Cooling system of DL Loader

All DL model

Jan., 24th,2007
Overseas P/S Team

Docu No : DLT 05 08 - Rev03

Cooling system

¾ Simple system logic.

Brake pilot & fan supply valve

Fan motor
(Variable speed motor)

Pilot pump Fan speed control

Cooling fan
Coolant temp. sensor
Controller Tank
Reverse fan
T/Mission temp. sensor
Reverse fan signal
Fan RPM is changed by coolant temp. & transmission oil temp.
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Cooling system

¾ Component of cooling system.

1. Engine.
2. Brake & pilot pump.
3. Cooler.
4. Electronic unit (ECU)
5. Fan motor.
6. Cooling fan.
7. T/M oil temperature sensor .
8. E/G coolant temperature sensor.
9. Transmission.

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Cooling system

¾ Schematic of cooling system.

Reverse fan Sol. valve

Fan speed
proportional valve

Sequence valve
Relief valve (190bar)
(120bar)

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Cooling system

¾ Oil circulation of cooling system.

Target temperature

- Coolant : 85˚C ~ 95 ˚C
- Mission oil : 95˚C ~103˚C

Hydraulic oil circuit

Transmission oil circuit

Water circuit

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Cooling system

¾ Fan motor (Fixed gear motor)

Inlet port
②
Drain port

Outlet port

③
①

1. Motor 2. Reverse fan solenoid valve

3. Prop. Pressure relief cartridge 4. Check valve
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Cooling system

¾ Schematic of fan motor.

1. Motor 2. Reverse fan solenoid valve (25Ω)

3. Prop. Pressure relief cartridge (25Ω) 4. Check valve

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Cooling system

¾ Fan motor inner parts.

Prop. Pressure relief cartridge

Reverse fan solenoid valve

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Cooling system

¾ Prop. Pressure relief cartridge.

Fan speed adjustment screw

Resistance 25 Ω (@20℃)

Current System Fan speed

Target temperature Remarks
(mA) Pressure (Bar) (RPM)
Lower then
Coolant : 85˚C ~ 95 ˚C 600 40 400
Target temperature
Mission Oil : 95˚C
~103˚C higher then
100 140 1,200 Revering fan
Target temperature

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6) Power train.

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4. Hydraulic system

6) Power train
I. Transmission.
¾ Applied transmission on DL machine.

DL200 : ZF4WG 160

DL250 : ZF4WG 190

DL300 : ZF4WG 210

DL400 : ZF4WG 260

DL500 : ZF4WG 310

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4. Hydraulic system

6) Power train
I. Transmission.
¾ Torque converter. Pump
(Connected with engine)
One of clutch,
Transmit (engine) power to power user by fluid not
using friction disc.

Turbine power output shaft

Turbine
(Connected with power user)
Fluid in side
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 4. Hydraulic system

6) Power train
I. Transmission.
¾ Torque converter theory.

Turbine Pump
(Connected with T/M input shaft) (Connected with flywheel)

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4. Hydraulic system

6) Power train
I. Transmission.
¾ Torque converter theory.

Pump
Turbine (Connected with
engine flywheel)

Pump is rotating by engine power Then, turbine will be rotating by pump power with
fluid oil in converter, wheel loader uses turbine
power for traveling.
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4. Hydraulic system

6) Power train
I. Transmission.
¾ Operation torque converter.

When pump rotate internal oil hits

turbine, then turbine will rotate.

The oil after hitting turbine changes

Direction by stator and go back to
pump bottom.

The oil come out to pump

to hit turbine again.

Stator

Turbine Pump
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4. Hydraulic system

6) Power train
I. Transmission.
¾ Freewheel stator.

Stator turning : Fixed When turbine speed is below If turbine speed is above 80% ~
Stator turning : Turn to same 80% ~ 85% of pump speed, 85% of pump speed, stator is
direction with pump & stator stator is fixed. turning with pump & stator together
together (Installed one way clutch) (Oil hits inside impeller) (Oil hits behind impeller)
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4. Hydraulic system

6) Power train
I. Transmission.
¾ Freewheel stator benefit.

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4. Hydraulic system

6) Power train
I. Transmission.
¾ Torque converter in transmission.

Turbine

Turbine Pump
Pump

Stator Stator

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4. Hydraulic system

6) Power train
I. Transmission.
¾ Drive shaft in transmission (connect with torque converter)

Connected with stator

Connected with turbine

Connected with HYD pump (PTO)

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4. Hydraulic system

6) Power train
I. Transmission (DL200 / DL250 / DL300)
¾ Internal section.

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4. Hydraulic system

6) Power train
I. Transmission (DL200 / DL250 / DL300)
¾ Exterior view ( I )

1. Lifting plug.
2. Diaphragm.
3. Transmission suspension hole .
4. Attachment for emergency steering pump.
5. Model I/D
6. Output flange converter side.
7. Oil drain plug.
8. Attachment for oil filter pipe.
9. Oil dipstick.
10. Torque converter.

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