
Variable Displacement
Servo Pumps 2 x 2 = 4 Axial Piston
Kracht Gear Pump Operating Speed 1950 RPM
Working Pressure 80 bar Max. Oil Flow 187 l / min
Operating Speed 1950 RPM Working Pressure 280 bar
Max Oil Flow 2 x 35 l / min
Gear Box Oil Circulation x 2
Kracht Gear Pump
Working Pressure 10 bar
Operating Speed 2308 RPM
Output 12.58 cm3/rev
34
Hey Fellows,

Caterpillar®
Chapter 6: Drive Unit

Chapter 7.4: Pump Gearboxes
35
CAT 6060
05. Tank, Pumps and Drive Controller
Dixio Torrez - 2012

Hydraulic Tank – Open System - Basics Service Training
Return Oil
10 bar Preload Valve
2 bar Bypass Valve
Pump Suction Line
2
Tank Assembly Service Training
2 Level Sensors
3
Tank Housing and Oil Flow Service Training
4
Tank and Pumps Service Training
5
Gearbox Servo
Cooling Pump Auxiliary
Swing
Pump Servo
Pump
Pump
Engine
Fan Drive
Pump
Swing
Charge
Pump
Oil Cooling
Pumps
Main
Pumps
Main
Pumps
6
Filter Block Assembly Service Training
P 3/5
P 4/6
P 1/7
P 2/8
7
Main Pump Assembly Service Training
P8
P7
P6
P5
P4
P3
P2
P1
8
Travel Supply: P3/P5 + P4/P6 Service Training
P3/P5
P4/P6
P1/P7
P2/P8
9
Attachment Main Valves Supply Service Training
P3/P5
P1/P7
P4/P6
P2/P8
Clam (Face Shovel)
10
Main Pump Service Training
Variable Displacement Pump

Nominal Size: 2 X 520 ccm
Pressure Range: 350 / 400 bar
(Specification from Supplier)
11
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
12
Minimum or Maximum Output??? Service Training
0° = Minimum Flow
Variable Displacement: Min. – 446 ccm
13
A4VSO – HD-B - minimum Flow Service Training
X2 X1 (5 bar) XB (+50 bar)
min. max.
P (80 bar) M
14
A4VSO – HD-B - Pump on Flow Service Training
X2 X1 (5-43 bar) XB (+50 bar)
min. max.
P (80 bar) M
15
A4VSO – HD-B - Pressure Cut Off (320 /370 bar) Service Training
X2 X1 (43bar) XB (+50 bar)
min. max.
P (80 bar) M
16
Pump Layout Service Training
Remote Control Valve Pressure Balance Valve Power Controller

(New System: blocked)
Cut-Off Valve
Qmax- Stop
Qmin- Stop
17
Pump Schematic Service Training
XLR - Power Controller Valve

PST - Controller Valve Pressure Balance Valve (New System: blocked)
+ 50 bar
from Solenoid -2Y24 + -2Y27
Cut-Off Valve
Qmin- Stop Control Piston Qmax- Stop

18
Pressure Boost or Not ??? Service Training
Backhoe Machines:
P3 / P4 / P5 / P6 => Travel Pressure Boost (-2Y24) 50 BAR
Face Shovel Maschines:
P3 / P4 / P5 / P6 => Travel Pressure Boost (-2Y24) 50 BAR
P2 / P8 => Clam Pressure Boost (-2Y27) 50 BAR
19
Pressure Check Points Service Training
M7
M8
M5
M6
M4
M3
M2
M1 20
PMS: Basics - LH Engine only Example 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
21
Drive Controller: Basics - LH Engine only Example Service Training
=> XLR Controller blocked

Voltage 24 V
Can Bus Signal 0 - 100 %
HAND / FOOT Temperature Signal
CONTROLLER 150 – 850 mA Current

Servo Controller 5 - 43 bar PMS Pressure
Engine RPM Signal
PST - Proportional Valve
24 Volts
XLR - Proportional Valve
Drive Controller
-3Y1
1/min
H.T.
(80)
P3 P4
Engine W.T.
(100)
P1 P2
22
Tank and Pumps Service Training
23
Servo Control Valves on Assembly Plate Service Training
New Assembly Plate

with Servo Controls.
=> Take Care of setup
of Proportional valves!
Y18 (XLR RH) (rear) Y72 (PST RH) (rear)
Y17 (XLR LH) (front) Y71 (PST LH) (front)
24
Servo Control Valves on Assembly Plate – Depends which Setup! Service Training
-4Y1(XLR RH) (rear)
-3Y1(XLR LH) (front)
25
PST / XLR ….???? WITH THE DRIVE CONTROLLER Service Training
Y18 (CAMP -4Y1) Y17 (CAMP -3Y1)

XLR - RH Main Pumps XLR - LH Main Pumps
Y72 Y71
PST - RH Main Pumps PST - LH Main Pumps
26
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
150 mA
X1 Signal: 5 bar 43 bar

to Main Pumps Min Flow Max. Flow
27
Location and Function of the Drive Controller Service Training
DCS
The _______________________________
-One independent box for each power train
-Controls the engine start/stop function
-Controls the flow of the main pumps
-Controls the hydraulic oil cooling
-Controls automatic rev. Reduction
-Cards collect all machine values (pressures,

contaminations, temperatures,…)
-Boxes are interchangeable
-Send signals to the BCS screen
28
Locations of the Controllers Service Training
Servo Controller
Auxiliary System
Drive Controller LH Drive Controller RH
29
Hey Fellows,

Caterpillar®
Chapter 8.5: Load Limit Regulation
30
CAT 6060
06. Servo System
Dixio Torrez - 2012

Pump Assembly - LH Side Service Training
Gearbox Servo
Swing
Pump Servo
Pump
Pump
Engine
Fan Drive
Pump
Swing
Charge
Pump
Oil Cooling
Pumps
Main
Pumps
Main
Pumps
2
Servo Pump Service Training
3
Pumps for Servo- and Auxiliary Pressure – LH Side Service Training
Servo
Pump
Auxiliary
Pressure
Pump
4
Pumps for Servo- and Auxiliary Pressure – RH Side Service Training
Auxiliary
Pressure
Pump
Servo
Pump
5
Pumps for Servo- and Auxiliary Pressure – RH Side Service Training
From Servo
Pump rh
FromServo
Pump lh
6
Lines to Operators Cab Service Training
7
Lines to Operators Cab Service Training
8
Emergency Lowering System Service Training
-2Y19
9
Servo Schematic Service Training
Servo Pump Servo Pump

RH LH
Emergency
Boom Down
System
Servo / Pilot
Pressure 50 bar
50
-2Y9 -2Y10 -2Y11 -2Y12 -2Y13 -2Y14 -2Y7 -2Y8
-2Y18 Track Tensioning

-2Y1 -2Y2 -2Y3 -2Y4 -2Y5 -2Y6 -2Y5 -2Y5
Pressure 60 / 80 bar
-2Y20
10
50 bar Servo System Service Training
2nd Speed and

Travel Brake Hydraulic Oil
at Travel Motors Cooling System
Rotary Travel Clam

Joint Boost Boost
Main Main
Pumps Pumps
not used
30 bar
Auxiliary Servo
Pressure 50 bar
not used not used
Servo
Pressure 50 bar
to Distributor
Swing
Park
Brake
11
50 bar Servo System Service Training
Swing Auto
Balance Greasing
Valve System
Reduced to
35 bar
Y
XLR - RH Main Pumps
Y
XLR - LH Main Pumps
Y Y
-4Y1
PST - RH Main Pumps
Service Lift
-3Y1
PST - LH Main Pumps
Servo
Pressure 50 bar
from Distributor
12
60 / 80 bar System Service Training
Track
Tensioning
System
Track Tensioning Ladder

Pressure 60 / 80 bar
13
Servo Adjustment Service Training
View from Outside on Cabin Module:

P3 P1
Test points P1 , P3 , P4
50 bar
P4
Prop.
Valves
-2Y18
P1: 60/80 bar (Servo Pump Supply)
P3: 50 bar (Servo Pressure)
-2Y20 P4: 60/80 bar (Track Tensioning)
14
35 bar Adjustment => Check Point P 2 Service Training
-2Y18
50 bar
-2Y18
-2Y20
Users of 35 bar are: -2Y20
• Prop. Valves for Attachment Control Valves

• Prop. Valves for Float Valves (Boom/Stick)
• Prop. Valves for Travel
• Prop. Valves for Swing Balance Valve Displacement
• Emergency Accumulator
15
P3
-2Y18
50 bar
-2Y18
-2Y20
-2Y20 Users of 50 bar are:
• Service Lift
• Swing Brake Solenoid Valve
•Travel Brake Solenoid Valve
• Prop. Valves for Main Pump Governing
• 2nd Speed for Travel System
• Travel and clam Pressure Boost
• Auto Lube System
16
Machine Working
(Attachment / Travel / Idle)
-2Y18
50 bar
P4
-2Y18
-2Y20
-2Y20 Users of 60 bar are:
• Track Tensioning System

• Swing Blocking Valves
60 bar servo to swing blocking valves and p-port on the main

pumps will only be present if the servo pump on the specific
engine is being driven.
17
80 bar Servo Adjustment => Check Point M 1 Service Training
If machine travels for more than 15 sec.:

10 sec after stop travelling,
-2Y20 energized for 5s.
50
bar
-2Y18
-2Y18
-2Y20
-2Y20
Please use the push button to switch

from 60 bar to 80 bar.
Then check / adjust the 80 bar pressure.
Users of 80 bar are:
• Track Tensioning System ( 5s after travelling)

• Service Ladder Pressure increase
18
80 bar Servo Service Training
80 bar servo pressure is only available if the solenoid -2Y20 is energized.

This happens in the following conditions:
1. After travelling for a time longer then 15 sec.:
=> 10 sec. after stop travelling the pressure increases to 80 bar for 5 sec.
2. If the access ladder is not complete lifted:
If the “ladder down” initiator is not switched, because the ladder is not complete lifted up.
(ladder is to heavy to be lifted with only 60 bar in the system)
Note: If the service lift or ladder are not complete lifted, the swing and travel function is not active! (Safety!!!)
19
Servo Valve Assembly – New Layout => #340099 Service Training
Emergency Accumulator Auxiliary Accumulator

Check Point Check Point
for 35 bar Circuit for 50 bar Circuit
35 bar 50 bar
(Nitrogen Charge: 30 bar) (Nitrogen Charge: 40 bar)
-2Y27 Clam Boost -2Y17 Travel Brake

Servo Pressure Proportional Valves for all Controls
Reserve -2Y24 Travel Boost Adjustments Attachment / Travel / Swing
Reserve -2Y22 2nd Speed Track Operator Seat
Tensioning Safety Solenoid
-2X23 Swing Brake Reserve
Solenoid -2Y18
-2Y20
20
Servo Valve Assembly – New Layout => #340099 Service Training
Emergency Boom Down Hydraulic Oil Cooling Proportional Valves

Solenoid (not used if thermostatically controlled!)
Swing Safety Valves
Solenoid Valve Blocks

for various Functions
Proportional Valveblock for all -2Y17 Travel Brake -2Y27 Clam Boost
Attachment / Travel / Swing Controls Pressure Reducing
-2Y24 Travel Boost Reserve
Valve 30 bar
Distributor Block only for Travel Brake -2Y22 2nd Speed Reserve
for Tank and 50 bar Connections Reserve -2Y23 Swing Brake
21
Solenoid Valve Banks Service Training
Travel park brake (Solenoid -2Y17 – (50 bar => reduced to 30 bar)
The travel park brake is spring applied and hydraulically released. The brake is released fully, if we use a pressure of 30 bar.
The solenoid valve -2Y17 is energized and oil flows to the travel park brakes. They are released and held in the released position.
The pressure is reduced to 30 bar to be sure that the brake is open, but 2nd speed should not be active if this valve is energized.
2nd speed travelling (Solenoid -2Y22 – 50 bar)
When the operator shifts the switch in the cab from 'low speed' (turtle) to 'high speed’ (rabbit) the pressure in the line to the travel park brake
and travel motor regulator is increased to 50 bar and the regulators are shifted to low displacement.
The 50 bar overcomes the 30 bar at the shuttle valve [47/1] and the 2nd speed is active.
Swing Park Brake (Solenoid -2Y23 - 50 bar)
The swing park brake is spring applied and hydraulically released. In the de-energised position of solenoid -2Y23, the swing brake is connected to tank.
=> Brakes are applied.
When the swing brake is released, -2Y23 is energised and 50 bar is supplied to the swing brakes, overcoming the spring tension => brakes are released.
Note: You can’t stop the swing movement by using the swing park brake!!! This will occur heavy demolition on the brake disks!
Travel Boost (Solenoid -2Y24 - 50 bar)
The solenoid valve (-2Y24) operates the pressure cut-off valves of main pumps 3 + 5 / 4 + 6 so that the pressure is increased to 320bar + 50bar = 370 bar.
Clam Boost (Solenoid -2Y27 – 50 bar)
The solenoid (-2Y27) operates the pressure cut-off valves of the main pumps 2 + 8, so that the clam pressure is increased to 320bar + 50bar = 370 bar.
22
Controller Set Up Service Training
23
Servo Controller Set Up Service Training
The servo controller is not interchangeable CPU module

with the drive / auxiliary controller.
The servo controller consist of two CPU
modules.
In emergency cases the controller can be
equipped with an I/O module instead of the
second CPU module.
CPU module
24
ICN-V Controller Set Up Service Training
The ICN-V controller is not interchangeable

with the drive / auxiliary or servo controller.
ICN-V module
25
EHSC Service Training
LH RH Clam LH RH
Adr.: 0 Adr.: 1 Adr.: 2 Adr.: 3 Adr.: 4
CAN Bus for operator controls
CPU
module
CPU
CAN Bus to module
Proportional
Drive Controller Valves
BCS
ICN-V
module
26
Joysticks Service Training
Handpiece
Locknut
Actuator
Plate
Spool
Plungers Dust Cover
Address
Adjustment
NB: refer to Operator Handbook for maintenance

of Joystick
27
Pedals Service Training
Address
Adjustment
28
Proportional Valve Block – New Style – Electric Side Service Training
Pressure Relief Valve Pressure Relief Valve

Servo Pressure 60bar Servo Pressure 80bar (test point P4)
Pos. 1.11 in hydraulic schematic. Pos. 1.10 in hydraulic schematic.
User: track Tensioning User: Track Tensioning
Switching Safety Valve

Servo Pressure
-2Y18
-2Y18
-2Y1 -2Y2 -2Y3 -2Y4 -2Y5 -2Y6 -2Y16 -2Y15
Travel Direction
Test point P2
35 bar servo pressure.
-2Y9 -2Y10 -2Y11 -2Y12 -2Y13 -2Y14 -2Y7 -2Y8
-2Y20
Pressure Reducing Valve

Servo Pressure 35bar
Switching Valve Pos. 1.20 in hydraulic schematic.
Track Tensioning User: proportional valves servo control.
-2Y20
Pressure Reducing Valve
Auxiliary Pressure 50bar
Pos. 1.30 in hydraulic schematic.
User: tanklift, Main Pump prop. valves -3Y1 and -4Y1,
travel boost, 2nd travel stage, ladder, balance valve.
29
Proportional Valve Block – Electric Side Service Training
1 2 3 4 5 6 7 8
Bucket BH fill Bucket BH empty Mono BH lower Float Valve Mono Mono BH hoist Stick BH in Swing right BH Swing left BH
Bucket LS fill curl in Bucket LS (curl out) Boom LS lower Float Valve Boom Boom LS hoist Stick LS in Swing right LS Swing left LS
Piston Side BH Rod Side BH Rod Side BH Float Valve BH Piston Side BH Piston Side BH Bal. Valve BH Y1 Bal. Valve BH Y2
Piston Side LS Rod Side LS Rod Side LS Float Valve LS Piston Side LS Rod Side LS Bal. Valve LS Y1 Bal. Valve LS Y2
-2Y1 -2Y2 -2Y3 -2Y4 -2Y5 -2Y6 -2Y16 -2Y15
Attention: -2Y18
-2Y1 -2Y2 -2Y3 -2Y4 -2Y5 -2Y6 -2Y16 -2Y15
On the new style valve block,
the proportional valves are in
the front.
There is only one safety

solenoid (-2Y18) for all
functions.
-2Y9 -2Y10 -2Y11 -2Y12 -2Y13 -2Y14 -2Y7 -2Y8
-2Y20
Travel Direction
1 2 3 4 5 6 7 8
BH no Function BH no Function Travel right backw. Travel right for. Travel left backw. Travel left for. BH no Function Stick BH out
Lip Door LS open Lip Door LS close Travel right backw. Travel right for. Travel left backw. Travel left for. Stick LS Float Valve Stick LS out
BH no Function BH no Function Travel Valve Travel Valve Travel Valve Travel Valve BH no Function Rod Side BH
Rod Side LS Piston Side LS Travel Valve Travel Valve Travel Valve Travel Valve Float Valve LS Piston Side LS.
-2Y9 -2Y10 -2Y11 -2Y12 -2Y13 -2Y14 -2Y7 -2Y8
30
Servo Block Connections – New Style – 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
31
Servo Block Connections – New Style – Hydraulic Side Service Training
Travel Direction View on Hydraulic Side
Backhoe Version
Swing Swing Stick in Boom Boom Boom Bucket Bucket

Left Right Piston Piston Side Float Valve Rod Side Rod Side Piston Side
Side
-2Y15 -2Y16 -2Y5 -2Y4 -2Y3 -2Y2 -2Y1
-2Y6
Stick out Stick Travel Travel Travel Travel Clam Clam

Rod Side Float Valve Left Fwd. Left Rev. Right Fwd. Right Rev. Piston Side Rod Side
-2Y8 -2Y7 -2Y14 -2Y13 -2Y12 -2Y11 -2Y10 -2Y9
32
Servo Assembly Plate Service Training
33
PST / XLR ….???? WITH THE DRIVE CONTROLLER Service Training
Y18 (CAMP -4Y1) Y17 (CAMP -3Y1)

XLR - RH Main Pumps XLR - LH Main Pumps
Y72 Y71
PST - RH Main Pumps PST - LH Main Pumps
34
Main Pump Regulation Service Training
Attention: On the new setup, the prop

valves are combined a different way.
(see picture on further pages)
35
Pump Regulation - LH Side Service Training
36
Pump Regulation - RH Side Service Training
37
80 bar Auxiliary Pressure Service Training
All Main Pumps are

supplied with 80bar
auxiliary pressure as
initial Pressure. LH
Auxiliary
Pump
to Pump No. 3/4
38
Auxiliary Pressure for Main Pumps Service Training
39
Swing Park Brake Connection Service Training
40
Travel Park Brake and 1st Speed Connection (30bar) Service Training
41
Travel Park Brake and 2nd Speed Connection (50bar) Service Training
42
Travel Park Brake and 1st / 2nd Speed Connection Service Training
43
Travel Park Brake and 1st / 2nd Speed Connection – LH Side Service Training
44
Travel Boost for Travel Main Pumps 3/4 and 5/6 Service Training
45
Travel Boost for Clam Main Pumps 2/8 Service Training
46
Lines for Automatic Lubrication System Service Training
47
Hey Fellows,

Caterpillar®
Chapter 8.5.3: Servo System
48
CAT 6060
07. Travel System
Dixio Torrez - 2012

Gearbox Servo
Swing
Pump Servo
Pump
Pump
Engine
Fan Drive
Pump
Swing
Charge
Pump
Oil Cooling
Pumps
Main
Pumps
Main
Pumps
2

Bomba de de giro lubricación y auxiliar Bomba
enfriamiento del pto
carga de 4 servo
giro
3 8
Bombas de
enfriamiento
hidraulico 6
7 Bomba de
lubricación y
giro del pto Bomba
5 Bomba
Bombas servo
servo

1 4
Bombas de
enfriamiento
hidraulico 2
3
Bomba de
1 carga de
Bombas giro
principales
3
Travel Pressure Boost on Main Pumps Service Training
Travel Boost (Solenoid -2Y24 - 50 bar) “DZ”
The solenoid valve (-2Y24) operates the pressure cut-off

valves of the main pumps 3+4 and 5+6, so that the travel
pressure is increased. 320bar + 50bar = 370bar
4
29
P8
P6
P7
P5 P4
P2
P3
P1
5
P3/P5
P4/P6
P1/P7
P2/P8
6
Travel Supply to Undercarriage Service Training
P3/P5
Case Drain
P4/P6
Travel Brake
and 2nd Speed
Secondary
Relief Valve
370 bar
7
Travel Motor Service Training
Operating Pressure = 320 + 50 bar = 370 bar
Displacement Travel Park

Control Piston Brake
45 bar
Flushing Valve
(Cooling)
2nd Speed
Control Valve
1st Speed => 250 cm³ Displacement => High Torque ~1,5 km/h
2nd Speed => 170 cm³ Displacement => Lower Torque ~2,0 km/h
8
2nd Speed
Connectio
n
Flushing Valve
(Cooling)
9
Travel Brake Service Training
Seals
Piston
Springs
Discs
30 / 50 bar Brake Release Pressure
10
Travel Park
Brakes
Flushing Valve
(Cooling)
2nd Speed
Connection
Flushing Valve
(Cooling)
11
Rotary Joint and Main Valves Service Training
Travel Valve
Travel Valve
Retarder
Valve
Retarder
Valve
Anti Cavitation Valves
Rotary Joint
12
Rotary Joint Service Training
Track Tensioning in the front

Undercarriage Greasing
Undercarriage Greasing
Case Drain
+ Leakage Oil Return
Leakage Oil Return
Track Tension 60 / 80 bar
Travel Brake 30 bar

+ 2nd Speed 50 bar
Travel Brake
+ 2nd Speed
(Shuttle Valve!)
Travel 0-370 bar
Travel 0-370 bar

(4 times)
Undercarriage
Greasing
13
Travel Main Valves and Proportional Valves Service Training
Travel
Proportional
Travel Valve Travel Valve Valves
14
Travel Valves Service Training
Stroke: 17mm
Spool
Centering
Springs
15
Case Drain Lines and Retarder Valve Sensing Lines Service Training
Retarder Valve
Sensing Lines
Retarder Valve
Sensing Lines
16
17
CMS Service Training
LH RH Clam LH RH
Adr.: 0 Adr.: 1 Adr.: 2 Adr.: 3 Adr.: 4
CAN Bus for Operator Controls
CPU
module
CPU
CAN Bus to module
Proportional
Drive Controllers Valves
and BCS
ICN-V
module
18
Servo Valve Assembly – New Layout Service Training
Emergency Accumulator Auxiliary Accumulator

Check Point Check Point
for 35 bar Circuit for 50 bar Circuit
35 bar 50 bar
(Nitrogen Charge: 30 bar) (Nitrogen Charge: 40 bar)
-2Y27 Clam Boost -2Y17 Travel Brake

Servo Pressure Proportional Valves for all Controls
Reserve -2Y24 Travel Boost Adjustments Attachment / Travel / Swing
Reserve -2Y22 2nd Speed Track Operator Seat
Tensioning Safety Solenoid
-2X23 Swing Brake Reserve
Solenoid -2Y18
-2Y20
19
Servo Valve Assembly – New Layout Service Training
Emergency Boom Down Hydraulic Oil Cooling Proportional Valves

Solenoid (not used if thermostatically controlled!)
Swing Safety Valves
Solenoid Valve Blocks

for various Functions
Proportional Valveblock for all -2Y17 Travel Brake -2Y27 Clam Boost
Attachment / Travel / Swing Controls Pressure Reducing
-2Y24 Travel Boost Reserve
Valve 30 bar
Distributor Block only for Travel Brake -2Y22 2nd Speed Reserve
for Tank and 50 bar Connections Reserve -2Y23 Swing Brake
20
Travel Solenoid Valves Service Training
Travel park brake (Solenoid -2Y17 – reduced to 30 bar)
The travel park brake is spring applied and hydraulically released.

The brake is released fully, if we use a pressure of 30 bar.
The solenoid valve -2Y17 is energized and oil flows to the travel
park brakes.
They are released and held in the released position.
The pressure is reduced to 30 bar to be sure that the brake is
open, but 2nd speed should not be active if this valve is
-2Y27 Clam Boost energized.
-2Y17 Travel Brake
Reserve
-2Y24 Travel Boost
2nd speed travelling (Solenoid -2Y22 – 50 bar)
Reserve -2Y22 2nd Speed When the operator shifts the switch in the cab from 'low speed'
(turtle) to 'high speed’ (rabbit) the pressure in the line to the travel
-2Y23 Swing Brake Reserve park brake and travel motor regulator is increased to 50 bar and
the regulators are shifted to low displacement.
The 50 bar overcomes the 30 bar at the shuttle valve [47/1] and
the 2nd speed is active.
Travel Boost (Solenoid -2Y24 - 50 bar) “DZ”
The solenoid valve (-2Y24) operates the pressure cut-off valves of

the main pumps, so that the travel pressure is increased.
320bar + 50bar = 370bar
21
Travel Schematic Service Training
R/H Main Control Valve
R/H
Travel
Valve
Secondary
Relief Valves
P3/ P5
Tank
380
Secondary P4/ P6
Relief Valves
L/H
Travel
Valve
L/H Main Control Valve
0 – 370 bar => Travel Pressure Boost

30 / 50 bar (Travel Park Brake and 2nd Speed)
60/80 bar (Track Tensioning)
22
Secondary Relief Valves Service Training
Forward direction. Reverse direction.

RHS cross-over relief valve. LHS cross-over relief valves.
The test point is at the RHS The test point is at the LHS
rear of the block. rear of the block.
Reverse direction. Forward direction.

RHS test point. LHS test point.
The relief valve is at the top The relief valve is at the lower
rear of the block rear of the block.
23
Condition: No Function activated Service Training
TO MAIN CONTROL
VALVE
24
Condition: RH Forward Service Training
92
12
Servo Controller
24 Volt 0 – 650mA 0 – 35 bar
25
Condition: RH Forward Service Training
26
1st Speed Forward Service Training
45 bar
30 bar Servo Pressure (Travel Park Brake released)
Tank
27
2nd Speed Forward Service Training
50 bar Servo Pressure (Travel Park Brake released and 2nd Speed)
Tank
28
Condition: RH Reverse Service Training
Servo Controller
24 Volt 0 – 650mA 0 – 35 bar
29
Condition: RH Reverse Service Training
30
1st Speed Reverse Service Training
45 bar
30 bar Servo Pressure (Travel Park Brake released)
Tank
31
2nd Speed Reverse Service Training
50 bar Servo Pressure (Travel Park Brake released and 2nd Speed)
Tank
32
Condition: Forward Downhill Service Training
33
Retarder Valves Service Training
HP Oil From Main

Pump 0-370 bar
Low Pressure
Return Oil
Restricted
Oil
Retarder OFF Retarder ON
34
Retarder Valves Service Training
Tank
Tank Tank
High Pressure from

Travel Control Valve.
Large Piston (Sleeve)
Spring
Opening for
Leak Oil restricted Travel.
35
Track Tensioning Service Training
36
60 / 80 bar Supply
Track Tension
Cylinder
Tank Return
Shock Relief Valves (330 bar) Accumulator
Isolation Valve
Pilot Operated
check Valves
70 bar
Switching Valve
37
Status 1: System loaded by Servo Pump (60 bar) Service Training
Servo Pump supplies Track

Tensioning System with 60 bar
A A
Y Y
X X
70 bar B B
Servo Pump
330 330
60bar
Nitrogen Charge
Tank
38
Status 2: Pressure build-up during Travelling (<330bar) Service Training
Servo Pump supplies Track

Tensioning System with 60 bar.
Travelling causes Pressure
A A
build-up in the System.
Y Y
X X
70 bar B B
Servo Pump
330 330
60bar
Up to 330 bar
Nitrogen Charge
Tank
39
Status 3: Pressure Release (80 bar for 5 sec.) Service Training

A A
Pressure more than 80 bar can escape to
Y Y the tank over the 80 bar relief valve.
X X
70 bar B B
Servo Pump
330 330
60bar
-2Y20
Up to 330 bar
energized
Nitrogen Charge
Tank
40
-2Y18
50

Y7
80
1.10
-2Y20 60
1.11
2Y20
41
Pilot Operated Check Valve Service Training
42
Hey Fellows,

Caterpillar®
Chapter 8.5.5: Travel System
43
CAT 6060
08. Attachment Functions FS
Dixio Torrez - 2012

RH Joystick Service Training
RH Joystick
Boom Down
(Float)
Horn Boom
(Power)
Down
Bucket Curl Bucket Curl

Close Open
Boom Up
2
LH Joystick Service Training
LH Joystick
Stick
Out
Stick In Spare
(Power)
Swing Swing
Left Right
Stick in
(Float)
3
4

Bomba de de giro lubricación y auxiliar
Bomba
enfriamiento del pto
carga de 4 servo
giro
3 8
Bombas de
enfriamiento
hidraulico 6
7 Bomba de
lubricación y
giro del pto Bomba
5 Bomba
Bombas servo
servo

1 4
Bombas de
enfriamiento
hidraulico 2
3
Bomba de
1 carga de
Bombas giro
principales
5
P8
P7
P6
P5
P4
P3
P2
P1
6
P3/P5
P4/P6
P1/P7
P2/P8
7
Attachment Main Valves Supply Service Training
P3/P5
P1/P7
P4/P6
P2/P8
8
Main Control Valves Service Training
Secondary- and
Anti Cavitation
Valves
Main
Valve
Spool
Load
Check
Valves
9
Attachment Main Valves Service Training
10
Secondary Relief Valves Service Training
11
Secondary Relief Valves with Anti Cavitation Function Service Training
Valve short before opening Valve open due to high pressure Anti cavitation function
12
Anti Cavitation Function Service Training
-0,75 bar * Area
-0,75 bar * Area
=> Valve sleeve will be lifted up
Valve short before opening Anti cavitation function
13
Servo Proportional Valves Service Training
-2Y18
Switch-on Valve
Servo on 1 2 3 4 5 6 7 8
Bucket BH fill Bucket BH empty Mono BH lower Float Valve Mono Mono BH hoist Stick BH in Swing right BH Swing left BH
Bucket LS fill curl in Bucket LS (curl out) Boom LS lower Float Valve Boom Boom LS hoist Stick LS in Swing right LS Swing left LS
Piston Side BH Rod Side BH Rod Side BH Float Valve BH Piston Side BH Piston Side BH Bal. Valve BH Y1 Bal. Valve BH Y2
Piston Side LS Rod Side LS Rod Side LS Float Valve LS Piston Side LS Rod Side LS Bal. Valve LS Y1 Bal. Valve LS Y2
-2Y1 -2Y2 -2Y3 -2Y4 -2Y5 -2Y6 -2Y16 -2Y15
1 2 3 4 5 6 7 8
BH no Function BH no Function Travel right backw. Travel right for. Travel left backw. Travel left for. BH no Function Stick BH out
Lip Door LS open Lip Door LS close Travel right backw. Travel right for. Travel left backw. Travel left for. Stick LS Float Valve Stick LS out
BH no Function BH no Function Travel Valve Travel Valve Travel Valve Travel Valve BH no Function Rod Side BH
Rod Side LS Piston Side LS Travel Valve Travel Valve Travel Valve Travel Valve Float Valve LS Piston Side LS.
-2Y9 -2Y10 -2Y11 -2Y12 -2Y13 -2Y14 -2Y7 -2Y8
-2Y20
Switch-on Valve Track
Tension
14
Main Valves on FS Attachment Service Training
15
P3/P5
P1/P7
P4/P6
P2/P8 Clam
16
17
Main Valves on Attachment – Tank Connections Service Training
18
Main Valves on Attachment – Tank Connections Service Training
19
Condition: Boom Up Service Training
20
21
22
23
24
Condition: Boom Down (Floating) Service Training
Stick
Bucket
Boom
Tank
35 bar Servo
25
35b
26
27
28
29
Condition: Boom Power Down Service Training
30
31
32
33
Condition: Stick Out Service Training
34
35
36
37
Condition: Stick In (Floating) Service Training
38
39
40
41
Only stick cylinders

are activated
Boom cylinders
in float position
42
Condition: Power Stick In Service Training
43
44
45
46
Condition: Bucket Curl Out Service Training
47
48
49
Condition: Bucket Curl In Service Training
50
51
52
Condition: Clam open and Clam close with Clam Boost P2+P8 Service Training
53
Condition: Close Clam Service Training
54
55
56
57
58
Condition: Open Clam Service Training
59
Condition: Open Clam Service Training
60
Clam Valve and Secondary's plus Safety Valve Service Training
P2/P8 to Main Valbe Block 161 / 2
P2/P8
61
Hey Fellows,

Caterpillar®
Chapter 8.5.4: Attachment Functions
62
CAT 6060
09. Hydraulic Oil Cooling
Dixio Torrez - 2012

Pump Assembly LH Service Training
Gearbox Servo
Swing
Pump Servo
Pump
Pump
Engine
Fan Drive
Pump
Swing
Charge
Pump
Oil Cooling
Pumps
1950 RPM
Main
Pumps
Main
Pumps
2
Cooling Pumps and Distributors Service Training
3
Distributors and Radiators Service Training
4
Distributors and Radiators Service Training
5
Cooling System - Thermostatically Controlled Service Training
65 bar
Relief Valve Flow Control Valve
< 40°C > 52°C
Tank
Flow from
Cooling Pumps Anti Cavitation Valve
to Fan Drive Motors

6
Distributor Block - Thermostatically Controlled Service Training
65 bar Relief Valve
Thermostat
Anti Cavitation
Valve
Flow Control
Spool
7
Cooling Schematic – Thermostatically Controlled Service Training
Tank
Thermostat
65 bar Relief
Valves
Flow Control
Spools
Anti
Cavitation
Valves
8
Oil Temperature < 42°C Service Training
Tank
Thermostat
65 bar Relief
Valves
Flow Control
Spools
Fan Drive Motor turns with low RPM

at Oil Temperature less than 40°C. Anti
(Approx. 200 with cold Oil) Cavitation
Valves
9
Oil Temperature > 52°C Service Training
Tank
Hot Oil -
Low Pressure
Thermostat
65 bar Relief
Valves
Fan Drive Motor turns with Anti

approx. 1500 RPM at Oil Temperature Cavitation
more than 52°C. Valves
10
Cooling System - Electronically Controlled Service Training
Rear Oil
Cooler
Distributor
Front Oil
Cooler
Distributor
Block
Proportional Valve 50 bar

Servo
Supply
Proportional Valve
11
Proportional Valves and Distributor Block Service Training
12
Control Specifications Service Training
Hydraulic Oil Cooling
700
Start of Regulation at 40°C
600
500
Current [mA]
400
300
Full Flow at 50°C
200
100
0
0 20 40 60 80 100
Temperatur [°C]
13
Condition: Hydraulic Oil below 40°C Service Training
Tank
65 bar Relief Valve
Thermostat
Flow
Control
Spool
Proportional Valves Anti

-3Y3 + -4Y3 Cavitation
45/1 45/2 Valves
Tank Return Line Circuit Pressure up to 65bar Control Pressure ~ 2 bar
14
Condition: Hydraulic Oil above 52°C Service Training
Tank
Hot Oil -
Low Pressure 65 bar Relief Valve
Flow
Control
Spool
Proportional Valves Anti

-3Y3 + -4Y3 Cavitation
45/1 45/2 Valves
Tank Return Line Circuit Pressure up to 65bar Control Pressure ~ 28 bar
15
Distributor Block Service Training
Signal from
Proportional Valve
Flow Control Valve
65 bar relief
valve
Tank
Flow from
Cooling Pumps
Anti Cavitation Valve
16
Hey Fellows,

Caterpillar®
Chapter 8.5.8: Hydraulic Oil Cooling System
17
CAT 6060
10. Swing System
Dixio Torrez - 2012

2
3
Swing Park Brake Service Training
Breather
Swing Motor
Disks
Release Pressure
Servo 50 bar
Oil Level
Dip Stick
4
Swing Park Brake Service Training
Swing Brake
Release Solenoid
Valve
– 2Y23
5
Servo Solenoid Valves Service Training
2nd Speed Travel -2Y22
Swing Brake -2Y23
+ 24V
Travel Brake
-2Y17
-321 Ground
Travel Pressure Boost

-2Y24
50 bar Servo
6
Closed Circuit Service Training
Swing Pump
A
B
A B
x1 x2
Neutral Position
Swing Motor B
7
Pump Assembly LH Service Training
Gearbox Servo
Swing
Pump Servo
Pump
Pump
Engine
Fan Drive
Pump
Swing
Charge
Pump
Oil Cooling
Pumps
Main
Pumps
Main
Pumps
8
Swing Pump Service Training
Rotary Group
Temperature
Switch
Contamination
Switch
Pressure
Cut-Off
Valve Not used!!!
Shock Relief
Valves 400 bar Swing Charge
Adjustment
9
Swing Pump Service Training
Temperature Switches: LH: -3B14 Contamination: LH: -3B6

92-87 C -3B15 Magnetic Particles -3B7
RH -4B14 RH: -4B6
-4B15 -4B7
Temperature
Contamination Swing
Switch 40 bar
Switch Charge Shock Relief
Pump Valve
+ Filter
Swing Charge
Adjustment
Swing Pump -
Main Pump
Element
Control Piston
10
Swing Motor Service Training
11
Swing Circuit Service Training
12
13
RH Servo
Pump
Swing
Pump 4
Swing
Pump 3
LH Servo
Pump
Swing
Pump 2
Swing
Pump 1
14
Twin Engine Operation – Swing Right Service Training
RH Servo
Pump
Swing
Pump 4
Engine 2
Swing
Pump 3
LH Servo
Pump
Swing
Pump 2
Engine 1
Swing
Pump 1
Tank
15
Single Engine Operatioon (RH) – Swing Right Service Training
RH Servo
Pump
Swing
Pump 4
Engine 2
Swing
Pump 3
LH Servo
Pump
Swing
Pump 2
Engine 1
Swing
Pump 1
Tank
16
Swing Filters Service Training
A A A
(B) (B) (B)
B B B
(A) (A) (A)
17
Swing Blocking Valves Service Training
18
Blocking Valve Service Training
High Pressure from Swing Motors

60 / 80 bar from
particular
“Drive Train”
LH or RH
19
RH Servo
Pump
Swing
Pump 4
Swing
Pump 3
LH Servo
Pump
Swing
Pump 2
Swing
Pump 1
20
Servo System: Swing Control Service Training
21
Swing Balance Valve Service Training
Servo 35 bar
Signal From Joystick 0-23 bar
Swing Pressure Sensing Ports 50 - 368 bar
Adjusting Screw
Ratio = 1:16
Pistons
Spool
Centring Springs
X1 Port Swing Pumps

Tank Return
X2 Port Swing Pumps
22
Swing Balance Valve Service Training
Y1: Joystick izquierdo

Y2: Joystick derecho
Ratio
1 : 16
Y1 Y2
23
Swing System - Balance Service Training
Joystick Signal Swing Left Joystick Signal Swing Right

35 bar
x1 x2
A B
24
Swing System – Swing Left Service Training
Joystick Signal Swing Left 22 bar Joystick Signal Swing Right

35 bar
x1 x2
A B
25
Swing System – Swing Right Service Training
Joystick Signal Swing Left Joystick Signal Swing Right 22 bar

35 bar
x1 x2
A B
26
Swing System – Swing Left – Swing Pressure Increasing Service Training
Joystick Signal Swing Left 22 bar Joystick Signal Swing Right

35 bar
x1 x2
A B
27
Swing Pump Control Service Training
28
Swing Charge System Service Training
29
Flushing System Service Training
30
Flushing Valve Service Training
Orifice
Centering
Spring
31
Flushing Valve Service Training
H.P Leg Swing L.P Leg Swing L.P Leg Swing H.P Leg Swing
Circuit Circuit Circuit Circuit
(Swing L/H) (Swing R/H)
32
Proportional Valves Service Training
50bar
50
Swing Balance
Valve
Ratio = 1:16
Swing
2Y25 2Y26 Swing
Safety
Valve Proportional
Valves.
Swing
Limiting
Relief Valve
23
35bar
33
Swing Circuit: Neutral Service Training
50bar
50
Charge
Swing Tank Pump
2Y25 2Y26
Safety
Valve Swing Pump
35bar
Swing
50 - 368 bar Motor
23 bar Servo
35 bar Servo
Tank
34
Swing Circuit: Swing Left Service Training
50bar
50
Charge
Swing Tank
Pump
2Y25 2Y26
Safety
Valve Swing Pump
35bar
Swing
50 - 368 bar Motor
23 bar Servo
35 bar Servo
Tank
35
Swing Circuit: Swing Right Service Training
50bar
50
Charge
Swing Tank
Pump
2Y25 2Y26
Safety
Valve Swing Pump
35bar
Swing
50 - 368 bar Motor
23 bar Servo
35 bar Servo
Tank
36
Hey Fellows,

Caterpillar®
Chapter 8.5.6: Swing System
37
8.6 PRESSURE CHECKING AND SETTING - BH
8.6 Pressure checking and set- 8.6.1.2 Safety

ting Observe accident prevention
8.6.1 Introduction and safety regulations at all
8.6.1.1 Foreword
times.
The pressure checking and setting
This Technical Handbook (THB) describes the
may only be done by special
pressure checking and setting procedures on the
trained and authorized personnel
excavator ´s hydraulic system.
with the appropriate technical
know-how.
It is valid from RH340B – serial-no. 340 032 The rated pressure relief valve set-
ting must not be modified without
explicit approval by Bucyrus.
The illustrations, descriptions and explanations
reflect the current standard configuration. Some of All personnel carrying out com-
the illustrations can show details that differ from a missioning, operation, inspection,
particular machine, but that does not affect the service and repair must have read
validity of the information given. and understood the operating in-
If any points are nevertheless unclear or seem to structions and in particular the
be incorrect, please contact your local Bucyrus chapter
dealer or your Bucyrus distributing centre. 'Fundamental Safety Instructions'
Further developments and alterations introduced before starting any work.

into the standard series production will be imple- Unauthorized conversions or modi-
mented into later re-prints of the THB. fications of the hydraulic excavator
are forbidden for reasons of safety.
When setting the pressure relief valves the
hydraulic oil temperature has to be higher than Secure the machine and the work-
50°C. ing attachment against inadvertent
and unauthorized starting. Place
working attachment on the ground
in such way as that no movements
can be made when mechanical or
hydraulic connections become
detached.
Tools, hoists, slings, trestles and
other devices must be in a reliable
safe state.
Systems and units (e.g. pipes,
coolers, hydraulic reservoirs,
compressed-air reservoirs) must
be properly depressurized before
being opened.
Protective devices on moving ma-
chine parts may be opened or re-
moved only when the drive unit is
stationary and protected against
inadvertent starting.
RH340B - Diesel - 3720618en - (01) - 04.09 Page 8.6 - 1

8.6.1.3 General
Before recommissioning, all pro-
tective devices must be refitted. The reference numbers used in the text and illus-
trations correspond to those used in the hydraulic
Catwalks on the boom are only to
circuit diagram.
be walked on when the excavator's
working attachment has been
Since the machine is equipped with the BCS-Board
brought into the position required
Control System, most pressures are available on
for checking/settings pressures.
the BCS display. If pressure must be reset, in any
Hydraulic cylinders must be case calibrated gauges have to be used, they have
brought into their end positions to be connected to the relevant test points.
before pressures are checked or
set to ensure that working attach-
ment does not move when pres- Numbering of main pumps
sure is applied.
The 8 main pumps (4 double pumps) are num-
The excavator operator must oper-
bered in travel direction from left to right and from
ate the relevant function gently
front to rear (Fig.1),
(gradual application of pressure)
thus P1/P2 and P3/P4 are driven by the LH en-
and then shift the joystick/pedals
gine, and P5/P6 and P7/P8 are driven by the RH
fully to their end position.
engine.
All Pressure test points on the ex-
cavator have Minimess connec-
tions. Pressure gauges used for Numbering of swing pumps
checking must therefore have cor-
responding fittings. Each drive unit is equipped with 2 swing pumps.
The swing pumps on the LH pump gearbox are
Always connect the Minimess-hose
named SP1 / SP2, the pumps on the RH pump
first to the gauge and then to the
gearbox are named SP3 / SP4 (Fig. 1).
test point on the machine to avoid
spillage of pressurized oil!
Auxiliary pumps (Fig. 1)
The springs in pressure relief
valves must never be tightened - Gear pump for the pilot pressure. (6)
fully to "block". The windings of - Charge pump (7)
the spring are then jammed so that - Hydraulic oil cooling pump (10)
the valve cannot open. - Variable displacement pump for the fan drive
of the engine radiator. (11)
Before setting/resetting a relief
valve (primary or secondary)
loosen the valve insert by approx.
2 turns:
Turning anti-clockwise (loosening)
= lower pressure setting
Turning clockwise (tightening)
= increase pressure setting
To set/reset a pressure relief valve
loosen the counter nut on the valve
insert, set the opening pressure
using the setting crew, and then
tighten the counter nut again.
When checking/setting pressures Fig. 1 642112
the hydraulic oil temperature must
be above 50°C.
Page 8.6 - 2 RH340B - Diesel - 3720618en- (01) - 04.09

8.6.2 Pressure setting
Description Unit RH 340 B

From No. 340 054
Pressure cut-off – main pumps Cylinders bar 320
Travel bar 370
Primary relief for main pumps Cylinders bar 380
Travel bar 380
Secondary relief for Boom cylinders bar 360
Stick cylinders bar 360
Bucket cylinders bar 360
Travel motors bar 380
Main pump control pressure XLR bar 8 – 43
PST bar 8 – 43
P bar 80
Pilot pressure bar 35
Auxiliary pressure 1 bar 50
Swing system – working pressure max. bar 370
Swing system – charge pressure (approx.) bar 50
Swing system – pilot pressure (approx.) bar 23
Travel system – parking brake release pressure bar 30
Fan drive - pressure Hydraulic oil cooling bar 65
Engine cooling bar 280
Track tensioning system Change over valve bar 70
pre-charge pressure of hy- Pilot pressure system - emer- bar (N2) 30

draulic accumulator gency lowering
pre-charge pressure of hy- Auxiliary pressure 2 bar (N2) 50
draulic accumulator
pre-charge pressure of hy- Ladder bar (N2) 65
draulic accumulator
pre-charge pressure of hy- Track tensioning system bar (N2) 55
draulic accumulator
Table 1

8.6.3 Tools
For pressure checking and setting the tools listed in table 2 are required.
Fig. 2 630640
Item Quantity Designation Part-No.
1 2 Test kit with gauges and hoses 1 476 323

2 1 Test adapter for proportional valve 1 433 919
3 1 Multimeter 1 088 932
4 1 O/E-ring spanner, 10 mm 0 717 903
9 1 Allan Key, 3 mm 0 014 122
10 1 Allan Key, 4 mm 0 014 123
11 1 Allan Key, 5 mm 0 014 124
12 1 Allan Key, 6 mm 0 014 125
13 1 Accumulator test and charging device 1 438 546
---- 1 Adapter for nitrogen cylinder (see chapter 3.2 in THB)
Table 2

8.6.4 Hydraulic circuits

The locations of the valves on the machine are
In table 3 the various valves are listed which are shown in fig. 3 to 5.
used for the pressure setting of the different hy-
draulic circuits.
Section Figure Valve function

A 3 Primary relief valves
B 3 Pump support pressure for main pumps 1 - 4
C 3 Pump support pressure for main pumps 5 - 8
D 3 Pressure limiting for the pilot pressure system „swing“
E 3 Flushing valve for swing system
F 3 Swing balance valve
G 3 Proportional valves (pump regulation)
H 4 Pilot pressure limiting
Auxiliary pressure 1 limiting
J 5 Pressure limiting for L.H. charge pump, swing system
K 5 Pressure limiting for R.H. charge pump, swing system
Table 3
Fig. 3 642113
The primary relief valves for main pumps P 1 to P8

are located on top of the HP-Filter block in front of
the Hydraulic tank. (Fig. 3).

Fig. 4 642114
Fig. 5 642115

8.6.4.1 Pilot pressure system

Layout and function of the pilot pressure system is
described in chapter 8.5.3.
Since the delivered oil from the pilot pressure

pumps has to be adjusted to the different pres-
sures required of the various auxiliary systems, it is
recommendable to adjust all involved valves lo-
cated in the central control valve block (1.10; 1.11;
1.20 and 1.30, Fig. 6) together in the sequence as
mentioned below.
Pressure checking and setting

Ladder (Option) must be in the upper position
Fig. 7 642116
Auxiliary pressure 3 of 80 bar
1. Connect pressure gauges to test points M1
(range up to 150 bar, Fig. 7), M2 and M3
(range up to 60 bar, Fig. 8 & 9) for the pilot
pressure system.
2. Start the both engines and let them run with

maximum speed.
3. Activate service switch S31 (Fig. 4) and check

the pressure at test point M1,
required value: 80 bar. If necessary adjust
valve 1.10.
Auxiliary pressure 2 of 60 bar

4. With service switch S31 (Fig. 4) deactivated,
check the pressure at test point M1, Fig. 8 642117
valve 1.11.
Pilot pressure of 35 bar
Auxiliary pressure 1 of 50 bar 6. With service switch S31 (Fig. 4) deactivated,
5. With service switch S31 (Fig. 4) deactivated, check the pressure at test point M2,
check the pressure at test point M3, required value: 35 bar. If necessary adjust
required value: 50 bar. If necessary adjust valve 1.20.
valve 1.30.
Fig. 6 642051 Fig. 9 642052

Pump support pressure of main pumps 1 - 4

7. Connect a pressure gauge to test point M4.
(range up to 150 bar, Fig. 10)
8. With service switch S31 (Fig. 4) activated,

check the pressure at test point M4,
valve 51.1 (Fig. 10).
Pump support pressure of main pumps 5 - 8

9. Connect a pressure gauge to test point M5.
(range up to 150 bar, Fig. 10)
10. With service switch S31 (Fig. 4) activated,

required value: 80 bar. If necessary adjust Fig. 12 642120
valve 51.2 (Fig. 10).
Note:
The pilot pressure of 35 bar is used for the follow-

ing functions:
- Supply of the proportional valves to control the

work functions.
- Displacement of the swing balance valve (Y1 /
Y2).
The auxiliary pressure 1 of 50 bar is used for the

following functions:
Fig. 10 642118
- Servicelift
Travel brake release pressure - Pressure increase of the main pumps for trav-
11. Connect a pressure gauge to test point M6. eling
(range up to 60 bar, Fig. 12) - Travel motor speed control (2. travel speed)
- Releasing the swing parking brake.
12. With toggle switch S27 (Fig. 11) activated, - Supply of the swing balance valve.
required value: 30 bar. If necessary adjust The auxiliary pressure 2 of 60 bar is used for the
valve 53 (Fig. 12). following functions:
- Track tensioning system.

- Activation of the „swing blocking valve“.
- Grease pump of the „central greasing system“
The auxiliary pressure 3 of 80 bar is used for the

following functions:
- Pressure relief of the track tensioning system

after traveling.
- Pressure increase to lift the ladder.
Fig. 11 642119

8.6.4.2 Load limit system (PMS) 3. Check pressure.

Both gauges must indicate approx. 8 bar
Layout and function of the load limit system is de-
(225 mA).
scribed in chapter 8.5.1.
4. Extend the stick cylinders.
For each engine an electronic load limit system is
installed.
5. Check pressure (Stick cylinders are in end-
The current from the electronic load limit system is
position; pressure cut-off in function):
converted into hydraulic pressure by proportional
valves (23.1 / Y71 & 23.2 / Y17, Fig. 13) and
(820 mA).
(23.3 /Y72 & 23.4 / Y18, Fig. 14).
Checking the load limit pressure for the RH
 The proportional valves, which are linked to the drive unit:
load limit system of the LH engine, are deliver-
ing pressure signals to the governor of main 1. Connect gauges (range 60 bar) to the test
pumps P1/P2 & P3/P4. points (M, 23.3 & 23.4, Fig. 14).
Valve Y17 is connected to port XLR at the
main pump governors and the pressure level at
is related to the load factor of the engine.
Valve Y71 is connected to port PST at the
main pump governors and the pressure level at
is related to the deflection of the joystick.
 The load limit system of the RH engine is regu-

lating the main pumps P5/P6 & P7/P8 with pro-
portional valves Y18 and Y72.
Fig. 14 642122
2. Run RH engine with maximum speed. The LH

engine has to be shut off.
3. Check pressure.
(225 mA).
Fig. 13 642121 4. Extend the stick cylinders.
Checking the load limit pressure for the LH 5. Check pressure (Stick cylinders are in end-
drive unit: position; pressure cut-off in function):
1. Connect gauges (range 60 bar) to the test (820 mA).
points (M, 23.1 & 23.2, Fig. 13).
2. Run LH engine with maximum speed. The RH In case the required pressures are not achieved
engine has to be shut off. the proportional valves must be checked.

For this checking an adapter (A, Fig. 15) is re-

quired to measure the current (mA) supplied by the
load limit system.
Fig. 15 630782
Connect adapter (A).
Do checks 1 to 5 as described before and measure

the current direct at the terminals of the propor-
tional valves 23.1, 23.2, 23.3 and 23.4.
 If the mA-values according to 3 & 5 are not

reached, there is a defect in the load limit cir-
cuit.
 If the mA-values are reached, but not the re-

quired pressure, the proportional valve is defec-
tive and has to be replaced.
Note:
It is also possible to check and read the current
values via the BCS

8.6.4.3 Pressure cut-off system

7. Check and set pressure cut-off valves of the RH
Layout and function of the pressure cut-off system
main pumps P5, P6, P7 & P8 (A, Fig. 18) ac-
is described in chapter 8.5.2.
cordingly with gauge connected to test points
M5, M6, M7 & M8 (Fig. 16).
The pressure cut-off function for the main pumps is
managed by the pressure cut-off valves A (Fig. 17
& 18). They are set to 320 bar and limit thus the
working pressure for the hydraulic cylinders.
When operating the travel system the pressure cut-

off valves are hydraulically adjusted to 370 bar via
a solenoid valve (Y31).
The electronic system of the machine ensures, that
the pressure increase is not operational, when the
attachment is operated at the same time, so that
operation of the hydraulic cylinders with 370 bar is
prevented.
Note:
Fig. 16 642123
As a precondition for the following tests and set-
tings it is essential that all primary- and secondary
valves are correctly adjusted.
Checking and setting
1. Connect 4 gauges (range: 400 bar) to the high

pressure circuits of pumps P1, P2, P3 & P4.
The relevant test points M1, M2, M3 & M4 are
to be found close to the high pressure filter-
housings (Fig. 16 & 17).
2. Start LH engine and bring it to maximum speed.
3. Extend the stick cylinders completely and posi-

tion the attachment on the ground.
Fig. 17 642124
4. Activate function "stick cylinder out" and check
pressure (rated: 320 bar).
If necessary adjust the valve for pump P1, P2,
P3 or P4 (A, Fig. 17).
5. To check the "pressure increase travel" operate

one travel pedal at the time with the attachment
placed on the ground and swing parking brake
applied.
The indicated pressure must then be 370 bar.
The travel parking brake must be

released. Press travel pedal gently
until pressure rise is recognized.
Machine might travel!
Fig. 18 642125
6. Shut of LH engine.

8.6.4.4 Primary relief system

 When a new primary relief valve is installed
Primary pressure relief for the main pumps is con-
screw the adjuster 1 turn out, to avoid pressure
trolled by 4 pressure relief valves. Each valve limits
peaks.
the pressure of two pumps.
The relief valves (PRV) are located on top of the
high pressure filter block (Fig. 20).  Screw the adjuster of the pressure cut-off
valve A at pump P1 & P7 completely in and
then ¼ turn back (Fig. 17 & 18). This is to raise
the set value of this valve above 380 bar.
 Screw the adjuster of the four secondary relief

valves “Bucket cylinder piston side” completely
in and then ¼ turn back (Pos. 3 + 9 + 15 + 21,
Fig. 24 chapter 8.6.4.5). This is to raise the set
value of these valves above 380 bar.
 Activate BCS Test mode. (see chapter

8.6.4.12)
 Start one engine (LH or RH) and bring it to

maximum speed.
Fig. 19 642123  Activate function "bucket fill" until the cylinders

are completely extended.
Test points to check the pump pressure:
 Check pressure (rated 380 bar).
Test Both engines Engine 1 Engine 2 If necessary reset primary relief valve PRV 1/7.
point ON ON ON
Pump pressure: Pump pressure: Pump pressure:
 Reset the four secondary relief valves “Bucket
M1/7 P1 & P7 P1 P7 cylinder piston side” back to 360 bar.
M2/8 P2 & P8 P2 P8
 After setting all secondary relief valves reduce
M3/5 P3 & P5 P3 P5 pressure cut-off valve back to 320 bar.
M4/6 P4 & P6 P4 P6
 After the settings are finished, stop the engine
Table 4 and interrupt the power supply with the key
switch, to deactivate the BCS Test mode.
Setting of PRV 1/7 (330 bar)
1. Connect a gauge (range: 400 bar) to test point

M 1/7. The test point is installed close to the
high pressure filter block (Fig. 19).
2. Start one engine. The other engine must be

switched off. The shovel teeth must be pushed
into the ground and the travel parking brake
must be applied (remove plug connector of so-
lenoid valve Y12), so that travel movements
are avoided during the check. The undercar-
riage has to be positioned with final drives at
the rear. The parking brake "swing" must be
activated to avoid turning of the superstructure.
3. Set primary relief valve of main pumps (P1/7)

Fig. 20 642126
at the high pressure filter block (PRV 1/7 Fig.
20) as follows:

Setting of PRV 2/8 Setting of PRV 3/5
1. Connect a gauge (range: 400 bar) to test point 1. Connect a gauge (range: 400 bar) to test point
M 2/8. The test point is installed close to the M 3/5. The test point is installed close to the
high pressure filter block (Fig. 19). high pressure filter block (Fig. 19).
2. Start one engine. The other engine must be 2. Start one engine. The other engine must be
switched off. The shovel teeth must be pushed switched off. The shovel teeth must be pushed
into the ground and the travel parking brake into the ground and the travel parking brake
must be applied (remove plug connector of so- must be applied (remove plug connector of so-
lenoid valve Y12), so that travel movements lenoid valve Y12), so that travel movements
are avoided during the check. The undercar- are avoided during the check. The undercar-
riage has to be positioned with final drives at riage has to be positioned with final drives at
the rear. The parking brake "swing" must be the rear. The parking brake "swing" must be
activated to avoid turning of the superstructure. activated to avoid turning of the superstructure.
3. Set primary relief valve of main pumps (P2/8) 3. Set primary relief valve of main pumps (P3/5)
at the high pressure filter block (PRV 2/8 Fig. at the high pressure filter block (PRV 3/5 Fig.
20): 20):
 When a new primary relief valve is installed  When a new primary relief valve is installed
screw the adjuster 1 turn out, to avoid pressure screw the adjuster 1 turn out, to avoid pressure
peaks. peaks.
 Screw the adjuster of the pressure cut-off  Screw the adjuster of the pressure cut-off
valve A, at pump P2 & P8 completely in and valve A, at pump P3 & P5 completely in and
then ¼ turn back (Fig. 17 & 18). This is to raise then ¼ turn back (Fig. 17 & 18). This is to raise
the set value of this valve above 380 bar. the set value of this valve above 380 bar.
 Screw the adjuster of the four secondary relief  Screw the adjuster of the four secondary relief
valves “Bucket cylinder piston side” completely valves “Bucket cylinder piston side” completely
in and then ¼ turn back (Pos. 3 + 9 + 15 + 21, in and then ¼ turn back (Pos. 3 + 9 + 15 + 21,
Fig. 24 chapter 8.6.4.5). This is to raise the set Fig. 24 chapter 8.6.4.5). This is to raise the set
value of these valves above 380 bar. value of these valves above 380 bar.
 Activate BCS Test mode. (see chapter  Activate BCS Test mode. (see chapter
8.6.4.12) 8.6.4.12)
 Start one engine (LH or RH) and bring it to  Start one engine (LH or RH) and bring it to
maximum speed. maximum speed.
 Activate function "bucket fill" until the cylinders  Activate function "bucket fill" until the cylinders
are completely extended. are completely extended.
 Check pressure (rated 380 bar).  Check pressure (rated 380 bar).
If necessary reset primary relief valve PRV 2/8 If necessary reset primary relief valve PRV 3/5
 Reset the four secondary relief valves “Bucket  Reset the four secondary relief valves “Bucket
cylinder piston side” back to 360 bar. cylinder piston side” back to 360 bar.
 After setting all secondary relief valves reduce  After setting all secondary relief valves reduce
pressure cut-off valve back to 320 bar. pressure cut-off valve back to 320 bar.
 After the settings are finished, stop the engine  After the settings are finished, stop the engine
and interrupt the power supply with the key and interrupt the power supply with the key
switch, to deactivate the BCS Test mode. switch, to deactivate the BCS Test mode.

Setting of PRV 4/6
1. Connect a gauge (range: 400 bar) to test point

M 4/6. The test point is installed close to the
high pressure filter block (Fig. 19).
2. Start one engine. The other engine must be

switched off. The shovel teeth must be pushed
into the ground and the travel parking brake
must be applied (remove plug connector of so-
lenoid valve Y12), so that travel movements
are avoided during the check. The undercar-
riage has to be positioned with final drives at
the rear. The parking brake "swing" must be
activated to avoid turning of the superstructure.
3. Set primary relief valve of main pumps (P4/6)

at the high pressure filter block (PRV 4/6 Fig.
20):
 When a new primary relief valve is installed
screw the adjuster 1 turn out, to avoid pressure
peaks.
 Screw the adjuster of the pressure cut-off

valve A, at pump P4 & P6 completely in and
then ¼ turn back (Fig. 17 & 18). This is to raise
the set value of this valve above 380 bar.
 Screw the adjuster of the four secondary relief

valves “Bucket cylinder piston side” completely
in and then ¼ turn back (Pos. 3 + 9 + 15 + 21,
Fig. 24 chapter 8.6.4.5). This is to raise the set
value of these valves above 380 bar.
 Activate BCS Test mode. (see chapter

8.6.4.12)
 Start one engine (LH or RH) and bring it to

maximum speed.
 Activate function "bucket fill" until the cylinders

are completely extended.
 Check pressure (rated 380 bar).

If necessary reset primary relief valve PRV 4/6
 Reset the four secondary relief valves “Bucket

cylinder piston side” back to 360 bar.
 After setting all secondary relief valves reduce

pressure cut-off valve back to 320 bar.
 After the settings are finished, stop the engine

and interrupt the power supply with the key
switch, to deactivate the BCS Test mode.

Test points to check the individual pump pressure Checking the pressure difference:
at the inlet and outlet of the HP-filters and to check
the function of the internal check valves. Pump Test point Fig. Test point Fig.
filter inlet filter outlet
1 MP1 21 MP1/1 21
2 MP2 21 MP2/1 22
3 MP3 22 MP3/1 22
4 MP4 22 MP4/1 22
5 MP5 23 MP5/1 23
6 MP6 23 MP6/1 23
7 MP7 21 MP7/1 23
8 MP8 21 MP8/1 23
Table 5
Fig. 21 642127 Checking the check valve function:
Engine 1 Engine 2
ON OFF
MP1 & MP1/1 MP7 & MP7/1
1 0
MP2 & MP2/1 MP8 & MP8/1
1 0
MP3 & MP3/1 MP5 & MP5/1
1 0
MP4 & MP4/1 MP6 & MP6/1
1 0
Table 6
Fig. 22 642128
1 = pressure
0 = no pressure
Engine 1 Engine 2
OFF ON
MP1 & MP1/1 MP7 & MP7/1
0 1
MP2 & MP2/1 MP8 & MP8/1
0 1
MP3 & MP3/1 MP5 & MP5/1
0 1
MP4 & MP4/1 MP6 & MP6/1
0 1
Fig. 23 642129 Table 7

1 = pressure
0 = no pressure

8.6.4.5 Secondary relief system for attachment two valves installed per section i.e. 12 at the A-
side and 12 at the B-side. The 3-spool control
The secondary relief valves (SRV) for the attach-
blocks are located on the boom.
ment are screwed into the 3-spool control blocks
(160, 161,162 & 163, Fig. 24). There are always
Fig. 24 642131
Valve arrangement for backhoe configuration (Fig. 24)
Position Relief valve for Position Relief valve for

1 + 11 + 13 + 23 Boom cylinder – piston side 2 + 12 + 14 + 24 Boom cylinder – rod side*
5 + 7 + 17 + 19 Stick cylinder – piston side 6 + 8 + 18 + 20 Stick cylinder – rod side
3 + 9 + 15 + 21 Bucket cylinder – piston side 4 + 10 + 16 + 22 Bucket cylinder – rod side
Table 8
* Switch off “float” for checking and setting

This pressure check has to be done with only one Example – stick cylinder rod side:
engine running. The pressure cut-off function
should be adjusted over 360 bar on one main Carefully apply pressure to rod side of stick
pump only. The smaller flow rate of one pump cylinders by shifting the joystick smoothly to
only allows a more accurate pressure setting. the end position “Stick OUT”.
Check pressure (rated: 360 bar), when cylin-
Check pressures with LH engine running and main ders are in end-position.
pump (P2) or with RH engine and main pump (P8),
because these pumps supply oil to all cylinders of 6. Because the pair of cylinders is connected via
the attachment. compensating lines and secured by 4 relief
valves, the gauge on the test point always in-
dicates the lowest pressure setting of the 4
valves. Therefore it is possible that, even with
an indicated pressure of 360 bar, one valve is
still set too high.
Therefore reduce pressure setting on 1st valve

of the valve-set to less than 360 bar. Gauge
reading must drop noticeably. Increase pres-
sure setting back up to 360 bar.
7. Set pressure on 2nd, 3rd, and 4th valve in the

same way: Lower it firstly, and than increase
back up to 360 bar.
8. After checking all secondary relief valves re-

Fig. 25 642124 duce pressure cut-off valves back to 320 bar.
To check the valves for 9. After the checks and settings are finished, stop
the engine and interrupt the power supply with
Rod side: retract cylinders fully the key switch, to deactivate the BCS Test
Piston side: extend cylinders fully mode.
Location of the secondary relief valves is shown in
Fig. 24. Valves are also installed on the opposite
side (bottom) of the main control blocks.
Checking and setting (with LH engine)
1. Connect gauge (Range: 400 bar) to test point

M2/8 (Fig. 26).
2. Screw the adjuster of the pressure cut-off

valve AP2 (Fig. 25) of pump (P2) completely in
and then ¼ turn back. This is to raise the pres-
sure above 360 bar (secondary relief setting).
3. Activate BCS Test mode. (see chapter

8.6.4.12)
Fig. 26 642123
4. Start LH engine and bring to maximum speed
5. Check pressures and reset if required

(see table 8).

8.6.4.6 Secondary relief system for travel

Note:
The check of the travel secondary relief valves

should only be carried out in case of travel per-
formance- or temperature problems.
Layout and function of the travel system is de-

The four secondary relief valves (126.1 to 126.4,

Fig. 27) for the travel motors are located in the
undercarriage module.
The valves (126.2 & 126.3) are on the rear side of

Fig. 28 642124
the housing.
Check pressures with LH engine running and main 5. Start LH engine and bring to maximum speed.
pumps (P3 & P4) or with RH engine and main The bucket teeth must be pushed into the
pumps (P5 & P6) ground to brake the machine and to prevent
travel of the machine during the test. The park-
ing brake "swing" must be activated to avoid
turning of the superstructure.
6. Engage the function 'LH travel forward' by

depressing the foot-pedal slowly into the end
position.
Press travel pedal gently until

pressure rise is recognized.
Machine might travel!
7. Check pressure on relief valve (126.1, Fig. 27).

It should be: 380 bar. Re-set the valve if nec-
essary.
Fig. 27 620280a
8. Activate the following functions, one after the
other:
Checking and setting (with LH engine) LH track reverse (valve 126.2)
RH track forwards (valve 126.3)
1. Engage travel parking brakes (remove plug RH track reverse (valve 126.4)
connector of solenoid valve Y12) and lower
working equipment to the ground. and check pressures in the same manner.
2. Activate BCS Test mode. (see chapter 9. After checking all secondary relief valves re-
8.6.4.12) duce pressure cut-off valve back to 320 bar.
3. Connect four 400 bar pressure gauges to the 10. After the checks and settings are finished, stop
check points (M1 to M4, Fig. 27) for the pres- the engine and interrupt the power supply with
sure relief valves. the key switch, to deactivate the BCS Test
mode.
4. Screw the adjuster of the pressure cut-off
valve AP3 & AP4 (Fig. 28) of pumps (P3 & P4)
completely in and then ¼ turn back. This is to
raise the pressure above 380 bar (secondary
relief setting).

8.6.4.7 Swing system

6.3 Pressures are identical:
Layout and function of the swing system is de-
Replace the 400-bar gauges with 60-bar
gauges (more accurate reading).
Do not operate the function 'swing'
1. Place attachment on the ground and block the as this would destroy the gauges!
superstructure (bucket in digging material).
The swing parking brake must be released.
The charge pressure will be indicated. The re-
2. Connect two gauges (range: 400 bar) to the quired value must be 50 bar at full engine RPM.
test points (MX5 & MX6, Fig. 29) of the swing The charge pressure is limited by the pressure cut-
balance valve (105). off valves of the charge pumps.
If the charge pressure differs from 50 bar the pres-
sure cut-off valve (J or K, Fig. 30) of the respective
charge pump (left or right) has to be adjusted.
Fig. 29 642132
3. Start LH engine and run at maximum speed.

Fig.30 642133
4. Check pressure; both gauges must indicate
the same pressure.
Note:
5. Start RH engine and run at maximum speed
In case one charge pressure limiting valve of a
6. Check pressure; both gauges must indicate swing pump is set to low, the required charge pres-
the same pressure. sure for the swing system cannot be reached. In
this case check the charge pressure limiting valves
6.1 If pressures are not equal with one engine in the housings of the swing pumps.
running:
One or both swing pumps are mechanically Adjustments at the pumps may
out of neutral. (Superstructure tries to turn) only be done with the appropriate
Correct the adjustment at the pump regulator. technical knowledge!
6.2 If pressures are not equal with any engine
running:
Swing balance valve (105, Fig. 29) is not ex-
actly in neutral position (not centered; the su-
perstructure tries to turn).
Connect two gauges (range: 60 bar) to the
test points (MX5 & MX6, Fig. 29) of the swing
balance valve (105). Adjust valve with ad-
juster screw (A Fig. 29) until both gauges in-
dicate the same pressure.

7. Check pilot pressure for swing:

 Connect pressure gauge (range: 60 bar) to
test points MY1 and MY2 (Fig. 31) of the
pressure relief valve 109 (Fig. 31).
 Run both engines with maximum speed.
 Activate 'swing left or right' and move joy
stick slowly into the end position.
 Check pressure (rated; 23 bar).
 If necessary adjust pressure relief valve
109 (Fig. 31).
8. To check the high pressure, replace the two

60-bar gauges (MX5 & MX6) at the swing bal-
ance valve 105 (Fig. 29) again with 400-bar
gauges. Fig. 31 642134
9. Activate 'swing right'. Move joy stick slowly into

the end position.
10. Checking pressures: The gauge related to the

high pressure side at the swing balance valve
105 (Fig. 29) must indicate approx. 370 bar;
the low pressure side must indicate approx. 50
bar.
The pilot pressure for the swing balance valve
will be approx. 23 bar at this stage.
The swing high pressure is determined by the
swing balance valve feed pressure (reduced
pilot pressure) and the swing balance valve ra-
tio (1 : 16).
11. Activate 'swing left' and move joy stick slowly

into the end position.
Fig. 32 642110
Now the other gauge must indicate approx.
370 bar on the high pressure side; the second
gauge must indicate approx. 50 bar.
Note: The secondary relief valves of the

swing system (2 valves for each
If the swing pressure varies from the rated swing pump) are set at 400 bar.
pressure (370 bar), the feed pressure must be This setting must not be altered!
checked and if necessary corrected at pres-
sure relief valve 109 (Fig. 31).
For cooling of the closed swing circuit a certain

volume of oil is flushed out by the flushing valve
106 (Fig. 31 & 32) and replaced by the charge
pumps (7).
Adjustment: Space "S" of the adjuster screw of

flushing valve 106 (Fig. 32) has to be 15 mm.

8.6.4.8 Track tensioning system Discharge function

Layout and function of the track tensioning system
5. Connect gauges (range: 150 bar) to test points
is described in chapter 8.5.7.
M-A2 and M-B1 (Fig. 34).
The pressure for the hydraulic track tensioning
6. Start both engines and let them run with ma-
system is taken from the 60-bar auxiliary circuit 2.
ximum speed.
The pressure to discharge the hydraulic track ten-
sioning system is taken from the 80-bar auxiliary
7. Check pressures.
circuit 3.
Rated:
The pilot controlled check valves and the change
At test point M-A2 = 60 bar
over valve, factory set to 70 bar, are located on the
At test point M-B1 = 0 bar
track tensioning valve block (133, Fig. 35).
8. Activate service switch S31 and check the
pressures.
Rated:
At test point M-A2 = 80 bar
Overview:
S31 M-A2 M-B1
OFF 60 bar 0 bar
ON 80 bar 80 bar
Table 9
Note:
If the pressures will not appear as shown in the

Fig. 33 642116 table, the function and setting of the change over
valve (SV, Fig. 34) has to be checked.
To make the switch point of the change over valve
Checking and setting visible, the auxiliary pressure 2 has to be tempo-
Ladder (Option) must be in the upper position rary increased to 70 bar (see chapter 8.6.4.1).
Inlet pressure:
1. Connect gauge (range: 150 bar) to test point

M1 (Fig. 33).

ximum speed.
3. Check pressure.
Rated: 60 bar;
If necessary adjust auxiliary pressure 2 (see
chapter 8.6.4.1).
4. Activate service switch S31 and check the

pressure at test point M1. Fig. 34 642062
Rated: 80 bar;
If necessary adjust auxiliary pressure 3 (see
chapter 8.6.4.1).

Change over pressure (70 bar)
9. Adjust auxiliary pressure 2 to 70 bar (see

chapter 8.6.4.1).
10. Connect gauges (range: 150 bar) to test point-

s M-A2 and M-B1 (Fig. 34).
ximum speed.
12. Check pressures.

There are two possible situations:
a) At test point M-A2 = 70 bar
or Fig. 35 630776a
b) At test point M-A2 = 70 bar
13. If the pressure at test point M-B1 is not 0 bar, Tensioning the tracks
the set screw of the change over valve (SV,
Fig. 34) has to be turned out (ccw) until the Tensioning and slackening the tracks is described
valve switches over to 0 bar. in the operator's manual.
14. Slowly turn in (cw) the set screw of change

over valve (SV, Fig. 34) until the pressure at
test point M-B1 switches over to 70 bar. This
setting has to be secured with the lock nut.
15. Readjust auxiliary pressure 2 to 60 bar (see

chapter 8.6.4.1).
16. Check the discharge function (see chapter

8.6.4.8).
Secondary relief system
The track tensioning system is protected by two

secondary relief valves, which are preset to 330
bar.
These valves are installed in the car body (134,

Fig. 35).

8.6.4.9 Hydraulic oil cooling 8.6.4.10 Fan-drive for radiators

Layout and function of the hydraulic oil cooling Layout and function of the fan-drive for radiators is
system is described in chapter 8.5.8. described in chapter 8.5.9.
The hydraulic oil is cooled by two independent The coolant of the engines is cooled by two inde-
cooling circuits. pendent cooling circuits.
Each circuit is related to one engine. Each circuit is related to one engine.
The two cooling pumps on the LH engine drive the
two front fan motors. The two cooling pumps on Fig. 37 is showing fan pump (11) with flanged on
the RH engine drive the two rear fan motors. proportional valve and its coil (C).
The fan speed is electronically controlled and var-
ies in relation to the hydraulic oil temperature.
Fig. 36 is showing the distributor block of one cool-

ing circuit which is protected by two pressure relief
valves (85-a + 85-b, Fig. 36). The circulating pres-
sure can be checked at test points Ma and Mb.
Fig. 37 642106
1. Connect a gauge (range: 400 bar) to the rele-

vant test point at the fan motor.
Fig. 36 620289a
2. Ensure that the coolant temperature is above
Checking and setting 95°C, so that the thermostats are closed com-
pletely.
1. Connect pressure gauges (range: 100 bar) to
the relevant test points at the distributor block 3. Check pressure.
of the cooling circuit to be checked.
With a temperature of the coolant of approx.
2. Ensure, that the hydraulic oil temperature is 98° C the pressure at the fan motor is approx.
above 52°C, so that the fan motors are run- 200 bar.
ning with maximum speed.
3. Check pressure: Pressure cut-off

Circulating pressure should be approx. 55 bar.
Pressure relief The fan pumps are equipped with a pressure cut-
off valve A (Fig. 37), which is set at the factory to
Pressure relief valves (85) are works set to approx. 280 bar.
65 bar. To check, proceed as follows: The adjustment of minimum flow is done at valve B
(Fig. 37). This valve is also set at the factory.
 Set valves to circuiting pressure. To do this,
reduce valve cracking pressure until the circuit-
ing pressure starts to drop.
 Then tighten valve inserts ½ of a turn (cracking

pressure is increased again).

8.6.4.11 Hydraulic accumulators

Layout and function of the hydro-pneumatic accu-
mulators within the hydraulic system is described
in chapter 8.5.3.
Hydraulic accumulators are used in the following

hydraulic systems:
a) In the pilot pressure system, a dia-

phragm accumulator (35, Fig. 38) is used
to ensure, that the attachment can be low-
ered in emergency cases with both en-
gines at standstill.
Gas pre-charge pressure: 30 bar
Fig. 39 642060
b) In the auxiliary pressure system 2, a dia-
phragm accumulator (38, Fig. 38) is used
to compensate pressure drops when vari-
ous consumers are activated at the same
time.
c) In the track tensioning system, one dia-

phragm accumulator (131, Fig. 39) per
crawler is used to compensate pressure
peaks which are produced by external
forces on the tracks.
d) In the hydraulic system of the ladder

(Option), a bladder accumulator (152, Fig.
40) is used to lower the access ladder
when the engines are shut down.
Gas pre-charge pressure: 65 bar Fig. 40 642061
Location of the accumulator below the cab module
Checking and setting:

All hydraulic accumulators installed in the machine
have to be checked at regular intervals and re-
charged if necessary (see Operation and mainte-
nance manual).
For this work, the recommended “charging and
testing unit” should be used. (see chapter 3.2,
THB).
A general procedure how to handle the “charging
and testing unit” is described on the following
pages:
Fig. 38 642135

Charging and testing unit for Charging and testing unit for
diaphragm accumulators bladder accumulators with
adaptor A3
Fig. 43 642065
Fig. 41 642063
Legend, Fig. 43
Legend, Fig. 41 1 = Hydr. accumulator 5 = charging hose
A = Spindle 2 = Adaptor A 6 = Connector
B = Pressure release 3 = Charging and test- 7 = pressure reducer l
C = Check valve ing unit 8 = adaptor
A3 = Adaptor 4 = Connector 9 = nitrogen bottle
Gas valve for diaphragm Gas valve for bladder accu- DESCRIPTION (Charging and testing unit)
accumulators mulators
FUNCTION
The charging and testing unit is used to charge ac-
cumulators with nitrogen or to check or to change the
existing pre-charge pressure in accumulators. For this
purpose the charging and testing unit is screwed onto
the gas valve of the hydraulic accumulator and con-
nected to a commercial nitrogen bottle via a flexible
charging hose. If the nitrogen pressure is only to be
checked or reduced, the charging hose does not
need to be connected. The unit has a screw-type
fitting with a built-in gauge, check valve and a spindle
for opening the accumulator gas valve to control the
pressure. Piston and diaphragm accumulators can be
charged and checked without the need for adaptors.
Bladder accumulators, however, require an adaptor
Fig. 42 642064
A3.
Legend, Fig. 42
S= Protective cap
O= O-Ring
SW6 = Allen key
H= Hexagon cap nut
P= internal hexagon screw
V= Valve

OPERATINGINSTRUCTIONS
INCREASING PRE-CHARGE PRESSURE
PREPARATION Only use nitrogen for charging accumulators.
Prior to each testing, topping-up or re-charging of
Never use oxygen! Danger of ex-
nitrogen, the accumulator must be isolated from the
pressurized system and the fluid released. plosion! If the gas pressure in the
nitrogen bottle is higher than the
a) Releasing the pilot pressure system by max. operating pressure of the
shifting both control levers repeatedly into accumulator, a gas pressure re-
all directions with both engines at stand- ducer must be fitted.
still, emergency switch S211 (attachment
down) activated and the electric system
switched on.  Connect the flexible charging hose to the
b) Releasing the auxiliary pressure system pressure reducer on the nitrogen bottle by
2 by shifting both control levers repeatedly means of the connector (Pos. 6, Fig. 43). For
into all directions with both engines at nitrogen bottles from other countries the ap-
standstill, emergency switch S211 (at- propriate adaptor is required (see chapter 3.2,
tachment down) activated and the electric THB). Connect connector (Pos. 4, Fig. 43) of
system switched on. the charging hose to the check valve C of the
c) Releasing the track tensioning system charging and testing unit. Open the shut-off
by opening the pressure relief valves (134, valve on the nitrogen bottle, and slowly re-
Fig 39) with both engines at standstill. lease nitrogen into the accumulator. Wait until
d) Releasing the hydraulic system of the approximately 1 bar has been reached before
ladder by shifting the control lever (151, opening the shutoff valve of the nitrogen bottle
Fig. 40) repeatedly with both engines at further to enable faster charging.
standstill.
 Interrupt the charging process from time to
Unscrew the protective caps S and H (only on time and check the pre-charge pressure rea-
bladder accumulators). Remove the O-ring O on ched. Repeat this process until the required
bladder accumulators. Slightly loosen the internal gas pre-charge pressure is achieved. After
hexagon screw P on piston and diaphragm accu- temperature equalization has taken place, re-
mulators by means of an Allen key SW 6, DIN 911 check the pre-charge pressure and adjust if
(approx. ½ turn). Place the charging and testing necessary. If the pressure is too high, it can
unit onto the accumulator and screw connector D be lowered via the pressure release B of the
by hand onto accumulator gas valve. At the same charging and testing unit
time, ensure that the release B of the charging and
testing unit is closed. Turn charging and testing  If the required gas pre-charge pressure has
unit to a position where the gauge can be easily been reached, turn the spindle anticlockwise
read. to close the gas valve on bladder accumula-
tors. On piston or diaphragm accumulators
TESTING close the internal hexagon screw P by turning
On bladder accumulators (Charging and testing the spindle clockwise. Discharge the charging
unit with adaptor A3) open valve by turning spindle and testing unit via the pressure release and
A clockwise. remove it by loosening the connector. On
On piston and diaphragm accumulators (Charg- bladder accumulators, unscrew the adaptor
ing and testing unit) open valve V by turning the and replace the O-ring O. On piston and dia-
internal hexagon screw anticlockwise with spindle phragm accumulators, tighten the internal
A. When the needle of the gauge begins to move, hexagon screw P with Allen key [20 Nm].
give the spindle another complete turn. The gauge
now shows the charging pressure in the accumula-  Check for leakages on the accumulator gas
tor. The check valve C prevents any escape of valve using a leak detector spray.
nitrogen.
 Screw on cap nut H (only on bladder accumu-
REDUCING THE PRE-CHARGE PRESSURE lators) and valve protection cap S onto the
Carefully open release B. The nitrogen escapes into gas valve of the accumulator and tighten.
the atmosphere.

WARNING
 Nitrogen and operating fluid can
escape when filling or testing
the accumulator due to a faulty,
i.e. leaking, bladder, diaphragm
or piston seals.
Caution!
Risk to health in the case of
aggressive fluids!
 The check valve C must not be
removed. The valve has a safety
function for the whole charging
and testing unit.

8.6.4.12 BCS Test mode

Layout and function of the BCS-System is de-
scribed in the operation manual.
Certain settings and tests in the hydraulic system

should be performed only with a defined amount of
oil. For this purpose a test mode can be activated
by using the BCS-System, which limits the main
pumps to 30% displacement.
Activation of the test mode
a) Start the engine.
b) Activate button “SERV“.

Fig. 45 642088
c) Select submenu – 9 “SERVICE TEREX“
and confirm with “ENTER“.
d) Enter access code and confirm with

“ENTER“.
e) Select submenu – 9 “CMS CHECK“ and

confirm with “ENTER“.
f) Activate button “HOLD“ => TEST MODE

activated. (i.e. Button Testmode is blinking
green)
Fig. 46 642089
Fig. 44 642087
Fig. 47 642090
Deactivation of the test mode

a) Stop the engine.
b) Switch off key switch (S4) => TEST MODE

deactivated.

CAT 6060
12. Cylinders
Dixio Torrez- 2012

Overview: Cylinders Service Training
FACE
SHOVEL STICK
CYLINDER
BOOM
CYLINDER
STICK
CYLINDER BOOM
CYLINDER
BACK HOE
BUCKET
CYLINDER BUCKET
CYLINDER
CLAM
CYLINDER
2
Examples: Cylinder Head Pieces Service Training
3
Cylinder Head Assembly Service Training
1. Clean all parts.

2. Screw headpiece on cylinder rod until the rod end gets contact (3) 2 1
with the headpiece. If necessary use a small wedge to open the
slot slightly.
3. Unscrew headpiece 15° to 30° to get a bit clearance between
headpiece and rod.
4. Apply Sealing Compound (Sikaflex®) in the slot and on the thread
area between rod and headpiece to avoid moisture enters the thread.
5. Torque bolts for specification in below table in sequence 1 - 2 (3).
Hexagon Bolts Din-EN Dodecagon Bolts

24014 and 24032 O&K Norm
Size Size
Sealing Compound (Sikaflex®)
(3) 2 1
All specifications valid for Bolt quality 10.9
M 195 x 3
4
Cylinder Head Assembly Service Training
1. Clean contact surfaces.

2. Insert dowel pin in head piece.
3. Screw nut on cylinder rod and position
headpiece on rod.
4. Take care of clearance between nut and headpiece.
5. Preassemble bolts.
6. Insert O-ring between headpiece and nut.
7. Torque bolts hand tight and check for similar
clearance all around.
8. Torque bolts in three stages crosswise stage by stage.
9. Cover exposed threads with sealing compound.
Sealing Compound (Sikaflex®)
Clearance: 1,5 – 3mm
Bolt Quality: 10.9 Wrech Size for Dodecagon Bolts!
Size M 14 M 16 M 18 M 20 M 22 M 24x2 M 27x2 M 30x2

Wrench size [mm] 15 19 22 24 27 30 32 36
MA [Nm] 1st Stage 65 110 135 200 225 335 570 850
MA [Nm] 2nd Stage 100 170 210 315 460 580 890 1350
MA [Nm] 3rd Stage 130 215 270 400 550 770 1135 1700
RH 340B Boom Cylinder
5
Assembly Procedure Service Training
6
Rod Seal Types Service Training
Low Pressure Seal High Pressure Seal
Low Pressure Seal High Pressure Seal
7
Seal between Guide and Cylinder Tube Service Training
Support Ring and O-Ring
8
Piston Sealing Service Training
Polyamid slipper ring with pre tension element
9
RH340B – Boom Cylinder Service Training
10
RH340B – Boom Cylinder Service Training
11
RH340B - Stick / Bucket Cylinder (Face Shovel) Service Training
12
RH340B – Stick / Bucket Cylinder Service Training
13
RH340 B – Clam Cylinder Service Training
14
RH340 B – Clam Cylinder Service Training
15
Dampening System - Extending Service Training
16
Dampening System - Retracting Service Training
17
Hey Fellows,

Caterpillar®
Chapter 8.8: Hydraulic Cylinders
18
CAT 6060
13.0 Central Greasing System - Attachment
Dixio Torrez - 2012

280 ltr. Tank Service Training
One single 280 ltr. container is used as the basic version for central greasing system.
Available for machines CAT6018 - CAT6060.
If there is a second 280 ltr. Container mounted, this one is used weather for standby, or for undercarriage greasing.
Available for machines CAT6030 – CAT6060.
Attention: If you want to use the service lift to fill in grease,

please make sure the empty grease drum is removed beforehand.
2
500ltr. Tank Service Training
One single pump for

superstructure and
attachment.
Optional: Second pump

for standby or under-
carriage greasing.
Available for machines

CAT6030.
3
1000ltr. Tank Service Training
One single pump for

superstructure and
attachment.
Optional: Second pump

for standby or under-
carriage greasing.
Available for machines

CAT6040 – CAT6090.
4
How comes the Grease into the Tank??? Service Training
5
Tank with one Pump and 2 Line Control Panel Service Training
Grease Pump Breather Level Indicator

Servo Oil Supply „max“
Level Indicator
Tank
„min“
Grease Tank
Control Panel
Line A
Line B
Grease Filter
From Service Arm
Filter after
Grease Pump
Servo Oil
Filter
Emergency
Grease Nipple
6
Filters Service Training
Breather Filter
(Clean Air can move in and out)
Grease Filter (200µm)
(Refill Line from Service Lift)
Servo Oil Filter (6µm)

Grease Filter (200µm)
with Contamination Switch
(Pump Line to Control Panel)
(Line from 50 bar Servo System
to supply the Greasing System)
7
Level Switches – capacitive digital switches Service Training
brown blue brown blue
-5B15 -5B13
black white
Level - Full Level - Empty
8
Control Panel Service Training
Unloader Valve
2 Line System
-5Y3
On/Off Solenoid
for Grease Pump
2 Line System
-5Y1
Pressure Sensor
2 Line System
-5B6
Grease Pressure Gage

Pressure Servo Oil
Gage
Grease Change Changeover

over Valve Solenoid
-5Y2
Servo Oil
Grease Supply
Grease
Grease from Tank
Grease to Distributors
Grease Pump Return
2 Line System
Tank Return Oil/Grease
Lines 1 / 2 9
-5Y3
-5Y1
-5B6
-5Y2
-5B4
10
Control Panel with second pump Service Training
-5Y1
-5Y5 -5Y3 -5Y4
-5B7 -5B6
-5Y2
-5B4
11
Grease Pump Service Training
Quantity / Speed Pressure

Adjustment Adjustment
Active Oil
Pressure on
Grease Pump
Grease Pump Ratio:

Oil Piston : Grease Piston
6,6 : 1
Example:
Servo Pressure: 48 bar
Max. Grease Pressure:
6,6 x 48 bar = 316.8 bar
12
Greasing System - Break Time Service Training
Grease
Pressure
Grease
Filter
Grease
Pump
Pressure
active
on Pump
-5B6
-5Y3
Unloader Grease
Valve Pressure
Sensor -5Y1
Pump
On /
Changeover Off
Valve Changeover
Solenoid
-5Y2
Line Line
1 2
Servo
Filter
Grease Tank Servo

Pump
Grease
Fill Line
with Filter
13
Grease System – Break Time Service Training
Active in Break Time:
Initiator Line 2 -5B3

Lamp Line 2 -5H24
Initiator Line 1
Initiator Line 2
Additional:
No Grease Pressure
on Sensor -5B6
14
Greasing System - Greasing Line 1 Service Training
Grease
Pressure
Grease
Filter
Grease
Pump
Pressure
-5Y3 active
on Pump
Unloader -5B6
Valve
Grease -5Y1
Pressure Pump
Sensor On / Off
Changeover
Valve Changeover
Solenoid
-5Y2
Line Line
1 2
Servo
Filter
Grease Tank Servo

Pump
Grease
Fill Line
with Filter
15
Service Training
Lube Cycle Line 1
Distributors
Change Over
Valve
Line 1 (B)
Line 2 (A) Initiator 1

vented to Tank
50 bar
Servo Pressure
Sensor -5B6
Hydraulic
Lube Pump
-5Y1 - ON/OFF
Solenoid
-5Y2 - Change
Auxiliary Over Solenoid
BCS
Grease
Container
16
Lube Cycle Line 1 Service Training
Active after completed cycle:

Lamp Line 1 -5H23
Additional:
250 bar Grease Pressure

on Sensor -5B6
17
Grease System – Line 1 Service Training

Lamp Line 1 -5H23
Initiator Line 1
Initiator Line 2
Additional:

on Sensor -5B6
Line 1
18
Greasing System - Greasing Line 2 Service Training
Grease
Pressure
Grease
Filter
Grease
Pump
Pressure
active
-5Y3 on Pump
Unloader -5B6
Valve
Grease -5Y1
Pressure Pump
Sensor On / Off
Changeover
Valve
Changeover
Solenoid
-5Y2
Line Line
1 2
Servo
Filter
Grease Tank Servo

Pump
Grease
Fill Line
with Filter
19
Service Training
Lube cycle line 2
Distributors
Change Over
Valve
Line 1 (B)
vented to Tank
Initiator 2
Line 2 (A)
50 bar
Servo Pressure
Sensor -5B6
Hydraulic
-5Y1 - ON/OFF Lube Pump
Solenoid
-5Y2 - Change
Auxiliary Over Solenoid
BCS
Grease
Container
20
Lube Cycle Line 2 Service Training

Lamp Line 2 -5H24
Additional:

on Sensor -5B6
21
Grease System – Line 2 Service Training

Lamp Line 2 -5H24
Initiator Line 1
Initiator Line 2
Additional:

on Sensor -5B6
Line 1
Line 2
22
Greasing System - Break Time Service Training
Grease
Pressure
Grease
Filter
Grease
Pump
Pressure
active
on Pump
-5B6
-5Y3
Unloader Grease
Valve Pressure
Sensor -5Y1
Pump
On /
Changeover Off
Valve Changeover
Solenoid
-5Y2
Line Line
1 2
Servo
Filter
Grease Tank Servo

Pump
Grease
Fill Line
with Filter
23
Time Adjustment and Grease Cycles Service Training
Adjusted Time (e.g. 1800 sec.)

1800 sec. → → → → → → → → → → → → → → → → → → → → → → → → → → → → → → → → → → → → 0 sec.
Lubrication Time (adjustable from 300sec. to 2400 sec.)
Greasing Line 1 4 sec. Greasing Line 2

Break Time
Greasing Time
If the operator starts the excavator and uses any attachment function, the greasing system also starts to lubricate the machine.
At first line 1, then line 2 is lubricated:
Line 1:
The system is waiting for the indication of a fully lubricated line 1:
 Feedback from the “line 1 initiator” (-5B2) on the stick.
 250 bar pressure signal from the “grease pressure sensor” (-5B6).
Both conditions must be fulfilled before the system stops the lube pump for 4 sec. to allow the pump pressure to decrease.
Then the system switches over from line 1 to line 2, ready to grease line 2.
Line 2:
Then the system is waiting for the indication of a fully lubricated line 2:
 Feedback from the “line 2 initiator” (-5B3) on the stick.
 250 bar pressure signal from the “grease pressure sensor” (-5B6).
Both conditions must be fulfilled before the system stops the lube pump.
The system switches over from line 2 to line 1. => System is ready to grease line 1 again.
Greasing Time:
Time which is necessary to grease both lines.
This time can only be affected by: Temperature, Grease Pump Speed, Grease Type, Amount of Distributers.
Break Time: (Remaining time until the next lube cycle starts)
Remaining time is the result of Lubrication Time minus Greasing Time.
24
Grease System – Easy to expand with an additional Distributor Service Training
Single Dosing
Initiator Line 1
Initiator Line 2
Double Dosing
25
Grease Distributor Service Training
Check Valves Rotary Valve
2 1
Directional Spool
Plugs
Pumping Piston
26
Grease Distributors - Single Greasing - Line 1 Service Training
2 1
27
Grease Distributors - Single Greasing - Line 2 Service Training
2 1
28
Grease Distributors – Double Greasing - Line 1 Service Training
Rotary Valve
2 1
29
Grease Distributors – Double Greasing - Line 2 Service Training
2 1
30
Grease Distributors Service Training
Indicators pins to show

the movement of the spool. Valve Inlet Counter Nut
Closed with a removable brass cap
Double Single
Amount Amount
Double Single
Amount Amount
This side (with the directional valves)

is always mounted to the machine part!
31
Counter Nut
Valve Inlet
Spare part distributers need to be adjusted

to the condition of the original.
They are always delivered in a
“single amount” condition.
Pleas find also a description in the technical
handbook.
32
VSG 4 - Distributor Connection

Lines A+B
VSL 2 - Distributor
33
VSG 8 Distributor with only 2 Outlets Service Training
34
What is shown? …. VSL or VSG??? Service Training
VSG 2 - Distributor VSL 2 - Distributor
35
Distributors Service Training
36
37
38
Distributors and Adjustment Screws Service Training
VSG 8 - Distributor
The distributor spools are machined very precise.

If not really necessary, do not open plugs of spools,
specially not in dirty environment!
If you have to control the movement of the spools,
you have to have a look at the telltale indicators.
For this you have to remove the brass or plexiglas cap.
39
Information Screen Service Training
 Start Page
 Click “Service” Button
 Click the “Greasing System”
 Information Screen opens.
40
Settings Screen Service Training
 Start Page
 Click “Settings” Button => Enter Code
 Click the “Controller” Button
 Click on “Auxiliary Controller”
 Click on “Settings”
 Settings Screen opens.
41
Example: Distributors A-Frame Service Training
42
Example: Distributors Swing Bearing / Greasing Pinion Service Training
43
Example: Distributors Boom (FS) Service Training
44
Example: Distributors on Stick Rear Wall (FS) Service Training
Standard
Version
Initiators
Extended
Version
45
Auxiliary Controller Service Training
I/O module
The auxiliary controller is fully interchangeable

with the drive controller. Only the software
needs to be changed. The hardware set up is
identical.
The auxiliary controllers consist of a CPU
module and an I/O module
CPU module
46
System Monitoring Service Training
Auxiliary Controller
Pressure Sensor -8B6
Proximity Switches -5B2 and -5B3

47
Superstructure Greasing System: Reset Function Service Training
48
Superstructure Greasing System: Reset Function Service Training
Test Cycles
The conditions of greasing (superstructure and undercarriage) in the normal and in the test mode:
As well in the normal mode as in the test mode the following conditions must be given:
 The engine must be in operation.

 The grease drum must not be empty.
 There may not be any fault message.
The functions of the reset button:
Press button: Function:

1 sec resets values and deletes fault messages
2 sec + starts one single greasing cycle (also done upon engine start!)
5 times shortly (within 5 sec) Starts the test mode (3 ongoing greasing cycles)
1 sec Stops the test mode (ongoing greasing cycle continues)
Test mode 1 cycle:
One separate cycle is started and operated by pressing the re-set button for 2 sec.
Test mode 3 cycles:
The test mode is initiated by pressing five times within 5 sec the re-set button. 3 complete grease cycles are run.
The test mode can be stopped by pressing the re-set button for 1 sec during the test mode. The current cycle, however, is finished.
(The number of the cycles to be run during the test mode is pre-set in the Auxiliary controller.)
49
Superstructure Greasing System: Fault Messages Service Training
Fault messages (and switch-off of the grease pump) in the superstructure:
 When pressure exceeding 350bar is built up.

 After 2 min. each if one of the two initiators does not switch over
 After 4 minutes, if the pressure of 250 bar can not be reached in one main line.
Fault messages can only be deleted by pressing the reset button (1 sec).
The fault message is suppressed 3 min after starting the engine (i.e. during the first greasing) in order to prevent possible faults
(e.g. a longer greasing because of cold oil or grease)!
Switch-off of the bucket cylinder:
After a fault message persisting during 15 min in the superstructure the bucket switches off.
BCS fault messages (without grease pump being switched off) superstructure:
 When a cable of the pressure sensor is broken
50
Hey Fellows,

Chapter 11.4: Function of Central Lubrication System
51
CAT 6060
13.1 Central Greasing System - Undercarriage
Dixio Torrez - 2012

1000kg Tank Service Training
2
On/Off Solenoid
for Grease Pump
Undercarriage System
-5Y4
Unloader Valve
-5Y5
Grease pressure sensor

-5B7
From Undercarriage
Grease Pump
Servo Oil
Tank Return
Oil / Grease
Grease Supply
Grease Tank Return
3
Grease Pump Service Training
Quantity / Speed Pressure

Adjustment Adjustment
Active Oil
Pressure on
Grease Pump
Grease Pump Ratio:

Oil Piston : Grease Piston
6,6 : 1
Example:
Servo Pressure: 48 bar
Max. Grease Pressure:
6,6 x 48 bar = 316.8 bar
4
1000kg Tank – 2 Pumps Service Training
1000 kg Tank with one Pump and

Superstructure Control Unit.
Additional Pump with

Undercarriage Control Unit.
5
Undercarriage Grease Supply Service Training
From Undercarriage Control Panel
Through the Rotary Joint to the Injectors

6
Undercarriage Greasing – Two Injectors per Roller Service Training
to the Injectors
7
Grease Injectors Service Training
8
Grease Injectors Service Training
I. II. III. IV.

Break Time. Pump Pressure is increasing End of Grease flows from Top
Grease Pump Grease enters the Injector and greasing Process. of Pumping Piston to the
is stopped. Operates the pumping Piston down. measuring Chamber.
Grease is pumped to the Bearing. => Break!
9
0,5bar
10
0,5bar
11
Greasing System Function Service Training
Grease
Grease Pump “ON” Grease Pump “ON”
Pump
Travel
Travel Function “activated”
Function
180
Pump
Pressure
[bar]
50
Unloader Unloader Valve energized “closed” Unloader Valve energized “closed”

Valve
min. 5 s 5s
[Time]
max. 30 s max. 60 s max. 60 s max. 30 s max. 60 s
12
Greasing System Function Service Training
Normal greasing time or duration of a greasing cycle undercarriage:
The complete greasing cycle should take about 10-15 sec.
The conditions of greasing:
As well in the normal mode as in the test mode the following conditions must be given:
• The engine must be running.
• The grease drum must not be empty.
• There must not be any error message.
Fault messages (and switch-off of the grease pump) in the undercarriage:
• No “50bar pressure built up” after start of the pump within 30sec (t2 – t1)
• No “50bar to 180bar pressure built up” within 60sec (t3 – t2)
• No “180bar to 50bar pressure decrease” after switch off the pump within 60sec (t4 – t3)
=>Fault messages can only be deleted by pressing the reset button (for 1 sec).
BCS fault messages (without grease pump being switched off) undercarriage:
• When cable of the pressure sensor is broken.
The functions of the reset button:
Press button: Function:

1 sec resets values and deletes fault messages (also done upon engine start!).
5 sec starts the test mode (15 min).
1 sec stops the test mode.
Test mode undercarriage:
The test mode is initiated by pressing the reset button for 5 sec. The pump operates 15 min. continuously.
The test mode can be stopped by pressing the reset button for 1 sec !
13
Hey Fellows,

Chapter 11.4.3.2 and 11.7:

Central Lubrication System for Undercarriage
14
Hydraulic Mining Excavators
CAMP – Electric System CAT-6060
14. Electrical Drawings
Dixio Torrez - 2012

Electrical Drawings Service Training
The main electrical cabinet on the machine is identified as X1 or Switch Cabinet.

This is located in the cab module.
The second electrical cabinet is located between the engines, behind the hydraulic tank and is identified as the
X10 or Engine Switch Cabinet.
X1 Electrical Cabinet houses the Servo Control System, the Auxiliary System, X1 main terminal strip, and various
relays and circuit breakers.
Machines are fitted with two Drive Control Systems.

One for the left engine and one for the right engine. They mounted by the pumps.
The X10 Electrical Cabinet houses the X10 terminal strip, Battery isolator and several relays and circuit breakers.
2
-X10 Electrical Cabinet
-X1 Electrical Cabinet
3
Switch Cabinet: X1 Service Training
4
Engine Switch Cabinet: X10 Service Training
5
Names and descriptions for components Service Training
6
Names and descriptions – component groups Service Training
Parts related to the

BCS tower belong to Parts not connected to any controller belong to
group number six. Components connected to group number one.
the Servo controller / ICN-V
These are parts like These are parts like the key switch, battery
belong to group number 2.
the BCS screen, FM main switches, working lights etc.
Radio, E.g.: 2K1; 2Y1; 2S4; 2H1
E.g.: 1H3; 1K0.1; 1S3

E.g.: 6A1; 6A2
Components connected to
Components connected the drive controller RH
to the drive controller belong to group number 4.
LH belong to group E.g.: 4K3; 4B9; 4Y3; 4F3
number 3.
E.g.: 3K1; 3B9; 3Y3;
3F9 Components connected to the
auxiliary controller belong to group
number 5.
E.g.: 5B2; 5H23; 5B4; 5K4 7
Names and descriptions Service Training
Names and description for electric components:

E.g.: 2K1
Group number: Identifying number:

Letter from DIN
2 K 1
8
The circuit diagram (current flow diagram) is a representation of the electrical circuits of the machine in all their details.
The diagram shows the way in which the electrical supplies and components are connected, as well as showing their
functions.
The circuit diagram comprises several DIN A 4 sheets arranged in function groups.
All components are shown in the de-energized state (i.e. no current flowing) and without any actuating elements acting.
Symbols used are according to the DIN standards 40 700, 40 703, 40 708 and 40 711 to 40 716.
Each page is divided into columns 0-9 or current paths with a description below each current path.
The power supply always is drawn across the top of the page and earth along the bottom.
Each page has a page number or “Blatt Sheet” located in the bottom right corner. On the bottom left corner is the machine
model that the electrical drawing is applicable to.
9
0 1 2 3 4 5 6 7 8 9
Current Path
RH 120E Blatt Sheet

7
10
Electrical Symbols Service Training
All symbols can be found in the technical handbook Vol.2
A Assembly or group of parts PLC, combinations of devices
B Transformation from non electrical Sensors

into electrical magnitudes and vice
versa.
E Miscellaneous Lights, heaters
F Safety devices Fuses, interlocks, circuit breakers
G Generators, power supplies Alternators, batteries.
H Monitors Warning lights, alarms.
K Relays Relay contacts and coils.
M Motors Starter motors, fan motors.
P Meters Hour meters, clocks
R Resistance's Variable resistors
11
Electrical Symbols Service Training
All symbols can be found in the technical handbook Vol.2
S Switches, Button Switches, Control switches
V Diodes Diodes
X Terminates, plugs, sockets Terminal stripes, isolating plugs/sockets, test sockets.
Y Electrically actuated mechanical

devices. Solenoid valves, proportional valves.
B Sensors Pressure sensors, temperature sensors, contamination sensors
12
Main Rule 1: References Service Training
If electric connections are separated on two different pages references will be used.
A reference can be identified by the arrow symbol:
13
IMPORTANT: The arrow indicates a reference only and NO connection.
Physically on the machine the shown connection of the reference might be a cable of 5cm length.
14
Reference information:
30/ 16.0
Page number and current path where the

reference continues
Reference name
Arrow indicates a reference
15
Main Rule 2: Relays – Different Contact Names Service Training
„Bosch“ type relay „CAT“ type relay
16
Main Rule 2: Relays Service Training
Relays are most of the time separated on two pages: Coil and contacts
17
Below the relay coil you can find the information

about the location of the contact.
11 14
14.1
Information about the relay contact. NO
contact. Contact names are 11 and 14
Page number and current path where the

contact is located
18
Directly below the relay contact you can find the

information about the location of the coil.
-1K10
15.7
Page number and current path where the coil is located

19
Understanding the Electric Symbols Service Training
20
21
22
23
24
Electrical Drawings – Key to Components Service Training
The key to electrical components in the circuit diagram is a systematically arranged list which supplements the circuit
diagram. Its purpose is to locate components both in the circuit diagrams and on the machine itself. It also contains
the components’ Part No’s.
The key is divided into the following columns:

Dev.desig
Amount
Function/ Description
Schematics
Location
Group
Part No.
Dev.desig: This column lists all electrical components alphabetically. The coding letters used designate the type of
component as specified in DIN 40 719.
Amount: States the number of particular component parts on the machine.
Function/ Description: This column states the type of component (e.g.. warning light) and its function (e.g.. hydraulic oil
level “min”).
Schematics: The current path numbers appear at the top edge of the circuit diagram sheets. They are provided to
help in the location of electrical components in the circuit diagrams.
Location: The location is the approximate position on the machine in which the electrical component is installed.
Group: States the Group where you can find this part in the Machine Parts List (e.g. Component 34.502 for the seat)
Part No: This is the Part No. for ordering spare parts. If no Part No. is given, then the part concerned is associated
with the electrical system but is contained in another assembly group. The Part No. must then be determined using
the relevant spare parts sheet.
25
Electrical Drawings – Key to Components Service Training
26
Connection Table Service Training
Connection Table – terminal strip X1

The “Connection tables – terminal strips” show the connections between electrical components. They are exact
illustrations of the terminal strips as fitted in the machine. The key to the circuit diagram gives the exact location of the
various terminal strips.The connection tables make it possible to locate the cable connections of a particular component
without having to “ring through” the cables.
Arrangement of the table:

End points (targets) Type of terminal End points (targets)
Cable cross section Jumpers
Terminal No.
End Point: The end point numbers serve in the location of the contact point of a terminal number. They state the
receiver and its connection point. End point numbers 1 and 2 are at the bottom, 3 and 4 at the top. The cables have
tagged sleeves with the appropriate end point number. This makes re-connection easy (and accurate) after several
cables have been disconnected at the same time (e.g.. during trouble-shooting).
Jumpers: If terminal points need to be extended, the relevant terminals are inter-connected with bridges (jumpers). The
terminal No. is then the same for all bridges terminals. Bridges are indicated by a vertical bar Terminal No: All terminals
on a particular strip are listed here. The numbers are also to be found on the strip (in switch box).
Type of terminal: This column contains the terminal coding used by the manufacturer.
Cable cross section: The cross section of the incoming/outgoing cable.
27
X1 Terminal Strip Service Training
X1
X1
X1
X1
28
X1 Terminal Strip Service Training
29
Connection Table – plug connections X4 & X71
The “Connection table – plug connections” gives the pin and sleeve connections of multi-pole plug connections
End Point – sleeve connections

Ø mm2
No.
End point – pin connections
End Point: This is the number of the end point of the sockets (sleeve connections).
Ø mm2 : The cross section of the incoming/outgoing cable
No: This number is that of the relevant pin or sleeve connection. The numbers are stamped into the plug housing.
End Point: End point no. of the plug (pin connections).
30
31
32
8.3 DESCRIPTION OF THE HYDRAULIC SYSTEM - BH
8.3 Description of the hydraulic system

8.3.1 Technical data
The technical data of the hydraulic system are listed in chapter 2 ‘Technical Data’.
8.3.2 Components of the circuit diagram
The position nos. refer to circuit diagram No. 3 693 430 (00) in chapter 8.3.4
Position Quantity Designation Location

1 2 Engine Engine module
2 2 Pump transfer gearbox Engine module
3 4 Main pump A20VO520 Pump gearbox
4 4 Swing pump A4V 250 Pump gearbox
5 ----
6 4 Servo pump Pump gearbox
7 2 Fan pump A 10 V for radiator fan Pump gearbox
8 ----
9 ----
10 4 Cooling pump KP 5 - 300 Pump gearbox
11 2 Charge pump for swing system Pump gearbox
12 - 22 ----
23 2 Pump governing valve Engine module
24 ----
25 1 Proportional valve plate Operator module
26 2 Solenoid valve bank Operator module
27 ----
28 3 Distributor block Engine module
29 1 Distributor plate (main pumps) Engine module
30 - 33 ----
34 4 Filter Engine module
35 1 Valve block for emergency lowering Operator module
36 1 Filter for proportional valve plate Operator module
37 1 Check valve
38 1 Accumulator for pilot oil Drivers cab module
39 - 44 ----
45 2 Pressure reducing valve
46 ----
RH340B - Diesel (BH) - 3720604en - (00) - 01.08 Page 8.3 - 1


47 1 Shuttle valve
48 – 50 ----
51 2 Pressure relief valve Superstructure
52 – 59 ----
60 1 Hydraulic oil tank Superstructure
61 2 Gate valve Hydraulic oil tank
62 2 Return oil filter Hydraulic oil tank
63 6 Bypass valve Hydraulic oil tank
64 4 Tank line pressurizing valve Hydraulic oil tank
65 - 79 ----
80 4 Hydraulic oil cooler Oil cooler module
81 4 Fan motor Oil cooler module
82 ----
83 ----
84 4 Fan Oil cooler module
85 2 Distributor plate (oil cooling) Oil cooler module
86 - 89 ----
90 1 Travel block Superstructure
91 1 Rotor Superstructure
92 1 Travel valve block RH Rotor
93 1 Travel valve block LH Rotor
94 ----
95 1 Travel retarder valve RH Travel block
96 1 Travel retarder valve LH Travel block
97 4 Anti – cavitation valve Travel block
98 ----
99 ----
100 4 Swing gearbox Superstructure
101 ----
102 4 Swing motor Swing gearbox
103 4 Blocking valve Engine module
104 ----
105 1 Pressure governing valve Engine module
106 1 Flushing valve Engine module
107 2 High pressure filters Superstructure
108 ----
Page 8.3 - 2 RH340B - Diesel (BH) - 3720604en - (00) - 01.08


109 1 Pressure relief valve Engine module
110 - 119 ----
120 2 Travel gearbox Undercarriage
121 4 Travel motor Travel gearbox
122 - 124 ----
125 1 Valve block (secondary relief) Undercarriage
126 4 Pressure relief valve Position 125
127 - 129 ----
130 2 Track tensioning cylinder Undercarriage
131 2 Diaphragm accumulator Undercarriage
132 ----
133 1 Track tensioning group Undercarriage
134 2 Pressure relief valve
135 - 139 ----
140 2 Motor for radiator fan Counterweight
141 2 Block with anti cavitation valve for fan motor Position 140
142 - 144 ----
145 1 Hydraulic cylinder for service lift Superstructure
146 1 Control valve for service lift Superstructure
147 1 Check valve Superstructure
148 ----
149 ----
150 1 Hydraulic cylinder for access ladder
151 1 Control valve for access ladder
152 1 Accumulator for access ladder
153 -159 ----
160 1 3-spool control valve Boom
164 1 Float valve Boom
165 ----
166 ----
167 2 Check valve
168 ----
169 ----


170 4 Throttled check valve Pos. 161 & 164
171 4 Throttled check valve
172 - 181 ----
182 2 Boom cylinder Boom
183 2 Stick cylinder Boom
184 ----
185 2 Bucket cylinder Stick
186 ----
187 ----
188 4 Distributor Boom

8.3.3 Components of the hydraulic Servo pump Pos. 6

system of the RH 340 (BH)
The 4 servo pumps are fixed - displacement gear -
Attention! type pumps that are mounted on the pump transfer
gearboxes (2) and that supply the servo circuit (40
Position nos. are referred to circuit diagram bar) and the auxiliary circuit (70 bar).
Part-No. 3 693 430 (00) in chapter 8.3.4.
Some items are numbered on the schematic

but not mentioned here. They are not important Fan pump A 10 V Pos. 7
for the hydraulic functioning.
The fan wheel for water cooling of the diesel en-
gine is driven by an adjustable axial-piston pump
Drive unit Pos. 1 per drive unit. The volume flow of the pump and
thus the speed of the fan wheel is electronically
The two water - cooled Cummins engines are 12 - controlled as a function of the water temperature.
cylinder „V“ engines with turbo-charging and inter -
cooling.
free Pos. 8
Pump transfer gearbox Pos. 2 free Pos. 9
Each of the 3 - stage spur - wheel gearboxes is Oil cooling pump Pos. 10
driven via a diaphragm coupling from one of the
engines and distributes engine output to the rele- Four fixed - displacement gear - type pumps are
vant hydraulic pumps. mounted onto the swing pumps (4). They con-
stantly draw oil from the tank and pump it to the
fan motors and the oil coolers.
Variable - displacement pump Pos. 3
The 4 main double pumps for working attachment Axial piston pump A 10 V Pos. 11
and travel movements are axial - piston swash
plate pumps with slipper bearing. Slipper bearings The 2 pressure regulated axial piston pumps are
are hydraulically „swimming“ bearings that in- working as charge pumps for the swing circuit.
crease the pump`s service life.
free Pos. 12 - 22
Swing pump Pos. 4
Pump governing valve Pos. 23
The 4 swing pumps to move the superstructure are
variable - displacement axial - piston swash plate The group comprises two proportional valves, two
pumps. They are especially suited for operation in metering connections and a housing.
closed circuits. The pump flow is infinitely variable These valves control the main pumps (3). They are
and increases from „0“ to „max“ while the pump controlled by the microprocessor in the PMS sys-
rotary group is being tilted out. If the swash plate is tem and govern the flows from the main pumps
de-stroked through the „zero“ position, the direc- depending upon the actual pressure. Each pair of
tion of the oil flow is altered smoothly. main pumps is governed by one proportional valve.
The valves are actuated by adjustable, oil - im-
mersed DC solenoids and transform electrical
free Pos. 5 currents proportionally into hydraulic pressure.

A solenoid current of 830 mA corresponds to a The valves are pilot controlled and have variable
pressure of 42 bar in the pump governors. A cur- settings.
rent of 230 mA corresponds to 10 bar.
free Pos. 30 - 33
free Pos. 24
Filter Pos. 34
Proportional valve plate Pos. 25
Filter the oil flows from the 4 swing circuit charge
The valve plate contains the proportional valves pumps.
and the 3/2 way valves for operation of cylinders,
swing and travel function.
Emergency lowering valve Pos. 35

Valve bank, compl. Pos. 26
The valve block consists of a solenoid valve, a
non-return valve and an accumulator. The solenoid
An assembly group comprising four solenoid will be activated by a button on the joystick and
valves and a housing. makes the single lowering down of the equipment
possible if both drive units should not work.
free Pos. 27
Filter Pos. 36
Distributor block Pos. 28
This filter is filtering the oil which is feeding the
2 distributor blocks are connected to the 60 bar proportional valve plate (25).
system. 1 Block is connected to the tank line sys-
tem.
Check valve Pos. 37

Distributor plate for main pumps
Pos. 29 The check valve prevents loss of oil out of the ac-
cumulator (52) for the access ladder.
An assembly group comprising four primary pres-

sure relief valves, eight high - pressure filters and
eight check valves. The check valves isolate the Diaphragm accumulator Pos. 38
main pumps P1 to P4) from the pumps P5 to P8)
when only one engine is running.
This accumulator is compensating pressure drops
The high - pressure filters in the high - pressure in the servo- and auxiliary system when various
lines from the main pumps protect the downline consumers are activated at the same time.
units (e. g. control blocks and cylinders) against
metal chips and particles from the pumps (3).
Other than in the return flow filters (62), the oil free Pos. 39 - 44
flows through the HP filters from outside to in.
The relief valves are used as primary pressure Pressure reducing valve Pos. 45
relief valves for the main pumps. They limit the
maximum pressure that can be reached by the The pressure reducing valve is receiving an elec-
pumps (3) and therefore protect the system trical signal from the Board Control System (BCS).
against overload. The signal is related to the temperature of the hy-

draulic oil. The valves are pressurising the pistons By - pass valve Pos. 63
in the distributor plate (85). The pistons are moved
against springs and control the volume flow and
thus the speed to the fan motors (81). The six by - pass valves open at a pressure of 1.5
bar and prevent the return flow filters (62) bursting,
e. g. due to clogging. Oil then flows unfiltered back
into the tank.
Shuttle valve Pos. 47
Tank line pressurizing valve Pos. 64
The shuttle valve is connecting either the control
pressure for the travel brakes or the control pres-
sure for the 2-speed operation to the travel motors. These four valves have fixed settings of approx. 12
bar. They are arranged in the return lines and keep
a constant level of pressure in the hydraulic sys-
free Pos. 48 - 50 tem.
Pressure relief valve Pos. 51 free Pos. 65
The pressure relief valve is reducing the auxiliary Check valve Pos. 66
pressure supplied by the servo pumps (6) to 80
bar.
These two valves have a cracking pressure of
approx. 1 bar and prevent oil escaping from the
free Pos. 52 - 59 servo caps on control block (161) for boom and
stick „float“ functions (164).
Hydraulic oil tank Pos. 60

free Pos. 67 - 79
The tank stores all of the oil for the system and
contains two return flow filters (62), six by - pass Hydraulic oil cooler Pos. 80
valves (63), four tank line pressurizing valves (64),
a check valve (66) and a pressure switch.
Pass the heat generated in the hydraulic system
on to the atmosphere using the air flows created
by the fans.
Gate valve for intake line Pos. 61
The gate valves can be used to isolate the hydrau- Fan motor Pos. 81
lic pumps from the oil tank. This makes it possible
to remove pumps without having to drain all of the
oil from the tank. Four fixed - displacement gear - type motors are
used to drive the fans on the oil coolers.
Return flow filter Pos. 62 free Pos. 82
Each return flow filter contains 7 filter elements to free Pos. 83

clean the oil returning from inside to out. Any metal
chips are trapped by the magnetic rods installed
above the filters. Fan Pos. 84
The fan produces the air flow to cool down the

hydraulic oil.

Distributor plate for oil cooling Pos. 85 free Pos. 94
Each of the two plates contains two thermostats Travel retarder valve RH Pos. 95
(87), two pressure relief valves (86) and two check
valves. The check valves function as anti - cavita-
tion valves while the engines are being shut down. Prevents the excavator from „running away“ down-
The two pilot controlled, variable setting pressure hill and keeps the track motors full of oil (to avoid
relief valves protect the cooler circuit against over- cavitation). The speed of the track motors is then
pressure, e. g. in case of a line blockage. always determined by the working pressure of the
pumps (3).
free Pos. 86 - 89
Travel retarder valve LH Pos. 96
free Pos. 87 - 89
See travel retarder valve (95).
Travel block Pos. 90
A complete group comprising rotor (91), the Anti - cavitation valve Pos. 97
„Travel“ spools (92 & 93), the travel retarder valves
(95 & 96), anti - cavitation valves (97) and cover
plates. The four valves mounted on the „Travel“ spools
(92 & 93) keep a constant column of oil in the track
motors. They crack open at the slightest pressure
so that oil can be drawn in from the tank line.
Rotor Pos. 91
free Pos. 98
Conducts hydraulic oil flows between superstruc-
ture and undercarriage. The seven ring channels
are for: Swing gearbox Pos. 100
 Travel (4 channels)
The gearbox are 2 - stage planetary reducers.
 Track parking brakes/Track motor adjustment
The spring applied multi disc brakes on the swing
 Track tensioning gearboxes serve to hold the superstructure sta-
tionary (parking brakes). They are actuated by a
toggle switch in the cab.
 Leakage oil
The brake must only be actuated when the super-
structure has stopped swinging.
Travel valve block RH Pos. 92 free Pos. 101

A servo - controlled single - spool block that actu-
ates the right - hand track. Swing motor Pos. 102
The swing motors are 40°, fixed - displacement

axial piston pumps whose output speed is propor-
Travel valve block LH Pos. 93 tional to the flow of oil. The output torque increases
with the pressure drop over the motor.
A servo - controlled single - spool block that actu-
ates the left - hand track.

Blocking valve Pos. 103 Pressure relief valve Pos. 109
These valves are leak free and are opened fully by The valve limits the pressure that controls the
oil from the servo pumps (6) as soon as the en- pressure governing valve (54) to max. 31 bar. The
gines are running. If one of the engines is shut valve is direct acting and has a variable setting.
down, the relevant blocking valves close absolutely
tightly and prevent the stationary engine from be-
ing turned over by pressure oil acting in reverse free Pos. 110 - 119
through swing motor, swing pump and transfer
gearbox.
Travel gearbox Pos. 120
free Pos. 104 3 - stage planetary reducer with integrated parking

brake.
Pressure governing valve Pos. 105 The four track parking brakes are wet, multi - disk
brakes that are engaged under spring force and
released by hydraulic pressure (18 - 20 bar).
Governs the torque in the closed - loop swing cir-
cuit.
The valve governs the pressure and direction of oil Travel motor Pos. 121
flow (and therefore extent and direction of the
swing motors` output ) depending upon the se-
lected control pressure The four track motors are variable - displacement,
The radio between control pressure and working bent - axis motors with tandem bearing arrange-
pressure is approx. 1 : 12, i. e. 10 bar control pres- ments. Servo pressure at port (X) sets the motors
sure on ports (Y 1 or Y 2) corresponds to 120 bar to either of two mechanically limited tilt angles. The
operating pressure in the swing circuit. maximum tilt angle is selected when servo pres-
sure is „O“ . The minimum tilt angle is reached
when servo pressure rises above 40 - 45 bar.
Flushing valve Pos. 106 max. tilt angle = max. motor displacement = max.
output torque = min. output speed
The valve flushes the oil in the closed - loop swing min. tilt angle = min. motor displacement = min.
circuit. Each time a swing function is summoned, a output torque = max. output speed
certain amount of oil is flushed out of the low pres-
sure side. The charge pumps mounted on the The governing pressure (at least 15 bar) is tapped
swing pumps replace this oil with filtered, cooled oil out of the respective high - pressure side using
from the tank. check valves.
free Pos. 122 - 124

High - pressure filter Pos. 107
Secondary relief block Pos. 125
The two HP filters in the swing circuit clean both
sides of the swing circuit. The check valves in the
filter heads lead the oil flows to the correct side to Assembly group comprising four pressure relief
flow through the filters. This is necessary as the valves (77), two metering connections and a hous-
high and low - pressure sections of the circuit ing.
change depending upon the direction of swing.
free Pos. 108

Pressure relief valve Pos. 126 Anti cavitation valve Pos. 141
Secondary pressure relief valves for the four track The check valve acts as an anti-cavitation valve for
motors that protect the motors against external the fan motor when the engine is shut down.
forces. Excess oil is cracked off into the relevant
low pressure side of the motors.
free Pos. 142 – 144
free Pos. 127 - 129
Hydraulic cylinder Pos. 145
Track tensioning cylinder Pos. 130
The double-acting hydraulic cylinder is installed on
the superstructure and moves the service station
Single - acting (plunger) cylinders that keep the up and down.
crawler tracks tensioned.
Hydraulic valve Pos. 146

Diaphragm accumulator Pos. 131
The 3/2 way valve has the function to activate the
The nitrogen accumulators act as shock absorbers cylinder for the service station.
to dampen external forces acting on the crawler
tracks.
Check (non-return) valve Pos. 147

free Pos. 132
The non-return valves are installed to avoid pres-
Track tensioning block Pos. 133 sure loss in the service system.
The block contains the valves for the automatic free Pos. 148 – 149
track tensioning system.
Cylinder for access ladder Pos. 150

Pressure relief valve Pos. 134
The hydraulic cylinder is operating the access
ladder.
The track-tensioning assembly comprises 2 pres-
sure-relief valves with hand wheel and 2 test
points.
The hand wheels can be used to relieve the hy- Control valve Pos. 151
draulic track tension independently for each track.
With the control valve the cylinder for the access

free Pos. 135 - 139 ladder is operated.
Fan motor Pos. 140

Accumulator Pos. 152
The gear motor with anti-cavitation valve is driving
the fans for the radiators. The accumulator supplies pressure oil for emer-
gency lowering of the access ladder in case of a
sudden engine shut-down.

free Pos. 153 - 159 Throttled check valve Pos. 170
3-spool control block Pos. 160 - 163 The check valves in the cylinder lines ensure
smooth operation of the attachment.
The servo controlled 3-spool blocks are operating

the functions ‘Boom’, ‘Stick’ and ‘Bucket’. On to the
valve blocks anti - cavitation valves and pilot con- Throttled check valve Pos. 171
trolled secondary relief valves are flanged.
The check valves in the cylinder lines ensure

free Pos. 162 smooth operation of the attachment.
free Pos. 163 free Pos. 172- 181
Float valve Pos. 164 Boom cylinder Pos. 182
The float valve saves time and energy when lower- The two double-acting hydraulic cylinders are in-
ing the boom. The valve connects the piston and stalled between superstructure and boom. They
rod sides of the cylinders so that the piston rods are lifting or lowering the boom and thus the com-
retract only as a result of the attachment`s own plete working equipment.
dead weight. Only the excess oil (piston - side
chamber has a greater volume than the rod - side)
is allowed to escape to the tank. The main pumps Stick cylinder Pos. 183
(3) are not activated. If it is required to lower the
boom with pressure, the „float“ valves can be
switched off by pressing a button in the RH joy The two double-acting hydraulic cylinders are in-
stick. stalled between boom and stick and ensure exten-
sion and retraction of the arm.
free Pos. 165

free Pos. 184
free Pos. 166
Bucket cylinder Pos. 185
Check valve Pos. 167
The two double-acting hydraulic cylinders are in-
stalled between the linkage of the bucket and the
These two check valves protect the two HP filters stick and are used to turn the bucket.
(32) for main pumps (P 3 & P 4). When the exca-
vator is being run on only one engine, the flows
from the relevant main pumps would run through free Pos. 186
the control blocks (161) and then into the filters in
the wrong direction. This would destroy the filters.
free Pos. 187
free Pos. 168
Distributor Pos. 188
free Pos. 169
The block allows for pressure balance between
both stick cylinders (183) and also between both
bucket cylinders (185).

8.3.4 Hydraulic circuit diagram
The position nos. in the circuit diagram Part-

No. 3 693 430 are referred to chapter 8.3.2.

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01.

Day 1 Day 2 Day 3 Day 4 Day 5

Break Break Break Break Break

Break Break Break Break Break

Superstructure Servo Systems Hydraulic Oil cooling Cylinders On the machine

 Extinguishers, Emergency Escapes

Dixio Torrez - 2012

1. Engines CAT / CUMMINS 4 4

2. Gearboxes with Hydraulic Pumps

10. Operators Seat

Dixio Torrez - 2012

Duo Cone Seals

Bush & Thrust Washer

Duo Cone Seals

Brake Release Chanel Brake Disks

Please find more Information

Dixio Torrez - 2012

Please find more Information

04. Engine and Pump Drive – Caterpillar 3512C

Dixio Torrez - 2012

2x CAT 3512 C 2x QSK 45

Total rated net power 2240 kW 2240 kW

Peak torque per engine 7130 Nm 6409 Nm

Max. altitude without power 3048 m a.s.l. 4267 m a.s.l.

Emission certification US EPA CARB, US EPA CARB,

Angle Engine cooling Pump

High Speed level Fan

Condition: Engine Temperature below 89°C

Condition: Engine Temperature above 99°C

Thermostats fully open.

Condition: Pressure cutoff activated oil pressure reaches 280 bar

Thermostat fully closed.

New: Version with 2 return hoses!!!

Between each of the pumps and the pump

Bomba Bomba de Bomba servo

Bomba para el ventilador de

Main Pump A20VS0 520 x 8 Cooling Pump 2 x 2 = 4

Swing Charge Pump A10 VO 100 x 2

Please find more Information

Chapter 6: Drive Unit

05. Tank, Pumps and Drive Controller

Dixio Torrez - 2012

10 bar Preload Valve

2 bar Bypass Valve

Pump Suction Line

Clam (Face Shovel)

Variable Displacement Pump

Displacement adjusted to 2 X 446 ccm

Variable Displacement: Min. – 446 ccm

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

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

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

Remote Control Valve Pressure Balance Valve Power Controller

XLR - Power Controller Valve

Qmin- Stop Control Piston Qmax- Stop

P3 / P4 / P5 / P6 => Travel Pressure Boost (-2Y24) 50 BAR

Face Shovel Maschines:

P3 / P4 / P5 / P6 => Travel Pressure Boost (-2Y24) 50 BAR

P2 / P8 => Clam Pressure Boost (-2Y27) 50 BAR

Can Bus Signal 0 - 100 %

HAND / FOOT Temperature Signal

CONTROLLER 225 – 820 mA Current

Engine RPM Signal

PST - Proportional Valve