SHOP TilANfIAI- sEN02861-{'1

o BULLDOZER
D155A-6

o
Machine model Serial number
D155A-6 85001 and up

10 Structure, function and

o maintenance standard
Engine and cooling system

o
D1554-6 rorri'lsu
sEr{02861{r1 10 Structure, function and maintenance standard

Radiator, oil cooler

Radiator (without sand protection grill)

t2

.gI
Ftl

=tl
ffiiit
JI I
t
M
tl
il

r!l
i[i
iil
rfll
lli
,ll
6Jl
:tl-ri

W
ltz

2 D155A-6
l0 Sfucturc, function and maintenanca standard

Or,/erflo,rr hose
2. Air bleed hoss
3. lnlet hose
4. Coolant filler cap
5 Radiator core assembly
o. Reservoir tank
7. Inlet hose (fiol circulating at low coolant
temperature)
n Outlet hose
Lower tank (power train oil oooler built-in)
10. Fan
11. Drain plug
12. Cushion
13. Breather cap
14. Pressurc valve

a: Aftercooler
b: Aftercooler outlet hos€
c: Aftercooler inlet ho€e

t The reservoir Enk is provided for radiator.

O The po ,er train oil moler is built in the lower
tank of the radiator.

Dl55A{ 3
sEN02861{ll l0 Structure, function and maintenance standard

Oil cooler

9,/G014?1

1. Hydraulic cooler A: Power train oil cooler inlet port

2. Power train oil cooler B: Power train oil cooler outlet oort
Outline
. The oower train oil moler is built in the lower
tank of the radiator.

4 D1554-6
10 Struc'turr, func'tion and malntenance standard

Dl5545 5
sEN02861{1 10 Structure, fun6tion and maintenance standard

Radiator (with sand protection grill)

r - :l

.l
,,ttl
I u";ft .

t3 t1

\/
_ffiR
B-B

Jz

9J003454

6 D155A{
10 Structure, lunction and malnlenance standard

1. Oveflow hose
2. Air blegd hose
3. Inlet hose
4. Cmlant filler cao
5. Radiator core assembly
6. Reservoir tank
7. Inlet hose (tor circulating at lo,rr coolant
temperature)
8. Ouflet hose
9. Low€r hnk (power train oil aooler built-in)
10. Fan
11. Drain plug
12. Cushion
13. Breath€r cap
14. Pressure valve

Aftercoolel
b: Afrercooler outlet hos€
c: Aflercooler inl€t ho6e

a The rgservoir tank is provided for radiator.

I The power train oil oooler is built in the lo!'yel
lank of the radiator.

Dt55A4 7
sEN028G1-01 10 Structure, funciion and maintenance standard

Oil cooler (sand protection grill)

sJ 0034 I l

1, Hydraulic cooler A: Power train oil cooler inlet port

2. Power train oil cooler B: Power train oil cooler outlet oort
3. Sand protection grill

Outline
. The power train oil cooler is built in the lower
tank of the radiator.

I D1554{
 10 Structure, funclion and maintenance standard sEl{0286141

Engine mount

824- | 030N!|
| 84- | 05ks|r

82,+- 1030Nn
t84- 105k.mI

Unit: mm
No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between bracket size Shaft Hole clearance limit
1
and cushion
60
+0.046 0.1 - Replace
-0.3 0 0.346
Standard clearance Clearance limit
Free heioht of mount rubber
86 84

?
Dl55A-6 I
sEN02861{1 10 Slructure, function and maintenance standard

Gooling fan pump

Type: LPV45

PEPC
PAEPC
| 1. 8-14. 7Nm
I l- 2-1- Stcml

I l- 8-14. 7Nm
{ l. 2-l- Skeml

5,9-8,8Nflr 107.8-r,+2.2N. g8-l 23Nn r0?.8-1,{2.2 |n

lll-1,+.sloml {10-12.5k.m1
9. 8- 12. ?ND
DEL VERY
t 1-1. 3teml
f

@
suc?,or fl' 5-4.5lrml E-2,f. 5Nn
t 9.
{2.0-2. 5 keIn)
7.8-9.8Nn 27.4-34.3ND 68.6-83,4Nlll 68.6-g3.4Nm
10,8-1,okc. {2.8-3. 5k.n} {?-8.5te|l]l (7-8.5kenl

59-74M|
{6-7.5k.n1

Pl : Pump discharge port 1. Servo valve

PAEPC: EPC output pressure pickup plug 2. Air bleeder
PEPC: EPC valve basic pressure input port
PS: Pumo suction Dort
TO: Drain oort

10 Dl55A6
 10 Structure, function and maintenance standard sEN02861{'1

I 34. 3-44.
{3. 5-,f.
I Nm
Sksml

--) rr---x
59-74N||l 19. 6-24, sN|n
t b- r. b Rcmt {2. 0-2. 5 keInl s Js04724

1. Shaft
2. Oil seal
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9" Spring
10. Servo piston

D155A-6 11
sEl{02861-01 10 Structure. func{ion and maintenance standard

Function Cylinder block (7) seals the pressurized oil to

r The pump converts the engine rotation trans- valve plate (8) and carries out relative rotation.
mitted to its shaft to oil Dressure and delivers This surface is designed so that the oil pres-
pressurized oil conesponding to the load. sure balance is maintained at a suitable level.
. lt is possible to change the delivery by chang- The oil inside each cylinder chamber of cylin-
ing the swash plate angle. der block (7) is suctioned and discharged
through valve plate (8).
Structure
o Cylinder block (7) is supported to shaft by
spline (1 1).
o Shafr (1) is supported with front and bearings
(12'r.
r The end of piston (6) has a spherical hollow
and is combined with shoe (5).
. Piston (6) and shoe (5) form a spherical bear-
ing.
o Shoe (5) is kept pressed against plane (A) of
rocker cam (4) and slid circularly.
o Rocker cam (4) slides around ball (13).
r Piston (6) carries out relative movement in the
axial direction inside each cvlinder chamber of
cylinder block (7).

12 D155A-6
10 Structure, function and maintenance standard
Operation of pump
Cylinder block (7) rotates together with shaft
(1), and shoe (5) slides on flat surface (A).
At this time, rocker cam (4) slants around ball
(13). As a result, angle (a) between cenler line
(X) of rocker cam (4) and the axis of cylinder
block (7) changes.
Angle (a) is called the swash plate angle.
D155A6
sEN0286141
With the condition of center line (X) of rocker
cam (4) has swash plate angle (a) to axial
direction of cylinder block (7), flat surface (A)
functions as cam against shoe (5).
In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between vol-
umes (E)and (F) is created inside cylinder
block (7).
A single piston (6) sucks and discharges the oil
by the amount (F) - (E).
As cylinder block (7) rotates and the volume of
chamber (E) becomes smaller, the pressurized
oil is discharged.
On the other hand, the volume of chamber (F)
grows larger and, in this process, the oil is suc-
tioned.
13
sEN0286t{ll
As center line (X) of rocker cam (4) matches
the axial direction of cylinder block (7) [swash
plate angle (a) = 01, the difference between vol-
umes (E) and (F) inside cylinder block (7)
becomes 0-
Suction and discharge of pressurized oil is not
carried out in this state. Namely pumping
action is not performed. (Actually, however, the
swash plate angle is not set to 0)
9JS01728
r Swash plate angle (a) is in proportion to the
pump delivery.
14
l0 Structure, func{ion and maintenance standard
Control of delivery
r lf the swash plate angle (a) becomes larger,
the ditference between volumes (E) and (F)
becomes larger and pump delivery (Q)
increases.
Swash plate angle (a) is changed with servo
piston (10).
Servo piston (10) reciprocates straight accord-
ing to the signal pressure of the servo valve.
This straight motion is transmitted to rocker
cam (4).
Rocker cam (4) supported with ball (13) slides
around ball (13).
9JS01729
015546
l0 Structure, function and malntenance standard
sEl{02861-01 10 Structure, function and maintenance standard

Servo valve

I
5. 9-8. 8Nr
{ 0. 6-0. gk.d

S. 0-12. 7Nr
{l-l.3ksnl

t '7
L

P: EPC valve basic pressure L Plug

PE: Control piston pressure 2, Lever
PH: Pump discharge pressure 3, Retainer
t Drain oort 4. Seat
5. Spool
6. Piston
7. Sleeve
8. Spring

16 D155AS
10 Structure. function and maintenance standard sEN0286't {1

8. 8il, oNm
{0. Sio. I kc|||l
27.4-34.3N|! 27.4-3,t. 3Nm
{2. 8-3. sksnl (2. 8-3. Skcml

5g-74Hm
{6-7.5ksml
EPC ouloJt

Function Then, the land of the servo piston pressure

. The servo valve controls the current input to passage is connecled to the pump discharge
the EPC valve and the pump delivery (Q) so passage by the notch of spool (5) and the dis-
that they will be related as shown in the dia- charge pressure is led to the servo piston.
qram. When the rocker cam is pushed up by the
servo piston, a position feedback is applied
and lever (2) moves to compress spring (8).
When spool (5) is pushed back, the pump dis-
charge circuit and the servo piston circuit are
cut off,
,] Pressure in the servo piston chamber drops
. and the rocker cam returns in the direction of a
maximum swash plate angle.
These processes are repeated until the swash
plate is fixed to a position where the EPC out-
put pressure is balanced with spring (8) force.
E.C currenl i The greater the EPC output pressure, the
3JS04451 smaller the swash plate angle. Conversely, the
smaller the EPC output pressure, the greater
The output pressure of the EPC valve flows in the swash plate angle-
the piston chamber to push piston (6).
Piston (6) pushes spool (5) until it is balanced
with the spring.

0155A{ 17
sEN02861-Ol 10 Structure, func'tion and maintenance standard

Cooling fan motor

Type: LMF75{651

157-l96Nrr
{ | 6-20ksd

lz
27-34Nr
{2.8-3.skcn} 9. g-12. ?Nr
t l. 0- l. 3 koInl

P: From fan pump Sp€cifications

T From cooler to tank Type: LMF75(65)
TC: To tank Capacity: 65.1 ccy'rev
Rated speed: 1,250 rpm
Rated flow: 81 .4 Llmm
Check valve crack pressure: 78.5 kPa {0.8 kg/cmr}

18 D155A-6
10 Structure, function and maintenance standard sEN02861-01

98l - 137. 2Nn

{ 1 0- l4k enl

r 0?. 8-142. 2Nm

( I 1-14. 5ker

1. Output shaft 7. End cover

2. Case L Center spring
3. Thrust plate 9. Check valve
4. Piston assembly 10. Pilot valve
5. Cylinder block 11. Spool for reversible valve
6. Valve plate 12, Safety valve

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x lnstallation lnstallation Free Installation
13 Spool return spring outer diarneter length load length load Replace spring
146 N 1'17 N if damaged or
62.66 x 19.8 53.5
{14.e ks} {11.9 ks}
13.7 N 11.0 N
14 Check valve spring 16.4 x 8.9 11 .5
{1.4 ks} {1.12 kg}

D155A-6 19
sEN02861-{r'l 10 Structure, fun€tion and maintenance standard

1. Hydraulic motor
Function
o This hydraulic motor is called a swash plate-
type axial piston motor. lt converts the energy
of the pressurized oil sent from the hydraulic
pump into rotary motion.

Plinciple of operation
The oil sent from the hydraulic pump flows
through valve plate (7) into cylinder block (5).
This oil can flow on only one side of the (Y-Y)
line connecting the top dead center and bottom
dead center of the stroke of piston (4). sl{z02 981
The oil sent io one side of cylinder block (5)
presses piston (4) [4 or 5 pieces], and gener-
ates force (Fl)[Fl = P x nD2l4].
This force is applied to thrust plate (2). Since
thrust plate (2) is fixed to the angle of (a")
degrees to the output shaft(1), the force is
divided into componenb (F2) and (F3).
The radial component (F3) generates torque ff
= F3 x ril against the (Y-Y) line connecting the
top dead center and bottom dead center.
The result of this torque [T = E (F3 x ri)l rotates
cylinder block (5) through the piston.
Since this cylinder block (5) is splined to the
9J502780
output shaft, the output shaft revolves to trans-
mit the torque.

\
Suog It
s rde

sJs02r60

20 D155A-6
10 Structure, function and maintenance standard
2. Suction valve
Function
e lf the fan pump stops, the pressurized oil does
not flow into the motor. Since the motor contin-
ues revolution because of the force of inertia,
however. the oressure on the outlet side of the
motor rises.
. When the oil stops flowing in from inlet port (P),
suction valve (1) sucks in the oil on the outlet
side and supplies it to port (MA) where there is
not sufficient oil to prevent cavitation.
Operation
1) When pump is started
lf the pressurized oil from the pump is supplied
to port (P) and the pressure on (lVlA) side rises
and starting torque is generated in the motor,
the motor starls revolution.The Dressurized oil
on the motor outlet (MB) side of the motor
retums through port (T) to the tank.
D15546
sEN02861.,01
2) When the pump is stopp€d
a lf the engine is stopped and the input revolu-
tion of the fan pump lowers to 0 rpm, the pres-
surized oil from the pump is not supplied to
port (P) any more, As the pressurized oil is not
supplied to the (MA) side of the motor, the
motor speed lowers gradually to stop.
lf the motor shaft is revolved by the force of
inertia while the oil flow in the port (P) is reduc-
ing, the oil in port (T) on the outlet side is sent
by the suction valve (1) to the (MA) side to pre-
vent cavitation.
21
sEN02861-01
3, Operation of reversible valve
1) When the ON-OFF solenoid is de-energized.
I lf ON-OFF solenoid (1) is "de-energized", the
pressurized oil from the pump is blocked by
ON-OFF selector valve (2), and port (C) opens
for the tank circuit.
a Spool (3) is pushed to the right by spring (4).
I Motor port (MA) opens and pressurized oil
flows in to revolve the motor in forward (clock-
wise).
sJ s0782I
22
10 Structure. func.tion and maintenance standard
2l When the ON{FF solenoid is energized.
a lf ON-OFF solenoid (1) is "energized', ON-
OFF selector valve (2) changes to let the pres-
surized oil from the pump flow through port (C)
into spool chamber (O).
The pressurized oil in chamber (D) pushes
valve spool (3) to the left against spring (4).
Motor port (MB) opens and pressurized oil
flows in to revolve the motor in reverse (coun-
terclockwise).
9JS07830
Dl55A-6
l0 Structure, func'tlon and maintenNnce standatd

s J s0783 |

r When the engine is started, the pressure in

port (P) of the fan motor is heightened in some
cases.
. Safety vatve (1) is installed to prctecl the ian
system circuit.

Operation
. lf the pressur€ in port (P) risBs above the
cracking pressurc of safety valve (1), valve (2)
of safety valve (1) opens to release the pres-
surized oil into port Cn.
. By this operation, generation of abnormal pre+
sure in port (P) is prevented.

23
sE[0:m61{l l0 Struc'turo, func{ion and maintenance standatd

Dl55A€ Bulldoz€r
Form No. SENm861-.0'l

@2007 KOMATSU
All Righb Reserved
Printed in Japan 0&07 (02)

24 Dl55A6
SIIOP TTfiANIIAI- sEN02062.01

BULLDOZER
D1554-6

Machine model Serial number

Dl55A{ 85001 and up

10 Structure, function and

maintenance standard
Power train, Part 1

Main relief valve and toroue converter reliefvalve.... ..,.-.,...,,,...---.....-...40

Power train and steering lubrication pump.......----..... --.............--....---...- 46

D155A6 nonrr'lsu
sEN02862-01
Powertrain skeleton
Outline
The power generated by engine (1) has its tor-
sional vibration dampened by damper (2), and
then passes through universal joint (3), and is
transmitted to t'orque converter (8).
The power from the engine is transmitted
through the oil by torque converter (8) to the
transmission input shaft (turbine shaft) in
accordance with the change in load. (with UU)
Transmission (9) uses a combination of a plan-
etary gear system and hydraulic clutches to
reduce the speed and shift the gears (3 for-
ward gears and 3 rever$e gears). lt connects
2 sets of clulches selected according to the
change in load, and transmits the power to
bevel gear (1 0) from the bevel pinion at the
rear end of the transmission.
2 Dl55A6
10 Structure, function and maintenance standard
9JC03460
The power transmitted to the bevel gear shaft
is transmitted to divided at right angles to the
left and right and transmitted to the respective
steering clutches ( 11).
The power transmitted from the bevel gear
shaft to the final drive is used to steer the
machine by engaging or disengaging steering
clutch (11).
The steering lever is operated to disengage
the steering clutch on the side to which the
machine is to be steered in order to change the
direction of travel. The side of the turning
radius id controlled by steering brake (12)
installed to the outside of the steering clutch.
Steering brake (12) uses the same disc system
that is used for the steering clutch.
The power sent from steering brake (12) is
transmitted to final drjve (13).
Final drive (13) consists of a single-stage spur
gear and a single-stage planelary gear system-
It reduces the speed and rotates sprocket (14)
to drive track shoe (15) and move the machine.
It also rotates cooling tan motor (17) with the
oil discharged from cooling fan pump (16)
driven with PTO (6).
10 Structure. function and maintenance standard sEN02862.01

l" r'
;_rr | F |

'rrr il,- +J \ lrll i.1

.lul ,r[l|L---]
"'i, |5e|\
\ \ +r I .H.t\ I
lr.l r\6L a,-I\
r+L
\t" 'a|

t-"
+l/t r' rtT /
t.t
t
r// tr,rtl T

-'
IL:]L
:-:=

10

1. Engine(SAA6D140E-5) 10. Bevel gear

2. Damoer '11. Steering clutch
3. Universaljoint 12. Steering brake
4. Scavenging pump (SAR(4)125) 13. Final drive
5. Hydraulic pump (HPV112) 14. Sprocket
6. PTO 15. Track shoe
7. Power train, lubricating pump (SAR(3)100+40) 16. Cooling fan pump (LPV45)
8- Torque converter 17. Cooling fan motor (LMF65)
9. Transmission

Dl55A{ 3
sEN02862{1 10 Structure, function and maintenance standard

Overall drawing of power train unit

4 D155AS
10 Structure, function and maintenance standard
tg
1. Steering brake
2. Transmission
3. Power train, lubricating pump (SAR(3)100+40)
4. Power train oil strainer
5. Main relief, torque converter relief valve
6. Torque converter, PTO
7. Scavenging pump (SAR(4)125)
8- Cooling fan pump (LPV45)
L Hydraulic pump (HPV112)
10. Brake control valve
Dl554{
sEN02862-01
@
Outline
. The power train unit can be broadly divided
into torque converter, PTO (7), transmission
(2), and steering brake (1).
So, after the power train unit has been
removed, it can be disassembled into the
torque converter, PTO (7), transmission (2),
and steering brake (1).
. Steering clutch consists of the bevel pinion
unit, bevel gear shaft, and steering brake.
5
sEN02862-01 10 Structure. function and maintenance standard

Power train hydraulic piping drawing

-J

t
L
10 Siructum, funcllon and maintenance standald

1. Hydraulic pump (HPV112)

2. Cenlralized prgssurs detection port
J. Power train, lubrication pump
(SAR(3)100+(3)40)
4. Brake control valve
5. Main r€lief, to.que converter relief valve
Power train oil filtel
7. Scavenging pump (SAR(4)1 25)
n Pow6r train oil cooler
(built in radiator lower tank)

A: Left brake oil pEssure pickup port (LB)

B: Right brake oil pressure pickup port (RB)
C: 3rd transmission clutch oil pressurB pickup po.t
(3RD)
D: 2nd fansmission clutcfr oil pressur€ pickup
port (2ND)
E: 1st transmission clutch oil pre$ur€ pickup port
(1Sr)
F: Reverse transmission clutch oil pr€ssure pickup
port (R)
G: Forward transmission dutch oil pressure pickup
pod (F)
H: Transmission main relief oil pressure pickup
polt (IM)
J: Lefi clutch oil pressure pickup port (LC)
K: Right clutch oil pressure pickup port (RC)
L: Torque converter oil pressure pickup port (lN)
M: Torqu€ coflv€rtar oil pressure pickup port (OUT)

Dl55A{ 7
sEN02862-01 l0 Structure, function and maintenance standard

Damper, universal joint

i'l
' ,,4
O.:

127.5-176,5Mi
{I 3- 18teml

98. r-t22.
{| 0-12. Sksirl

245.2-308. gH||l
{ l5-31. Slsnl

tl
rl

58.8-78. 5ND
{ 6-8 kenl
58. 8-73. sNn
(6-?. 5kerl

S8. I -122, 6Nn

(10-l2.5krnl
98. l-122,6Nflt
(l0-l2.5k.nl
sJG03+58

8 D155A-€
 10 Structure, function and maintenance standard sEN02862-01

1. Breather
2. Dipstick
3. Drain plug
4. Output shaft
5. Flywheel
6. Outer body
7. Coupling
8. Universaljoint
9. Cover
10. Rubber coupling
11. Inner body

Unit: mm
No. Checft item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between flywheel size Shaft Hole clearanc€ limit
housing and cover
511.18
4.02 +0.070 0.o22 - o.2
-{.092 0 o.162
Replace
13
Clearance between fl ywheel
466.72
-{.020 f0.063 0.020 - o.2
and damoer -{.083 0 0.146
Standard size Tolerance Repair limit
'14 Outside diameter of coupling
oil seal ooniac{ surface 0
90 89.8
-o.087

Outline
. The damper, dampens the torsional vibration
caused by the change in engine torque and
the impact torque generated when accelerat-
ing suddenly or when carrying out heavy-duty
digging. In this way, it acts to protect the torque
converter, transmission, and other parts of the
power train.
. The damper has few component parts: it uses
a rubber coupling, so the vibration is absorbed

i
by the dampang effect of the rubber material.

Operation
. The molive force from the engine passes
through flywheel (5) and is transmitted to outer
body (6).
The torsional vibration of the engine is absorbed
by rubber coupling (10), and the power is trans-
mitted to inner body (11). lt passes through unF
versal joint (8), and is then transmitted to the
torque mnverter and transmission.

t
I

I
D1554-6 I
I
sEN02852{tl 10 Structure, func{ion and mainlenance standard

Torque converter, PTO

* PTO: Abbreviation for Power Take Off

3-44.
5-,0. I Y
+

lz

34. 3-14. rNn

(3.5-4.skenl

sJ 801235

A: To power train oil cooler D: To transmission case

B: From main relief valve E: From oower train oil cooler
C: From transmission case

10 D t 55A-6
10 Structure. tunction and maintenance standard sEN02862-01

t0

('i

D155A-6 11
sEN02862{'l 10 Structur€. function and maintenance standard

1. Work equipment pump mounting port

2. Cooling fan pump mounting port
3. Scavenging pump mounting port
34.3-44. lt{m 58. 8-73. 5Nn
4. Power train and steering lubrication pump
{3. 5-4. stsnl {6-7. skonl mounting port
5. Toroue converter case
6. Coupling
7. Input transfer drive gear (Number of teeth: 58)
8. PTO idler gear (Number of teeth: 66)
9. PTO idler gear shaft
10. Turbine
11. Drive case
12. Rase
13. Slator
14. Pump
15. Retainer
16. Stator shaft
'17. Transmission inDut shaft
18. Turbine boss
19. PTO gear A (Number of teeth: 49)
20. PTO gear B (Number of teeth: 48)
21. Scavenging pump drive gear
(Number of teeth: 56)
22. Power train oil strainer
23. Sleeve

, (r6)

fi-L
_,4 ltl
23

-r trc[-]
(51

9,1804237

12 D155A-6
l0 Structurc, funclion and maintBnanca standard

Gen€ral
. 3-element, 1-shge and 2-phase type is
employod for the torque converter. lt is inte-
grated with the transmis$ion.
Pump (14) is intograt€d with coupling (6), input
shaft (7) and drive case (1 1), and rotated by
the pow€r from the engine.
Turbine (10) is integrated with turbine boss
(18) and transmission input shaft (17), and
rotates using th€ oil from pump (14) as the
medium.
Slator (13) is int€grated with stabr shafi (16),
and fixed to torque converter case (5).
The PTO system is consist€d of input shaft (7),
PTO idler gear (8), PTO gear A (19), PTO gear
B and scavenging pump drive gear (21).

Dt55A4 t3
sEN02862{t1 10 Structure, function and maintenance standard

245-30gNm 49-58,8Nm 58. 8-73. 5Nm g8-123N|n

{25-31. Skenl {5-6kom) {6-7.5trn) (10-12. sksml

98- | 231'lm 14.7-lg.6N|Il

{to-12.5ksml ( 1. 5-2 k!ml

98-123l{m S8- | 23M!

{ | 0-1 2. 5k.t { | 0-12. 5k.

'14 Dl55A-6
10 Structure, function and maintenance standard sEN02862{1

Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
Outside diameter of coupling oil
1
seal contact surface 0 Repaif by hard
100 -0.054 99.8
chromium-plal
Ing Or replace
Inside diameter of stator shaft +0.030
65 65.1
seal rino contact surfac 0
-0.01
2 Wear on seal ring width -0.03 2_7
ofthe transmission Replace
input shaft Thickness 2.7 10.1

Inside diameter of retainer seal +0.040 Repair by hard

3 150 '150.5 chromium-plat-
rino contact surface 0
ing or replace
Backlash between inout shaft
and PTO idler oear
0.198 - 0.484

Backlash between PTO idler

5 gear and PTO gear A 0.1s8 - 0.484

Backlash between PTO idler

6 gear and PTO gear B 0.'198 - 0.484

Backlash between inout shaft

7 and scavenging pump drive 0.198 - 0.484

Standard Tolerance Standard Clearance

stze Shaft Hole crearance limit
Tolerance for ft-
ness of PTO idler
gear beanng
Outside
diameter
140
0
-0.018
-0.008
-0_033
0.033
0.0'10
-
lnside
diameter
80
0
-0.0'r s
0
-0.015
0.015
0_019
-
Outside
diameter 140
0
-0.0'18
+0.026
-0.014
0.014
0.044
-
Cover side)
Outside
Tolerance for fit-
ness of drive gear diameter 120 0
-0.015
+0.o22
-0.013
0.013
0.037
-
bearing on work (Case side)
I equipment, power
Replace
lnside
train and steering diameter 65
+0.030
+0.011
0
-0.015
0.045
0.011
-
lubrication pump (Cover side
lnside
diameter
+0.030
+0.011
0
-0.015
0.045
0.011
-
(Case side)
Outside
diameter 120 0
-0.015
+0.022
-0-013
0.013
0.037
-
(Cover side
Outside
diameter 120
0
-0.015
+O-022
-0.013
0.013
0.037
-
Tolerance for fit- (Case side)
10 ness of fan pump
drive gear bearing Inside
diameter
+0.030
+0.011
0
-0.015
0.045
0.011
-
(Cover sidel
lnside
diameter 65
+0.030
+0.011
0
-0.0'15
0.045
0.011
-
(Case side)

Tolerance for fit- Outside

diameter
85
0
-0.015
+0.010
-0.025
0.025
0.02s
-
ness of scaveng-
11
ing pump drive
gear b€anng
lnside
diameter
45
+0.018
+0.002
0
-0.o12
0.030
0.002
-

0155A{ 15
sEN02862-01 10 Structure. function and maintenance standard

Power transmitting route Oil flow

9J80423S gJ 801110

Power generated from engine The oil flows through the main relief valve and
J its pressurB is reduced to less than the set
Damper pressure by the torque conveTter relief valve,
J then it flows through inlet port (A) and oil pas-
Universal joint sage of torque converter case (1), stator shaft
J (2), retainer (3), to pump (4).
Input coupling (1) The oil is given a centrifugal lorce by pump (4),
J and then it enters turbine (5) to transmit its
Input shaft (2) energy to turbine (5).
J The oil from turbine (5) is sent to stator (6), and
Drive case (3) and pump (4) rotate integral to each then returned to pump (4). Part of this oil is
other sent to the power train oil cooler through stator
J (6) and outlet port (B).
Oil is used as medium
I
Turbine (5)
J
Transmission input shaft (6)

16 Dr 55A-6
l0 Shucture, function and malntenance standard

Dl55A-6 17
sEN02862-01 10 Structure. function and maintenance standard

Transmission

39.6-42.2tlm
{4-4.3tem)

,f4- | -53. gNm

(4.5-5.5*smi

44- | -53. gNm

| 4. 5-5. Sksnl

lz

Dl554-6
 '10 Structure. function and maintenance standard sEN0286241

157-l77Nn
(16-l8ksnl

,.", I o

o@

B-B
3.e042r2 ]

A: 1st clutch pressure pickup port (1ST) K: To torque converter

B: 3rd clutch pressure pickup port (3RD) L: To scavenging pump
C: R clutch oil pressure pickup port (R) [/: To torque converter c€se
D: 2nd clutch pressure pickup port (2ND) N: From torque converter case
E: F clutch oil pressure pickup port (F) P: To R clutch
F: From power train pump R: To 3rd clutch
G: To brake control valve S: To '1st clutch
H: From steering case T: To 2nd clutch
J: From power train oil cooler U: To F clutch

o
D1554-6 19
sEN02862{1 10 Struc{ure, funclion and maintenance standard

1.E

llr\lli
I J[ 3 531 JI
lri
25 21 2t 22
'U

! J 8012{3

20 Dt 55A-6
10 Structure. function and maintenance standard sEN02862-01

1. Transmission ECMV General

Main relief valve and toroue converter relief . The transmission consists of planetary gear
VAIVe systems and disc clutches and has "3 forward
3, Transmission case gear speeds and 3 reverse gear speeds".
4. Sleeve r Among the 5 sets of planetary gear system
5. Transmission inout shaft and disc clutches of the transmission, 2
6. Tie bolt clutches are fixed hydraulically with the ECMV
7. R ring gear (hub) to select'1 rotating direction and gear speed.
8. R planetary pinion (number of teeth: 26) o The transmission transfers the power received
9. R ring gear (number of internal teeth: 86) by the transmission input shaft to the output
10. F planetary pinion (number of teeth: 24) shaft while changing the gear speed (forward
11. F ring gear (number of internal teeth: 91) 1st-3rd or reverse 1st3rd) by any combination
12. 3rd planetary pinion (number of teeth: 35) of the F, R clutches and 3 speed clutches.
13. 3rd ring gear (number of internal teeth: 89)
14. 2nd planetary pinion (number of teeth: 3'l) Number of plates and discs used
15. 2nd ring gear (number of internal teeth: 9'1)
16. 1st ring gear (number of intemal teeth: 91)
17. 1st planeiary pinion (number of teeth: 27)
18. Transmission outout shaft
(3rd sun gearxnumber of teeth: 19)
19. 1st clutch housing
20. 1st clutch piston
21. 1st sun gear (number of teeth: 37)
22. 1st carrier
23. 2nd clutch housing
24. 2nd clutch piston
25. 2nd sun gear (number of teeth: 29) Combinations of clutches at respective gear
26. 2nd canier speeds and reduction ratio
27. 3rd clutch housing Reduction
28. 3rd clutch piston Gear speed Operated clutches
ralto
29. 3rd carrier Forward 1st F x 'lst 1 .705
30. F clutch housing
Forward 2nd Fx2nd 1.151
31. F clutch oiston
32. F carrier FoMard 3rd Fx3rd 0.540
33. R clutch housing Neutral
34. F sun gear (number ofteeth: 44) Reverse 1st R x '1 st '1.406
35. R clutch piston
Reverse 2nd Rx2nd 0.949
36. Washer spring
37. Clutch plate Reverse 3rd Rx3rd 0.445
38. Clutch disc ': The 1st, 2nd, or 3rd clutch is filled with low-pressure
39. Piston return spring orl.
40. R carrier
41. Front housing
42. R sun gear (number of teeth: 34)

D155A5 21
sEN02862{t1 10 Structure, funclion and maintenance standard

157-l77Nn
{ l6-l8ken 19 20
tt \r
l9
\'
20 19

t,//1 i

t3 l|| I J 1 58,8-73.5Nn
{E-7.5ked
c-c
s J B0-1244

22 Dl554€
10 Structure. function and maintenance standard sEr{02862-01

unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Installed lnstalled lnstalled
Free length Free length
1 R clutch spring ('12 springs) length toao toao
59.8 N 51.0 N
81.7 72.4 76.8
{6.1 ks} i5.2 ks)
34.3 N 29.4 N
2 F clutch spring ('12 springs) 81.7 76.4 76.8
{3.5 ks} {3.0 ks}
97. '1 N 82.4 N
3 3rd clutch spring ( 12 springs) 70.0 50.2 65.8
{e.e ks} {8.4 ks}
90.2 N 76.5 N
2nd clutch spring (12 springs) 70.0 51 .6 65.8
{e.2 ks} {7.8 ks}
'1st 66.7 N 56.9 N
5 clutch spring (12 springs) 66.0 51.8 62.0
{6.8 ks} {5.8 ks}
Standard size Tolerance Repair limit
Total assembled thickness of 6
disks and 6 plates for R clutch 51.6 !0.35 48.4

Total assembled thickness of 7

7 57.0 10.36
disks and 6 Dlates for F clutch
Total assembled thickness of 4
R 31.2 lo-26 29.1
disks and 3 plates for 3rd clutch
Total assembled thickness of 4
I disks and 3 plates for 2nd clulch
10.26 29.1

Total assembled thickness ol 3

10 22.6 xo.22 21.0
disks and 2 olates for lst clutch Replace

11 Thickness ot clutch disk 5.4 r0.1 4.9

Thickness of clutch plate 3.2 10.1

-0.01
width 3.0
-0.03
2.70
,t2 Weaf of input shaft
seat flng
Thickness n0.1 2.55

Wear of seal ring on -0.01

widrh 4.0 -0.04 3.60
the ftont housing, F
14
clutch housing and
3rd carrier Thickness 5.0 r0.15 4.85

-0.01
width 4.O
-0.04 3.60
Wear of seal ring
(large) on 2nd carrier
Thickness 4.0 r0, t5 3,85

-0.01
widrh 4.O
-0.04 3.60
Wear of seal ring
to
(small) on 2nd carrier
Thickness 4.0 !0.15
-0.01
width 4.0 -0.04 3.60
Wear of seal ring
17
(large) on 1st canier
Thickness 4.0 r0.15 3.85

D1554{ 23
sEN02862-01 10 Structure, function and maintenance standard

Unit: mm
l'lo. Check item Criteria Remedy
Standard size Tolerance Repair limit
-0.01
Wear of seal ring width 4.0 3.60
18
asmalll on lst canier
-0.04

Thickness 5.0 !0.15 4.85

R,E
Backlash betw€en 3rd, 1st
0.14 - 0.35
lo sun gear ano pEne- Replace
tary pinion 2nd 0.13 - 0.32

R 0.'15 - 0.39
Backlash between
F, ZNO,
20 planetary pinion and 'lst 0.15 - 0.38
ring gear
3rd 0.16 - O.42

Disc clutch
Structure Operation
When clutch is "engaged" (fixed)

Sr 801395

. The disc clutch consists of piston (2), plates
(3), discs (4), pin (5), retum spring (6) etc. to fix
ring gear (1).
Inside teeth of disc (4) are engaged with out-
side teeth of ring gear (1 ).
Plate (3) is assembled to clutch housing (7)
with pin (5).
sJB0r3s6
The oil sent from the ECMV flows through the
oil passage in clutch housing (7), is pressure-
fed to the back side of piston (2), and pushes
piston (2) to the left.
Piston (2) contacb plate (3) closely against
disc (4) to stop rotation of disc (4) by use of the
friction force generat€d between them.
Since inside teeth of disc {4) are engaged with
outside teeth of ring gear (1), move of ring gear
(1) is stopped.

24 D1s5A6
10 Structure, function and maintenance standard
When clutch is "dis€ngaged" (released)
As the oil from ECMV is stopped, piston (2) is
pushed back rightward by return spring (6).
The friction force between plates (3) and discs
(4) is released and ring gear (1) is released.
Dl55A-6
sEN02862{'1
Oil passage in speed clutch
* The figure shows the case in which "1st" gear
soeed is selected.
I
al
lst c utlh riston :J80
When the steering/directional/gear shiff lever is
set in the "neutral" position, the 1st, znd, or 3rd
sDeed is selected.
The piston chamber of the clutch correspond-
ing to the selected gear speed is filled with oil
by electronically controlling the hydraulic circuit
of each clutch.
When the steering/directional/gear shift lever is
shifted from the "neutral' oosition to the''for-
ward" or "reveTse" position, the pump is
required to supply oil of quantity to fill the pis-
ton chamber of the F clutch or R clutch.
When the gear speed is changed from "for-
ward 1st' to 'forward 2nd", the pump is
required to supply oil of only quantity to fit the
plate and disc of the znd clutch together since
the F clutch has been filled with the oil.
The time lag in the gear shifting operation is
reduced by controlling the oil in the clutch cir-
cuit as explained above.
25
sEN02862-01 10 Structure, function and maintenance standard

Power transmitting route

Forward 1st speed

lt ls

*G

rlrl
rll
r{ 2t t7 20
9.r804245

D1554{
10 Structure, ftrnction and maint€nance standard

F ring g€ar (4) of F clutch and lst ring gear (19) of 1st clutch are fixed with oil prcssurE.

Po/€r from torqug converter

I
Input shafl (1)

F sun gear (2)

J
F planetary pinion (3)

F canier (10)
J
3rd canier (11)
J
3rd planetary pinion (12)
J
3rd ring gear (13)
.t
2nd carrier (14)
J
2nd planetary pinion (15)
!
znd ring gear (16)
v
1st carier (17)
I
1st planetary pinion (18)
J
1st sun gear (20) 2nd sun g6ar (21)
I

Output shafr (22)

D155AS 27
sEN02862-0'l l0 Structure, function and maintenance standard

Forward 2nd speed

28 D155A-6
l0 Struclure, func'tion and malntenance standard

F ring gear (4) of F clutch and 2nd ring gear (16) of 2nd clutch are fixed wilh oil pEssure.

Pos'€r fmm torque convert€r

Input shafi (1)

J
F sun gear (2)
I
F planetary pinion (3)
J
F ca.rier (10)

3rd carrier (11)

3rd planetary pinion (12)

J
3rd ring gear (13)
J
2nd canier (14)

2nd planetary pinion (15)

J
2nd sun gear (21)

Output shafi (22

Dl55A6 29
sEN02862-01 10 Struc{ure. function and maintenance standard

Fonvard 3rd speed

30 D15546
l0 Structur€. function and maintenanc€ standard

F ring gear (4) of F clutch and 3rd ring gear {13) of 3rd clutch are fixed with oil pressure.

Povver ftom torque oonvertel

.yI
Input shafr (1)

F sun gear (2)

F plnehry pinion (3)

Fcanier(t0)
J
3rd canier (11)
J
3rd planetary pinion (12)

Output shaft (22)

D155A4 31
sEN02862{tl 10 Structure, function and maintenance standard

Reverse l st speed

3rd

12
i,l ,, ,,

*0

9J804248

32 Dl55A{
l0 Structure, functlon and malntenance rtandard

R ring g€ar (7) of R clutch and 1st ring gear (19) of lst clutch are fixed with oil pressure.
Porer fmm toroue conve er

Input shafr ('l )

t
R sun gear (5)
+
R planetary pinion (6)

R ring gear {9)

(R carrier (8) is fixed with R ring gear =
R ring gear (9) rotatE in reverse with
regard to input shafi (1)
Not fanslated
.t
F car €r (10)

3rd canier (11)

I
3d planetary pinion
+
3rd dng gear (13)
J
2nd canier (14)

2nd planetary pinion (15)

J
2nd ring gear (16)
J
1st caFier (17)
t
1st planetary pinion (18)
,t 2nd sun gear (21)
't st sun g€ar (20)
J
Outsut shaft (22)

D155A5 33
sEN02862-01 10 Structure, lunclion and maintenance standard

Transmission ECMV
* ECMV: Abbreviation for Electronic Control lr4odulation Valve
* Dont try to disassemble it since adjustment for maintaining the performance will be needed.

I 44. I -53. gNi'

t4.5-5.5kernl 12..... _Dr
Dr
13 '"-.. , t$
2
tf
tiT
II
3 Dr
tI
Dr

Dr
P
lz
I
Dr
5 '--- 24. 5-34. 3Nm
( 2, 5-3. sleml

,+. 9-6. gNn

{0.5-0.7k.n}
_0
PI

P3

PR

P2

PF

A2

AR

L'T

gJB03r22

34 D155A{
 10 Structure. function and maintenance slandard sEN02862-01

t AF: To F clutch
AR: To R clutch
A1: To 1st clutch
Operation table of ECMV

Gear-
ECMV
F R 1st znd 3rd
A2: To 2nd clutch speeo
43: To 3rd clutch N C o
P: From power train pump
i) o
T: Drain
Dr: Drain F2
PF: F clutch oil pressure pickup port F3 o
PR: R clutch oil pressure pickup port
P1: 1st clutch oil pressure pickup port
R1 c
P2: znd clutch oil pressure pickup port R2 o
P3: 3rd clutch oil pressure pickup port R3 c
1. 3rd clutch proporlional solenoid * When the directional lever is in (neutral) posi-
2. 1st clutch proDortional solenoid tion, the speed clutch of the speed selected by
3. R clutch proportional solenoid gear shift lever activates.
4. F clutch proportional solenoid
5. 2nd clulch proportional solenoid
6. 3rd clutch fill switch
7. znd clutch fill switch
8. 1st clutch till switch
9. R clutch fill switch
10. F clutch fill switch
11. Transmission oil filter
12. Connector for lstclutch proportional solenoid
13. Connectorfor 3rd clutch fill switch
14. Connector for 3rd clutch proportional solenoid
15- Connector for R clutch proportional solenoid
16. Connector for 2nd clutch Jill switch
17. Connectorfor 2nd clutch proportional solenoid
18. Connectorfor F clutch proportional solenoid
19. Connector for 1st clutch flll switch
20. Connector for R clutch fill switch
21. Connector for F clutch fill switch

I
D't55A6 35
sEN02862{t1 10 Structure, function and maintenanc€ standard

D-D

1- Fill switch
2- Pressure control valve
3. Body (upper)
4. Body (lower)
5. Proportionalsolenoid
6. Filter
7. Pressure detection valve
8. Sleeve

36 D155A{
l0 Structure, function and maintenance standard sEN02862{1

Outline of ECMV ECMV and proportional solenoid

The ECMV consists of 'l pressure oontrol valve
and 1 fill switch.
Pressure control valve
A proportional solenoid in this valve receives a
current sent from the controller and this vaive
converts il to an oil pressure.
Fill switch
This switch detects that the clutch is filled with
oil and has the following functions.
t- Outputs a signal (a fill signal) to the controller
to notify that filling is completed when the
clutch is filled with oil.
Keeps outputting signals (fill signals) to the
controller to notify whether oil pressure is
applied or not while oil pressure is applied to
the clutch.
. :
:
o For each ECMV 1 proportional solenoid is
installed.
The proportional solenoid generates thrust
shown below according to the command cur-
rent from the controller
The thrust generated by the proportional sole-
noid is applied to the pressure control valve
spool to generate oil pressure as shown in the
figure below. Accordingly, the thrust is changed
by controlling lhe command cunent to operate
the pressure control valve to control the flow
and pressure of the oil.
Current - propulsion force characleristics of
proportional solenoid
(Nt oi)
':
!

(A)
0 Currert
{S:cl
T ime sJB0lt32

iM Pa {ke/:m'l l
Propulsion force - Hydraulic pressure charac-
teristics of proportional solenoid

(MF a {k s / :n'l I

t
(Sec)

_9':' .:
.; I I

=
::. I
OFF

-: I
{\ {k!l
-; I
>-{S€c; C ?rcou,sior 'orce )

T me
gJB01t3, 9J 8C r733

Range A: Before shifting gear (When draining)

Range B: During filling ECMV and fill switch
Range C: Pressure regulation . For each EC|V, 1 fill switch is installed.
Range D: During filling (During triggering) lf the clutch is filled with oil, the fill switch is
Point E: Start of filling turned "ON" by the pressure of the clutch. The
Point F: Finish of {illing oil pressure is built up according to this signal.
* The logic is so made that lhe controller will not
recognize completion of filling even if the fill
switch is turned "ON" during triggering (Range
D).

D155A-6 37
sEN02862.01 10 Structure, func{ion and maintenance standard

Operation of ECMV Before shifting gear (when draining) (Range A

o ECMV is controlled with the command current in chart)
sent from the controller to the proportional
solenoid and the fill switch output signal,
The relationship between the proportional
solenoid command current of ECMV, clutch
input pressure, and fill switch output signal is
shown below.

.3'

(Sec)
T irne

(l.iPa { ks,/cn'l )

.=

:,-'
(Sec)
T ire
; (v) r

r Under the condition where any current is not

s€nt to the proportional solenoid (1), pressure
OI\ c,ontrol valve (3) drains the oil from clutch port
>{Sec) (A) through drain port (T).
Time
gJB0t73l Also at this time, fill switch (5) is turned 'OFF'
because oil pressure is not applied to pressure
Range A: Before shifring gear (When draining) detection valve (4).
Range B: During filling
Range C: Pressure regulation
Range D: During filling (During triggering)
Point E; Start of filling
Point F:
Finish of iilling
* The logic is so made that the controller will not
recognize completion of filling even if the fill
switch is turned "ON" during triggering (Range
D).
o When gear is shifted with gear shift switch, the
clutch is compressed by piston- lf high pres-
sure is suddenly applied, the piston suddenly
engages clutch, causing sudden start of
machine and excessive shock-
ECMV reduces a shock at the start of the
machine by increasing the oil pressure applied
to the piston gradually to set pressure, and
puts clutch smoothly 'engaged". lt aims to
increase durability of power transmitting route
and enhances an oDerator mmfort.

38 Dl55A-6
 10 Structure, function and maintenance standard
During filling (Range B in chart)
. lf current is supplied to proporlional solenoid
(1) with no oil in the clutch, the oil pressure
force balanced with the solenoid force is
applied to chamber (B) and pushes pressure
control valve (3) to the right. As a result, pump
po (P) and clutch port (A) are opened and oil
starb filling the clutch. lf the clutch is filled with
oil, fill switch (5) is tumed ''on".
D1554-6
sEN02852-0t
Pressure adiustment (Range C in chart)
g-303r26
o lf cunent flows in proportional solenoid (1), the
solenoid generates thrust in proportion to the
cunent. This thrust of the solenoid is balanced
wilh the sum of the thrust generated by the oil
pressure in clutch port and the repulsion of
pressure control valve spring (2) to regulate
the pressure.
39
sEN02862-01 '10 Structure. function and maintenance standard

Main relief valve and torque converter relief valve

P8b

_- |

44. l-53, gNm

{4,5-5,5ksnl

9J 8C3 | 27

Unit: mm
No- Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between main relief size Shaft Hole c|earance limit
1
valYe and bodv
28
-0.035
.0.045
+0.013 0.035 - 0.078
0.058
Clearance between the torque con"
22
"0.035
-0.045
+0.013 0.035 - 0.078
verter reliefvalve and the bodv 0 0.058
Standard size Repair limit
Replace
lnstallation Installation lnstallation
Main relief valve spring Free length Free length
3 length loao load
(oubide)
481 N 457 N
122 78.0 118.3
{49 ks} {46.6 ks}
l\,lain relief valve spring 368 N 349 N
4 108 7S-O 1M.8
(inside) {37.5 ks} {35.6 ks}
Torque @nverter relief valve 182 N '1
74 N
50 40.5 48.5
spring {18.6 ks} {17.7 ks}

6. Body A: Drain (Torque converter relie0

7. Piston B: Drain
8. Torque converter relief valve C: From pump
9. Piston D: Drain
10. Main relief valve E: To torque converter
P'1: Main relief oil pressure pickup port
PBa: Torque converter relief oil pressure pickup
port
P8b: Torque converter inlet oil pressure pickup
pon

40 Dl554-6
10 Structure, function and maintenance standard sEN02862-{11

General Operation of main relief valve

Torque converter relief valve

. The torque converter relief valve maintains the
oil pressure in the torque converter inlet circuit
always below the set pressure in order to pro-
tect the torque converter from abnormally high
oressure.
Set pressure:
1.06 i 0.05 MPa {10.8 r 0.5 kgi cm,}
(Cracking pressure)

Main relief valve

r The main relief valve is keeping each hydraulic
circuit of the transmission and the parking . The oil from the hydraulic pump flows to cham-
brake at set pressure- ber (F) through the filter, port (C) of the relief
Set oressure: valve and orific€ (a) of main relief valve (1).
3.18 r 0.1 MPa {32.4 t 1 .0 kg/cm'?}
(Engine at rated speed)

Operation

Op€ration of torque converter relief valve

c As the oil pressure in the circuit goes beyond

lhe sel pressure, the oil conducted to chamber
(F) pushes piston (2) and the resulting reaction
force pushes main relief valve (1) leftward,
opening ports (C) and (E).
Above operation conducts the oil from port (E)
to the torque converter.
The oil from the main relief valve is conducted
to the torque converter through port (E) and, at
the same time, also conducted to chamber (G)
through orifice (b) ol torque converter relief
valve (3).
As the oil pressure to the torque converter
rises beyond the set pressure, the oil con-
ducted to chamber (G) pushes piston (4) and
the resulting reaction force pushes torque con-
verter relief valve (3) rightward, opening ports
(E) and (A).
As a result, the oil in port (E) is drained through
port (A).

D155A6 4',1
sEN02862-01 10 Structure. function and maintenance standard

Lubricating oil relief valve

af
I
l

sJ80424S

Unit mm
No. Check item Criteria Remedy
Slandard size Repair limit
lnst€llation lnstallation Installation
Free length Free length
1 Lubrication relief valve spring length |oao load Replace
12.5 N 11.9 N
26 23.6 25.2
{1.27 kgl i1.21 ksi

2. F clutch housing General

5- R clutch housing r The oil leaving the torque converter passes
4- Piston through the power train oil cooler built in the
radiator lower tank. lt then goes through the
A: From oil cooler lubrication relief valve and lubricates the trans-
B: Drain mission and PTO.
Drain . The lubricatron relief valve is installed to the
right side face ofthe F clutch housing. lt keeps
the lubricating oil pressure below the set pres-
sure.

0.1410.05
{1.4 r 0.5}

o
42 D1554-6
l0 Structure, funcllon and maintcnance atandard

D1554{ 43
sEN02862-t!1 10 Structure, tunction and maintenance standard

Scavenging pump
Type: SAR(4)125
Serial No.: 85001 - 85024

.. | 57- | 96Nn
I l6-20kgnl

9J 803165

Unit: mm
No. Check item Criteria Remedy
Sitandard clearance Clearance limit
1 Side clearance
0.11 - 0.'16 0.19
Clearance between plain bear-
2 ing inner diameter and gear 0.06 - 0.14 o.20
Replace
shalt outer diameter
Slandard size Tolerance Repair limit
Pin driving depth 0
21
-0.5
4 Spline shaft rotating torque 9.8 - 14.7 Nm {l.0 - 1.5kgm}
Standard Discharge
Delivery amount Rotation speed Delivery pressure discharge amount
Oil: SAEloWCD (rpm) MPa{kgicml amount limit
Oiltemperature: 45 (4/min) (4/min)
- 55"C
2,200 2.94{30} 264 234

General
. The scavenging pump is installed to the torque
converter case and is driven with the power
ftom the engine. lt retums the oil collected in
the bottom of the transmission case to the
steering case.

4 D155A-6
 10 Structure. funclion and maintenance standard sEN02862-01

t Type: SAR(3)125
Serial No.: 851125 and up

245-309Ntr
(25-31, Skcnl

9J0039CS

Unit: mm
No. Check item Criteria Remedy
Standafd clearance Clearance limit
1 Side clearance
0.10 - 0.1 5 0.1s
Clearance belween Dlain b€ar-
2 ing inner diameter and gear 0.078 - 0.149 o.20
Replace
shafr outer diameter
Standard size Tolerance Repair limit
Pin driving depth 0
14
-0.5
Spline shatt rotating torque 6.9 - 11.8 Nm {0.7 - 1 .2 kgm}
Standard Discharge
Delivery amount Rotation speed Delivery pressure discharge amount
Oil: SAE1oWCD (rpm) MPa{kg/cm,} amounl limit
Oil temperature: 45 55'C (0/min) (r/min)
-
2,000 2.94{30} 240.7 213.1

General
. The scavenging pump is installed to the torque
converter case and is driven with the power
from the engine. lt returns the oil collected in
the bottom of the transmission case to the
steering case.

D1554-6 45
sEN02862{tl 10 Structure, function and maintenance standard

Power train and steering lubrication pump

Type: SAR(3)100+(3)40
t 5?-196 n 98-123Nm
{ l6-20keml (10-l2.5keml

245-309Nr
{25-3 t, 5k.i}

1. Power fain pump General

2. Sleering lubrication pump . The power train pump and the steering lubrica-
tion pump are installed to the torque converter
case. They are driven by the power from the
engine to supply the oil pressure to the torque
converter, the transmission and the steering
unit.

46 o155A.6
10 Struciurc, tunctlon and maintenanco standard

Unit mm
Fb. Check item Cdterh Remedy
Type Sandard dearance Clearancs limit
3 Sida clearance sAR(3)100
sAR(3)40
0.10 - 0.15 0.19

Clearance between olain bear- &AR(3X00

4 ing inner diameter and gsar 0.06 - 0.1s 0.20 Rt
shafi outer diametel sAR(31r0
Type Stardard size Tolerance Repair limit
Pin driving depth sAR(3)100 0
14
sAR(3)40 -0.5

b Rotating brque ot spline shat 13.7 - 23.5 Nm {1.4 -2.4 kgm)

Rotatlon
D€livery $andad Disdrarge
prsssu]e dkchaqe amount
Type 3p€€o
Delivery amount (MPa(ks/ amount limit
(rPm)
Oil: SAEIoWCD cm1) (S/min) (4/min)
Oll temoerature: 45 - 55'C sAR(3)100 2,500 2 s4{30} 241 96
sAR(3)40 2,500 2 94{30} 239 85

D{5544 47
sEN02862.01 10 Structure, function and maint€nance standard

D1554-6 Bulldozer
Fofm No. SEN02862-01

@2008 KOMATSU
All R'rghts Reserved
Printed in Japan 0e08 (02)

48 Kofrilu D155A-6
 SHOP hilANfIAI- sEN02863-00

BULLDOZER
D155A-6

o
Machine model Serial number
Dt55A-6 85001 and up

10 Structure, function and

o maintenance standard
Power train, Parl2

o
D15546 rorrrlsu
sEH02863-00 10 Structure, function and maintenance standard

Work equipment pump

Type: HPV95 (112)

34- 3-4,+. lNm

(3.5-4.5lem)
132-1 5?t'lm
{13.5-16klml

0E r lvE RY

f PLS

PC
COUNTER CLOC(IISE
REVOLUIION

lz
LSC

0
SUCI ION

PD2 s8.8-78.4Nn
{ 6-8ksml

2 D15546
10 $tructure, function and malnlanance slandard

Outline
. The pump unit is composed of the variable
capadty swash date type piston pump and LS
valve,

PA Pump discharge port

PB: Pump pressur€ input port
PC: Pump dischaqe pressurc pickup port
PDl: Case drain port
PD2: Drain plug
PEN: Contml prcssure pickup port
PLS: Load pressure input port
PLSC: Load prEssure pickup port
PS: Pump sudion port

1. Main pump
2. LS valve

D1554{ 3
sEN028G3-00 10 Structure, function and maintenance standard

58.8-78,,|Nm
313!151,, rl { 6-8 k rrnl
REI/OLUT ION V

153-l90ND
{ | 5. 5-l S. 5kon}

9JS0l8r7

1. Shaft
2. Cradle
3. Front case
4. Rocker cam
5. Shoe
6. Piston
7 Cylinder block
8. Valve plate
L End cap
10. Servo piston

4 D1554{
10 Structure, function and maintenance standard sEN02863.00

Function Piston (6) carries out relative movement in the

. The pump converts the engine and torque rota- axial direction inside each cylinder chamber of
tion transmitted to its shaft to oil oressure and cylinder block (7).
delivers pressurized oil corresponding to the Cylinder block (7) seals the pressurized oil to
toao. valve plate (8) and carries out relative rotation.
. lt is possible to change the delivery by chang- This surface is designed so that the oil pres-
ing the swash plate angle. sure balance is maintained at a suitable level.
The oil inside each cylinder chamber of cylin-
Structure der block (7) is suctioned and discharged
r Cylinder block (7) is supported to shaft (1) by through valve plate (8).
spline (12).
r Shaft (1) is supported with bearings (13).
o The end of piston (6) has a spherical hollow
and is combined with shoe (5).
o Piston (6) and shoe (5) form a spherical bear-
ing.
. Rocker cam (4) has flat surface (A), and ghoe
(5) is always pressed against this surface while
sliding in a circular movement.
. Rocker cam (4) conducts high pressure oil to
cylinder surface (B) with cradle (2), which is
secured to the case, and forms a slatic pres-
sure bearing when it slides.

D1554{ 5
sEN02863{0 10 Structure, function and maintenance standard

Operation of pump As center line (X) of rocker cam (4) matches

Cylinder block (7) rotates together with shaft
(1), and shoe (5) slides on flat surface (A).
When this happens, rocker cam (4) moves
along cylindrical surface (B), so angle (a)
between center line (X) of rocker cam (4) and
the axial direction of cylinder block (7)
changes.
Angle (a) is called the swash plate angle.
the axial direction of cylinder block (7) (swash
plate angle (a) = 0), tne difference between
volum€s (E) and (F) inside cylinder block (7)
becomes 0-
Suction and discharge of pressurized oil is not
carried out in this state. Namely pumping
action is not performed. (Actually, however, the
swash plate angle is not set to 0)

9 t s0364 8 s0P0t4tl

With center line (X) of rocker cam (4) at swash

plate angle (a) in relation to the axial direction
of cylinder block (7), flat surface (A) acts as a
cam in relation to shoe (5).
In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between voF
umes (E) and (F) is created inside cylinder
block (7).
A single piston (6) sucks and discharges the oil
by the amount (F) - (E).
As cylinder block (7) rotates and the volume of
chamber (E) becomes smaller, the pressurized
oil is discharged.
On the other hand, the volume of chamber (F)
grows larger and, in this process, the oil is suc-
tioned.

sJS0364S

6 D155A-6