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D155AX-6 GST Apr 2006 Page 1/122
D155AX-6D155AX-6Structure and Function ofStructure and Function of
Power line and Hydraulic systemPower line and Hydraulic system
Section 1_1
D155AX-6 GST Apr 2006 Page 2/122
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
D155AX-6 GST Apr 2006 Page 3/122
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
D155AX-6 GST Apr 2006 Page 5/122
Engine unit
R.H.
L.H.
Damper
SAA6D140E-5
D155AX-6 GST Apr 2006 Page 6/122
Cooling system
Power train oil cooler
Hydraulic oil coolerRadiator
Main frame
D155AX-6 GST Apr 2006 Page 7/122
Radiator
Cooling fan motor
Option: Steel fan
photo : Grid EU specification
Standard: Hybrid fan
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Power train skeleton
D155AX-6 GST Apr 2006 Page 9/122
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
D155AX-6 GST Apr 2006 Page 16/122
Cooling fan pump, Servo valve
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Relationship between EPC current and Pump delivery
D155AX-6 GST Apr 2006 Page 18/122
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)
D155AX-6 GST Apr 2006 Page 21/122
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℃
D155AX-6 GST Apr 2006 Page 23/122
Sectional view of Torque converter
Pump Turbine
Lockup clutch Stator Stator clutch
(T/C control valve)
D155AX-6 GST Apr 2006 Page 24/122
Lockup Torque converter
Stator
Lockup clutch
Pump Turbine
Stator clutch
Cutaway Model: D375 A-1
Engine side
D155AX-6 GST Apr 2006 Page 25/122
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
D155AX-6 GST Apr 2006 Page 26/122
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
D155AX-6 GST Apr 2006 Page 31/122
T/C control valve
T/C control valve
T/C oil filter
Lockup clutch ECMVStator clutch ECMV
D155AX-6 GST Apr 2006 Page 32/122
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
D155AX-6 GST Apr 2006 Page 34/122
Transmission ECMV
11
6
7
8
9
10
1 ~ 5. Clutch proportional solenoid 6 ~ 10. Clutch fill switch 11. Transmission oil filter
D155AX-6 GST Apr 2006 Page 35/122
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
D155AX-6 GST Apr 2006 Page 39/122
Hydraulic circuit diagram T/M ECMV 2/3
Transmission casePower train pump
T/M control valveat Forward 2nd
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Hydraulic circuit diagram T/M ECMV 3/3
T/M control valveat Forward 2nd
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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
D155AX-6 GST Apr 2006 Page 44/122
Hydraulic circuit diagram T/C and Lubrication
Lockup clutch T/M valveBrake valve
D155AX-6 GST Apr 2006 Page 45/122
HSS system
D155AX-6 GST Apr 2006 Page 46/122
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)
D155AX-6 GST Apr 2006 Page 48/122
HSS motor sectional view
・ Type: KMF140 ・ Theoretical
delivery: 141.1cm3/rev ・ Rated output
pressure: 41.2Mpa(420kg/cm2) ・ Rated rpm: 2205rpm
D155AX-6 GST Apr 2006 Page 49/122
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
D155AX-6 GST Apr 2006 Page 51/122
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
D155AX-6 GST Apr 2006 Page 53/122
PC valve sectional view
D155AX-6 GST Apr 2006 Page 54/122
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
D155AX-6 GST Apr 2006 Page 56/122
PC valve operation
D155AX-6 GST Apr 2006 Page 57/122
Pump control system
balance
balance
D155AX-6 GST Apr 2006 Page 58/122
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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HSS operation principle 3/6
Output shaft speed
Sun gear input speed(by HSS motor)
video screen
3. PCCS lever operated to LEFT TURN L.H. Output shaft speed by HSS motor only
D155AX-6 GST Apr 2006 Page 61/122
HSS operation principle 4/6
video screen
4. PCCS lever operated to LEFT TURN R.H. Output shaft speed by combined T/M with HSS motor
Output shaft speed
Sun gear input speed(by HSS motor)
Transmission output speed(Bevel gear shaft input)
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HSS operation principle 5/6
video screen
5. PCCS lever operated to LEFT TURN L.H. Output shaft speed by combined T/M with HSS motor
Output shaft speed
Transmission output speed(Bevel gear shaft input)
Sun gear input speed(by HSS motor)
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HSS operation principle 6/6
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
D155AX-6 GST Apr 2006 Page 64/122
HSS operation principle by 3D model
Ring gear
Carrier
Sun gear
Ring gear
Sun gear
Carrier
Sun (HSS) Carrier Ring (T/M)InputOutput
D155AX-6 GST Apr 2006 Page 65/122
HSS operation principle 1/6
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
D155AX-6 GST Apr 2006 Page 66/122
HSS operation principle 2/6
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 ○→
D155AX-6 GST Apr 2006 Page 67/122
HSS operation principle 3/6
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 ←○
D155AX-6 GST Apr 2006 Page 68/122
HSS operation principle 4/6
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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HSS operation principle 5/6
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 ○→
D155AX-6 GST Apr 2006 Page 70/122
HSS operation principle 6/6
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
D155AX-6 GST Apr 2006 Page 71/122
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
D155AX-6 GST Apr 2006 Page 72/122
Operation of Brake ECMV 1/3
1. Brake pedal “ Released ” ・ Parking brake lever “Free”
D155AX-6 GST Apr 2006 Page 73/122
Operation of Brake ECMV 2/3
2. Brake pedal “ Partially depressed ” ・ Parking brake lever “Free”
D155AX-6 GST Apr 2006 Page 74/122
Operation of Brake ECMV 3/3
3. Brake pedal “ Completely depressed ” Stop position ・ Parking brake “Free”
D155AX-6 GST Apr 2006 Page 75/122
Parking brake
D155AX-6 GST Apr 2006 Page 76/122
Sudden stop prevention valve
Sudden stop prevention valve
D155AX-6 GST Apr 2006 Page 77/122
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
D155AX-6 GST Apr 2006 Page 79/122
Hydraulic circuit diagram Brake ECMV 1/3
Brake control valveat traveling
fromPower train pump
D155AX-6 GST Apr 2006 Page 80/122
Hydraulic circuit diagram Brake ECMV 2/3
Brake control valveat traveling
fromPower train pump
D155AX-6 GST Apr 2006 Page 81/122
Hydraulic circuit diagram Brake ECMV 3/3to ripper pin pullersolenoid valve
Brake control valveat traveling
D155AX-6 GST Apr 2006 Page 82/122
Hydraulic system
Quick dropvalve
D155AX-6 GST Apr 2006 Page 83/122
Work equipment control, Blade and Ripper
D155AX-6 GST Apr 2006 Page 84/122
Sectional view of Control valve 1/4
5-spool valve
D155AX-6 GST Apr 2006 Page 85/122
Sectional view of Control valve 2/4
5 spool valve
D155AX-6 GST Apr 2006 Page 86/122
Sectional view of Control valve 3/4
Unload valve and LS relief valve
D155AX-6 GST Apr 2006 Page 87/122
Sectional view of Control valve 4/4
Ripper tilt spool to LS valve of pump
to tank
EPC valve inlet from self pressure reducing valve
D155AX-6 GST Apr 2006 Page 88/122
Operation of Unload valve
D155AX-6 GST Apr 2006 Page 89/122
Hydraulic circuit diagram “ Hold ” 1/4
Unload valve
Steering
Blade Lift
D155AX-6 GST Apr 2006 Page 90/122
Hydraulic circuit diagram “ Hold ” 2/4
4. Steering priority valve move to right →
Steering spool
to Blade circuit
D155AX-6 GST Apr 2006 Page 91/122
Hydraulic circuit diagram “ Hold ” 3/4
LS by- pass valve
3. Pressure compensation valve moves to right→
steering spool
1. Blade Lift spool
D155AX-6 GST Apr 2006 Page 92/122
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
D155AX-6 GST Apr 2006 Page 93/122
Steering relief operation 1/3
Steering spool
Unload valve
LS relief valvesteering
D155AX-6 GST Apr 2006 Page 94/122
Steering relief operation 2/3
E J
LS pressure: Port (E), (J)
D155AX-6 GST Apr 2006 Page 95/122
Steering relief operation 3/3
LS relief valve (5)
LS check valve steering
D155AX-6 GST Apr 2006 Page 96/122
Blade Tilt relief operation 1/3
D155AX-6 GST Apr 2006 Page 97/122
Blade Tilt relief operation 2/3
D155AX-6 GST Apr 2006 Page 98/122
Blade Tilt relief operation 3/3
LS relief valve (5)Work equipment
D155AX-6 GST Apr 2006 Page 99/122
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
D155AX-6 GST Apr 2006 Page 100/122
Operation of Quick drop valve 2/3
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
D155AX-6 GST Apr 2006 Page 101/122
Operation of Quick drop valve 3/3
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
D155AX-6 GST Apr 2006 Page 102/122
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
D155AX-6 GST Apr 2006 Page 103/122
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)
D155AX-6 GST Apr 2006 Page 104/122
Self pressure reducing valve
D155AX-6 GST Apr 2006 Page 105/122
Hydraulic circuit diagram (Self pressure reducing valve)
1. At engine stop (total low pressure)
D155AX-6 GST Apr 2006 Page 106/122
Operation of Self pressure reducing valve 1/4
1. At engine stop (total low pressure)
D155AX-6 GST Apr 2006 Page 107/122
Operation of Self pressure reducing valve 2/4
2. Load pressure (P2) is lower than output pressure (PR) of Self pressure reducing valve
D155AX-6 GST Apr 2006 Page 108/122
Operation of Self pressure reducing valve 3/4
3. At raise of load pressure (P2)
D155AX-6 GST Apr 2006 Page 109/122
Operation of Self pressure reducing valve 4/4
4. In the case of abnormal high pressure (PR)
D155AX-6 GST Apr 2006 Page 110/122
Self pressure reducing valve
Work equipmentlock solenoid
Self pressure reducing valve
D155AX-6 GST Apr 2006 Page 111/122
Hydraulic circuit diagram 1/3
5 spools
D155AX-6 GST Apr 2006 Page 112/122
Hydraulic circuit diagram 1/3
D155AX-6 GST Apr 2006 Page 113/122
Hydraulic circuit diagram 3/3
D155AX-6 GST Apr 2006 Page 114/122
Hydraulic Main control valve 1/2
5 – Spool valve
LS pressure pickup
pump pressure pickup Main relief valve
EPC valve
LS relief workequipment
D155AX-6 GST Apr 2006 Page 115/122
Hydraulic Main control valve 2/2
5 spool LS relief valve
Top
Accumulator
EPC solenoidconnector
D155AX-6 GST Apr 2006 Page 116/122
Hydraulic control valve 1/6
Steering spool
Hereafter Cutaway model : D65-12
D155AX-6 GST Apr 2006 Page 117/122
Hydraulic control valve 2/6
Steering priority valve
2. When steering is in operation
1. When steering is in neutral
To Blade circuit
To Steering circuit
D155AX-6 GST Apr 2006 Page 118/122
Hydraulic control valve 3/6
Pressure compensation valve
Unload valve
Lift spool
D155AX-6 GST Apr 2006 Page 119/122
Hydraulic control valve 4/6
Main relief valve
Steering relief valve
D155AX-6 GST Apr 2006 Page 120/122
Hydraulic control valve 5/6
Preset check valve
LS check valve for steering
LS check valve for work equipment
D155AX-6 GST Apr 2006 Page 121/122
Hydraulic control valve 6/6
LS by-pass valve
By-pass orifice
D155AX-6 GST Apr 2006 Page 122/122
Outline of electronic control system
1. At engine stop (total low pressure)
D155AX-6 GST Apr 2006 Page 123/122
Electronic controlled hydraulic system
D155AX-6 GST Apr 2006 Page 124/122
Electronic Hydraulic control
R.H. operator seat L.H.
Work equipment controller Power train controller
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