—— Lesson 4: 906 Compact Wheel Loader Hydrostatic Drive System Introduction: ‘The 906 Compact Wheel Loader hydrostatic drive system is similar to the hydrostatic drive systems used on other Caterpillar machines. ‘The information learned in this lesson will allow students to understand, test and adjust the hydrostatic drive systems used on other machines. Objectives: ‘At the completion of this lesson, the student will be able to: 1. Identify components of the 906 Wheel Loader hydrostatic drive system, 2. State the function of the components in the 906 Wheel Loader hydrostatic drive system. ‘Trace the oil flow through the 906 Wheel Loader hydrostatic drive system in each operation mode. Pecform the testing and adjusting procedures for the 906 Wheel Loader hydrostatic drive system as stated in the service manual. References: ‘Service information to cover the machine(s) used in the lab exercises. Toolin; Appropriate tooin ‘machine(s) used in the lab exercises. 12s listed inthe service information for the42 Machine Hydrauli Systems COMPACT WHEEL LOADER HYDROSTATIC DRIVE SYSTEM ceseren vate Tommevenr moroveren Pay 0 2 —-—-E5 MF F Fig 41 Compact Wheel Loder Hydrostatic Drive Syste, ‘The main components of the hydrostatic drive system include a pump group, a motor group and a filter group. The “ereeper" valve is optional. The creeper valve enables the operator to infinitely vary the top speed of the machine in either speed position while the engine is ‘at maximum rpm. The system shares the same hydraulic tank with the implement and steering systems. ‘The motor is mounted to a gear box which mounts to the rear axle. ‘The motor drives an input gear which meshes with the output gear in the gear box. The output gear transmits power directly to the rear axle and to the front axle through a drive shaft ‘The hydrostatic drive system also supplies ol to the implement pilot system and the brake master cylinder.443 HYDROSTATIC DRIVE SySTEM. PUM AND ATEN ORO Fig 442 Hydrostatic Drive System Purp and Fier Schematic ‘The hydrostatic drive pump and filter group consists of the following ‘components: Hydrostatic drive pump: The variable displacement, over-center piston pump provides flow to drive the bi-directional motor. Charge pump: Fills the system with ol at start-up, provides makeup oil and provides the source for signal pressure to control the pump and motor. Speed sensing valve: Controls signal oil and makeup oil Orifice: Located inthe signal line above the speed sensing valve, it allows the pressure override valve and the brake master cylinder to function as designed. Combination crossover relief and makeup valves: Maintains a ‘minimum pressure in the drive loop low pressure side and limits ‘maximum pressure inthe drive loop high pressure side Charge pump relief valve: Controls the maximum charge oil pressure, the maximum hydrostatic system pressure in NEUTRAL, ‘and the maximum implement pilot system pressure. FORWARD-NEUTRAL-REVERSE (F-N-R) valve: Controls the direction of output flow from the hydrostatic drive pump. Pressure override (POR) valve: Limits the maximum drive loop pressure. Filter bypass valve and switch: Limits the pressure differential ‘across the filter and signals when the filter bypass is open44 Machine Hydrautle Systems HYDROSTATIC DRIVE SYSTEM. ur Fit 443 HydrotateDrive Sytem Motor and Crosper Valve Schematic ‘The hydrostatic drive motor group consists ofthe following components: Hydrostatic drive motor: A bi-directional, variable displacement, bent axis piston motor and actuator convert hydraulic power into ‘mechanical power. ‘Throttle pin (Orifice check valve): Controls motor stroking time from minimum stroke to maximum stroke. Motor displacement control valve: Controls the motor swashplate angle. ‘Speed selector valve: Controls the signal oil to the motor displacement contro valve. Reverse solenoid valve: Maintains drive oil pressure to motor displacement control valve in both forward and reverse Flushing valve: Continuously drains some oil from the low pressure side ofthe loop through the motor bearings to case drain and. ‘maintains a minimum pressure in the low pressure side of the loop, Optional "creeper" valve: Drains te signal ol from the speed sensing valve directly to the tank. NOTE: The 906 has a maximum motor displacement of 80 ce (4.88 cu, in.) per revolution at the rated engine speed of 2600 rpm. The 906 has a minimum motor displacement of 33.5 cc (2.04 cu. in.) per revolution,44s Machine Hydraulic Systems Fig. 44 Hydrostatic Drive Components (right side of rear compartment) From the right side ofthe rear compartment the fllowing components are visible: Hydrostatic dive pump (1), bya oi filter @), S-0°S tap (3), charge pressure tp (4, and lank sight ) gauge (3). The hydraulic ol tank (not visible) is located on the right Sido ofthe machine below the eab A Fig, 44S Adeltonal Component Locations right ie of machine Beind cab) ‘The hydraulic oil cooler (1) is located just behind the cab on the right ‘side of the machine, The oil cooler is hinged at the inner end to permit cleaning between the cooler and the radiator. ‘The hydraulic tank fill tube (2) is located in front of the oil cooler, t4 unit +46 Machine Hydrauti Systems Fig. 446 Hydeostae Pump Components ‘The pump actuator (1) moves the swashplate in the pump. The angle Of the swashplate controls the amount and direction of oil flow from the pump to the motors. ‘The charge pump (2) fills the system at start-up and provides makeup oil, The charge pump also provides the source for signal pressure to ‘control the pump and motor. ‘The POR valve (3) limits the maximum drive loop pressure. ‘The Forward-Neutral-Reverse (F-N-R) solenoid valve (4) direets the signal pressure to one end or the other end ofthe pump actuator to stroke it for forward or reverse direction and speed. The F-N-R solenoid valve is energized by an Electronic Control Module (ECM), ‘which receives an input signal from the electric direetional control switeh mounted in the joystick. “The pressure tp (5) for drive loop pressure (MH) is located on top of the pump.447 Machine Hydraulle Systems Fig, 447 Pump Solenoid Valves ‘When the forward (F-N-R) solenoid (1) is enengized, the solenoid valve spool is shifted and sends signal oil to actuate the pump to provide oil flow for the forward direction. When the reverse (F-N-R) solenoid (2) is enengized, the solenoid valve spool is shifted and sends signal oil to actuate the pump to provide oil flow for the reverse directionnied Lesson “8 Machine Hyrautie Systems ig. 44.8 Hydrostaie Pump Components ‘The crossover relief and makeup valves (1) combine two separate functions into one valve as described in Unit 4, Lesson 2. The ‘crossover relief section of the valves limit the maximum pressure in the drive side of the loop. The makeup sections close the connection between the drive side of the loop and the charging system and open the charging system to the low pressure side ofthe loop to supply’ ‘makeup oil fo the loop. One crossover relief and makeup valve (1) is shown in Figure 4.4.8. The other crossover relief and makeup valve is located in the same position on the opposite side of the pump. “The charge pump relief valve (2) limits the charge pressure oil. The valve also limits the maximum hydrostatic system pressure in NEUTRAL and the maximum implement pilot system pressure. “The speed sensing valve (3) senses the charge oil flow and converts some of it to signal oil. The signal oil is used to control the pump ‘and motor. ‘The following pressure taps are located on the bottom of the pump: = Charge pressure tap (4) = Signal pressure tap (5) = Case drain pressure tap (6)449 Machine Hydraulie Systems Fig. 449 Hydrostatic Dive Motor Location ‘The hydrostatic drive motor (1) is mounted to the hydrostatic drive box (2). The hydrostatic drive box is connected to the rear axle (3). ‘The motor drives an input gear which meshes with the output geer in the hydrostatic drive box. The output gear transmits power direetly to the rear axle and to the front axle (not visible) through a drive shaft (4). Blas44 40 Machine Hydrautie Systems Fig. 44.10 Hydeostatte Drive Motor Components The bi-directional, variable displacement, bent axis piston motor converts hydraulic power into mechanical power. The motor actuator piston controls the motor displacement by changing the angle ofthe rotating group relative to its output shaft. The longer the stroke (increased displacement), the higher te torque and lower the speed. The shorter the stroke (decreased displacement, the lower the torque and higher the speed. ‘The speed selector valve (1) when energized, blocks the signal oil from reaching the motor displacement control valve to keep the motor fully upstroked, Machine ground speed is reduced while engine speed and implement pump flow are maintained. The machine i in the SLOW speed mode. “The reverse solenoid valve (2) directs oil from the drive side of the Joop, either FORWARD or REVERSE, to the motor displacement ‘control valve and the actuator. This drive side oil pressure is used to Lpstroke and destroke the motor in both forward and reverse. When the reverse solenoid valve is de-energized, the pressurized oil from the FORWARD drive side ofthe loop goes tothe motor displacement ‘control valve and the actuator. When the reverse solenoid valve is ‘energized, the pressurized oil from the REVERSE drive side ofthe Toop goes to the motor displacement control valve andthe actuator, Hydrostatic motor actuator pressure can be checked at the M1 pressure tap (3).units Lesson 4 | aan Machine Hydraule Systems Fig 4A. Hydrostatic Drv Stern (NEUTRAL) ‘At machine start-up with the directional control switch in NEUTRAL, the charge pump sends oil through the oil filter tothe speed sensing valve. Oil flows from the speed sensing valve to the charge circuit, the implement pilot circuit, the F-N-R Valve, the brake ‘master cylinder, andthe ereeper valve. Most ofthe speed sensing valve oil enters the charge circuit and } flows to the crossover relief and makeup valves and the charge pump relief valve. “The charge relief valve in the charging circuit limits the maximum ‘charge pressure in the closed loop. As pressure in the charge circuit jnoreases, the charge relief valve opens to maintain the charge pressure, “The makeup valve (in each crossover relief and makeup valve) opens nd allows charge oil to flow through the drive loop to the hydrostatic drive pump, hydrostatic motor, lushing valve, and the reverse solenoid valve, When the system is charged, the charge pump relief ‘valve opens and charge oil flows to the pump case and back to the tank. The charge pressure can be checked at the test port stamped "G" on the pump. In NEUTRAL, the reverse solenoid valve directs FORWARD érive loop pressure oil to the motor displacement control valve and the ‘motor actuator piston. '| an Machine Hydractic Systems ‘Charge oil in the drive loop also flows through the ball resolver in the Pressure override valve. rive loop pressure can be checked attest ort "MH." In NEUTRAL, this pressure is the same as charge pressure, SPEED SENSING VALVE ASCELERAT OG Fig. 44.12 Speed Sensing Valve ‘The speed sensing valve regulates signal pressure oil (based on ‘engine speed) to the F-N-R valve, the hydrostatic motor, and the brake. ‘When the machine is started, the speed sensing valve is in the start-up/charging mode (Figure 4.4.12, left diagram), The charge pump oil flows to the speed sensing valve. From the speed sensing valve, oil flows through the crossover relief and makeup valves to ‘charge the closed drive loop system. Initially, no signal (drive signal) is sent to the F-N-R valve and the hydrostatic motor and brake. When the drive loop is charged, the charge pressure increases. The higher charge pump oil pressure on the left side of the speed sensing valve assists the spring and causes the speed sensing valve to shift 10 the right (Figure 44.12, center diagram). The signal oil flows to the F-N-R valve and the hydrostatic motor and brake. ‘An increase in engine speed results in an increase in flow from the fixed displacement charge pump. The flow increase through the orifice at the bottom of the speed sensing valve results in a larger pressure differential across the orifice and shifts the speed sensing vvalve farther to the right. This increases the oil low through the speed sensing valve and increases the signal pressure to the F-N-R ‘valve and the hydrostatic motor. Ifthe F-N-R valve is shifted to cither FORWARD or REVERSE position when engine speed is increased, the ground speed will increase.nit Lesson 443 ‘Machine Hydraulic Systems When the engine speed decreases, the charge pump sends les oil flow to the speed sensing valve (Figure 44.12, right diagram). The charge oil pressure is now lower on the left side ofthe speed sensing valve than on the right side. ‘This causes the speed sensing valve to shift to the ef, directing the signal il to the tank. With a reduced signal at the hydrostatic motor and the hydrostatic pump, the motor rapidly upstrokes and the pump begins to destroke. This action prevents engine lug. When the accelerator pedal is depressed, the speed sensing valve creates a signal which flows to the pressure override valve, the F-N-R valve, the brake master eylinder, the speed selector solenoid valve, and the motor displacement control valve. In NEUTRAL, the F-N-R valve blocks the signal oil, which prevents the pump from upstroking. ‘When the speed selector valve switch is in the FAST speed mode, ‘with the F-N-R valve in neutral, the speed selector solenoid is not energized, Signal oil flows to the motor displacement control valve. (The motor will destroke, but since no pump flow is produced, no ‘power is transferred to the hydrostatic gear box.) When the speed selector valve switch is in the SLOW speed mode, the speed selector solenoid is energized. The signal oil is blocked and the motor will not destroke when the transmission selector is moved to either FORWARD or REVERSE. In NEUTRAL, "MI" is equal to charge ‘pressure (at high idle). ‘Pump case pressure can be checked at test port "72." NOTE: Always use at least 2 60000 kPa (8500 psi) pressure gauge (such as 8T0861) when checking the drive loop pressure at test ports "MH" and "M1" unless a pressure limiter (such as 109161) is used to protect the gauge. Lower range pressure {gauges may be used when checking pressures in NEUTRAL as Tong a care is taken not to shift the directional control switeh.id wnt oe “Machine Hydraulic Systems HYOROSTATIC DRIVE SYSTEM Fig, 44:13 Hydeostae Drive Sytem (FORWARD/IGH) When the hydrostatic drive control isin the HIGH position and the ‘operator moves the directional control switch to FORWARD, the forward solenoid moves the F-N-R valve to the lef. Signal oil from the speed sensing valve flows to the pump actuator. The signal oil pressure acts against the actuator centering springs, but the signal oil i pressure is t00 low at low idle to overcome the spring and move the ‘actuator. The pump will not upstroke and the machine will not move. {As the operator depresses the accelerator pedal, the engine speed | increases the charging pump oil flow which causes the signal pressure to increase. The increase in signal pressure overcomes the actuator centering spring and upstrokes the pump. The pump sends flow to the motor and the machine begins to move. AAs the engine speed increases, the increasing signal pressure upstrokes the pump. The pump sends more ol o turn the motor and increases the machine speed. ‘The engine speed and signal pressure continue to increase. The increasing signal pressure is also sensed at the motor displacement control valve. The increased signal pressure moves the motor displacement control valve to the left. High pressure drive loop oil flows past the reverse solenoid valve, the motor displacement control valve, and the throttle pin to the motor actuator to destroke the motor, Destroking the motor causes the motor to rotate faster. The machine is at maximum speed when the motor is fully destroked, the pump is fully upstroked, and the engine is at maximum rpm.units Lesson sais Machin Hydrate Systems Any resistance to motor rotation increases the drive pressure, which ‘acts on the left end of the motor displacement control valve. This hhigher pressure moves the motor displacement control valve to the right and drains oil in the motor actuator tothe tank. The motor actuator then moves tothe left, causing the motor to upstroke, thus reducing machine speed. ‘The motor displacement control valve continuously balances the signal and drive loop pressures to prevent excessive engine lug. NOTE: When FORWARD/HIGH or REVERSE/HIGH is selected, the machine speed ranges from zero to maximum.nie Lesson d 4416 Machine Hydraulic Systems Fig 44.14 Hydrostatic Drive Sytem (FORWARDILOW) ‘When the hydrostatic drive control is in the LOW position and the ‘operator moves the direction switch to forward, the system operation js similar to FORWARD/HIGH, When in the FORWARD/LOW position the hydrostatic drive control energizes the speed selector valve solenoid. The speed selector solenoid valve blocks signal oil flow to the motor displacement control valve. The motor is held at ‘maximum stroke due tothe drive loop pressure acting on the right side of the actuator piston. High engine speed can be maintained, while machine speed is relatively low with high torque. With high engine speed, the {implement pump is able to provide more flow to improve productivity during applications such as truck loading.ua aur Machine Hydraulic Systems Fig 44.15 Hydrstati Drive Spt (REVERSEMIGH) { Operation in REVERSE/HIGH (Figure 4.4.15) and REVERSE/LOW is similar to operation in FORWARD/HIGH and FORWARD/LOW ‘ ‘except that the F-N-R valve moves tothe right. The reverse solenoid valve for the motor is energized and also moves to the the right. High pressure oil is then sent from the opposite side of the drive loop to the motor displacement control valve and the motor actuator. If the brake is applied in ether FORWARD or REVERSE, signal pressure (PS!) will be reduced, upstroking the motor (if itis destroked) and destroking the pump.nit Machine Hydraaic Systems Student Copy La Shop Lab Exereise Directions: Identify the Hydrostatic Drive System components by matching the lettered or numbered tags on the components with the names on the worksheets. After locating the components on the machine, explain the function of each component and locate and record the appropriate schematic item ‘number (from the hydraulic schematic) for each component. References: Appropriate Hydrostatic Drive Systems Operation manual and hydraulic schematic ‘Tooling: None Hydrostatic Drive System Pump Location: Funetion: tem Numb ___ Charge Pump Location: ae ee Fncikar oes Cleese ee ee ee Item Number: Bee Hydrostatic Drive Motor re eee ee i Remstige Seer ih See CaS aes ee eae r leapt rem eee eee ____ Hydrostatic Drive Box ; ‘Location: —_ 2 Function: io a 1a ey Lab tt a Machine Hydeaue Systems ‘Student Copy Hydraulic System Filter Funetion; tem Number: _— Hydrautic Oi Cooter Location: Funetion; em Number: Hydraulic Tank Location: Funetion: Item Number: Hydrostatic Drive Pump Pressure Tap (MH) Location: Function: Item Number: Charge Pressure Tap (G) Location: unctod eats ee tem Number: ___ Pump Signal Pressure Tap (PS1) Fe hens ae eS een ec Carne sev jr ee ub ne crea Rg Fee aa ANF Titi eavn e Stent Copy ab 44.1 ’ Machine Hydraulic Stems ___ Pump Case Pressure Tap (12) eseiee cect og cscan aR ices eee fen Nags eek Motor Actuator Pressure Tap (M1) ee ccc es Maer ee esse te MR ree eee iss Nine eee __ Flushing Valve Ey a ee ipa eee ae Function: Item Number: FORWARD-NEUTRAL-REVERSE (F-N-R) Valve Location: Function: em Number Crossover Relief and Makeup Valves (2) oe ae Function: tem Number: Charge Relief Valve a Ree ee ee eenied of ‘Machine Hydrate Systems Student Copy Lab 44.1 Speed Sensing Valve Location: Funetion: pays aan ee oe __ Pressure Override (POR) Valve peutic eee Mieco aa Vee ea eee Misia ees anlar et ee eine ee oe eee aa oe ee Motor Displacement Control Valve ition te ee Pate: hi i ee than Nuiben! in i ‘Speed Selector Solenoid Valve Reverse Solenoid Valve Ma cn eet fide fae St ee eenit 1 Stident Copy Lab 44a ‘Shop Lab Exercise Directions: Follow the procedures in the service manual to perform the tasks below on the hydrostatic drive system. Locate and record the specifications from the service manual in the appropriate area of the worksheet. Perform the tests and record the actual readings on the worksheet References Appropriate Steering System Testing and Adjusting Service Manual module, Tooling: Appropriate tooling as listed in the service information, ‘Test A: BASELINE (902 Wheel Loader) Test Low Tale High Tle Specification ‘Aetual Specification ‘Actual Engine Speed Charge Pressure Pump Signal Pressure Pump Case Pressure ‘Test A: BASELINE (906 Wheel Loader) Test Low Idle High Idle ‘Specification ‘Actual Specification ‘Aetwal Engine Speed Charge Pressure Pump Signal Pressure Pump Case Pressure