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Matthias Aust - 2013
Servo Pump Service Training

Type: Gear Pump KP 2/28

Working Pressure: 60 bar (80 bar)

Servo

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Pump

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Cat 6040 before #170100: 2 Gear-Type Servo Pumps

Cat 6040 #170100 - #170109: A11 Servo Pumps

Cat 6040 #170110 - #170xxx: A10VO45 Pumps

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Servo Pump Service Training

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Servo Pressure – Pressure Adjustment Service Training

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Safety Solenoid -2Y18
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Track Tensioning Solenoid -2Y20

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Servo Schematic Service Training

Servo Servo
Pump RH Pump LH

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Emergency
Boom Down
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Auxiliary Servo

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Pressure 50 bar

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50
-2Y9 -2Y10
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-2Y11 -2Y12 -2Y13 -2Y14 -2Y7 -2Y8
50

Track Tensioning
-2Y18
Pressure 60 / 80 bar
-2Y1 -2Y2 -2Y3 -2Y4 -2Y5 -2Y6 -2Y5 -2Y5

-2Y20

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 Servo Schematic Service Training

to P 2

300 / 350
Track
Tensioning
System Swing
Balance
Valve

Auxiliary Servo -3Y1 -4Y1

Pressure 50 bar Main Pump

Prop. Valves
Travel Swing
2nd Speed Boost Brake
-2Y22 -2Y24 -2Y23 not used
Swing
50 50 50 50
Park
Brake to P3 / P4
Track Tensioning
Pressure 60 / 80 bar
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152 Ladder
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Auto Lube System

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 Servo Solenoid Valves Service Training

2nd Speed Travel -2Y22

Travel Brake -2Y17

Swing Park Brake -2Y23

Travel Pressure Boost -2Y24

50 bar Servo

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Servo System Service Training

50 bar Check Point 35 bar Check Point

-2Y22

-2Y17
-2Y3 -2Y4 -2Y5 -2Y6 -2Y16 -2Y15
-2Y18 -2Y1 -2Y2
-2Y23

-2Y24

-2Y12 -2Y13 -2Y14 -2Y7 -2Y8

-2Y9 -2Y10 -2Y11

-2Y20

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 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)

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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

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50 bar Adjustment  Check Point P 3 Service Training

P3
-2Y18

50 bar

-2Y18
-2Y20

-2Y20 Users of 50 bar are:

• Service Lift
• Swing Brake Solenoid Valve
• Prop. Valves for Main Pump Governing
• 2nd Speed for Travel System
• Travel Pressure Boost
• Auto Lube System

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60 bar Adjustment  Check Point P 4 Service Training

Machine Working
(Attachment / Travel / Idle)

-2Y18
50 bar

P4

-2Y18

-2Y20

-2Y20 Users of 60 bar are:

• Track Tensioning System

• Swing Blocking Valves
• P-Port on the Main Pumps

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.
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80 bar Servo Adjustment  Check Point M 1 Service Training

If machine travels for more than 15 sec:

5 sec after stop travelling,
-2Y20 energized for 5s.
50
bar

-2Y18

-2Y18

-2Y20

-2Y20

Users of 80 bar are:

Please use the push button to switch
• Track Tensioning System from 60 bar to 80 bar.
(5 s after travelling) Then check / adjust the 80 bar pressure.
• Service Ladder Pressure
increase

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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!!!)

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 Proportional Valve Block – Electric Side Service Training

Pressure Relief Valve Pressure Relief Valve

Servo Pressure 60 bar Servo Pressure 80 bar (test point P4)
Pos. 1.11 in hydraulic Pos. 1.10 in hydraulic schematic.
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 35 bar
Pos. 1.20 in hydraulic schematic.
User: proportional valves servo control.
Switching Valve
Track Tensioning
-2Y20 Pressure Reducing Valve
Auxiliary Pressure 50 bar
Pos. 1.30 in hydraulic schematic.
User: tanklift, Main Pump prop. valves -3Y1
and -4Y1, travel boost, 2 nd travel stage,
ladder, balance valve.
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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 l eft 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 S ide LS.
-2Y9 -2Y10 -2Y11 -2Y12 -2Y13 -2Y14 -2Y7 -2Y8

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Servo Block Connections – 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

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Servo Block Connections – 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 -2Y6 -2Y5 -2Y4 -2Y3 -2Y2 -2Y1

Stick out Travel Travel Travel Travel

Rod Side Reserve Left Fwd. Left Rev. Right Fwd. Right Rev. Reserve Reserve

-2Y8 -2Y7 -2Y14 -2Y13 -2Y12 -2Y11 -2Y10 -2Y9

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Servo for Attachment – BH Service Training

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Servo for Travel System Service Training

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 CAN-BUS II

Left Hand Lever

Foot Pedal Left

Foot Pedal Middle

Foot Pedal Right

Right Hand lever

Tree
Harness
Service Training

Main Cabinet (Servo Controller)

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CAN-BUS II 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

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Joysticks Service Training

Handpiece

Locknut

Actuator
Plate

Spool Dust Cover

Plungers
Address
Adjustment

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Joystick Functions in BCS Screen Service Training

Demand Value

Active Value

Float Valve

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RH Joystick Service Training

RH Joystick

Boom Down
(Float)

Horn Boom
(Power)
Down

Bucket Curl Bucket Curl

Close Open

Boom Up

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LH Joystick Service Training

LH Joystick

Stick
Out
Stick In
(Power) Spare

Swing Swing
Left Right

Stick in
(Float)

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Pedals Service Training

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More Information? Service Training

Hey Fellows,

Please find more Information

in the Technical Handbook!

Chapter 8.5.3: Servo System

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