Hydraulic Mining Shovel

Cat® 6020B

07. Servo System

Carlos Miragalla – 2018

 Cat® 6020B – Cabin Controls Service Training

(1) Left joystick control lever

4 5 7 8
(2) Right joystick control lever

(3) Switch Not used

(4) Push-button: Not used 3 6

(5) Push-to-speak button (on a radio) or Toggle
between cameras button (if equipped)

(6) Truck counter switch

(7) Horn push-button

(8) Boom power down push button

(9) Left foot pedal

(10) Right foot pedal

(11) Servo activation switch 9 10

1
2

11

2
Cat® 6020B – Servo System ON – OFF Service Training

Servo
enable switch(-2S13)

Servo
Seat contact (-2S1)
3
Cat® 6020B – Joystick Service Training

Handpiece

Locknut

Actuator
Plate

Spool Dust Cover

Plungers

4
Cat® 6020B – Joystick Address Service Training

Address Table Hand Lever / Foot Pedals Adjustment of Joysticks and Foot pedals

Control Unit Address

- Left Hand Lever 0

- Right Hand Lever 1
- Foot Pedal Left 2
- Foot Pedal Middle 3
- Foot Pedal Right 4

Address
Adjustment

5
Cat® 6020B – RH Joystick - Boom Service Training

6
Cat® 6020B – RH Joystick - Bucket Service Training

7
Cat® 6020B – LH Joystick - Stick Service Training

8
Cat® 6020B – LH Joystick - Swing Service Training

9
Cat® 6020B – Pedals - Travel Service Training

10
Cat® 6020B – Joystick Functions (Proportional mA) in BCS Screen Service Training

Demand Value

Active Value

11
 Cat® 6020B – Servo Pump Service Training

The servo pump is variable-type pump mounted to the back of main pumps three and four.
The servo system has a cut-off pressure of 90 bar.
The servo pump supplies 90 bar to the main servo manifold, where the pressure is reduced for various
machine functions.

Type: Variable Pump with pressure control A10 VNO 45

Max. Working Pressure 90 bar (Cut-Off)

12
Cat® 6020B – Servo Pump - Schematic Service Training

Oil flows from the pump to the cut-off valve. If the pressure is below 90 bar the oil is blocked.
If the pressure reaches 90 bar, the valve moves and the oil flows to the head end of the control cylinder
moving the swash plate to the minimum flow direction.
When the pressure is below 90 bar, the pump is in maximum flow and the oil flows from the head end of
the control cylinder to the tank.

max min

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Cat® 6020B – Servo Pump - Suction Line Service Training

14
Cat® 6020B – Servo Pump Case - Drain Line Service Training

It is recommended to purge the air from the system at the case drain connector tube hose connection.

15
Cat® 6020B – Pilot Pressure Supply Service Training

-2B30 filter monitoring

pressure switch

Pilot filter in
Power Module

Servo pressure
sensor

Identification numbers
stamped on connection plate
16
Cat® 6020B – Main Pilot Manifold Service Training

Pilot Pressure
Supply

17
 Cat® 6020B – Main Pilot Manifold Service Training

PRV PRV PRV

Pump support 50 bar Auxiliary Pressure 60 bar Track Tensioning 80 bar
PRV Spare
2nd Speed travel 50 bar
PRV
Swing Park Brake 50 bar
PRV
Pilot Pressure 100 bar

-2KH2
Servo Solenoid

-2KH8

-2KH12
-2KH38
-2KH11
-2KH6
-2KH1

-1KH1 Pilot
-2KH2.1 Disengage (Safety)
PRV
Servo Solenoid Valve
Servo Pressure 35 bar

18
Cat® 6020B – Main Pilot Manifold - Schematic Service Training

-1KH1
Disengage all servo
pressures

-2KH2 & -2KH2.1

Pressure Pressure
Disengage
Reducing Valve Relief Valve
35 bar output
19
Cat® 6020B – Propel & Swing Pilot Manifold Service Training

The oil pressure is reduced to 35 bar via pressure reducing valve.

The operator must be in the seat to activate the pilot system via -2KH2 & -2KH2.1 safety valves.

20
Cat® 6020B – Propel & Swing Pilot Manifold Service Training

-2B1: Pressure Sensor “Swing Left”

-2B2 -2KH5
-2B2: Pressure Sensor “Swing Right”
-2KH4: Switch Valve (Safety) “Swing Left”
-2B1
-2KH5: Switch Valve (Safety) “Swing Right”
-2KH13: Proportional Valve “Swing Left”
-2KH14: Proportional Valve “Swing Right”
-2KH4
-2KH19: Proportional Valve “Travel Left Reverse”
-2KH20: Proportional Valve “Travel Left Forward”
-2KH21: Proportional Valve “Travel Right Reverse”
-2KH22: Proportional Valve “Travel Right Forward”

-2KH14
-2KH22
-2KH21
-2KH20
-2KH19
-2KH13

21
Cat® 6020B – Pilot pressure to Propel & Swing Valves Service Training

Port a

Swing Right
Port b

Port a Swing Left Right swing valve

Swing Right
Port b
RH
Reverse
Swing Left
LH
Reverse

RH
Forward Right travel valve
Left swing valve
LH
Forward Left travel valve

22
Cat® 6020B – Oil Supply to Attachment Pilot Manifold Service Training

To the attachment 35 bar pilot manifold through line

23
 Cat® 6020B – Oil Supply to Attachment Pilot Manifold Service Training

Attachment pilot manifold

24
Cat® 6020B – Attachment Pilot Manifold Service Training

Float valve (Return)

35 bar Supply from the

main servo manifold

Hydraulic oil to tank

25
Cat® 6020B – Attachment Pilot Manifold Service Training

-2KH25
BOOM UP RH
-2KH30
STICK IN RH
Attachment pilot -2KH15
manifold BUCKET CURL RH

-2KH16
BUCKET CURL LH
-2KH31
STICK IN LH
-2KH26 -2KH23
BOOM UP LH BOOM DOWN RH
-2KH28
STICK OUT RH
-2KH17
BUCKET DUMP RH
-2KH18
BUCKET DUMP LH -2KH27
-2KH29 FLOATING VALVE
STICK OUT LH
-2KH24
BOOM DOWN LH
Note:
Proportional valves are not interchangeable.
They must be calibrated via BCS screen / Commissioning / Service Mode. 26
Cat® 6020B – Pilot Pressure Lines to Main Valve Blocks Service Training

Boom HE
Stick HE
Bucket HE
Bucket HE
Stick HE
Boom HE

27
Cat® 6020B – Pilot Pressure Lines to Main Valve Blocks Service Training

Boom RE
Stick RE
Bucket RE
Bucket RE
Stick RE
Boom RE

28
Cat® 6020B – Pilot Pressure Lines to Float Valve Block Service Training

29
 Cat® 6020B – Main Pilot Manifold - Pilot Pressure Service Training

Servo Pump
Cut-Off at 90 bar

Accumulator Pressure Switch

Pressure
Sensor Check Valve
90bar

Servo Filter

100 bar

Safety switch
Seat Safety
switch

Pressure Pressure
Sensor Sensor
35bar 50bar

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Cat® 6020B – Propel & Swing Pilot Manifold Service Training

31
Cat® 6020B – Attachment Pilot Manifold Service Training

32
Cat® 6020B – Servo Solenoid Valve – Swing Park Brake Service Training

100 bar

102/2
Swing Park Brake -2KH1

90 bar 102/1

50 bar

Tank

33
Cat® 6020B – Servo Solenoid Valve – Swing Park Brake Service Training

The swing brakes auto apply with any of the following conditions:
• Key OFF
• Ladder in the down position
• Manual switch in cab is activated after a certain period of time.

50 bar

50 bar

34
Cat® 6020B – Servo Solenoid Valve – 2nd Speed Travel Service Training

100 bar

2nd Speed Travel -2KH6

90 bar

50 bar

Tank

35
Cat® 6020B – Servo Lines (Superstructure) – 2nd Speed Travel Service Training

50 bar

36
Cat® 6020B – Servo Lines (Undercarriage) – 2nd Speed Travel Service Training

37
Cat® 6020B – Servo Lines (Undercarriage) – 2nd Speed Travel Service Training

38
Cat® 6020B – Servo Solenoid Valve – Pump Support Control Service Training

100 bar

Pump support
-2KH11

90 bar

50 bar

Tank

39
Cat® 6020B – Servo Lines – Pump Support Control Service Training

50 bar

40
Cat® 6020B – Servo Lines – Pump Support Control Service Training

50 bar

41
Cat® 6020B – Servo Lines – Pump Support Control Service Training

42
Cat® 6020B – Servo Solenoid Valve – Spare Service Training

100 bar

Spare -2KH38

90 bar

50 bar

Tank

43
Cat® 6020B – Servo Solenoid Valve – Auxiliary System Service Training

90 bar
100 bar

80 bar

60 bar

50 bar

Tank

Auxiliary System -2KH12

44
Cat® 6020B – Track Tensioning Service Training

80 bar servo pressure is only available if the solenoid -2KH8 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

Note: If the service lift or ladder are not complete lifted, the swing and travel function are not active! (Safety!!!)

45
Cat® 6020B – Servo Solenoid Valve – Track Tensioning Service Training

90 bar
100 bar

80 bar

60 bar

50 bar

Tank

Track Tensioning -2KH8

46
Cat® 6020B – Servo Controller Service Training

The servo controller is located inside the electrical cabinet below the operator’s cabin.

The Servo controller communicates with the (BCS)

and the drive controller.

• Main pumps
• Hydraulic system
• Servo system
• Travel system
• Track tensioning system
• Attachments
• Hydraulic oil cooling system
• Swing system
• Greasing system
• Maintenance/boarding lights
• Boarding ladder

Servo
Controller

47
 Cat® 6020B – Servo Monitoring Screen Service Training

The pilot system can be monitored on several screens within the (BCS).
This screen is used to monitor the 90 bar and the 35 bar circuits.
The 90 bar servo pressure has a normal operating range from 40-140 bar. The sensor itself has an overall range 0-400 bar and a
4-20 mA signal. A value outside of the normal operating range will generate a fault.
The 35 bar servo pressure has normal operating range from 20-50 bar. The sensor itself has a overall range 0-100 bar and 4-20
mA signal range. A value outside of the normal operating range will generate a fault.

48
Cat® 6020B – Servo Monitoring Screen Service Training

The analog pressure IN signal for the servo valve can be monitored on the screen

49
Cat® 6020B – Servo Monitoring Screen Service Training

The analog mA IN signal for the servo valve can be monitored on the screen

50
Cat® 6020B – Servo Monitoring Screen Service Training

The digital IN signal for the servo system can be monitored on the screen

51
Cat® 6020B – Servo Monitoring Screen Service Training

The digital OUT signal for the servo valve can be monitored on the screen

52