Star

Basis

L 544 - L 580 2plus2 Travel

Drive
Variable Disp. Motor 1
A6VM .. EP

Variable Disp. Motor 2

A6VM .. EP

DANA - SPICER
2plus2 Transmission

Variable Disp. pump

A4VG .. EZ

1st Gear 10,6 km/h

2nd Gear 20,2 km/h
3rd Gear 44,0 km/h

2002/09

Slide 2

L 544 - L 580 2plus2 Travel drive

redundant
signal

L 544 - L 580
2plus2
Travel drive
2002/09

Slide 3

L 544 - L 580 2plus2 Travel drive

2plus2 Drive System / 1. Gear

Activated

Var. displ. motor 2

A6VM .. EP

active

Clutch 2
Engaged

Var. displ. motor 1

A6VM .. EP

active

Clutch 3
Disengaged

Clutch 1
Engaged

Page 4

L 544 - L 580 2plus2 Travel drive

2plus2 Drive System / 2. Gear

Activated

Var. displ. motor 2

A6VM .. EP

Var. displ. motor 1

A6VM .. EP

active

Clutch 2
Engaged

Clutch 3
Disengaged

Clutch 1
Disengaged

Page 5

L 544 - L 580 2plus2 Travel drive

2plus2 Drive System / 3. Gear

Activated

Var. displ. motor 2

A6VM .. EP

Var. displ. motor 1 Active

A6VM .. EP

Clutch 2
Disengaged

Clutch 3
Engaged

Clutch 1
Disengaged

Page 6

L 544 - L 580 2plus2 Travel drive

Regulation of Variable Displacement

Motors

200

Page 7

L 544 - L 580 2plus2 Travel drive

Regulation of Variable Displacement

Motors

200

Page 8

L 544 - L 580 2plus2 Travel drive

Travel Hydraulic Components

Variable Disp. Motor 1
A6VM .. EP
Variable Disp. Motor 2
A6VM .. EP

Machine

2002/09

Variable Disp. Pump

A4VG .. EZ

Variable
disp. pump
Verstellpumpe

Verstellmotor
Variable
disp. Motor11

Verstellmotor
Variable
disp. Motor22

L 544

A4VG 90 EZ

A6VM 80 EP

A6VM 80 EP

L 554

A4VG 90 EZ

A6VM 80 EP

A6VM 107 EP

L 564 L 580

A4VG 125 EZ

A6VM 107 EP

A6VM 140 EP

slide 9

L 544 - L 580 2plus2 Travel drive

Travel hydraulics - Main

parts

1
2
3
4
5
7
8
9
10
2002/09

Hydraulik tank
Travel pump
Var. displ. motor 1
Var. displ. motor 2
Solenoid valve
Over speed protection
Oil Cooler
Scavenging pump
Fan pump
Fan motor
Folie 10

L 544 - L 580 2plus2

Travel drive

Bearing lubrication, var. displacement

motor

1
2
3
6
7
8
9
2002/09

Fan motor
Fan pump
Scavenging pump .
Oil cooler
Var. displ. motor 1
Var. displ. motor 2
Orifice 4,2 mm
Folie 11

L 544 - L 580 2plus2 Fahrantrieb

Travel drive - Hydrostatic Drive

System

1
2
3
4
5

Control piston
Travel direction valve
Pressure cut-off valve
Pressure relief valve
Proportional solenoid

Page 12

6
7
8
9
10

Relief valve replenishing pressure

High pressure relief valve forward
Replenishing pump
Control lens
Pump rotary group

L 544 - L 580 2plus2

Travel drive

11 Motor rotary group

12 Control lens
13 Proportional
solenoid
14 Control valve
15 Servo piston
16 Discharge valve

Variable Displacement Pump

A4VG...EZ
1
2
3
4
5
6

Drive shaft
Control piston
Travel directional valve
Pressure cut-off valve
Replenishing pump
High pressure relief
valve reverse

7
8
9
10
11
12
Page 13

L 544 - L 580 2plus2

Travel drive

Proportional valve
Replenishing pressure relief valve
High pressure relief valve forwards
Rotary group
Swash plate
Pump housing

Var. displacement Pump

A4VG...EZ
The proportional solenoid valve regulates the control
pressure of the variable displacement pump.
Depending on the operating conditions of the
machine, the micro controller determines the
amount of current applied to the DRE valve
and thereby the control pressure,.
The following parameters
influence the regulation:

Accelerator pedal position

Load limiting regulator - var. displ. pump
Inching function
Tractive force control
Excessive temperature
20 km/h version
Over speed protection

Page 14

L 544 - L 580 2plus2

Travel drive

Proportional solenoid valve

Travle pump A4VG...EZ

Depending on the working conditions of the
machine the MC6 micro-controller will alter the
amount of current to the proportional solenoid
valve.

Depending on the amount of current supplied to the solenoid 3, the PSP oil is
directed to the PST port, this results in a proportionate control pressure.
The control pressure PST is directed to the tank port T when the solenoid is not
energised.

2002/09

Folie 15

L 544 - L 580 2plus2

Travel drive

Variable Displacement Motor

A6VM .. EP

1
2
3
4
5
6
7
8

2
Drive shaft
Motor housing
Rotary group
Proportional solenoid
Control lens
Servo piston
Adjusting unit
Discharge valve

Page 16

L 544 - L 580 2plus2

Travel drive

2002/09

Slide 19

Travel Hydraulic - Schematic L544 -

2002/09

Slide 20

Travel Hydraulic - Schematic L564 -

Micro Controller
MC6
The micro controller MC6 is used for programmable control
of proportional solenoids as well as shifting functions and
thereby makes it possible to control or regulate extensive
drive systems with a single electronic.

Slave

Internally, the micro controller MC6 consists of two identical

circuit boards with one each digital computer unit and analogue
controls for inputs and outputs.
Both circuit boards are interconnected with an internal data
communication.
Analogue currents between 0V and 5V are processed as input
signals and shift information.
All inputs are protected against over voltage and electrical
problems. The potentiometer inputs are equipped with
monitoring controls to recognize broken cables or short
circuits.

Master
Following function are control:

Hydrostatic drive
2plus2 transmission
Fan drive
Emergency steering
Joystick - steering
Reversible fan (optional)
Over speed protection
Ride control system
Page 21

L 544 - L 580 2plus2

Travel drive

The end stages of the micro controller MC6 deliver regulated

currents as output signals to the connection of proportional
solenoids for the control of pumps, motors or valves.
Additional power outputs are designed to directly shift relays,
indicator lights and switch solenoids.
The serial interfaces RS232 allow for a connection of a PC
with PC- BODEM Software for service functions as well as
diagnostics, adjust parameter or process sizing view.

Safety functions of Micro-controller

MC6
Over speed protection (Service Code E 91 and E 96)
Should the engine or the travel motor RPM become excessive the over speed protection will
be activated.
The solenoid valve will direct replenishing oil to the rear axle brake. The brake will remain
active until such time as the RPM is reduced to within the normal range.

1
2
3
4
5

2002/09

Folie 30

Compact brake valve

Oil from the replenishing pump
Solenoid valve over speed protection
Solenoid valve block
Rear axel

L 544 - L 580 2plus2

Travel drive

Safety functions of Micro-controller

MC6
Protection from excessive output speed (Service Code E 91)
From a certain real out-put speed on, the current to the proportional solenoid valve is
reduced from max. to min. (200 mA) and the buzzer is activated.
Should the out-put speed be further increased , the over speed protection will then be
activated.

Protection from excessive motor speed (Service Code E 91)

At a pre-set travel motor RPM the current to the proportional solenoid valve is reduced to
min. (200 mA) and the buzzer is activated. The operator can only select a travel direction
again, once the motor RPM is below the limit value.
When reaching the limit value the over speed protection will be activated.

Machine

2002/09

Folie 32

1. Gear

2. Gang

3. Gang

L 544

5900 min-1

5900 min-1

5900 min-1

L 554

5900 min-1

5292 min-1

5292 min-1

L 564 L 580

5292 min-1

4950 min-1

5292 min-1

L 544 - L 580 2plus2

Travel drive

Functions of the Micro-controller

MC6
Emergency steering
The emergency steering
pump is controlled by the
MC6.

Emergency steering Check

After starting the engine (engine RPM more than 700 min-1 longer than 2 sec and in-put signal from KL 61 D+)
the emergency steering pump is tested by the electronics.
The emergency steering pump will be active for three seconds, until 5 bars of pressure is indicated by the
pressure switch. The pressure must be attained within (3 Seconds), to ensure that the indication symbol
Emergency steering Check and the test can be ended.
Should the Hydraulic pressure not be reached within 3 seconds, the indication symbol 3 Emergency steering
Check will remain illuminated until the engine is switched off.

Operating the emergency steering system

The emergency steering pump will be activated for 50 sec, should the steering pressure fall below 18 bar
(switch B8). When the emergency steering pump is activated the indication symbol 4 Emergency steering will
be illuminated.
An additional activation is made possible by pressing button 2 Emergency steering. A temperature switch in
the electric motor ensures that it can not be over heated.

2002/09

Folie 35

L 544 - L 580 2plus2

Travel drive

Basis