Drive and Control Systems for Loaders

Drive and control systems for loaders

Very high demands are placed on the drive As with the travel drives the efficiency, high performance and
technology of mobile loading machines with operator comfort of the service hydraulics is of equal importance.
regard to efficiency and driver comfort.
As well as the conventional open center controls and load sensing
The Mannesmann Rexroth Group of companies, systems with fixed or variable displacement pumps the LUDV
with its business sectors of Brueninghaus Hydromatik control, which has been developed and patented by Rexroth
and Rexroth Hydraulics, supply complete drive and control systems Hydraulics, is being increasingly applied.
that fully meet these requirements.
For loaders in the power range of up to 60 kW purely hydrostatic
drives are the norm. Advantages of hydrostatic drive systems
For the higher power range (> 60 kW) as well as the hydrostatic
Optimum ergonomic
drives with a subsequent power shift gearbox, multiple motor
drives with a summation gearbox are also utilised. Functional operation Comfort

With multiple motor drives two hydraulic motors operate in parallel Low mechanical forces
and are connected to the drive shaft via a mechanical summation Optimum power utilisation
gearbox.
Optimum machine utilisation Efficiency
For the power range above 125 kW multi-motor concepts with
switchable summation gearboxes provide the ideal solution. High availability

The management of the entire drive train is controlled via a micro- Reduced fuel consumption
controller. Environment
Reduced exhaust emissions protection
Reduced noise emissions

Standardised components
Operational
Modular design safety
Reduction of mechanical components

2
3
An overview of travel drive systems

Correlation of drive systems to power range

Bucket volume (m3)

Unladen weight of unit (t)

30 6

5
25
4

20 3

2
15
1
0,5
10

30 60 90 120 150 180 210 250

Hydrostatic
transmission Drive power (kW)

with
summation
gearbox
k 2 motors

with mecha-
nical dircet
through
drive

with
summation
gearbox
k 2 motors
k 1 coupling

with
summation
gearbox
k 2 motors
k 3 couplings

with
power shift
K1 K
2 K
gearbox
3 K
4

4
Power range < 60 kW Drive

Hydrostatic

k Hydraulic conversion, stepless

k Shift (hydraulic motor) shock-free
k No interruption of tractive effort

A4VG + A6VM

Power range > 50 kW

Hydrostatic + summation gearbox

k Hydraulic conversion, stepless

k Shift (hydraulic motor) shock-free
k No interruption of tractive effort

A4VG + 2 x A6VM + summation gearbox

(without/with gear shift coupling)

Power range 50 – 100 kW

Hydrostatic + mechanical
k Hydraulic conversion,
stepless + mechanical direct through drive
k Shift virtually shock-free
k Brief interruption of the tractive effort

A4VG + A6VM + summation gearbox

(with gear shift clutch)

Power range > 60 kW

Hydrostatic + power shift gearbox

k Hydraulic conversion,
stepless + mechanical switching stages
k Shift (gearbox) virtually shock-free
k Brief interruption of the tractive effort

A4VG + A6VM + power shift gearbox

5
Hydrostatic transmission

Tractive effort
Accelerator Inching Direction Override
pedal pedal of travel
1 2

Pump

Brakes
Motor

Vehicle velocity

A4VG..DA
Mechanical
injection pump A6VM..HA1R

Variable displacement pump A4VG...DA

Data sheet RE 92003

Variable displacement pump A10VG...DA

Data sheet RE 92750

Drive direction valve

DA control valve for

RPM related speed definition
Load limitation control
Integrated inching function,
inching valve can be
optionally controlled by the
brake pressure

Pressure cut-off

Variable displacement motor

A6VM...HA1R
Data sheet RE 91604

Load dependent control (HA1)

Vg max circuit:
Motor can be held in the Vg max
position via a switching solenoid

Valve for direction of travel signal

sensing

6
Hydrostatic transmission with a power shift gearbox

BB-3 Software Change

Tractive effort
Bodem manual/
Direction of Gear automatic Accelerator
travel selection pedal MC
+ 1. Gear
BB-3
Software
Diagnostics LSG
Parameter setting
RS 232 Process monitoring

2. Gear
command value

Actual RPM
actual value

Inching
Position

Position

Gear 2

Gear 1
RPM
Vehicle speed
K2

STM

A4VG..DA A6VM..DA
Mechanical Electrical
injection pump actuator
K1

Variable displacement motor

A6VM...DA2
Data sheet RE 91604

RPM dependent speed selection

Vg max circuit:
Motor can be held in the Vg max
position via a switching solenoid

Valve for direction of travel signal

sensing

Power shift gearbox with an A6VM

Data sheet RE 91604

7
Hydrostatic transmission with summation gearbox

Tractive effort
Accelerator Inching Direction Override
pedal pedal of travel
1 2

A6VM..HA1U
Brakes

Vehicle speed

A4VG..DA
Mechanical
injection pump

A6VM..HA1R

Summation gearbox with/without coupling

BB-3 Software
Bodem
Tractive effort

Gear Direction of Accelerator Inching

selection travel pedal pedal MC A6VM1 x i1
+ A6VM2 x i3
BB-3 Software
Diagnostics A6VM1 /De-coupled
Parameter setting A6VM2 x i3
RS 232 Process monitoring
A6VM1 x i2
A6VM2 /De-coupled
command value

actual value

RPM
Position

Position

A6VM1 Vehicle speed

K1 K2

STM

A4VG K3
Mechanical Electrical A6VM2
injection pump actuator

Summation gearbox with 3 gear shift clutches

8
Hydrostatic transmission with a mechanical direct
through drive
BB-3 Software
Bodem

Tractive effort
Gear Direction of Accelerator Inching
selection travel pedal pedal MC
+
BB-3 Software
P
Diagnostics nL
Parameter setting
RS 232 Process monitoring
Switching point
Hydrostatic
drive
K1
command value

Mechanical
actual value

direct drive
Position

Position

RPM

Vehicle speed

Hydromechanical drive
A6VM
k Combines the advantages of the
STM
hydrostatic drive with that of the
mechanical drive

A4VG K2

Mechanical Electrical Hydrostatic drive (working range)

injection pump actuator
k Maximum tractive effort at low diesel
Hydromechanical drive speeds
k High start-up efficiency
k Jerk-free change of travel direction
k Load limiting control also with power
consumed by auxiliary actuators
k Requirement dependent power
BKM
distribution between the travel drive and
service hydraulics

Hydrostatic
Mechanical drive (changing the
operating location)
k Low efficiency losses
k Reduced noise emissions

BKM

Mechanical

Hydromechanical drive - force transmission

9
Hydrostatic transmission for compact loaders

n1
BKM

n2

n1 = – n2 n1 < n2 n1 = n2

Steering via speed differences at the wheels on each side

2 circuit drive with a compact tandem pump

special design for compact loaders
4TH6 4TH6 MCR

G2
G3
A10VG

MCR

3 SM12

Tandem pump A10VG + A10VG

Bucket
Option

Boom

Wheel drive via MCR radial piston motor

Control of the implement hydraulics and the hydrostatic transmission via a joy-stick

10
11
Electronic control

Travel direction: Tractive effort

forwards/neutral/ limitation
BB-3 Software reverse
Bodem
Accelerator Inching Constant
pedal pedal Speed Drive MC
+
Software
BB-3 FGR
Diagnostics
Parameter setting
RS 232 Process monitoring Variable displacement pump A4VG
For closed circuit travel drives with electro-
proportional control. The pump for the
command value

implement hydraulics is fitted to the through

actual value

drive (100% through drive torque).

Position

Position

RPM

Data sheet RE 92003

Implement hydraulics

STM

A4VG A10VO/A11VO A6VM

Mechanical Electrical
injection pump actuator
Variable displacement motor A6VM
For closed circuit transmission with electro-
Electronics for travel controls proportional control
Data sheet RE 91604

Variable displacement pump

A10VO/A11VO
For open circuit implement hydraulics
controlled via a microcontroller
Control Data sheets RE 92701 (A10VO)
block M7 Micro- and RE 92500 (A11VO)
controller

Diesel
motor
A4VG A10VO/A11VO
Control block M7
Load sensing and LUDV
– Anti-cavitation - pre-charge valve
– Electrical float position
– Separate tank line with regeneration
Electronic control for implement hydraulics Data sheet RE 64291

12
Electronic travel controls Electronic implement hydraulics
k Direction of travel pre-selection k Optimum levelling capability even due to
k Pre-set speed the Z-kinematics
k Acceleration/deceleration pre-selection k Load limitation, i.e. protection against
over-loading the bucket
k Drive characteristics
k Weighting facility for the bucket contents
– Working mode: flat characteristic curve
k Diesel motor load limitation
– Travel mode: steep characteristic curve
k Matching the working speed to the
k Load limiting control operator Microcontroller MC7 + Software FGR
k Inching/braking function k Steering control via a joy-stick with a Encapsulated microcontroller for mobile
k Over-speed safety for the engine safety switch applications
k Hydraulic motor adjustment device k Networking the diesel motor and travel Software with load limiting control for hydro-
– Electronic DA control hydraulics via a CAN-bus is possible static transmission with automotive speed
(see below) control
– Vg max circuit
Data sheets RE 95050, RE 95057

Additional functions
k Tractive effort limitation
k Speed limitation
– Crawl gear
– Constant speed drive (CSD)
k Fuel economizing driving
k Integration of the service hydraulics

Electronic amplifier cards MHVA, MHVT

Data sheets, RE 29875, RE 29880,
RE 29882, RE 29883

Network via a CAN-bus

Travel Accelerator Inching Tractive CSD Diesel Variable Variable Service Steering
direction pedal pedal effort motor displacement displacement hydraulics
pump motor

PC + Software Bodem

BODEM MC
MC + FGR Service
Travel controls
hydraulics

Control panel BB-3 Display

Process monitoring
Diagnostics (actual values)
Parameter setting
Process CAN-Bus
BB-3 monitoring

13
Implement hydraulics for wheel loaders

Bucket volume (m3)

Unladen weight of unit (t)
30 6

5
25
4

20 3

2
15
1
0,5
10

30 60 90 120 150 180 210 250

Drive power (kW)
60 KW
80 KW
100 KW
Fixed displacement Variable displacement
pump G2/G3 pump A10VO/3
For further information see data For further information see
sheets RE 10030 and RE 10039 data sheet RE 92701

Fixed displacement pumps Variable displacement pumps

Steering

Steering
Bucket

Bucket
Boom

Boom

14
 Fixed or variable displacement pumps
for the implement hydraulics can be mounted
onto the through drive of (100% through
drive torque) the variable displacement travel
Control
block drive pump. A splitter box is not required.

Priority
valve
Control block M1 and MO
Diesel Open center control
motor
– Electrical float position
– Regeneration valve
Data sheets RE 64263 and RE 64266
Drive with fixed displacement pump

Control block M7
Load sensing and LUDV
– Electrical float position
– Separate tank line with regeneration
Data sheet RE 64291

Control
block

Pilot control units 4THF6, 5THF6, 4TH6,

2TH6
Priority – Electrical or mechanical detent
valve
– Float position function
Diesel Data sheets RE 64522, 64553, 64555
motor
Steering units LAGUV and LSPSD
– Amplification and conversion for emergency
operation
Drive with variable displacement pump – Priority valve
Data sheet RE 14365
Cartridge valves and complete control
blocks Data sheet RE 00182

15
Implement hydraulics for backhoe loaders

Fixed displacement pumps G2/G3

For further information see data sheets
RE 10030 and RE 10039
Slew

Control block excavator

Support Variable displacement pumps A10VO/3
Boom For further information see data sheet

equipment
Additional
RE 92701

Bucket
Dipper
Hoist
Bucket Fixed or variable displacement pumps
Loader control block for the implement hydraulics can be mounted
with priority valve onto the through drive of (100% through
drive torque) the variable displacement travel
drive pump
A splitter box is not required

Control block M1 and MO

Open center control
Diesel
– Electrical float position
motor – Regeneration valve
For further information see data sheets
RE 64263 and RE 64266

Drive with variable displacement pump Control block M7

Load sensing and LUDV
– Electrical float position
Service hydraulics for telescopic loaders – Separate tank line with regeneration
For further information see data sheet
RE 64291

Pilot control units 4THF6, 5THF6, 4TH6,

2TH6
– Electrical or mechanical detent
Additional equipment

– Float position function

Level compensation

For further information see data sheets

RE 64522, RE 64553, RE 64555
Telescope
Boom/tilt

Support

Steering units LAGUV and LSPSD

– Amplification and conversion for emergency
Loader control block
with priority valve operation
– Priority valve
For further information see data sheet
RE 14365

Cartridge valves and complete control

blocks
Diesel
motor For further information see data sheet
RE 00182

Drive with variable displacement pump

16
Hydraulic remotely powered brake

Compact design
k Piping reduced to a minimum
k Parking brake electrically actuated
k Possibility of directly mounting the
accumulator
Brake light
switch
Brake pedal k Sensitive metering

2 circuit brake
valve
Accumulator pressure
warning switch
Accumulator Parking brake
loading valve valve

Additional (optional)
actuators

Compact brake block Compact brake block

LT13, Data sheet LT17, (for mounting in
Diesel RE 66220 the drivers cab)
Diesel

Spring loaded Accumulator loading Data sheet RE 66222

accumulator
valve LT06, Data sheet
RE 66191

Modular design
k Components have a low space
requirement
k Components can be located wherever
Brake pedal required
k Sensitive metering
2 circuit brake k Quickly ready for operation
valve

Brake light
switch

Parking brake
valve
Accumulator
pressure warning

Additional (optional)
actuators
Accumulator
loading valve

1 circuit remotely Inching brake valve

powered brake valve LT31, Data sheet
Diesel LT05, Data sheet RE 66226
Spring loaded RE 66144
accumulator

17
Steering

Steering systems
k Open centre steering with non reaction
k Closed centre steering with non reaction
(load sensing dynamic)
Non reaction means that the occurring wheel
forces do not act on the steering wheel via
the steering hydraulics

EF
Service hydraulics
Priority valve
P
High pressure (not metered)
High pressure (metered) LAG and LAS
Low pressure
Suction pressure
Entrapped oil
Ambient pressure

Steering with chamber isolation - servo operation

RSM System
The Rexroth stabilisation system RSM is built
into the lift cylinders of the wheeled loaders
and dampens out the pitching oscillations
which occur whilst the vehicle is moving.
The installation of the RSM system in wheel
loaders result in the following further
advantages:
k Shorter braking distances
k Stable steering characteristics
k Higher transport speeds
k Higher transfer rates
k Greater comfort for driver
k Lower repair costs or idle times

1 RSM valve
2 Logic valve
3 LFA-D2 valve
4 4/2-way directional
valve
5 DBD valve
(design tested)
6 Accumulator

Stabilisation module RSM

For further information see data sheet
RE 64615

18
Filtration
Criteria for the functional safety of axial piston units

Standard: suction filtration Filter rating

(A4VG / A10VG) To guarantee the functional safety of the axial
piston units the following cleanliness
classes are the minimum requirements
B necessary of the pressure fluids
k 9 to NAS 1638
k 6 to SAE
k 18/15 to ISO/DIS 4406

For very high pressure fluid temperatures

(90° C up to a maximum of 115°C) the
A following cleanliness classes are the minimum
requirement
k 8 to NAS 1638
k 5 to SAE
k 17/14 to ISO/DIS 4406

Variant: pressure filtration The finer the filtration the better the fluid
(A4VG / A10VG) cleanliness class obtained and the higher the
service life of the axial piston units.

Use filter without bypass.

Recommendation: use clogging indicators.

B Further information regarding filtration of the

pressure fluids can be found in the pump
data sheets.

Optimum cold start conditions for pressure filtration is

achieved via the integrated filter short circuit valve

Variant: suction/return filtration

B

Return oil from the

implement hydraulics

Advantages k Low space requirements

k Improved suction characteristics

19
Components

Variable displacement pump Variable displacement pump

A4VG A10VO
Closed circuit Open circuit
Nominal pressure 400 bar Nominal pressure 280 bar
Peak pressure 450 bar Peak pressure 350 bar
For further information see For further information see
data sheet RE 92003 data sheet RE 92701

Variable displacement pump Control block M7

A11VO Load sensing and LUDV
Open circuit For further information see
Nominal pressure 350 bar data sheet RE 64291
Peak pressure 400 bar
For further information see
data sheet RE 92500

Radial piston motor MCR Stabilisation module RSM

Closed circuit For dampening the pitching
Nominal pressure 400 bar movements which occur during
Peak pressure 450 bar operation
For further information see For further information see
data sheets RE 15205 data sheet RE 64615
to 15210

Variable displacement motor Control blocks

A6VM SM 12/18 RE 64122/124
Open and closed circuit SP 12/18 RE 64145/148
Nominal pressure 400 bar SX 18 RE 64127
Peak pressure 450 bar M1-16/22/32 RE 64263
For further information see M7-22 RE 64287
data sheet RE 91604 Pilot control units
4/5THF6 RE 64553
4TH6 RE 64555
2-2TH6 RE 64552

Drive and Control

Brueninghaus Hydromatik GmbH Mannesmann Rexroth AG

RE 98056/04.98

Glockeraustraße 2 Rexroth Hydraulics

D–89275 Elchingen, Germany Jahnstraße 3-5
Tel +49 (0) 7308 820 D–97816 Lohr am Main, Germany
Fax +49 (0) 7308 7274 Tel +49 (0) 9352 180
Fax +49 (0) 9352 181040