Hydraulic Mining Excavator

CAT 6060

07. Travel System

Dixio Torrez - 2012

Pump Assembly Service Training

Gearbox Servo
Cooling Pump Auxiliary
Swing
Pump Servo
Pump
Pump

Engine
Fan Drive
Pump

Swing
Charge
Pump

Oil Cooling
Pumps

Main
Pumps

Main
Pumps

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Pump Assembly Service Training

Bomba Bomba de Bomba servo

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
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
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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

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Main Pump Assembly Service Training

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P8

P6
P7

P5 P4

P2
P3

P1

5
Travel Supply: P3/P5 + P4/P6 Service Training

P3/P5

P4/P6

P1/P7

P2/P8

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Travel Supply to Undercarriage Service Training

P3/P5

Case Drain
P4/P6

Travel Brake
and 2nd Speed

Secondary
Relief Valve
370 bar

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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
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Travel Motor Service Training

2nd Speed
Connectio
n

Flushing Valve
(Cooling)

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Travel Brake Service Training

Seals

Piston
Springs

Discs

30 / 50 bar Brake Release Pressure

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Travel Motor Service Training

Travel Park
Brakes

Flushing Valve
(Cooling)

2nd Speed
Connection

Flushing Valve
(Cooling)

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Rotary Joint and Main Valves Service Training

Travel Valve

Travel Valve

Retarder
Valve

Retarder
Valve
Anti Cavitation Valves

Rotary Joint

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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

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Travel Main Valves and Proportional Valves Service Training

Travel
Proportional
Travel Valve Travel Valve Valves

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Travel Valves Service Training

Stroke: 17mm

Spool

Centering
Springs

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Case Drain Lines and Retarder Valve Sensing Lines Service Training

Retarder Valve
Sensing Lines

Retarder Valve
Sensing Lines

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Pedals Service Training

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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

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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
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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

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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

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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)
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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.

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Condition: No Function activated Service Training

TO MAIN CONTROL
VALVE

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Condition: RH Forward Service Training

Servo Controller

24 Volt 0 – 650mA 0 – 35 bar

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Condition: RH Forward Service Training

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1st Speed Forward Service Training

45 bar

0 – 370 bar => Travel Pressure Boost

30 bar Servo Pressure (Travel Park Brake released)

Tank

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2nd Speed Forward Service Training

0 – 370 bar => Travel Pressure Boost

50 bar Servo Pressure (Travel Park Brake released and 2nd Speed)

Tank

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Condition: RH Reverse Service Training

Servo Controller

24 Volt 0 – 650mA 0 – 35 bar

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Condition: RH Reverse Service Training

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1st Speed Reverse Service Training

45 bar

0 – 370 bar => Travel Pressure Boost

30 bar Servo Pressure (Travel Park Brake released)

Tank

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2nd Speed Reverse Service Training

0 – 370 bar => Travel Pressure Boost

50 bar Servo Pressure (Travel Park Brake released and 2nd Speed)

Tank

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Condition: Forward Downhill Service Training

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Retarder Valves Service Training

HP Oil From Main

Pump 0-370 bar

Low Pressure
Return Oil

Restricted
Oil

Retarder OFF Retarder ON

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Retarder Valves Service Training

Tank

Tank Tank

High Pressure from

Travel Control Valve.
Large Piston (Sleeve)

Spring

Opening for
Leak Oil restricted Travel.

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Track Tensioning Service Training

36
Track Tensioning Service Training

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
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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

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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

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Status 3: Pressure Release (80 bar for 5 sec.) Service Training

If machine travels for more than 15 sec.:

10 sec after stop travelling,
-2Y20 energized for 5s.
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

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Track Tensioning Service Training

-2Y18

50

If machine travels for more than 15 sec.:

10 sec after stop travelling,

Y7
-2Y20 energized for 5s.

80
1.10

-2Y20 60
1.11

2Y20

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Pilot Operated Check Valve Service Training

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More Information? Service Training

Hey Fellows,

Please find more Information

in the Technical Handbook!
Caterpillar®

Chapter 8.5.5: Travel System

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