Technical Presentation Kit

Bulldozers

Power Train

D85EX/PX-15

Komatsu D65EX/PX-15
Bulldozers
MN20030410
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POWER TRAIN SKELETON Hydraulic oil cooler
Fan motor
(LMF28) P/L Oil cooler
Radiator Engine (SA6D125E-3)
Condenser Damper
Universal joint

Engine speed sensor Scavenging pump

(BAR(3)-80)
Power train pump
(SAL(3)-63) Hydraulic & HSS pump
Steering lub pump (HPV160)
(SAL(2)-50)
PTO
Fan pump
(LPV30)
Torque converter
(TCS46-4Z)
Transmission

Bevel gear
Final drive
Brake
Bevel gear
speed sensor

Track shoe
(STD:560mm) HSS motor
(OPT:610 ・ 710mm) Sprocket (HMF180) HSS unit
HYDRAULIC PIPING OF POWER TRAIN
4. Brake control
[No.1] valve
Condenser
5. HSS motor
(HMF112)
3. Power train pump
[SAL(3)63]
2. Steering lubricating oil
pump [SAL(2)50]

1. Hydraulic, HSS pump

[HPV160]

6. Main relief
valve
7. Centralized pressure
pick-up ports
8. Scavenging pump
[SAR(3)80]

10. Power train oil cooler 9. Power train oil filter

(built in radiator lower tank)
HYDRAULIC PIPING OF POWER TRAIN
[No.2] Power train pump

Steering lubricating
oil pump

HSS motor
Fan pump
HSS unit

Hydraulic, HSS
pump (HPV160)
Transmission

Hydraulic press sensor

Main relief valve

Hydraulic oil temp’ sensor

T/C outlet oil press

P/L strainer Scavenging pump T/C oil tem’p

 Hydraulic press sensor

P/L Pump
Hydraulic oil temp’ sensor

P/L strainer Scavenging pump

OUTLINE OF ELECTRONIC CONTROL SYSTEM

Inclinometer

T/M Speed
sensor
Engine controller T/M & Steering controller

STC3 STC2
STC1

EGC3
EGC2
EGC1

Hexagonal wrench

4 mm

View from bottom side of

the controller
 ECMV (Electronic Control Modulation Valve) for T/M
Transmission ECMV
(14X-15-25501)

１ 3 R F

714-23-15520
MANEUVERABILITY FEATURES (PCCS)
Transmission D85EX-15 D85A-21

Modulation
comparison

Preventing time
lag and torque off.
Inclinometer

D65EX-15 T/M output speed sensor

Inclinometer

D85EX-15
Inclinometer

T/M output speed sensor

ENGINE & TORQUE CONVERTER MATCHING CURVE
Torque converter output RPM
Kg・m Example e= Torque converter input RPM

Engine performance curve e=0 ( Engine RPM )

Torque
e = 0.4
e = 0.6
●

× e = 0.8

1540rpm Engine stall RPM

Eng (Example:1600rpm)

ENGINE RPM
 Before gear shift (When draining)
TRANMISSION ECMV [No.1]
Filling starts (During
trigger)filling
During
 Outline of ECMV
Voltage regulation
 The ECMV (Electronic Control Modulation Valve)
Filling finishes
consists of the following two units, a pressure control
valve and fill switch.
 Pressure control valve
 Converts a current sent from the transmission controller
to the proportional solenoid valve, to an oil pressure.
 Fill switch
 Detects that the clutch is filled with oil. It has the
functions below.
 1) It outputs a signal (fill signal) to the controller as
soon as the clutch is filled with oil to report 　 the
completion of filling.
 2) It outputs a signal (fill signal) to the controller while
an oil pressure is applied to the clutch to report the
presence/absence of oil pressure.
 TRANMISSION ECMV [No.2]
 ECMV and proportional solenoid
 One proportional solenoid is attached to one ECMV.
After receiving the command current from the
controller, it produces thrust in the figure below.
　　 By making the proportional solenoid-produced
thrust act on the pressure control valve spool, it
produces an oil pressure shown in the figure below.
By controlling the amount of command current, the
thrust is changed to operate the pressure control
valve, controlling the oil flow and oil pressure.
 ECMV and fill switch
 One fill switch is attached to one ECMV.
 When the clutch completes filling, the pressure of
the clutch turns "ON" the fill switch. By this signal,
the oil pressure starts build-up.
 TRANMISSION ECMV [No.3]

 Operation of ECMV
 The ECMV is controlled by the command current
sent from the controller to the proportional
solenoid and the fill switch output signal.
 The relation among the proportional solenoid
command current of the ECMV, the clutch input
pressure, and fill switch output signal is as shown
in the figure to the right.
 A region: Before gear shift (When draining)
 B region: Filling starts (During trigger)
 C region: Filling finishes
 D region: Voltage regulation
 E region: During filling
 TRANMISSION ECMV [No.4]
 The clutch is crimped by the piston when
shifting the gear with the gear shift switch. If
a high oil pressure is applied suddenly,
however, the piston connects to the clutch
suddenly, causing the machine to make a
sudden start and give an excessive shock
to the machine.
To prevent them, it is designed so that if
you connect the ECMV to shift gears with
the gear shift switch, the oil pressure to the
clutch may be gradually increased up to the
specified level. By this design, the clutch is
excited smoothly to eliminate the shock at
the start, improve the durability of the
power transfer system, and also provide
operator comfort.
 Fill switch:OFF
TRANMISSION ECMV [No.5]

1. Before gear shift (Region A in the diagram)

Proportional
 When a current is not carried to the solenoid :
proportional solenoid (1), the pressure OFF Valve
control valve (2) is draining the oil at the
clutch port A through the drain port dr.
Since, at that time, no oil pressure acts on
the oil pressure detection valve (3), the fill
switch (4) is OFF.

P/L Pump
Clutch : OFF
 Fill switch:
TRANMISSION ECMV [No.6]
OFF→ON

Proportional
solenoid :
2. When filling ON Valve
(When inputting the trigger command
to the pressure control valve)
(B and C regions in the diagram)

 If you supply a current to the proportional

solenoid (1) with no oil in the clutch, an oil
pressure proportional to the solenoid force acts
on the chamber B, pushing the pressure control
valve (2) rightward. This operation opens the
pump port P and clutch port A to start filling the
clutch with oil. When the clutch is filled with oil,
the fill switch (4) is turned ON.

P/L Pump Clutch : ON

 Fill switch : ON
TRANMISSION ECMV [No.7]
3. Pressure regulation (D region in the diagram)

 If you flow a current to the proportional

solenoid (1), the solenoid produces thrust
proportional to the current. Pressure is
regulated by striking a balance among the Valve
thrust of the solenoid, the thrust of the oil
pressure of the clutch port, and reaction
force of the pressure control spring (5).

Proportional
solenoid :
ON

P/L Pump Clutch : ON

 T/M neutral safety switch
STEERING, BRAKE CONTROL
PCCS lever
Safety lever

Potentiometer Free

Lock
Cable

T/M Control valve

 Engine
HSS SYSTEM controller
Engine control Hydraulic oil
CAN communication information pressure signal
network

Steering Engine
signal

Potentiometer Hydraulic,
Servo valve HSS pump
PCCS lever
N EPC
valve
Transmission, steering HSS opening
circuit
controller
Hydraulic,
HSS valve

Sprocket
Forward,
reverse signal EPC
valve
Final
drive

Hydraulic
tank
HSS
motor

Potentiometer
 BRAKE VALVE 　 [1]

Brake : OFF

Parking
brake : OFF

Brake pedal:
OFF
 BRAKE VALVE [No.6]
BRAKE VALVE 　 [2]

Brake : ON

Parking brake :
OFF

Brake pedal :
ON
 BRAKE VALVE 　 [3]

Brake : ON

Parking brake :
ON

Brake pedal :
OFF
 pedal.
When changing setting of the steering controller and readjusting the potentiometer,
adjust the potentiometer voltage in the following manner.
1. Parking lever "ON". Key switch "ON".
①
2. Turn buzzer cancel SW to [◇] and service SW "ON" for 3 seconds.
Display B shows ①.
3. Turn information SW ( ＞ ) for five times. Display B shows ②. ②
4. Set buzzer cancel SW in the [◇] position.
Display A shows "5R" Display B shows ③.
5. Press the shift-up button five times.
Turn information SW ( ＞ ) two times. ③
Press the shift-up button four times. Display B shows ④.
7. Set buzzer cancel SW in the [◇] position. Display B shows ⑤.
8. Adjust the potentiometer so that the value on Display B is 2500±50mV. ④ 5 4
( Loosen the bolt① to turn. )
9. If the value on Display B does not come within the range of 2500±50mV
even after the adjustment, try to adjust the brake potentiometer initial set.
Brake potentiometer initial set.
⑤ 4 B R A K E P E D L
1. Set "8-SERVICE ADJUST MODE" by buzzer cancel SW [◇] and [□].
Display B shows ⑥.
2. Set buzzer cancel SW in the [◇] position. ⑥
Display A shows "Cb". Display shows ⑦.
3. Turn information SW ( ＞ ) three times. Press the shift-up button five times.
Display B shows ⑧.
4. Set buzzer cancel SW in the [◇] position. Display B shows ⑨. ⑦
　　 ( A currently recorded value will appear on Display B. )
5. Set buzzer cancel SW in the [◇] position. and check that the caution buzzer sounds.
Display B shows the difference from the value with the brake pedal in the N position. (2500mV) 5
( The difference from the neutral position is indicated, for example, as 70mV
If the Brake pedal value is 2570mV, and likewise as -70mV value
⑧
if the Brake pedal valve is 2430mV )
6. The neutral position of the brake pedal is adjusted.
7. Turn buzzer cancel SW to [□] until display B shows normal condition.
⑨
 BRAKE PEDAL
BRAKE PRESSURE-PEDAL FORCE-STROKE
Kg/cm2 Kg
30 　 (Brake OFF)
28--32Kg/cm2
Brake pressure

20 　 Brake pressure
Pedal force

18.7 Kg/cm2

10 20 10.7 Kg/cm2

Pedal force
10

0 0 (Brake ON)

20 40 60 80 100
Pedal stroke ％
 28--32 Kg/cm2
Adjusting brake pedal Kg/cm2
18.7 Kg/cm2
Pressure
10.7 Kg/cm2
Bolt①

Stroke mm

Potentiometer Brake valve

Pedal stroke: 77 mm

Brake pedal rod

Pedal stopper distance (b): 24 mm

After adjusting the pedal, adjust the Zero

point of the brake potentiometer.
( Adjust mode: 0005 ) Brake valve
Adjusting at parking brake lever
Brake valve
Spool stroke: 13 mm
Lever ass’y

Limit switch

Parking lever g:: 90 mm

f: 88 mm Brake valve

Monitoring code: 40910

(for limit switch)
New Brake Control System
Brake Pedal Limit switch

Potentiometer for Brake Pedal

Brake pedal rod

Brake pedal rod

turn buckle Parking lever cable
Access to Power Train ECMV for T/M

Forward

P/T pump Fan pump