007 Cat-6060 Travel System

Hydraulic Mining Shovels Cat ® 6060/6060FS 07. Travel System

Dixio Torrez - 2013

Service Training

Pumps Assembly Swing Pump

Swing Charge Pump

4

Gearbox Cooling Pump

Servo pump 4 Servo pump 3

3

4 Oil Cooling Pumps

8

3

6

7

Main Pumps

Swing Pump

5

Gearbox Cooling Pump

2 Engine Fan Drive Pump

Servo pump 2

1

2 Oil Cooling Pumps

4

1

2

3

Main Pumps

1

Swing Charge

Servo pump 1

Main Pump Assembly

Service Training

P8 P7

P6 P5

P4 P3 P2 P1

Filter Block Assembly

Service Training

P 1/7 P 2/8 P 3/5

P 4/6

3/5

4/6 1/7

2/8

Travel Supply: P1/P7 and P2/P8 (P3/5 and P4/6 Attachment) Tank return lines

Service Training

P3/P5

Tank return lines

P4/P6

P1/P7

P3/P5

P4/P6

P2/P8

P1/P7

P2/P8

P1/P7

P2/P8

Travel Supply: P1/P7 + P2/P8 P1 /P7 P3 /P5

P4 /P6 P2 /P8

Service Training

Rotary Joint and Main Valves

Service Training

Travel Valve

Travel Valve

Retarder Valve

Retarder Valve

Anti Cavitation Valves

Rotary Joint

Rotary Joint and Main Valves (side view)

Service Training

Rotary Joint and Main Valves (side views)

Service Training

Rotary Joint and Main Valves (side views)

Service Training

Travel Valves

Service Training

Stroke: 17mm

Spool

Centering Springs

Rotary Joint

Service Training

Track Tensioning in the front Undercarriage Greasing

Case Drain + Leakage Oil Return Leakage Oil Return Undercarriage Greasing

Track Tension 50 / 80 bar Travel Brake 30 bar + 2nd Speed 50 bar

Travel Brake + 2nd Speed (Shuttle Valve!)

Travel 0-360 bar (4 times)

Undercarriage Greasing

Travel 0-360 bar 

Travel Main Valves and Proportional Valves

Service Training

Travel Proportional Valves

Travel Valve Travel Valve

Case Drain Lines and Retarder Valve Sensing Lines

Retarder Valve Sensing Lines

Retarder Valve Sensing Lines

Service Training

Travel Supply to Undercarriage

Service Training

P1/P7

P2/P8

Case Drain

Travel Brake and 2nd Speed

Secondary Relief Valve 370 bar 

Travel Pressure Boost on Main Pumps

Service Training

Travel Boost (Solenoid -2Y24 - 40 bar) “DZ”

2

The solenoid valve (-2Y24) operates the pressure cut-off valves of the main pumps 1+7 and 2+8, so that the travel pressure is increased. 320bar + 40bar = 360bar

4

1

3 8

7

6

5

Travel Motor

Service Training

Operating Pressure = 320 + 40 bar = 360 bar 

Displacement Control Piston

Travel Park 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

Travel Motor

Service Training

2nd Speed Connection

Flushing Valve (Cooling)

Travel Brake

Service Training

Seals

Springs

Piston Discs

30 / 50 bar Brake Release Pressure

Travel Motor

Service Training

Travel Park Brakes Flushing Valve (Cooling)

2nd Speed Connection

Flushing Valve (Cooling)

Pedals

Service Training

CMS

Service Training

LH Adr.: 0

RH Adr.: 1

Clam Adr.: 2

LH Adr.: 3

RH Adr.: 4

CAN Bus for Operator Controls

Proportional Valves

CAN Bus to Drive Controllers and BCS

Servo System  – Travel Proportional Valves Servo Pump 2+3

Service Training

Servo Pumps 1+4

Travel Proportional Valves The travel proportional valves are supplied by 35 bar servo pressure. They are controlled by the foot pedal deflection (CanBus). The servo controller box coverts this signal into a c urrent (70-650mA) which is active on the coil of the valve. The valve outlets (0-35bar) are connected to the travel main valves and control the position of the valve s pool. Left forward: -2Y14 Left reverse: -2Y13 Right forward: -2Y12 Right reverse: -2Y11

Servo System  – LH Block

Service Training

-2Y22 -2Y17 -2Y23

Pilot 60 bar

-2Y18

35 bar Supply to prop. valves

Tank Swing Balance Valve 35 bar

2nd Speed 50 bar

Servo Pump 1+4 Travel Park Brake 30 bar Pump Regulation Swing Park Brake 50 bar

50 bar

Pilot 35 bar

Servo System  – LH Block

Service Training

Swing Balance Valve Supply - 35 bar  This Valves reduces the 60 bar servo Pressure to 35 bar as supply on the p-port of the swing balance valve. 2nd speed travelling  – 50 bar When the operator shifts the switch in the cab f rom '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 on the rotary joint and the 2nd speed is active. (Solenoid -2Y22) Travel Park Brake

 – 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 enters the travel park brake piston via the rotary joint. T hey are released and held in the released position. The pressure is reduced to 30 bar to be sure that the brake is open. Swing Park Brake - 50 bar The swing park brake is spring applied and hydraulically released. In the de-energized position of solenoid -2Y23, the swing brake is connected to tank. => Brakes are applied. When the swing brake is released, -2Y23 is energized and 50 bar is supplied to the swing brakes, overcoming the spring tension => brakes are released. Note: You must not stop the swing movement by using the swing park brake!!! This will occur heavy demolition on the brake disks ! Pump regulation  – 50 bar  This valves supplies 50 bar pressure to the pump control proportional valve. Pilot Pressure 60 bar This relief valve limits the incoming pressure from Servo Pump 1+4 to 60 bar. Servo On/Off (Solenoid -2Y18 - 35 bar) This solenoid is operated by the seat switch and switches the 35 bar Pressure supply to the consumers on or off.

Servo System  – RH Block Pilot 50 bar

Service Training

Track Tensioning 80 bar Travel Boost 40 bar

Servo Pump 2+3

80 bar Ladder, Clam Boost Service Arm, 40 bar Grease System

Tank

P-Port Main Pumps -2Y18

Pilot 100 bar

-2Y24 -2Y20 -2Y27

Servo System  – RH Block

Service Training

P-Port on Main Pumps This outlet is used to supply the main pumps with an initial pressure on the p-Port of each main pump. (X2 Port on older pumps). Servo On/Off (Solenoid -2Y18 - 50 bar) This solenoid is operated by the seat switch and switches the 50 bar Pressure supply to the consumers on or off.

Travel Boost (Solenoid -2Y24 - 40 bar) The solenoid valve (-2Y24) operates the pressure cut-off valves of main pumps 1 + 7 / 2 + 8 so that the pressure is increased to 320bar + 40bar = 360 bar . Track Tensioning (Solenoid -2Y120  – (80 bar) This valve increases the track tensioning pressure from 50bar to 80 bar. This causes a pressure release in the track tensioning system.

Clam Boost (Solenoid -2Y27  – 40 bar) The solenoid (-2Y27) operates the pressure cut-off valves of the main pumps 4 + 6, so that the clam pressure is increased to 320bar + 40bar = 360 bar

80 bar Outlet Port This outlet is used to supply the hydraulic ladder, the service arm and the automatic lubrication system. .

Travel Schematic

Service Training

P1/P7 P3/P5

P4/P6 P2/P8 0  – 360 bar => Travel Pressure Boost 30 / 50 bar (Travel Park Brake and 2nd Speed) 60/80 bar (Track Tensioning)

Secondary Relief Valves

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

Reverse direction. RHS test point. The relief valve is at the top rear of the block

Service Training

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

Forward direction. LHS test point. The relief valve is at the lower rear of the block.

Condition: RH Forward

Service Training

  r   e    l    l   o   r    t   n   o    C   o   v   r   e    S

24 Volt

0  – 650mA

0  – 35 bar

Condition: RH Forward

Service Training

1st Speed Forward

Service Training

45 bar 

0  – 360 bar => Travel Pressure Boost 30 bar Servo Pressure (Travel Park Brake released) Tank

2nd Speed Forward

0  – 360 bar => Travel Pressure Boost 50 bar Servo Pressure (Travel Park Brake released and 2nd Speed) Tank

Service Training

Condition: RH Reverse

Service Training

  r   e    l    l   o   r    t   n   o    C   o   v   r   e    S

24 Volt

0  – 650mA

0  – 35 bar

Condition: RH Reverse

Service Training

1st Speed Reverse

Service Training

45 bar 

0  – 360 bar => Travel Pressure Boost 30 bar Servo Pressure (Travel Park Brake released) Tank

2nd Speed Reverse

0  – 360 bar => Travel Pressure Boost 50 bar Servo Pressure (Travel Park Brake released and 2nd Speed) Tank

Service Training

Condition: Forward Downhill

Service Training

Retarder Valves

Service Training

HP Oil From Main Pump 0-340 bar Low Pressure Return Oil Restricted Oil

Retarder OFF

Retarder ON

Retarder Valves

Pump Pressure

High Pressure Pressure reduced due

Service Training

Track Tensioning

Service Training

Track Tensioning

Service Training

50 / 80 bar Supply Track Tension Cylinder Tank Return

Shock Relief Valves (330 bar)

Accumulator

Isolation Valve

Pilot Operated check Valves

70 bar Switching Valve

Status 1: System loaded by Servo Pump (50 bar)

Service Training

Servo Pump supplies Track Tensioning System with 50 bar A

A  Y

 Y X

X

70 bar

B

B

Pilot pump 1/4

Servo Pump

82 330

50bar Nitrogen Charge Tank

330

Status 2: Pressure build-up during Travelling

(