Large Size Bulldozer 1

Troubleshooting Training Course

D155A-6
Power Train System
Part II

Dubai Training and Demonstration Center

 Transmission & Transmission Control valve 2

The transmission is a "forward 3-speed and reverse 3-

speed" transmission which consists of the planetary
gear trains and the disc clutches.
Transmission selects and locks two clutches out of the
five sets of planetary gear trains and disc clutches
hydraulically by using the modulation control valve
to select one travel direction and one gear speed.

Transmission
Control valve

Transmission D155A-6 power train circuit

 Transmission Control : Components 3

Coin filters (5 pcs.)

(for foreign particles
prevention)
6 7

8
9
6
10
7
1

3
5
2
4
1 2 3 5 4
5 Forward

Proportional solenoid Fill switch

1: 3rd clutch 6: 3rd clutch
2: 1st clutch 7: 2nd clutch
3: Reverse clutch 8: 1st clutch
4: 2nd clutch 9: Reverse clutch
5: Forward clutch 10: Forward clutch
 Electric Control System Flow 4

Powertrain Clutch
Controller

feedback

feedback
Signal

Electrical

Signal
Hydraulic

feedback

Mechanical

Signal

ECMV fill switch and Pressure detection valve

proportional solenoid and control valve spool
 D155A-6 Electric Control System 5

The powertrain controller

Monitor carries all control for power train
Pre-set mode switch (T/M, Steering)

Input Signal
• Steering lever (Potentio meter)
• Pre-set mode switch
Engine controller Power train controller • Gear shift switch
• Feed back signals from
chassis
-Engine speed
-T/M out put shaft speed

Transmission
control valve
Steering and brake Output Signal
control valve
• T/M (F.R.1.2.3) shift ECMV
• Steering clutch & brake ECMV

Engine
T/M output shaft
Torque speed sensor
converter Transmission
Steering and brake
 ECMV 6

ECMV : Electronic Control Modulation Valve

Pressure test port

Fill switch

Proportional
solenoid
 ECMV: Operation (Range “A”) 7

Range “A” before shifting gear

No current is supplied
to solenoid and the Solenoid
ball is fully open. Port valve OFF
“B” and “T” are
connected.
Pressure control valve
is completely pushed
to LHS by spring.
Pump Pressure is
drained from “B” to
tank through “T”.

T
Clutch B
pressure is Fill switch
also drained to OFF
tank. The A
clutch is
disengaged.
 ECMV: Operation (Range “B”) 8

Range “B” During Filling

Controller sends
command current to
solenoid, and Solenoid
magnetic force valve ON
pushes rod and
closes ball on seat.
Pressure on “B
“pushes valve to
RHS, then oil starts
to fill clutch from “P”
through “A”.

Trigger (D
range) makes
Fill switch ON B
one time but Fill switch ON
Controller does (Trigger)
not recognize A P
it as clutch
engaged.
 ECMV: Operation (Range “C”) 9

Range “C” Pressure Adjustment

The magnetic force
decides the pressure in “B”
by pushing ball on seat. Solenoid
Pressure control valve is valve ON
returned to LHS to close
the passage from pump
line (P) and balanced
with LHS pressure
against to clutch
pressure and spring
force.

Clutch
pressure
modulation
is completed.
Fill switch is
turned ON.
B
Controller Fill switch ON
recognizes that (engaged)
this clutch is P
engaged by the
2nd ON signal.
 D155A-6 Transmission Assembly 10

7. R ring gear (hub)

8. R planetary pinion (number of teeth: 26)
9. R ring gear (number of internal teeth: 86)
10. F planetary pinion (number of teeth: 24)
11. F ring gear (number of internal teeth: 91)
12. 3rd planetary pinion (number of teeth: 35)
13. 3rd ring gear (number of internal teeth: 89)
14. 2nd planetary pinion (number of teeth: 31)
15. 2nd ring gear (number of internal teeth: 91)
16. 1st ring gear (number of internal teeth: 91)
17. 1st planetary pinion (number of teeth: 27)
18. Transmission output shaft
(3rd sun gear)(number of teeth: 19)
19. 1st clutch housing
20. 1st clutch piston
21. 1st sun gear (number of teeth: 37)
22. 1st carrier
23. 2nd clutch housing
24. 2nd clutch piston
25. 2nd sun gear (number of teeth: 29)
26. 2nd carrier
27. 3rd clutch housing
28. 3rd clutch piston
29. 3rd carrier
30. F clutch housing
31. F clutch piston
32. F carrier
33. R clutch housing
34. F sun gear (number of teeth: 44)
35. R clutch piston
36. Washer spring
37. Clutch plate
38. Clutch disc
39. Piston return spring
40. R carrier
41. Front housing
42. R sun gear (number of teeth: 34)
Planetary mechanism video 11
 D155A-6 Gear speed & clutch combination 12

Gear
(R) (F) (3 rd) (2 nd) (1st)
speed
F-1st
F-2nd
F-3rd
Neutral
R-1st
R-2nd
R-3rd

* Clutch pack of pre-set

speed is filled with low
pressure oil

* Max. pressure
No. of plate s & discs at Hi-idling
Clutch No No. of No. of Clutch
plates discs pressure
Clutch plate Sun gear No.1 (R) 6 6 3.14 MPa
Clutch disc Carrier No.2 (F) 6 7 3.04 Mpa
Ring gear Input shaft No.3 (3 rd) 3 4 3.33 MPa
No.4 (2nd) 3 4 3.09 MPa
Planetary pinion Output shaft
No.5 (1st) 2 3 3.33 MPa
 Power flow at F1 13

“F” clutch ring gear and “1st”clutch gear are locked. Input shaft

F clutch sun gear

F clutch planetary pinion

F clutch carrier

3 rd clutch carrier

3 rd planetary pinion

3 rd Ring gear

2 nd carrier

2nd planetary pinion

2nd Ring gear

1st carrier

2nd sun gear

1st planetary pinion

1st sun gear

Output shaft
Transmission plastic model video 14
 Gear shift mode selector switch 15

Automatic gearshift Manual gearshift

Mode screen mode screen

Shifts up and down This mode is effective when load is

automatically according to the easy to fluctuate, it can shift down
load. only.
 Pre-Set Mode (Automatic Mode) 16

AUTO F1 – R1
Shift up Shift down

AUTO F1 – R2
Shift up Shift down

AUTO F2 – R2
Shift up Shift down

Shift up AUTO F2 – R3L

button You can shift up
Shift down F3L – R3L F3 – R3L
button after shifting to “F” or “R”.
Neutral When shifting F3L or R3L speed range of
position T/M is 3rd. But Engine speed is controlled
lower. So Max. travel speed is limited.

Auto shift up and shift down

 Automatic Shift Mode 17

Example : Pre-set mode F2-R2

Auto shift up and shift down

Auto shift up and shift down

Pre-Set Mode (Manual Mode) 18

F1 – R1
Shift up Shift down

F1 – R2
Shift up Shift down

F2 – R2
You can shift up

F3 – R3
Shift up
after shifting to “F” or “R”.
button
Shift down
button
N position
Auto shift down only
 Manual Shift Mode 19

Example : Pre-set mode F2-R2

Auto shift down only

Auto shift down only

 20

END