0p_d155_6_syf_v4gst_ 0330

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D155AX-6D155AX-6Structure and Function ofStructure and Function of

Power line and Hydraulic systemPower line and Hydraulic system

Section 1_1

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Index 1/2Power train outline　　　　　　　　　

4Engine unit　　　　　　　　　　　　 5Cooling system　　　　　　　　　　　 6Radiator　　　　　　　　　　　　　　 7Power train skeleton　　　　　　　

8Power train hydraulic piping drawing　

9Overall drawing of Power train Unit

10Power train unit　　　　　　　　　　 12Layout of Power line unit

13Power line pump　　　　　　　　　　 15Cooling fan pump, Servo valve　　

16 Relationship between EPC current and 　

　　　　　　　 Pump delivery　　　　　　　　　　 17

Cooling fan motor　　　　　　　　　　18

Cooling fan motor control valve　　　　19

Operation of Reversible valve　　　　20

Operation of Safety valve　　　　　　 21

Sectional view of Torque converter 　　 23

Lockup Torque converter 　　　　　　　　24

Operation of Lockup Torque converter 　　 25

Lockup clutch ECMV and Stator clutch ECMV　 26

ECMV for Lockup clutch　　　　　　　　　 27

Operation of ECMV for Lockup clutch　　　　 28

ECMV for Stator clutch　　　　　　　　　 29

Operation of ECMV for Stator clutch 　　　 30

T/C control valve　　　　　　　　　　　 31

Hydraulic circuit diagram Lockup clutch 32

Transmission clutch combination table 　 33

Transmission ECMV　　　　　　　　　　　 34

Characteristic of ECMV of T/M　　　　　 35

Operation of ECMV of T/M　　　　　　　　 36

T/M control valve　　　　 37

Hydraulic circuit diagram T/M ECMV 　 40

Operation of Main relief valve 　　 41

Operation of Torque converter relief valve　 43

Hydraulic circuit diagram T/C and　　　　　 Lubrication 　　　　　　　　　　　　　 44

HSS system　　　　45

Sectional view of Steering unit　　　　 46

Steering operation, HSS 47

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Index 2/2HSS motor sectional view　　　　　　　

48HSS pump and motor

49Operation of LS valve

50PC valve sectional view　　　　　

53PC valve

54PC valve function　　　　　　　　　　

55PC valve operation　　　　　　　

56Pump control system 　　　　　

57HSS operation principle by Animated Mechanism

58HSS operation principle by 3D model

　 64HSS operation principle 　　　

65Additional video materials

71Operation of Brake ECMV

72Parking brake 　　　　　　

75Sudden stop prevention valve

76Brake valve　　　　　　　　　　

77Hydraulic circuit diagram Brake ECMV

78Hydraulic system 　　　　　　　　　　　

82Work equipment control, Blade and

Ripper 83

Sectional view of Control valve 　　　 84

Operation of Unload valve　　　　　　 88

Hydraulic circuit diagram “ Hold ” 　 89

Steering relief operation　　 93

Blade Tilt relief operation 　　　　　　 96

Operation of Quick drop valve 　　　 99

Hydraulic cylinder speed mode 　　　 102

Self pressure reducing valve　　　　 104

Hydraulic circuit diagram (Self pressure reducing valve)

105Operation of Self pressure reducing

valve 106 Self pressure reducing valve　　　　　

110Hydraulic circuit diagram

111Hydraulic circuit diagram 　

　　 112Hydraulic Main control valve

114Hydraulic control valve

116Outline of electronic control system

122Electronic controlled hydraulic system

　 123　　　　

Electronic Hydraulic control 124

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Power train outline

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Engine unit

R.H.

L.H.

Damper

SAA6D140E-5

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Cooling system

Power train oil cooler

Hydraulic oil coolerRadiator

Main frame

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Radiator

Cooling fan motor

Option: Steel fan

photo : Grid EU specification

Standard: Hybrid fan

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Power train skeleton

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Power train hydraulic piping drawing

Quick drop valve

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Overall drawing of Power train Unit 1/2

5. HSS motor6. Main relief, T/C relief valve7. Torque converter, PTO 8. Scavenging pump9. Cooling fan pump10. Hydraulic, HSS pump11. Brake control valve

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Overall drawing of Power train Unit 2/2

56

Centralized pressure detection port

56 1. HSS unit

2. Transmission3. Power train, Lubricating pump4. Power train oil strainer5. Transmission ECMV6. Brake valve

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Power train unit

R.H.

L.H.

HSS unitT/M unit

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Layout of Power line unit 1/2

Universal joint

Hydraulic, HSS pump

Scavenging pump

Cooling fan pump

T/C, PTO

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Layout of Power line unit 2/2

Working lever lock solenoid

Cooling fan pump

Hydraulic, HSS pump

Power train, Lubricatingpump

Self pressure reducing valve

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Power line pump

Cooling fan pump Hydraulic, HSS pump

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Cooling fan pump, Servo valve

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Relationship between EPC current and Pump delivery

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Cooling fan motor

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Cooling fan motor control valve

1. When pump is started 2. When pump is stopped

Suction valve

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Operation of Reversible valve

1. When the ON-OFF solenoid is de-energized. The motor in forward (clockwise)

2. When the ON-OFF solenoid is energized. The motor in reverse (counterclockwise)

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Operation of Safety valve

3. Safety valve

Set pressure24.48Mpa{240kg/cm²}

Fan Control System

Water temp' : 95℃ P/L Oil temp' : 108℃ Hyd Oil temp' : 95℃

FAN CONTROL MAP

Fan speed

70% mode: 875rpm

642 rpm

Water temp' : < 80℃P/L Oil temp' : < 92℃

481 rpm

50

100

1000

1500

Temperature

℃

rpm

Water temp' : < 40℃P/L Oil temp' : < 52℃

0

1250 rpm×1120φEngine: thermostat.

76-90 ℃

Adjustment ID : 0010

D155AX-6

500

95℃108℃

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Sectional view of Torque converter

　 Pump 　 Turbine

　 Lockup clutch Stator 　 Stator clutch

(T/C control valve)

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Lockup Torque converter

Stator

　 Lockup clutch

　 Pump 　 Turbine

　 Stator clutch

Cutaway 　 Model: D375 A-1

　 Engine side

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Operation of Lockup Torque converter

Contents:1. Lockup clutch2. Direct drive range Lockup clutch : ON Stator clutch : OFF 3. Torque converter range Stator clutch : ON Lockup clutch : OFF ( recording : 1min.16sec.)

　 video screen

Cutaway 　 Model: D375 A-1

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Lockup clutch ECMV and Stator clutch ECMV

Both valves are the same outside,discriminate between lockup and stator by name plate.

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ECMV for Lockup clutch

1. Lockup pressure ・ Torque converter travel →　 Direct travel

2. Lockup pressure　　　・ At gear shift (in direct travel)

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Operation of ECMV for Lockup clutch

1. Traveling in Torque converter range 2. Torque converter travel →Direct travel During filling

3. Pressure adjustment1. Proportional solenoid2. Spring3. Pressure control valve4. Pressure detection valve5. Fill switchA: clutch portB: chamberP: pump portT: drain port

BAP

2

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ECMV for Stator clutch

1. Stator clutch pressure・ Direct travel → Torque converter travel

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Operation of ECMV for Stator clutch

1. Traveling in direct range 2. Direct travel → Torque converter travel During filling

3. Pressure adjustment1. Proportional solenoid2. Spring3. Pressure control valve4. Pressure detection valve5. Fill switchA: clutch portB: chamberP: pump portT: drain port

BAP

2

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T/C control valve

T/C control valve

T/C oil filter

Lockup clutch ECMVStator clutch ECMV

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Hydraulic circuit diagram Lockup clutch

T/C range:・ Stator clutch

ECMV: ON・ Lockup

clutch ECMV: OFF

fromPower train pump

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Transmission clutch combination table

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Transmission ECMV

11

6

7

8

9

10

1 ～ 5. Clutch proportional solenoid 6 ～ 10. Clutch fill switch 11. Transmission oil filter

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Characteristic of ECMV of T/M

1. Proportional solenoid command current

2. Clutch input pressure

3. Fill switch output signal

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Operation of ECMV of T/M

1. Before shifting gear (range A in chart)

3. Pressure adjustment (range C in chart)

2. During filling (range B in chart)

2

1. Proportional solenoid2. Spring3. Control valve4. Pressure detection valve5. Fill switch A: Clutch portB: ChamberP: Pump port

5

B

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T/M control valve

T/C relief valve

T/M ECMV valve

Front

Main relief valveFill switch

ECMV solenoid

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Hydraulic circuit diagram T/M ECMV 1/3

T/M control valveat Forward 2nd

from power train pump to transmission case

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Transmission casePower train pump


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Operation of Main relief valve 1/2

Before shifting gear (when draining) (Rage A in chart)

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Operation of Main relief valve 2/2

Stage 1

Power train pump

Stage 2

1. Spool2. Pistona: orifice

Power train pump

to T/C

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Operation of Torque converter relief valve

Torque converter inlet pressure maintenance

to T/C

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Hydraulic circuit diagram T/C and Lubrication

Lockup clutch T/M valveBrake valve

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HSS system

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Sectional view of Steering unit

Output shaft

Ring gearBrake hub Carrier

Brake

Bevel gearSun gear

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Steering operation, HSS

When steering is at “Neutral” (straight travel)

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HSS motor sectional view

・ Type: KMF140 　　　　　　　　　　　　　　　　・ Theoretical

delivery: 141.1cm3/rev ・ Rated output

pressure: 41.2Mpa(420kg/cm2) 　・ Rated rpm: 2205rpm 　　

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HSS pump and motor

Hydraulic, HSS pumpHSS motor

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Operation of LS valve 1/3Direction of Minimum pumpdelivery (Q)

1. Control valve at “Neutral” : ・ Spool (6) is pushed to

right ・ Servo piston (10) moves

to right PL: Load pressure=0Mpa

2. LS differential pressure (ΔPLS) becomes larger : ・ Spool (6) is pushed to

right ・ Servo piston (10) moves

to right PP: Pump discharge pressure PL: Load pressure ΔPLS=PP - PLS

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Operation of LS valve 2/3

Direction of Maximum pumpdelivery (Q)

1. LS differential pressure (ΔPLS) becomes smaller : ・ Spool (6) is pushed to left ・ Servo piston (10) moves

to left

PP: Pump discharge pressure PL: Load pressure ΔPLS=PP - PLS

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Operation of LS valve 3/3

Servo piston is balanced:

・ Area ratio of receiving pressure at both ends of servo piston

A0 : A1 = 3 : 5PP : PEN ≒　5 : 3

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PC valve sectional view

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PC valve

Large pressure receiving area

Servo piston

PC valve

Small pressure receiving area

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PC valve function

・　 To preventive engine stall, under engine low rpm,

　　 heavy traction and combined steering operation,

increase PC-EPC solenoid current.

・　 Engine torque ≧ traction torque + Hydraulic pump absorption torque

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PC valve operation

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Pump control system

balance

balance

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HSS operation principle 　 by Animated Mechanism 1/6

　 video screen

1. Traveling straight forward Transmission power only

Output shaft speed

Transmission output speed(Bevel gear shaft input)

　・ View from machine L.H. hereafter

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HSS operation principle 　 2/6

2. PCCS lever operated to LEFT TURN R.H. Output shaft speed by HSS motor only

　・ View from machine L.H.Output shaft speed

Sun gear input speed(by HSS motor)

　 video screen

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Output shaft speed


　 video screen

3. PCCS lever operated to LEFT TURN L.H. Output shaft speed by HSS motor only

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　 video screen

4. PCCS lever operated to LEFT TURN R.H. Output shaft speed by combined T/M with HSS motor

Output shaft speed



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　 video screen

5. PCCS lever operated to LEFT TURN L.H. Output shaft speed by combined T/M with HSS motor

Output shaft speed



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L.H. Output R.H. Output

6. PCCS lever operated to LEFT TURN L.H. and R.H Output shaft speed

Please click on both video screens

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HSS operation principle by 3D model

Ring gear

Carrier

Sun gear

Ring gear

Sun gear

Carrier

Sun　(HSS) Carrier Ring　(T/M)InputOutput

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Ring gear

Carrier

Sun gear

　 video screen

1. Traveling straight forward, Transmission power only

Sun　(HSS) Carrier Ring　(T/M)Input ○→→Output ○→:　Rotation　direction　from　view　Z ○→Right

←○Left

Z

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2. PCCS lever operated to LEFT TURN R.H. Output shaft speed by HSS motor only

Ring gear

Carrier

Sun gear　 video screen

Z

Sun　(HSS) Carrier Ring　(T/M)Input ○→Output ○→

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　 video screen

Ring gear

Carrier

Sun gear

3. PCCS lever operated to LEFT TURN L.H. Output shaft speed by HSS motor only

Sun　(HSS) Carrier Ring　(T/M)Input ←○Output ←○

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　 video screen

Ring gear

Carrier

Sun gear

4. PCCS lever operated to LEFT TURN R.H. Output shaft speed by combined T/M with HSS motor

Sun　(HSS) Carrier Ring　(T/M)Input ○→ ○→→Output ○→→→

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　 video screen

5. PCCS lever operated to LEFT TURN L.H. Output shaft speed by combined T/M with HSS motor

Ring gear

Carrier

Sun gear

Sun　(HSS) Carrier Ring　(T/M)Input ←○ ○→→Output ○→

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6. PCCS lever operated to LEFT TURN L.H. and R.H Output shaft speed

L.H. Output R.H. Output

Please click on both video screens

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Additional video materials

Contents:1.Traveling straight forward2. Right turn3. Left turn4. Counter rotation, Left turn5. Counter rotation, Right turn ( recording : 2min.13sec.)

Video model: D65-12 HSS Input (T/M)→ Carrier Output 　 →　 Ring gear

　 video screen

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Operation of Brake ECMV 1/3

1. Brake pedal “ Released ” ・ Parking brake lever “Free”

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2. Brake pedal “ Partially depressed ” ・ Parking brake lever “Free”

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3. Brake pedal “ Completely depressed ” Stop position　・ Parking brake “Free”

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Parking brake

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Sudden stop prevention valve

Sudden stop prevention valve

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Brake valve

Front

Brake solenoid valve

R.H.

Parking break lever solenoid valve

L.H.

Parking break PedalSudden stop prevention valve

T/M control valve

Front

0 10

20

30

10

20

30

40

50

500045000400003500030002500

10

mV Kg/cm2

Kg

0 20 30 40 50 60 70 80Brake pedal stroke (mm)Brake pedal stroke (mm)

2500mV 3731mV 4456mV

Potentiometer voltage

Brake pressure

Brake pressure and pedal force--Stroke

Pedal stroke end : 79mm

Limit switch ON:3940--4150mV

Potentiometer voltage

Brake pressure

Pedal force

Brake OFF

Brake ON

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Hydraulic circuit diagram Brake ECMV 1/3

Brake control valveat traveling


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Hydraulic circuit diagram Brake ECMV 2/3



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Hydraulic circuit diagram Brake ECMV 3/3to ripper pin pullersolenoid valve


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Hydraulic system

Quick dropvalve

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Work equipment control, Blade and Ripper

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Sectional view of Control valve 1/4

5-spool valve

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5 spool valve

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Unload valve and LS relief valve

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Ripper tilt spool to LS valve of pump

to tank

EPC valve inlet from self pressure reducing valve

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Operation of Unload valve

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Hydraulic circuit diagram “ Hold ” 1/4

Unload valve

Steering

Blade Lift

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4. Steering priority valve　　 move to right →

Steering spool

to Blade circuit

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LS by- pass valve

3. Pressure compensation valve moves to right→

steering spool

1. Blade Lift spool

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Hydraulic circuit diagram “ Hold + Preset ” 4/4 Preset check valve (5)・ To improves the response of system,including the pump swash plate and pressurecompensation valve by sending the pilot pressure to the LS circuit and push to left 　

←(P1) + (F0) ＞　 (P)P : Unload pressureP1 : Pilot pressure ( from Self press. reducing valve) F0 : load of spring (6)

Part Z

Part X

Z

X

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Steering relief operation 1/3

Steering spool

Unload valve

LS relief valvesteering

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E J

LS pressure: Port (E), (J)

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LS relief valve (5)

LS check valve steering

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Blade Tilt relief operation 1/3

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LS relief valve (5)Work equipment

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Operation of Quick drop valve 1/3

Stage1: Fine control range of lowering blade speed

Condition:・ Stroke of lever is less than70% ( Lowering blade)・ QDV solenoid : OFF・ QDV: No oil circulating

condition

1. Normal mode

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Solenoid function : ON-OFF only

Stage2: Increase the blade Lowering speed

Condition:・ Stroke of lever is more

than70% ( Lowering blade)・ QDV solenoid : ON X=1000mA・ QDV: Oil circulating condition

1. Normal mode

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Stage3: From the circulating condition of lowering blade to the blade tensed

Condition:・ Stroke of lever is more

than70% ( Lowering blade)・ QDV solenoid : ON・ Pressure P ≧

3.43Mpa{35kg/ ㎠ }・ QDV: No oil circulating

condition

1. Normal mode

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Hydraulic cylinder speed mode 1/2

1. Blade Fine control mode

・ Relationship between PCCS stroke and cylinder speed is slower than Standard mode. “RAISE “and “LOWER”・ Relationship between PCCS stroke and input current of EPC valve for control spool is changed by controller.

Raise

Lower

EPC valve EPC valve

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Hydraulic cylinder speed mode 2/2

・ Cancel QDV function, so blade lowering speed is proportional tolever stroke to the end of stroke.

3. Blade slow down mode

4.Blade Float mode

Lower

Float button

Condition:1. Float mode switch ON2. Float button ON3. Full lever stroke ( Lowering blade)

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Hydraulic circuit diagram (Self pressure reducing valve)

1. At engine stop (total low pressure)

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Operation of Self pressure reducing valve 1/4


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2. Load pressure (P2) is lower than output pressure (PR) of Self pressure reducing valve

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3. At raise of load pressure (P2)

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4. In the case of abnormal high pressure (PR)

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Work equipmentlock solenoid


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Hydraulic circuit diagram 1/3

5 spools

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Hydraulic Main control valve 1/2

5 – Spool valve

LS pressure pickup

pump pressure pickup Main relief valve

EPC valve

LS relief workequipment

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Hydraulic Main control valve 2/2

5 spool LS relief valve

Top

Accumulator

EPC solenoidconnector

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Hydraulic control valve 1/6

Steering spool

Hereafter Cutaway model : D65-12

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Steering priority valve

2. When steering is in operation

1. When steering is in neutral

To Blade circuit

To Steering circuit

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Pressure compensation valve

Unload valve

Lift spool

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Main relief valve

Steering relief valve

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Preset check valve

LS check valve for steering

LS check valve for work equipment

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LS by-pass valve

By-pass orifice

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Outline of electronic control system


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Electronic controlled hydraulic system

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Electronic Hydraulic control

R.H. operator seat L.H.

Work equipment controller Power train controller

0p_d155_6_syf_v4gst_ 0330

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