PM-clinic For D155A-6

Purpose of Pm-clinic
Prevent machine breakdown and improve functional capability by :
(1) Periodically inspecting the major items which will affect
the machine performance
(2) Predicting possible problem before real trouble occurs.

Pm-clinic will enable the following.

Ex : 1. Check stock availability and placing order of spare parts.
2. Plan trouble shooting and repairing at the periodical maintenance.

Criteria

500Hr 1000Hr 1500Hr 2000Hr 2500Hr 3000Hr

Machine
deliver Important
 Prepared by : N.NAMIKI
D155A-6
Pm-clinic Training Manual
ITEMS
1. How to check Hot bushing of link.
2. How to measure Engine RPM.
Engine & Torque converter matching curve
Deceleration pedal adjustment.
3. How to measure Exhaust gas temperature.
4. How to measure Blow-by pressure.
5. How to measure Boost pressure.
6. How to measure Engine oil pressure.
7. How to measure Torque converter Inlet/Outlet oil pressure.
8. How to measure T/M oil pressure.
9. How to measure Steering & Brake oil pressure.
10. How to check Brake performance.
11. How to measure PPC oil pressure.
12. How to measure Work equipment circuit oil pressure.
( Unload pressure, Work equipment relief pressure.)
13. How to measure Fan speed.
14. How to measure Work equipment speed.
15. How to measure Hydraulic cylinder drift.

Data sheet. : 2 pages

1. How to check hot bushing of link pin
LH Shoe assy’

Note: Touch the surface of link pin, If you feel warm or hot.
Measure the surface of link pin by the Digital emission thermometer.

　 Digital emission thermometer

 2. How to measure Engine speed RPM.
Preparation
1. Adjust the P mode and Manual mode.
2. Warming up power train oil temperature with engine stall three to five times.

F3
F3 STALL

Do not shift F1 stall

2-2. Engine stall speed measuring items.

1. Measuring the engine stall RPM. MAX

Adjusting : ID “0530” High idling
High idling
( Torque converter stall rpm measuring mode. )
1. Parking lever “OFF”. Fuel dial is MIN position.
2. Brake pedal “ON” completely.
3. PCCS lever shift to forward, Press the shift-up button twice. MIN
Low idling
4. Monitor panel shows “F3” then fuel dial to MAX position.
5. Measure engine stall RPM when T/C Temperature at 116 ℃
Criteria : 1615--1715 rpm

2. Measuring the engine stall + work equipment relief RPM.

* Measure engine stall + blade tilt relief or ripper lift relief RPM
when T/C Temperature at 116℃

Criteria : 1580--1680 rpm

2-3. Engine speed measuring items.
　　★： Condition
1. After warming up. MAX
2. Fan speed : Low High idling

1. Measuring the engine low idling.

* Adjust the fuel dial min position.
Criteria : 715—765 rpm
MIN
2. Measuring the engine high idling. Low idling
Adjusting : ID “0007”
( Engine deceleration cut mode. )
* Adjust the fuel dial max position.
Press deceleration pedal
Criteria : 2000—2100 rpm

3. Measuring the engine deceleration pedal slow.

* Adjust the fuel dial max position.
* Press the deceleration pedal to stroke end.
Criteria : 850—900 rpm Deceleration slow stopper
Deceleration slow RPM : 850--900rpm
Deceleration pedal adjustment

High idle : 2050±50rpm

( Adjust mode : ID 0007 )

Deceleration pedal
STD ：
34.8mm

STD ： 35mm

Deceleration slow RPM : 850—900rpm

Potentiometer
Deceleration pedal adjustment
Deceleration pedal N position
adjustment rod.

Remove the RH step

STD dimension: 50mm

Deceleration slow stopper adjustment

Deceleration slow RPM : 850--
Stroke: 50mm 900rpm
3. How to measure Exhaust gas temperature
★ ： For details of the measurement conditions, T/C stall
See T/C Stall in Engine RPM measurement
Temp
.
1.Measure the ambient temperature by the temperature sensor
2.Firstly, carry out torque converter stall Exhaust gas temp
3.Measure exhaust gas temperature at T/C Temp’ 118℃.
during the torque converter stall.
Criteria : ＜ 670 ℃
Digital Thermometer Time

DT Connector must be install

Temperature sensor
Exhaust gas temperature sensor outlet
 4. How to measure Blow-by pressure.
* Measure the Blow-by pressure by monometer.
* Start the engine and measure the blow-by pressure
with the T/C Stalled.
Criteria : ＜ 300 mmAq
Monometer
★ ： For details of the measurement conditions,
See T/C Stall in Engine RPM measurement.
H

Adapter

Monometer gauge : mmAq

Slit
Push the level gauge and filler completely
 5. How to measure Boost pressure.
* Users mode condition : P mode, Manual mode
* Measure the boost pressure with the stalled.
* Measure the boost pressure by Pm-clinic mode
* Measure the boost pressure at T/C Temp’ 116 ℃.

See T/C Stall in Engine RPM measurement.

Pm-clinic mode 1/2 Pm-clinic mode 2/2

T/C oil Temperature

Boost pressure
6. How to measure Engine oil pressure.
Users mode condition : P mode, Manual mode
* Measure the engine oil pressure after the coolant temperature more than 70 ℃.
* Measure the engine oil pressure by Pm-clinic mode
* Measure the engine oil pressure at low idling and high idling.
See T/C Stall in Engine RPM measurement.

Coolant temperature :
Engine oil pressure
More than 70 ℃
7. How to measure Torque converter Inlet/Outlet oil pressure
Users mode condition : P mode, Manual mode
* Measure the Torque converter Inlet/Outlet pressure after measuring Engine stall RPM.
* With the PCCS lever at N, with the engine idling and high idling.

T/C IN oil pressure

T/C OUT oil pressure
 Test port

White+Blue Red+Blue
Red+Black Yellow White Colorless

TM F R
OUT RB LB IN : T/C IN
OUT: T/C OUT
3RD : 3RD Clutch
2ND : 2ND Clutch
Front 1ST: 1ST Clutch
R : Reverse
F : forward
TM : Transmission
Main Relief
LB : Left Brake
IN 1ST 2ND 3RD RC LC
LC : Left Clutch
Blue+Black Red White+Yellow White+Black Black RB : Right Brake
Yellow+Black RC : Right Clutch
8. How to measure T/M oil pressure
Users mode condition : P mode, Manual mode
8-1. T/M main oil pressure Criteria : 28.7-31.7 / 31-34 Kg/cm2
* Measure the T/M Main oil pressure with the PCCS lever at N.
* Measure the T/M Main oil pressure with the engine at low idling and high idling.
8-2. T/M each clutch oil pressure
・ Brake pedal ON. with the engine at low idling. Criteria : 26-30 / ---- Kg/cm2
* Measure the 1ST, 2ND, 3RD, FWD, R, clutch pressure with the PCCS lever at engine slow stall.
Pressure gauge : 60 Kg/cm2

TM F R

Front

1ST 2ND 3RD

Nipple
 9. How to measure Steering & Brake oil pressure.
Users mode condition : P mode, Manual mode
* With the PCCS lever at Ｎ , measure the brake oil pressure with engine
at low idling and high idling when the brake pedal are not operated.
* The PCCS lever at Ｎ and Lever LH stroke end and RH stroke end.
* Make sure that the brake oil pressure is ０ when the Brake pedal is locked.
Pressure gauge : 60Kg/cm2

★ ： Make sure that the brake oil pressure is ０

when Parking lever is ON position. Test port area
Criteria :
Steering : 23.5-26.5 / 23.5-26.5 Kg/cm2
Brake : 25-31 / 25-31 Kg/cm2
RB LB

Front

RC LC
 10. How to check Brake performance.
Users mode condition : P mode, Manual mode
1. Stop the machine on flat level ground and set the blade
in the travel position.
2. Run the engine at low idling, the brake pedal firmly,
and set shift change F2.
★ ： Don't carry out this test F1 under any circumstance.
3. Depress the decelerator pedal and move the engine dial to MAX Position.
4. Release the decelerator pedal slowly to raise the engine speed to high idling.
at this time, check that the machine does not move.
　　★： If the machine should start moving, depress the decelerator pedal
and return the PCCS lever to N position.

1. Engine dial : MIN position

2. Brake pedal : ON (firmly)
3. Set shift change F2
4. Confirm monitor panel display : F2
5. Deceleration pedal : Depress
6. Engine dial : MAX position
7. Deceleration pedal : Release
 Travel Performance curve
F1 Stall
(1.6W)

F2 Stall
(1.03W)

F3 Stall
(0.48W)
11. How to measure PPC oil pressure.
( Self pressure reducing oil pressure. )
Users mode condition : P mode, Manual mode
* With the Safety lock lever at FREE, Criteria : 40.5-45.5 Kg/cm2
measure the pressure reducing oil pressure To accumulator
with engine with at low idling and high idling.

Pressure gauge : 60Kg/cm2

To accumulator

Air bleeder for work equipment pump

12. How to measure work equipment circuit oil pressure.
Users mode condition : P mode, Manual mode
12-1, Unload oil pressure.
* Measure the unload oil pressure with PCCS lever, Blade lever, Ripper lever at FREE.
* Measure the unload oil pressure with at high idling.
Criteria : 25-39 Kg/cm2
12-2, Work equipment relief oil pressure.
* Measure the work equipment relief oil pressure with ripper lift relief, blade tilt relief.
* Measure the work equipment oil pressure with at high idling.

Pm-clinic mode 2/2

Criteria : 265-295 Kg/cm2

Hydraulic pump pressure 1

Temp’ in hydraulic tank : 50—80 ℃

Hydraulic main valve
Hydraulic Ls relief valve

Pump pressure
check plug

Ls pressure check plug

Unload valve Main relief valve
Hydraulic main valve

Hydraulic Ls relief valve

Adjusting nut
Lock nut

Amount of adjustment : 200 Kg/cm2 / 1 turn

 Sectional view of Control valve 　
Unload valve and LS relief valve

Ls relief valve (for Hydraulic)

Main relief valve Suction valve Suction valve

Unload valve
Hydraulic pump pressure sensor
 Reflex tape
13. How to measure Fan speed.
Users mode condition : P mode, Manual mode

* Adjust the service mode adjustment mode.

* Adjusting : ID “1005” ( Fan speed : High ).
* Measure the fan speed the engine at high idling.
by the digital tachometer.
Measuring fan speed
Criteria : 1045-1155 rpm

Temp’ in hydraulic tank : 50—80

℃

1005

Digital tachometer
 D155A-6
Water temp' : 95℃
FAN CONTROL MAP P/L Oil temp' : 108℃
Hyd Oil temp' : 95℃
rpm
1500
Fan Control System
1100 rpm×1180φ
Engine: thermostat. 76-90 ℃ 95℃
108℃
1000

Fan speed 642 rpm

500 481 rpm

Water temp' : < 40℃ Water temp' : < 80℃

P/L Oil temp' : < 52℃ P/L Oil temp' : < 92℃

0 50 100 ℃
Temperature
14. How to measure Work equipment speed.
1. Blade lift speed
① Stop the machine on flat level ground and
the blade completely lowering it to the ground
horizontally, then apply the brake.
② With the engine speed at low idling and high idling. Lift
Measure the time required for the blade to reach the maximum
height above the ground by using a stop watch.

2. Single tilt speed. (Single tilt dozer) RH tilt → LH tilt

① Stop the machine on flat level ground and
about 400mm height above the ground, then apply the brake.
② With the engine speed at low idling and high idling.
Measure the time required for the blade single LH-tilt. LH tilt

3. Dual tilt speed. (Dual tilt dozer) RH D. tilt → LH D. tilt

① Stop the machine on flat level ground and
about 600mm height above the ground, then apply the brake.
② With the engine speed at low idling and high idling.
Measure the time required for the blade single LH-tilt.

4. Ripper tilt in speed. Ripper tilt out → Ripper tilt in

① Stop the machine on flat level ground and
about 400mm height above ground, then apply the brake.
② With the engine speed at low idling and high idling.
Measure the time required for the ripper to reach the tilt in.

Ripper tilt in
15. How to measure Hydraulic cylinder drift
★ Hydraulic tank oil temperature.
① Stop the machine on the flat level ground
② Measure the surface of Hydraulic tank by Digital emission thermometer.
Temperature of hydraulic oil must be more than ５０℃。
1. Blade lift cylinder drift
① Raise the cutting edge of the blade to a position of
about 400mm above ground.
② At measurement position, stop the engine and wait for one minute.
After that, measure the hydraulic drift of the blade lift cylinder 400mm
for 5 minutes.

2. Ripper lift cylinder drift

① Raise the cutting edge of the ripper to a position of
about 400mm above ground.
② At measurement position, stop the engine and wait for one minute.
After that, measure the hydraulic drift of the ripper lift cylinder
for 5 minutes.

Note: For the first 1 minute, the drift speed becomes high,
because of an effect of bubbles in the oil. 400mm