Power train of DL Loader

DL200 / 250 / 300 Transmission

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

Docu No : DLT 05 08 - Rev03

Power train

Transmission (DL200 / DL250 / DL300)

¾ Internal section.

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Power train

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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Power train

Transmission (DL200 / DL250 / DL300)

¾ Exterior view ( II )

1. Lifting lugs.
2. Power take off (Installed main pump)
3. Electro- Hydraulic control block.
4. Return port.
5. Parking brake.
6. Transmission suspension hole.
7. Oil dipstick hole.
8. Disc brake.
9. Output flange (Front axle)
10. Fine filter.
11. Filter head.
12. System pressure port.

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Power train

Transmission (DL200 / DL250 / DL300)

¾ Exterior view ( III )

15. Connection port (To oil cooler)

16. Connection port ( From oil cooler)
52/63. Behind converter pressure
70. Emergency steering pump (Discharge port)
71. Emergency steering pump (Suction port)

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Power train

Transmission (DL200 / DL250 / DL300)

¾ Transmitter location.

21. Turbine inductive transmitter

34. Out put speed sensor
47. Central gear inductive transmitter
48. Engine inductive transmitter
54. Filter contamination switch

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Power train

Transmission (DL200 / DL250 / DL300)

¾ Inner parts.

1. Clutch shaft “ KR”

2. Power take off coaxial shaft
3. Clutch shaft “KV”
4. Clutch shaft “K2”
5. Clutch shaft “K3”
6. Output flange (Front axle)
7. Output flange (Rear axle)
8. Output shaft
9. Transmission pump
10. Input flange
11. Converter
12. Transmitter for engine speed
13. Clutch shaft “K4”
14. Converter relief V/V
15. Clutch Shaft “K1”

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Power train

Transmission (DL200 / DL250 / DL300)

¾ Pressure check point on mission control block.

49. Electric cable connection

51. In front of converter pressure (11 bar)
53. Forward clutch pressure (16+2 bar)
55. Reverse clutch pressure (16+2 bar)
56. K1 Clutch pressure (16+2 bar)
57. K2 Clutch pressure (16+2 bar)
58. K3 Clutch pressure (16+2 bar)
60. K4 Clutch pressure (16+2 bar)
65. System pressure (16+2 bar)
68. System pressure (Option)
69. Control (Option)

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Power train

Transmission (DL200 / DL250 / DL300)

¾ Oil circulation. B D

FDV : Filter pressure valve (ΔP=5.5 bar)

RV-9 : Pressure reducing valve (9 bar) NFS
HDV : System pressure (16+2 bar) Y
B : Orifice
D : Vibration damper
NFS : Follow-on Slide RV-9
Y : Proportional valve
WSV : Converter relief valve 11 bar HDV
WGV : Converter back pressure valve(4.3 bar) FDV

WSV
: Main pressure
Converter
: Regulated main pressure
: Pilot pressure Fine filter
: Converter input pressure WGV
: Converter output pressure
: Lubrication Charging pump
Oil cooler
: Return to the sump

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Power train

Transmission (DL200 / DL250 / DL300)

¾ Proportional valve.

Current connection (100 mA ~ 500 mA)

There are 6 pcs proportional valve on control block

500 mA : Proportional valve is closed

100 mA : Proportional valve is opened

To Tank

Do not clean it up with solvent.

Solvent makes special lubricant in proportional valve melt out.
9.0 bar pressure

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Power train

Transmission (DL200 / DL250 / DL300)

¾ Operation of proportional valve.

500 mA 100 mA

Engaged clutch : 500 mA

Proportional valve is closed

Neutral : 100 mA
Proportional valve is opened

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Power train

Transmission (DL200 / DL250 / DL300)

¾ System oil circulation.

65 (K)

51 (H). 51(H)
In front of converter pressure (6~7 bar)
52/63. 52,63
Behind converter pressure (4.3 bar)
65 (K).
System pressure (16+2 bar)

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Power train

Transmission (DL200 / DL250 / DL300)

¾ System oil circulation (Forward 1st)

K1 KV
56 (D) 53 (B)

Driving Engage
Speed Y1 Y2 Y3 Y4 Y5 Y6
Direction d Clutch
1st ◆ ◆ K1,KV
2nd ◆ ◆ KV,K2
Forward
3rd ◆ ◆ K3,KV
4th ◆ ◆ K4,K3
1st ◆ ◆ KR,K1
Reverse 2nd ◆ ◆ KR,K2
3rd ◆ ◆ KR,K3
Neutral
Related Clutch K4 KR K1 K3 KV K2
Location F E D C B A
Measuring Point 60 55 56 58 53 57
System Pressure (bar) 16+2 16+2 16+2 16+2 16+2 16+2
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Power train

Transmission (DL200 / DL250 / DL300)

¾ System oil circulation (Forward 2nd)

KV K2
53 (B) 57 (A)

Driving Engage
Speed Y1 Y2 Y3 Y4 Y5 Y6
Direction d Clutch
1st ◆ ◆ K1,KV
2nd ◆ ◆ KV,K2
Forward
3rd ◆ ◆ K3,KV
4th ◆ ◆ K4,K3
1st ◆ ◆ KR,K1
Reverse 2nd ◆ ◆ KR,K2
3rd ◆ ◆ KR,K3
Neutral
Related Clutch K4 KR K1 K3 KV K2
Location F E D C B A
Measuring Point 60 55 56 58 53 57
System Pressure (bar) 16+2 16+2 16+2 16+2 16+2 16+2
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Power train

Transmission (DL200 / DL250 / DL300)

¾ System oil circulation (Reverse 1st)

KR K1
55 (E) 56 (D)

Driving Engage
Speed Y1 Y2 Y3 Y4 Y5 Y6
Direction d Clutch
1st ◆ ◆ K1,KV
2nd ◆ ◆ KV,K2
Forward
3rd ◆ ◆ K3,KV
4th ◆ ◆ K4,K3
1st ◆ ◆ KR,K1
Reverse 2nd ◆ ◆ KR,K2
3rd ◆ ◆ KR,K3
Neutral
Related Clutch K4 KR K1 K3 KV K2
Location F E D C B A
Measuring Point 60 55 56 58 53 57
System Pressure (bar) 16+2 16+2 16+2 16+2 16+2 16+2
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 Power train

Transmission (DL200 / DL250 / DL300)

¾ Summary of engaging clutch.

Driving Engage
Speed Y1 Y2 Y3 Y4 Y5 Y6
Direction d Clutch
1st ◆ ◆ K1,KV
2nd ◆ ◆ KV,K2
Forward
3rd ◆ ◆ K3,KV
4th ◆ ◆ K4,K3
1st ◆ ◆ KR,K1
Reverse 2nd ◆ ◆ KR,K2
3rd ◆ ◆ KR,K3
Neutral
Related Clutch K4 KR K1 K3 KV K2
Location F E D C B A
Measuring Point 60 55 56 58 53 57
System Pressure (bar) 16+2 16+2 16+2 16+2 16+2 16+2

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Power train

Transmission (DL200 / DL250 / DL300)

¾ Internal section of control block.

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Power train

Transmission (DL200 / DL250 / DL300)

¾ Power flow.

Forward 1st Reverse 1st

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Power train

Transmission (DL200 / DL250 / DL300)

¾ LIS (Load Isolation System)

When machine travels high speed on off road with full bucket, the machine has big jerky.

LIS function makes machine traveling jerky absorb by full bucket.

LIS accumulator absorbs traveling jerky under full bucket.

C/V
LIS System

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Power train

Transmission (DL200 / DL250 / DL300)

¾ LIS valve.
Accumulator : Nitrogen charged piston type.

X2
A Solenoid valve
(Accumulator)
Relief valve
Safety valve 250 bar

Safety valve
B

T
Relief valve (250 Bar)
Solenoid valve C/V

Safety valve : Remove pressure in accumulator for repairing (Un-tightening screw)

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Power train

Transmission (DL200 / DL250 / DL300)

¾ Operation of LIS.

Accumulator Accumulator

Neutral condition Neutral condition (Charged Acc. Completely)

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Power train

Transmission (DL200 / DL250 / DL300)

¾ Operation of LIS.

Accumulator Accumulator

Neutral condition (Over charged Acc.) LIS working

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Power train

Transmission (DL200 / DL250 / DL300)

¾ Safety valve.

Safety valve

Tightening valve Loosen valve

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Power train

Transmission (DL200 / DL250 / DL300)

¾ Maintenance of transmission.

1. Oil change interval : Every 1,000 hours (First 100 Hours)

2. Check oil level : Everyday (at engine idling condition with oil temp. 70 ~90)
3. Oil grade : Engine oil 15W40
4. Oil filter : Use same part number filter (Blue color filter)

¾ Towing machine.

1. Towing speed : Below 10 km/h.

2. Towing distance : Below 10 km.

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