POWER TRAIN .......................................... 10- 2 PPC CONTROL PIPING DIAGRAM ........... 10-101 OVERALL DRAWING OF POWER TRAIN
WORK EQUIPMENT CONTROL ................ 10-102 UNIT ...................................................... 10- 4 HYDRAULIC TANK ..................................... 10-104 POWER TRAIN HYDRAULIC PIPING
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING, BRAKE CONTROL
STEERING, BRAKE CONTROL
Regarding the transmission-related description of the operation of the PCCS lever, refer to the Transmission Control. PCCS: Palm Command Control System
10-52 D375A-5 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING, BRAKE CONTROL 10-53 D375A-5
1. Brake pedal 2. Safety lever 3. PCCS lever (Steering) 4. Limit switch 5. Steering controller 6. Steering ECMV 7. Brake valve 8. Parking brake lever (From safety lever) 9. Cable 10. Rod (From brake pedal) 11. Potentiometer Positions of lever and pedal 1: Neutral 2: Forward straight-travel 3: Reverse straight-travel 4: Left clutch OFF 5: Left clutch OFF Left brake ON 6: Right clutch OFF 7: Right clutch OFF Right brake ON 8: Brake RELEASE 9: Brake ON :: Free A: Lock
Outline The PCCS lever (3) sends an electric signal to the steering controller (10). After receiving it, the steering controller (10) sends a proportional cur- rent to the steering ECMV (6) to operate the steering clutch and brake. The brake pedal (1) sends an electric signal to the steering controller (10) via the potentiometer (11). After receiving it, the steering controller (10) sends a proportional current to the steering ECMV (6) to operate the brake. In this case, the right and left brakes operate at the same time to activate braking. The rod (5) operates the brake via the brake valve (9) for redundant use. (Only at the time of complete braking) If you slightly tilt the PCCS lever (3) leftward, the left steering clutch is partially disengaged, caus- ing the machine to make a slow left swing.
If you completely tilt the PCCS lever (3) leftward, the left steering clutch is turned OFF complete- ly and the left steering brake is turned ON, causing the machine to make a sudden left swing. The safety bar (2) is connected to the parking brake lever (8) and it also serves as a parking brake. STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSFER, BEVEL GEAR SHAFT, STEERING 10-55 D375A-5
TRANSFER, BEVEL GEAR SHAFT, STEERING
1. Transmission unit 2. Input shaft 3. Steering unit 4. Breather 5. Parking brake valve 6. Left brake ECMV 7. Right brake ECMV 8. Transmission output rotation sensor 9. Filter 10. Left clutch ECMV 11. Right clutch ECMV 12. Sudden braking prevention valve
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSFER, BEVEL GEAR SHAFT, STEERING
Transfer Bevel Gear Pinion
1. Input shaft 2. Drive gear (35 teeth) 3. Transmission output rotation sensor 4. Rear cover 5. Bearing gauge 6. Driven gear (33 teeth) 7. Bevel pinion (23 teeth) 8. Bevel gear (40 teeth) Outline The transfer bevel pinion is mounted at the rear part inside the steering case, which receives the power from the transmission output shaft by its input shaft (1). The transfer consists of the drive gear (2) and the driven gear (6) to reduce the power speed from the input shaft (1), transferring it to the bevel pinion (7). It is also provided with the transmission output rotation sensor (3) to send the pulse signal of the drive gear (2) to the torque converter lock-up controller using an electric signal.
10-56 D375A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSFER, BEVEL GEAR SHAFT, STEERING
Unit: mm
No.
Check item
Criteria
Remedy
1
Backlash of transfer gear Standard clearance Clearance limit
Adjust or replace 0.24 0.63 0.75
2
Thickness of collar between transfer gear and bearing Standard size Repair limit
Replace 24 23.6
3 Standard shim thickness for bearing cage mount
2.0
Adjust
D375A-5 10-57
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSFER, BEVEL GEAR SHAFT, STEERING
BEVEL GEAR SHAFT, STEERING CLUTCH, BRAKE
10-58 D375A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSFER, BEVEL GEAR SHAFT, STEERING
1. Clutch cage 2. Clutch housing 3. Clutch spring 4. Clutch piston 5. Torque pin 6. Clutch disc (One side: 9 sheets) 7. Clutch plate (One side: 9 sheets) 8. Spacer 9. Clutch stopper 10. Clutch hub 11. Bearing cage 12. Bevel gear (Number of teeth: 40) 13. Bevel gear shaft 14. Bevel gear shaft 15. Bearing cage 16. Pipe 17. Brake stopper 18. Brake hub 19. Brake disc (One side: 9 sheets) 20. Spacer 21. Brake plate (One side: 9 sheets) 22. Torque pin 23. Brake piston 24. Brake case 25. Brake spring 26. Brake cage 27. Sleeve 28. Output shaft Outline As steering clutches, wet-type, multiple disc type, and spring-boosted types are adopted. If you operate the PCCS lever, the controller out- puts a proportional solenoid current to hydrauli- ca ll y op er a t e t h e st ee r i n g E C M V w h i l e interlocking with the brake. As a lubrication method, forced lubrication is adopted, which makes oil from the power train oil cooler flow through the passage in the steering case to the housing and cage, and up to the disc plate. As steering brakes, wet-type, multiple disc type, and spring-boosted types brakes are adopted. If you operate the brake pedal and PCCS lever, the controller outputs a proportional solenoid current to hydraulically operate the steering valve ECMV while interlocking with the brake. As a lubrication method, forced lubrication is adopted, which makes oil from the power train oil cooler flow through the passage in the steering case to the housing and cage, and up to the disc plate. When the engine is stopping, the steering brake is ON since the back pressure of the brake pis- ton lowers unless you press the brake pedal. Since the brake is released as the oil pressure in the circuit goes up when the engine restarts, the parking lock lever must be locked.
D375A-5 10-59
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSFER, BEVEL GEAR SHAFT, STEERING
10-60 D375A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSFER, BEVEL GEAR SHAFT, STEERING
Unit: mm
No.
Check item
Criteria
Remedy
1
Thickness of brake, clutch plate Standard size Repair limit
Replace 2.9 2.5
Distortion of brake, clutch plate Tolerance Repair limit
Repair or replace Less than 0.3 0.4
2
Thickness of brake, clutch disc Standard size Repair limit
Replace 4.7 4.2
Distortion of brake, clutch Tolerance Repair limit
Repair or replace Less than 0.3 0.4
3
Overall assembled thickness of brake plates and discs Standard size Repair limit
Replace 68.4 64.7
4 Overall assembled thickness of clutch plates and discs
68.4
65.4
5
Backlash between brake, clutch disc and brake hub Standard clearance Repair limit 0.17 0.52 1.0
6 Backlash between bevel gear and pinion
0.3 0.4
0.75
Adjust or replace
7 Clearance between piston seal ring groove and seal ring
0.5 0.8
0.8
Replace
8 Clearance between cage seal ring groove and seal ring
0.5 0.8
0.8
9
Inside diameter of cage seal ring contact surface
Standard size Tolerance
Standard clearance
Clearance limit Shaft Hole
290 0.5 0.7 +0.081 0 0.5 0.781
10 Inside diameter of piston seal ring contact surface
245 0.050 0.122 +0.046 0 0.050 0.168
11
Brake belleville spring Standard size Repair limit
Free length Installed length Installed load
Free length Installed load
17.1
11.2 38.7 kN {3,950 kg}
16.5 33.9 kN {3,460 kg}
12
Clutch belleville spring
17.6
11.35 37.9 kN {3,860 kg}
17.0 36.0 kN {3,670 kg}
13
Interference between bevel gear and reamer bolt
Standard size Tolerance
Standard interference
Interference limit Shaft Hole
16 +0.019 +0.001 +0.027 0 0.026 0.019
0.02 14 Runout of back face of bevel gear Repair limit: 0.05 (measure after installing to bevel gear) Repair or replace
15
Preload of bevel gear shaft taper roller bearing Standard rotating torque: 4.9 5.9 Nm {0.5 0.6 kgm} (At tip of bevel gear teeth with bevel pinion and gear not meshed: 23.5 28.4 N {2.4 2.9 kg})
Adjust
16 Standard shim thickness for bear- ing cage
2.0
Adjust shim
D375A-5 10-61
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING ECMV
STEERING ECMV
(Electronic Control Modulation Valve)
10-62 D375A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING ECMV
1. ECMV (For left clutch) 2. ECMV (For right clutch) 3. Sudden braking prevention valve 4. Parking brake valve 5. ECMV (For left brake) 6. ECMV (For right brake) 7. Filter 8. Valve seat A. Left clutch operating pressure pick-up port B. Right clutch operating pressure pick-up port C. Left brake operating pressure pick-up port D. Right brake operating pressure pick-up port E. To left clutch F. To left lubrication G. To left brake H. To right clutch J. To right lubrication K. To right brake L. Bevel gear shaft lubrication inlet M. To pin puller solenoid valve N. From pin puller solenoid valve P. From pump
D375A-5 10-63
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING ECMV
10-64 D375A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING ECMV
Outline This machine employs four ECMV (electronic- controlled modulation valve) on the steering con- trol valve. The steering control valve is provided on respec- tive valve sheets as the assembly. The steering control valve is situated in the cir- cuit between the power train pump via the main relief valve and the piston of the steering clutch and the brake. It is configured with two pairs of the steering ECMV (right and left) and the brake ECMV (right and left). Shifting the PCCS lever (steering and forward/ reverse) right or left disconnects the steering clutch. Shifting it further turns ON the brake. The controller sends the instruction to respective ECMV to cause the gradual or sudden turn whichever is designated by the operating posi- tion of the PCCS lever (steering lever). Depending on depth of the pedal depression, the controller instructs ECMV to apply the right and left brakes to stop the machine. The controller that is electrically connected to the PCCS lever and pedal performs above opera- tions by switching the steering control valves (each ECMV). The steering control valves feed the oil from the power train pump to the steering clutch and brake to operate their disk clutches. The sudden stop prevention valve disables sud- den braking that can result when a failure is de- tected in the electric systems. Shifting the parking brake lever to the Lock po- sition switches the port of the parking brake valve, thereby draining the oil between the ECMV for left-and-right brakes and the brake. As the result, the machine brake is turned on. The parking brake is also connected to the brake pedal via the linkage.
D375A-5 10-65
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING CLUTCH, STEERING BRAKE ECMV
STEERING CLUTCH, STEERING BRAKE ECMV
(Electronic control modulating valve)
A: To clutch or brake P: From pump T: Drain Dr: Drain P1: Clutch or brake pressure pick-up port P2: Pilot pressure pick-up port 1. Fill switch connector 2. Proportional solenoid connector 3. Pressure detection valve 4. Fill switch 5. Proportional solenoid 6. Pressure control valve
10-66 D375A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING CLUTCH, STEERING BRAKE ECMV
Outline of ECMV The ECMV (Electronic Control Modulating valve) consists of a pressure control valve and a fill switch. Pressure control valve This valve allows a proportional solenoid to re- ceive a current sent from a steering controller and converts it to oil pressure. Fill switch This component detects that a clutch is filled with oil and has the following functions. 1) When the clutch is filled with the oil, at the same time, a signal (fill signal) is output to the controller and transmits filling termina- tion. 2) While oil pressure is applied to the clutch, the signal (fill signal) is output to the control- ler and transmits the presence of oil pres- sure.
ECMV and Proportional Solenoid One proportional solenoid is mounted for each ECMV. A thrust is generated according to the command current of the controller. The thrust generated by the proportional sole- noid is actuated on a pressure control valve spool and generates oil pressure. Accordingly, by controlling an amount of the command cur- rent, the thrust changes and the pressure control valve is actuated, then a flow of oil and the oil pressure is controlled.
Operation of ECMV The ECMV is controlled using the command cur- rent from the controller to the proportional sole- noid and a fill switch output signal.
ECMV for Steering Clutch and Steering Brake
Outline This valve sets the steering clutch oil pressure or the steering brake oil pressure to a set pressure and switches a circuit to the clutch chamber and the brake chamber.
D375A-5 10-67
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING CLUTCH, STEERING BRAKE ECMV
Operation
1. In case of PCCS lever Neutral, brake pedal Released: Straight travel (Left and right clutch ON, left and right brake Released, parking brake OFF)
In the position of PCCS lever Neutral and brake pedal Released, because the solenoid valve (1) of the steering ECMV is deenergized, the sealing portion of the ball (2) is opened. The oil from the power train pump enters the port Pc of the steering ECMV via the main relief valve. The oil that entered the port Pc passes through the orifice a and passes through the sealing portion of the ball (2), then is drained. The valve (3) is moved right by the tension of the spring (4) and closes the Pc and C ports, then opens the C and Dr ports. At this time, the oil from the back pressure port of a clutch piston is drained from the port C and the clutch is set to ON by the tension of the clutch spring. The oil pressure of the brake circuit is ensured by the orifice a. Further, the proportional solenoid valve (5) of the brake ECMV is energized and pushes the ball (6) to the left direction, then closes the sealing portion. The oil that entered the pump port Pb enters the E port, pushes the valve (7) left, opens the Pb and B ports, and closes the B and Dr ports. The oil that entered the Pb port passes through the B port and flows into the back pressure port of the brake pis- ton. Subsequently, the piston moves to the left di- rection waiting for the rise of the circuit oil pressure and compresses the brake spring, then sets the brake Released. In the parking brake OFF, the parking brake is closed and the oil of the brake circuit is not drained.
10-68 D375A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING CLUTCH, STEERING BRAKE ECMV
2. When the PCCS lever is actuated halfway to the left: Slow swing (Left clutch OFF, left brake Semi-released, right clutch ON, right brake Released, parking brake OFF)
When the PCCS lever is actuated halfway to the left, the solenoid valve (1) of the left steering ECMV is energized and pushes the ball (2) to the left direc- tion, then closes the sealing portion. The oil from the power train pump passes through the orifice a from the port Pc and enters F. Subse- quently, the oil pushes the valve (3) to the left and opens the Pc and C ports, then closes the C and Dr ports. The oil of the C port flows into the clutch pis- ton port and becomes the back pressure, then sets the left clutch to OFF. Further, the proportional solenoid valve (5) of the left ECMV is energized and pushes the ball (6) to the left direction, then closes the sealing portion. The oil that entered the pump port Pb enters the E port and pushes the valve (7) to the left. Besides, the oil pressure of the port B and later out- puts a command current from the controller to the proportional solenoid valve (5) in accordance with the stroke of the PCCS lever. When the current flows into the proportional solenoid (5), the sole- noid generates a thrust in proportion to the current. The sum of the thrust of this solenoid, the thrust caused by the brake port oil pressure, and the res- titution of the pressure control valve spring (8) is balanced and pressure-adjusted. Accordingly, if the stroke of the PCCS lever is small, the oil pressure of the port B and later is also specified high and the brake changes from Re- leased to Semi-released. If the stroke is large, the oil pressure is specified low and the brake changes from Semi-released to ON. In the parking brake OFF, the parking brake valve is closed and the oil of the brake circuit is not drained.
D375A-5 10-69
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING CLUTCH, STEERING BRAKE ECMV
3. When the PCCS lever is actuated fully to the left: Sudden swing (Left clutch OFF, left brake ON, right clutch ON, right brake Released, parking brake OFF)
When the PCCS lever is actuated fully to the left from the state of Section 2, the proportional so- lenoid valve (5) of the left brake ECMV is deen- ergized and sets the ball (6) free, then opens the sealing portion. Because the oil of the port E passes through the sealing portion and is drained, the valve (7) is moved right by the tension of the spring (8). At this time, the port Pb closes and the port B and drain port Dr open. The oil from the power train pump passes through the orifice b from the port Pb and passes through the sealing portion, then is drained. The oil pressure of the clutch circuit is ensured by the orifice b. On the other hand, the oil that flows into the brake piston port and reached the back pres- sure is drained from the port B to Dr. The left brake is set to ON by the tension of the brake spring. In the parking brake OFF, the parking brake valve is closed and the oil of the brake circuit is not drained.
10-70 D375A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING CLUTCH, STEERING BRAKE ECMV
4. In case of brake pedal Stepped on (Clutch ON, brake ON, parking brake OFF)
When the brake pedal is stepped on, the propor- tional solenoid valve (5) of the left and right brake ECMVs is deenergized from energization by the pedal full actuation. A command current is output from the controller to the proportional solenoid valve (5) in accor- dance with the actuation stroke of the brake ped- al. When the current flows into the proportional solenoid valve (5), the solenoid generates a thrust that is proportional to the current. The sum of the thrust of this solenoid, the thrust caused by the oil pressure of the brake port, and the resti- tution of the pressure control valve spring (8) is balanced and oil pressure is specified, thereby enabling adjustment of the effect of the brake. Besides, because the PCCS lever is not actuat- ed, the solenoid valve (1) of the left and right steering ECMVs is deenergized and the left and right clutches are set to ON. Further, when the brake pedal is stepped on, the parking brake valve linked using a linkage is ac- tuated and drains the oil of the brake circuit.
D375A-5 10-71
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING CLUTCH, STEERING BRAKE ECMV
5. In case of parking brake ON (Clutch ON, brake ON, PCCS lever Neutral, braking pedal Released)
When the safety lever for the PCCS lever is set to the position of Locked, the parking brake valve (1) moves to the left direction and the ports A, B, and C open. Accordingly, the oil that flows into the brake piston port and reached the back pressure passes through the port C from the ports A and B and is drained. The back pressure of the brake piston port continues decreasing and the brake is fully set to ON, then is held in the state. Further, because the ports A and B continue be- ing opened together with the drain port C even if the engine is restarted, the state of the brake ON is held. In the parking brake OFF, the parking brake valve (1) moves right and is closed between the port A, port B, and drain port C, then the brake is set Released by oil pressure.
10-72 D375A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PARKING BRAKE VALVE
PARKING BRAKE VALVE
Unit: mm
No.
Check item
Criteria
Remedy
1
Clearance between parking brake valve spool and valve body
Standard size Tolerance
Standard clearance
Clearance limit
Replace Shaft Hole
14 0.020 0.030 +0.011 0 0.020 0.041
0.05
2
Sliding portion outside diameter (spool) with dust sealing and V- packing
14 Tolerance Repair limit
Hard chrome plating correction and replace 0.020 0.030
13.9
3
Parking brake valve spool spring Standard size Repair limit
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING ELECTRONIC CONTROL
STEERING ELECTRONIC CONTROL
1. Monitor panel (Speed range display) 2. Auto shift down switch 3. Engine controller 4. Transmission controller 5. Steering controller 6. Steering control valve 7. Transmission output shaft speed sensor 8. Transmission control valve 9. Engine speed sensor
10-202 D375A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING ELECTRONIC CONTROL
Shift Mode Function 1. Function If you shift the lever to the forward or reverse, the gear speed selected from the shift mode is turned on.
2. Type of Modes 1) F1-R1 (Manual mode) 2) F1-R2 (Shift mode 1) 3) F2-R2 (Shift mode 2)
3. Selecting method Shift the PCCS lever to "N". Select the shift mode using UP or DOWN switch.
Up switch ON Up switch ON
Manual mode Shift mode 1 Shift mode 2
Down switch ON Down switch ON
4. Display The selected shift mode is displayed on the monitor panel.
Auto-shift-down function 1. Function If the load is increased while the machine is traveling or working at the 2nd or 3rd gear speed, the gear speed is shifted down automat- ically. 1) The drawbar pull (load on the machine) is calculated from the engine speed, travel speed, and throttle information from the steering controller, and the gear speed is shifted down automatically according to the load and travel speed. 2) Once the gear speed is automatically shifted down, it is not automatically shifted up to the former position. (Gear speed can be shifted up with the manual switch.) 3) This function is applicable to both forward and reverse travels.
2. How to use Turn the auto-shift-down switch (1) ON.