10 Structure, function and maintenance standard sEN02863-00

Control of delivery
lf swash plate angle (a) becomes larger, the
difference between volumes (E) and (F)
becomes larger and pump delivery (Q)
increases.
Servo piston (10) is used for changing swash
plate angle (a).
Servo piston (10) carries out linear reciprocal
movement according to the signal pressure
from the LS valve.
This linear movement is transmitted to rocker
cam (4) through slider ('14).
Being supported by cradle (2) on the cylindrical
surFace, rocker cam (4) slides on the surface
while continuing revolving movement.
Space of the pressure receiving area of servo
piston (10) are not identical on the left side and
right side. Main pump discharge pressure (self
pressure) (PP) is always brought to the pres-
sure chamber of the small diameter piston
side.
Output pressure (PEN) of the LS valve is
brought to the chamber receiving the pressure
at the large diameter piston end.
The relationship in the size of pressure (PP) at
the small diameter piston end and pressure
(PEN) at the large diameter piston end, and
the ratio behveen the area receiving the pres-
sure of the small diameter piston and the large
diameter piston controls the movement of
servo piston ('10).

sJS0't816

D1554-6 7
sEN02863-00 10 Structure, function and maintenance standard

LS valve

sJ s0?8ls

PA: Pump port 1. Sleeve

PDP: Drain oort 2. Piston
PLP: LS control pressure output port 3. Spool
PLS: LS pressure input port 4. Spring
PP: Pump port 5. Seat
PSIG: Drain port 6. Sleeve
7. Plug
8. Locknut

Function
e The LS (load sensing) valve detects the load
and controls the delivery. l!/n in)
e This valve controls pump delivery (Q) accord-
ing to differential pressure (APLS) o
t = (PP) - (PLS)I (called LS differential pres-
sure) between pump discharge pressure (PP) ,:
and control valve outlet port pressure (PLS). ;
r Main pump pressure (PP), pressure (PLS) E
(called the LS pressure) coming from the cjon- d
trol valve output enter this valve.
2.0t201
2.0t201 (sPa { krlcm'l )
tS d ilferent ia I oressure AptS sJs07B20

8 Dl55A4
10 Sbuc'ture, function and maintenance standard

Dt55A6 I
sEtrt02863{0 10 Structure. function and maintenance standard

Operation o
1) When the control valve is situated al neutral

o
10 Dl5sA6
 10 Structure, function and maintenance standard sEN02863{0

The LS valve is a 3-way selector valve, with

pressure (PLS) (LS pressure) from the inlet
port of the control valve brought to spring
chamber (B), and pump discharge pressure
(PP) brought to port (H) of sleeve (1 ).
Magnitude of the force resulting from this LS
pressure (PLS), force of spring (4) and the
pump discharge pressure (self pressure) (PP)
determine the position of spool (3).
Before starting engine, servo piston (10) is
pressed to the right. (See the figure to the
right)
lf the control lever is in neutral at start of the
engine, LS pressure (PLS) is set to 0 MPa {0
kg/cm?]. (lt is connected with the drain circuit
lhrough the control valve spool,)
Spool (3) is pushed to the right, and port (C)
and port (D) will be connected.
Pump discharge pressure (PP) enters the
o large diameter side of the piston from port (K).
Pump pressure (PP) is present in port (J) on
the small diameter side of the piston.
Accnrding to the difference in the areas on
servo piston (10), servo piston (10) moves in to
the direction of minimizing the swash plate
angle.

50 7822

D15546
sEN02863-00 10 Structure, function and maintenance standard

2) Action for the direction of maximizing the pump delivery

PLS

llex rmum o irecl io'l 9JS07823

When the difference between pump discharge o The pres.sure at the large diameter end of
pressure (PP) and LS pressure (PLS), in other servo piston (10) becomes drain pressure
words, LS differential pressure (APLS) (PT), and pump pressure (PP) enters port (J)
bemmes smaller lfor example, when the area at the small diameter end, so servo piston (10)
of opening of the control valve becomes larger is pushed to the left side. Therefore, servo pis-
and pump discharge pressure (PP) dropsl, ton (10) is moved in the direction to make the
spool (3) is pushed to the left by the combined delivery larger.
force of LS pressure (PLS) and the force of
spring (4).
When spool (3) moves, port (D) and port (E)
are interconnected and connected to the drain
port.

12 D 155A-6
10 Structure. function and maintenance standard sEN02863-00

3) Action for the direction of minimizing the pump delivery

PLS

V n m!m d i'ec t ion 9JS0r824

lf LS differential pressure (aPLS) becomes

larger (for example, when the area ol control
valve op€ning becomes smaller and the pump
pressure (PP) increases), spool (3) is pressed
to the right by the force of pump pressure (PP).
As a result of the movement of spool (3), pump
discharge pressure (PP) flows from port (C) to
port (D), then from port (K) to the large diame-
ter side of the piston.
While main pump pressure (PP) is present in
port (J) of the smaller diameter side of the pis-
ton, servo piston (10) is pressed to the right by
its area difference between the larger and the
smaller diameter sides. As the result, servo
piston (10) moves in the direction io minimize
the swash plate angle.

D1554-6 13
sEN02863-00 10 Structure, function and maintenance standard

4) When servo piston is balanced

9JS07825

Let us take lhe area receiving the pressure at And the swash plate of the pump will be held in
the large diameter end of lhe piston as (A1), an intermediate position. [Spool (3) will be
the area receiving the pressure at the small stopped at a position where the distance of the
diameter end as (A0), and the pressure flowing opening from port (D) to port (E) and the dis-
into the large diameter end of the piston as tance from port (C) to port (D) is almost the
(PEN), same.l
lf the main pump pressure (PP) of the LS valve The formula (A0) : (A1) = 3 : 5 represents the
and the combined force of spring (4) and LS relation of pressure receiving areas across the
pressure (PLS) are balanced, and the relation- end of servo piston (10). And (PP) : (PEN) = 5 :
ship is (A0) x (PP) = (A1) x (PEN), servo pis- 3 represents the pressure applied across the
ton (10) will stop in that position. piston when balanced-
The force of spring (4) is adjusted to determine
the balanced stop position of this spool (3) at
the center of the standard when (PP) - (PLS) =
2.0 MPa {20 kgi cmz}.

14 Dt 55A-6
 10 Structure. function and maintenance slandard sEN02863-00

ro Work equipment cooler bypass valve

1. Body Outline
2. Va lve r This valve is installed in the oil cooler inlet cir-
J- Spring cuit. lf any abnormal pressure is generated in
the oil flowing to the oil cooler, this valve acts
Hydraulic oil cooler inlet to return the oil directly to the hydraulic tank.
o. To hvdraulic tank

Cracking pressure ( MPa ikgicm4)

D15546
sEN02853-00 10 Structure, function and maintenance standard

Steering, brake control

* Regarding the transmission-related description of the operation of the PCCS lever, see Transmission
control.
* PCCS: Palm Command Control System

tx

.l

I J G034 5S

16 Dl55A-6
10 Structure, function and maintenance standard sEN02863{0

1. Potentiometer Outline
2. Lock lever r PCCS lever (3) sends electric signals to power
3. PCCS lever (Steering) train controller (5). Upon receiving those sig-
4. Limit switch nals, power train controller (5) sends signals to
5. Power train controller the EPC valve of the control valve.
6. Rod (From brake pedal) . Brake pedal (7) receives signals from potenti-
7. Brake pedal ometer (1) through rod (6). Then, power train
controller (5) sends signals to the brake valve
Positions of levers and pedals to oDerate the brake.
A: Neutral o Lock lever (2) is connected to limit switch (4)
B: Forward straighl and used as the parking brake lever, too.
C: Reverse straight When it is in lock position "J", power train con-
D: Left turn troller (5) does not send turning signals to the
E: Right tum EPC valve of the control valve.
F: Brake OFF
G: Brake ON
H; Free
J: Lock

D155A-6 17
sEN02863-00 10 Structure, function and maintenance atandard

Steering unit
(Bevel gear shaft, steering clutch and steering brake)

lz

S8-1?3Nnr
(10-l2.sk.nl

18 D155A{
10 Structure, function and maintenance standard sEf{02863-00

13. 7-21. 6Nn

{ l. 4-2. 2ken} 13.7-2l.6Nm
( 1, 4-2. 2 t.m)

F.

- -- 13. 7-21.6Nm
13. 7-2 t. 6Nn '' {1, +-2,2kcml
| 1, 4-2, zkoml

9J804251

A: To transmission case
B: From scavenging pump and steering lubrication pump
R.H. brake oil pressure pickup port (RB)
D: L.H. brake oil pressure pickup port (LB)
E: From pin puller solenoid valve (drain)
F: R.H. steering clutch oil pressure pickup port (RC)
ti: L.H. steering clutch oil pressure pickup port (LC)

D1554-6
sEN02863.00 10 Structure, function and maintenance standard

ID

9J804252

D155A-6
10 Structure, function and maintenance standard sEN0286340

D155A{ 21
sEN0286:t-00 10 Structure, function and maintenance standard

1. Bevel gear rotation sensor

2. Drain plug
3. Drain valve
4. Steering clutch and brake oontrol valve
5. Case
6. Brake cylinder
7. Brake spring
8. Bmke piston
9. Brake plate
10. Brake disk
11. Brake drum
12. Brake hub
13. Tube
14. Bevel gear shaft
15. Bevel gear (Number of teeth: 32)
16. Clutch hub
17. Clutch plate
18. Clutch disk
19. Clutch piston
20. Clutch spring
21. Clutch cylinder
22. Clutch drum
23. Clutch stopper
24. Shim B (For bevel gear adjustmont)
25. Bevel gear shaft bearing B
26. Bevel gear shaft bearing A
27. Shim A (For bevel gear adiustment)
28. Retainer
29. Spacer
30. Shim C (For bevel pinion adjustnent)
31. Gauge
32. Bevel pinion bearing
33. Nut (For bevel pinion)
34. Bevel pinion (Number of teeth: 17)

22 D155A6
10 Structure. function and maintenance slandard sEN02863{t0

General

Bevel gear shaft Steering brake

. Using the meshing of bevel pinion (34) and . The steering brake being connected to the
bevel gear (15), the bevel gear shaft system R.H. and L.H. steering clutches damps the
directs the power being transmitted through machine by damping the power from the steer-
the engine, torque converter and transmission ing clutch to the final drive.
orthogonally in the right and left directions and, o The wet type multi-disk clutch and spring-
at the same time, reduces the revolution. boosted type are employed for the steering
. A spiral bevel gear is employed for bevel pin- clutch. lt hydraulically actuates sleering brake
ion (34) and bevel gear (15) on the bevel gear control valve (4) through the operation of its
shaff system. And as for the lubrication, spat- brake oedal.
tering by use of the oil from the steering lubri- The forced lubrication approach employed for
cation pump and scavenging pump is the lubrication conducts lhe oil from the steer-
employed. ing lubrication pump and sc€venging pump to
. The bevel gear shaft system is consisted of brake disk ('10) and brake plate (9) through
bevel pinion (34), bearing (32) and cage (31) passage in the steering case, case (5) and
supporting the bevel pinion, bevel gear (15) to brake drum (11).
be meshed with the bevel pinion, bevel gear When the engine is stopped, back pressure of
shaft (14) and bearings (25) and (26) and brake piston (8) drops without pressing the
retainer (28) supporting the bevel gear shaft. brake piston, setting the steering brake to
"actuated' state. However, if the engine is
Steering clutch restarted and oil Dressure in the circuit
The steering clutch is connected to both ends increases, the brake is "released". Thus, the
of bevel gear shaft (14) through the spline. lt parking brake must be set to the "lock" posF
changes the machine turn direciion by con- tion.
necting or disconnecting the power from bevel The steering brake is consisted of clutch cylin-
gear shaft (14) to the linal drive. der (21), clutch drum (22) (connected to brake
The wet type multi-disk clutch and spring- hub (12)), brake disk (10), brake plate (9),
boosted type are employed for the steering brake drum (11), brake piston (8), brake spring
clutch. lt is hydraulically actuated, in conjunc- (21) and brake cylinder (6) supporting above
tion with the brake, by the pressurized oil from componenls. Brake drum (11) is fixed to the
the steering clutch valve. steering case.
The lubrication system employed the forced
lubrication approach by use of the oil from the
steering lubrication pump and scavenging
DUMD.
The steering clutch is consisted of clutch hub
(16) (connected to the bevel gear shaft), clutch
disk (18), clutch plate (17), clutch drum (22),
clutch piston (19), cluch spring (20), and clutch
cylinder (21) supporting above components.
Clutch drum (22) and the clutch cylinder being
connected to the brake hub transmit the power
from the bevel gear shaft to the output shaft
through brake hub ( 12).

D155A-6
sEN02863-00 10 Structure, function and maintenance standard

z,

z.

EE

@Z-

,l

-l

'2,.

-l

z- \ Eb

,l

E,'
z^
t.
,l
I J 804254

24 D155A-6
10 Structure, function and maintenance standard sEN02863-{r0

Unit; mm
No. i Check item Criteria Remedy
Standard size Tolerance Repair limit
Replace
Thickness 4.5 r0. '1
4.0
1 Steering brake disk
Repair or
Strain 0.05 o.14
replace

Thickness 2.9 10. 1 2.6 Replace

2 Steering brake plate
Repair or
Strain 0.05 0.15
replace
Total assembled thickness of 6
3 disks and 5 plates for steefing 41.5 r0.33 38.3
brake Replace

Thickness 4.5 10.1 4.1

Steering clutch disk
Repair or
Strain 0.05 o.14
replace

tntcKness 2.9 10.',l 2.6 Replace

5 S'teering dutch plate
Repair or
Strain 0.05 0.15
replace
Total assembled thickness of 5
disks and 5 plates for steering 37.0 to.32 34.3
clutch
Inside diameter of brake cylin- +0.040
125 125.5
der seal ring contact surface 0

7 widh -{.08 4.2

Wear of brake hub -{.13
seal ring
IncKness 4.5 10.15 4.05

Large +0.081
lnside diameter of diamete 280 280.1
portion 0
mntact surface of
o
seal ring on steering Small
brake piston +0.o72
diameter 220 220.1
0
ponron
Large +0.081
lnside diameter of diamete 280 280.'1 Replace
0
contact surface of portion
seal ring on steering Small
clutch piston +0.072
diameter 220 220.1
portion 0

Standard size Repair limit

lnstallation lnstallation lnstallation
Steering brake spring (2 springs Free length Free length
10 length toac load
make up a set)
35.7 kN 33.9 kN
19.6 32.0
{3,640 kg} {3,460 ks}
Steering clutch spring (2 springs 35.7 kN 33.9 kN
11 19.6 32.O
make up a set) {3,640 kg} {3,460 kg}
Standard Tolerance Standard Clearance
Clearanc€ between bevel gear size Shaft Hole ctearance limit
12
and reamer bolt
16
+0.0'19
+0.001
+O.O27 -0.019 - 0.026
0

D155A€ 25
sEt{02863{t0 {0 Struc'tur8, functlon and malntontnce standard

Unit mm
o
1'lo. Check ltem Crlterla Rernedy
Backlash between braks hub
13
and disk
0.23 - 0.42

Backlash bstw€€n brake drum

14
and olatB
0.23 - 0.42
Replace
Backlash b€tlv€€n clutch hub
15
and disk
o.23 - O.42

't6 Backhsh b€t$reon dutch drum o.23 - 0.42

and olate
Sandad shim thickness of 2.0
17
rctainer A of
't8 Sandad shim thicl$ess of 2.0
retainer B
Rotary torque: 4.2 - 5.1 Nm {o.,ff} -0.52 kgm}
Prdoad of bevel g€ar shaft (22.6
19 - 26.5 Nm {2.3 - 2.7 kgm} at the b6/el gEar add€ndum
bearings A and B
when the b€vel pinion gear b not rn€8hed)

t
26 D{ 55A-6
10 Structure, function and maintenance standard sEN02863{0

E
2,.

.:-

No- Check item Criteria Remedy

Backlash between bevel gear Ad.iust or
1 0.25 - 0.33
and bevel pinion
Standard shim thickness of of
2_O
cage SNIMS

D1554-6
sEl{02863-00 10 Structure, function and maintenance standard

Operation of the steering clutch

When the st€ering clutch is turned "on" when the steering clutch is turned "off,'

sJ 3012 5 6 9J801257

Oil pressure to the back side of clutch piston (19) is Oil being pressure-fed to the back side of clutch
stopped, and the repulsion of clutch spring (20) ls piston (19) releases clutch hub (16).
used for fixing clutch hub (16).
Power from transmission
Power from transmission T
J Bevel pinion
Bevel pinion J
J Bevel gear
Bevel gear T
J Bevel gear shaft (14)
Bevel gear shaft (14) J
Clutch hub ('16)
Clutch hub (16)
J
Clutch drum (22)
J
Brake hub (12)
J
Output shafr
J
Final drive

D155A{
10 Structure, function and maintenance standard sEN02863{0

Operation of steering brake

When the steering brake is "released" When the steering brake is "actuated"
(When PCCS lever is in "operation")

sJBtl25S
When the PCCS lever is set to the "neutral'
position and the brake pedal is not pressure, As the PCCS lever is operated in the right or
the brake pressure alone is set to the maxi- left, the steering clutch is "disengaged" by the
mum pressure by the steering control valve. steering control valve and, at the same time,
Thus, oil pressure works on the back side of draining of oil to the back side of brake piston
brake piston (8) as soon as the steering clutch (8) is started.
is "engaged''. At this point, brake piston (8) is pushed back
At this point, brake piston (8) compresses and rightward by the tension of brake spring (7),
moves brake spring (7) leftward with the pressu re-bon d ing disk (10) and plate (9)
increased oil pressure, relieving the pressure- against brake drum (11).
bonding force of disk (10) and plate (9). Brake piston (8) and brake drum (11) are fixed
The power being transmitted fmm bevel gear to the steering case.
shaft (14) to brake hub (12) through the steer- Pressure-bonding disk (10) and plate (9) stops
ing clutch is then transmitted to the final drive the inertia-based rotation of brake hub (12)
through the output shaft. and output shaft even if the steering clutch is
''disengaged".
Adiustment of the tum radius and swing
becomes available by adjusting the braking
force through controlling the oil pressure to the
back side of brake piston (8) corresponding to
the rightward and leftward stroke of the PCCS
lever.

D155A-6 29
sEN02863.{t0 10 Structure, function and maintenance standard

When the steering blake is "applied'

(when the PCCS lever is in "neutral" and brake
pedal is "depr6s€d')

9J 804 2 69

lf the brake pedal is pressed while the PCCS

lever is at "neutral", the steering control valve
starts draining the oil on the back side of brake
piston (8), "engaging' the steering clutch and
actuating the steering brake. Thus, rotation of
the output shaft is stopped,
Adjustlng the braking force bemmes available
by controlling the oil pressure to the back side
of brake piston (8) corresponding to the stroke
of the brake oedal.

30 D l55A-6
Dt55A6
sEN02863{t0 10 Structure, function and maintenance standard

Steering control valve

19. 6-24. sNn

(2.0-2. 5keml

A Oe

Y+
11. 8-14, 7N|n
{ 1. 2-1. 5l!.1

7. g-9. 8Nn
(0.8-l.okem)
5-

I1.8-!4.7Nn
{1.2-1. 5 krml

LL LC

DRC DLC

. BSL

BGL

9J 8012 6 0

32 Dl55A-6
10 Structure. function and maintenance standard sEN0286340

15. 7-19. 6Nm

{ 1, 6-2kert

34. 3-44. INm

{3.5-4,5ksm}

P: From power train pump General

L: Scavenging pump The steering mntrol valve controls the steering
From steedng lubrication pump clutch and steering brake by use of 4 ECMVS,
PS: To pin puller solenoid valve parking brake solenoid valve and sudden stop
LB: To L.H. steering brake prevention valve installed on the valve seat.
LL: To L.H. steering brake lubrication The steering c,ontrol valve is provided in the
LC: To L.H. steering clutch circuit across the power train pump, steering
RB: To R.H- brake clutch and steering brake piston. lt is consisted
RL: To R.H. brake lubrication of the steering clutch ECMV (R.H. and L.H.)
RC: To R.H. ste€ring clutch and sleering brak€ ECMV (R.H. and L.H.).
BSL: To bevel gear shaft and bearing lubrication The steering control valve conducts the oil
BGL: To bevel gear lubrication from the power train pump to the steering
DLB: Drain (L.H. steering brake) clutch and steering brake to control the R.H.
DRB: Drain (R.H. steering brake) and L.H. disk clutches and the disk brake.
DLC: Drain (L.H. steering clutch) lf the PCCS lever is leaned to the right or left,
DRC: Drain (R.H. steering clutch) the steering clutch is disengaged. The steering
DB: Drain (Sudden stop prevention valve) brake will operate by further leaning the PCCS
DPB: Drain (Parking brake) lever
PLB: L.H. steering brake oil pressure pickup port The controller sends signals to each ECMV
PRB: R.H. steering brake oil pressure pickup port according to the right or left stroke of the
PLC: L.H. steering clutch oil pressure pickup port PCCS lever and adjusts the gradual or sharp
PRC: R.H. steering clutch oil pressure pickup port turns.
As the brake pedal is pressed, the controller
L.H, steering brake ECMV sends the command, corresponding to the
R.H. steering brake ECMV pedal stroke, to the steering brake ECMV to
L.H. steering clutch ECMV actuate the R.H. and L.H. brakes and. thus. to
R.H. steering clutch ECMV apply braking to the machine.
Steering oil filter The controller, which is electrically mnnected
Valve seat to the PCCS lever and brake pedal, operates
Parking brake solenoid valve the steering clutch and steering brake by con-
Sudden stop prevention valve trolling each ECMV and solenoid valve.
Check valve The sudden stoo orevention valve is installed
to prevent the machine from stopping sud-
denly, when an abnormality takes place in the
electric syslem.
As the parting brake lever is set to the "lock"
position, the controller sends the signal to the
parking brake solenoid valve to drain the oil
between the R.H. and L.H. steering brake
EClvlvs and brake piston in order for actuating
the brake. The parking brake solenoid valve is
electrically connected to the brake pedal, too.

D1554€ 33
sEN02863{0 10 Structure. function and maintenance standard

Steering clutch ECMV steering brake ECMV

* ECMV: Abbreviation for Electronic Control Modulation Valve
* Don't try to disassemble it since adiustment for maintaining the performance will be needed.

I l. 27t1.,l7Nn
{r, 1510. t skc.}

9J803||]

A: To clutch or brake General

P: From pump r Ea<;h ECMV keeps the steering clutch oil pres-
S: To parking brake solenoid valve sure and steering brake oil pressure to the set
T: Drain pressuTe and furthermore changes the circuit
DR: Drain to the piston chamber of the steering clutch
P1: Brake oil pressure pickup port and steering brake.

1. Fill switch connector

2. Proportionalsolenoidconnector
3. Pressure detection valve
4. Fill switch
5. Proportionalsolenoid
6. Pressure control valve
7. Name plate ('1)

34 D155A-6
10 Structure. function and maintenance standard sEN02863-00

Outline of ECMV
. The ECMV consists of 1 pressure control valve
and 1 fill switch.
. Pressure control valve
A proportional solenoid ln this valve receives a
current sent from the controller and this valve
converts it to an oil pressure.
. Fill switch
This is a switch to detect that a clutch or brake
is filled wlth oil and has the following functions.
1. At the moment when the clutch or brake is
filled with oil, the fill switch outputs the signal
(Rll signal) to the controller to notify the finish-
ing of filling.
2. While the oil pressure is applied to the clutch
or brake, the fill switch outputs the signal (fill
sagnal) to the controller to notify the presence
of the oil pressure.

ECMV and proportional solenoid

. One orooortional solenoid is mounted for
each ECMV.
The propulsion force is generated accord-
ing to the command currenl ftom the con-
troller.
The propulsion force generated by the
proportional solenoid is actuated on the
soool of the DTessure control valve and
generates the oil pressure. Accordingly, by
controlling the amount of the command
current, the propulsion force changes and
the pressure control valve is actuated,
then the oil flow and oil pressure is con-
trolled.

ECMV and fill switch

r For each EClVlV, 1 fill switch is installed.
lf the clutch is filled with oil, the fill switch
is turned "ON' by the pressure of the
clutch. The oil pressure is built up accord-
ing to this signal.

Operation of EGMV
o The ECMV is controlled by the command
current from the controller to the 0ropor-
tional solenoid and the fill switch outpui
signal.

D15546
sEN02863-00 10 Structure, function and maintenance standard

When the PCCS lever is in "neutral" position, brake pedal is "released", and pa.king brake lever is in
"free' position: Straight travel
(L.H. and R.H. brake are "released", parking brake is "released")

Lef I brake ECNV 1a LeJ t cl!1cl'ECliV

t
brake ECtiv To ri!h1 brake
EC}'IV.iloi
Df circLit
'Tc pln pLr

a
I lel
LJ Su dd en slop

4l: T:;"
To : oht +13r1,"n" "'o'
cluich Ecliv
@

peda I
Par!inB braie

Lei t br,ke
Pafk nr 'lu

wi
t:
Fron'ioht teJ t clLlcf
' 0N'
G3':l:,"'n 9J804262

When the PCCS lever is in "neutral" position The oil in port (Pb) of the brake ECMV flows in
and the brake pedal is "released", proportional port (E) and pushes valve (7) to the left to con-
solenoid (1 ) of the clutch ECNIV is demagne- nect port (Pb) with port (B) and disconnect port
tized and the sealing part of ball (2) is opened. (B) from port (Dr). At this time, the oil flows in
The oil from the power train pump flows the back pressure port of the brake piston. As
through port (Pc) of the clutch ECMV to oriflce the oil pressure rises, the brake piston is
(a), then it is drained through the sealing part pushed to the left to compress the brake
of ball (2). spring, then the brake is "released".
Valve (3) is moved to the right by the tension of When the parking brake lever is set in the
spring (4) to disconnect port (Pc) from port (C), "free'' position, the pilot pressure of brake
and connect port (C) with port (Dr). At this ECMV port (S) remains, because the parking
time, the oil from the back pressure port of the brake solenoid valve is de-energized.
clutch piston is drained through port (C) and
the clutch is turned ''on" by the tension of the
clutch spring.
The oil pressure in the brake circuit, etc. is
secured by orifice (a).
Proportional solenoid (5) of the brake ECMV is
energized and pushes ball (6) to the left and
closes the sealing part.

36 Dl55A-6
10 Structure. function and maintenance standard sEN02863-00

When the PGCS leyer is "operaied to the left halfway", brake pedal is "released", and parking brake
lever is in 'Tree" position: Gradual lefr turn
(L.H. brake is "half released-, R.H. brake is ''released", parking brake is "released")

IJT c
"
Tr I shl
brake ECHv
To risht .h.ake I I
ft :crvv.i 0t
Ir circuit

I Su dd er sl op

@
+l: 'l:i'", ,,
Tc
: lr
s
l:1. tlr,l!
w oa;:*i"n'" "'o'
@
Park ns
bfak3
leJal

l/\

l 'zj
Le't c utcl
brake. 'CFF,
@ aCMl
3r8lr2:3

r When the PCCS lever is "operated to left half- solenoid (5) according to the stroke of the
way" and the brake pedal is "released", propor- PCCS lever.
tional solenoid (1 ) of the L. H. clutch ECMV is Proportional solenoid (5) generates the propul-
energized and the sealing part of ball (2) is sion force in proportion to the command cur-
ctoseo. rent. This propulsion force is balanced with the
The oil from the power train pump flows sum of the propulsion force generated by the
through port (C) of the clutch EMCV and orifice oil pressure in the back pressure port of the
(a) to port (F) and pushes valve (3) to the lefl to brake piston and the tension of spring (8), then
connect port (Pc) with port (C) and disconnect the brake pressure is set up to adjust the brake
port (C) from port (Dr). At this time, the oil flows force.
in the back pTessure port of the clutch piston. Accordingly, if the stroke of the PCCS lever is
As the oil pressure rises, the clutch piston is short, the oil pressure after port (B) is set high
oushed to the left to comoress the clutch and the brake is tumed from "released" to "half
spring, then the clutch is turned "off. released". lf the stroke of the PCCS lever is
Proportional solenoid (5) of the brake ECMV is long, the oil pressure after port (B) is set low
energized and pushes ball (6) to the left and and the brake is tumed from "half released" to
closes the sealing part. "aoolied".
The oil in port (Pb) of the brake ECMV flows in When the parking brake lever is set in the
port (E) and pushes valve (7) to the lefr. As for "free" position, the pilot pressure of brake
the oil pressure after port (B), the controller ECMV port (S) remains, because the parking
outputs the command current to proportional brake solenoid valve is de-energized.

D155A4 37
sEN02863-00 10 Structure, function and maintenance standard

*operated fully to the |eft", brake pedal is

When the PCCS lever is "released', and parking brake lever
is in "free" position: Shano left turn
(L.H. clutch is turned "off", L.H. brake is "applied", R.H. clutch is turned "on", R.H. brake is "released", and
parking brake is "released'.)

brake ECl,lY a 3 Lell c utch ECl,lV

PD Dr D^
I
l:"1;'ll*' t I
"l
To r ioht hroke I I
tr ECMV ! lot
Dr circLr 1

Io rin ouller Sudden sioD

so leno id !alv€
d
413,ill'",,,.
To riohl
clutch tCMV
+ ISui'"n"' '"'on

Parkins
!edal
' Re | €ase' Parkilo brake

Lef I brake
Parkine T

ltu@,/t
J l-'-.
l_ Ffon rtonr Lel t clutch
€3'ili""u I J 80t264

When the PCCS lever is shifted fiom "ooerated . When the parking brake lever is set in the
to left halfifiay" to "operated to left fully", pro- "free'position, the pilot pressure of brake
portional solenoid (5) of the L-H. brake ECMV ECMV port (S) remains, because the parking
is demagnetized and the sealing part of ball (6) brake solenoid valve is de-eneroized.
is fully opened.
Since the oil in port (E) is drained through the
sealing part, valve (7) is moved to the right by
the tension of spring (8) to disconnect port (Pb)
from (B) and connect port (B) with port (Dr), At
this time, the oil from the back pressure port of
the brake piston is drained through port (B)
and the brake is turned "applied" by the ten-
sion of the brake spring.
The oil from the power train pump flows
through port (Pb) of the brake ECMV and ori-
lice (b), then it is drained through sealing part
of ball (6).
The oil pressure in the clutch circuit, etc. is
secured by orifice (b)-

38 D155A-6
10 Structure, function and mainlenance standard sEN02863{0

When lhe PCGS lever is in "neutral", brake pedal is "depressed", and parking brake lever is in "free"
position: Stop
(L.H. and R.H. brake are "operated", parking brake is "released")

{) slil Dr
Io rirft f1 IAl
D
' 6 5
V)
rrake ECV! V) I lilt t I
VI
a VI
rl ECIIV p,
Df c if
lot
cu it
r,r
Tl

@
LJ l'.1
t/l
t/l
tl
4 avl
,
la,
t4
IA
t4
r7't
rf-
v1
ul
4l: T:;",, ,"
l4 vl
rl oa l3ul,"n'n'"''n
cl!ich EllvV L "4
li' VI
@ f k nt

frcr r i!r: LEli c,rt:h

brake ECI'lV
' 0N'
5 qDrt
sJ€04265

When the brake pedal is depressed fully, prG o When the brake pedal is depressed tully, the
portional solenoids (5) of L.H. and R.H. brake brake pedal switch is turned "ON", and the
ECMV are demagnetized to open the sealing parking brake solenoid valve is energized lo
part of ball (6). drain the pilot pressure of the brake ECMV port
The controller outputs the command current to (S).This carries out the same function as when
proportional solenoids (5) according to the the parking brake lever is set at the "lock" posi-
brake pedal stroke. tion.
Proportional solenoid (5) generates the propuF
sion force in proportion to the command cur-
rent. This propulsion force is balanced with the
sum of the propulsion force generated by the
oil pressure in the back pressure port of the
brake piston and the tension of spring (8), then
the brake pressure is set up to adjust the brake
force.
Since the PCCS lever is in "neutral" position,
proportional solenoids (1) of L.H. and R.H.
clutch ECMV are demagnetized and L.H. and
R.H. clutch are turned "on".

D155A{
sEt{02863-00 10 Structure, function and maintenance standard

Parking brake solenoid valve

6. 9-7, gNn
5 (0.7-0.8keml

R.-
47. I-53. gNm
(,t.8-5.5krml
I

0r

P: From brake ECMV

Drain
Dr: Dra in

1. Parking brake lever solenoid valve

Brake pedal solenoid valve
J. Connector for parking brake lever solenoid valve
4. Connector for brake pedal solenoid valve

Sol€noid valve
6 Coil (ON-OFF type)
o. Push pin
7. Spring
8. Spool
9. Body

D155A-6
10 Struc{ure, function and maintenance standard sEN02863{0

When PCCS lever is in "neutral" position, brake pedal is "released", and parking brake lever is in
"lock" position: Parking
(L.H. and R.H. brake are "operated", parking brake is "operated")

ic
r-ake i\ )i
Par[
+F eYer ii r
ri:11",". sb
Loc [' il
UI

friorl
ECN V

R orl brake

\i'";" ptn"+r,1,:: lf i:"' ;: i,,

When the parking brake lever is in the "lock" When the parking brake lever is in the "tree"
position, the parking brake lever switch is position, the parking brake lever switch is
turned 'ON'' and coil (1) of the parking brake "OFF'' and coil (1) of the parking brake sole-
solenoid valve is energized. noid valve ig de-energized.
Spool (3) is pushed to the right direction by Spool (3) is retumed to the left, and close port
push pin (2), then port (P) and (T) are opened (P) and (T) to remain the pilot pressure of the
to drain the pilot pressure of the L.H. and R.H. L.H. and R.H. brake ECMV.
brake ECIVIV The oil oressure from the brake ECMV is
The oil which had flown into the brake piston applied to the back p[essure port of the brake
back pressure port is drained through the oiston. and brake is "released".
brake ECIVIV
The oil pressure in the back pressure port of
the brake piston continues to decrease, then
the brake is fully ''applied" and that situation is
kept.
When the engine is started again, as port (P)
and (T) are still opened, the brake is continu-
ously "applied".

D155A-6 41
sEN02863-00 l0 Structure, function and maintenance standard

Sudden stop prevention valve

lz

o i /o
dD rorcn
\-'l/-a\\./v

o(q, o

3. 9t0. sNm A- A 19. 6-21. 6ND

{0.4t0.05ten} {2.0-2. 2keml (5t0.5krml

A: From power train pump

B: From brake ECMV
dr1: Drain
dr2: Drain

1. Sudden stop prevention valve

EPG valve
2. Coil (proporlional type)
3. Push pin
4. Valve
Ball
6. Spool
7. Body

42 Dt55A-6
10 Struclure. function and maintenance standard sEN02863-00

Erake
'Seni-fe eased' 9J302881

General
. The sudden stop prevention valve is installed
to prevent the machine from stopping suddenly
when an abnormality takes place in the electric
system.
r Sudden stop prevention valve (1) is installed in
the drain circuit of the brake ECMV so that the
sudden oil pressure drop of port (DR) and con-
sequently the sudden brake can be avoided
when coil (2) of brake ECMV is de-energized.
e lf an abnormality takes plac€ in the electric
system, also coil (3) of the sudden stop pre-
vention valve (1) is de-€nergized. Then, the oil
ot port (DR) is drained through orifice (a) so
that the brake is applied gradually.

Dl5546
sEN02863-00 10 Structure, func{ion and maintenance standard

D155A6
10 Structure, function and maintenance standard s8N02863{0

Final drive

Outline
The final drive is a single stage spur gear, sin-
gle stage planetary gear reduction type. The
lubrication is of splash type using the rotation
of the gears. The final drive can be removed
and inslalled as a single unit.
Floating seal (1) is installed to the rotating slid-
ing portion of the sprocket to prevent the entry
of dirt or sand and to prevent leakage of lubri-
cating oil.

D155A6
sEN02863-00 10 Structure. function and maintenance standard

230-289Nm
(23.5-29.5leml

1225- l47oNrl
{ 125-l50 kcml

127-176N||l
{ | 3- 18teml 130-lSgNil
(23.5-2S.5kenl

1 I 50-1440ND
(l l8-l47kenl

230-289Nm
{23. 5-2S- stefll
455-5EsNm | 27- | 76Nm
(46.5-Sokcml t13-lSkenl 9,0034 3 3

46 D155A-6
 10 Structure, function and maintenance standard sEN02863-00

io 1. Floating seal 10. No.1 pinion

2. Sun gear 11 . Final drive c€se
3. Carrier 12. Bearing cage
4. Sprocket boss 13. No.1 gear
5. Sprocket teeth 14- No.l gear hub
6. Cover 15. Shaft
7. Planetary gear 16. Wear guard
8. Ring gear 17. Pivot shaff
9. Cover

Unit mm
No. Check ilem Criteria Remedy

Backlash between No.1 Dinion Standard clearance Clearance limit

18
and No.1 gear 0.25 - O.77 0.77
Backlash between sun gear Replace
and planetary gear
0.20 - 0.55 0.55

Backlash between planeiary

20 0.22 - O.71 0.71
gear and ring gear
Standard size Tolerance Repair limit
Outside diameter of No.1 Din- Repair or
21 0
ion oil seal coniaci surface 95 s4.913 replace
-{.087
Thickness of thrust collar of
23 22.95
inner body roller bearing

Standard Tolerance Standard Clearance

Clearance between outer size crearance limit
Shaft Hole
diameter of planet gear shaft
23
and inner diameter of carrier (Max.
hole. (Small diameter) 68.262 -0.015 {.00s - 0.024 - clearance)
Replace
-{.034 -{.039 + 0.0.25
+ 0.025
Clearance between outer
24
diameter of planet gear shaft
90 -0.036 -{.066 - 0.065 - - 0.008
and inner diameter of canier -{.058 -{.101 - 0.008
hole.(Large diameter)
Standard shim thickness for
25 Adjust
No.1 pinion bearing cage
Standard size Repair limit Repair or
26 wear of wear guard replace
21

D155A{
sEN0286:t-00 10 Structure, funclion and maintenance standard

Path of power transmission

s Jc0020 ?

e The power from the bevel gear shaft and steer- Then, the rotating force of sun gear (2) forms
ing clutch is transmitted to 1st pinion (10) to the rotating force of carrier (3), lvhich supporb
rotale 1st gear (13) meshed with the 1st pinion the planetary gear (7), via shaft (15), and is
and sun gear (2) meshed with the 1st gear. transmitted to sprocket boss (4).
The totation of sun gear (2) is hansmitted to The rotating direction of cafiier (3) is the same
planetary gear (7). Since ring gear (8) meshed with sun gear (2).
with the planetary gear is fixed to cover (6), the The rotational force transmitted to sprocket
planetary gear (7) rotates along the ring gear boss (4) is further transmifted to sprocket teeth
(8) and revolves around the sun gear (2). (5).

48 Dl554-6
sEN0286340 10 Structure. function and maintenance standard

Sprocket

s1003434

Unit: mm
No. Check item Criteria Remedy
Strandard clearance Repair limit
1 Wear of sprocket tooth tip
2El 339
t Wear ot sDrocket tooth root 21.7 15.5
Rebuid or
Wear of width of sprocket replace
83
tooth tip
Wear of width of sprocket
4 105
tooth root

50 D155A-6
 10 Structure, function and maintenance standard sEN02863{t0

Sprocket tooth shape of full scale

o
]

Dt55A6 51
sEt{02863{tt l0 $trucfure, func{lon and malnbnanoe sttndard

D1564-O BulEoEer
Fom tlo. SEN0286$00

@2007 KOMATSU
All Righb Reseryed
Pilnted in Japan 04-07 (02)

52 tmilfiu D15544
 SHOP IfiANI.IAI-
o BULLDOZER
Dl55A-6

o
Machine model Serialnumber
Dl554-6 85001 and up

10 Structure, function and

io maintenance standard
Undercarriage and frame

o
D15546 ronrrlsu
SEN0286/t-00 10 Structure, function and maintenance standard

Track frame

1l!
llc
\:

784-g81Nn
{46.5-58k.n) ( 80- 100 ksnl sJG03136

1. Equalizer bar Outline

2. Pivot shaft . The track rollers are mounted on an K-shaoed
3. ldler bogie. This increases the actual ground con-
4. Track frame tact area between the track shoes and the
ground on rough surfaces, and helps increase
5. Carrier roller
the drawbar pull.
6. Sprocket
r The K-shaped bogies are equipped with rubber
7. Sprocket cover guard pads to absorb the shock from the ground sur-
8. Track roller face.

Track roller, bogie

Track roller flange type anangement
'1st 2nd 3rd 4th 5th 6th 7th
D D D D D S
D: Double
S: Single

D155A{
l0 Struc'ture, function and maintenence standard sEN02E64{0

Unit mm
No. Check item Crilsda Remedy
Item R€p€ir limit
Curvafure 7 (o\rer length of 3,000) Cored or
1 Defomation of track fram€
Twistlng 3 (ov€r length of 300) rsp|aoe

Dsnts (pipa porlion) 12

Dl55A6 3
sEit02864-00 l0 Structure, ftinction and maintenance standard

Recoilspring

9JC03437

'1. Yoke Outline

2. Dust seal r Recoil spring (4) is used to adjust the track ten-
3. Rod sion by pumping in or releasing grease from
4. Recoil spring lubricator (6) to move rod (3) forward or back-
5. Wear ring ward. The recoil spring also acts to dampen
any sudden shock brought to bear on the idler.
6. Lubricator
7. Nui
8. Housing
9. Cylinder
10. Holder
11. Bushing

4 D155A-6
10 Sbuctur€, function and maintenance standard

Unit mm
nb. Chsd( abm Criteria Remedy
Pre€s-fitting forcc fol
1 392 kN {40 ton} Adiust
idler !,oke

Strandard Tol€rance Slandard Clearancei

Clearance b€tween rod sizs Shaft Hole c|oarance limit
11 ]

and bushing r{.277

110 -o.036 0.098 - 1.0
-{.090 +0.062 0.367
$andad size Repair limit l
Replace

lnstalled lnstall€d lnstalled

Frcs l€ngth Free length
4 Recoil spring length load load
298 kN 274 kN
7U 597 687 l

{30,388 ks} {27,soo kc}

D155A6
sEH02864{0 10 Structure, function and maintenance standard

ldler

| ,'',i;.ll
(16-26kcm)
'57-l5uNn'
,i,l ,')i
tE .'\

6 D1554-6
l0 Structure, function and maantenance standard

Unit mm
No- C h€ck item CdtBda Remedy
Sbnda.d Eize Repair limit
1 Outer diameter of orotusion
850
? Oubr diarneter of tread 800 781
Rebuild or
5 Depth oft€ad 25 34.5
repaoe
4 Thickness of t€ad 21 11.5
5 Overall vYitth 245
o Width of tread 62
Sltandard Tolerance Sbndad Clearance
Clearance between shaft 8t26 Shaft Hole clearance limit
and bushing
85
4.210 +0.255
+0.??0
0.430
0.515
-
-0.260 Replac6
Tolerancs bushing
S[andard Standad I nterference
Interfu rence b€tr,veen idler siz€ Shaft Hole interference limit
8
and bushing
135
+0.130 +0.100 0.02 -
+0.080 {.05{t 0.18
S'tandard size Repair limit
I Shafr fange widlh
Redaoe
20 -3.0s
'10 Play of shaft in axial diroction o-49- O.72

DtsriAS 7
sENOIS6{-00 l0 Structurc, function and mdlnGnance standad

Track roller o

206-49ND
{21-5kcnl

s., G0313I

I Dt 55A-6
 10 Siructure, function and maintenance standard sEN02864.00

ro
Unit: mm
No. C heck item Criteria Remedy

Outef diameter of flange Standard size Repair limit

1
(outside flange) 298
Outer diameter ot flange
2
(inside flange)
282

Outer diameter of tread 255 230

4 Thickness of tread 60 47.5
5 Overall width 294
Rebuild or
Width of tread
(single flange)
64 replace

Wdth of tread
7 (double flange)
62

Flange width
8
(outside of double flange)
25

Flange width
(inside of double flange)
10 Shatt flange width 20

S-tandard Tolerance Standard Glearance

Clearance between shaft SEE Shaft Hole ctearance limit Replace
11
and bushing bushing
-0.210 +0.255
+o-220
0.430 -
-0.260 0.515

Slandard Tolerance S;tandard lnlerfere nce

lnterierence between bushi ng size Shaft Hole inte rference limit
12 Replace
and roller
135
f0.130
+0.080
+0.063
-{.020
o.o17
0.150
-
Standard size Clearance limit Adjust or
End play
replace
0.5 - 0.75

D155A-6
sEN02864{0 l0 Structuro, functlon and maintenanca standard

Carrier roller

206.
{21i5krn}

sJ003140

,|0 D155A6
10 Struc'ture, functlon and maintenance stendard

No. Check item Criteria Remedy

Standard siz6 R€pah limit
1 Outsr diameter offlange
220
Outer diarnetsr of trsad 190 197 Rebuild or
3 Wdth of tread 63 r€dace
4 Thickness of tre€d 37.5 26
5 Width of fiange 21
Tolerance Standard
$andard size intederence
Int€rfur€nce bstwesn Shaft Hol€
o
shafi and ring +0.166 +0.030
70 +0.120
0.090 - 0.10t
0
Toleranoe S-tandard
Standard size Redace
Clearance b€tween Shaft Hole dearance
shafi and support +0.300
0
68
4-2 0 0-0.5
Slandard clearance
8 Play of roller in axial dir€clion
0.010 - 0.230

D15sA-6
sEN02864-00 l0 Structure. function and maintenance standard

Track shoe
Dry type

* P portion shows the link of bushing pre$s fitting end.

12 DlssA-6
10 Structure, funciion and maintenance standard sEN02864{0

Unit: mm
I'b Check item Criteria Remedy
Standard size Repair limit
1 Link pitch 231.9 (Heavy-duq areas)
224.9
233.9 (Standard areas)
When turned Reverse or
Standard size feprace
2 Bushing outside diameter Normal load lmpact load
81 75.0 77.0
Thickness ol bushing metal 15.8 9.8 11.8
Standard size Repair limit
Link height
'144 128 Repair or
replace
Thickness of link metal
(bushing press-fitting portion) 45.5 2S.5

Tightening torque Additional tightening

6 Shoe bolt (Nm {kgm}) angle (deg.) Retighten
590 r 60 {60 i 6} 120 ! 10
Tolerance Standard
Slandard size
Interference b€tween Shaft Hole interference
7
bushing and link
+0.404 +o.074
77.O +0.304 0.230 - 0.404
0
Interference between +0.484 -0.038
8a 48.5 +0.334 0_372 - 0.584 Adjust or
regular pin and link -0.100
replace
lnterference between +0.230 -0.038
8b 48.5 +0.200 0.238 - 0.330
master pin and link -0.100
Sltandard clearance
I Clearance between links One side Both side
1_4 2.8

D1554-6 13
sEN02864-00 l0 Structure, function and mainienance standard

Sealed and lubricated track

* P portion shows the link of bushing press fitting end.

14 D155A-6
10 Struc{ure. function and maintenance standard sEN0286440

Unit: mm
No. Check item Criteria Remedy
Slandard size Repair limit
1 Lin k pitch
228.9 231 .S

When tumed Reverse or

Standard size
2 Bushinq outside diameter Normal load lmpact load replace

81 72.5 7 5.O

3 Thickness of bushing metal 15.8 7.3 9.8

Standard size Repair limit
4 Link height
144 't28 Repair or
replace
Thickness of link metal
45.5 29.5
(bushing press-litting portion)
]lghtening torq ue Additional tightening
a. Regular link (Nm {ksmi) angle (deg.)
Shoe bolt Retighten
590 ! 60 {60 r 6} 120 r'10
b. Master link 590 I 60 {60 r 6} 180 i 10

Standard Tolerance Srtandard

lnterference between SiZE Shafi Hole interference
7
bushing and link +0.404 +0.074
77.0 +0.304 0
0.230 - 0.404
Adjust or
Interference between +0.484 -0.038
48.5 +0.334
0.372 - 0.584 reprace
regular pin and link -0.100
Standard clearance
9 Clearance between links One side Both side
1.4 2.8

Dl55A4
sEN02864{0 10 Structure, function and maintenance standard

Single shoe, heavy duty shoe

sJG0t118

Unit: mm
No. Check item Criteria Remedy
Srtandard size Repair limit

:,:ggl' sinsre
heavy duty
80
80
30
30
Repair or
replace
Overall height single 97 47
ofsho€ heavy duty 99 49

DlssA6
l0 litructurr, func'tion and maintenance atandard sEN028G4{0

Dt55A6 17
sEN02864-00 10 Structure, function and maintenance standard

Main frame

L
E -tl

18 D155A6
{0 Suucture, functlon and malntenanc€ standard sEN02864{t0

1. Main frame
2. Cage
3. Clamp
4. Cover
5. Seal
6. Coupling
7. Cap
8. Plate

Unit mm
nb. Check item Criteria Remody

Standard Toleran€ S[andad Clearance

Clearance belween siza clearance limit
Shaft Hole
I e{ualizer bar shaft Replace
and bushing
95
-0.036 +0.213 0.165 - 1.0
4.090 +0.129 0.303
Pre6s-flffng forc€ br
10 equalizer bar shafr 29.42 - 68.65 kN (3 - 7 ton) Adjust
mounting bushing

Dl55A-6 l9
sEN0286{-00 l0 Structure, function and maintenance standard

Suspension

r:l
I
I
.-
/'l
i

qT 'I I

{: i- <-;
{i

' 'u''
\ i/' "li

I JG0344 3

20 t)l55A6
10 Structure, function and maintenance standard sEN02864{0

1. Equalizer bar 6. Pivot shaff

2. Pivot shaft assembly 7. Seal cage
3. Cover 8. Seal
4. Thrust plate '10. Side pin
5. Thrust plate 'l1. Center pin
Unit: mm
No. Check item Criteria Remedy
Press-fitting force for side
9 pin bushing 27.46 - 64.7 kN {2.8 - 6.6 ton}

Pressjitting force for center

pin bushing 47 .o7 - 131.41 kN {4.8 - 13.4 ton}

Standard Tolerance Standard Clearance

Clearance belween center size Shaft Hole clearance limit
pin and bushing
95
-{.036 +0.279
+0.213
0.249
0.369
- '1
.0
--0.090

'14 Clearance between side pin 70 -0.030 +0.046 0.030 - '1.0

and bushing -{.060 0 0.106

Standard Tolerance Srtandard I nte rference

lnterference between size Shaft Hole inte rference limit
15
side pin boss and bushing Replace
130
+0.033
+0.015
-0.028
-{.068
0.043
0.1 01
- bushing

16
Interference between pivot
shafr and seal stopper ring
17o +0.083
+0.043
-{.053 0.096
0.176
-
-0.093
Standard Tolerance Standard Clearance
Ciearance between pivot size Shaft Hole clearance limit
shafr and bushing (outer)
148 -{.145
-{.208
+0.099
+0.035
0.180
0.307
- 1_0

'18 Clearance between oivot 175 -0.145 +0,095

+0.025
0.170 - 1.0
shafr and bushing (inner) -0.208 0.303

Outline
The front of the track frame rocks up and down
using the rear pivot shafts (6) as a fulcrum.
Equalizer bar (1)rocks using center pin (11) as
a fulcrum. The left and right track frames are
connected by side pin (10).

D155A-6
sEN0286&00 l0 StruL:furs, function and malntanance standatd

D1554{ Bulldozer
Form No. SEN02864-00

@ 2OO7 KOMATSU
All Rights Rese.r/ed
Printed in Japan 0rt-07 (02)

22 ilorr|lu Dl554-6
 SIIOP DfiANI.IAI- sEN02865.{r2

BULLDOZER
Dl554-6

o
Machine model Serialnumber
D1554-6 85001 and up

10 Structure, function and

o maintenance standard
Hydraulic system

o
sEN02865-02 l0 Structure, function and maintenance standard

Work equipment hydraulic piping diagram

Semi U-dozer

I J G0344 6

1. Blade tilt cylinder 5. Hydraulic tank

2. R.H. blade liff cylinder o- Hydraulic pump
3. Accumulator L.H. blade lift cylinder
4. Control valve 8. Oil cooler

Dl5546
10 Struc{ure, function and maintenance standard sEN0286542

Multi-shank ripper

1. Control valve
Divider block
3. Ripper lift cylinder
A
Ripper tilt cylinder

D155A6
sEN02865{'2 10 Structure, funclion and maintenance standard

Giant ripper

sJ c0 315 2

1. Control valve
2. Divider block
3. Ripp€r lift cylinder
4. Pin puller cylinder
5. Ripper tilt cylinder
6, Pin puller solenoid valve

4 D 155A-6
10 Structure, function and maintenance standard sEN02865{2

t)1554-6 5
sEN02865-02 10 Structure, function and maintenance standard

Work equipment control piping diagram

Blade, ripper control
Serial No.: 85001 - 85024

I JC03453

1. Accumulator 3. Work equipment lock valve

2. Control valve 4. Self pressure reducing valve

6 D155A-6
10 Structure, function and maintenance standard sEN02865-02

Se.ial No.: 85025 and up

1. Accumulator Self pressure reducing valve

Control valve q Filter
Work equipmenl lock valve

D1554€ 7
sEN0286tt-02 l0 Structure, function and maintenance standard

Work equipment control

,.-:.*,\y-_
,.' -/ ,,' -'.-
,-".''' ,' ,'--
,.} 'I

).'- I l,

) ,,, i
-/ ;t
!l

'.
,-"1t: ti
!l

--\

AJG00278

I D 155A-6
10 Structfis, funclion and malntenanoe standard sEN02865{2

,|
Work equipment lock lever
2. Blade PPC valve
3. Ripper PPC valve
4. Work equipm€nt lock switcfl
5. Control valvs

Lever positions
A: Blade HOLD
B: Blade LOWER
B+C:BladeFLOAT
D Blad6 RAISE
E Blade LEFT TILT
F Blade RIGHT TILT
Ripper HOLD
H Ripper RAISE
J RipperLOWER
K Ripper DECREASE TIP ANGLE
(with variabl€ ripp€r)
L Ripper INCREASE TIP ANGLE
(with vadable ripper)
M FREE
N LOCK

Outline
r The work equipment confol emplo)ts a PPC
system which uses a PPC valve to move the
sDools of th6 contrcl valve.

D155A.G
sEN0286s-02 10 Structure, function and maintenance standard

Hydraulic tank and filter

1. Pressure valve 7. Strainer

2. Drain valve 8. Suc'tion valve
3. Drain plug 9. Spring
4. Cover 10. Hydraulic filter element
5. Covet . Oil filler cap
11
6. Hydraulic tank 12, Sight gauge

D155A6
10 Struc{ure, function and maintenance standald sEN02865{2

$ecilied
value
Tank c€pacity (4) 125
Hydraulic Hi (41 95
Level
tank inside Cenier 85
Q)
tank
Lo^' (9) 75
Cracking pressure 16.7 t 2.5
(kPa {kgi cm,}) {0.17r0.025}
Breather
Vacuum valve actuating 2r0.3
pressure (kPa {kgicm4) {0.02i0.003}
Cracking pressure 147 x29.4
(kPa iks/cm1) i1.5r0.31)
Hydraulic
filter
Mesh sizs (p m) 20110t5
Filtering area (cmt) 13,600
flo'/r'
Filtering cil (f,/min) 550
Mesh size (U m) 105
Sltrainer
Filtering area (cmrl 1 ,85{t

11
sEN02865-{'2 {0 Structure, function and maintenance standard

Accumulator Function
I The accumulator is installed between the
For EPC valve redusing valve and the EPC valve. Even if the
engine is started with the work equipment still
raised, the pressure of the nitrogen gas com-
pressed inside the accumulator sends the pilot
pressure to the control valve to actuate it and
enable the work equipment to move down
under ib own weight.

Operation
After the engine is stopped, when the EPC
valve is at neutral, chamber (A) inside the blad-
der is compressed by the oil pressure in cham-
ber (B).
When the EPC valve is operated, the oil pres-
sure in chamber (B) goes below 2.9 MPa {30
kg/cm2), and the pressure of the nitrogen gas
in chamber (A) expands the bladder, so the oil
in chamber (B) acts as lhe pilot pressure and
actuates the main control valve.
Befofe actuat ion Altef actuatiDn

sic03447

1. Gas plug
2. Shell
3. Poppet
4. Hold€r
sBD0t365

5. Bladder
6. Oil port

Specifications
Type of gas: Nitrogen
Gas volume: 300 cc
Max. actuation pressure: 3,14 MPa {32 kg/cm,}
Min. actuation pressure: 1 ,18 MPa {12 kglcmzl

'|-2 D155A6
 l0 Structure, function and maintenance standard sEN0t865-02

O PPG vatve
Blade PPG valve

P: valve
From self pressure reducing P3: To blade tilt valve (LEFT TILT)
FLOAT)
P1: To blade liff valve (LOWER, P4: To blade tilt valve (RIGHT TILT)
(RAISE)
P2: To blade lift valve T To tank

o
o155A-6 l3
sEN02865-02 {0 Structure, function and maintenance standard

I t.8-1,+. 7Nn
(1.2-l.5krnl

t0

f'lt tt'
,o-norn -/
{3.5-,f.skenl

6-l lNn
{0. 6-1. I keml
D-D
4-gNn
(0.,r

11. 8-14. 7Xm

( 1. 2-l. 5k e|rll

15

9J S07832

1. Spool 6. Plate
2. Piston 7. Retainer
3. Disc 8. Body
4. Nut (For connecting lever) 9. Filter
5. Joint

14 D155A-5
10 Stuc'tum, func{ion and malntenance standard sE {02865{2

Unit mm
No. Check itam Cdteria R6medy
Sandard size Rspair limit
Frc6 l€ngth
lnstalled lnstallsd Installed
Metering spring x Outside Free langth
10 (For po1t8 length load litad
P3 and P4) diameter
16.7 N 13.3 N
26.53 x 8.15 2'1.9
(r.7 ks) fl.36 k9)
Centedng spring 107.9 N 80.3 N Replace
11 48.57 x |5.5 32.5
(For porb P3 and P4) {11 ks} {8.8 ks} spring lf
Met€ring spring 16.7 N 13.3 N
12 26.3 x 8.15 24.1
(For port P2) {1 7 ks} (l36 kg}
Centedng spring 78.5 N 62.8 N
t3 (For pod P2)
43-2 x 15.5 34
tB k9) t6.4 ks)
Centering spring
14 (For port 34.0 x 15.5 31.S
94N 75.3 N
P1) {e.6 ks} {7.68 ks}
Melering spring 16.7 N 13.3 N
15
(For port Pl)
29.27 x8.15 25-l
{1.7 kS} tl.36 k9]

Dt55A6
sEN02865-02 l0 Structure, func{ion and maintenance Etandard

Operation
1. When in neutral
1) For lifting blade 2) For tilting blade
. Ports (A) and (B) of the blade lift valve of the- a Ports (C) and (D) of the blade tilt valve of the
control valve and ports (P1) and (P2) of the control valve and ports (P3) and (P4) of the
PPC valve are connected through fine control PPC valve are connected thraugh fine control
hole (0 of spool (1) to drain chamber (D). hole (f) of spool (1) to drain chamber (D).

s J s01543 sJ s01544

16 D155A-6
10 Structure, function and maintenance standard sEN02865{t2

2. When in fine control

(Neutral -J Fine controll
lf piston (2) is pushed by disc (3), retain€r (7) is
pushed and spool (1)is al$o pushed down
through metering spring (15).
Accordingly, fine control hole (f) is discon-
nected from drain chamber (D) and connected
to pump pressure chamber (PP) almost simul-
taneously, and then the pilot oil flows from port
(P1) through fine control hole (f) to port (B).
lf the pressure in port (P1) rises, spool (1) is
pushed back and fine control hole (f) is discon-
nected from pump pressure chamber (PP) and
connected to drain chamber (D) almost simul-
taneously to release the pressure in port (P1),
As a result, spool (1) moves up and down to
balance the force of metering spring (15) with
the pressure in port (Pl ).
The positional relationship between spool (1) Sell P
and body (8) [where fine control hole (f) is
between drain chamber (D) and pump pres-
sure chamber (PP)l does not change until
retainer (7) comes in contact with spool (1 ).
Since metering spring (15) is compressed in
proportion to the stroke ofthe control lever, the
pressure in port (Pl ) rises in proportion to the
stroke of the control lever.
Accordingly, the control valve spool moves to a
position at which the pressure in port (B) lequal
to the pressure in port (P1)l is balanced with
lhe force of the control valve soool return
spring.

D155A-6 17
sEN0286542 10 Structure, function and maintenance standard

3. When in fine control 4. When lever is operated to stroke end

(When control lever is retumedl o lf disc (3) pushes down piston (2) and retainer
lf disc (3) begins to retum, the f'orce of center- (7) pushes down spool (1), fine conhol hole (f)
ing spring (14) and the pressure in port (Pl ) is disconnected {rom drain chamber (D) and
push up spool (1). connected to pump pressure chamber (PP).
As a result, fine control hole (f) is connected to Accordingly, the pilot oilflows through fine con-
drain chamber (D) and the oil in port (P1) is trol hole (f) and port (P1) into port (B) and
released. pushes the control valve spool-
lf the pressure in port (P1) lowers too much, The qil retuming from port (A) flows through
spool (1) is pushed down by metering spring port (P2) and fine control (f') into drain cham-
(15) and fine control hole (f) is disconnected ber (D).
from drain chamber (D) and connected to
pump pressure chamber (PP) almost simulta-
neously. Then, the pump pressure is applied
until the pressure in port (Pl ) is restored to the
level corresponding to the position of the lever
When the control valve sDool returns, the oil in
drain chamber (D) flows in through fine contml
hole (f') of the valve which is not in operation
and then flows through port (P2) into port (A).

sJs07835

9JS07834

18 D 155A-6
 10 Structure, function and maintenance standard sEN02865{2

o 5.
a
When blade is "floated"
lf piston (2) on ihe "LOWER" side of port (P1)
6.
a
When "FLOAT" state of blade is reset
Disc (3) is pushed down with a force larger
is pushed down by disc (3), ball (18) touches than the oil pressure in chamber (E) to return
projection (a) of the piston in the middle of the from the "FLOAT" position.
stroke (The detent starts to operate). As a result, chamber (E) is disconnected from
lf piston (2) is pushed in further, ball ('18) passage (d) and connected to the drain cham-
pushes up collar (17) supported on detent ber. Accordlngly, the oil pressure in chamber
spring ('16) and escapes out to go over projec- (E) is lost and the "FLOAr state is reset.
tion (a) of the piston.
At this time, piston (2) on the opposite side is
pushed up by spring (19).
As a result, the oil in chamber (F) flows
through (b) and (c) to chamber (E) and piston
(2') follows disc (3). Since passage (d) is con-
nected to port (P1), almost the same pressure
is applied to passage (d) and port (P1 ).
Chamber (E) is normally connected lo drain
chamber (D). lf ball (18) goes over projection
(a) of the piston, passage (d) and chamber (E)
o are connected and the oil starts flowing.
At this time, the control valve moves to the
"FLOAT" position and the blade is floated-
Since piston (2') is pushed up by the pressure
in chamber (E), the "FLOAT" state is kept even
if the lever is released.

tI
ll
IE

sJs0t835

D155A6
sEN02865-02 10 Structuae, function and maintenance standard

Ripper PPC valve

/ -il l\-

P From self pressure reducing valve

P1 To ripper tilt valve (OUT)
P2 To ripper tilt valve (lN)
P3 To ripper lift valve (LOWER)
P4 To ripper lifl valve (RAISE)
T To tank

20 0155A6
10 Structur€, func'tion and maintenance standard sEl{02865{2
sEN02865-02 10 Structure, function and maintenance standard

g8-l27Nm
{ l0- 13konl

3S-4SNn
(4-5kcm)

7 11. B- 14. lNn

( l. 2-1. Sleml

r-) t0

/t 0

t2

34-44Nrl
(3.5-4.5koml

6-l I Nn
(0.8-1. lte.rl

,f-gNr
{0.,f-0. gkt||}
(l

22 Dl55A-6
l0 Sbuc{urE, func'tion and mainienanca standard sEN02865{r2

1. Spool
2. Piston
3. Disc
4. Nut (for connec{ing lev€r)
5. Joint
6. Plate
7. Retainer
8. Body
9. Filter

Unif mm
No. Check item Crit€ri€ Remedy
Slandard sizs Repair limit
Fr€€ lenglh
x OuElds
lmtallsd lnstallsd lnstallsd
C€ntering spring F ee length
10 lsnglfl load lo€d
(For ports P3 and P4) diameter
Replac€ spring
50.35 x 15.5 v 55.9 N
{5.7 k9}
4.7
t4.so
N
lq)
if damaged ol

Centerlng spring r 7'!.4 N 57.1 N

11
(For porb Pl and P2)
50.05 15.5 34
{7.28 ks} {5.8lq}
't6.7 N 13.3 N
12 Metering spring 26.53 r 8.15
{1.7 ks} {1.36 l(g}

Dt55A6 23

i
sEN02865.02 10 Structure, function and maintenance standard

Op€ration Since metering spring (2) is compressed in

1. When in neutral oroportion to the stroke of the control lever, the
o Ports (A) and (B) of the control valve and ports pressure in port (P1) rises in proportion to the
(Pl ) and (P2) of the PPC valve are connected stroke of the control lever.
through fine control hole (f) of spool ('1) to drain Accordingly, the control valve spool moves to a
chamber (D). position at which the pressure in chamber (A)
[equal to the pressure in port (Pl)] is balanced
with the force of the control valve soool return
spring.

grS076Tl

2. When in fine control sls0TBm

(Neutral -+ Fine control)
lf piston (4) is pushed by disc (5), retainer (9) is
pushed and spool (1) is also pushed down
through metering spring (2).
Accordingly, fine control hole (f) is discon-
nected from drain chamber (D) and connecled
to pump pressure chamber (PP) almost simul-
taneously, and then the pilot oil flows from port
(P1) through tine mntrol hole (0 to port (A).
lf the pressure in port (Pl) rises, spool (1) is
pushed back and fine control hole (f) is discon-
nected from pump pressure chamber (PP) and
connected to drain chamber (D) almost simuF
taneously to release the pressure in port (P1).
As a result, spool (1) moves up and down to
balance the force of metering spring (2) with
the pressure in port (P1). The positional rela-
tionship between spool (1 ) and body (10)
lwhere fine control hole (f) is between drain
chamber (D) and pump pressure chamber
(PP)l does not change until retainer (9) c,omes
in contact with spool (1).

24 D155A6
10 Structure, function and mainlenance standard sEN02865-02

3. When in fine control 4. When leyer is operated to stroke end

(When control lever is returned) a lf disc (5) pushes down piston (4) and retainer
lf disc (5) begins to return, the force of center- (9) pushes down spool (1), fine control hole (f)
ing spring (3) and the pressure in port (P1) is disconnected from drain chamber (D) and
push up spool (1)- connected to pump pressure chamber (PP).
As a result, llne mntrol hole (f) is connected to Accordingly, the pilot oil flows through fine con-
drain chamber (D) and the oil in port (P1) is trol hole (f) and port (P1 ) into chamber (A) and
released. oushes the control valve sDool.
lf the pressure in port (P1) lowers too much, The oil returning from chamber (B) flows
spool (1 ) is pushed down by metering spring through pori (P2) and fine control (f) into drain
(2) and fine control hole (f) is disconnected chamber (D).
from drain chamber (D) and connected to
pump pressure chamber (PP) almost simulta-
neously. Then, the pump pressure is applied
until the pressure in port (Pl ) is restored to the
level corresponding to the position of the lever.
When the control valve spool returns. the oil in
drain chamber (D) flows in through flne conlrol
hole (f) of the valve which is not in operation
and then flows through port (P2) into chamber
(B).

D1554-6 25
sEN02865-02 10 Structure, func{ion and maintenance atandard

Work equipment lock valve

s,JG02024

1. Solenoid
2. Body
3. Spool

Outline
o The work equipment lock valve is installed
b€tween the basic oressure valve and control
valve in the work equipment contml circuit. lf
the work equipment lock lever is set in the
FREE position, the work equipment lock switch
operates and the work equipment lock valve
opens the work equipment control circuit so
that the op€rator can operate the work equip
menL

Op€ration
. The solenoid is operated by the electric signal
to move the spool. As a result, the circuit
between port (A) connected to the basic pres-
sure valve and port (B) connected to the con-
trol valve is ooened,

26 D155A6
10 Struc'turc, functlon and malntcnance standald sEN02865{2
sEN02865-02 10 Structure, function and maintenance standard

Control valve
General view

29.4-39, 2Nln
( 3-4koml
| ?6. 6-r 96. zNm
{ l8-20trm)

lS. 6-27. 5Nm T

{2-2.8keml

21.4-34.3Nn 27,4-34.3Ni|
(2. 8-3. Sksnl (2.8-3.5k0|t|)

PA4

PB3
PA3

PA2
PB2
lz
PAI

2S.4-39.2Nm
{3-4 kcnl

il It

-o

28 D15546
10 Sbuc{ul€, functlon and maintenance atandard sEl{02865{'2

A: Pump pr€ssure pick-up port

A1: Toblade tilt cylinder head
A2: Toblade lift cylind€r head
A3: Toripper lifr cylinder head
A4: Toripper tilt cylinder bottom
B: LS preseure pick-up pon
81: To blade tilt cylinder botbm
82: To blade lifr cylinder bottom
83: To ripper lifi cylinder bottom
84: To ripper tilt cylinder head
C: PPC main pressure port
LS: To DumD LS valv€
P: From pump
PA1: Fmm blade PFC valve
PA2: From blade PPC valvo
PA3: From ripper PPC valve
PAA: From dpper PPC valve
PBl: From blade PPC valve
PBZ; From blade PPC valve
PB3: From ripper PPC valve
PB4: From ripper PPC valve
t: to lanK

Dts5A{ 29
sEN02865{12 10 Structure, function and maintenance standard

Sectional view
(1/3)

I l7- 7-l6l.8Nr
( 12- | 6, 5lsnl

127.5-176.6Nm
{I3-lSlenl

274.6-367.7Nm
(28-37. Sksr

29.4-39.2ND
( 3-4 ko|r]l

IJ

sJ s077sB

30 D1554-6
 l0 Struc{ure, function and malnt€nance standard

1. Valve block E Blade tilt spool

2. Ripper tilt spool Valve body
3. Ripper liff spool 7. Load check valv€
4. Blade lift soool 8. Prgssureoompensalion

Unh: mm
No. Chsck item CriEria Rem€dy
$andard siz6 Rep€ir limit
Fres l€ngth
InstElled Insblled lnstall€d
x Oubide Free length
9 Spool retum spring l€ngth load load
diamet€r
224N 178N
76.3 x 3{) 68.5
{22.8ks} {r8.2ks}
lf damaged or
140N 112N
10 Spool retum spring 51.7 x 31.3 50 dsfomsd,
t14.3ks} {11./tkg} t€placs spring
217N t74N
11 Spool r€turn spring 54.7 x 36.5 :t:t_5
122-lksI {17.7ks}
12.7N 9.8N
12 Load check valve spring 2O.8 x 12.2 '| 3.5
{1.3ks} t1.oks)
r93N 154N
t3 Unload valv€ spring 86.7 x 30 66
{1e.63ks} tl5.7ks]

o
Dt55A-6
sEN02865-02 10 Structure, function and maintenance standard

(2/3)

58. 8-78. Siln

( 6-8kenl

58. 8-78. sNm

( 6-8leml

oo E-E

oo
107.8-140.7Nn
{ | l. o-15. okerl
3

137-l5?Nm 176. 6-196. I Nrn

{1,t-l6t!nl ( l8-201.r
107. g-14?. l Nrt
(| 1-t 5trm)

t?6.6-196. lN.
( l8-20ted

181.,+-2,f0.3Nn 372- 7-465- BNr

{18.5-24.5[em] {38-,f?.5keml

sJs07799

Dl55A-6
10 Structure, funclion and maintenance standard sEN02865{t2

.
'l LS check valve 4. Unload valve
2. Main relief valve 5. Suction valve
3. LS relief valve 6. Check valve (built in spool)

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
lnstalled lnstalled Installed It damaged or
x Oulside Free length
7 Suction valve spring length load |oao deformed,
daameter
replace spring
6.37N 5.1N
M.S x 12.5 56
i0.65ksl {0.s2ks}

D155A6 33
sEN0286542 1O Structure, function and maintenance standard

(3/3)

2S.4-39. zNb

L-
Or--rO o L

lg. 6-27, Stln

{2-2.8ked

Cr--'O o

9,is0780l)

34