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93216-00460

June 2009

Foreword
To ensure good machine performance, reduce failures or problems, and prolong the service life of each component,
it is necessary to operate the machine as is directed in the Operator and Maintenance Manual.
To effectively diagnose and repair the machine, it is important to follow the guidelines laid out in this Technical
Manual.
General Information
Functions and structure
For the engine, refer to the engine Shop Manual provided by the engine manufacturer.
The purpose of this manual is to provide information on the product and the correct maintenance and repair methods. Please read this manual to ensure correct troubleshooting and good repair service.
This manual will be periodically reviewed and revised for more satisfactory content. If you have any opinion or
requests, please inform us.

Safety Symbols
An accident may occur if you disregard safety rules.
In this manual, several expressions are used according to levels of danger for inspection and repair work as shown
below. Read the work procedures and cautions described in this manual, and take preventive measures against
possible problems before starting service work.

DANGER
This danger symbol identifies special warnings or
procedures which, if not strictly observed, will result
in death or serious injury.

WARNING
This warning symbol identifies special warnings or
procedures which, if not strictly observed, could result
in death or serious injury.

CAUTION
This caution symbol identifies special instructions or
procedures which, if not strictly observed, may result
in minor or moderate injury.

IMPORTANT
This important symbol identifies special instructions
or procedures which, if not correctly followed, may
result in serious machine damage.

We cannot predict all possible accidents or incidents that may occur during service work. Therefore, an accident that
is not specifically mentioned in this manual may occur. To protect yourself from all accidents, be careful when doing
service work.

CONTENTS
General Information ............................................................................................................................................... 00-1
How to Use Manual ........................................................................................................................................... 00-2
Safety precautions ...................................................................................................................................... 00-2
Symbols ...................................................................................................................................................... 00-3
Outline ............................................................................................................................................................... 00-4
Layout of main components ........................................................................................................................ 00-4
Inspection and maintenance table .............................................................................................................. 00-5
Recommended lubricants ........................................................................................................................... 00-8
Coolant ....................................................................................................................................................... 00-9
Lubrication chart ....................................................................................................................................... 00-10
Weight of main components ......................................................................................................................00-11
Bolt tightening torque ................................................................................................................................ 00-12
Hose band tightening torque ..................................................................................................................... 00-16
Liquid gasket and screw lock agent .......................................................................................................... 00-17
Cautions regarding welding repair service ................................................................................................ 00-19
Measurement for Performance Check .................................................................................................................. 03-1
Cautions on Safety ............................................................................................................................................ 03-2
Standard Measurement Values for Performance Check ................................................................................... 03-3
Function & Structure Chassis Group ..................................................................................................................... 12-1
Front Chassis .................................................................................................................................................... 12-2
Loading linkage ........................................................................................................................................... 12-2
Loading linkage pin ..................................................................................................................................... 12-4
Rear Chassis .................................................................................................................................................... 12-5
Fuel tank ..................................................................................................................................................... 12-5
Floor board mount ....................................................................................................................................... 12-6
Center Pin ......................................................................................................................................................... 12-7
Upper center pin ......................................................................................................................................... 12-7
Lower center pin ......................................................................................................................................... 12-8
Dust seal ..................................................................................................................................................... 12-9
Check & Adjustment Chassis Group ..................................................................................................................... 13-1
Linkage Pin ....................................................................................................................................................... 13-2
Liner ............................................................................................................................................................ 13-2

Center Pin ......................................................................................................................................................... 13-6


Adjusting shim ............................................................................................................................................. 13-6
Installing bearing cover ............................................................................................................................... 13-6
Installing bearing outer ring ......................................................................................................................... 13-7
Function & Structure Power Group ........................................................................................................................ 22-1
Power Line ........................................................................................................................................................ 22-2
Engine / Transmission ....................................................................................................................................... 22-3
Engine / transmission mount ....................................................................................................................... 22-3
Radiator ............................................................................................................................................................. 22-4
Radiator mount ............................................................................................................................................ 22-5
Propeller Shaft .................................................................................................................................................. 22-6
First propeller shaft assembly ..................................................................................................................... 22-7
Second propeller shaft assembly ................................................................................................................ 22-8
Third propeller shaft assembly .................................................................................................................... 22-9
Axle Assembly ................................................................................................................................................. 22-10
Axle Support .................................................................................................................................................... 22-12
Differential Gear .............................................................................................................................................. 22-14
Conventional type ..................................................................................................................................... 22-14
Function of differential gear ....................................................................................................................... 22-17
Operation of differential gear ..................................................................................................................... 22-17
Check & Adjustment Power Group ........................................................................................................................ 23-1
Engine ............................................................................................................................................................... 23-2
Measuring engine speed ............................................................................................................................. 23-2
Measuring engine oil pressure .................................................................................................................... 23-2
Propeller Shaft .................................................................................................................................................. 23-3
Propeller shaft phase .................................................................................................................................. 23-3
Second propeller shaft alignment ................................................................................................................ 23-3
Propeller shaft tightening torque ................................................................................................................. 23-4
Axle ................................................................................................................................................................... 23-5
Axle nut tightening procedure ..................................................................................................................... 23-5
Differential gear adjustment procedure ....................................................................................................... 23-6

Function & Structure Torque Converter and Transmission Group ........................................................................ 32-1
Torque Converter .............................................................................................................................................. 32-2
Torque converter structure .......................................................................................................................... 32-3
Power flow path .......................................................................................................................................... 32-3
Torque multiplication ................................................................................................................................... 32-3
Torque Converter (Lock-up) (Option) ................................................................................................................ 32-4
Lock-up clutch structure .............................................................................................................................. 32-5
Lock-up clutch function (only forward) ........................................................................................................ 32-5
Torque Converter Gear Pump ........................................................................................................................... 32-7
Gear pump specifications ........................................................................................................................... 32-7
Transmission ..................................................................................................................................................... 32-8
Clutch combination ..................................................................................................................................... 32-9
Planetary gear ............................................................................................................................................. 32-9
Shift lever position ....................................................................................................................................... 32-9
Downshift button operation ......................................................................................................................... 32-9
Gear train and number of teeth ................................................................................................................. 32-10
Clutch Pack ..................................................................................................................................................... 32-14
Power Flow Path in the Transmission ............................................................................................................. 32-15
Hydraulic System Diagram ............................................................................................................................. 32-19
Hydraulic Circuit Diagram ............................................................................................................................... 32-20
Oil Flow ........................................................................................................................................................... 32-22
Oil flow in the torque converter line ........................................................................................................... 32-22
Oil flow in the transmission line ................................................................................................................. 32-22
T/C and T/M Oil Circulation ............................................................................................................................. 32-24
Modulator Valve Unit ....................................................................................................................................... 32-25
Interior schematic (not exact representation) ............................................................................................ 32-27
Modulation Mechanism ............................................................................................................................. 32-28
Modulator valve operation ......................................................................................................................... 32-29
Control Valve Assembly .................................................................................................................................. 32-31
Clutch solenoid valve assembly ................................................................................................................ 32-33
Clutch valve assembly .............................................................................................................................. 32-36
Accumulator assembly .............................................................................................................................. 32-37
Direct charge valve ................................................................................................................................... 32-38
Lock-up clutch solenoid valve ................................................................................................................... 32-39

Check & Adjustment Torque Converter and Transmission Group ........................................................................ 33-1
Clutch Oil Pressure and Time Lag .................................................................................................................... 33-2
Measuring clutch oil pressure ..................................................................................................................... 33-2
Function & Structure Hydraulic Group ................................................................................................................... 42-1
Flushing Hydraulic Circuit ................................................................................................................................. 42-2
Purpose of flushing ..................................................................................................................................... 42-2
Cautions on Hydraulic Parts Replacement ....................................................................................................... 42-3
Hydraulic Circuit Symbols ................................................................................................................................. 42-4
Hydraulic lines ............................................................................................................................................. 42-4
Pumps & motors .......................................................................................................................................... 42-4
Cylinders ..................................................................................................................................................... 42-4
Operation methods ...................................................................................................................................... 42-5
Pressure control valve ................................................................................................................................. 42-5
Flow control valve ....................................................................................................................................... 42-5
Directional control valve .............................................................................................................................. 42-6
Check valve ................................................................................................................................................. 42-6
Miscellaneous hydraulic symbols ................................................................................................................ 42-7
Hydraulic System Operation ............................................................................................................................. 42-8
Hydraulic system operation outline ............................................................................................................. 42-8
Layout of Hydraulic Units ................................................................................................................................ 42-10
Hydraulic Tank ................................................................................................................................................. 42-11
Hydraulic tank breather valve (tank cap) ................................................................................................... 42-12
Hydraulic tank specifications ..................................................................................................................... 42-13
Hydraulic oil level check ............................................................................................................................ 42-14
Hydraulic Pump ............................................................................................................................................... 42-15
Loading and pilot and brake pump ............................................................................................................ 42-15
Pump specifications .................................................................................................................................. 42-15
Steering pump ........................................................................................................................................... 42-16
Steering pump specifications .................................................................................................................... 42-16
Hydraulic pump principle ........................................................................................................................... 42-17
Hydraulic pump wear plate ........................................................................................................................ 42-18
Hydraulic pump bushing lubrication .......................................................................................................... 42-18

Hydraulic Cylinder ........................................................................................................................................... 42-19


Boom cylinder ........................................................................................................................................... 42-19
Bucket cylinder .......................................................................................................................................... 42-19
Steering cylinder ....................................................................................................................................... 42-20
Hydraulic cylinder specifications ............................................................................................................... 42-21
Loading System .............................................................................................................................................. 42-22
Reducing Valve (for Pilot Pressure) ................................................................................................................ 42-23
Pilot Valve ....................................................................................................................................................... 42-24
Pilot valve function .................................................................................................................................... 42-26
Pilot valve operation (modulated position) ................................................................................................ 42-26
Pre-detent and detent magnet solenoid .................................................................................................... 42-28
Multiple Control Valve (KML35A/2T103) ......................................................................................................... 42-29
Multiple control valve specifications .......................................................................................................... 42-30
Multiple control valve main relief valve ..................................................................................................... 42-31
Multiple control valve overload relief valve (with make-up function) ......................................................... 42-33
Multiple control valve make-up valve ........................................................................................................ 42-34
Multiple control valve bucket spool ........................................................................................................... 42-35
Multiple control valve boom spool ............................................................................................................. 42-37
Adapter (Orifice) .............................................................................................................................................. 42-40
Ride Control (OPT) ......................................................................................................................................... 42-41
Ride control hydraulic circuit ..................................................................................................................... 42-41
Ride control operation ............................................................................................................................... 42-42
Ride control valve assembly (Reducing valve circuit) ............................................................................... 42-44
Ride control valve assembly (Accumulator circuit) ................................................................................... 42-47
Accumulator (for ride control) .................................................................................................................... 42-50
Steering System .............................................................................................................................................. 42-51
Orbitrol .......................................................................................................................................................... 42-52
Orbitrol structure ..................................................................................................................................... 42-52
Orbitrol specifications .............................................................................................................................. 42-53
Orbitrol operation .................................................................................................................................... 42-54
Orbitrol feed-back mechanism operation ................................................................................................ 42-56
Steering speed and flow rate control ........................................................................................................ 42-57
Hydraulic pump oil amount and steering force .......................................................................................... 42-57
Orbit rotor operation principle ................................................................................................................... 42-58

Steering Valve (KVS32-A4.0/21) ..................................................................................................................... 42-59


Steering valve operation ........................................................................................................................... 42-61
Steering spool variable throttle .................................................................................................................. 42-63
Steering valve flow control spool ............................................................................................................... 42-64
Steering valve main relief valve ................................................................................................................ 42-65
Steering valve overload relief valve .......................................................................................................... 42-67
Steering pilot circuit and its operation ....................................................................................................... 42-69
Stop Valve ....................................................................................................................................................... 42-71
Stop valve function .................................................................................................................................... 42-72
Stop valve operation ................................................................................................................................. 42-72
Reducing Valve (for Orbitrol) ......................................................................................................................... 42-73
Steering Line Filter .......................................................................................................................................... 42-74
Efficient Loading System ................................................................................................................................. 42-75
Efficient loading system outline ................................................................................................................. 42-75
Mounting of the ELS valve ........................................................................................................................ 42-76
Mounting of the variable kickout sensor .................................................................................................... 42-77
Efficient loading system operation ............................................................................................................ 42-78
Fan Motor System ........................................................................................................................................... 42-79
Mounting of fan motor ............................................................................................................................... 42-79
Fan Motor Line ................................................................................................................................................ 42-80
Hydraulic circuit (fan motor normal rotation) ............................................................................................. 42-82
Proportional relief valve (S/N 9001~9050) ................................................................................................ 42-84
Proportional relief valve (S/N 9051~) ........................................................................................................ 42-86
Reversing Fan Motor Line (OPT) .................................................................................................................... 42-91
Reversing fan motor function .................................................................................................................... 42-91
Hydraulic circuit (Reverse rotation) ........................................................................................................... 42-95
Secondary Steering ......................................................................................................................................... 42-96
Secondary steering circuit ......................................................................................................................... 42-96
Check & Adjustment Hydraulic Group ................................................................................................................... 43-1
Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT) ........................................... 43-2
Loading circuit relief valve setting pressures .............................................................................................. 43-2
Ride control circuit reducing valve setting pressures (OPT) ....................................................................... 43-7
Steering circuit relief valve setting pressures ............................................................................................ 43-10

Hydraulic Cylinder ........................................................................................................................................... 43-15


Cylinder natural drift .................................................................................................................................. 43-15
Stop Valve ....................................................................................................................................................... 43-17
Stop valve adjustment procedure ............................................................................................................. 43-17
Function & Structure Brake Group ........................................................................................................................ 52-1
Brake System Outline ....................................................................................................................................... 52-2
Service brake .............................................................................................................................................. 52-2
Parking brake .............................................................................................................................................. 52-2
Adjustment of axle internal pressure ........................................................................................................... 52-2
Brake Units Layout ............................................................................................................................................ 52-3
Unloader Valve .................................................................................................................................................. 52-4
Unloader valve operation ............................................................................................................................ 52-6
Valve Unit .......................................................................................................................................................... 52-7
Accumulator ...................................................................................................................................................... 52-9
Brake Valve ..................................................................................................................................................... 52-10
Brake valve performance chart ..................................................................................................................52-11
Brake valve outline .................................................................................................................................... 52-12
Service Brake .................................................................................................................................................. 52-14
Service brake operation ............................................................................................................................ 52-14
Service brake friction disc ......................................................................................................................... 52-15
Service brake steel plate ........................................................................................................................... 52-16
Service brake piston ................................................................................................................................. 52-17
Service brake pedal stroke adjusting mechanism ..................................................................................... 52-18
Brake circuit air bleeding procedure ......................................................................................................... 52-20
Parking Brake ................................................................................................................................................. 52-22
Parking brake operation ............................................................................................................................ 52-25
Parking brake friction disc ......................................................................................................................... 52-28
Parking brake steel plate .......................................................................................................................... 52-28
Parking brake solenoid valve .................................................................................................................... 52-29
Parking Brake Manual Release ...................................................................................................................... 52-30
Brake Circuit Check Valve ............................................................................................................................... 52-32
Auto Brake ...................................................................................................................................................... 52-33
Auto brake circuit ...................................................................................................................................... 52-33
Auto brake operation set value ................................................................................................................. 52-33

Reducing valve (for Autobrake circuit) ...................................................................................................... 52-34


Solenoid valve (for Autobrake circuit) ....................................................................................................... 52-35
Pressure Sensor (for stop lamp and declutch) ................................................................................................ 52-36
Pressure sensor (for stop lamp) ................................................................................................................ 52-36
Pressure sensor (for Declutch) ................................................................................................................. 52-37
Check & Adjustment Brake Group ......................................................................................................................... 53-1
Brake Circuit Oil Pressure ................................................................................................................................. 53-2
Unloader valve setting pressure .................................................................................................................. 53-2
Brake valve oil pressure .............................................................................................................................. 53-4
Service Brake .................................................................................................................................................... 53-6
Service brake performance check ............................................................................................................... 53-6
Service brake friction plate wear measurement .......................................................................................... 53-7
Cautions on installing brake discs ............................................................................................................... 53-8
Parking Brake .................................................................................................................................................... 53-9
Parking brake performance check .............................................................................................................. 53-9
Function & Structure Electrical Group ................................................................................................................... 62-1
How to Use Electrical Wiring Diagram .............................................................................................................. 62-2
Utilisation des schmas des cblages lectriques (FRANAIS) ...................................................................... 62-3
Verwendung des elektrischen Schaltplans (DEUTSCH) ................................................................................... 62-4
Modalit di utilizzo dello schema dei collegamenti elettrici (ITALIANO) ............................................................ 62-5
Cmo utilizar un Diagrama de Alambrado Elctrico (ESPAOL) ..................................................................... 62-6
Como Utilizar o Diagrama de Ligaes Elctricas (PORTUGUS) .................................................................. 62-7
Electrical Cable Color Codes ............................................................................................................................ 62-8
Electrical Circuit Symbols .................................................................................................................................. 62-9
Sensor Mount .................................................................................................................................................. 62-10
Fuse ................................................................................................................................................................ 62-11
Fuse box ................................................................................................................................................... 62-11
Fusible link ................................................................................................................................................ 62-12
Engine Start Circuit ......................................................................................................................................... 62-13
Engine start circuit diagram ....................................................................................................................... 62-13
Neutral starter ........................................................................................................................................... 62-14
Starter switch ............................................................................................................................................. 62-15
Battery relay .............................................................................................................................................. 62-16

Alternator I terminal wire ........................................................................................................................... 62-17


Diode unit .................................................................................................................................................. 62-17
Neutral relay .............................................................................................................................................. 62-18
Magnetic switch ........................................................................................................................................ 62-19
Voltage relay ............................................................................................................................................. 62-20
Power Generating/Charging Circuit ................................................................................................................ 62-21
Alternator .................................................................................................................................................. 62-21
ECM (Engine Controller) ................................................................................................................................. 62-22
Function of ECM ....................................................................................................................................... 62-22
Connection diagram .................................................................................................................................. 62-22
Monitor lamp test ...................................................................................................................................... 62-23
Failure diagnosis ....................................................................................................................................... 62-24
Quantum fault code information ................................................................................................................ 62-27
Accelerator pedal ...................................................................................................................................... 62-33
Transmission Control Circuit and Monitor Circuit ............................................................................................ 62-35
Machine control unit (MCU) ...................................................................................................................... 62-35
MCU connection diagram ......................................................................................................................... 62-37
Machine control unit (MCU) function ......................................................................................................... 62-39
Modulator valve operation ......................................................................................................................... 62-46
Adjustable declutch preset switch ............................................................................................................. 62-47
Monitoring system ..................................................................................................................................... 62-57
Operation monitor lamps ........................................................................................................................... 62-59
Instrument Panel and Switch .......................................................................................................................... 62-60
Instrument panel ....................................................................................................................................... 62-60
Instrument panel rear surface ................................................................................................................... 62-61
Gauge circuit ............................................................................................................................................. 62-62
Fuel gauge circuit ...................................................................................................................................... 62-64
MODM ............................................................................................................................................................. 62-65
MODM function ......................................................................................................................................... 62-65
Monitor Changeover ................................................................................................................................. 62-65
Information Monitor ................................................................................................................................... 62-68
Replacement Monitor ................................................................................................................................ 62-72
Fault Log Monitor ...................................................................................................................................... 62-78
Input/Output Monitor ................................................................................................................................. 62-85

Parameter Setting Monitor ........................................................................................................................ 62-89


Specification Setting Monitor ..................................................................................................................... 62-98
Electrical Detent Circuit ................................................................................................................................. 62-104
Bucket leveler .......................................................................................................................................... 62-104
Detent solenoid ....................................................................................................................................... 62-105
Lift kickout & lower kickout ...................................................................................................................... 62-106
Sensor assy ............................................................................................................................................ 62-107
Detent solenoid ....................................................................................................................................... 62-109
Preset height adjustment ........................................................................................................................ 62-109
Diode ............................................................................................................................................................. 62-110
Diode check method ................................................................................................................................62-111
Caution for diode check method ..............................................................................................................62-111
Surge voltage and surge suppression diodes ......................................................................................... 62-113
Function & Structure Operator Station Group ....................................................................................................... 72-1
Cabin ................................................................................................................................................................. 72-2
Glass ........................................................................................................................................................... 72-4
Wiper mount ................................................................................................................................................ 72-7
Wiper motor ................................................................................................................................................. 72-8
Operator Seat .................................................................................................................................................. 72-10
Steering and Transmission Shift Lever ............................................................................................................ 72-11
Tilt case ..................................................................................................................................................... 72-12
Column shaft ............................................................................................................................................. 72-13
Shift lever .................................................................................................................................................. 72-13
Air Conditioner ................................................................................................................................................ 72-14
Air conditioner components ....................................................................................................................... 72-14
Denso air conditioner structure ................................................................................................................. 72-15
Function of cooling mechanism ................................................................................................................. 72-20
Cooling circuit ............................................................................................................................................ 72-23
Electrical circuit ......................................................................................................................................... 72-24
Air conditioner functions of components ................................................................................................... 72-25
Charge of refrigerant ................................................................................................................................. 72-53
Troubleshooting ............................................................................................................................................... 72-70
Air conditioner ........................................................................................................................................... 72-70

Check & Adjustment Operator Station Group ....................................................................................................... 73-1


Air Conditioner .................................................................................................................................................. 73-2
Adjustment of lubricating oil quantity when components of air conditioner are replaced ............................ 73-2
Adjustment of air gap (between hub and rotor) in compressor magnetic clutch ......................................... 73-5
Compressor V-belt adjustment .................................................................................................................... 73-6
Parts to be replaced periodically ................................................................................................................. 73-7
Function & Structure Supplement ...........................................................................................................................80-1
Foreword ............................................................................................................................................................80-2
Quick Coupler .....................................................................................................................................................80-3
Power Boost Circuit ............................................................................................................................................80-7
Short Boom (OPT) ...........................................................................................................................................80-15
Limited Slip Differential (LSD) ...........................................................................................................................80-17

03-6
Measurement for Performance Check

MEMO

00-1
115ZV-2 General Information

General Information
How to Use Manual ................................................. 00-2
Outline ..................................................................... 00-4

00-2
General Information
How to Use Manual

How to Use Manual


Safety precautions

- Do not start to work in an enclosed area if adequate


ventilation is not provided.

The most important point in providing repair service is


safety. To ensure safety, observe the general cautions
described below.

- To remove a heavy unit (20 kg (40 lbs) or more), be


sure to use a crane or other lifting device.

- This manual is intended for properly trained and


equipped service technicians.
- Any work on the machine must be performed by the
trained personnel only.
- Carefully read this manual to thoroughly understand
the operation method before you operate or repair
the machine.
- Be sure to wear appropriate clothes and protectors,
such as safety boots, hard hat and goggles.

- Just after stopping operation, be careful not to


directly touch a hot component. You may get burned.
- Contact tire manufacturer's local dealer for tire servicing and changing.
- Always store the tools in good condition, and use
them properly.
- Keep the work area clean. Clean up spills immediately.
- Avoid the use of flammable solvents and cleaners.

- Place the machine on level and solid ground, and


place chocks against the wheels to prevent movement.

- When working outdoors keep work areas, ladders,


steps, decks and work platforms clear of snow, ice,
and mud.

- Remove the cable from the battery before starting


the service work, and attach a "DO NOT OPERATE!"
tag to the steering wheel.

- Use safe work platforms to reach higher areas of the


machine.

IMPORTANT
If a battery terminal is removed from a machine in
less than 30 seconds after the key is put into the
OFF position, it can corrupt the ECM program,
which can disable the engine. Always wait 1 full
minute to be sure to be past this write to memory
function prior to removing battery terminals.
- Be sure to release the internal pressure before you
remove a pipe, such as the hydraulic oil, air, or
engine coolant pipe.
- Be sure to apply the articulation stopper before starting work.
- While supporting the bottom of the chassis using a
jack, be sure to support the chassis using the blocks.
- When the boom or bucket is raised or when a unit is
lifted by a crane, be sure to place a stand or adequate cribbing under the unit to prevent unexpected
dropping.

- Any technician that operates a refrigerant recovery


and recycling machine must first be certified through
an EPA approved testing program.
More information is available at http://www.epa.gov/
ozone/title6/608/technicians/608certs.html.

00-3
115ZV-2 General Information
How to Use Manual

Symbols
For safe and effective service work, the following symbols are used for notes and useful information in this
manual.
Symbol

Item

Description

Reference

Shows the condition or procedure that will be useful


or efficient in doing service work.

Weight

Shows the weight of a part or unit. The weight


should be considered in selecting wire rope or cable
for slinging work or determining the working posture.

Tightening Shows the tightening torque of a section that should


torque be carefully tightened during assembly work.

Coating

Shows the type of coating or adhesive and the coating section.

Oil or
water
supply

Shows the oil or water supply port and the refill


amount.

Drainage

Shows the oil or water drain port and the drain


amount.

IMPORTANT
If the specified conditions are not satisfied or the specified procedure is not
observed, there is a strong possibility that the product will be damaged or the performance of the product will be reduced.
The message shows the preventive measures.

Abbreviation
To save space, abbreviations are used in sentences. To understand the contents of this manual, refer to the following abbreviation list. Additional abbreviations are listed on page 92-20.
E/G
T/C
T/M
SOL
SW
F
A/M
B
R

........... Engine
........... Torque converter
........... Transmission
........... Solenoid valve
........... Switch
........... Front or Forward
........... Auto/Manual
........... Battery
........... Rear or Reverse

RH ............Right hand side


LH ............Left hand side
H
............High
L
............Low
GND ............Ground
OPT ............Option
Assy ............Assembly
1st ............1st speed
2nd ............2nd speed

3rd ............3rd speed


4th ............4th speed
M/C ............Machine
min-1 ............RPM
ELS ............Efficient loading system
MODM ........Machine operation diagnostic module
MCU ...........Machine control unit

00-4
General Information
Outline

Outline
Layout of main components

16

10

19

11

23

9
2

15

17

22

20

21

18

14

12

13

115V2E00001

1. Engine assembly
(Cummins QSK19)
2. Torque converter assy
3. Transmission
4. Hydraulic pump
5. Multiple (loader) control valve
6. Steering valve
7. Pilot valve (for loading)
(right side)
8. Transmission control valve

9.
10.
11.
12.

Air cleaner
Muffler
Radiator
Hydraulic oil cooler
(air-to-oil type)
13. T/C oil cooler
(lower tank of radiator)
14. T/C oil cooler (installed on E/G)
15. Charge air cooler

16. Efficient loading system (ELS)


valve
17. Front axle assembly
18. Rear axle assembly
19. 1st propeller shaft
20. 2nd propeller shaft
21. 3rd propeller shaft
22. Parking brake
23. Fan motor

00-5
115ZV-2 General Information
Outline

Inspection and maintenance table


Refer to Operation & Maintenance Manual for maintenance procedures.

IMPORTANT
Severe application require more frequent maintenance.
Severe conditions include heavy dust, extremely
abrasive material, caustic chemicals, exremely wet
conditions or abnormally hot or cold ambient temperatures.
: First time replacement or cleaning only

Section

Item for check

Operating hours
10

50

250

500

1000

2000

When
Required

Check Engine Oil Level


Check Engine Coolant Level
Drain Water and Sediment from Fuel Prefilter
Check Drive Belt
Check Air Intake System
Check Cooling Fan
Check Warning Lamps
Check Fuel Level
Check Exhaust Gas
Drain Water and Sediment from Fuel Tank
Replace Fuel Filter Cartridge
Replace DCA4 Coolant Filter Cartridge

*1

Clean Crankcase Breather Tube


Engine

Adjust Belt Tension


Replace Engine Oil and Oil Filter Cartridge
Check and Adjust Injection Timing
Check Engine Compression Pressure
Check Injection Pressure
Replace Fuel Tank Breather
Clean Fuel Tank
Check and Adjust Valve Lash Clearance
Check Vibration Damper
Clean Crankcase Breather
Clean or Replace Air Cleaner Element
Clean Radiator / Air cooler / Hydraulic oil cooler Fins
Replace Ether Cylinder
Clean or Replace Air Cleaner Element
Replace Coolant

After six cleanings or once a year


Every 2 years or 3000 hours

Note:
*1 applies to machines from S/N 9101 and thereafter. Refer to the Operation & Maintenance Manual for details.

00-6
General Information
Outline

: First time replacement or cleaning only


Section

Item for check

Operating hours
10

50

250

500

1000

Check Transmission Oil Level


Transmission &
Torque
Converter

Replace Transmission Oil Filter


Replace Transmission Oil
Clean or Replace Transmission Breather
Check Tire for Damage, Air and Tread Depth
Greasing (Axle support)
Check Tire Air Pressure
Greasing (Pillow block bearing unit)
Check Differential Gear Oil
Check Planetary Gear Oil

Axle system

Check Tightness of Wheel Bolts


Greasing (Differential seals)
Greasing (2nd Propeller Shaft Spline)
Replace Differential Gear Oil
Replace Planetary Gear Oil
Greasing (1st Propeller Shaft)

Every 12000 hours

Greasing (2nd Propeller Shaft)

Every 12000 hours

Greasing (3rd Propeller Shaft)

Every 12000 hours

Check Steering Operation


Steering system Greasing (Steering Cylinder)
Clean Filter for Orbitrol
Check Service Brake Operation
Check Parking Brake Operation
Check Parking Brake Oil
Brake system

Clean Filter for Brake Line


Replace Parking Brake Oil
Check Service Brake Disk Wear
Check Brake Accumulator

2000

When
Required

00-7
115ZV-2 General Information
Outline

: First time replacement or cleaning only


Section

Item for check

Operating hours
10

50

250

500

1000

2000

Check Hydraulic Oil Level


Greasing
Replace Hydraulic Oil Return Filter
Loading system Replace Hydraulic Oil, Clean Filter
Replace Filter in the Hydraulic Tank Cap
Replace Bucket Teeth (option)
Replace Cutting Edge (option)
Adjust and Check Rear View Mirrors
ROPS (Roll Over Protective Structure)
Chassis

Greasing (Center Pin)


Check Ride Control Accumulator (option)
Check and/or Replace Seat Belt
Check Windshield Washer Fluid
Check Wiring Harnesses
Check Horn Operation

Electrical
system

Check Monitor Panel Operation


Check Back-up Alarm Operation
Check Battery Electrolyte Level
Check or Replace Fuses
Check and Adjust Air Conditioner Belt
Clean Air Conditioner and Heater Filter Element

Air Conditioner

Check Air Conditioner Refrigerant


Replace Air Conditioner Filter Elements
Clean Air Conditioner Condenser
Replace Air Conditioner Receiver Dryer

Others

Walk-Around Inspection

Every 3 years or 6000 hours

When
Required

00-8
General Information
Outline

Recommended lubricants
Refill capacity
(Approximate)

Kind of Oil

Engine

66 liter

Engine oil
(CH4 or CI4)

Transmission

90 liter

Engine oil (CD) or


ATF

Hydraulic tank

225 liter

Hydraulic oil

Differential &
Planetary

Front: 180 liter


Rear: 180 liter

Engine oil (CD)

Parking brake

3 liter

Fuel tank

660 liter

Diesel fuel

Ambient Temperature (C)


-30

-20

-10

10

20

30

40

Change Interval
(Hours)

SAE10W-30
SAE15W-40
SAE10W
ATF
ISO VG32
ISO VG46

Engine oil SAE40 or SAE50

ASTM D975 No.1


ASTM D975 No.2

500
1,000
2,000

2,000

daily

Note: 1 shows "Hydraulic tank oil capacity at level gauge center."


Engine

Use oil that meets engine oil classification API CH4, CI4 or CG4.
2. Change engine oil every 250 hours if CG4 is used.
Engine oil drain intervals need to be reduced by 50 % when fuel sulfur content exceeds
0.5 %.

Transmission

Use engine oil classification API CD or A.T.F. (Auto Transmission Fluid).


Never mix engine oil and A.T.F.

Hydraulic System

Use industrial-type hydraulic oils which are certified by suppliers having anti-wear, antifoam, anti-rust and anti-oxidation additive properties for heavy duty use. Use of the wrong
viscosity of oil can cause improper operation of hydraulic functions or premature pump failure.
3. In a case that fire-resistant fluid is used in the hydraulic circuit, replace hydraulic pump
every 6,000 hrs operation.

Differential &
Planetary

Use class API CD engine oil with 5 % "Antichatter" additive or friction modifier.

Lubricating Grease

Use multipurpose-type EP/MOLY grease for most applications.


NLGI NO.2 grease is suitable for most temperatures.
NLGI NO.1 or NO.0 grease for extremely low temperature.
Use lithium base grease for universal joints and a propeller shaft spline.

00-9
115ZV-2 General Information
Outline

Diesel Fuel

Requirements for diesel fuel

Specifications

Grade No. 1-D

Grade No. 2-D

Flash Point C.

min.

38

52

Water and Sediment % vol.

max.

0.05

0.05

Distillation Temperature C. 90% vol. recovered

max.

288

338

min.

1.3

1.9

max.

2.4

4.1

Ash % mass

max.

0.01

0.01

Sulfur % mass

max.

0.50

0.50

Cetane Number

min.

40

40

Carbon residue on 10% distillation residue % mass

max.

0.15

0.35

Kinematic Viscosity mm2/s at 40C

Coolant
Coolant specification
The machine is originally filled with Long Life Coolant
(non-Amin type ethylene glycol) which need not be
replaced for the first two years or 3,000 hours.
Do not use Amin type Long Life Coolant in cooling system. It may cause a corrosion against radiator or heater
core.
If standard antifreeze (not Long Life Coolant) is used for
the replacement, it should be replaced every six
months.

Recommended mixture of antifreeze


Expected Minimum
Ambient Temperature

-35C
-30C
-25C
(-31F) (-22F) (-13F)

-20C
(-4F)

-15C
(-5F)

Pure Water

liter
(gal)

68.1
(18.0)

75.4
(19.9)

82.6
(21.8)

89.9
(23.7)

97.1
(25.6)

Antifreeze

liter
(gal)

76.9
(20.3)

69.6
(18.4)

62.4
(16.5)

55.1
(14.6)

47.9
(12.7)

53

48

43

38

33

Mixture Ratio (%)

- Too much antifreeze in the coolant mixture may


cause engine overheating.
Keep 33% antifreeze mixture (same as the mixture
for a minimum ambient temperature of -15C (5F)) if
the engine overheats in a high ambient temperature.
- Do not use hard water or water with high levels of
calcium and magnesium ions as the coolant water.

IMPORTANT
Do not mix different brands of antifreeze because
they each contain special additives.
Careless mixing often diminishes the effect of these
additives that causes the packing damage or water
leakage.

00-10
General Information
Outline

Lubrication chart

BUCKET LINK SYSTEM


G
G

DIFF &
GEAR BOX

HYD. TANK

DIFF &
GEAR BOX

EVERY 12000Hr

GO

HO

GO

EVERY 2000Hr

GO

TRANSMISSION
DIFF
G
TO
PILLOW
UNIT G
CENTER
PIN G
TO

DIFF

ENGINE OIL PAN


EO

GO

AXLE
SUPPORT

EVERY 50Hr
EO

G
CENTER PIN

EVERY 500Hr
EVERY 250Hr

HO

EVERY 1000Hr

EVERY DAY

G
G

STEERING CYL.

PROPELLER SHAFT
G
SPLINE
2ND PROPELLER
SHAFT

G
1ST & 3RD PROPELLER
SHAFT

115ZV2-44794-23630EU

Grease point

G
Multipurpose grease

HO
Hydraulic oil

Check and add if necessary

GO
Gear oil

TO
Engine oil

Oil replacement

EO
Engine oil

00-11
115ZV-2 General Information
Outline

Weight of main components


Item
Part name

Approx.
weight (kg)

Approx.
weight (lb)

Bucket

4,985

10,970

Boom

3,210

7,070

"Z" -Lever

515/pc

1,135/pc

Link (Bucket to Lever)

90/pc

200/pc

Unit name

Engine room

Screen board

175

385

Roof

70

155

Radiator guard

115/pc

250

Access panel

35/pc

80/pc

360

795

Excluding oil

Fuel tank

330

730

Excluding fuel

Floor board

285

630

Including ope. board, instrument panel and control box

Cab

270

600

Soft cab

Rops
Deck

950

2,090

Left side

105

230

With handrail

Right side

80

175

With handrail

Center
Front chassis

Other

35

80

3,800

8,360

Rear chassis

4,300

9,460

Counter weight

2,150

4,730

Engine

1,980

4,360

Excluding oil

Radiator assembly

890

1,960

With air cooler, hyd. cooler and duct. Excluding water


and oil

Torque converter

440

970

Excluding oil

Transmission

1,310

2,880

Excluding oil

First propeller shaft

20

45

Second propeller shaft

130

290

Third propeller shaft

35

80

Front axle assembly

2,970

6,530

Excluding tires and oil

Rear axle assembly

2,940

6,470

Excluding tires and oil (Including axle support)

Front

745

1,640

Including parking brake

Rear

560

1,235

Multiple control valve

100

220

Pilot valve

15

Steering valve

50

110

Orbitrol

13

40

90

Switch

40

90

Main & pilot

Differential

Hydraulic system

RVT bucket

Hydraulic tank
Chassis

Power line

Remarks

Gear pump
Fan motor

25

55

Boom cylinder

520/pc

1,145/pc

Excluding oil

Bucket cylinder

245/pc

540/pc

Excluding oil

Steering cylinder

40/pc

90/pc

Tire

1,580/pc

3,480/pc

Battery

65/pc

145/pc

Excluding oil
With rim (35/65R33

00-12
General Information
Outline

Bolt tightening torque


Hexagon bolt
1. Thread type
Metric thread, Unified thread
2. Bolt strength
8.8 (8T) ~ 10.9 (11T)
3. Thread pitch
Metric thread: Coarse pitch thread (C), fine pitch thread (F)
Unified thread: Coarse pitch thread (UNC), fine pitch thread (UNF)
(N-m)
Bolt size
Type

Metric thread

Nominal
diameter

Pitch

M8

(C) 1.25

26

38

(C) 1.5

53

76

(F) 1.25

55

80

(C) 1.75

90

132

(F) 1.25

96

142

(C) 2.0

142

206

(F) 1.5

152

221

(C) 2.0

216

314

(F) 1.5

226

330

(C) 2.5

299

436

(F) 1.5

324

476

(C) 2.5

417

608

(F) 1.5

451

662

(C) 2.5

559

814

(F) 1.5

598

878

(C) 3.0

721

1,030

M10

10

M12

12

M14

14

M16

16

M18

18

M20

20

M22

22

M24

24

M27
M30

Unified thread

Bolt strength

Nominal
dimension

27
30

M33

33

5/16

05

8.8 (8T)

10.9 (11T)

(F) 2.0

770

1,128

(C) 3.0

1,030

1,520

(F) 2.0

1,128

1,618

(C) 3.5

1,422

2,109

(F) 2.0

1,569

2,256

(C) 3.5

1,912

2,844

(F) 2.0

2,059

3,040

18 UNC

25

35

3/8

06

16 UNC

44

65

7/16

07

14 UNC

71

103

1/2

08

13 UNC

103

147

9/16

09

12 UNC

147

216

5/8

10

11 UNC

201

294

3/4

12

10 UNC

358

525

7/8

14

9 UNC

554

809

16

8 UNC

868

1,275

Note: Tighten the bolts according to the above list, unless otherwise specified.

00-13
115ZV-2 General Information
Outline

(kgf-m)
Bolt size
Type

Metric thread

Nominal
diameter

Pitch

8.8 (8T)

10.9 (11T)

M8

(C) 1.25

2.7

3.9

(C) 1.5

5.4

7.8

(F) 1.25

5.6

8.2

(C) 1.75

9.2

13.5

(F) 1.25

9.8

14.5

M10

10

M12

12

M14

14

M16

16

M18

18

M20

20

M22

22

M24
M27
M30

Unified thread

Bolt strength

Nominal
dimension

24
27
30

M33

33

5/16

05

(C) 2.0

14.5

21.0

(F) 1.5

15.5

22.5

(C) 2.0

22.0

32.0

(F) 1.5

23.0

33.7

(C) 2.5

30.5

44.5

(F) 1.5

33.0

48.5

(C) 2.5

42.5

62.0

(F) 1.5

46.0

67.5

(C) 2.5

57.0

83.0

(F) 1.5

61.0

89.5

(C) 3.0

73.5

105.0

(F) 2.0

78.5

115.0

(C) 3.0

105.0

155.0

(F) 2.0

115.0

165.0

(C) 3.5

145.0

215.0

(F) 2.0

160.0

230.0

(C) 3.5

195.0

290.0

(F) 2.0

210.0

310.0

18 UNC

2.5

3.6

3/8

06

16 UNC

4.5

6.6

7/16

07

14 UNC

7.2

10.5

1/2

08

13 UNC

10.5

15.0

9/16

09

12 UNC

15.0

22.0

5/8

10

11 UNC

20.5

30.0

3/4

12

10 UNC

36.5

53.5

7/8

14

9 UNC

56.5

82.5

16

8 UNC

88.5

130.0

Note: Tighten the bolts according to the above list, unless otherwise specified.

00-14
General Information
Outline

(lb-ft)
Bolt size
Type

Metric thread

Nominal
diameter

Pitch

8.8 (8T)

M8

(C) 1.25

19.5

28

(C) 1.5

39

56

(F) 1.25

40

59

(C) 1.75

66

97

(F) 1.25

70

105

(C) 2.0

105

150

(F) 1.5

110

160

(C) 2.0

160

230

(F) 1.5

165

245

(C) 2.5

220

320

(F) 1.5

235

350

(C) 2.5

305

450

(F) 1.5

330

490

(C) 2.5

410

600

M10

10

M12

12

M14

14

M16

16

M18

18

M20

20

M22

22

M24
M27
M30

Unified thread

Bolt strength

Nominal
dimension

24
27
30

M33

33

5/16

05

10.9 (11T)

(F) 1.5

440

650

(C) 3.0

530

760

(F) 2.0

565

830

(C) 3.0

760

1,120

(F) 2.0

830

1,190

(C) 3.5

1,050

1,550

(F) 2.0

1,160

1,660

(C) 3.5

1,410

2,100

(F) 2.0

1,520

2,240

18 UNC

18.0

26

3/8

06

16 UNC

32

47

7/16

07

14 UNC

52

76

1/2

08

13 UNC

76

105

9/16

09

12 UNC

110

160

5/8

10

11 UNC

150

215

3/4

12

10 UNC

265

385

7/8

14

9 UNC

410

595

16

8 UNC

640

940

Note: Tighten the bolts according to the above list, unless otherwise specified.

00-15
115ZV-2 General Information
Outline

Flanged hexagon bolt


1. Bolt type: Metric thread
2. Bolt strength: 8.8 (8T)
3. Thread pitch: Coarse pitch thread (C)
(N-m)
Bolt size
Type

Metric thread

Bolt strength

Nominal
dimension

Pitch

M5

0.8

M6

12

M8

1.25

28

8.8 (8T)

M10

1.5

53

M12

1.75

94

M16

231

M20

2.5

441

M24

765
(kgf-m)

Bolt size
Type

Metric thread

Bolt strength

Nominal
dimension

Pitch

8.8 (8T)

M5

0.8

0.7

M6

1.2

M8

1.25

2.9

M10

1.5

5.4

M12

1.75

9.6

M16

23.5

M20

2.5

45.0

M24

78.0
(lb-ft)

Bolt size
Type

Metric thread

Bolt strength

Nominal
dimension

Pitch

8.8 (8T)

M5

0.8

5.0

M6

8.6

M8

1.25

20.9

M10

1.5

38.9

M12

1.75

69.1

M16

169.2

M20

2.5

324.0

M24

561.6

00-16
General Information
Outline

Hose band tightening torque


Low pressure hose
(heat resisting hose)

Hose band

Tightening torque
(N-m)

Tightening torque
(kgf-cm)

Tightening torque
(lb-ft)

69002-02200

1.6

16

1.2

40

2.9

Hose band

Tightening torque
(N-m)

Tightening torque
(kgf-cm)

Tightening torque
(lb-ft)

69002-02200

1.6

16

1.2

40

2.9

Inner dia. (mm) Outer dia. (mm)


6.3

16.5

7.9

18.5

9.5

20.5

12.7

24.5

15.9

29.9

19.0

30.0

25.4

38.0

69002-04400

31.8

45.8

69002-05200

38.1

52.1

69002-05700

50.8

67.8

69002-07100

60.5

76.0

69002-08200

75.5

93.0

69002-09500

Low pressure hose


Inner dia. (mm) Outer dia. (mm)
6

16.5

18.5

20.5

22.0

12

24.5

12

26.0

15

29.0

15

30.5

19

32.0

19

34.0

25

39.5

25

41.5

32

46.0

32

48.0

38

54.0

50

70.5

50

73.0

69002-02700
69002-03100

69002-02300
69002-02700
69002-03100
69002-03800
69002-04400
69002-05200
69002-05700
69002-07600

To connect the hose to the pipe, tighten the hose band


at the following position:

Hose

Center of pipe
protrusion

Pipe

Hose band

10~20 mm

70ZV00003

00-17
115ZV-2 General Information
Outline

Liquid gasket and screw lock


agent

Cautions regarding reassembly

To reassemble the disassembled parts, be sure to use


the specified liquid gasket or screw lock agent or the
equivalent according to the following lists:

Completely remove the hardened lock agent from the


screw and the threaded hole before reassembling the
screw.

Code
Liquid
gasket

Screw lock
agent

Manufacturer

Product name

AA01

Loctite

Plastic Gasket 568

AA02

Loctite

Hydraulic sealant

AA03

Three Bond

Three Bond 1215

AB01

Loctite

Loctite 262

AB02

Three Bond

Three Bond 1327

AB03

Three Bond

Three Bond 1374

Cautions regarding parts removal


If a screw or shaft to be removed has been locked by
one of the above agents, remove the screw or shaft
using a general tool, such as a wrench or puller.
If it is difficult to remove the screw or shaft, heat the bolt
to soften the agent (200~250C) using a soldering iron
or gas torch.

Caution
If there is a seal near the screw or shaft to be removed,
carefully use the heating method for removal, to avoid
damage to the seal.
If heat has been used to remove the bolt a new bolt
should be used during reassembly.

To reassemble a screw

Note
A piece of hardened lock agent may be peeled off and
remain in the component. The remaining piece may
cause malfunction during fastener installation.

To bond a plane or to fit a shaft


Remove the hardened lock agent using a wire brush or
the like, and polish the surface using sand paper. Use of
a Loctite primer like Locquic Primer T prepares
metal surface of the threads and speeds curing time.
Antiseize Agent
Code

Manufacturer

AC01

Loctite

Product name
Loctite 767
(Paste or spray)

00-18
General Information
Outline

Screw lock agent application procedure

How to wind a seal tape

Through-hole
Apply screw lock agent one or two lines on the male
threads.
Seal tape

Screw lock agent


Leave 1~2 screw

65ZV00004

65ZV00002

To avoid a piece of seal tape left in the circuit, leave 1 or


2 screws from the end of the thread and start threading
it clockwise.

00-19
115ZV-2 General Information
Outline

Cautions regarding welding repair service


If welding is needed to repair the chassis, observe the
following precautions to protect the hydraulic cylinders,
hydraulic units, gear sets, and electrical units from possible damage.

Cautions
1. Turn the starter switch OFF.

4. Ground the welder near the section to be welded.

2. Remove the battery terminals both positive and


negative sides from the battery.

5. To ground the welder, check that the electric current


will not flow through the cylinders.
Cylinder head covers for some models have a low
conductive metal that will cause spark if the welding
current flows. The spark may damage the cylinder
rod.

IMPORTANT
If a battery terminal is removed from a machine in
less than 30 seconds after the key is put into the
OFF position, it can corrupt the ECM program,
which can disable the engine. Always wait 1 full
minute to be sure to be past this write to memory
function prior to removing battery terminals.
3. Disconnect the connector for MCU (machine controller), ECM (engine controller) and air conditioner.

6. Calibrate throttle pedal to ECM.


(a) Turn the starter switch to "ON".
(b) Fully depress and release the throttle pedal
three times.
(c) Turn the starter switch to "OFF".

Example 1

Section to be welded
Do not ground this section.
Electric current may flow
through the cylinders.
Ground this section.
(correct grounding)

35C00002

Example 2

Do not ground this section.


Electric current may flow
through the cylinders.

Section to be welded

Ground this section.


(correct grounding)
35C00006

00-20
General Information
Outline
7. The weld spattered on the hydraulic cylinders and
on the plated sections of pins will damage the cylinders and pins. There are other parts that may be
damaged by the spatter; hydraulic units, harnesses, hydraulic hoses, and nylon tubes.
Be sure to mask these units and parts before welding.

Hydraulic cylinder

Heat-resistant
cloth
Section to
be welded

Hydraulic hose
Nylon tube
Harness
Chassis

Remove
and if
necessary
wrap

35A00005

Plated section (Mask this section.)

(c) Hydraulic hoses, nylon tubes, or harnesses are


easily damaged by the heat during welding. To protect them from the heat, remove them from the section to be welded to make enough clearance.

Pin section with pin


temporarily inserted
Pin

Plated section (Mask this section.)

35C00003

(a) Plated section


Cover the plated sections with heat-resistant cloth,
such as glass wool or canvas.
Note
The weld spattered on the plated sections causes corrosion.

1m or more

Scrap material, etc.

Section to
be welded

1m or more
35C00004

(b) Cover the hydraulic units, electrical units, harnesses, hydraulic hoses, nylon tubes, etc. with
heat-resistant cloth (glass wool or canvas) or scrap
material to protect them from spatter.

03-1
115ZV-2 Measurement for Performance Check

Measurement for
Performance Check
Cautions on Safety .................................................. 03-2
Standard Measurement Values for Performance Check
............................................................................ 03-3

03-2
Measurement for Performance Check
Cautions on Safety

Cautions on Safety
WARNING
Unexpected movement of the machine may cause an
accident resulting in injury or death.
Therefore, to provide repair service with the engine
running, be sure to observe the following items:
- Park the machine on level ground.
- Apply the parking brake.
- Block the tires with chocks to prevent the tires from
moving.
- Determine the signals between the service man.
- Prohibit any person from walking into dangerous
areas.
- Near articulation areas of the machine
- Under the machine
- Around the engine
- In front of or behind the machine

WARNING
Operation under the boom or the bucket may lead to
severe accidents.
Make sure to apply the safety lock of the boom and
the bucket control lever provided in the cab, remove
the starter key, and attach a "DO NOT OPERATE!"
tag to the cab.

CAUTION
Be careful not to be burnt by bursting high pressure
oil.
Release the pressure remaining inside the circuit and
open the cap of the hydraulic tank before removing
the plug from the pressure measurement port so that
the internal pressure of the hydraulic tank is released
and burst of the high pressure oil can be prevented.

WARNING
Entering the articulation area of the machine body
while the engine is running may cause severe accidents.
Make sure to stop the engine, pull out the starter key,
and attach a "DO NOT OPERATE!" tag to the cab
before entering the articulation area.

CAUTION
Touching the fan or the V belt of the engine or the hot
area while the engine is running may cause severe
accidents.
Make sure to stop the engine before opening the
engine room access panel.

03-3
115ZV-2 Measurement for Performance Check
Standard Measurement Values for Performance Check

Standard Measurement Values for Performance Check


Measurement conditions
Temperature of torque converter oil: 50~80C (120~180F)
Temperature of hydraulic oil: 50~80C (120~180F)
Temperature of engine coolant: 50~80C (120~180F)
Standard measurement
values for performance check

Item
Measurement item

System

Minimum no-load speed, Low Idle (LI)


Engine speed
(min-1) (rpm)

Engine

(S/N 9001~9100)

92550

(S/N 9101~)

Maximum speed in torque converter stall mode

1,780100

1,690100

Maximum speed in multiple control valve relief mode

1,855100

1,705100

Maximum speed in torque converter stall plus multiple


control valve relief mode

1,420 +150
- 100

1,375 +150
- 100

1,91050

1,70050

Maximum speed in torque converter stall mode

1,780100

1,690100

Maximum speed in multiple control valve relief mode

1,850100

1,850100

Maximum speed in torque converter stall plus multiple


control valve relief mode

1,420 +150
- 100

1,380 +150
- 100

Engine speed
Clutch pressure
MPa (kgf/cm2) (psi)
Clutch time lag
(sec)

92550

Maximum no-load speed, High Idle (HI)

Main pressure
MPa (kgf/cm2) (psi)

Remarks
775 in hibernate mode

1,91050

Minimum no-load speed, Low Idle (LI)


Engine speed
(min-1) (rpm)

Transmission

Maximum no-load speed, High Idle (HI)

Fuel efficient
mode

Normal

775 in hibernate mode

Idling (LI)

2.60.2 (272) (38428)

Maximum (HI)

2.60.2 (272) (38428)

Idling (LI)

2.50.2 (262) (37028)

Maximum (HI)

2.50.2 (262) (37028)

NeutralForward 1st speed


(engine speed: 1,500 min-1 (rpm))

0.30.1

Before wheels move

03-4
Measurement for Performance Check
Standard Measurement Values for Performance Check

Standard measurement
values for performance
check

Item
Measurement item

System

Cylinder drift
(when boom and
bucket are horizontal and with no load)
(mm/min) (in/min)
Boom rising time
(no load)
(sec)

Hydraulic line

Full steering time


(sec)

Relief valve setting


pressure
MPa (kgf/cm2) (psi)

Boom cylinder

3 (1/8) or less

Bucket cylinder

4 (5/32) or less
Idling (LI)

Engine speed

Engine speed

253.0
-1

1,500 min (rpm)

10.51.0

Maximum (HI)

8.40.5

Idling (LI)

5.00.5
-1

1,500 min (rpm)

3.90.3

Full accelerated engine speed

3.90.5

Loading line main relief pressure (HI)

20.60.5 (2105)
(2,98671)

Loading line overload relief pressure (LI)

23.50.5 (2405)
(3,41371)

Steering line main relief pressure (HI)

20.60.5 (2105)
(2,98671)

Steering line overload relief pressure (LI)

+10
24.5 +1.0
0 (250 0 )
+142
(3,555
0 )

Run engine at lowest


possible speed while
setting

3.5 (36)
(512)

Run engine at lowest


possible speed while
setting

Pilot line reducing pressure (LI)

Fan maximum
revolution (HI)
min-1 (rpm)
Fan minimum
revolution (LI)
min-1 (rpm)

Remarks

Engine water temp. <80C (180F)


T/C oil temp. <110C (230F)
Hydraulic oil temp. <90C (195F)

1,120 +75
- 200

Engine water temp. >95C (205F)


T/C oil temp. >115C (240F)
Hydraulic oil temp. >95C (205F)

1,300 +100
- 50

Engine water temp. <60C (140F)


Engine idle revolution

900 +50
- 200

Run engine at lowest


possible speed while
setting

03-5
115ZV-2 Measurement for Performance Check
Standard Measurement Values for Performance Check

Item
Measurement item

System

Shift lever position

2nd speed reverse

Engine speed

Maximum (HI)

Shift lever position

3rd speed reverse

Performance of
service brake

Performance of
parking brake
Maximum (HI)

Off (Cut-out)

11.80.5 (1205)
(1,70671)

On (Cut-in)

6.91.0 (7010)
(995142)

Brake

Unloader valve
setting pressure

Low-pressure alarm switch setting pressure


(For brake accumulator circuit)
Auto brake reducing pressure
The time from the low-pressure alarm is
turned off till the unloading valve cuts off
pressure

Accumulator charge
time (sec)

Engine speed (LI)

Number of brake
pedal applications

Run engine 1 minute high idle, then stop the engine.


(Turn key switch "ON" with engine off.)
Step on the brake pedal and release, and check the number
of times until the low-pressure alarm is turned on.

Declutch
engagement
(cm) (in)

Engine: Maximum speed/ Declutch pedal: Quick release


(Distance the loader rolls back before moving forward.)

Note
These are the standard measurement values for the
machines at the time when delivered from the factory.

Remarks

Slowly increase the


engine speed, and
check that the machine
does not move at the
maximum engine
speed.

Same as above
Engine speed

Brake line setting


pressure
MPa (kgf/cm2) (psi)

Standard measurement values for performance check

Before brake check, be


sure to disconnect the
cable connector of
parking brake solenoid
valve.

3.90.5 (405)
(56971)
1.3 (13)
(185)
16

at least 11 times

Repeat stepping on the


brake pedal as follows:
On: 5 sec.
Off: 5 sec.

15 (6) or less

1/5 slope
(approx. 11), unladen,
1st speed

03-6
Measurement for Performance Check

MEMO

12-1
115ZV-2 Function & Structure Chassis Group

Function & Structure


Chassis Group
Front Chassis .......................................................... 12-2
Rear Chassis........................................................... 12-5
Center Pin ............................................................... 12-7

12-2
Function & Structure Chassis Group
Front Chassis

Front Chassis
Loading linkage

10

6
115ZV12001

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Bucket
Link
Lever
Boom
Bucket cylinder
Boom cylinder
Dump stopper surface
Roll-back stopper surface
Lever stopper surface
Bucket stop plate
(Design differs by manufacturer of the attachment)

12-3
115ZV-2 Function & Structure Chassis Group
Front Chassis

Even contact both sides

5040

Hinge pin height at


300 bucket on ground

Typical bucket roll-back stopper adjustment


(Contact attachment supplier for details on non-standard
attachments)

Note for setting roll-back stops:


When installing roll-back stops, the stops must have a
smooth radius and must contact boom on both sides.
The cylinder must retain 3~5 mm of rod with in the cylinders so the piston does not hit the cylinder head.

Typical bucket dump stopper clearance


(Contact attachment supplier for details on
non-standard attachments)
To increase clearance increase height of #9
To reduce clearance decrease height of #9

115V2E12001

12-4
Function & Structure Chassis Group
Front Chassis

Loading linkage pin


mm (in)
1. Bucket - Boom

2. Boom - Lever

4. Front chassis - Boom

5. Bucket - Rod

6. Lever - Rod

7. Lever - Bucket cylinder

8. Bucket cylinder Front chassis

9. Boom cylinder Front chassis

10. Front chassis Steering cylinder

11. Steering cylinder Rear chassis

3. Boom - Boom cylinder

10

11

115V2E12002

12-5
115ZV-2 Function & Structure Chassis Group
Rear Chassis

Rear Chassis
Fuel tank

10

7
A-Detail

A
2

10

6
115V2E12003

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Fuel tank
Fuel level sensor
Fuel tank filler assembly
Filter
Drain plug
Inspection hole cover
Gasket (Rubber seal type)
Suction pipe
Pipe (for vacuum prevention)
Fuel return pipe

12-6
Function & Structure Chassis Group
Rear Chassis

Floor board mount

Viscous mount

Floor board
1

2
3

4
115ZV12008

1. Floor board
2. Rubber cushion

5
6
7

The floor board is installed on the rear chassis by the


rubber cushion. The instrument panel, control box,
operator's seat and the air conditioner unit are on the
floor board.

8
9

10

11

95ZV12008

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Stud bolt
Stud
Cushion rubber
Case
Seal plate
Damping rubber
Damping plate
Silicone oil
Plain washer
Hexagon head bolt
Plug

The floor board is supported by a viscous mount in four


positions so that vibrations, impacts and sounds generated in the chassis are not transmitted to the inside of
cabin.

12-7
115ZV-2 Function & Structure Chassis Group
Center Pin

Center Pin
Upper center pin

Upper

4 9, 10

5
Front
chassis
6

11
2
Upper

8, 10

Rear
chassis
115ZV12010

6
4
9, 10

7
3

11

Grease pipe

Split shim

2
5
8, 10

115V2E12004

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Center pin
Plate
Bearing cover
Sleeve
Shim
Bearing assy
Dust seal
Bolt
Bolt
Washer
Bushing

12-8
Function & Structure Chassis Group
Center Pin

Lower center pin

Lower

6
7
2
3
Front
chassis

Rear
chassis

Lower

115ZV12011

6, 7

Grease pipe

4
3

4
2
115V2E12005

1.
2.
3.
4.
5.
6.
7.

Center pin
Bearing retainer
Bearing assy
Dust seal
Bushing
Bolt
Plate

12-9
115ZV-2 Function & Structure Chassis Group
Center Pin

Dust seal

Center
pin

Dust seal position

90ZV12007

When installing the dust seal, check that the lip faces
toward the outside. If the lip faces toward the outside,
the dust will not be drawn through the seal.

12-10
Function & Structure Chassis Group

MEMO

13-1
115ZV-2 Check & Adjustment Chassis Group

Check & Adjustment


Chassis Group
Linkage Pin ............................................................. 13-2
Center Pin ............................................................... 13-6

13-2
Check & Adjustment Chassis Group
Linkage Pin

Linkage Pin
WARNING

CAUTION

Unexpected movement of the machine may cause an


accident resulting in injury or death.
Before starting adjustment work, be sure to observe
the following items:
- Park the machine on level ground.
- Apply the parking brake.
- Remove the starter key, and attach a "DO NOT
OPERATE!" tag on the cab.
- Block the tires with chocks to prevent the tires from
moving.

Unexpectedly dropped parts may cause an accident


resulting in injury.
- Before liner insertion, be sure to lift the cylinder
using a crane to prevent the cylinder from unexpectedly dropping during liner insertion.
- Wear protective clothes like work gloves and steel
toed shoes.

Liner

4
8

115ZV12005

Adjustment
portion
Liner hole diameter
(mm)

110

91

91

121

101

121

7
Adjustment
unnecessary

8
71

13-3
115ZV-2 Check & Adjustment Chassis Group
Linkage Pin

Bucket hinge pin section (#1)


Boom

Bucket

Bushing

Bushing

Hinge pin (#1)

Bolt

Dust seal

Shim

Seal retainer assy

Shim
95V2E13001

Adjust the clearance (*) to 1.0 mm or less for the hinge


pin (#1).

How to assemble
2. Align the pin holes in the bucket and the boom then
insert the pin.

R142

3. Place the shim between the bucket boss and the


seal retainer assy so that the clearance between
the boom boss and the seal retainer (* marked) is
less than 1mm.

R5

Tighten the bolt for the seal retainer assy.


: 417 N-m (42.5 kgf-m) (307 lb-ft)

Shim
115V2E13001

1. Attach the seal retainer assy to the bushings.


(When installing the dust seal to the seal retainer
assy, be sure to check the direction of the dust
seal.)

Shim thickness
1.0, 0.5 mm (0.039, 0.020 in)
(2 kinds of shim thickness)

13-4
Check & Adjustment Chassis Group
Linkage Pin

Bucket link pin section (#2)


Bushing

Bucket

Link

*
Bushing

Pin

Dust seal

Shim
Seal ring assy
115V2E13002

How to assemble
1. Insert the bushings into the link boss and attach the
seal ring assy to the bushing.

91 +10

18

80 -10

(When installing the dust seal to the seal ring assy,


be sure to check the direction of the dust seal.)
2. Place the shim between the bucket boss and the
seal ring assy so that the clearance between the
link boss and the seal ring (* marked) is less than
1mm.
Shim thickness:
1.0, 0.5 mm (0.039, 0.020 in)
(2 kinds of shim thickness)
Shim

115V2E13003

3. Align the pin holes in the bucket and the link. Then,
insert the pin.

13-5
115ZV-2 Check & Adjustment Chassis Group
Linkage Pin

Adjustment

95ZV12005

Adjust the clearance (*) to 1.2 mm or less for #3 ~ #8


between the bosses using liners.
For the steering cylinder, be sure to adjust the clearance
on the rear chassis side first and then on the front chassis side while checking that the cylinder is not inclined.

13-6
Check & Adjustment Chassis Group
Center Pin

Center Pin
Adjusting shim

The clearance between the front chassis and bearing


cover (3) is 0.750.5 mm (0.030.02 in) before shim
adjustment.
1

4 9, 10

Add shims (5) so that the clearance is 0.10.05 mm


(0.0040.002 in). After that, tighten bolt (9).
5

Front
chassis
6

Torque for assembly:


:
Bolt (8): 662 N-m (67.5 kgf-m) (488 lb-ft)
Bolt (9): 441 N-m (45.0 kgf-m) (326 lb-ft)
(with lubricating oil (Engine oil or gear oil))

Installing bearing cover

11
2
Upper

8, 10

Rear
chassis
115ZV12010

Front

Grease pipe

Upper

115V2E13004

6
4
9, 10

Install the bearing cover (3) so that the grease nipple


mounting hole is positioned at the specified angle as
shown in the figure.

7
3

11

Grease pipe

Split shim

2
5
8, 10

115V2E12004

13-7
115ZV-2 Check & Adjustment Chassis Group
Center Pin

Installing bearing outer ring

6
7

Front

Rear

Center line

Split of outer
bearing

3
2
3
Front
chassis

Rear
chassis

Lower

115ZV12011

6, 7

Grease pipe

4
3

4
2
115V2E12005

Install the bearing outer ring (3) so that the split is perpendicular to the frontrear line of the machine.

95ZV13003

13-8
Check & Adjustment Chassis Group

MEMO

22-1
115ZV-2 Function & Structure Power Group

Function & Structure


Power Group
Power Line .............................................................. 22-2
Engine / Transmission............................................. 22-3
Radiator................................................................... 22-4
Propeller Shaft......................................................... 22-6
Axle Assembly......................................................... 22-10
Axle Support............................................................ 22-12
Differential Gear ...................................................... 22-14

22-2
Function & Structure Power Group
Power Line

Power Line

11

10

12

15 4

13

14
115V2E22001

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

Engine
Torque converter
Transmission
Radiator
1st propeller shaft
2nd propeller shaft
3rd propeller shaft
Front axle differential gear
Rear axle differential gear
Parking brake
Air cleaner
Muffler
Hydraulic oil cooler
Torque converter oil cooler (bottom tank of radiator)
Charge air cooler

The power output from the engine is transmitted to the


transmission through the torque converter and the first
propeller shaft. The speed and direction are changed
according to the engagement of the transmission
clutches. The power is then transmitted through the
second and third propeller shafts to the differential
gears of front and rear axles.
Finally the power is transmitted through the axles to the
planetary gears, and tires to move the machine.
On the fan side of the engine, there is a radiator. The
radiator incorporates engine coolant, torque converter
oil cooler, charge air cooler and an external air type
hydraulic oil cooler. A parking brake is installed on the
front differential gear.

22-3
115ZV-2 Function & Structure Power Group
Engine / Transmission

Engine / Transmission
Engine / transmission mount

C
D

E,F
A

C
T/C
side

E/G
side

Spacer

4
1

2
3

A-Detail

B-Detail

E/G flywheel
housing
C-Detail

D-Detail

E-Detail

F-Detail

115V2E22002

1.
2.
3.
4.

Rubber cushion
Ring gear
O-ring
Plug

Bolts are used to connect the engine flywheel housing


to the torque converter housing, and a spline ring coupling is used to transmit the engine power to the torque
converter. Therefore no thrust load is placed on the
engine flywheel or crankshaft.
Rubber cushions are used to mount the engine, torque
converter and the transmission on the chassis.

22-4
Function & Structure Power Group
Radiator

Radiator

Charge air
cooler OUT

Coolant IN

Charge air
cooler IN

3
D D

A
C
A

Hydraulic oil
cooler IN

Hydraulic oil
cooler OUT
T/C oil
cooler OUT

T/C oil
cooler IN

Coolant
OUT

115V2E22003

1. Radiator assembly
2. Radiator duct
3. Stay (Bracket)

4. Charge air cooler


5. Hydraulic oil cooler
6. T/C oil cooler

The radiator incorporates the engine coolant, cooling


fin, air charged cooler, and an external air type hydraulic
oil cooler. For the engine coolant, air charge cooler,
hydraulic oil cooler, the air-cooling system is used. For
the torque converter oil, the water-cooling system is
used.

The torque converter oil cooler is in the radiator lower


tank.
When the coolant is hot, the thermostat opens and the
coolant flows to the radiator.
When the coolant is cold enough, the thermostat is
completely closed and no coolant flows to the radiator.
The air charge cooler is required to meet engine emission regulations.

22-5
115ZV-2 Function & Structure Power Group
Radiator

Radiator mount

A-Detail

B-Detail

C-Detail

D-Detail
115V2E22004

1.
2.
3.
4.
5.
6.
7.
8.

Strip seal

Capacity in radiator:
Cooling water
86 L (23 gal)
Hydraulic oil
14 L (3.7 gal)
Torque converter oil 3 L (0.8 gal) x 2 pcs
Dry weight

890 kg (1,960 lbs)

22-6
Function & Structure Power Group
Propeller Shaft

Propeller Shaft

1.
2.
3.
4.
5.
6.

1st propeller shaft


2nd propeller shaft
3rd propeller shaft (fixed type)
Pillow block
Parking brake
Slip joint

115V2E22005

The engine power is transmitted to the torque converter,


the first propeller shaft and the transmission, and is
then, transmitted to the second and the third propeller
shafts to the front and the rear axle.
For the second propeller shaft, the universal joint and
slip joint type spline shaft are used for smooth power
transmission at any steering angle or change in propeller shaft length.
A parking brake is installed on the front differential gear.
The third propeller shaft is the fixed type with universal
joints.

22-7
115ZV-2 Function & Structure Power Group
Propeller Shaft

First propeller shaft assembly


Transmission Torque converter
1

2
b

Grease nipple installation


angle (a,b)

Z
View Z

a
2

1
1

Every 12000
hours greasing

115V2U22002

1. Journal spider assy


2. Propeller shaft

22-8
Function & Structure Power Group
Propeller Shaft

Second propeller shaft assembly


Front differential Transmission
1

Grease nipple installation


angle (a,b,c,d)

a
45
Z

View Z

Every 12000 hours greasing

d
4
Every 2000 hours greasing

b
2

3
1
c
5

1
Every 12000
hours greasing

a
115V2U22003

1.
2.
3.
4.
5.

Journal spider assembly


Propeller shaft assembly
Pillow block
Spline yoke
Sleeve yoke assembly

22-9
115ZV-2 Function & Structure Power Group
Propeller Shaft

Third propeller shaft assembly


Transmission Rear differential
1

2
b

Grease nipple installation


angle (a,b)

1
a

View Z

1
b

Every 12000 hours greasing


115V2U22004

1. Journal spider assy


2. Propeller shaft

22-10
Function & Structure Power Group
Axle Assembly

Axle Assembly
1
50
22

2
3
36

45

44 42

45

35

43 28

37

11

40
52

23 31

16 34
12
30 29

17

41
18
17

18

15

19

32

21

14
25 9

13

10

24

26

18
25
14

49
38

20

48

46

47

5
39

37

51

27
33

115V2E22009

22-11
115ZV-2 Function & Structure Power Group
Axle Assembly
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.

Differential assembly
Axle housing assembly
Wheel hub
Spider
Cover
Axle shaft
Sun gear
Disc gear
Planetary gear
Internal gear
Internal gear hub
Snap ring
Planetary pin
Wear ring
Wear ring
Brake piston
Separation disc
Friction disc
Brake backing plate
Plate
Axle nut
Taper roller bearing (inner)
Taper roller bearing (outer)
Separation disc
Needle cage
Axle lock plate
Snap ring
Floating seal
D-ring
D-ring

31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.

O-ring
O-ring
O-ring
Socket bolt
Spring
U-nut
Magnet plug
Bolt
Socket bolt
Air bleeder screw
Spring pin
Ring
O-ring
Spring pin
Plug
Spring
Sleeve
Bushing
Socket bolt
Bolt
Bolt
Flange bolt

22-12
Function & Structure Power Group
Axle Support

Axle Support
Grease pipe
connection port
(PT1/8)

9
Grease pipe
connection port
(PT1/8)

Pin
(Axle housing)

Axle housing

Front

5
16

4
15

6
2
A

A-A

10

13

16

11

11

Groove at
bushing end

12
10

14

#11 Details

#10 Details

115V2U22001

1.
2.
3.
4.
5.
6.
7.
8.

Shaft
Rear axle support (front)
Rear axle support (rear)
Wear ring
Plate
Plate
Lip seal
Lip seal

9.
10.
11.
12.
13.
14.
15.
16.

Breather
Bushing
Bushing
Ring
Snap ring
Bolt
Bolt
Bolt

22-13
115ZV-2 Function & Structure Power Group
Axle Support

Grease piping

9
2
10
7

12

6
4
5
4
Grease piping

14

11

16

15

16

8
13
1

115V2E22011

1.
2.
3.
4.
5.
6.
7.
8.

Shaft
Rear axle support (front)
Rear axle support (rear)
Wear ring
Plate
Plate
Lip seal
Lip seal

9.
10.
11.
12.
13.
14.
15.
16.

Breather
Bushing
Bushing
Ring
Snap ring
Bolt
Bolt
Bolt

22-14
Function & Structure Power Group
Differential Gear

Differential Gear
Conventional type
Front differential gear (S/N 9001~9050)
2

23

24
28

3
29

26

33
35

32

31

30

27

5
6

34

22

8
9

15

10
21
25

11
12
13

14

17

16 18 19

20
115V2E22012

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Nut
Flange yoke
Oil seal
Plug
Housing
Shim
Taper roller bearing
Spacer
Spiral gear set
Carrier assembly

11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

Taper roller bearing


Adjusting nut
Plate
Wear ring
Side gear
Differential pinion
Pin
Wear ring
Spider
Housing

21.
22.
23.
24.
25.
26.
27.
28.
29.
30.

Roller bearing
O-ring
O-ring
O-ring
Snap ring
O-ring
O-ring
Gear
Piston assembly
Oil seal

31.
32.
33.
34.
35.

Friction disc
Separation disc
Pin
Spring pin
Spring

22-15
115ZV-2 Function & Structure Power Group
Differential Gear
Front differential gear (S/N 9051~9100)
2

29

3
36

K115V2U22002

Front differential gear (S/N 9101~)


2

29

3
36

K115V2U22003

1.
2.
3.
29.
36.

Nut
Flange yoke
Oil seal
Piston assembly
Oil seal (Double lip) (S/N 9051~)

22-16
Function & Structure Power Group
Differential Gear
Rear differential gear
1

22

31
23

28

24

21

6
9

20

10

27

25

11
7

12
18

30

19

14
13

1.
2.
3.
4.
5.
6.
7.
8.

Nut
Flange yoke
Oil seal
Trunnion
Housing
Taper roller bearing
Taper roller bearing
Sleeve

9.
10.
11.
12.
13.
14.
15.
16.

26

17

15

16

Spiral gear set


Carrier assembly
Adjusting nut
Lock plate
Straight pin
Wear ring
Wear ring
Diff pinion

17.
18.
19.
20.
21.
22.
23.
24.

29

Side gear
Spider
Housing assy
Roller bearing
O-ring
O-ring
O-ring
Shim

K115V2U22004

25.
26.
27.
28.
29.
30.
31.

O-ring
Bolt
Snap ring
Bolt
Bolt
Bolt
Oil seal (Double lip)
(S/N 9051~)

22-17
115ZV-2 Function & Structure Power Group
Differential Gear

Function of differential gear

Operation of differential gear

Power transmission

Straight

6
1

2
3
4
5

4
115K22005

1. The power output from the engine is transmitted to


the front and rear axle through the torque converter
and the transmission.
2. The power is transmitted from pinion gear (1) to
axle shaft (2) through bevel gear (5) and differential
(4) in the axle housing.
3. Finally the power is transmitted to the planetary
gears and tires to move the machine.

2
115ZV22013

When moving in a straight direction, each wheel holds


the same amount of torque.
Therefore, pinion gears (4) in the differential assy do not
turn.
Torque from carrier (6) is transmitted to each wheel
equally through pinion gears (4), side gears (3) and axle
shafts (2).

22-18
Function & Structure Power Group
Differential Gear

Turn

2
115ZV22014

When turning, the inside wheel needs more torque than


the outside wheel because of the resistance on it. The
outside wheel rotates faster than the inside wheel.
Then, pinions (4) turn on side gears (3) and torque from
carrier (6) is transmitted to each wheel through pinion
gears (4), side gears (3) and axle shafts (2).

23-1
115ZV-2 Check & Adjustment Power Group

Check & Adjustment


Power Group
Engine ..................................................................... 23-2
Propeller Shaft......................................................... 23-3
Axle ......................................................................... 23-5

23-2
Check & Adjustment Power Group
Engine

Engine
WARNING
Unexpected movement of the machine may cause an
accident resulting in injury or death.
Therefore, to provide repair service with the engine
running, be sure to observe the following items:
- Park the machine on level ground.
- Apply the parking brake.
- Block the tires with chocks to prevent the tires from
moving.
- Determine the signals between the service men.
- Prohibit any person from walking into dangerous
areas.
- Near articulation area of the machine
- Under the machine
- Around the engine
- In front of or behind the machine

CAUTION
Do not touch the fan or V-belt of the engine or hightemperature section if the engine is running.
An accident resulting in injury may occur.
Be sure to stop the engine before you open the
access panel of the engine room.
Keep all guards in place.
Avoid high temperature components even when the
engine is stopped.
Use a photo tachometer when checking engine revolution.

Measuring engine oil pressure


Measurement instrument
- Pressure gauge

Install position
1. Location (A)
2. Measuring port: 9/16-18 UNF
3. Oil pressure gauge: 1.0 MPa (10 kgf/cm2) (150 psi)

Standard measurement value


Engine speed

Service standard

92550 min-1

0.14 MPa (1.4 kgf/cm 2) (20 psi)

1,91050 min-1

0.34~0.48 MPa (3.5~4.9 kgf/cm2) (50~70 psi)

[Engine coolant temperature 50C (120F)]

Measuring engine speed


Measurement instrument
- Tachometer

Standard measurement value


Low idle (min-1): 92550
High idle (min-1): 1,91050

115V2E23001

23-3
115ZV-2 Check & Adjustment Power Group
Propeller Shaft

Propeller Shaft
Propeller shaft phase

Third propeller shaft

Second propeller shaft

Front differential

Transmission

Rear differential

95ZV22007

Adjust the yokes of the second and third propeller shafts


to the same direction (phase).
- The propeller shaft attaches to the transmission
shaft. The shaft from the front differential to the rear
differential is referred to as the propeller shaft. The
propeller shaft articulates as the machine turns.
When the propeller shaft is articulated due to
machine steering, differences in the yoke phases
(directions) will cause unbalance between the transmission torque and the reaction force. As a result,
the propeller shaft extremely vibrates, and the service life of the shaft will be shortened.

Second propeller shaft alignment

Top view
Differential side

(C)

(B)

(A)

Transmission side

Side view
95ZV22008

- As misalignment may produce an abnormal noise,


be sure to align points (A), (B), and (C) of the yokes
when reassembling the propeller shaft.

23-4
Check & Adjustment Power Group
Propeller Shaft

Propeller shaft tightening torque

2nd propeller shaft

1st propeller shaft

3rd propeller shaft

Front differential

1
4

Rear differential

5
2nd propeller shaft

1st propeller shaft

3rd propeller shaft

115V2E23002

1.
2.
3.
4.
5.
6.

:
221 N-m (22.5 kgf-m) (163 lb-ft)
142 N-m (14.5 kgf-m) (105 lb-ft)
441 N-m (44.9 kgf-m) (325 lb-ft)
162 N-m (16.5 kgf-m) (119 lb-ft)
220 N-m (22.4 kgf-m) (162 lb-ft)
155 N-m (15.8 kgf-m) (114 lb-ft)

1.
2.
3.
4.

Screw lock agent (Loctite 262)


Screw lock agent (Loctite 262)
Screw lock agent (Loctite 262)
Screw lock agent (Loctite 262)

23-5
115ZV-2 Check & Adjustment Power Group
Axle

Axle
Axle nut tightening procedure
9

8
PT3/8
(Brake oil inlet)

4
2

10
115V2E23003

1. Tighten axle nut (6) with 3,923 N-m (400 kgf-m)


(2,894 lb-ft) tightening torque to install taper roller
bearings (7)(8).
2. Loosen axle nut (6).
3. Tighten axle nut (6) again with 3,923 N-m (400 kgfm) (2,894 lb-ft) tightening torque.
4. Turn wheel hub (9) 2~3 turns back and forth, and
measure the preload applied to section ( part).
Preload of section ( part)
353~392 N (36~40 kgf) (79~88 lbs)
This is "breakaway" force. The force required to
start the wheel turning.
Note
Use jig to install the floating seal to the axle assembly.

:
1.
2.
3.
4.
5.

89.7 N-m (9.15 kgf-m) (66 lb-ft)


721 N-m (73.5 kgf-m) (532 lb-ft)
33.3 N-m (3.40 kgf-m) (25 lb-ft)
53.0 N-m (5.40 kgf-m) (39 lb-ft)
86.3 N-m (8.80 kgf-m) (64 lb-ft)

#1, 2, 4, 10: Screw lock agent (Loctite 262)

23-6
Check & Adjustment Power Group
Axle

Differential gear adjustment procedure


(S/N 9001~9050)
1

2
10

3
115V2E23004

:
1,030 N-m (105 kgf-m) (760 lb-ft)
314 N-m (32.0 kgf-m) (232 lb-ft)
1,130 N-m (115 kgf-m) (832 lb-ft)
52.5 N-m (5.35 kgf-m) (39 lb-ft)
314 N-m (32.0 kgf-m) (232 lb-ft)
86.3 N-m (8.80 kgf-m) (64 lb-ft)
Front differential only
7. 230 N-m (23.5 kgf-m) (170 lb-ft)
Front differential only
1.
2.
3.
4.
5.
6.

#2, 3, 4, 5, 7: Screw lock agent (Loctite 262)


#1: Liquid gasket
(Three Bond 1215 or a locally procured Room
Temperature Vulcanizer (RTV) that does not contain Acetic Acid)

23-7
115ZV-2 Check & Adjustment Power Group
Axle

Preload adjustment

Front differential gear (S/N 9051~9100)

Measure the preload at the bolt holes of cage (2)(7).


1

Standard preload

Front differential:
24.5~29 N (2.5~3 kgf) (6~7 lbf)
Rear differential:
39~49 N (4~5 kgf) (9~11 lbf)

9
11
K115V2U23001

If the preload is out of the above range, replace spacer


(10) to adjust the preload to the specified range.
Preload is the force required to start the cage movingbreakaway force.

Front differential gear (S/N 9101~)

Note
There are 20 types of spacers from 29.10 mm (1.146 in)
to 29.48 mm (1.161 in) in increments of 0.02 mm
(0.0007 in). Thicker spacers reduce preload; thinner
spacers increase preload.

1
7

9
11
K115V2U23002

Rear differential gear

10

K115V2U23003

23-8
Check & Adjustment Power Group
Axle

Bearing installation

Oil seal installation

Install bearing (8) so that part faces to the drive pinion.

Before installing oil seal (9)(11), be sure to apply grease


to the lip.

Pinion gear

Snap ring

Apply grease
when
assembling.
3 mm
(0.118 in)

Bearing (8)

3.6 mm
(0.142 in)
K85ZV23003

11 (S/N 9051~) (double lip)


9 (S/N ~9050) (single lip)
K95V2U23003

Note
A snap ring is set to bearing (8) as shown above. Incorrect installation of bearing (8) may cause the snap ring
to drop, resulting in a serious mechanical trouble.

After reassembling the differetial assembly, apply


grease to the grease nipple until the grease comes out
from the breather.

23-9
115ZV-2 Check & Adjustment Power Group
Axle

Adjusting tooth contact


Tooth contact

Possible cause

Adjusting method

Correct

Ring gear is too close to the


drive pinion

Loosen the bearing adjuster on the rear


side of ring gear, and tighten the adjuster of
tooth side at the same quantity as loosening, so that the ring gear is far apart from
the drive pinion. Check again the backlash
and tooth contact.

Ring gear is too far from the


drive pinion

Do the reverse adjusting as B.

Drive pinion is too close to the


ring gear.

Increase the thickness of shim at the part


of bearing cage being installed and makes
drive pinion apart from the ring gear.
Check again the backlash and tooth contact.

Drive pinion is too far from the


ring gear.

Decrease the thickness of shim reverse as


D, and makes drive pinion approach the
ring gear.
Check again the backlash and tooth contact.

After adjusting the backlash to the standard value,


check that manual rotation of the gear is possible. After
that, paint blue or red on the tooth surface of ring gear,
and check the tooth contact. To adjust the tooth contact,
adjust the thickness of the shim between the pinion and
cage, and turn the adjustment nut.

23-10
Check & Adjustment Power Group
Axle
Three types of tooth contact shown below are acceptable as the best tooth contact.
Tooth contact position and length (rate)

10
Pattern
A

5
TOP

HEEL

4~5

Pitch line
TOE

10

BOTTOM

10
Pattern
B

2
Pitch line

4
TOP

HEEL

4~5

TOE

10

BOTTOM

10
3
Pattern
C

TOE
Pitch line

4
TOP

3
HEEL

4~5

10

BOTTOM

Service parts
After adjusting the tooth contact and backlash in our
factory, we will wrap the bevel gear and drive pinion as
a unit. Therefore, replace the bevel gear and drive pinion as a unit.
Note
Single sale of the bevel gear or the drive pinion is not
possible.

32-1
115ZV-2 Function & Structure Torque Converter and Transmission Group

Function & Structure


Torque Converter and Transmission Group
Torque Converter .................................................... 32-2
Torque Converter (Lock-up) (Option) ...................... 32-4
Torque Converter Gear Pump ................................. 32-7
Transmission ........................................................... 32-8
Clutch Pack ............................................................. 32-14
Power Flow Path in the Transmission ..................... 32-15
Hydraulic System Diagram...................................... 32-19
Hydraulic Circuit Diagram........................................ 32-20
Oil Flow ................................................................... 32-22
T/C and T/M Oil Circulation ..................................... 32-24
Modulator Valve Unit ............................................... 32-25
Control Valve Assembly .......................................... 32-31

32-2
Function & Structure Torque Converter and Transmission Group
Torque Converter

Torque Converter
9

11

10

4
115V2E32001

1.
2.
3.
4.
5.
6.

Pump impeller
Turbine impeller
Stator
Turbine shaft
Stator shaft (Fixed)
Drive cover

7.
8.
9.
10.
11.

Ring gear
P.T.O. drive gear
P.T.O. driven gear
P.T.O. driven gear
Output flange

32-3
115ZV-2 Function & Structure Torque Converter and Transmission Group
Torque Converter

Torque converter structure

Torque multiplication

Output

Torque ratio (t)

Input

1
S
P

0.5
Speed ratio (e)
95ZV32002

The torque converter is between the engine and transmission, and consists of three impellers as shown in the
figure. The three impellers are pump (P), turbine (T),
and stator (S) impellers.

Power flow path


The pump is connected to the engine flywheel, and
rotates together with the engine.
The turbine is connected to the torque converter output
shaft to transmit the power to the transmission.
The stator is fixed to the torque converter case. The
area of the impellers is filled with oil. When the engine is
started, the pump impeller rotates, therefore the oil will
circulate to rotate the turbine impeller (circulation order:
pumpturbinestatorpump). Oil is redirected by the
fixed stator impeller back to the pump impeller. When
the turbine impeller rotates, the power will be transmitted to the output shaft.

1.0

115ZV32002

If the engine speed/pump impeller speed stays the


same but the turbine impeller speed is reduced due to
the transmission load-output torque is increased. This is
"torque multiplication". Heat is also generated.
Turbine impeller speed (min 1 ) (rpm)
Speed ratio(e)= -----------------------------------------------------------------------------------------------Pump impeller speed (min 1 ) (rpm)

32-4
Function & Structure Torque Converter and Transmission Group
Torque Converter (Lock-up) (Option)

Torque Converter (Lock-up) (Option)

Oil from Lock-up


solenoid valve

T
S

1
3

115V2E32024

1.
2.
3.
4.
5.

Lock-up piston
Friction plate
Steel plate
Turbine shaft
Drive cover

32-5
115ZV-2 Function & Structure Torque Converter and Transmission Group
Torque Converter (Lock-up) (Option)

Lock-up clutch structure

Lock-up clutch function (only forward)

Lock-up clutch

Output

Input
Oil from
Lock-up
Solenoid
valve

T
S

S
Lock-up clutch
P

95V2E32030

The torque converter is equipped with the lock-up


device.
When the lock-up clutch is engaged, the power from the
engine is directly transmitted to the turbine. As a result,
slip between the pump and the turbine is eliminated.
This is an advantage during high speed travel and in
"load and carry" operations. Less fuel is used, higher
ground speed can be reached, and less heat is generated.

5
4
1
3

115V2E32028

While the machine is moving at the 3rd speed or the 4th


speed in the automatic speed change mode, and the
machine reaches the preset speed, the solenoid valve
for lock-up is activated by the signal from the MCU.
The torque converter oil flows through the oil hole provided in the center of turbine shaft (4) and the oil hole
provided in drive cover (5), then presses the lock-up piston onto the pressure plate.
As a result, drive cover (5) is coupled with turbine shaft
(4) to complete the lock-up status.

32-6
Function & Structure Torque Converter and Transmission Group
Torque Converter (Lock-up) (Option)

Automatic shift (with lock-up solenoid)


Shift up
Shift down

Speed

F4L
F4
F3L
3
2
12.0 10.0
(7.5) (6.3)

Reverse

Shift Up

Shift Down

10.0 11.0 13.5 15.5 20.5 21.5 26.5 28.5


(6.3) (6.9) (8.4) (9.7) (12.8)(13.4) (16.6) (17.8)

Forward
Speed km/h (mile/h)
Automatic shift map (Normal mode) 115V2U62008

3rd 3rd lock-up

15.5 km/h (9.6 MPH)

4th 4th lock-up

28.5 km/h (17.7 MPH)

4th lock-up 4th

26.5 km/h (16.5 MPH)

3rd lock-up 3rd

13.5 km/h (8.4 MPH)

32-7
115ZV-2 Function & Structure Torque Converter and Transmission Group
Torque Converter Gear Pump

Torque Converter Gear Pump

Torque converter
pump

Torque converter

115V2E32002

Gear pump specifications


Theoretical
discharge

100.4 cm3/rev (6.13 in3/rev)

Maximum operation
pressure

20.6 MPa (210 kgf/cm2) (2,986 psi)

Maximum operation
speed

2,500 min-1 (rpm)

Actual discharge

Approx. 70 L/min (18.5 gpm)


Conditions:
Pump speed 900 min-1 (rpm)
Oil temp. 80~100C (176~212F)
Oil viscosity 10CST (SAE10W)
Discharge pressure 3.4 MPa
(35 kgf/cm2)
(498 psi)

32-8
Function & Structure Torque Converter and Transmission Group
Transmission

Transmission
14

13

12

4
2
7

11

10
115V2E32003

1.
2.
3.
4.
5.
6.

Input flange
Low range clutch
High range clutch
Reverse clutch
1st speed clutch
2nd speed clutch

7.
8.
9.
10.

3rd speed clutch


Output gear
Output shaft
Output flange
(3rd propeller shaft side)

11. Output flange


(2nd propeller shaft side)
12. Modulator valve unit
13. Clutch solenoid valve assembly
14. Clutch valve assembly

32-9
115ZV-2 Function & Structure Torque Converter and Transmission Group
Transmission

Clutch combination
Clutch
Speed range

Shift lever position


2

Position of shift
lever

F1
F2
F3
F4
N

R1

(Either 1st or 2nd or


3rd)

R2
R3

The transmission is equipped with six clutches:


Forward low range, forward high range, reverse, and
1st, 2nd and 3rd speeds. Combining the clutches as
shown in the table here provides four forward speeds,
and three reverse speeds for a total of seven speeds.
Two clutches must be engaged at the same time to
move the machine.

Function

Held in 1st speed range for both forward and


reverse.

Held in 2nd speed range for both forward and


reverse. Downshift button operation.

Held in 3rd speed range for both forward and


reverse.

Automatic speed change according to shift map


(computer) for 2nd through 4th speeds forward
and 2nd through 3rd speeds reverse.
Downshift button operation.

Automatic or manual speed change is available


depending on the position of the shift lever, as shown in
the table.
Automatic speed change refers to one where the best
speed range is determined by a computer according to
the engine speed and the machine speed detected.

Downshift button operation

Planetary gear

This feature permits quick up and down shifting when in


2nd and Automatic.
It operates from 2nd to 1st, and 1st to 2nd.

Ring gear

Planetary
gear carrier
Planetary gear

Sun gear
95V2E32021

Gear reduction is by the planetary gear method. As


shown, each reduction gear set consists of a sun gear
at the center, three (four) planetary gears located
around it, a ring gear around them, and a carrier (frame)
supporting the planetary gears. The speed is changed
by fixing or releasing the ring gear or the carrier.

32-10
Function & Structure Torque Converter and Transmission Group
Transmission

Gear train and number of teeth

2
94

94

94

94

25

25

26

44

44

42

31

32

H
From 1st propeller shaft

59
83

2nd propeller shaft

3rd propeller shaft

115V2E32008

L: Low range clutch


H: High range clutch
R: Reverse clutch
1: 1st speed clutch
2: 2nd speed clutch
3: 3rd speed clutch

Clutch specifications
Friction plate
Name of clutch

Piston stroke
(mm)

Low range clutch

6.00.5

Steel plate

Number of
Inner
Outer
Inner
Outer
Thickness (mm) return spring
Thickness (mm) Number
Number
diameter diameter
diameter diameter
New/Wear limit
New/Wear limit of plate
of plate
(mm)
(mm)
(mm)
(mm)
6

Reverse clutch

7.00.5

High range clutch

3.00.5

1st speed clutch

5.00.5

2nd speed clutch

3.00.5

3rd speed clutch

4.00.5

420
260
420

330

40.15 / 3.5
(Sintered)

171

40.15 / 3.8
(Paper)

330

40.15 / 3.8
(Paper)

7
7
4
4

482

350

3.20.1 / 3.0

276

187

3.20.1 / 3.0

482

350

3.20.1 / 3.0

9
12
12
12
12
12

32-11
115ZV-2 Function & Structure Torque Converter and Transmission Group
Transmission

Friction plate: mm (in)


For low, reverse clutch

0.6 (0.02)

60

0.2 (0.008) above


Detail drawing of groove
115V2E32027

1. Plate
2. Facing (sintered)
For 2nd, 3rd speed clutch

2.0 (0.08)

0.2 (0.008) above


Detail drawing of groove
115V2E32004

1. Plate
2. Facing (paper)

32-12
Function & Structure Torque Converter and Transmission Group
Transmission
For high, 1st speed clutch

2.0 (0.08)

2
0.2 (0.008) above
Detail drawing of groove
115V2E32005

1. Plate
2. Facing (paper)

Steel plate: mm (in)


For low, reverse, 2nd, 3rd speed clutch

115V2E32006

32-13
115ZV-2 Function & Structure Torque Converter and Transmission Group
Transmission
For high, 1st speed clutch

115V2E32007

32-14
Function & Structure Torque Converter and Transmission Group
Clutch Pack

Clutch Pack
Inlets for 2nd and 3rd
speed clutch oil

13 14 25

27

21 22

Inlets for reverse and


low range clutch oil

18

17

10 9

7
3

31
33
Inlet of 1st speed
clutch oil

Inlet of high
range clutch
oil

Inlet of
lubricating
and cooling
oil

34
2

32

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.

30

26

29 28

Clutch input shaft


High range clutch drum
High range clutch piston
High range clutch piston return spring
Spider
Friction plate
Steel plate
Reverse clutch piston
Reverse planetary gear carrier
Reverse planetary gear
Reverse ring gear
Reverse sun gear
Friction plate
Steel plate
Anchor pin
Piston return spring
Low range clutch piston
Low range planetary gear

24 23

35

19

19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.

20 15 16

12

11

2
115V2E32009

Low range ring gear


Low range sun gear
3rd speed clutch piston
3rd speed planetary gear
3rd speed ring gear
3rd speed sun gear
2nd speed clutch piston
2nd speed planetary gear carrier / 1st speed clutch
gear
2nd speed planetary gear
2nd speed ring gear
2nd speed sun gear
1st speed clutch drum
1st speed clutch piston
Drop gear
1st speed clutch piston return spring
Clutch output shaft
Low/3rd speed planetary gear carrier

32-15
115ZV-2 Function & Structure Torque Converter and Transmission Group
Power Flow Path in the Transmission

Power Flow Path in the Transmission


Forward 1st speed power flow path
Low range
clutch

22

1st speed clutch

33

18

Inlet of low
range clutch oil

17

31

Input power

Inlet of 1st speed


clutch oil

34
32

Output power

26

24 23 35

29

When first speed forward is selected by the operator or


the computer, oil is sent from the modulator valve to the
low range clutch and the 1st speed clutch. When the
clutch plates are pressed by low range clutch piston
(17), low range ring gear (19) is locked to the housing
by anchor pins (15). The torque converter rotates low
range sun gear (20) via clutch input shaft (1). This
causes low range planetary gears (18) to rotate around
sun gear (20) while rotating on their own axis. This
forces the carrier to rotate. Since the low range planetary carrier and 3rd speed planetary carrier (35) are one
piece, 3rd speed planetary gears (22) also rotate
around sun gear.

Sun gear (20)

Low range ring gear (19)

Low range planetary gear (18)


95ZV32006

20

15

19

K115V2J32007

When the 1st speed clutch is engaged, drop gear (32),


1st speed clutch gear (26), 3rd speed ring gear (23), 3rd
speed sun gear (24), 2nd speed sun gear (29) and
clutch output shaft (34) form one unit.
As a result, the rotation of 3rd speed planetary gear (22)
around sun gear is output as the rotation of drop gear
(32).

3rd speed planetary gear (22)


(does not rotate on its own axis)

3rd speed ring gear (23) and clutch


output shaft (34) form one unit

95ZV32007

The low range planetary decreases the speed of the


input shaft but increases torque. The first speed clutch
is used to directly transmit this high torque-low speed to
the output shaft.

32-16
Function & Structure Torque Converter and Transmission Group
Power Flow Path in the Transmission

Forward 2nd speed power flow path


2nd speed
clutch oil Low range Low range clutch oil
clutch
2nd speed clutch

Input power

Output power
115V2E32011

Forward 3rd speed power flow path

3rd speed clutch

3rd speed
clutch oil Low range Low range clutch oil
clutch
Input power

Output power

115V2E32012

32-17
115ZV-2 Function & Structure Torque Converter and Transmission Group
Power Flow Path in the Transmission

Forward 4th speed power flow path


2nd speed clutch oil

High range clutch

2nd speed clutch

Input power

High range clutch oil

Output power
115V2E32013

Reverse 1st speed power flow path


Reverse clutch oil
1st speed clutch

Reverse clutch

Input power

1st speed clutch oil

Output power

115V2E32014

32-18
Function & Structure Torque Converter and Transmission Group
Power Flow Path in the Transmission

Reverse 2nd speed power flow path


2nd speed clutch oil

Reverse
clutch oil

2nd speed clutch

Reverse clutch
Input power

Output power

115V2E32015

Reverse 3rd speed power flow path


3rd speed Reverse
3rd speed clutch oil clutch
clutch oil Reverse clutch
Input power

Output power
115V2E32016

32-19
115ZV-2 Function & Structure Torque Converter and Transmission Group
Hydraulic System Diagram

Hydraulic System Diagram


Note
Numbers below correspond to page 32-20.

Option

LU

Shift lever

35

MCU

32

34

33

36

10

24

22
25

14
23

20

18
15

19

16
21

8
11

30

29

13

26
27
28
31

2
1

115V2E32017

17

32-20
Function & Structure Torque Converter and Transmission Group
Hydraulic Circuit Diagram

Hydraulic Circuit Diagram


Neutral position

(T/M type: PS400D02-S/N 0101~


PS400D03-S/N 0101~)

Limit switch

PMa PMb
Dr (T/M side)

11
32

29

P1

21

33

12

44cc
0.1 - 0.58 MPa
(1 - 5.9 kgf/cm2)
(14 - 84 psi)

44cc
0.1 - 0.58 MPa
(1 - 5.9 kgf/cm2)
(14 - 84 psi)

20

36

1st
175cc

Option

35
PR

27

17

16

ACC2

PH

15

13

Dr (T/M side)
ACC1

P3

P2

220cc

26

T/C
T

14

PG

10

0.007 MPa
(0.07 kgf/cm2)
(0.1 psi)

H
75cc

28

PF

19

0.39 ~ 2.65 MPa


(4 ~ 27 kgf/cm2)
(56.8 ~ 384 psi)

18
PG

Dr (T/M side)
P4

L
150cc

P2

30

23

PG

22

30L/min

4.0
0.88 MPa
(9 kgf/cm2)
(128 psi)

2nd
113cc

P3

31

25

P5

34
24

PG
Dr (T/M side)

PM

P1

PG

Dr (T/M side)

3rd
113cc

4
Clutch valve
assembly

Clutch solenoid
valve assembly

Modulator valve unit

Modulator valve unit


Direct charge
valve

Lock-up clutch
solenoid valve

100.4
cc/rev

3
1

Clutch solenoid
valve assembly
Clutch valve
assembly

K115V2U32002

32-21
115ZV-2 Function & Structure Torque Converter and Transmission Group
Hydraulic Circuit Diagram

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.

Transmission oil pan


Strainer
Torque converter gear pump
Line filter with bypass valve
Clutch pressure regulator valve
Proportional relief valve
Priority valve
T/C inlet relief valve
Check valve (1)
Check valve (2)
Torque converter
T/C outlet relief valve
Oil cooler
High range clutch solenoid valve
High range clutch valve
Reverse clutch solenoid valve
Reverse clutch valve
Low range clutch solenoid valve

Note
The orifice in the clutch valve 17, 19 and 23 is to reduce
shock at clutch engagement.

19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.

Low range clutch valve


1st speed clutch solenoid valve
1st speed clutch valve
2nd speed clutch solenoid valve
2nd speed clutch valve
3rd speed clutch solenoid valve
3rd speed clutch valve
High range clutch
Reverse clutch
Low range clutch
1st speed clutch
2nd speed clutch
3rd speed clutch
Accumulator (for Reverse, 1st clutch valve)
Accumulator (for High, Low, 2nd, 3rd clutch valve)
Direct charge valve
Lock-up clutch solenoid valve (option)
Torque converter (lock-up clutch) (option)

32-22
Function & Structure Torque Converter and Transmission Group
Oil Flow

Oil Flow
Oil flow in the torque converter
line
From torque converter gear pump to torque
converter
The oil discharged from torque converter gear pump (3)
goes through line filter (4) into priority valve (7). Priority
valve (7) will transfer the specified amount (30 L/min) of
the oil to the clutch circuit, and the rest amount of the oil
will be supplied to torque converter (11).
When the input pressure at torque converter (11) inlet
exceeds 0.9 MPa (9 kgf/cm2) (128 psi), torque converter
inlet relief valve (8) automatically opens to release the
excessive pressure to the cooler line.

From torque converter to cooling circuit


Return oil from the torque converter flows through outlet
relief valve (12) (set pressure = 0.3 MPa (3 kgf/cm2)
(42.7 psi)) in the torque converter housing and to torque
converter cooler (13).

From cooler to lubrication circuit


Oil cooled in the cooler flows to the lubrication paths in
the transmission. This lubricates and cools each bearing and the clutch plates, and then drops into the oil
pan.

Oil flow in the transmission line


From torque converter gear pump to clutch
solenoid valve assembly
The clutch solenoid valve consists of the solenoid
valves for the forward and backward driving gears and
the shift gears. By the specific shift operation, the clutch
solenoid valve is activated to send the pressure oil to
the clutch valve as the pilot pressure.

From clutch solenoid valve to clutch valve


assembly
The pilot pressure sent from the clutch solenoid valve
moves the spool to open the hydraulic line in the clutch
valve. The pressure-adjusted oil by proportional relief
valve (6) will go through the specified clutch valve, and
filled in the clutch piston chamber to complete the clutch
engagement.

From torque converter gear pump to lockup clutch (option)


The oil sent from torque converter gear pump (3) is
transferred through line filter (4) and priority valve (7) to
lock-up solenoid valve (35). When the machine speed
reaches the preset level, the MCU sends the signal activating solenoid valve (35) to open the hydraulic line.
The pressure-adjusted oil by proportional relief valve (6)
will be filled in lock-up clutch piston chamber (36) to
engage the lock-up clutch.

32-23
115ZV-2 Function & Structure Torque Converter and Transmission Group
Oil Flow

From accumulator to clutch valve

From direct charge valve to clutch valve

Refer to "Hydraulic Circuit Diagram" page 32-20.

This valve is to supply the hydraulic pressure to the


clutch valve subsidiarily, in case it is short depending on
the selected shift gear, in order to keep the potential
time lag at clutch engagement.

Two accumulators (32)(33) are installed between proportional relief valve (6) and the clutch valve assembly.
One (32) is for the reverse clutch and the 1st speed
clutch. The other (33) is for the high range clutch, low
range clutch, 2nd speed clutch and 3rd clutch.
- Initial oil charging into clutch piston chamber
In order to make the initial oil charging into the clutch
piston chamber quickly, the accumulated oil (0.58
MPa (5.9 kgf/cm2) (84 psi)) in the accumulator is
supplied to the clutch piston chamber first.
- Accumulator filling
Torque converter gear pump (3) supplies the oil to
the clutch piston chamber and the accumulator
simultaneously. Torque converter gear pump (3) continues to fill the oil into the accumulator and it also
increases the oil pressure in the clutch piston chamber gradually.

Limit switch
The limit switch is built-in the accumulator, and is turned
ON when the accumulator is fully filled up with the pressure oil.
When the limit switch is turned ON, the MCU determines the pressurization and starts gradually increasing
the pressurizing current to proportional relief valve (6).

The hydraulic pressure is supplied from the torque converter gear pump to direct charge valve (34) through P1
port, and then, directly supplied to the clutch valve by
switching the solenoid valve without going through the
modulator valve.
Direct charge valve solenoid valve (34) is closely controlled by the signals from the MCU.

32-24
Function & Structure Torque Converter and Transmission Group
T/C and T/M Oil Circulation

T/C and T/M Oil Circulation


Radiator

Torque converter
oil cooler

Engine

Modulator
valve unit
Torque converter
Transmission
oil filter
Clutch solenoid
valve assembly
Clutch valve
assembly
Transmission

115V2E32019

32-25
115ZV-2 Function & Structure Torque Converter and Transmission Group
Modulator Valve Unit

Modulator Valve Unit


T/M type:
PS400D01 - S/N 0101~0126
8

5
(P4)

9
10
(P2)

Orifice
1.0

10
(Acc2)

Orifice
3.0

(Acc1)
(P3)

(P)
(PM)

(P1)

8
(P5)

5
115V2E32020

Numbers below also correspond to page 32-20.


1.
2.
3.
4.
5. Clutch pressure regulator valve

6.
7.
8.
9.
10.

Proportional relief valve


Priority valve
T/C inlet relief valve
Check valve (1)
Check valve (2)

32-26
Function & Structure Torque Converter and Transmission Group
Modulator Valve Unit
T/M type:
PS400D01 - S/N 0127~
PS400D02 - S/N 0101~
PS400D03 - S/N 0101~
8

5
(P4)

9
10
(P2)

Orifice
1.0

10
(Acc2)

Orifice
3.0

(Acc1)
(P3)

(P)
(PM)

(P1)

8
(P5)

5
115V2E32035

Numbers below also correspond to page 32-20.


1.
2.
3.
4.
5. Clutch pressure regulator valve

6.
7.
8.
9.
10.

Proportional relief valve


Priority valve
T/C inlet relief valve
Check valve (1)
Check valve (2)

32-27
115ZV-2 Function & Structure Torque Converter and Transmission Group
Modulator Valve Unit

Interior schematic (not exact representation)


From direct
charge valve
PG

To clutch
valve

ACC2

To lock-up clutch
solenoid valve
(opt)
ACC1

10 5

Relief
valve

P3

Drain

8
P1

P2

P5

To clutch From To Drain


solenoid pump T/C
valve
To direct
charge valve

P4

To T/C
To T/M
lubrication cooling
line
line
ACC2

6
To T/C
P3

ACC1

Drain

P2

10

PG

Numbers below also correspond to page 32-20.


1.
2.
3.
4.
5. Clutch pressure regulator valve
From direct
6. Proportional relief valve
charge valve PG
7. Priority valve
8. T/C inlet relief valve
PG
9. Check valve (1)
10. Check valve (2)

0.007 MPa
(0.07 kgf/cm2)
(0.1 psi)

0.39 - 2.65 MPa


(4 - 27 kgf/cm2)
(56.8 - 384 psi)
P4

To T/C
return line

8
30L/min
0.88 MPa
(9 kgf/cm2)
(128 psi)

Drain (T/M side)

Drain
(T/M side)

PG

PM

P1

PG

T/M solenoid From T/C


valve
gear pump

To T/M
lubrication
P5
line

Drain (T/M side)


115V2E32021

32-28
Function & Structure Torque Converter and Transmission Group
Modulator Valve Unit

Modulation Mechanism
When changing direction or speed, the modulation
mechanism works to reduce the time required for clutch
engagement (time lag). This prevents the shock at
clutch engagement, improves the work efficiency and
durability of the power system, and to ensures the operator's comfort.

Modulator valve function


From direct
To clutch
charge valve valve

To lock-up clutch Clutch pressure


solenoid valve
regulator valve

Drain

The modulation mechanism controls the clutch oil pressure rising time as follows.
P

For information on the MCU refer to section "Electrical


Group".

F
f

To T/C
To clutch From To Drain To T/M
Drain
Proportional
lubrication cooling
solenoid pump T/C
relief valve
line
line
valve
Modulator valve 115V2E32022

The modulator valve is a solenoid-operated proportional


relief valve. Downward magnetic force (F) acts on the
top of the spool in proportion to the amount of current
applied to the coil.
The bottom of the spool is acted upon by the upward
hydraulic force (f). When this upward force (f) and magnetic force (F) are in balance, the spool is stationary,
which generates the specified pressure at port P.
The hydraulic force adjusted by proportional relief valve
acts on the left end of the clutch pressure regulator
valve, and so the hydraulic force from the torque converter gear pump to the clutch is also controlled by the
proportional relief valve.
In other words, when the control pressure from the proportional relief valve is low, oil from the pump easily
moves the clutch pressure regulator valve to the right
end and relieves the oil to the torque converter oil cooler
circuit, reducing clutch oil pressure.
The relief valve (2.65 MPa (27 kgf/cm2) (384 psi)) is
installed inside of the clutch oil pressure regulator valve.

32-29
115ZV-2 Function & Structure Torque Converter and Transmission Group
Modulator Valve Unit

Modulator valve operation

Initial oil charging (t1) into the clutch piston


chamber
When the shift lever is shifted from the neutral to the 1st
speed forward, the low range clutch solenoid valve is
energized and oil in the accumulator flows into the
empty clutch piston chamber first.

Modulation chart (Neutral1st forward)


ON

Then oil under pressure flows into the clutch piston


chamber. After a given time, the control current to the
modulator valve is reduced. Accordingly the main clutch
oil pressure is reduced, concluding the initial oil charging into the clutch chamber.

Low range clutch OFF


solenoid valve
ON

1st speed clutch


solenoid valve

Modulator
valve

Oil filling completed Engagement


(clutch) (Acc.)
completed

The time taken for this initial charging, which depends


on the capacity of the clutch piston chamber, is controlled by a MCU.

Current
(mA)

Clutch piston chamber filling (t2)

Main
pressure

Pressure
MPa
(kgf/cm2)
(psi)

Low range
clutch
Pressure
pressure
MPa
(kgf/cm2)
(psi)

P1

P2

The holding pressure in this time depends on the speed


of the engine: lower pressure with lower engine speed,
higher pressure with higher engine speed.
0

This time is also controlled by the MCU.

t2
t1

t3

When shifted

t4

Shift completed

115V2E32023

t1

Initial charging
time

Changes with combination of


clutches

0~0.12 sec

t2

Low pressure
holding time

Changes with engine speed

Less than
0.5 sec

t3

Pressure rise
time

Changes with combination of


clutches

0.3~0.7 sec

t4

Restoration time

Changes with combination of


clutches

0.5~1.3 sec

P1

0.5~1.5 MPa (6~15 kgf/cm2) (85~213 psi)

P2

2.6~2.9 MPa (27~30 kgf/cm2) (384~427 psi)

- E/G high idle

To reduce clutch engagement shock, it is necessary to


engage the clutch while allowing some slippage of it. To
do this, the current to the modulator valve is held low for
a given time. The torque converter gear pump fills the
oil both into the accumulator and into the clutch piston
chamber. During this time, the clutch piston moves
while compressing the piston return spring.

Accumulator filling (t3)


The pump continues to fill the oil into the accumulator.
At the same time the clutch oil pressure is raised slowly.
This prevents the clutch engagement shock caused by
a rapid pressure rise.

32-30
Function & Structure Torque Converter and Transmission Group
Modulator Valve Unit

Pressure rise (t4)


Since the accumulator is completely accumulated at the
start point of t4, the limit switch is turned ON, sending
the signal to the MCU. At that point, the clutch piston
comes into contact with the clutch plate and the clutch
plates start to transmit power. The MCU recognizes that
the accumulator is at the full accumulation by this signal, and gradually increases the driving current to the
modulator valve.
Then the hydraulic pressure for the clutch will consequently increases to complete the clutch engagement.

32-31
115ZV-2 Function & Structure Torque Converter and Transmission Group
Control Valve Assembly

Control Valve Assembly


T/M type:
PS400D01 - S/N 0101~
Valve location

Torque converter
Transmission

1
2

1st propeller shaft

115V2E32025

1.
2.
3.
4.
5.

Clutch solenoid valve assembly


Clutch valve assembly
Accumulator assembly
Direct charge valve
Lock-up clutch solenoid valve (option)

32-32
Function & Structure Torque Converter and Transmission Group
Control Valve Assembly
T/M type:
PS400D02 - S/N 0101~
PS400D03 - S/N 0101~
Valve location

Torque converter
Transmission

1
2

1st propeller shaft

115V2E32036

1.
2.
3.
4.
5.

Clutch solenoid valve assembly


Clutch valve assembly
Accumulator assembly
Direct charge valve
Lock-up clutch solenoid valve (option)

32-33
115ZV-2 Function & Structure Torque Converter and Transmission Group
Control Valve Assembly

Clutch solenoid valve assembly


T/M type:
PS400D01 - S/N 0101~
PS400D02 - S/N 0101~
5
P3

2
PL

PH

P2

2nd

A
P1

PR

P3~PR

T
H

3rd

1st
P

A-A

A
P

P3

3rd

T
P2
2nd
T
PH
H
T
PL
L
T
P1
1st
T
PR
R
T

Hydraulic Diagram
115V2E32037

1.
2.
3.
4.
5.
6.

High range clutch solenoid valve


Low range clutch solenoid valve
Reverse clutch solenoid valve
1st speed clutch solenoid valve
2nd speed clutch solenoid valve
3rd speed clutch solenoid valve

32-34
Function & Structure Torque Converter and Transmission Group
Control Valve Assembly
T/M type:
PS400D03 - S/N 0101~
5
P3

2
PL

PH

P2

2nd

P1

PR

P3~PR

T
3rd

1st

H
P

A-A

A
P
3rd

P3

T
P2
2nd
T
PH
H
T
PL
L
T
P1
1st
T
PR
R
T

Hydraulic Diagram
K115V2U32001

1.
2.
3.
4.
5.
6.

High range clutch solenoid valve


Low range clutch solenoid valve
Reverse clutch solenoid valve
1st speed clutch solenoid valve
2nd speed clutch solenoid valve
3rd speed clutch solenoid valve

32-35
115ZV-2 Function & Structure Torque Converter and Transmission Group
Control Valve Assembly

For high, low, reverse and speed clutches


After power-off (clutch disengaged status)
5 4
Modulator
valve

A
Transmission
C
oil pan

B
Clutch valve

3
80ZVE32026

1. Coil
2. Plunger
3. Push rod

4. Spring
5. Spool
6. Manual control push button

Under such a condition, pressing manual control push


button (6) (for emergency) opens the line between port
A and B, and engages the clutch.
Releasing the manual control push button returns spool
(5) fully to the right, and disengages the clutch.

When the power of the coil is turned off, spool (5), push
rod (3), and plunger (2) are returned fully to the right,
and the line from port A to port B is closed. The line
between port B and C is opened, and the clutch is disengaged.
After power-on (Clutch engaged status)

Modulator
valve

A
Transmission
C
oil pan

B
Clutch valve

3
115V2E32033

When the power is supplied to the coil, the magnetic


power attracts the plunger (2) to the left, and the line
between port A and B is opened. Pressure oil flows into
the clutch valve.

32-36
Function & Structure Torque Converter and Transmission Group
Control Valve Assembly

Clutch valve assembly

P3

P2

PH

PL

P1

PR

PM

PM

PM

PM

PM

PM

PC

PC

PC

PC

PC

PC

From clutch
solenoid valve
(P2, PL, PR)

From clutch
solenoid valve
(P3, PH, P1)

Orifice

PM

PM

PC

PC

T1

T1

A-A

B-B

3
T1

PC
T1

PC
T1

PC
T1

PC
T1

PC
T1

PC

T
PM
PR
T
PM
P1
T
PM
PL
T
PM
PH
T
PM
P2
T
PM
P3

Hydraulic Diagram

1.
2.
3.
4.
5.
6.

High range clutch valve


Low range clutch valve
Reverse clutch valve
1st speed clutch valve
2nd speed clutch valve
3rd speed clutch valve

K115V2J32013

32-37
115ZV-2 Function & Structure Torque Converter and Transmission Group
Control Valve Assembly

Accumulator assembly

1st, reverse clutch, ACC1

High, low, 2nd,


3rd clutch

From ACC2

9
Drain
115V2E32029

Accumulator structure

4
PC

45.5

60.5

D4

Stroke
28.3
115V2E32030

1.
2.
3.
4.
5.
6.
7.
8.
9.

Tube
Piston
Rod cover
Spring
U-packing
O-ring
Wear ring
Socket bolt
Limit switch

Operating pressure

0.1~0.58 MPa (1~5.9 kgf/cm2) (14~84 psi)

32-38
Function & Structure Torque Converter and Transmission Group
Control Valve Assembly

Direct charge valve

To clutch valve

P
P
4.0 mm

PA

From torque
converter gear
pump

PA
Hydraulic Diagram

PA

PA
From T/C
gear pump

P
Solenoid power OFF

P
To clutch valve
Solenoid power ON
115V2E32031

1. Direct charge solenoid valve


2. Plug (Orifice: 4.0 mm)

32-39
115ZV-2 Function & Structure Torque Converter and Transmission Group
Control Valve Assembly

Lock-up clutch solenoid valve

Lock-up solenoid valve

From modulator valve


To lock-up clutch

T
Drain (T/M side)

Hydraulic Diagram

Transmission
oil pan

Lock-up clutch

Lock-up clutch

Transmission
oil pan

Modulator
valve unit

Modulator
valve unit

Solenoid power OFF

Solenoid power ON

115V2E32032

32-40
Function & Structure Torque Converter and Transmission Group

MEMO

33-1
115ZV-2 Check & Adjustment Torque Converter and Transmission Group

Check & Adjustment


Torque Converter and Transmission Group
Clutch Oil Pressure and Time Lag .......................... 33-2

33-2
Check & Adjustment Torque Converter and Transmission Group
Clutch Oil Pressure and Time Lag

Clutch Oil Pressure and Time Lag


Measuring clutch oil pressure
WARNING
Unexpected movement of the machine may cause an
accident resulting in injury or death.
Therefore, to provide repair service with the engine
running, be sure to observe the following items:
- Park the machine on level ground.
- Apply the parking brake.
- Block the tires with chocks to prevent the tires from
moving.
- Determine the signals between the service man.
- Prohibit any person from walking into dangerous
areas.
- Near articulation areas of the machine
- Under the machine
- Around the engine
- In front of or behind the machine

Gauge port
1. Location:
T/M type: PS400D01 - S/N 0101~
Main clutch

Transmission
Torque converter

Reverse clutch
1st clutch
Low range clutch
High range clutch
2nd clutch
3rd clutch
Lock-up clutch

Measurement instrument
- Pressure gauge
- Tachometer (MODM)
- Stop watch
Transmission oil pressure test port location

115V2E33001

33-3
115ZV-2 Check & Adjustment Torque Converter and Transmission Group
Clutch Oil Pressure and Time Lag

Clutch oil pressure measurement procedure

T/M type: PS400D02 - S/N 0101~


PS400D03 - S/N 0101~
Main clutch

Standard measurement value


Main pressure
(engine speed)

Transmission

Reverse clutch
1st clutch
Low range clutch
High range clutch
2nd clutch
3rd clutch

Lock-up clutch

Clutch pressure
(engine speed)

Idling (LI)

2.60.2 MPa
(272 kgf/cm2) (38428 psi)

Maximum (HI)

2.60.2 MPa
(272 kgf/cm2) (38428 psi)

Idling (LI)

2.50.2 MPa
(262 kgf/cm2) (37028 psi)

Maximum (HI)

2.50.2 MPa
(262 kgf/cm2) (37028 psi)

1. Press the brake pedal, and set and confirm the


transmission shift lever is at the neutral position.
2. Set and confirm the parking brake is at the "ON"
position.
3. Press the brake pedal, and lower the bucket onto
the ground.
4. Stop the engine.

Torque converter

Transmission oil pressure test port location

K115V2E33001

2. Measuring port: PF 1/4


3. Oil pressure gauge: 5 MPa (50 kgf/cm2) (1,000 psi)
with 2~3 m (6~10 ft.) hose
Note
Warm-up the engine before measuring the clutch oil
pressure and time lag

5. Attach the pressure gauge to the pressure measurement port. Place the gauge inside the operator's area, and start the engine.
6. As the clutch oil pressure rises just after the engine
is started, keep the engine at low-idling before the
pressure measurement.
7. Measure and record the pressure in each speed
range.
8. Set the declutch ON/OFF switch to ON.
Press down the brake pedal all the way to the floor
to avoid the fuel saving mode at idle time.
Note
In the fuel saving mode at idle time, the engine is not
activated promptly and may not reach the maximum
revolution.
9. As the clutch oil pressure rises just after the engine
is started, adjust the engine at high-idling before
the pressure measurement.

33-4
Check & Adjustment Torque Converter and Transmission Group
Clutch Oil Pressure and Time Lag
10. Measure and record the pressure in each speed
range.
Note
Change the transmission speed range while keeping
the shift lever at the neutral position. Check that the
pressure instantaneously lowers just after speed
change, and then rises to the original pressure again.

Possible causes for low clutch pressure


Possible cause
Malfunctioning modulator valve operation
Defective MCU
Oil leakage from clutch

Solution
Inspection &
repair
Replacement

Time lag measurement procedure

WARNING
Unexpected movement of the machine may cause an
accident resulting in injury or death.
To crawl under the machine, be sure to stop the
engine, and block the tires with chocks to prevent
them from moving. Give signals to the person in the
cab during the work.

Standard measurement value


Clutch time lag (sec)

Disassembly &
repair

Neutral1st forward speed


(engine speed: 1,500 min-1
(rpm))

0.30.1

1. Press the brake pedal, and set and confirm the


transmission shift lever is at the neutral position.
2. Set and confirm the parking brake is at the "ON"
position.
3. Press the brake pedal.
4. Lower the boom to the lowest limit, and fully roll
back the bucket until the bucket contacts to the
stopper.
5. Set the parking brake switch to the "OFF" position.
Do not apply the service brakes.
6. Set the transmission shift lever to the neutral 1st
speed.
7. Keep the engine speed at 1,500 min-1 (rpm).
8. Move the shift lever to the forward position. At the
same time, start the stop watch to measure the
time required before the machine moves.

Possible causes for clutch time lag


Possible cause

Solution

Defective accumulator limit switch

Replacement

Malfunctioning modulator valve operation

Inspection &
repair

Defective MCU

Replacement

Defective clutch

Disassembly &
repair

42-1
115ZV-2 Function & Structure Hydraulic Group

Function & Structure


Hydraulic Group
Flushing Hydraulic Circuit........................................ 42-2
Cautions on Hydraulic Parts Replacement.............. 42-3
Hydraulic Circuit Symbols ....................................... 42-4
Hydraulic System Operation.................................... 42-8
Layout of Hydraulic Units ........................................ 42-10
Hydraulic Tank......................................................... 42-11
Hydraulic Pump ....................................................... 42-15
Hydraulic Cylinder ................................................... 42-19
Loading System ...................................................... 42-22
Reducing Valve (for Pilot Pressure) ........................ 42-23
Pilot Valve................................................................ 42-24
Multiple Control Valve (KML35A/2T103) ................. 42-29
Adapter (Orifice) ...................................................... 42-40
Ride Control (OPT).................................................. 42-41
Steering System ...................................................... 42-51
Orbitrol ................................................................... 42-52
Steering Valve (KVS32-A4.0/21) ............................. 42-59
Stop Valve ............................................................... 42-71
Reducing Valve (for Orbitrol) ................................. 42-73
Steering Line Filter .................................................. 42-74
Efficient Loading System......................................... 42-75
Fan Motor System ................................................... 42-79
Fan Motor Line ........................................................ 42-80
Reversing Fan Motor Line (OPT) ............................ 42-91
Secondary Steering ................................................. 42-96

42-2
Function & Structure Hydraulic Group
Flushing Hydraulic Circuit

Flushing Hydraulic Circuit


Purpose of flushing

Debris
To tank

95ZV42001

If the inside of a cylinder, pump, or a valve of the


hydraulic system is broken, the debris will be sent into
the hydraulic line together with the oil. Most of the
debris will flow into the return filter or hydraulic tank.
However, there are some debris that will remain in the
valves, cylinders, or pipes. Therefore, even if the damaged cylinder or valve is replaced, the debris sticking in
other valves, cylinders, or pipes will break loose and
then is fed into the cylinders, where the debris may
damage the inside of the cylinders, or stick into the
valve spools, reducing valves, or relief valves, and
cause another malfunction. To prevent such problems,
be sure to remove all the debris from the system.

42-3
115ZV-2 Function & Structure Hydraulic Group
Cautions on Hydraulic Parts Replacement

Cautions on Hydraulic Parts Replacement


After oil or a part is replaced, malfunction or seizure
may occur during running-in. Such trouble is often
caused by faulty air bleeding or lubrication after replacement.
After replacing oil or a part, be sure to observe the following work procedure to prevent occurrence of trouble.
Work procedure
1. In the case of new oil pump, lubricate its inside with
new oil prior to installation, and confirm that it can
be turned smoothly by hand.
2. After the oil pump or cylinder was made empty for
oil replacement, repair, etc., restart the operation as
follows.
(a) Before installing pipes, pour new oil into the pump
or the cylinder.
(b) Operate the engine at low-idling speed for 5 minutes or more. Do not operate any hydraulic functions during this period.
(c) While keeping the engine at low-idling speed, move
each cylinder 5 times or more respectively.
At this time,
- Move each cylinder to a place near the
stroke end so that hydraulic pressure does
not go over relief.
- Lower the boom slowly. Dump the bucket
slowly. Do not activate the make up valves
from rapid activation of circuits.
(d) Perform general operations, and confirm that
abnormal sound, heat generation and any other
abnormality is not detected.
(e) Observe the hydraulic oil level sight gauge and
confirm that there are no bubbles in the hydraulic
oil.

42-4
Function & Structure Hydraulic Group
Hydraulic Circuit Symbols

Hydraulic Circuit Symbols


Hydraulic lines

Pumps & motors


(1)

Working hydraulic
line

Fixed
displacement,
Hydraulic pump
(1) Unidirectional
(2) Bidirectional

Pilot line
Drain line

Variable
displacement,
Non-compensating
hydraulic pump
(1) Unidirectional
(2) Bidirectional

Lines joining

Flexible line

Fixed
displacement,
Rotary hydraulic
motor
(1) Unidirectional
(2) Bidirectional

Lines passing

Line to tank
(Above fluid level)

Line to tank
(Below fluid level)

Variable
displacement,
Rotary hydraulic
motor
(1) Unidirectional
(2) Bidirectional

Hydraulic tank
(Pressurized type)

Fixed restriction

(2)

(1)

(2)

(1)

(2)

(1)

(2)

Cylinders
(1)

Rotary joint
(1) one line
(Unidirectional)
(2) three line
(Bidirectional)

(2)

Single acting
cylinder
(without spring)

Single acting
cylinder
(with spring)

Double acting
cylinder
(single rod)

Double acting
cylinder
(double rod)
(1) detail symbol
(2) mnemonic symbol

(1)

(2)

(1)

(2)

(1)

(2)

(1)

(2)

42-5
115ZV-2 Function & Structure Hydraulic Group
Hydraulic Circuit Symbols

Operation methods

Pressure control valve

Spring

Single flow path


valve,
Normally closed

Adjustable spring

Single flow path


valve,
Normally open

Control methods
Pressure relief
valve

Lever

Push button
Unloading valve
Pedal or treadle
Mechanical control

Sequence valve

Plunger

Pressure reducing
valve

Spring
Solenoid control
Single acting
solenoid

Flow control valve

Double acting
solenoid

Flow control valve,


Adjustable noncompensated

Electric motor
control
Unidirectional

Pressure
compensated flow
control valve
fixed

Bidirectional

M
variable

Detent
Flow dividing valve

42-6
Function & Structure Hydraulic Group
Hydraulic Circuit Symbols

Directional control valve

Check valve

Two position
Two ports

Check valve

Three position
Four ports

Check valve
Pilot operated

Four ports with


restrictor

Shuttle valve

Two position
Two ports
Mechanical
control
Spring offset
Pressure
control
Two position
Three ports
Pressure control

Spring offset
Solenoid
control
Restrictor
Two ports

Three ports

Four ports

Servo valve

42-7
115ZV-2 Function & Structure Hydraulic Group
Hydraulic Circuit Symbols

Miscellaneous hydraulic symbols


(1)
Hydraulic tank
(1) Vented
(2) Pressurized

(2)

Manual shut off


valve

Pressure switch

Accumulator

Electric motor

Internal
combustion

Power source

Filter or strainer

Heater

Cooler

Pressure gauge

Temperature
gauge

Flow meter

42-8
Function & Structure Hydraulic Group
Hydraulic System Operation

Hydraulic System Operation


Hydraulic system operation outline
The hydraulic system consists of the following systems:
- Loading system
- Steering system
- Efficient loading system
- Fan motor system
- Ride control system (OPT)

Return oil from the cylinders flows through the valve to


the oil cooler, return filter (12) and into the hydraulic
tank.
Even if no hydraulic pump supplies oil to the loading
and pilot control circuits due to trouble, or if the engine
is shut off, the boom can be lowered to the ground by
the pressure in accumulator (33) in the brake circuit in
case of an emergency.

Steering system
The steering system consists of the following components.

Loading system
The loading system consists of the following components. All numbers base on page 92-4.
-

Hydraulic pump (2)


Unloader valve (22)
Line filter (81)
Check valve (32)
Reducing valve (38)
Pilot valve (16)
Multiple control valve (3)
Boom cylinders (5)
Bucket cylinders (6)

Oil from pump (2) flows to pilot valve (16) through


unloader valve (22), line filter (81), check valve (32) and
reducing valve (38). Oil to pilot valve (16) is reduced to
3.5 MPa (36 kgf/cm2) (512 psi) by reducing valve (38).
When the pilot control lever is operated, the pilot valve
line is opened, and the oil pressure is generated
depending on the position of the pilot control lever.
The pilot pressure entering the oil pack to multiple control valve (3) moves the spool against its return spring.
The spool press-in distance (displacement) depends on
the pilot valve pressure.
Oil from the loader pump is then directed through multiple control valve (3) to boom cylinders (5) and bucket
cylinders (6).

Hydraulic pump (1)


Steering valve (4)
Line filter (81)
Reducing valve (18)
Orbitrol (14)
Stop valve (15)
Steering cylinder (8)

Oil from pump (1) flows to Orbitrol (14) through steering valve (4), line filter (81) and reducing valve (18). Oil
to Orbitrol (14) is reduced to 3.5 MPa (36 kgf/cm2) (512
psi) by reducing valve (18).
A small amount of pilot oil supplied from Orbitrol (14)
controls steering valve (4) to realize steering operations.
When the steering wheel is turned, oil at a flow rate proportional to the turning speed is sent from Orbitrol (14)
and supplied to the oil pack of steering valve (4).
At this time, the pilot pressure is generated. The pilot
pressure strokes the spool of steering valve (4), and
supplies hydraulic oil at large flow rate proportional to
the flow rate of the supplied pilot oil to the cylinder line.
The excessive pilot oil flows through steering valve (4)
to the other side of the pilot port.
Stop valves (15) are used in the circuit to stop the flow
of oil from Orbitrol (14) to steering valve (4) when the
machine reaches full turn.

42-9
115ZV-2 Function & Structure Hydraulic Group
Hydraulic System Operation
When the steering wheel is not turned, the flow control
spool built in steering valve (4) supplies almost all
amount of the hydraulic oil fed from steering pump (1) to
the loading circuit.
Oil returns from steering cylinders (8) flows through
steering valve (4) and oil cooler or cooler bypass valve
(11).
Finally it returns to the tank through return filter (12).

Efficient loading system


The efficient loading system consists of the following
components.
-

Hydraulic pump (2)


Pressure sensor (49)
Relief valve (62)
Check valve (63)
Solenoid valve (64)

When the ELS switch is turned off, the oil discharged


from the switch pump (hydraulic pump (1)) flow into
steering valve (4) P port. When the steering wheel is not
turned, this oil is discharged from steering valve (4) P.B.
port.
On the other hand, the oil discharged from the main
pump (front pump of (2)) opens the check valve,
because cracking pressure of check valve (63) is less
than the setting pressure of relief valve (62).
The oil from switch pump and main pump are joined
together and flow into multiple control valve (3) P port.
When the ELS switch is turned on and the ELS operation condition set by the MCU is satisfied, solenoid valve
(64) in the ELS valve is energized and the spool is
moved.
Therefore, the oil discharged from the main pump (front
pump of (2)) opens relief valve (62) and all the hydraulic
oil from the main pump goes to the hydraulic tank.
But the oil from the steering valve P.B. port flow into
multiple control valve (3) P port.
Therefore when the ELS is operated, most of the engine
power is applied to the wheels to exert maximum driving
force by turning off the loading pump and reducing the
pump driving load on engine.

Fan motor system


The fan motor system consists of the following components.
-

Hydraulic pump (2)


Unloader valve (22)
Fan motor (71)
Proportional relief valve (72)

The cooling fan is driven by hydraulic motor (71). The


pressure oil from unloader valve (22) flows into the port
P of fan motor and then turns fan motor (71).
Three kinds of signals sent from the engine water temperature sensor (S/N 9001~9050), ECM (S/N 9051~),
torque converter oil temperature sensor, and hydraulic
oil temperature sensor, are input into the machine control unit (MCU) as information to regulate the maximum
fan revolution.
The fan revolution is regulated by proportional relief
valve (72). The setting pressure of the proportional relief
valve is changed in proportion as the engine revolution
and electric current value from MCU.

Ride control system (OPT)


Refer to "Ride Control (OPT)" page 42-41 for the information.

42-10
Function & Structure Hydraulic Group
Layout of Hydraulic Units

Layout of Hydraulic Units

10

15

17

16

12 3 16 4

11

18

14

13

115V2E42001

1.
2.
3.
4.
5.
6.
7.
8.
9.

Multiple control valve


Pilot valve
Pilot valve (for stick steering)
Steering valve
Hydraulic pump (for steering)
Hydraulic pump (for loading, for pilot and brake)
Fan motor
Proportional relief valve (for fan)
Bucket cylinder

10.
11.
12.
13.
14.
15.
16.
17.
18.

Boom cylinder
Steering cylinder
Reducing valve (steering pilot)
Reducing valve (loading pilot)
T/C line filter
ELS valve
Secondary steering pump
Stop valve
Torque converter pump

42-11
115ZV-2 Function & Structure Hydraulic Group
Hydraulic Tank

Hydraulic Tank
13

Viewed from top

10

8
7
A-A

13
A

A
Outside of
machine

As seen from
chassis out

To chassis

15,16

14

12

11

1.
2.
3.
4.
5.
6.
7.
8.

Hydraulic tank
Oil level gauge
Breather valve (tank cap)
Filter
Suction strainer (loading, pilot & brake)
Suction strainer (steering)
Return filter element
Filter bypass valve

: #16: 11.8 N-m (1.2 kgf-m) (8.7 lb-ft)


Dont use the air tool when fasten #16.

9.
10.
11.
12.
13.
14.
15.
16.

Spring
Cover
Drain plug
Inspection port
Vent pipe (to axle housing)
Temperature sensor
Oil level sensor
Flange bolt

115V2E42002

42-12
Function & Structure Hydraulic Group
Hydraulic Tank

Hydraulic tank breather valve


(tank cap)
1

4 5

a
b

1.
2.
3.
4.

Cover
Filter element
Spring (for exhaust valve)
Valve assembly
(a) Exhaust valve
(b) Suction valve
(c) Air bleeder valve
5. Spring (for suction valve)
6. Key (same as starter key)
7. Attaching bolts (3 pcs) socket head

Viewed from section A

70ZV42005

When the pressure inside the hydraulic tank drops


below the outside air pressure, the outside air flows
through filter element (2) and to valve assembly (4).
Suction valve (b) is then opened to let the air flow into
the tank.
When the air pressure inside the hydraulic tank rises to
a certain point 29 kPa (0.3 kgf/cm2) (4.3 psi), Exhaust
valve (a) is lifted (opened) so that the air can flow out of
the tank through filter element (2).
One cycle (down and up) of the boom applies pressure
to the inside of the tank.
Therefore 29 kPa (0.3 kgf/cm2) (4.3 psi) pressure is
always applied to the inside of the hydraulic tank.
The pressure applied to the inside of the hydraulic tank
prevents the dust and dirt from being drawn into the
tank and improves performance of the pump.
The positive pressure pushes the oil to the pump reducing the possibility of pump cavitation.
To release the internal pressure from the hydraulic tank,
press downward on cover (1). Air bleeder valve (c) will
be lowered to release the internal pressure.
The pressure is also applied to the axles.

Installing cap
The cap can be installed in any boom or bucket position.

42-13
115ZV-2 Function & Structure Hydraulic Group
Hydraulic Tank

Hydraulic tank specifications


Type

Semi-closed type

Capacity (at center of oil level sight gauge) L (gal)

225 (59 US gal)

Filtration area (cm2)

16,900 x 2

Filtration particle size (m)

Return filter

28
2

Relief valve opening pressure (filter bypass) (MPa) (kgf/cm ) (psi)


Loading
Pilot & brake
Suction strainer

Filtration area (cm )

2,550

Filtration particle size (m)

105

Steering

Filtration area (cm )

2,550

Filtration particle size (m)

105
2

Suction valve setting pressure (kPa) (kgf/cm ) (psi)


2

Discharge valve setting pressure (kPa) (kgf/cm ) (psi)


Breather valve (oil filling port)

0.10.02 (1.00.2) (142.8)

1 (0.01) (0.14)
29 (0.3) (4.3)

Filtration area (cm2)

235

Filtration particle size (m)

10

Pushing load before turning cap required for venting pressure,


removing or installing cap N (kgf) (lb)

186.2~215.6 (19~22) (42~48)

42-14
Function & Structure Hydraulic Group
Hydraulic Tank

Hydraulic oil level check

Bucket on ground

Hydraulic tank

(59 US gal)

225 L

Oil level sight gauge

115ZV42005

Before checking the hydraulic oil level, observe the following items:
- Check that the machine is on level ground.
- Check the hydraulic oil level before operation (when
oil is not warm).
- Lower the boom to the lowest limit, and set the
bucket level on the ground.
Check that the oil level is at the center of the oil level
sight gauge.
Oil amount
225 L (59 US gal)
Note
If the oil is at operating temperature 60C ~ 90C (140F
~ 200F) the oil level may be at or near the top of the oil
level sight gauge.

42-15
115ZV-2 Function & Structure Hydraulic Group
Hydraulic Pump

Hydraulic Pump
Loading and pilot and brake pump
5

2
6

7
115V2E42003

1.
2.
3.
4.

Drive gear (front)


Drive gear (rear)
Driven gear (front)
Driven gear (rear)

5. Oil seal
6. Bushing
7. Wear plate (floating type)

Pump specifications
Applicable circuit
Theoretical discharge
Maximum operation pressure
Maximum speed

cm3/rev
MPa (kgf/cm2) (psi)
min-1

Measurement conditions:
Oil temperature 50~80C (120~180F)
Hydraulic oil ISO VG46

Front

Rear

Loading circuit

Pilot & Brake circuit

100.4

71.3

20.60.5 (2105) (2,98671)

11.8 (120) (1,711)


2,500

42-16
Function & Structure Hydraulic Group
Hydraulic Pump

Steering pump
5

2
6

7
115V2E42004

1.
2.
3.
4.

Drive gear (front)


Drive gear (rear)
Driven gear (front)
Driven gear (rear)

5. Oil seal
6. Bushing
7. Wear plate (floating type)

Steering pump specifications


Front
Applicable circuit
Theoretical discharge
Maximum operation pressure
Maximum speed

Rear
Steering circuit

cm3/rev
MPa (kgf/cm2) (psi)
min-1

Measurement conditions:
Oil temperature 50~80C (120~180F)
Hydraulic oil ISO VG46

90.7
20.60.5 (2105) (2,98671)
2,500

42-17
115ZV-2 Function & Structure Hydraulic Group
Hydraulic Pump

Hydraulic pump principle

Inlet

Outlet

Inlet

Outlet

Inlet

Outlet

95ZV42040

The oil at the inlet area is taken in the cavities between


the gear teeth right after disengagement and transferred
towards the outlet area enclosed in between the teeth
and the gear casing.
When the gear teeth mesh again, the oil is extruded out
of the tooth cavities and forwarded to the outlet.

42-18
Function & Structure Hydraulic Group
Hydraulic Pump

Hydraulic pump wear plate

Both sides of the gear consists of floating type pressure


plates having balancing functions. The pressure plates
maintain optimum clearance on both sides of the gear
(pressure balance mechanism) so that the high volumetric efficiency is ensured.

General structure of pressure plate


Suction

Discharge

Rotating gears feed the pressurized oil along the circumference of the case to the outlet port. The pressurized oil is also sent to the high-pressure area in the rear
of the pressure plate. The pressure plate is pressed to
the gear side so that the clearance between the pressure plate and the side surface of the gear is kept very
small. The pressing force to the plate is adjusted to an
appropriate value by setting the optimum high-pressure
area of the plate.
The high-pressure area in the rear of the pressure plate
is enclosed by the plate seal, backup seal, and isolation
plate.

Discharge
High pressure area
Backup ring

To prevent the gear-sealing area from extremely high


pressure due to confined oil, there is a confined oil
bypass groove at the gear-sealing area of the pressure
plate.

Hydraulic pump bushing lubrication

O-ring

The lubrication system uses the oil fed from the pressurized tank.

Suction

Oil groove for


lubricating bearing

Part of the oil fed from the inlet port is sent to the bushings to lubricate them. After that, the oil is returned to
the inlet side and then sent to the discharge side.
Bushings require lubrication to maintain a long service
life. Avoid bushing damage due to a lack of lubrication
oil by:

Suction

Starting up a new pump with oil supplied to it.


- Allow new pump to idle (low rpm/no load) for 5 minutes.
Confinement
prevention groove

Discharge

115ZV42006

- Use the proper viscosity for the coldest possible start


up temperature. Change viscosity if seasonal temperature changes are great (always more than 20C
(68F)).

42-19
115ZV-2 Function & Structure Hydraulic Group
Hydraulic Cylinder

Hydraulic Cylinder
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Piston
Piston rod
Cylinder tube
Rod cover
Dust seal
Backup ring
U-packing
Buffer ring
Bushing
Backup ring

11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

O-ring
Slipper ring
Back ring
O-ring
Wear ring
Piston nut
Stop ring
Flange bolt

Dust seal

21.
22.
23.
24.
25.
26.
27.
28.

Wear ring
Stop ring
Bushing

Bolt
Washer
Plug
O-ring

Boom cylinder
20,23

16

21

14 12,13 15 1

22

9 10,11

6,7 5,17

18

115V2E42011

: Piston nut (16): 9,807 N-m (1,000 kgf-m) (7,235 lb-ft)


: Bolt (18): 843 N-m (86 kgf-m) (622 lb-ft)

Bucket cylinder
20,23

22 16 21 14 13 12 10 15 1

6 11 9 17 5

20,23

(Gauge port PF1/4)

27,28
25,26

A
A

27,28 (Gauge port PF1/4)

: Piston nut (16): 5,884 N-m (600 kgf-m) (4,340 lb-ft)


: Bolt (25): 883 N-m (90 kgf-m) (651 lb-ft)

115V2E42012

42-20
Function & Structure Hydraulic Group
Hydraulic Cylinder

Steering cylinder

20,23

16,22 21 14 13 12 1

8 6,7 10,11 9 11 17 5

20,23

4
115V2E42013

: Rod cover (4): 2,550 N-m (260 kgf-m) (1,880 lb-ft)


: Piston nut (16): 1,373 N-m (140 kgf-m) (1,013 lb-ft)

42-21
115ZV-2 Function & Structure Hydraulic Group
Hydraulic Cylinder

Hydraulic cylinder specifications


mm (in)
Inner diameter x rod diameter x stroke
Boom cylinder

Pin hole
(inner diameter x width)

Piston rod

120 x 272
(4.72 x 10.70)

Cylinder

120 x 208.5
(4.72 x 8.21)

Inner diameter x rod diameter x stroke


Bucket cylinder

Pin hole
(inner diameter x width)

Pin hole
(inner diameter x width)

190 x 100 x 767


(7.48 x 3.93 x 30.19)

Piston rod

100 x 120
(3.93 x 4.72)

Cylinder

100 x 120
(3.93 x 4.72)

Inner diameter x rod diameter x stroke


Steering cylinder

225 x 120 x 1,132


(8.85 x 4.72 x 44.56)

110 x 60 x 720
(4.33 x 2.36 x 28.34)

Piston rod

70 x 80
(2.75 x 3.14)

Cylinder

70 x 80
(2.75 x 3.14)

42-22
Function & Structure Hydraulic Group
Loading System

Loading System
The pilot operation system uses the pilot valve pressure
to control the spool of the multiple control valve and
move the boom cylinder(s) and bucket cylinder(s).
When the control lever is operated, the pilot valve line is
opened, and the oil pressure is generated depending on
the position of the control lever.
The pilot pressure entering the oil pack to the multiple
control valve moves the spool against its return spring.
The spool press-in distance (displacement) depends on
the pilot valve pressure.
Control lever

Oil from the loader pump is then directed through the


valve to the cylinder.

Pilot valve

Return oil from the cylinders flows through the valve to


the oil cooler, return filter and into the tank.
Oil to the pilot valve is supplied from the brake line while
being reduced to 3.5 MPa (36 kgf/cm2) (512 psi) by the
reducing valve.

Valve
(for safety
lock)
Reducing
valve

From brake
line

Oil packs

Multiple
control
valve

From
steering
valve

Oil packs

Cooler

P
Return filter

85V2E42004

Even if no hydraulic pump supplies oil to the loading


and pilot control circuits due to trouble, or if the engine
is shut off, the boom can be lowered to the ground by
the pressure in the accumulator in the brake circuit in
case of an emergency.

42-23
115ZV-2 Function & Structure Hydraulic Group
Reducing Valve (for Pilot Pressure)

Reducing Valve (for Pilot Pressure)


Pressure
adjustment stud
Locknut
PPDB-LAN
CXCD-XAN

Ball

CXCD-XAN

Passage Y
(T)

(P)
(TA)
(ACCR)

(PARKING)

(ACCF)

(PA)
(Z1)

(Z)

Orifice 2

From front brake


accumulator circuit

Tank

(Z2)

(PPI)

Valve assembly

Note: Valve is shown rotated 180 from normal.

A
Orifice 1

Passage Z

Plunger

Pilot oil circuit

This valve provides pilot oil pressure to operate the park


brake and loader pilot valve functions.
The oil fed from the brake accumulator circuit flows into
the pilot oil circuit by way of passage Z. The oil pressure
in the pilot oil circuit is applied also on chamber C by
way of orifice 1.
When the oil pressure in the pilot oil circuit is at or
above the set pressure, the oil in chamber C unseats
the ball by way of orifice 2, and escapes to the tank by
way of passage Y. As a result, the pressure in chamber
C decreases, then the plunger moves up and closes
passage Z so that the pressure on the pilot oil circuit
side does not exceed the set pressure.

T
Hydraulic circuit diagram

85V2E42005

When the oil pressure on the pilot oil circuit side


becomes less than the set pressure, the ball moves
down and the pressure at chamber C becomes equivalent to the pressure on the pilot oil circuit side (B). As a
result, the plunger moves down by a spring, opens the
passage Z, then introduces the accumulator pressure to
the pilot oil circuit side so that the pressure is maintained at the specified value.
This pressurized oil is supplied to the multiple control
valve oil pack through the pilot valve and moves the
multiple control valve spool.
Set pressure
3.5 MPa (36 kgf/cm2) (512 psi)

42-24
Function & Structure Hydraulic Group
Pilot Valve

Pilot Valve
Float/Down
Raise (Detent)

White (Female)
(for port 4 solenoid)
White (Male)
(for port 3 solenoid)

Roll back (Detent)


Dump

18.20

16.20

Blue (Female)
(for port 1 solenoid)

For
bucket control

B
For
boom control

A
(Port 1, 2)

B
(Port 3, 4)

K115V2U42003

42-25
115ZV-2 Function & Structure Hydraulic Group
Pilot Valve

Dump

Roll back
(Detent)

Float
(Detent) Down

Raise
(Detent)

2
7

21

21

20

20

19

19

18

18

3
9

4
6

Identifying
mark

8
10

10

2
5
Identifying
mark

9
10

10

11

13
22

23

25

12

13

23

22

To tank port

14
15

16

15

16

24

From pump
port

14

17
Port1
Port2
To/from MCV oil packs

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

Port3
Port4
To/from MCV oil packs

For bucket control

For boom control

(Section A-A)

(Section B-B)

Lever
Push rod
Push rod
Push rod
Detent solenoid coil (boom down / float)
Detent solenoid coil (boom raise)
Detent solenoid coil (bucket level)
Fixing disc
Fixing disc (identifying mark)
Push rod
Spring
Plug
Spring seat

14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.

Spring
Spring
Spring
Spool
Detent bushing
Spring
Detent ring
Steel ball (4 pieces per spool)
Spring seat
Spring seat
Casing
Spring

115V2U42021

42-26
Function & Structure Hydraulic Group
Pilot Valve

Pilot valve function

The pilot valve applies oil pressure in proportion to the


operating angle of the lever, there-by carrying out
remote control of the spool in the multiple control valve.

19

Pilot valve operation


(modulated position)

21
20

3
Predetent section

10

10

12

12

22
14

23
14

15
24

16

17

Lever is in the neutral position


85V2E42009

The pilot valve has holes of lengthwise direction in


which the reducing valve is built. The reducing valve
section consists of spool (17), spring for secondary
pressure (15)(16), return spring (14) and spring seat
(22)(23). Being inserted in plug (12), push rod (10) can
be moved smoothly to change the bending quantity of
secondary pressure spring (15)(16).

T
P
Reducing
valve
Multiple
control valve
Oil pack

From front brake


accumulator
85V2E42008

Return spring (14) contacts casing (24) and spring seat


(22)(23). This spring works on returning push rod (10) to
its original position without relation to secondary pressure, therefore it ensures returning the spool to neutral.
Also it has the effect as reactive force spring to give the
modulation feeling to operator.
When lever (1) is in the neutral position, the force of
secondary pressure spring (15)(16) is not worked on
spool (17) and spool is pushed up to push rod (10) by
return spring (14). As spool (17) closes the pump port
and the tank port is opened, the oil pressure is not
applied to the multiple control valve oil pack. The spool
of multiple control valve is held in neutral by its centering springs. There is no oil flow to the cylinder.

42-27
115ZV-2 Function & Structure Hydraulic Group
Pilot Valve

19

18

21
20

3
Predetent section

10

10

25
13
22

23

15

16

17

17

Accordingly the oil pressure in the multiple control valve


oil pack is reduced below the desired pressure. Spool
(17) moves down again by spring (16) and closes the
tank port. The pump port is opened. It raises the oil
pressure in the multiple control valve oil pack again.
This cycling action provides pressure reduction to only
have sufficient pilot pressure pass to the multiple control
valve to actuate it in a normal modulated manner and
maintains a constant pressure to the multiple control
valve.
The oil pressure to the multiple control valve is proportional to lever (1) angle, and is balanced with the lever
angle. This results in the multiple control valve spool
being moved the desired amount. Oil flow from the loading pump to the cylinder is also proportional. Cylinder
speed is easily controlled.
When lever (1) is moved fully forward or back the multiple control valve spool should also be moved full stroke.
This allows maximum oil flow to the cylinders for the
fastest cylinder movement.

Lever is shifted from the neutral


85V2E42010

When lever (1) is shifted from the neutral, push rod (10)
and spring seat (23) are pushed down at the same time,
the value of secondary pressure spring is changed.
Spool (17) is forced down by secondary pressure spring
(16), and then, the tank port is closed and the pump port
is opened.
As a result, the pressurized oil from the pump flows into
the multiple control valve oil pack. The spool of the multiple control valve moves allowing oil from the loading
pump to flow to the cylinder.
When the oil pressure in the multiple control valve oil
pack reaches over the desired pressure, spool (17)
moves up. As a result, the tank port is opened and the
pump port is closed. This action also contributes to feeling of modulation.
- Spool diameter at tank side is greater than spool
diameter at pump side.

In addition, spring seat (13) and spring (25) are installed


inside of push rod (10) in the "Boom Float" or "Bucket
Dump". When lever (1) is shifted more than a desired
angle, spring (25) makes contact with the bottom of
push rod (10) inside diameter. The inclination of second
pressure changed by this spring force. Then, to be sure
the multiple control valve spool is fully stroked, spring
(25) and spring seat (13) are used. This allows spool
(17) to be fully stroked and full pilot pressure will be
directed into the oil pack, thus fully stroking the multiple
control valve spool.

42-28
Function & Structure Hydraulic Group
Pilot Valve

Pre-detent and detent magnet


solenoid

1
21
20

19
3

21

19

20

2
18

7
8
18

The figure that fixing


disc (8) is absorbed
by the detent
solenoid coil (7).

10
T
P
T
Actuation of electromagnetic detent

85V2E42012

Actuation of pre-detent
85V2E42011

The pre-detent function is installed in the "Bucket Roll


Back" or "Boom Float" position that extends the change
of feeling to operator just before electromagnetic detent.
The pre-detent section consists of detent bushing (18),
spring (19), detent ring (20) and steel ball (21).
Push rod (3) installed in the "Bucket Roll Back" or
"Boom Float" position has the notch that steel ball is fitted in.
When push rod (3) is shifted and steel ball run upon the
step, operation load increases by reactive force of
spring, because the spring is shortened.
This extends the change of feeling to operator just
before electromagnetic detent.

In addition, the detent magnet works to hold the lever at


its position, when the lever is shifted to "Bucket Roll
Back" or "Boom Raise" or "Boom Float" position.
Detent magnet section consists of detent solenoid coil
(7), fixing disc (8)(9) and push rod (2)(3).
When the circuit for the bucket leveler or the boom kickout (option) is turned on, detent solenoid coil (7) is energized and magnetized so that fixing disc (8) of forced up
side (opposite side) is held by magnetic force of detent
solenoid coil (7).
For this reason, lever (1) is held at that position if you
keep the hand away from lever (1).
Therefore displacement of push rod (10) is maintained,
and it is the structure that continues generating the second pressure constantly.
When the circuit is turned off, detent solenoid coil (7) is
de-energized and de-magnetized and lever (1) is
returned to the neutral position.
In addition, the detent magnet can be cancelled if the
lever is operated toward the neutral direction with
enough force to overcome the power of detents.

42-29
115ZV-2 Function & Structure Hydraulic Group
Multiple Control Valve (KML35A/2T103)

Multiple Control Valve (KML35A/2T103)

7
3
B2

b2

A2

C
B1

b1

A1

B
P

2
P

A
1

10
Bucket Spool

B1

A-A
Boom Spool

B2

A1
4

A2

5
a1

B-B

a2

C-C
95ZV42074

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Main relief valve


Spool (Bucket)
Spool (Boom)
Overload relief valve (Bucket circuit)
(with make-up valve)
Make-up valve (Boom circuit)
Load check valve
Casing
Spring cover
Cover
Gauge port

42-30
Function & Structure Hydraulic Group
Multiple Control Valve (KML35A/2T103)

Boom

B2 A2

a2

Multiple control valve specifications

Bucket

B1 A1

a1

Model

KML35A/2T103

Main relief valve setting pressure

20.6 MPa
(210 kgf/cm2)
(2,986 psi)

Overload relief valve setting pressure

23.5 MPa
(240 kgf/cm2)
(3,413 psi)

P1

b2
b1
Hydraulic line diagram

P
95ZV42023

The bucket priority line is used for the multiple control


valve, and consists of the following units:
1. Main relief valve
Relieves the pressure when the working pressure
exceeds the relief setting pressure.
2. Bucket spool
Used for bucket operation, such as roll back, holding a tilt angle, and dumping.
3. Boom spool
Used for the boom operation, such as raising, holding height, lowering, and floating.
4. Overload relief valve
(With make-up function, on the bucket side)
Relieves the high pressure from the cylinder if the
pressure is extremely high. Protects the cylinders
from a vacuum (negative pressure.)
5. Make-up valve (On the boom side)
Protects the cylinders from a vacuum (negative
pressure).
6. Load check valve
Prevents the reversed oil flow or momentary "load
drop".

Overload
relief valve
installation
point
Make-up
valve
installation
point

Bucket
Boom
Bucket
Boom

Rod side

Installed

Bottom side

Installed

Rod side

Non-installed

Bottom side

Non-installed

Rod side

Installed

Bottom side

Installed

Rod side

Installed

Bottom side

Non-installed

Note
A third spool for an auxiliary function (Log clamps, Side
dump bucket, etc.) is available. If required, the inlet
cover is removed and the third spool is installed. The
inlet cover is reinstalled.
Priority oil then goes to the third spool function.

42-31
115ZV-2 Function & Structure Hydraulic Group
Multiple Control Valve (KML35A/2T103)

Multiple control valve main relief


valve

Main relief valve operation


Relief poppet

The main relief valve is installed between the pump and


the control spool. When the cylinder comes to the stroke
end, or if the pressure is above the set pressure, the oil
fed from the pump will be discharged into the tank
through this valve (main relief valve) to prevent pump
and pipe damage.

Plunger Orifice 1

Passage B
Tank
port

Pump
port

Spring
Body
seat
Passage A
Seat Filter

Spring

95V2E42005

Passage C
Adjusting screw

Passage D
Tank
port

Pump
port

Lock nut
Cap nut

Plug

Plunger
95V2E42006

When the oil pressure is at the set point or below


- The pressurized oil from the pump flows into the
chamber A through the orifice 1, and the plunger is
pressed against the body by the spring force. Oil in
the chamber A passes through passage B of the
spring seat and acts on the relief poppet. The spring
force to the relief poppet left side is stronger, so the
relief poppet and plunger remain closed preventing
any oil from escaping to tank.
When the oil pressure exceeds the set point
- When the oil pressure in the cylinder line rises above
the pressure set by the spring, the relief poppet is
moved to the left and opens the port. Then the oil in
the chamber A flows to the tank through passages C
and D.
- As a result, the pressure in the chamber A rapidly
lowers and the plunger is moved to the left. Then the
plunger opens the port to the tank port and the pressurized oil in the pump port escapes to the tank port.

42-32
Function & Structure Hydraulic Group
Multiple Control Valve (KML35A/2T103)
Note
Clogging of the orifice in plunger will cause low pressure.
Another possible cause of low pressure is contamination in, or damage to, the seat of relief poppet or
plunger.

Adjusting set pressure


Remove the cap nut. Loosen the lock nut and adjust the
pressure by the adjusting screw. Turn clockwise the
adjusting screw to raise the set pressure, or turn counterclockwise the adjusting screw to lower the set pressure.
After adjustment, be sure to tighten the lock nut.
Set pressure
20.60.5 MPa (2105 kgf/cm2) (2,98671 psi)

IMPORTANT
Always be certain to tighten locknuts when finished
with adjustment.
Only set pressures in accordance with setting specifications.

42-33
115ZV-2 Function & Structure Hydraulic Group
Multiple Control Valve (KML35A/2T103)

Multiple control valve overload


relief valve (with make-up function)
(Installed on both the rod and bottom sides of the bucket
circuit)

Overload relief valve operation


When the oil pressure is at the preset valve or less

Relief poppet

Passage A

Orifice 1 Plunger
Plunger seat

Each overload relief valve (with make-up function) is


installed in the circuit between the cylinder and the control valve spool. When the spool is in the NEUTRAL
position, if external force on the cylinder becomes too
high and the oil pressure will be greatly increased, the
overload relief valve returns the oil to the tank to protect
the cylinders and pipes from breakage.

Spring
Seat

Tank
port

Passage B

Cylinder
port
95V2E42007

The pressurized oil from the cylinder flows to the chamber A through the orifice 1, and the plunger is pressed
against the plunger seat by the spring force and the
pressure area difference.
Oil in the chamber A passes through passages A and B,
and acts on the relief poppet. The spring force to the
relief poppet left side is stronger, so the relief poppet
and plunger remain closed preventing any oil from
escaping to tank.
When the oil pressure exceeds the preset valve

Adjusting screw

Passage C

Passage D

Plunger

Lock nut
Body

Tank
port

Cylinder
port
95V2E42008

When the oil pressure in the cylinder line rises above


the pressure set by the spring, the relief poppet is
moved to the left and opens the port. Then the oil in the
chamber A flows to the tank through passages C and D.
As a result, the pressure in the chamber A rapidly lowers and the plunger is moved to the left. Then the
plunger opens the port to the tank port and the pressurized oil in the cylinder port escapes to the tank port.

42-34
Function & Structure Hydraulic Group
Multiple Control Valve (KML35A/2T103)

Make-up valve operation

Adjusting set pressure


Plunger
Plunger seat

Adjusting screw

Spring
A

Tank
port

Cylinder
port

Passage E

Tank
port

When the pressure at the cylinder port becomes less


than tank pressure, the plunger seat is moved to the
right by the pressure area difference of the plunger seat
between the right and left. The plunger seat opens the
port and the oil flows to the cylinder port through passage E. It prevents a vacuum (negative pressure) in the
cylinder.

Cylinder
port
95V2E42010

95V2E42009

When the overload relief valve on one side of the cylinder port is actuated, the plunger in the control valve is in
neutral. The port opposite to the one in which high pressure was produced has a greatly reduced pressure.
When the pressure is reduced below the tank pressure,
the make-up valve is opened.

Note
The make-up valve function is non-adjustable.

Lock nut

Loosen the lock nut and adjust the pressure by the


adjusting screw. Turn clockwise the adjusting screw to
raise the set pressure, or turn counterclockwise the
adjusting screw to lower the set pressure.
After adjustment, be sure to tighten the lock nut.
Set pressure
23.50.5 MPa (2405 kgf/cm2) (3,41371 psi)

Multiple control valve make-up


valve
(Installed on the rod side of the boom circuit)
The make-up valve is installed in the circuit between the
control spool and boom cylinder.
Extremely quick boom lowering may generate low pressure due to low oil supply speed compared with boom
lowering speed. The low pressure could form a vacuum
that may cause cavitation.
The purpose of the make-up valve is to prevent generation of such a vacuum. When the pressure in the rod
side is lower than tank pressure, the make-up valve is
opened to feed oil from the tank to the cylinder.

Make-up valve operation


The make-up valve has the same structure as the overload relief valve with make-up valve does. Refer to the
description on "overload relief valve" for the makeup
valve operation.

42-35
115ZV-2 Function & Structure Hydraulic Group
Multiple Control Valve (KML35A/2T103)

Multiple control valve bucket spool


Bucket spool operation
1. "Bucket Roll Back" position

D
B1

A1
From pilot valve

Pa1

To pilot valve
Pb1

Spool

C
From pump

95ZV42024

- When the control lever is set to the "Bucket Roll


Back" position, the pilot pressure is applied on the
right oil pack (Pa1), the spool moves to the left, and
the spool shoulder (C) closes the center bypass line.
As a result, the oil from the pump opens the load
check valve (D), flows from the A1 port into the bottom side of the bucket cylinder, and finally rolls back
the bucket.

- On the other hand, the oil on the rod side of the


bucket cylinder returns from the B1 port to the tank.

42-36
Function & Structure Hydraulic Group
Multiple Control Valve (KML35A/2T103)
2. "Bucket Dump" position

D
A1

B1

To pilot valve

Pa1

From pilot valve


Pb1

Spool

C
From pump

95ZV42025

- When the control lever is set to the "Bucket Dump"


position, the pilot pressure is applied on the left oil
pack (Pb1), the spool moves to the right, and the
spool shoulder (C) closes the center bypass line.
As a result, the oil from the pump opens the load
check valve (D), flows from the B1 port into the rod
side of the bucket cylinder, and finally dumps the
bucket.
- On the other hand, the oil on the bottom side of the
bucket cylinder returns from the A1 port to the tank.

- Extremely quick dumping generates negative pressure (or a void) on the rod side. To prevent generation of negative pressure (or a void), the make-up
valve (E) opens so that the oil in the tank port flows
into the rod side of the cylinder.

42-37
115ZV-2 Function & Structure Hydraulic Group
Multiple Control Valve (KML35A/2T103)

Multiple control valve boom spool


Boom spool operation
1. "Boom Raise" position

D
B2

A2
From pilot valve

Pa2

To pilot valve
Pb2

Spool

C
From pump

- When the control lever is set to the "Boom Raise"


position, the pilot pressure is applied on the right oil
pack (Pa2), the spool moves to the left, and the
spool shoulder (C) closes the center bypass line.
As a result, the oil from the pump opens the load
check valve (D), flows from the A2 port into the bottom side of the boom cylinder, and finally raises the
boom.
- On the other hand, the oil on the rod side of the
boom cylinder returns from the B2 port to the tank.

95ZV42026

42-38
Function & Structure Hydraulic Group
Multiple Control Valve (KML35A/2T103)
2. "Boom Down" position

D
B2

A2
To pilot valve

Pa2

From pilot valve


Pb2

Spool

C
From pump

- When the control lever is set to the "Boom Down"


position, the pilot pressure is applied on the left oil
pack (Pb2), the spool moves to the right, and the
spool shoulder (C) closes the center bypass line.
As a result, the oil from the pump opens the load
check valve (D), flows from the B2 port into the rod
side of the boom cylinder, and finally moves down
the boom.
- On the other hand, the oil on the bottom side of the
boom cylinder returns from the A2 port to the tank.
- Extremely quick lowering of the boom while the
engine (pump) revolution is low generates negative
pressure (or a void) on the rod side of the cylinder.
To prevent generation of negative pressure (or a
void), the make-up valve (E) opens so that the oil in
the tank port flows into the rod side of the cylinder.

95ZV42027

42-39
115ZV-2 Function & Structure Hydraulic Group
Multiple Control Valve (KML35A/2T103)
3. "Boom Float" position

B2

A2
To pilot valve

Pa2

From pilot valve


Pb2

Spool

From pump

- When the control lever is pushed downward beyond


the "Boom Down" position to the "Boom Float" position, the control spool moves fully to the right by the
pressure oil from the Pb2.
- As a result of this, all ports (i.e., pump port, tank port,
cylinder bottom end port, and cylinder rod end port)
are connected to the tank port.
- Therefore, the boom cylinder piston is not held by
the oil pressure force any more and can move freely
up and down by external force, which is useful for
leveling uneven ground.
Note
Low pilot pressure can cause the boom circuit to "power
down" when in float.

95ZV42028

42-40
Function & Structure Hydraulic Group
Adapter (Orifice)

Adapter (Orifice)

1.3 mm

O-ring

Orifice

Adapter

Installation position

Port b2

Multiple
control
valve

80ZV42018

The adapter is installed in the boom lowering line


between the pilot valve and the multiple control valve.
When the lever is shifted back to the holding position
just after lowering the boom, the boom spool of the multiple control valve is quickly returned to the holding position by the return spring. At this time, the boom lowering
inertia causes a shock to the machine body.
To lessen this shock to the machine body, the adapter
(orifice) controls the spool return speed by slowly returning the pilot oil which was pushing the spool.

Note
When the oil is very cold it will pass very slowly through
the orifice. As a result it will take longer than normal for
the spool to shift to neutral or holding position.
Always warm up the oil before beginning normal operation.

42-41
115ZV-2 Function & Structure Hydraulic Group
Ride Control (OPT)

Ride Control (OPT)


Ride control hydraulic circuit
4
(15)

(18)

(16)

(H)
(X)

(Ac)

(14)

(Ac2)

(T)

(5)
(13)
Multiple control
valve P line

Multiple control
valve T line

1. Valve assy
(11) Solenoid valve
(13) Reducing valve
(14) Check valve
2. Valve assy
(15) Selector valve
(16) Solenoid valve
(18) Shuttle valve
3. Accumulator
4. Boom cylinder
5. Bleeder valve

(Ac1)

Capacity: 9.5 L
Gas pressure:

(Ac1)

1.96 MPa
(20 kgf/cm2)
(284.2 psi)

From multiple
control valve

(br)
(R)
(P)

8.34MPa
(85 kgf/cm2)(1,209 psi)

(11)

(T)

95V2E42011

Ride control function


Ride control reduces fore and aft pitching motion to the
machine in roading by using the boom cylinder and
hydraulic circuit with the accumulator. Ride control can
be operated or released by turning the ride control
switch ON/OFF.
Turn the ride control switch ON, and when the machine
travelling speed reaches more than 7 km/h (4.3 mile/h),
solenoid valves (11)(16) come to ON by a signal from
the machine control unit (MCU), then the ride control
works.
When the machine travelling speed goes down to 5 km/
h (3.1 mile/h) or slower, no signal transferred from the
MCU, as a result, the ride control does not work.

42-42
Function & Structure Hydraulic Group
Ride Control (OPT)

Ride control operation


Preparation mode (ride control switch is
OFF)
4
(15)

(18)

(16)

(H)
(X)

(Ac)

(14)

(Ac2)

(T)

(5)
(13)
Multiple control
valve P line

Multiple control
valve T line

(Ac1)

Capacity: 9.5 L
Gas pressure:

(Ac1)

1.96 MPa
(20 kgf/cm2)
(284.2 psi)

From multiple
control valve

(br)
(R)
(P)

8.34MPa
(85 kgf/cm2)(1,209 psi)
(T)

The oil from the pump is reduced to 8.3 MPa (85 kgf/
cm2) (1,209 psi) by reducing valve (13), and the oil flows
into accumulator (3) through check valve (14), port Ac1
and Ac of valve assembly (2).
The accumulator pressure applies to the upper part of
selector valve (15) through shuttle valve (18) and solenoid valve (16), and presses down the poppet.
Although the accumulator pressure applies to the lower
part of selector valve (15), the boom cylinder bottom
pressure is being kept because the poppet is pressed
down by area difference.
When the boom cylinder bottom pressure is higher than
the accumulator pressure, the boom cylinder bottom
pressure from port H of valve assembly (2) applies to
the upper part of selector valve (15) through shuttle
valve (18) and solenoid valve (16), and to the lower part
of selector valve (15). Because the poppet is pressed
down by area difference of both chambers, the boom
cylinder bottom pressure is being kept.

(11)
95V2E42011

42-43
115ZV-2 Function & Structure Hydraulic Group
Ride Control (OPT)

Running mode (ride control switch is ON)


4
(15)

(18)

(16)

(H)
(X)

(Ac)

(14)

(Ac2)

(T)

(5)
(13)
Multiple control
valve P line

Multiple control
valve T line

(Ac1)

Capacity: 9.5 L
Gas pressure:

(Ac1)

1.96 MPa
(20 kgf/cm2)
(284.2 psi)

From multiple
control valve

1
(br)
(P)

(R)
8.34MPa
(85 kgf/cm2)(1,209 psi)
(T)

The ride control switch is ON, and when the machine


travelling speed reaches more than 7 km/h, solenoid
valves (11)(16) come to ON by a signal from the MCU.
Pressurized oil in the upper part of selector valve (15) is
drained to the tank port when solenoid valve (16) is
switched.
In the lower part of selector valve (15), the accumulator
pressure and boom cylinder bottom pressure are
applied, and it causes that the poppet is pressed
upward.
As a result, the hydraulic line between the boom cylinder bottom side and accumulator (3) is connected. Then
the accumulator absorbs the oil pressure fluctuations in
the boom cylinder bottom side.
On the other hand, when solenoid valve (11) comes to
ON, the hydraulic line between the boom cylinder rod
side and the tank port is connected.

(11)

115V2E42029

Therefore, when the pressure develops at the boom cylinder rod side by pitching motion in roading, oil is
drained to the tank. When the negative pressure develops at the boom cylinder rod side, oil from the tank fills
the boom cylinder rod side.

42-44
Function & Structure Hydraulic Group
Ride Control (OPT)

Ride control valve assembly (Reducing valve circuit)


Outline drawing

1
Tank

Pump

(T)
(P)

(R)

Boom cylinder
rod side

(Ac1)
Accumulator

4
6
5

1.
2.
3.
4.
5.
6.

Block
Reducing valve
Solenoid
Valve
Check valve
Bleeder valve

(T)
#2
(P)

#3,#4
(R)

#5

(Ac1)
#6

(br)
Hydraulic circuit
95V2E42012

42-45
115ZV-2 Function & Structure Hydraulic Group
Ride Control (OPT)

Reducing valve

Check valve

Passage A

Accumulator

Bleeder valve

Passage B
Passage B
Tank
Ball

Poppet

Tank
Orifice 2

Orifice 1

Pump

Sleeve
Reducing valve

95V2E42014

Oil from the reducing valve pushes the poppet up and


flows to the accumulator circuit.

Passage A

Plunger
Check valve
95V2E42013

Oil from the pump flows to the check valve through the
passage A. Also the oil pressure in the check valve circuit applies to the chamber (A) through the orifice 1.
When the oil pressure in the check valve circuit exceeds
the set pressure, the oil pressure in the chamber (A)
flows through the orifice 2 and pushes the ball up. Then
it flows to the tank through the passage B. As a result,
the pressure in the chamber (A) lowers and the plunger
moves up. Then the passage A is closed.
This controls the oil pressure in the check valve circuit
does not exceed the set pressure.
When the oil pressure in the check valve circuit lowers
than the set pressure, the ball is pushed down by the
spring and the oil pressure in the chamber (A) becomes
the same oil pressure at the check valve side.
Then the plunger is moved down by the spring. As a
result, the passage A is opened, the oil from the pump
flows to the check valve side and it maintains the oil
pressure.
Set pressure
8.34 MPa (85 kgf/cm2) (1,209 psi)

When the oil pressure at the reducing valve side lowers,


the oil pressure in the accumulator circuit applies to the
chamber (A) of the poppet through the passage A, B,
and pushes the poppet down with the spring force. As a
result, the oil never flows back.

42-46
Function & Structure Hydraulic Group
Ride Control (OPT)

Solenoid valve

Solenoid

Chamber A
Spring

Orifice

Boom cylinder
rod side

Sleeve

Seat face
Spool
Tank

95V2E42015

When the solenoid valve is not energized, the spool is


pulled up by the spring, and the chamber A is connected to the tank port through the orifice. The same
pressure is applied to both upper and lower sides of the
spool, and the spool is pulled up by the spring force.
Therefore the surface of both the sleeve and the spool
is surely fit.
When the solenoid valve is energized, the spool is
pushed down. The seat face between the spool and the
sleeve opens, and the boom cylinder rod side port is
connected to the tank port.
Solenoid specifications
Voltage

DC 24 V

Current

0.92 A

Resistance

26.2

42-47
115ZV-2 Function & Structure Hydraulic Group
Ride Control (OPT)

Ride control valve assembly (Accumulator circuit)


Outline drawing
6

Tank

Boom cylinder
bottom side

AC1

AC2

AC
Accumulator

1.
2.
3.
4.
5.
6.

Reducing valve

Block
Selector valve
Solenoid
Valve
Shuttle valve
Plug

95V2E42016

#3,#4

#2
(H)
#5

(X)
(Ac1)
(T)

(Ac2) (Ac)
Hydraulic circuit

95V2E42017

42-48
Function & Structure Hydraulic Group
Ride Control (OPT)

Shuttle valve

Solenoid valve

Movable iron core


Passage A

Solenoid
valve
Solenoid
Passage B

Accumulator

Rod
Passage C

Ball

Boom cylinder
bottom side

Spool

Passage B
95V2E42018

When the pressure at the accumulator side is higher


than the one at the boom cylinder bottom side, oil flows,
pushing the ball down, to the solenoid valve through the
passage A and B.
When the boom cylinder bottom pressure is higher, oil
pushes the ball up, and it flows to the solenoid valve
through the passage C and B. The shuttle valve
switches the oil flow direction by selecting higher oil
pressure side.

Tank
Shuttle valve

Passage A
A Selector

valve

Sleeve
95V2E42019

When the solenoid valve is not energized, the oil from


the accumulator flows to the check valve, via the shuttle
valve, through the passage A and the oil port A of the
spool.
When the solenoid valve is energized, the movable iron
core moves downward and pushes down the rod and
the spool. As a result, the oil port A and the passage A
are closed, and both the oil port B and the passage B of
the spool are connected. Then the oil is drained from
the check valve to the tank.
Solenoid specifications
Voltage

DC 24 V

Current

0.92 A

Resistance

26.2

42-49
115ZV-2 Function & Structure Hydraulic Group
Ride Control (OPT)

Selector valve
Passage B

Reducing valve
(solenoid valve)

Pressure receive
face E
Poppet

Passage A

Passage C
Boom cylinder
bottom side

Shuttle valve

Passage D

Pressure receive
face F

Sleeve

Seat face
Accumulator

95V2E42020

When the solenoid valve is not energized, the


the reducing valve flows into the chamber (A)
the passages A and B. Then the poppet is
down, and the circuit between the accumulator
boom cylinder bottom side is closed.

oil from
through
pushed
and the

In this time, the boom cylinder bottom pressure applies


to the pressure receive faces E and F. Also the accumulator pressure applies to the bottom side of the poppet.
However the poppet is pushed down because the pressure receive area at the chamber (A) side is larger.
When the solenoid valve is energized, the oil in the
chamber A flows to the tank port through the solenoid
valve. As a result, the oil pressure in the chamber (A)
lowers, and the accumulator pressure pushes the poppet up.
At the same time, the boom cylinder bottom pressure
applies to the pressure receive faces E and F on the
poppet through the passages C and D, and the poppet
is pushed up. As a result, the circuit between the boom
cylinder bottom side and the accumulator is connected,
and the accumulator absorbs the oil pressure fluctuations in the boom cylinder bottom side.

42-50
Function & Structure Hydraulic Group
Ride Control (OPT)

Accumulator (for ride control)

7
2

3
13
10

12
11
5
8
9
6

95ZV52058

1.
2.
3.
4.
5.

Body
Hydraulic cap
Gas cap
Piston
V-O ring

6.
7.
8.
9.
10.

Back up ring
Wear ring
O-ring
Back up ring
Gas valve

Accumulator function
While the ride control operates, the accumulator
absorbs fluctuation of the boom cylinder bottom pressure by air cushion function of the nitrogen gas charged
in the cylinder.
The cylinder contains N2 (Nitrogen) gas at 1.96 MPa (20
kgf/cm2) (284 psi).

11. Gas valve O ring


12. Gas valve guard
13. Bolt

Accumulator specification
Maximum operation pressure MPa (kgf/cm2)(psi) 20.6 (210)(2,986)
Nitrogen gas pressure MPa (kgf/cm2) (psi)

1.96 (20) (284)

Capacity (l)

9.5

42-51
115ZV-2 Function & Structure Hydraulic Group
Steering System

Steering System
The pilot operating method is adopted in the steering
system. A small amount of pilot oil supplied from the
Orbitrol controls the steering valve to realize steering
operations.
When the steering wheel is turned, oil at a flow rate proportional to the turning speed is sent from the Orbitrol
and supplied to the oil pack of the steering valve.

From
reducing
valve

Orbitrol

At this time, the pilot pressure is generated. The pilot


pressure strokes the spool of the steering valve, and
supplies hydraulic oil at large flow rate proportional to
the flow rate of the supplied pilot oil to the cylinder line.

Steering
cylinder

The excessive pilot oil flows through the steering valve


to the other side of the pilot port.

Stop valve

Stop valve
RH

LH

While the steering wheel is not turned, almost all


amount of hydraulic oil from the steering pump is sent to
the loading line by the action of the flow control spool.
The pilot oil pressure from the steering pump is limited
by the reducing valve, then supplied to the Orbitrol.

Steering valve
To loading line

To Orbitrol

Reducing
valve

Cooler bypass valve

Shortly before the full turn, the stop valve activates, the
pilot circuit is closed.

Oil returns from the steering cylinders flows through the


steering valve and oil cooler or cooler bypass valve.

Oil cooler

Finally it returns to the tank through the return filter.

Return filter

Note
When the oil is very cold it will pass very slowly through
the orifice. As a result it will take longer than normal for
the spool to shift to neutral or holding position.
Always warm up the oil before beginning normal operation.
80ZV42006

42-52
Function & Structure Hydraulic Group
Orbitrol

Orbitrol
Orbitrol is used as a pilot valve, and it operates the
spool of the steering valve by discharging oil, that is in
proportion to rotation amount of the steering wheel, to
the steering valve.
This Orbitrol is the closed center and non-load reaction
type.
The pump and tank ports are blocked when the steering
wheel is in neutral. This system is superior to response
steering machine because high oil pressure always
works on P port.

Orbitrol structure
1.
2.
3.
4.

Spool
Sleeve
Stator
Rotor

5.
6.
7.
8.

Drive shaft
Centering spring
Cross pin
Check valve

Valve part

6
7

T
L
Valve

1
2

3
4

Rotor

85V2E42018

42-53
115ZV-2 Function & Structure Hydraulic Group
Orbitrol
- Spool (1) and sleeve (2) as a set form a rotary-type
directional change-over valve. Spool (1) in this valve
is linked to the steering wheel by means of a spline.

Orbitrol specifications

- When the steering wheel is not being turned, spool


(1) and sleeve (2) are held in the neutral position by
centering spring (6); the oil groove of the spool does
not match the oil hole of the sleeve, so the flow route
of oil is totally closed.

Theoretical discharge (cm3/rev)

120

Operation pressure MPa (kgf/cm2) (psi)

3.5 (36) (512)

- When the steering wheel is turned, the oil groove of


the spool matches the oil hole of the sleeve, opening
the oil passage, permitting oil to flow.

Rotor part
1

Oil groove
To tank
To steering valve
To steering valve
Oil hole
From reducing
valve (pump)

70ZV42023

- A kind of internal gear, when the valve opens, it functions as a hydraulic motor.
- Rotor (4) rotation is transmitted to the valve part by
means of connected drive shaft (5), and the degree
of valve opening is regulated depending on how fast
the steering wheel is being turned.

Model

ND-K5-D

42-54
Function & Structure Hydraulic Group
Orbitrol

Orbitrol operation
Neutral
(When the steering wheel is not being turned)
6
1

T
8

L
Oil hole

6
7

T
L

Oil groove

1
2

70ZV42025

3
4

85V2E42019

1.
2.
3.
4.

Spool
Sleeve
Stator
Rotor

5.
6.
7.
8.

Drive shaft
Centering spring
Cross pin
Check valve

- Spool (1) and sleeve (2) of the valve part each have
a slit into which centering spring (6) consisting of
plate springs is set.
- When the steering wheel is not being turned, spool
(1) and sleeve (2) are kept in the neutral position by
means of center spring (6).
- This Orbitrol is the closed center and non-load
reaction type.
When in the neutral position, the oil groove of the
spool does not match the oil hole of the sleeve, so
the flow route of oil from the pump to the steering
valve is totally closed.

42-55
115ZV-2 Function & Structure Hydraulic Group
Orbitrol

Turn
(When the steering wheel is being turned)

8
6
1

2
Oil hole

6
7

Oil groove

5
1

To steering
valve Pa port
From steering
valve Pb port

From reducing valve


(pump)

3
4

85V2E42020

65ZV42036

1.
2.
3.
4.

Spool
Sleeve
Stator
Rotor

5.
6.
7.
8.

Drive shaft
Centering spring
Cross pin
Check valve

- When in the neutral position, the valve part is totally


closed and oil remains sealed inside the rotor, and
the rotor cannot move. Sleeve (2) is directly linked to
the rotor by means of a cross pin (7) and drive shaft
(5); it is also fixed.
- When the steering wheel begins to be turned, rotary
force is applied to spool (1), which then pushes and
compresses centering spring (6) set in the slit; the oil
groove of the spool matches the oil hole of the
sleeve, and opens the hydraulic circuit.
- As a result, all four ports (pump, tank and oil pack on
right and left side of steering valve) are opened,
allowing the oil to flow and rotating the rotor.

42-56
Function & Structure Hydraulic Group
Orbitrol

Orbitrol feed-back mechanism


operation

To Steering valve
Pa port
From Steering valve
Pb port

70ZV42027

- When an angle of displacement (deviation in circumferential direction) is generated between the spool
and the sleeve through operation of the steering
wheel, oil from the pump enters the steering valve
(pilot) and turns the rotor; this oil flows into the steering valve. At this time, the rotor rotation is transmitted to the sleeve by the drive shaft and the cross pin.
- As a result, the sleeve starts rotating slightly behind
the spool as if to follow its rotation. This way the
spool can continue rotating, allowing the steering
wheel to be turned and the machine to be turned.

- If the turning of the steering wheel stops, the spool


immediately stops rotating; but, as long as there
exists an angle of displacement between the spool
and the sleeve, oil continues flowing into the
Orbitrol, and the rotor can continue rotating. Due to
this rotation, the sleeve catches up with the spool,
and closes the hydraulic circuit. Finally, the centering
spring returns the spool and the sleeve to the neutral
position and flow of oil is completely stopped.

42-57
115ZV-2 Function & Structure Hydraulic Group
Orbitrol

Steering speed and flow rate control


Low steering speed

- When there is plenty of oil flowing from the pump,


the force required to turn the steering wheel need
only overcome the sliding resistance of the sleeve or
rotor, so the steering wheel turns very smoothly.

High steering speed

1
Small
displacement
angle

Large
displacement
angle

Hydraulic pump oil amount and


steering force

3
2

70ZV42028

1. Spool
2. Sleeve
3. Centering spring
- For this steering mechanism, the flow rate must be
regulated depending on the speed at which the
steering wheel is turned.
- For the steering valve (pilot), the flow rate is regulated by changing the displacement angle of spool
(1) sleeve (2). In other words, while the steering
wheel is being turned, sleeve (2) chases spool (1) in
rotation, trying to close the hydraulic circuit.
- As steering speed increases, the amount of delay
(displacement angle) of sleeve (2) increases, and
the flow rate rises.

- When the amount of oil from the pump is small, the


displacement angle of the spool and sleeve reaches
a maximum point; even if the hydraulic circuit is wide
open, the flow of oil from the pump to the rotor is
small, so the rotor turns slowly.
- For this reason, the spool rotates faster than the
rotor, and the displacement angle reaches a maximum point, and the spool turns the rotor by means of
the cross pin and drive shaft. At that time, the rotor
works as a hydraulic pump, and the steering wheel is
harder to turn.

42-58
Function & Structure Hydraulic Group
Orbitrol

Orbit rotor operation principle


Drive shaft (0 rotation)
Rotor center

Drive shaft (1/14 rotation)

Drive shaft (1/7 rotation)

Rotor (rotation)
Stator (fixed)

Locus of rotor center

1
7

6
4

3
5

3
5

1
2

:Flow of high-pressure oil


:Flow of low-pressure oil

- Inside the rotor there is a stator with 7 internal gears


that is fixed to the housing and a 6-tooth rotor that is
engaged with the stator.
- Half of the chamber formed by the stator and the
rotor is connected to the high-pressure side and the
other half to the low-pressure side.
When high-pressure oil flows into the chamber, the
rotor is forced to turn in the direction that will expand
the area of the chamber (by means of pressure difference).
- When overrunning the power assist capacity of the
gerotor due to very fast rotation or turning the steering wheel vigorously, rotation of the sleeve and spool
takes place by means of the cross pin.
- With this rotation, and at the same time due to the
relationship of the position between the sleeve port
and the housing port, the position of oil flowing into
the rotor part is gradually delayed in sequence.

70ZV42029

- The rotor makes a 1/6 turn per rotation of the rotor,


pushing out oil equivalent to 7 chambers. When the
rotor rotates once, oil equivalent to 42 chambers (7
chambers x 6 turns) is pushed out.
- For the motor, it has 6 times larger torque or a 1/6
reduction effect.

42-59
115ZV-2 Function & Structure Hydraulic Group
Steering Valve (KVS32-A4.0/21)

Steering Valve (KVS32-A4.0/21)


To loading line
From pump
To reducing
valve
P
PC
2

(G)

MR 3

Pb

Pa

Pilot operation
port

To loading line

P. B.

Pilot operation
port

T
Tank port
(F)
2

MR

A-A

Orifice
Cylinder port

(LC)

Cylinder port

BR

AR

Pb

Pa

Drain port

1.
2.
3.
4.
5.

Dr

B-B

Steering spool
Flow control spool
Main relief valve
Overload relief valve (with make-up valve)
Gauge port
115V2U42001

42-60
Function & Structure Hydraulic Group
Steering Valve (KVS32-A4.0/21)
1. Steering spool

AB
AR

The movement of the steering spool is controlled by


the pilot pressure from the pilot valve.
At the center of the spool, there is a variable orifice
with chamfers (throttle grooves). This orifice controls the oil flow rate.
Also inside the steering spools are check valves
which apply a back pressure to oil returning from
the cylinders.

BR
Pa

(G)

Pb
0.5
RF
3.0

T
MR

Orifice

P. B.
Pc

P
Hydraulic circuit

115V2E42031

IMPORTANT
Flow control plunger orifice must not be blocked.
Pump damage may result.

2. Flow control spool


The flow control spool sends oil to the steering line
depending on the displacement of the steering
spool.
The excess oil goes to the loading line.
3. Main relief valve
The main relief valve controls the maximum operating pressure when turning the steering wheel.
4. Overload relief valves with make-up function
These valves prevent excessive oil pressure
caused by external force and a vacuum in the
steering oil line.
Model

KVS32-A4.0/21

Main relief valve setting pressure

20.6 MPa
(210 kgf/cm2)
(2,986 psi)

Overload relief valve setting pressure

24.5 MPa
(250 kgf/cm2)
(3,555 psi)

42-61
115ZV-2 Function & Structure Hydraulic Group
Steering Valve (KVS32-A4.0/21)

Steering valve operation


Neutral position
(steering spool in "Neutral")

Loading circuit

115V2E42015

- In the NEUTRAL position, steering spool (1) closes


all the ports to stop flow of the pressurized oil from
the steering pump. The pressure in the pump line,
therefore, will rise.

- When the pump line pressure increases to 0.63 MPa


(6.4 kgf/cm2) (91.4 psi), flow control spool (2) is
moved to the right due to the pressure difference
between chambers A and B.
Thus the flow control spool is opened, and all the oil
from the steering pump is sent to the loading line.

42-62
Function & Structure Hydraulic Group
Steering Valve (KVS32-A4.0/21)

Left turn position

Loading circuit Pump

Pilot pressure

Check valve

1
Tank
Variable throttle

115V2E42016

- When steering spool (1) is pushed in to the left, the


pressurized oil from the pump is sent to steering cylinders through the variable throttle section and the
check valve. The pressurized oil moves the cylinder
rods and the machine turns to the left.

- During low-speed turning, displacement of steering


spool (1) is small. However, since the oil flow rate to
the steering cylinder is reduced at the variable throttle section at the spool center, the pressure difference between the front and rear of the throttle
section is increased. When the pressure difference is
increased to 0.63 MPa (6.4 kgf/cm2) (91.4 psi), flow
control spool (2) is opened to discharge excess oil to
the loading line. In this way, the flow control spool
prevents extreme increase in the amount of the oil
from the steering pump, and adjusts the oil flow rate
to the cylinder.

42-63
115ZV-2 Function & Structure Hydraulic Group
Steering Valve (KVS32-A4.0/21)
- For high-speed turning, steering spool (1) is pushed
all the way to the left, and the variable throttle is fully
opened. Under such a condition, all the oil is used for
steering to enable high-speed turning.
- At a low engine speed, the oil flow rate from the
steering pump is low, therefore the pressure difference between the front and rear of the throttle section is small, and flow control spool (2) is closed.
- At a high engine speed, oil flow rate to the variable
throttle is increased, therefore the pressure difference between the front and rear of the throttle section is increased to activate the flow control spool. As
a result, the excess oil is sent to the loading line.

Steering spool variable throttle

PA

PB

Variable throttle
115V2E42017

When the steering spool is pushed in, the variable throttle is opened, and the pressurized oil from the pump
goes through the variable throttle, the pressure generated before and after the variable throttle leads to the
chambers A and B. The pressure difference is small at
that time, and shifts the flow control spool to the left.
The pressure difference varies depending on the opening area of the variable throttle and the passing oil flow
rate, and the control pressure is set to 0.63 MPa (6.4
kgf/cm2) (91.4 psi).

42-64
Function & Structure Hydraulic Group
Steering Valve (KVS32-A4.0/21)

Steering valve flow control spool


Loading circuit Pump

Spring

PA
PB

Variable throttle

Steering circuit

Loading circuit Pump

PA
PB

Variable throttle

Steering circuit

115V2E42018

When the pump discharge amount is small, the pressure difference between the chambers A and B is small
(pressure PA in chamber A
pressure PB in chamber
B), and the flow control spool is being pushed to the left
by the spring. Accordingly, the oil sent from the pump
flows into to the steering circuit.
When the pump discharge amount is increased and the
pressure difference (PA-PB) is increased to 0.63 MPa
(6.4 kgf/cm2) (91.4 psi) or more, the flow control spool
starts to be shifted to the right and the excessive oil is
bypassed to the loading circuit.
As described above, the steering circuit is given priority
in receiving the pressurized oil from the pump.
However, when the number of rotations of the engine
becomes larger and the oil flow rate exceeds the preset
value, the flow control spool bypasses the excessive oil
to the loading circuit. This keeps the oil flow rate constant in the steering circuit.

42-65
115ZV-2 Function & Structure Hydraulic Group
Steering Valve (KVS32-A4.0/21)

Steering valve main relief valve


When the pressure is at the preset value or
less

Loading circuit

Pump

Flow control spool


Filter

Steering spool

Cylinder

Tank

Cylinder

115V2E42019

The figure above shows the status in which the steering


spool is open. The chambers A and B are filled with oil,
and the flow control spool is balanced in the position
shown above. If the filter becomes plugged, the relief
valve will not operate properly.
Always check and clean the filter during repairs.

42-66
Function & Structure Hydraulic Group
Steering Valve (KVS32-A4.0/21)

When the pressure exceeds the preset


value

Loading circuit

Pump

Flow control spool

Steering spool

Tank

115V2E42020

When the pressure in the cylinder circuit exceeds the


preset value (and the oil pressure rises naturally in both
the chambers A and B), the relief valve opens and the
oil in the chamber B escapes into the tank circuit. As a
result, the pressure in the chamber A becomes relatively high, the flow control spool is shifted to the right,
and the oil sent from the pump flows into the loading circuit.

42-67
115ZV-2 Function & Structure Hydraulic Group
Steering Valve (KVS32-A4.0/21)

Steering valve overload relief


valve
External force

Makeup function

Overload relief function

Tank

Overload relief valves with makeup valve are located in


the circuit between the steering cylinder and the steering spool on the both sides of the steering cylinder.
While the steering spool is located in the neutral position, the steering cylinder circuits are closed.

115V2E42021

Overload relief function


In this situation, if an external shock (force) is applied to
one side of the cylinder (the bottom side in the figure
above) causing abnormally high pressure to build up in
the circuit, the oil escapes through the valve on side A,
in order to prevent damage to the piping and the cylinder.
Makeup function
On the other side of the cylinder (the rod side in the figure above), the oil is allowed to enter from the drain to
tank circuit as is required from the oil that escaped from
the bottom side of the cylinder, in order to prevent vacuum (negative pressure (or void)) from developing in
the circuit.

42-68
Function & Structure Hydraulic Group
Steering Valve (KVS32-A4.0/21)

Overload relief valve operation


C

Make-up valve operation


K

G
A
Cylinder

Cylinder

E
D

Tank

115ZV42052

When the oil pressure is at the preset value or less


The pressurized oil is sent to the internal space X
through the orifice of the piston C. Because the oil pressure is at the preset value or less, the poppet E is
closed and the area between the cylinder and the tank
is completely blocked.
Sleeve K fits completely in the cylinder port because the
pressure receiving area of the internal space X is wider
than the pressure receiving area on the cylinder side.
C

Cylinder

E
D

Tank

115ZV42053

When the oil pressure exceeds the preset value


The pilot poppet E is opened, and the oil escapes into
the tank around sleeve K.
As a result, the pressure in the internal space X is relatively lower than that on the cylinder side, then the piston C moves to the right and fits in the pilot poppet E.
Because the internal space X leads to the tank, the poppet D moves to the right and the high pressure oil
escapes from the cylinder to the tank.

Tank

115ZV42054

When the cylinder pressure drops below the tank pressure, sleeve K moves to the right due to the difference
in the pressure receiving area (G - A) between the left
side and the right side of sleeve K, and the oil flows
from the tank to the cylinder so that the cylinder pressure does not drop below the tank pressure.

42-69
115ZV-2 Function & Structure Hydraulic Group
Steering Valve (KVS32-A4.0/21)

Steering pilot circuit and its operation

From pump
Orbitrol

Reducing valve
To tank

Filter

Steering valve

To tank

From cylinder

Stop
valve

To cylinder

Stop
valve

End cover

End cover

Flow amp. notch


Pilot circuit

To tank

Pilot orifice

K115V2J42009

Oil flow
- Oil from the steering pump flows into the steering
valve. The oil flow direction is separated in the steering valve.
The oil is supplied to the Orbitrol from the steering
valve through the reducing valve where the oil pressure is reduced.
- The hydraulic oil from the Orbitrol first enters the
end cover of the steering valve, then passes through
the steering spool flow amplifier notch and the pilot

orifice and flows to the end cover on the opposite


side, returning to the tank through the Orbitrol.
- As the amount of oil flowing through the amplifier
notch and the pilot orifice increases, the pressure of
the oil inside the end cover increases, pushing in the
steering spool.
The variable throttle opens, regulating the amount of
oil flowing to the cylinder circuit, depending on flow
volume, and thus the distance the spool is pushed in.

42-70
Function & Structure Hydraulic Group
Steering Valve (KVS32-A4.0/21)

Return spring force

Return spring

Pilot oil

Hydraulic force

Pilot pressure

Flow amplifier notch and pilot orifice

End cover
Pilot orifice
Flow amplifier notch
Pilot line

K115V2J42005

Return spring force

Hydraulic force

Pilot pressure

- If no oil is sent from the Orbitrol, the spool is held in


the neutral position by the return spring and the flow
amplifier notch is closed.
When pilot oil is sent from the Orbitrol the oil flows
through the pilot orifice, the pressure of the oil inside
the end cover rises, pushing the spool and opening
the flow amplifier notch.
Then, the oil flows through the flow amplifier notch
and the pilot orifice.

Flow amp. notch opening


Pilot orifice
80V2U42005

- When pilot flow is low, when the spool is pushed in a


little, opening the flow amplifier notch a little, the pilot
oil easily flows out, and the spool will not be pushed
in any further. (The hydraulic force applied at the end
of the spool is in balance with the force of the return
spring.)
Note
There are filter screens at the pilot orifice. These
screens are there only to keep the orifice from plugging
due to loose debris.

Flow amp. notch opening


Pilot orifice
80V2U42006

- When pilot flow rises, as the opening of the flow


amplifier notch is narrow, the pressure inside the end
cover is raised higher, pushing the spool in.
When the spool is pushed in, the opening of the flow
amplifier notch becomes larger, making it easier for
pilot oil to flow out ; thus, the rise in pressure stops
and the spool is stopped at a position where the
hydraulic force applied to the end of the spool is in
balance with the force of the return spring.

42-71
115ZV-2 Function & Structure Hydraulic Group
Stop Valve

Stop Valve

17
(0.67")

(Full stroke)

From Orbitrol

A
B

To steering valve

DR

11

13

10

12

14

95V2E42038

1.
2.
3.
4.
5.
6.
7.
8.

DR

97ZV42042

Housing
Spool
Check valve
Plug
Washer
Plug
Flange
Spring

9.
10.
11.
12.
13.
14.

Spring
Spacer
Boot
U-packing
Dust seal
O-ring

42-72
Function & Structure Hydraulic Group
Stop Valve

Stop valve function

Stopper
(bolt)

Port B
To
steering valve

Stop valve operation


Port A
From
Orbitrol

Spool

P
Installed on
front chassis

Check valve
Installed on rear chassis
90V2U42003

A stop valve is provided to reduce the impact caused to


the chassis steering stopper block when the machine is
making a full turn while the hydraulic pressure of the
steering cylinder is still working.

Pb

Pa

95V2E42049

Shortly before a full turn, the stopper installed on the


front chassis pushes the spool of the stop valve
installed on the rear chassis to shut down the port A and
the port B. As a result, the pilot line is closed, returning
the steering valve spool to the neutral position.
After a full turn, when the steering wheel is turned in the
opposite direction, the spool of the stop valve remains
pushed in, closing the line. As a result, the pilot oil
opens the check valve and flows out.

42-73
115ZV-2 Function & Structure Hydraulic Group
Reducing Valve (for Orbitrol)

Reducing Valve (for Orbitrol)

Spring

(T)

Sleeve

Tank

Plunger
Pump

Passage Z

(A)

B
A

Passage Y
(TS)

TS
A

T
Hydraulic circuit diagram

(B)
Orbitrol

The oil fed from the pump flows into the Orbitrol circuit
by way of passage Y and port A in the plunger.
When the oil pressure in the Orbitrol circuit reaches or
exceeds the set pressure (spring force), the plunger is
moved up by the oil pressure and passage Y is closed
from port A so that the Orbitrol side does not exceed
the set pressure.
When the pressure exceeds the value which closes
passage Y, the plunger is moved up further, the oil hole
B is connected to the passage Z, and the oil escapes to
the tank so that the pressure in the circuit on the
Orbitrol side does not exceed the set pressure.
When the oil pressure in circuit on the Orbitrol side
decreases, the plunger is moved down by the spring
force, passage Y is open, and the pump pressure is
introduced to the Orbitrol side so that the pressure is
maintained at the specified value.

90ZV42012

This oil is supplied from the Orbitrol to the steering


valve pilot port, and moves the spool.
Set pressure
3.5 MPa (36 kgf/cm2) (512 psi)

42-74
Function & Structure Hydraulic Group
Steering Line Filter

Steering Line Filter

From pump
(steering valve)

To
reducing valve

FILTER

5
70ZV42040

1.
2.
3.
4.
5.

Case
Nipple
Strainer
O-ring
O-ring

The line filter is integrated into the pilot line of the steering line, and prevents foreign objects from entering the
pilot line.

ELS valve
Stop valve (RH)
Stop valve (LH)

Center pin
Center line

Reducing valve
Line filter
Steering valve

115V2E42006

Note
The line filter design shown above is also used for the
brake line.
The filter prevents debris from entering the brake accumulator reducing valve assembly.
These filters must be removed, inspected and cleaned
or replaced every 2,000 hours of operation.

42-75
115ZV-2 Function & Structure Hydraulic Group
Efficient Loading System

Efficient Loading System


Efficient loading system outline

Efficient loading system (it is assumed ELS as follows)


improves the performance of excavating and scooping
when operating, and shortens the cycle time.
When the ELS switch at the instrument panel is turned
on and excavating, more specifically, the ELS operation
condition showing as follows is satisfied, the solenoid
valve in the ELS valve is energized and all the hydraulic
oil from the main pump goes to the hydraulic tank.

Fast

Therefore most of the engine power is applied to the


wheels to exert maximum driving force by turning off the
main pump and reducing the pump driving load on
engine.
Slow and higher
driving force

In addition, as for the loading operation, it becomes


easy to operate slightly by reducing the quantity of total
oil to the loading circuit, and is improved the performance of operating when excavating and scooping.

When excavating and scooping


Switch
pump

Multiple
control
valve

Steering
valve

Main
pump

Boom
Bucket

ELS
valve

In addition, the height range of the boom that ELS operates can be set up to the arbitrary height depending on
setting of the variable kickout sensor.

Hydraulic tank
When raising the boom
Switch
pump

Main
pump

Multiple
control
valve

Steering
valve

Fuel efficient mode switch is also installed at the instrument panel when operating at the time of fuel saving
driving. If the combination of ELS switch and fuel efficient mode switch is selected properly, it can be able to
improve the fuel consumption without reducing the
operation efficiency.

Boom
Bucket

The operation condition of ELS


The ELS switch ON

ELS
valve
Hydraulic tank
Concept of the ELS operation

Shift lever

Forward position

Machine speed

Less than 5 km/h

Boom height

The setting position of the variable kickout sensor


is less than it.

85V2E42054

Note
The efficient loading system works under the condition
that the engine revolution is lower than 1,000 min-1,
even if the efficient loading system switch is OFF position.
When the engine revolution becomes higher than 1,300
min-1, it stops working.

42-76
Function & Structure Hydraulic Group
Efficient Loading System

Mounting of the ELS valve


3

From main pump

PG1

(P)

(A) Multiple
control valve

(T1)

2
Center pin
Center line

PG2

(T2)

To hydraulic
tank

From Orbitrol

Hydraulic line

ELS valve

Rear chassis

2
PG2

4
PG1
A
T2
T1

1
3

Detail of ELS valve section


115V2E42007

1. Solenoid valve
2. Relief valve
Setting pressure
20.6 MPa (210 kgf/cm2) (2,987 psi)
3. Check valve
Cracking pressure
0.2 MPa (2 kgf/cm2) (29 psi)
4. Pressure sensor

42-77
115ZV-2 Function & Structure Hydraulic Group
Efficient Loading System

Mounting of the variable kickout sensor


5

8 2
3

Apply grease
at
area

1
Detail of grease applying

A
Boom

When the boom


is horizontal

5,8

Chassis

3
1,7
1

Detail of A
85V2E42056

1.
2.
3.
4.
5.
6.
7.
8.
9.

The variable kickout sensor


Link
Plate
Plate
Shaft
Ball bearing
O-ring
Spring pin
Rod

42-78
Function & Structure Hydraulic Group
Efficient Loading System

Efficient loading system operation


While the ELS is not operating

While the ELS is operating


3

Multiple control
valve P line

From main pump

From main pump

To hydraulic
tank

115V2E42008

115V2E42009

The oil discharged from the switch pump flow into the
steering valve P port. When the steering wheel is not
turned, this oil is discharged from the steering valve P.B.
port.

When the ELS switch is turned on and the ELS operation condition set by the MCU is satisfied, the solenoid
valve in the ELS valve is energized and the spool is
moved.

On the other hand, the oil discharged from the main


pump opens the check valve, because cracking pressure of check valve (3) is less than the setting pressure
of relief valve (2).

After that, the setting pressure of relief valve drops to


the hydraulic tank pressure level.

Cracking pressure of check valve (3)


0.2 MPa (2 kgf/cm2) (29 psi)
Setting pressure of relief valve (2)
20.6 MPa (210 kgf/cm2) (2,987 psi)
The oil from switch pump and main pump are joined
together and flow into the multiple control valve P port.
Therefore it can be able to operate the boom and
bucket at normal speed.
In addition, pressure sensor (4) is installed in the discharged side of the main pump and detects oil pressure
of loading line and sends the signal to the MCU.

Therefore, the oil discharged from the main pump


opens relief valve (2) that setting value dropped and all
the hydraulic oil from the main pump goes to the
hydraulic tank.
But the oil from the steering valve P.B. port cannot flow
into relief valve (2) because of check valve (3), and flow
into the multiple control valve P port.
Therefore when the ELS is operated, most of the engine
power is applied to the wheels to exert maximum driving
force by turning off the main pump and reducing the
pump driving load on engine.
In addition, it becomes easy to operate slightly by
reducing the quantity of total oil to the loading circuit,
and is improved the performance of operating when
excavating and scooping.

42-79
115ZV-2 Function & Structure Hydraulic Group
Fan Motor System

Fan Motor System


Mounting of fan motor
3

T1 L1 L2

T2 L1

115V2E42010

1. Fan motor
2. Fan
3. Proportional relief valve
: Bolt tightening torque
T1: 93.7 N-m (9.55 kgf-m) (69 lb-ft)
T2: 441~539 N-m (45~55 kgf-m) (326~398 lb-ft)
L1: Screw lock agent (Loctite 262)
L2: With lubrication oil (Engine oil or gear oil)

42-80
Function & Structure Hydraulic Group
Fan Motor Line

Fan Motor Line


Fan revolution
(min-1)

Engine coolant: High temperature


[94C (201.2F)]

1,300
Stepless
control range

1,120
Middle range temperature
[60~80C (160~180F)]

(900)
0
725
(Hibernate mode) 925

Low temperature
[below 60C (160F)]

1,200

(1,260)
Engine revolution (min-1)

Fan revolution * (controlled by MCU)

(1,787)

Values inside ( ) are


offered as reference.

* To shorten the warm-up time, when the engine water temperature is 60C (140F) or less and the engine
revolution is 1,200 min-1 or less, the fan revolution is kept minimum without reference to the engine revolution.

Cooling fan

Fan motor (1)

K115V2E42001

The cooling fan is driven by the hydraulic motor. The


pressure oil from the unloader valve flows into the port
P of fan motor and then turns fan motor (1).
Three kinds of signals sent, one each is from the engine
water temperature sensor (S/N 9001~9050), ECM (S/N
9051~), torque converter oil temperature sensor, and
hydraulic oil temperature sensor, are input into the MCU
as information to regulate the maximum fan revolution.

To return
filter
Proportional relief valve (2)
Hydraulic circuit diagram

From
unloader
valve
95V2E42041

Note
Hydraulic oil temperature must be at operating temperature to do this fan revolution test.
When proportional relief wire is disconnected, fan revolution should go to high speed mode.

The fan revolution is regulated by proportional relief


valve (2). The setting pressure of the proportional relief
valve is changed in proportion as the electric current
value from MCU.

42-81
115ZV-2 Function & Structure Hydraulic Group
Fan Motor Line

Number of
revolutions of
fan (min-1)

Output current F for control of


the fan revolution
Proportional
relief valve [mA]

Proportional
relief valve [mA]

Proportional
relief valve [mA]

About

1,120

270
F H/D
F T/M
F E/G

1,300

0
0

80
(176)

94

( C)

(201.2) ( F)
T E/G

The signal of the engine


coolant temperature

110
(230)

90

115 ( C)
T T/M

(239) ( F)

The signal of the torque


converter oil temperature

(194)
T H/D

95 ( C)
(203) ( F)

The signal of the


hydraulic oil temperature

Control of the fan revolution


K115V2E42002

When the input electric current value to proportional


relief valve (2) is maximum (approximately 270 mA), the
fan revolution is minimum value (1,120 min-1) because
bypass oil amount at proportional relief valve (2) is
increased. When this value is minimum (0 mA), the fan
revolution is maximum value (1,300 min-1) because
bypass oil amount at proportional relief valve (2) is
decreased.
When the engine water temperature is low, the electric
current value from the MCU to proportional relief valve
(2) is big. As a result, bypass oil amount from port P to
fan motor (1) line becomes big, and then the fan revolution becomes low.
For example, when the torque converter oil temperature
is below 110C (230F) and the hydraulic oil temperature is below 90C (194F), the fan revolution is controlled only by engine water temperature.

In normal condition, fan revolution is regulated by


engine water temperature. But when the torque converter oil temperature exceeds 110C (230F) or the
hydraulic oil temperature exceeds 90C (194F), in each
signal input into a MCU from the engine water temperature, torque converter oil temperature and hydraulic oil
temperature sensors, the lowest signal in the electric
current value is chosen (the fan revolution becomes
high to lift the cooling performance), and the control
electric current is input into proportional relief valve (2).

42-82
Function & Structure Hydraulic Group
Fan Motor Line

Hydraulic circuit (fan motor normal rotation)


Fan motor (1)

MB

MA

Make-up valve (3)

Safety valve (4)

Proportional relief valve (2)

MCU
(Engine water temp. sensor
T/C oil temp. sensor
Hydraulic oil temp. sensor)

Brake
circuit

For brake and pilot pump

Unloader valve

Hydraulic tank

Hydraulic circuit diagram

95V2E42043

Make-up valve
When the pressure oil from the hydraulic pump is supplied to the inlet port P, the pressure in the MA side circuit of the fan motor will increase. The starting torque for
the fan motor is generated, and the motor starts to
rotate. The oil in the MB side circuit of the fan motor
returns to the hydraulic tank via the outlet port T.
When engine stops, the pressurized oil from the pump
is not supplied to fan motor (1) inlet port, as a result, the
fan motor revolution speed gradually decreases.

Oil supply is stopped, however the fan is still turning by


the inertial force.
This condition generates negative pressure at the motor
inlet port.
To prevent generation of negative pressure, make-up
valve (3) opens so that the oil in the tank port flows into
the fan motor inlet port.

42-83
115ZV-2 Function & Structure Hydraulic Group
Fan Motor Line

Safety valve
When accelerating engine, pump discharge pressure
may rise extremely high.
To prevent the fan motor line from damages, safety
valve (4) is installed.
If the pump discharge pressure exceeds the set pressure, safety valve (4) relieves the pressurized oil to the
tank port.

42-84
Function & Structure Hydraulic Group
Fan Motor Line

Proportional relief valve (S/N 9001~9050)


The proportional relief valve is installed between the
unloader valve and the fan motor. This valve is the normally closed, pilot operated type.
The setting pressure of the proportional relief valve is
changed in proportion as the engine revolution and
electric current value from the MCU.

Proportional relief valve operation


When the oil pressure is at the preset value or less

Plunger

Solenoid

Chamber A

Body

Lock nut
Adjusting screw

Inlet pressure

Orifice 1
Spring 1

Orifice 2 Pilot poppet

Moving iron core

Spring 2

Coil lock nut


95V2E42044

The pressurized oil from the pump (the unloader valve)


flows into the chamber A through the orifice 1, and the
plunger is pressed against the body by the spring 1
force.
When the solenoid coil is not energized, the setting
pressure is regulated by the spring 2 force.
If the solenoid coil is energized by the signal of the
MCU, the pressure setting is changed. As the electric
current is applied to the coil, the movable iron core is
pulled to the right and pushes the spring 2, so the spring
2 force is reduced with the increasing current, the setting pressure also decreases. Once a constant electronic signal is given, the pilot poppet is held in a given
potion, holding the setting pressure.
This is maintained by the balance between the electronic spring 2 force and inlet pressure.

42-85
115ZV-2 Function & Structure Hydraulic Group
Fan Motor Line
When the oil pressure exceeds the set point

Plunger

Chamber A

Solenoid
Lock nut

Body

Adjusting screw

Tank port
Inlet pressure

Orifice 1
Spring 1

Orifice 2

Pilot poppet Moving iron core

Spring 2

Coil lock nut


95V2E42045

When the oil pressure against the pilot poppet through


the orifice 2 rises above the setting pressure, pilot poppet is moved to the right and opens the port. Then the
oil in the chamber A flows to the tank through clearance
between the body and sleeve. As a result, the pressure
in the chamber A rapidly lowers and plunger is moved to
the right. Then the plunger opens the port to the tank
port and the pressurized oil in the pump port escapes to
the tank port.
Adjusting set pressure
Disconnect the cable connector of proportional relief
valve and loosen the lock nut and adjust the pressure
by the adjusting screw. Turn clockwise the adjusting
screw to raise the set pressure, or turn counterclockwise the adjusting screw to lower the set pressure
After adjustment, be sure to tighten the lock nut
High pressure set:
19.60.5 MPa (2005 kgf/cm2) (2,84471 psi)
at 0 mA

42-86
Function & Structure Hydraulic Group
Fan Motor Line

Proportional relief valve (S/N 9051~)

(G1)
T1

(P1)

(T1)

(G1)
P1

(P2)

P2
(G1)

(G3/8)
PG2

(PG2)
(T2)

3
(PG1)

T2
(G1)

PG1
(G1/4)

Hydraulic line diagram

5
1

K115V2U42001

1.
2.
3.
4.
5.
6.
7.
8.

Block
Relief valve
Adapter
Elbow adapter
Plug (Gauge port)
Plug
Relief valve
Solenoid valve

42-87
115ZV-2 Function & Structure Hydraulic Group
Fan Motor Line

Adjusting set pressure


It is not possible to adjust the set pressure on the
machine. Replace relief valve cartridge (7), if necessary.
: Tightening torque
Relief valve (2): 60~70 N-m (6.1~7.1 kgf-m)
(44~51 lb-ft)
Relief valve (7): 35~40 N-m (3.5~4.0 kgf-m)
(25~29 lb-ft)

K115V2U42002

42-88
Function & Structure Hydraulic Group
Fan Motor Line
Fan motor

Port P

Port Tc

Port T

Fan motor specifications


Displacement capacity
Rating

Speed
control

3
3
90.3+2
-0 cm /rev (55.1 in /rev)

Pressure

21.3 MPa (217 kgf/cm2) (3,089 psi)

Speed

1,600 min-1

Flow

144 L/min (38 gal/min)

Control method

Continuous variable control with the


proportional valve (not included in
fan motor)

115V2E42030

42-89
115ZV-2 Function & Structure Hydraulic Group
Fan Motor Line
Fan motor structure
1

11

13

12

10

A-A

14

MA

MB

TC
17

T
16

15
B-B

1.
2.
3.
4.
5.
6.
7.
8.
9.

Output shaft
Case
Thrust plate
Piston assy
Cylinder block
Valve plate
Retainer guide
Retainer shoe
Main bearing

K95V2J42001

10.
11.
12.
13.
14.
15.
16.
17.

Sub bearing
Oil seal
End cover
Center spring
Make-up valve
Safety valve
Main spool
Spring

42-90
Function & Structure Hydraulic Group
Fan Motor Line
Fan motor function and the operation principle
Y

The oil sent from the hydraulic pump is led into cylinder
block (5) through valve plate (6). This oil is led only onto
a half of plate (6) separated by Y-Y line which links a
bottom dead center to a top dead center at piston (4)
process.

F3

ri
F3

The pressure a oil in a half of cylinder block, that is separated by Y-Y line, pushes each piston (4) (two or
three), and then generates the force F1 (F1=P (kgf/cm2)
x /4 x D2 (cm2)).

85V2E42043

F1

This hydraulic motor is swash plate type axial piston


motor. This converts the power of pressured oil sent
from the hydraulic pump into rotary motion.

This force pushes thrust plate (3) fixed at a certain angle


for output shaft (1), and it is divided into two component force F2 and F3.
Among the component forces, radial component force
F3 generates the torque T (T=F3 x ri) at each piston (4)
located at a half of the plate (6) separated by Y-Y line
linking a top dead center to a bottom dead center.

F3

Resultant force of this torque (T= (F3 x ri)) goes


through a piston as turning force and turns cylinder
block (5).

F2

85V2E42044

4
5

Supply side

3
Discharge side

85V2E42045

Because this cylinder block (5) is connected to the output shaft, the output shaft turns, and then torque is
transmitted.

42-91
115ZV-2 Function & Structure Hydraulic Group
Reversing Fan Motor Line (OPT)

Reversing Fan Motor Line (OPT)


Reversing fan motor function

Functional limitation conditions:


When either one of the following temperature exceeds
the preset upper limit(s), the cooling fan reverse rotation
function does not work.
1. Signal of engine water temperature
> 94C (201.2F)

Switch

2. Signal of torque converter oil temperature


> 115C (239F)
3. Signal of the hydraulic oil temperature
> 95C (203F)
115V2U62017a

Engaging this switch reverses the rotation of the cooling


fan for cleaning the radiator fins.
When pushing this switch for more than 2 seconds with
the engine running, the switch turns "ON", the pilot lamp
on the switch lights up and the cooling fan turns in
reverse rotation for 1 minute, after which it returns to it's
normal rotation.
The fan turns continuously in reverse direction for 1
minute at 30 minute intervals.
When the switch is pushed again for more than 2 seconds, the cooling fan reversal switch turns "OFF" and
the pilot lamp on the switch turns "OFF". Then the cooling fan turns in the normal direction.
The cooling fan reversal switch can be operated any
time the engine is running. It is not necessary to stop
the machine to push the reversal cooling fan switch.
If the fan turns in reverse direction under the following
conditions, reverse control of fan is canceled. The
reversal fan indicator lamp flashes at 0.5 sec cycle (ON:
0.25 sec, OFF: 0.25 sec) for 3 seconds, and then the
lamp turns off and the fan turns in normal rotation.

42-92
Function & Structure Hydraulic Group
Reversing Fan Motor Line (OPT)

Reversing fan motor (OPT)


This figure is shown the optional reversing fan motor.

Reversing solenoid
(Electrical connector)

Port P

Gauge port
(M10 x 1.25)

Port Tc

Port T

95V2E42046

Fan motor specifications


Displacement capacity
Rating

Speed
control

3
3
90.3+2
-0 cm /rev (55.1 in /rev)

Pressure

21.3 MPa (217 kgf/cm2) (3,089 psi)

Speed

1,600 min-1

Flow

144 L/min (38 gal/min)

Control method

Continuous variable control with the


proportional valve (not included in
fan motor)

42-93
115ZV-2 Function & Structure Hydraulic Group
Reversing Fan Motor Line (OPT)
Fan motor structure
1

11

13

12

10

A-A

20
14

MA

MB

TC
17

18

19

T
16

15
B-B

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Output shaft
Case
Thrust plate
Piston assy
Cylinder block
Valve plate
Retainer guide
Retainer shoe
Main bearing
Sub bearing

K95V2J42002

11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

Oil seal
End cover
Center spring
Make-up valve
Safety valve
Main spool
Spring
Filter (15 m) (*)
Selector valve (*)
Reversing solenoid (*)

(*) Optional parts for reversing fan motor

42-94
Function & Structure Hydraulic Group
Reversing Fan Motor Line (OPT)

Reversing fan control chart


Reversing control

Normal control
ON

Reversing
solenoid valve

OFF

FVR1
Proportional solenoid
valve output current Fv
Proportional
solenoid valve

FVR2

t FV1

t FV1

t FV1

t FV2

t FV2

t AR2

t AR1

t AR2
ON

Reversing
fan switch

OFF
2 sec
Switching timing chart of reversing fan
t: sec
F: mA

t FV1

16

t FV2

18

t AR1

1,800

t AR2

60

F VR1

approx. 340

F VR2

85V2E42047

42-95
115ZV-2 Function & Structure Hydraulic Group
Reversing Fan Motor Line (OPT)

Hydraulic circuit (Reverse rotation)


Fan motor (1)

MB

MA

Reverse solenoid (6)

Selector valve (5)

To MCU
(Reversing cooling
fan switch)

Make-up valve (3)

Safety valve (4)


MCU
(Engine water temp. sensor
T/C oil temp. sensor
Hydraulic oil temp. sensor)

Proportional relief valve (2)

Brake
circuit

For brake and pilot pump

Unloader valve

Hydraulic tank

Hydraulic line (reverse revolution)

When the cooling fan reversal switch is "ON", reverse


solenoid valve (6) is magnetized. The solenoid valve
spool moves to the left. Oil from the pump pushes selector valve (5) to the left. As a result, the fan motor turns
into reverse.

115V2U42025

42-96
Function & Structure Hydraulic Group

Secondary Steering
Secondary steering circuit
Speed sensor

Pilot lamp
F13

MCU

To steering valve
Pressure
sensor

Check valve

Check valve
G1/2
G1/2

+24 V

Secondary
steering motor
and pump

G1/2
G1/2

F5

16
cm3/rev

G3/8

11.7MPa
(119 kgf/cm2)
(1696 psi)

G1/2

Check valve

Secondary
steering relay

G1/2

+24 V

Secondary
steering motor
and pump
11.7MPa
(119 kgf/cm2)
(1696 psi)

16
cm3/rev

M
Magnetic switch
(on motor and pump)

Steering pump

90.7 90.7
cm3/rev cm3/rev

Hydraulic line
Electrical circuit

115V2E42025

42-97
115ZV-2 Function & Structure Hydraulic Group
Secondary Steering

Secondary steering operation

Motor and
pump

Steering
valve

Check valve

Check valve

The signal from MCU


to magnetic switch

Hose

Machine speed signal

Hose

ON

Machine speed

OFF

(km/h)

85V2E42051

Hose

Block

Pump

Hose

Motor and pump

From
hydraulic tank

Secondary steering hydraulic line diagram


115V2E42026

In normal operation, the oil from the steering pump


flows into the steering valve through the check valve.
And the signal of the pressure sensor is always sent to
the MCU.
With some problems, as the steering hydraulic pressure
goes down while the engine is running, the pressure
sensor signal becomes less than the preset value at the
MCU more than 1 sec. In this condition, if the machine
speed is more than 2 km/h, the MCU sends a signal to
the magnetic switch.
As a result, the secondary steering motor and pump is
driven. Then it is ready to steer the machine.
Pressure sensor preset value
Steering hydraulic pressure
ON: at 0.3 MPa (3 kgf/cm2) (44 psi) or lower
OFF: at 0.4 MPa (4 kgf/cm2) (58 psi) or higher

42-98
Function & Structure Hydraulic Group
Secondary Steering

Secondary steering motor and pump


CW rotation

Magnetic switch

Relief valve

+24 V

Motor

+24 V

Pump

Relief valve
11.7 MPa
(119.3 kgf/cm2)

Customer's power
connection

Customer's
MCU
connection

16

Customer's
ground
connection
Electric/Hydraulic schematic

85V2E42053

Secondary steering motor and pump


Model

ND-K2-D

Discharge (cm3/rev)

16

Relief valve setting pressure


MPa (kgf/cm2) (psi)

11.7 (119.3) (1,696)

85V2E42052

43-1
115ZV-2 Check & Adjustment Hydraulic Group

Check & Adjustment


Hydraulic Group
Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)
........................................................................... 43-2
Hydraulic Cylinder ................................................... 43-15
Stop Valve ............................................................... 43-17

43-2
Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Loading/Steering Circuit Relief Valve/Ride Control Circuit


Reducing Valve (OPT)
Loading circuit relief valve setting
pressures
WARNING
Unexpected movement of the machine may cause an
accident resulting in injury or death.
Therefore, to provide repair service with the engine
running, be sure to observe the following items:
- Park the machine on level ground.
- Apply the parking brake.
- Block the tires with chocks to prevent the tires from
moving.
- Determine the signals between the service man.
- Prohibit any person from walking into dangerous
areas.
- Near articulation areas of the machine
- Under the machine
- Around the engine
- In front of or behind the machine

CAUTION
Be careful, you may get burned if the high pressure
oil spouts out. To prevent such an accident, be sure
to release the residual pressure from the pipe, and
open the cap of the hydraulic tank before removing
the plug from the pressure measurement port.

CAUTION
Do not touch the fan or V-belt of the engine or a hightemperature section if the engine is running. An accident resulting in injury may occur.
Be sure to stop the engine before you open the
access panel of the engine room. Keep all guards in
place.
Avoid high temperature components even when the
engine is stopped.

Measurement instruments
Pressure gauge
30 MPa (300 kgf/cm2) (5,000 psi)
(for loading line with 3 m (10 ft.) hose)
5 MPa (50 kgf/cm2) (1,000 psi)
(for pilot line) with 2~3 m (6~10 ft.) hose
Note
For safety purpose, route the gauge to an area where it
may be safely read by the person doing the test.

Gauge port
Gauge port location
Main relief pressure (1), (2), (3)
Overload relief
pressure

(1), (2), (3)

Pilot line pressure


(Reducing valve)

(4)

Port size
(1), (2), (3)
G (PF) 1/4 with O-ring

(4)
G (PF) 3/8 with O-ring

43-3
115ZV-2 Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Measuring loading circuit main relief pressure

Standard measurement value


Loading line main relief pressure
(at maximum speed) MPa (kgf/cm2) (psi)

20.60.5
(2105) (2,98671)

Loading line overload relief pressure


(at idling speed) MPa (kgf/cm2) (psi)

23.50.5
(2405) (3,41371)

Pilot line

MPa (kgf/cm2) (psi)

3.5
(36) (512)

Hydraulic oil temperature: 505C (1209F)


Reference
Releasing residual pressure from tank and pipes
Keep the bottom surface of the bucket horizontal,
and stop the engine when the bucket is approximately 30 cm (1 ft.) above the ground.
Tilt down the bucket until it comes in contact with
the ground. Place the bucket control lever in the
roll back position, and then lower the boom.
Push down on, then open the cap of the hydraulic
tank to release the residual pressure.

1. Unload the bucket.


2. Press the brake pedal, and set and confirm the
transmission shift lever is at the neutral position.
3. Set and confirm the parking brake is at the "ON"
position.
4. Press the brake pedal, and lower the boom to the
lowest limit.
5. Attach the pressure gauge 30 MPa (300 kgf/cm2)
(5,000 psi) to the bucket cylinder bottom side (2).
6. Set the declutch ON/OFF switch to ON.
Press down the brake pedal all the way to the floor
to avoid the fuel saving mode at idle time.
Note
In the fuel saving mode at idle time, the engine is not
activated promptly and may not reach the maximum
revolution.
7. Move the bucket control lever to the roll back position. Hold the lever at that position.
8. Increase the engine speed to the maximum, and
measure and record the pressure using the pressure gauge.

Adjusting main relief pressure


Loosen the lock nut and adjust the pressure by the
adjusting screw.
Turn clockwise the adjusting screw to raise the set pressure, or turn counterclockwise the adjusting screw to
lower the set pressure.

IMPORTANT
At the completion of check and adjustment of main
relief valve pressure, be sure to tighten the lock nut.

43-4
Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)
Main relief valve

Bucket cylinder
Note
North America equipped M/c's
have a quick connector in port
(3) for testing.

Cap
Lock nut

(1)

Adjusting
screw

(2)
K115V2J43001

Multiple control valve

Make-up valve
Overload relief
valve

Overload relief
valve

Main relief valve

(3)
95ZV43002

Valve assembly
(4)
(PPI)

(Z2)
(PA)
(PARKING)

(Z)

(Z1)
ACF

(ACCF)

(ACCR)

(TA)
(T)

(P)

Reducing valve
(for pilot)
85V2E43006

95ZV43004

43-5
115ZV-2 Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Measuring loading circuit overload relief


pressure
1. Attach the pressure gauge to the port (3).
((1) for the rod side, (2) for the bottom side, (3) for
the both sides.)
2. Adjust the main relief valve pressure to 24.5 MPa
(250 kgf/cm2) (3,555 psi) + 1/4 additional turn, so
the pressure is above the overload relief pressure.
Bucket cylinder bottom side (gauge port (2) or (3))
1. Lower the boom to the lowest limit.
2. Move the bucket control lever to the roll back position.

Adjusting overload relief pressure


Loosen the lock nut and adjust the pressure by the
adjusting screw.
Turn clockwise the adjusting screw to raise the set pressure, or turn counterclockwise the adjusting screw to
lower the set pressure.

IMPORTANT
At the completion of check and adjustment of overload relief valve pressure, be sure to reset the main
relief valve to the original condition.

Overload relief valve

3. Keep the engine speed at low idle.


4. Hold the bucket control lever at the roll back position and record the pressure.

Lock nut

Bucket cylinder rod side (gauge port (1) or (3))


1. Lower the boom to the lowest limit.
2. Move the bucket control lever to the roll back position.
3. Place the shift lever to the forward position.
Note
Avoid Hibernate mode during the measurement.
In the Hibernate mode, the engine speed is decreased
to 775 min-1 at idling under the following coditions:
- when the transmission shift lever is placed at N
position,
- the engine coolant temperature is higher than 60C
(140F), and
- the engine speed is held at 950 min-1 or less for 10
seconds.
4. Keep the engine speed at low idle.
5. Hold the bucket control lever at the roll back position and record the pressure.

Adjusting screw

95ZV43005

43-6
Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Measuring pilot circuit reducing valve pressure

WARNING
Trapped pressure in brake circuit could cause serious
injury when the plug is removed.
Fully release all residual accumulator pressure
before servicing.
1. Attach the pressure gauge to port (4).

Adjusting pilot line pressure


Loosen the lock nut and adjust the pressure by the
adjusting screw.
Turn clockwise the adjusting screw to raise the pilot line
pressure.

IMPORTANT
After the completion of the adjustment of the pilot line
pressure, be sure to tighten the lock nut.

2. Place the shift lever to the forward position.


Note
Avoid Hibernate mode during the measurement.
In the Hibernate mode, the engine speed is decreased
to 775 min-1 at idling under the following coditions:
- when the transmission shift lever is placed at N
position,
- the engine coolant temperature is higher than 60C
(140F), and
- the engine speed is held at 950 min-1 or less for 10
seconds.
3. Keep the engine speed at low idle (when the brake
line pressure is normal) and then measure and
record the pressure.

Reducing valve

Lock nut

Adjusting screw

90ZVE43004

43-7
115ZV-2 Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Ride control circuit reducing valve


setting pressures (OPT)
WARNING
Unexpected movement of the machine may cause an
accident resulting in injury or death.
Therefore, to provide repair service with the engine
running, be sure to observe the following items:
- Park the machine on level ground.
- Apply the parking brake.
- Block the tires with chocks to prevent the tires from
moving.
- Determine the signals between the service man.
- Prohibit any person from walking into dangerous
areas.
- Near articulation areas of the machine
- Under the machine
- Around the engine
- In front of or behind the machine

CAUTION
Be careful, you may get burned if the high pressure
oil spouts out. To prevent such an accident, be sure
to release the residual pressure from the pipe, and
open the cap of the hydraulic tank before removing
the plug from the pressure measurement port.

CAUTION
Do not touch the fan or V-belt of the engine or a hightemperature section if the engine is running. An accident resulting in injury may occur.
Be sure to stop the engine before you open the
access panel of the engine room. Keep all guards in
place.
Avoid high temperature components even when the
engine is stopped.

Measurement instruments
Pressure gauge
15 MPa (150 kgf/cm2) (3,000 psi)
(for ride control line) with 3 m (10 ft.) hose
Note
For safety, route the gauge to an area where it may be
safely read by the person doing the test.

Gauge port
Gauge port location
Reducing pressure

AC2

Port size
G (PF) 1/4 with O-ring

43-8
Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Measuring ride control circuit reducing


pressure

Standard measurement value


Ride control line pressure (reducing valve)
MPa (kgf/cm2) (psi)

8.340.3
(853) (1,20943.5)
X

Hydraulic oil temperature: 505C (1209F)

Reference
Tank

Boom cylinder
bottom side

Valve assembly
(Reducing valve circuit)

AC1

Valve assembly
(Accumulator circuit)
Plug

Reducing
valve

AC

AC2

Accumulator

Valve assembly (Accumulator circuit)

Pump

(T)

Tank

95V2E43003

Reducing valve
Lock nut

(P)

115V2E43001

Adjusting screw
(R)

Releasing residual pressure from tank and pipes


(Ac1)

Keep the bottom surface of the bucket horizontal,


and stop the engine when the bucket is approximately 30 cm (1 ft.) above the ground.

Air bleeder nipple

Tilt down the bucket until it comes in contact with


the ground. Place the bucket control lever in the
roll back position, and then lower the boom.
Push down on, then open the cap of the hydraulic
tank to release the residual pressure.

Valve assembly (Reducing valve circuit)

95V2E43004

1. Loosen the air bleeder nipple for releasing internal


pressure from accumulator circuit.
2. Attach the pressure gauge to the gage port AC2.
: Plug AC2: 16.7~20.6 N-m (1.7~2.1 kgf-m)
(12.3~15.2 lb-ft)
3. Keep the engine speed at low idle and then measure and record the pressure.

43-9
115ZV-2 Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Adjusting reducing valve pressure


Loosen the lock nut of the reducing valve and adjust the
pressure by the adjusting screw.
Turn clockwise the adjusting screw to raise the set pressure, or turn counterclockwise the adjusting screw to
lower the set pressure.

IMPORTANT
At the completion of check and adjustment of reducing valve pressure, be sure to tighten the lock nut.

43-10
Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Steering circuit relief valve setting


pressures
WARNING
Unexpected movement of the machine may cause an
accident resulting in injury or death.
Therefore, to provide repair service with the engine
running, be sure to observe the following items:
- Park the machine on level ground.
- Apply the parking brake.
- Block the tires with chocks to prevent the tires from
moving.
- Determine the signals between the service man.
- Prohibit any person from walking into dangerous
areas.
- Near articulation areas of the machine
- Under the machine
- Around the engine
- In front of or behind the machine

CAUTION
Be careful, you may get burned if the high pressure
oil spouts out. To prevent such an accident, be sure
to release the residual pressure from the pipe, and
open the cap of the hydraulic tank before removing
the plug from the pressure measurement port.

CAUTION
Do not touch the fan or V-belt of the engine or a hightemperature section if the engine is running. An accident resulting in injury may occur.
Be sure to stop the engine before you open the
access panel of the engine room. Keep all guards in
place.
Avoid high temperature components even when the
engine is stopped.

Measurement instruments
Pressure gauge
30 MPa (300 kgf/cm2) (5,000 psi)
(for loading line with 3 m (10 ft.) hose and steering line
with 1.5~3 m (4~10 ft.) hose)
5 MPa (50 kgf/cm2) (1,000 psi)
(for pilot line) with 2~3 m (6~10 ft.) hose
Note
For safety, route the gauge to an area where it may be
safely read by the person doing the test.

Gauge port
Gauge port location

Port size

Main relief pressure


Overload relief
pressure
Reducing pressure

(1), (2)

G (PF) 1/4 with O-ring

(3)

Rc (PT 1/8)

43-11
115ZV-2 Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Standard measurement value

Steering valve

Steering line main relief pressure


(at maximum speed)
MPa (kgf/cm2) (psi)

20.60.5
(2105) (2,98671)

Steering line overload relief pressure


(at idling speed)
MPa (kgf/cm2) (psi)

24.5 +1.0
0
(250 +100 ) (3,555 +1420 )

Pilot line
MPa (kgf/cm2) (psi)

3.5
(36) (512)

Main relief valve

Hydraulic oil temperature: 505C (1209F)


Reference
Releasing residual pressure from tank and pipes
Keep the bottom surface of the bucket horizontal,
and stop the engine when the bucket is approximately 30 cm (1 ft.) above the ground.
Tilt down the bucket until it comes in contact with
the ground. Place the bucket control lever in the
roll back position, and then lower the boom.
Push down on, then open the cap of the hydraulic
tank to release the residual pressure.

Overload relief
valve
95ZV43006

43-12
Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Measuring steering circuit main relief pressure

Adjusting steering line main pressure

1. Unload the bucket.


2. Press the brake pedal, and set and confirm the
transmission shift lever is at the neutral position.

Steering cylinder

(2)

3. Set and confirm the parking brake is at the "ON"


position.
4. Press the brake pedal.
5. Attach the pressure gauge to the gauge port ((1) or
(2)).
6. Set the declutch ON/OFF switch to ON.
Press down the brake pedal all the way to the floor
to avoid the fuel saving mode at idle time.
Note
In the fuel saving mode at idle time, the engine is not
activated promptly and may not reach the maximum
revolution.
7. In case the pressure gauge is installed to (1), steer
the machine to the left until the front and rear chassis contact each other.
Continue to hold the steering wheel fully turned.

Note
(1)
North America equipped
M/c's have quick
connectors at ports (1)
and (2).

K115V2J43002

Loosen the lock nut and adjust the pressure by the


adjusting screw.
Turn clockwise the adjusting screw to raise the steering
line main pressure.
Main relief valve
Lock nut
Adjusting
screw

Note
Because the stop valve is installed into the steering line,
oil pressure does not reach the set point when the
steering is fully turned.
When measuring oil pressure, be sure to apply the articulation stopper or screw the stopper (bolt) in until the
front and rear chassis contact each other.

WARNING
If the machine begins to move with the articulation
stopper applied, it may cause an accident resulting in
injury or death.
After the measurement, be sure to disconnect and
store the articulation stopper.
8. Increase the engine speed to high idle, and measure and record the pressure.

95ZV43007

43-13
115ZV-2 Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Measuring steering circuit overload relief


pressure

Adjusting overload relief pressure


Lock nut

Stopper
(bolt)

Installed on
front chassis

Port B to
steering valve

Adjusting
screw

Port A from
pilot valve

Spool

Installed on rear chassis

95ZV43008
115V2U43001

1. Attach the pressure gauge to the port ((1) for the


left turn, (2) for the right turn).
2. Adjust the main relief valve pressure to 25.5 MPa
(260 kgf/cm2) (3,697 psi) + 1/4 additional turn, so
the pressure is above the overload relief pressure.
3. Steer the machine until the front and rear chassis
contact each other. Continue to hold the steering
wheel fully turned.
Note
Because the stop valve is installed into the steering line,
oil pressure does not reach the set point when the
steering is fully turned.
When measuring oil pressure, be sure to apply the articulation stopper or screw the stopper (bolt) in until the
front and rear chassis contact each other.
4. Place the shift lever to the forward position.
Note
Avoid Hibernate mode during the measurement.
In the Hibernate mode, the engine speed is decreased
to 775 min-1 at idling under the following coditions:
- when the transmission shift lever is placed at N
position,
- the engine coolant temperature is higher than 60C
(140F), and
- the engine speed is held at 950 min-1 or less for 10
seconds.
5. Keep the engine speed at low idle, and measure
and record the pressure.
Raise the engine speed to 1,000 min-1 if fail to do.

Loosen the lock nut and adjust the pressure by the


adjusting screw.
Turn clockwise the adjusting screw to raise the set pressure, or turn counterclockwise the adjusting screw to
lower the set pressure.

WARNING
If the machine begins to move with the articulation
stopper applied, it may cause an accident resulting in
injury or death.
After the measurement, be sure to disconnect and
store the articulation stopper.

IMPORTANT
At the completion of check and adjustment of overload relief valve pressure, be sure to reset the main
relief valve to the original condition.

43-14
Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Measuring pilot circuit relief pressure


(reducing pressure)

4. Keep the engine speed at low idle and record the


pressure.
5. Hold the bucket control lever at the roll back position and record the pressure.

Adjusting screw
Lock nut

Adjusting pilot line pressure


Loosen the lock nut and adjust the pressure by the
adjusting screw.
Turn clockwise the adjusting screw to raise the pilot line
pressure.

IMPORTANT

(T)

After the completion of the adjustment of the pilot line


pressure, be sure to tighten the lock nut.

(A)

(3)
(TS)

(B)

115ZV43007

1. Attach the pressure gauge to the port (3).


Gauge port plug width across flat: 5 mm
2. Move the bucket control lever to the roll back position.
3. Place the shift lever to the forward position.
Note
Avoid Hibernate mode during the measurement.
In the Hibernate mode, the engine speed is decreased
to 725 min-1 at idling under the following coditions:
- when the transmission shift lever is placed at N
position,
- the engine coolant temperature is higher than 60C
(140F), and
- the engine speed is held at 950 min-1 or less for 10
seconds.

43-15
115ZV-2 Check & Adjustment Hydraulic Group
Hydraulic Cylinder

Hydraulic Cylinder
Cylinder natural drift

Measurement procedure
1. Unload the bucket.

WARNING
Standing under the boom or bucket during service
work is dangerous. An accident resulting in injury or
death may be caused.
To prevent such an accident, be sure to lock the
boom and bucket control levers in the cab, securely
support the boom, and remove the starter key.
In addition, hang a "DO NOT OPERATE!" tag on the
steering wheel.

2. Keep the boom and bucket horizontal.


3. Set the parking brake switch to the "ON" position.
4. Lock the boom and bucket control levers using the
safety lock.
5. Stop the engine.
6. Mark the cylinder rod at a point 100~150 mm (4~6
in) away from the cylinder head cover.

Measurement instrument

7. Measure the accurate distance from the cylinder


head cover to the vinyl tape. This is distance "A"
mm (in). Measure the distance again 5 minutes
later. This is distance "B" mm (in).

- Scale
150~300 mm (1 ft.)
- Stop watch

Cylinder drift (mm/min)


A B (mm) (in)
= -------------(in/min)
5 (min)

- Black vinyl "electrician's" type


Note
Warm-up the hydraulic oil before measuring cylinder
drift.

Standard measurement value


Boom cylinder (mm/min) (in/min)

3 (1/8) or less

Bucket cylinder (mm/min) (in/min)

4 (5/32) or less

43-16
Check & Adjustment Hydraulic Group
Hydraulic Cylinder
Reference

Mark
(Vinyl tape)
Scale
95ZV43009

Drift rate depends on the viscosity of the hydraulic oil


and its temperature. In other words, high temperature of
the hydraulic oil reduces the viscosity. Reduction in oil
viscosity increases oil leakage through the seals, and
increases the drift rate. Cold thick oil reduces the drift
rate.

IMPORTANT
At the completion of measurement, if the vinyl tape
used for measurement is not removed from the cylinder rod, the tape may be caught by the rod seal. The
tape will cause oil leakage from the rod seal. To prevent oil leakage, be sure to remove the vinyl tape.

43-17
115ZV-2 Check & Adjustment Hydraulic Group
Stop Valve

Stop Valve
Stop valve adjustment procedure

Reference dimension
Front chassis

Stop valve
(rear chassis)

Stopper
(bolt)

(L.H, R.H)

Front chassis

Rear chassis

Reference dimension
23~27.5 mm
(0.9~1.1 in)
Stopper (bolt) length

Reference dimension
28~48 mm (1.1~1.9 in)
115ZV43004

WARNING
When the machine turns, the clearance in the articulation area closes. As a result, people may be caught,
leading to a severe accident. To prevent such an
accident, observe the following items strictly when
adjusting the steering stopper.
- Stop the engine before starting adjustment of the
stopper bolt.
- When confirming the operation after setup, keep
proper distance from the articulation area of the
machine.
The stop valve works when the spool is pushed in 3 mm
(0.118 in).
Adjust the stopper bolt by using the following procedure.
- Adjust the stopper (bolt) length so that the clearance
between the machine body and the stopper
becomes the reference dimension "28~48 mm
(1.102~1.890 in)" shown in the table below.

Clearance between machine body and stopper


Articulation angle ( )

37

36

115ZV43005

35

Clearance between machine body and


stopper (mm) (in)

28
38
48
(1.102) (1.496) (1.890)

Stopper (bolt) length (mm) (in)

23
25
27.5
(0.906) (0.984) (1.083)

*The target value should be the articulation angle "36",


while not rolling machine.
- After adjustment, turn the steering wheel slowly at a
rate of 5 sec or more per turn, and confirm the clearance between the machine body and the stopper.
- When adjustment is completed, tighten the lock nut
of the stopper (bolt).
: 90 N-m (9.2 kgf-m) (67 lb-ft)

43-18
Check & Adjustment Hydraulic Group

MEMO

52-1
115ZV-2 Function & Structure Brake Group

Function & Structure


Brake Group
Brake System Outline.............................................. 52-2
Brake Units Layout .................................................. 52-3
Unloader Valve ........................................................ 52-4
Valve Unit ................................................................ 52-7
Accumulator ............................................................ 52-9
Brake Valve ............................................................. 52-10
Service Brake .......................................................... 52-14
Parking Brake.......................................................... 52-22
Parking Brake Manual Release............................... 52-30
Brake Circuit Check Valve....................................... 52-32
Auto Brake .............................................................. 52-33
Pressure Sensor (for stop lamp and declutch) ........ 52-36

52-2
Function & Structure Brake Group
Brake System Outline

Brake System Outline


The brake system is the all-hydraulic type, and has two
independent systems consisting of the front system and
the rear system for enhancing safety. The service brake
and the parking brake are the wet disc type.
(Refer to "Hydraulic & Brake Circuit" page 92-4 and
"Brake Circuit" page 92-5.)

Service brake
Oil from the pump is regulated in a range from 6.9~11.8
MPa (70~120 kgf/cm2) (995~1,706 psi) by unloader
valve (22), and accumulated in accumulator (33) provided for the front and rear wheels.
When brake valve (23) is depressed, the pressure oil in
the accumulator enters the disc brake piston chamber
for the front and rear wheels, pushes the piston, and
generates braking power.

Parking brake
The parking brake is the spring applied oil pressure
released type.
Turning on the parking switch turns off solenoid valve
(35) for parking, returns the oil in brake piston chamber
(55) to the tank, pushes the piston with the spring, and
makes the brake effective.
Turning off the parking switch turns on solenoid valve
(35) for parking, oil flows into piston chamber (55),
pushes the pistons over coming the spring force, and
release the brake.

Adjustment of axle internal pressure


While the brake pedal is not pressed, the internal pressure of the hydraulic tank is always applied on the brake
piston chamber, and there is a possibility that the brake
may drag.
To prevent the brake from dragging, the axle housing air
chamber is connected to the hydraulic tank air chamber
so that the pressure inside the axle housing becomes
equivalent to the pressure inside the hydraulic tank.

52-3
115ZV-2 Function & Structure Brake Group
Brake Units Layout

Brake Units Layout


The brake system is the all-hydraulic type, and has two
independent systems consisting of the front system and
the rear system for enhancing safety.

The service brake is the wet disc type. The parking


brake is the spring applied oil pressure released type.

115V2E52001

1. Accumulator
2. Solenoid valve (for parking)
3. Solenoid valve (for auto-brake)

4. Brake valve
5. Parking brake
6. Unloader valve

52-4
Function & Structure Brake Group
Unloader Valve

Unloader Valve
(S/N 9001~9050)

To accumulator

B-B

22

24

To fan motor

23

21

20

8
9

To tank

19
Filter

18

17
Pilot port
(accumulator
feedback port)

16
A-A

10

15
12

11

From pump

14

Pump port

Fan motor port

13

Accumulator port

Fan motor port


Pilot port
(accumulator
feedback port)
Tank port

Tank port

Accumulator port

1.
2.
3.
4.
5.
6.
7.
8.

Body
Spring
Spool
O-ring
Plug
Orifice
Orifice
O-ring

PP

Rc
1/8

Hydraulic circuit diagram

9.
10.
11.
12.
13.
14.
15.
16.

AC

P
Pilot port
(accumulator
feedback port)

Plug
Plug (gauge port)
Governor plunger
Spring
O-ring
Plug
Pilot valve
Spring seat

Pump port
Outline drawing

17.
18.
19.
20.
21.
22.
23.
24.

Spring
Spring
O-ring
Plug
Adjusting screw
Lock nut
Packing
Cap

K115ZV52001

52-5
115ZV-2 Function & Structure Brake Group
Unloader Valve
(S/N 9051~)

To
accumulator

B-B

To tank

22
8

20

25

10
1

19

26
18

To fan motor

21

17

16

Filter

15
12

11

Pilot port
(accumulator
feedback port)

13

A-A

From pump

A
Pump port

Fan motor port

14

Accumulator port

Fan motor port


Pilot port
(accumulator
feedback port)

AC

Tank port

PP

Rc
1/8

Tank port

Accumulator
port

Pilot port
(accumulator
feedback port)

Pump port

Hydraulic circuit diagram

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

Body
Spring
Spool
O-ring
Plug
Orifice
Orifice
O-ring
Plug
Plug (gauge port)
Governor plunger
Spring
O-ring

K115ZV52002

14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.

Plug
Pilot valve
Spring seat
Spring
Spring
O-ring
Plug
Adjusting screw
Lock nut

Seat
O-ring

52-6
Function & Structure Brake Group
Unloader Valve
The unloader valve controls the flow rate and the pressure of the hydraulic oil sent from the pump to the accumulator. Body (1) is equipped with ports (pump, fan
motor, accumulator, pilot and tank).
Spool (3) which opens and closes the pump port to the
fan motor port, orifice (6) which regulates the flow rate
to the accumulator port with high priority, and the pressure governor mechanism which controls the pressure
on the accumulator port side are built in the unloader
valve.

Unloader valve operation


While the unloader valve is not operating, spool (3) is
pushed back by spring (2) and the pump port to the fan
motor port is closed. Oil flowing from the pump port is
sent to the accumulator port through orifice (6), and the
pressure at the accumulator port increases accordingly.
When an excess flow rate is generated, spool (3) moves
to the fan motor port side and the excess flow rate flows
out to the port to the fan motor.
The pressure at the accumulator port is transferred to
the inside of the pressure governor through orifice (7).
When the pressure at the accumulator port increases
and exceeds the load of springs (17)(18) applied on
pilot valve (15), the pilot valve opens and increase of
the pressure at the accumulator port stops (cut-out
pressure). At this time, the pressure in the accumulator
connected to the pilot port pushes governor plunger
(11), and continuously releases the pilot valve.
When the pressure in the accumulator decreases and
the spring attached to the pilot valve pushes back the
governor plunger, the pilot valve is closed and the pressure at the accumulator port starts to increase again
(cut-in pressure).
Setting
pressure

OFF

11.80.5 MPa (1205 kgf/cm2) (1,70671 psi)

ON

6.91.0 MPa (7010 kgf/cm2) (995142 psi)

52-7
115ZV-2 Function & Structure Brake Group
Valve Unit

Valve Unit
4

Note
Unloader valve (PI)
"Feed back" signal is
acquired from front
brake accumulator.

Loading line
pilot valve

(PPI)

(Z)
(Z1)

(Z2)
(PA)

ACF

(PARKING)

Wet type
parking brake

(ACCF)

(ACCR)

(PI)

(TA)
(P)

Tank

(T)

High pressure
test ports

Unloader valve
"feed back" signal.
Pump port
(from unloader
valve)

P=Pump supply
T=Tank circuit
PI=Pump feedback to unloader
(From ACCF circuit)
ACCR=Accumulator circuit-rear
ACCF=Accumulator circuit-front
PPI=Pilot valve
85V2E52002

WARNING

ACCR

ACCF
To parking brake
ACF
Rc1/8

PI

1
B

2
P

PA

Z2
G1/4

T
ACF T
Rc1/8 G1/2

Z PPI TA Z1
G1/4 G3/8 G3/8 G1/4

115V2U52002

1. Solenoid valve for parking brake


2. Reducing valve [3.5 MPa (36 kgf/cm2) (512 psi)]
(Serves as pressure for loading pilot control and park brake)
3. Check valve
4. Accumulator low pressure sensor
Set value by MCU
[3.90.5 MPa (405 kgf/cm2) (56971 psi)]

Injection Hazard
High pressure test ports contain accumulator pressure [11.8 MPa (1,706 psi)]
that can escape from these 2 plugs.
Depress brake pedal 80~100 times to
completely discharge the brake accumulators prior to removing these test
plugs.

135ZV52035

52-8
Function & Structure Brake Group
Valve Unit

Accumulator low pressure sensor

View A
1: Power (+)
2: Output (+)
3: Common

(V)
5
4
3
2
1
0

10
(102)
(1422)

20
(204)
(2844)

MPa
35
30
2
(306) (351) (kgf/cm )
(4351) (4991) (psi)

95V2E52095

52-9
115ZV-2 Function & Structure Brake Group
Accumulator

Accumulator

7
2

3
13
10

12
11
5
8
9
6

95ZV52058

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

Body
Hydraulic cap
Gas cap
Piston
V-O-ring
Backup ring
Wear ring
O-ring
Backup ring
Gas valve
Gas valve O-ring
Gas valve guard
Bolt

The accumulator holds a reserve of pressurized oil for


the brake circuit prevent disability of the brakes caused
by a problem with the pump, etc. Two accumulators are
provided in the service brake line. Nitrogen gas at 2.94
MPa (30 kgf/cm2) (427 psi) is charged in the gas chamber.
One accumulator of the same type is provided also in
the dry type parking brake line, locate in the front chassis.
Accumulator specifications
Maximum operating pressure MPa
(kgf/cm2) (psi)

11.80.5
(1205) (1,70671)

Nitrogen gas charging pressure MPa


(kgf/cm2) (psi)

2.940.1
(301) (42714)

Nitrogen gas capacity L (gal)

3.0 (0.793)

52-10
Function & Structure Brake Group
Brake Valve

Brake Valve
37

38

36

35

39

40

44

35

28

55

29

34

17

54
53

16

31

42

41

43

47
A-A

48

49

50

52

51

18

14

Pilot port

19

20

23

32
33

26

21
22

25

Rear
brake port

Accumulator
port

12

24

Tank port
Universal joint assembly

10
2
5

Front brake
port

11

Accumulator
port

5
Pressure sensor port

3
B

1
8

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

45

30

15

13

46

Body
Spool
Spring seat
Snap ring
Plunger
Spring
Plug
O-ring
C-ring
Orifice
O-ring

4
B-B

12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.

Body
Spring
Cover
Oil seal
Plate
C-ring
Spool input
Spring seat
Pilot piston
Case
Spring

23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.

Spring
Case
Snap ring
Spring

Seat
Dust cover
Mounting plate
Pedal bush
Bolt
Spring washer

34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.

Pedal
Roller
Spacer
Pedal pin
L-pin
Washer
Pin
Shaft
Spacer
Joint
Pin

115V2E52009

45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.

Boot
Snap ring
Shaft
Bolt
Washer
Nut
Plate
Spring
Screw
Nut
Pedal cover

52-11
115ZV-2 Function & Structure Brake Group
Brake Valve

Brake valve performance chart

Pedal pressing force (F)

N
(kgf)
(lbf)

338 (34.5)
(75)

300
(30.6)
(67)
200
(20.4)
(45)

162(16.5)
(36.4)

100
(10.2)
(22)

93.3(9.5)(21)

76.1
(7.76)
(17)

67.1(6.84)
(15)
0

Output oil pressure (Brake port)

MPa
(kgf/cm2)
(psi)
4
(40)
(580)

3.9

10

15

18.5 19

10

15

18.5 19

Pedal stroke

4.90
(50.0)
(711)

2
(20)
(290)
1.57
(16.0)
(229)

0.36
(3.7)
(52)

( )
0

MPa
(kgf/cm2)
(psi)

Output oil pressure (Brake port)

( )
5

4
(41)
(580)

3.9 5

Pedal stroke

4.94
(50.4)
(716)

2
(20)
(290)

0 0.41
(4.2)
(59)

2
(20)
(290)

4
(41)
(580)

5.35
(54)
(768)

MPa
(kgf/cm2)
(psi)

Pilot oil pressure (pilot port input)


K115V2U52006

52-12
Function & Structure Brake Group
Brake Valve

Brake valve outline

While the valve is not operating

The brake valve is integrated into the pedal and converts the pump oil pressure into the pressure corresponding to the pedal pressing force, and transmits it to
the brake.
The brake valve is the tandem type, and consists of two
independent systems. When the right side pedal is
depressed, the movement of right side pedal is transmitted to a left side pedal by the linkage and brake is
applied. But when the left side pedal is depressed, only
left pedal is worked.
The valve is the closed center type (in which the import
is closed while the pedal is released). High pressure is
always applied on the in-port side to improve the
responsiveness during operation.

35

18

Pilot port
23

20
26

22

B1 Rear brake

Accumulator A1

2
5

13

B2 Front brake

Accumulator A2

2
5

T Tank

Pressure sensor port


B-B

95V2E52003

52-13
115ZV-2 Function & Structure Brake Group
Brake Valve
Between spool input (18) and spools (2) in the brake
valve, springs (22)(23) which convert pedal pressing
force into output oil pressure are installed.
In addition, two spools (2) are installed for series in the
center of the main body of the brake valve. Plungers (5)
which transmit the control oil pressure to spool as the
hydraulic reactive force are built in each spool.
While the valve is not operating, each spool is returned
to the non-operation position by springs (6)(13).
As a result, the passages from out-ports B1, B2, and
pressure sensor port to tank port are opened, and the
pressure inside the brake piston chamber becomes
equivalent to the pressure in the tank.
In addition, oil sent from the pump is stored in the accumulator, and sent to the in-ports A1 and A2. But the passages from in-ports A1, A2 to out-ports B1, B2 and
pressure sensor port are shut down by each spool (2),
and high pressure oil from the accumulator is maintained.

While the valve is operating


When the brake pedal is pressed, spool input (18) and
pilot piston (20) are pushed by way of roller (35).
Spool input (18) and pilot piston (20) lets each spool (2)
drop down by way of springs (22)(23). When spools (2)
are pushed down, at first the passage from out-port B1,
B2, and pressure sensor port to the tank port are shut
down.
When spools (2) are pushed down further, the passages
from in-ports A1, A2 to out-ports B1, B2 are opened and
pressure oil from the accumulator is sent to the brake
piston chamber to apply the brake.
Pressure oil of in-ports A1, A2 side act on plunger (5)
inside the each spool (2) through the orifices and works
as the hydraulic reactive force to return spools (2)
upward.
When the sum of hydraulic reactive force and spring
load (6)(13) becomes balanced with spring load
(22)(23), it returns spools (2) to shut down the passages
A1-B1 and A2-B2 to hold the pressure.
By this operation, spring load (22)(23)(26) by deflection
are transmitted to the operator as pedal pressing force
and the pressure in proportion to the pedal pressing
force is obtained.

While the valve is releasing


When the brake pedal is released, spool input (18) and
pilot piston (20) are pushed back by spring (26). Compressed springs (22)(23) are extended, and each spool
(2) is returned upward to the non-operation position by
the sum of hydraulic reactive force and spring load
(6)(13).
After the passages from out-ports B1, B2 and pressure
sensor port to in-ports A1, A2 is shut down by spool (2),
the pressure of out-ports B1, B2 and pressure sensor
port is opened to tank port, and then the brake operation
is released.

52-14
Function & Structure Brake Group
Service Brake

Service Brake
Piston stroke adjuster

15

16

13

Service brake operation


Oil from the pump is regulated in a range from 6.9~11.8
MPa (70~120 kgf/cm2) (995~1,706 psi) by the unloader
valve, and accumulated in the accumulator provided for
the front and rear wheels.

Wheel hub

14

When the brake valves are depressed, the pressure oil


in the accumulator enters the disc brake piston chamber
for the front and rear wheels, pushes the piston, and
generates braking power.

Brake oil
inlet port

While the brake pedal is not pressed, the internal pressure of the hydraulic tank is always applied on the brake
piston chamber, and there is a possibility that the brake
may drag. To prevent the brake from dragging, the axle
housing air chamber is connected to the hydraulic tank
air chamber so that the pressure inside the axle housing
becomes equivalent to the pressure inside the hydraulic
tank.
12
Axle housing

1
5

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.

10 11

115ZV52003

Internal gear hub


Brake piston
Piston return spring
Steel plate
Friction disc
Disc gear
Axle shaft
O-ring (for brake piston)
O-ring (for brake piston)
O-ring (for gear hub)
O-ring (for gear hub)
Air bleeder nipple
Socket bolt
Tolerance ring
Sleeve
Bushing

The service brake is an enclosed wet type multi-plate


hydraulic brake, and is incorporated in the axle housing.
This type of service brake ensures good braking power
even in muddy or sandy soil.
Even if the brake disc is worn, the integrated adjustment
mechanism always adjusts for a constant pedal stroke.

52-15
115ZV-2 Function & Structure Brake Group
Service Brake

Service brake friction disc


6.8 0.1 mm (0.268 0.004 in)

430 mm (16.9 in)

5 0.15 mm (0.197 0.006 in)

1.2 mm (0.047 in)

0.55 mm (0.022 in)


Detailed drawing of groove
115V2E52011

Each friction plate has linings (paper material) on the


contact faces on both sides.
To reassemble the brake disc plates, be sure to align
holes (H) of three friction plates with each other to
ensure smooth flow of gear cooling oil.
Note
When installing friction discs, soak these in oil and antichatter mixture for at least 30 minutes prior to installation.

52-16
Function & Structure Brake Group
Service Brake

Service brake steel plate

The steel plate shown in the lower figure has the section
(A) where several teeth are intentionally absent. This
steel plate should be installed on the brake backing
plate side (outer side of the machine body). The section
(A) of this plate is used for measurement of friction plate
wear. If this steel plate is installed incorrectly, measurement of wear is disabled.

Spring pins

Therefore, this steel plate should be installed correctly


with regard to the tooth location so that the teeth cut-off
section is located (or indexed) as shown in the figure.

Friction disc

There is no inside or outside on this plate either. It may


be installed either way.
(A)
Cooling
holes

(A)

Steel plate

Spring pins

Internal gear

Friction disc wear


measurement
point

115ZV52005

A brake disc includes three steel plates, and the tooth


pattern of three steel plates differ from each other. Carefully install the steel plates.
The steel plate shown in the upper figure should be
installed on the piston side. As to the installation direction, this steel plate can be installed either side inward
as there is no inward or outward direction.

52-17
115ZV-2 Function & Structure Brake Group
Service Brake

Service brake piston


Upper side

4
4

6
3

4
A

4
6

1. Hole for piston return spring


(16 positions on circumference)
2. Hole for brake pedal stroke adjusting mechanism
(6 positions on circumference, M10 x 1.5)
3. Hole for pushing in piston
use a M10 x 1.5 - 45~50 L (1.8~1.97 in)
(Fully threaded) for this.
(4 equivalent divisions of circumference)
4. Hole for removing piston
(6 positions on circumference)
5. Hole for prevention of close contact between piston
and internal gear hub
6. Cooling oil hole

A-A
115ZV52006

52-18
Function & Structure Brake Group
Service Brake

Service brake pedal stroke adjusting mechanism

Fig. 2

1.8 mm
(0.07 in)

Brake stroke
adjusting
mechanism

115ZV52030

115ZV52007

This shows the automatic adjuster function which


always offers a constant pedal stroke as the brake disc
wears.
Fig. 1

When the brake disc wears and the brake piston is


shifted by approximately 1.8 mm (0.07 in) or more, the
sleeve is gradually pulled out to the left by the socket
bolt by the amount corresponding to the wear. At that
time, there is clearance of approximately 1.8 mm (0.07
in) between the sleeve and the socket bolt.
Fig. 3

Piston Sleeve

Tolerance ring

Approx.
1.8 mm
(0.07 in)

1.8 mm
(0.07 in)

Socket bolt

Bushing

115ZV52028
115ZV52031

When the brake disk is not worn and the hydraulic pressure is not applied on the brake piston, the piston is
pulled back by the return spring. At that time, there is
clearance of approximately 1.8 mm (0.07 in) between
the sleeve and the socket bolt.

When the brake pedal is released and the hydraulic


pressure is not applied on the brake piston, the brake
piston is pulled back by the return spring by approximately 1.8 mm (0.07 in), and stopped by the sleeve. In
other words, the brake piston return amount is set to
approximately 1.8 mm (0.07 in) so that a constant pedal
stroke is always offered. Motions of the sleeve are regulated by the tolerance ring (spring). The sleeve is not
moved by the return spring force of the piston.

52-19
115ZV-2 Function & Structure Brake Group
Service Brake

Tolerance ring
Wave

Tolerance ring
95ZV52020

The tolerance ring tightens easily the shaft (sleeve) and


the boss (bushing) to transmit the torque and the thrust
force. The tolerance ring is a press-in ring made of elastic wave sheet steel.
Installation procedure
Boss (bushing)

Tolerance ring

Shaft (sleeve)

95ZV52021

- Attach the tolerance ring to the boss (bushing).


- Press-fit the shaft (sleeve).

52-20
Function & Structure Brake Group
Service Brake

Brake circuit air bleeding procedure


Valve assembly
(Brake manifold block assembly)

Solenoid valve
for auto brake

Solenoid
valve for
parking

Service brake valve

WARNING
Unexpected movement of the machine may cause a
severe accident. To prevent such an accident, take
the following safety measures when performing air
bleeding with the engine running.
- Park the machine on level ground.
- Apply the parking brake.
- Block the tires with chocks to prevent the wheel
from moving.
- Determine the signals between the persons related
to this work for engine starting to prevent an accident.
- When moving up the boom, install a safety column
under the boom.
- Apply the articulate stopper.

IMPORTANT
Before bleeding the service brakes, it is important to
remove all air from the brake valve manifold block,
and all related valves.
These include the reducing valve and park brake
valve. Failure to do this correctly will result in unsatisfactory brake modulation.
Perform the following to do this:
1. Verify that the wheels are securely blocked, and the
articulation lock is in the "locked" position.
Air bleeder
nipple

2. Charge the accumulator to full pressure, and then,


shut off the engine.

Auto brake solenoid valve

3. Turn the parking brake solenoid valve release knob


counterclockwise, then, back to neutral, five times
at five-second intervals between each turn.
Position the knob back to the normal position when
finished.
4. Connect a clear vinyl tube [About 1.5 meters (5 ft.)
long] to the brake pedal air bleeder nipple, and
open the bleeder nipple.

Reducing valve

Button
(diameter:
approximately
4 mm)

Solenoid valve
for auto-brake

5. Press the auto-brake solenoid valve release button


five times at five-second intervals between each
turn. Position the knob back to the normal position
when finished.

Solenoid valve
pressure nut

6. Close the bleeder nipple and remove the vinyl tube


from the brake valve.

115V2E52002

52-21
115ZV-2 Function & Structure Brake Group
Service Brake

Bleeding air from brake pipes and axle


housing hubs

Bleeding air from parking brake housing


Air bleeder nipple

Air bleeder nipple


Vinyl tube

2nd propeller shaft


Vinyl tube
115V2E52010
70ZV52019

1. Connect a vinyl tube to the air bleeder nipple provided in the axle housing, and place an oil can for
hydraulic oil recovery.
(The air bleeder nipple is equivalent to the one provided in the brake valve).
2. Loosen the air bleeder nipple a little. Press and
hold the left brake pedal until oil containing no air
comes from the air bleeder nipple. After that,
tighten the air bleeder nipple.
Perform this operation for each of the four wheels.
: Air bleeder nipple
9 N-m (0.9 kgf-m) (6.5 lb-ft)

1. Connect a vinyl tube to the air bleeder nipple provided in the axle housing, and place an oil can for
hydraulic oil recovery.
(The air bleeder nipple is equivalent to the one provided in the brake valve).
2. Loosen the air bleeder nipple a little. Turn the park
brake solenoid valve release knob counterclockwise until oil containing no air comes from the air
bleeder nipple. After that, tighten the air bleeder
nipple.
: Air bleeder nipple
9 N-m (0.9 kgf-m) (6.5 lb-ft)
Position this release knob to the normal position
when finished.

52-22
Function & Structure Brake Group
Parking Brake

Parking Brake
(S/N 9001~9050)
2nd Propeller shaft

13

14

10

7
17
8

15

19
21

12
11

18
16
20

Front differential assy

115V2E52003

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Housing
Piston
Housing
Spring
Spring
Head pin
Bolt
Straight pin
O-ring
Back-up ring

11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

Friction disc
Separation disc
Flange nut
Nut
Gear
Flange
Oil seal (single lip)
Oil seal
Pin
Spring pin

21. Spring

52-23
115ZV-2 Function & Structure Brake Group
Parking Brake
(S/N 9051~9100)
2nd Propeller shaft

7
14
19

2
12

8
3

11

16

10

13
18
17
15

Front differential assy

K115V2J52003

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Housing
Piston
Housing
Spring
Spring
Head pin
Bolt
Straight pin
O-ring
Friction disc

11.
12.
13.
14.
15.
16.
17.
18.
19.

Separation disc
Gear
Housing
Oil seal (single lip)
Oil seal
Pin
Spring pin
Spring
Oil seal (double lip)

52-24
Function & Structure Brake Group
Parking Brake
(S/N 9101~)
2nd Propeller shaft

7
2

14
19

12

8
3

11

16

10

13
18
17
15

Front differential assy

K115V2J52004

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Housing
Piston
Housing
Spring
Spring
Housing
Bolt
Straight pin
O-ring
Friction disc

11.
12.
13.
14.
15.
16.
17.
18.
19.

Separation disc
Gear
Housing
Oil seal (single lip)
Oil seal
Pin
Spring pin
Spring
Oil seal (double lip)

52-25
115ZV-2 Function & Structure Brake Group
Parking Brake

Parking brake operation


The parking brake is the spring applied oil pressure
released type.
Turning on the parking switch turns off the solenoid
valve for parking, returns the oil in the brake piston
chamber to the tank, pushes piston (2) with springs
(4)(5), and makes the brake effective.
Turning off the parking switch turns on the solenoid
valve for parking, oil flows into the piston chamber,
pushes pistons (2) to the upward over coming spring
force (4)(5), and release the brake.

Operation of parking brake


Parking switch

ON

OFF

Solenoid valve

Power OFF

Power ON

Oil discharge

Oil charge

Braking

Released

Brake piston chamber


Parking brake

Turning the starter key off works the same as turning the
parking switch "ON".

13

14

5
A

(0.197~0.236 in)

5~6 mm

(S/N 9001~9050)

1
7

Brake oil

115V2U52005

52-26
Function & Structure Brake Group
Parking Brake
(S/N 9051~9100)
A

1
5
4

Brake oil

K115V2J52004

(S/N 9101~)

5
1

7
Brake oil

K115V2U52005

52-27
115ZV-2 Function & Structure Brake Group
Parking Brake
Note
- To check the wear on parking brake, stop the engine
and measure the dimension A.
A: the dimension from the end face of manual
release bolt (7) to machined surface of housing (1).
With new discs and plates, this measures
26.41.3 mm (1.0390.051 in) (S/N 9001~9100)
42.41.3 mm (1.6690.051 in) (S/N 9101~)
With completely worn out discs, and plates this measures
22.41.3 mm (0.8810.051 in) (S/N 9001~9100)
38.41.3 mm (1.5120.051 in) (S/N 9101~)
- When the parking brake is operated as emergency
around maximum speed out of necessity, check the
wear on parking brake.
- Bolt (7) must be tight in the piston to take this measurement.

52-28
Function & Structure Brake Group
Parking Brake

Parking brake friction disc


Seven friction plates and seven steel plates are assembled in the parking brake disc.
7.40.1 mm (0.2910.004 in)
5.00.1 mm (0.1970.004 in)

220 (8.7 in)


330 (13.0 in)

0.82 mm (0.032 in) or more


1.0 mm (0.039 in)

5.7 mm (0.224 in)


Detail drawing of groove
95V2E52009

1. Core plate
2. Lining (paper material)

Parking brake steel plate

394 (15.5 in)

220 (8.7 in)

P.C
(14 .D 3
6
.4
i n) 5 m
m

5.00.1 mm (0.1970.004 in)

Flatness: 0.5 mm (0.020 in) or less


95V2E52010

52-29
115ZV-2 Function & Structure Brake Group
Parking Brake

Parking brake solenoid valve


Spring chamber (brake actuator)
B

Reducing
valve

Solenoid

Knob

T
Seat
face A

Seat
face B

Manual release
(counterclockwise
rotation)

Spool

Tank

P T
Hydraulic circuit diagram

Solenoid valve operation

Solenoid valve specifications


Voltage

Amp

a
0

Volt

Varistor
95ZV42079

While the parking switch is ON (that is, while the power


is not supplied to the solenoid), the seat face A is closed
and the seat face B is open. As a result, the spring
chamber port is connected to the tank, and the parking
brake is applied.
When the parking switch is set to OFF (that is, when the
power is supplied to the solenoid), the spool is pushed
to the left, the seat face A is open, and the seat face B is
closed. As a result, the oil from the reducing valve
enters the spring chamber, and the parking brake is
released.
Note
The varistor (variable resistor) is used for the solenoid
coil to protect the circuit.

DC 24 V

Current

0.92 A

Resistance

26.2

85V2E52007

52-30
Function & Structure Brake Group
Parking Brake Manual Release

Parking Brake Manual Release


If the park brake cannot be released due to an electrical
problem, such as a failed park brake solenoid valve coil
or electrical circuit, perform the following operation.

WARNING
Sudden accidental movement of the machine could
result in serious injury or death.
Before manually operating the parking brake solenoid:
- Lower the boom and attachment to the ground.
- Place chocks on both sides of the tires.
- Be sure the machine is in neutral and engine is
stopped.

(S/N 9001~9050)
14
13

1
7

WARNING
If the flange nuts are not returned to the original position, the parking brake is disabled and may result in a
severe accident.
Make sure to return the flange nuts to the original
position after manually releasing the parking brake.

115V2E52005

1. Remove each of two places of lock nuts (14) from


manual release bolt (7) and tighten flange nuts (13)
until contacting with housing (1).
2. Furthermore tighten each of the two places of
flange nuts (13) alternately and evenly.
When flange nuts (13) are tightened until they feel
rather tight, the brake is released.
Reference:
After contacting with housing (1), approximately 3 or 4
additional turns of flange nuts (13) will release the parking brake.

52-31
115ZV-2 Function & Structure Brake Group
Parking Brake Manual Release
(S/N 9051~)
Top
Hose band

Rubber cap

7
1

Lock bolt

Flange nut

Detail of A

1. Remove the lock bolt on the front differential and


remove the flange nuts from both parts (A).
2. Loosen the hose band and remove the rubber cap
from manual release bolt (7).
3. Install the flange nuts, which were removed at step
1, to manual release bolt (7).
4. Tighten the flange nuts alternately and evenly until
contacting with housing (1).
5. Then, tighten the flange nuts until you feel the nuts
are rather tight; the brake is released.
Reference
After contacting with housing (1), approximately 3 or 4
additional turns of the flange nuts will release the parking brake.

K115V2J52005

52-32
Function & Structure Brake Group
Brake Circuit Check Valve

Brake Circuit Check Valve

Poppet
(T)

(P)

Pump supply
through reducing
valve

(TA)

Seat face

(ACCR)

(PARKING)

(ACCF)

(PA)
(Z1)

(ACF)
(Z)

(Z2)

(PPI)

B (ACCF)
Reducing
valve

Accumulator

Valve assembly

Hydraulic circuit diagram

The pressure oil fed from the pump pushes down the
poppet, opens the seat face, and flows into the accumulator circuit. It also flows into the reducing valve. (ACCF
side only)
When the pressure oil is not fed from the pump (either
the unloader valve is "cut-out" or the engine is shut off),
the poppet is pushed up by the pressure in the accumulator circuit, and the seat face is closed to prevent back
flow.
This allows the accumulator circuit to store oil under
pressure for emergency braking.
There is one check valve for the front brake accumulator circuit and another for the rear.

P=Pump supply
T=Tank circuit
PI=Pump feedback to unloader
(from ACCF circuit)
ACCR=Accumulator circuit-rear
ACCF=Accumulator circuit-front
PPI=Pilot valve circuit
85V2E52010

52-33
115ZV-2 Function & Structure Brake Group
Auto Brake

Auto Brake
When the traveling direction is switched over between
forward and reverse at a machine speed of 12 km/h (7.5
mph) or more, the auto brake is applied to protect the
transmission clutches.
When the machine speed is too high, the auto brake is
applied also to prevent problems caused by excess
speed in the engine and the transmission (over speeding).

Auto brake circuit


To front
service brake

23

From unloader
valve (Pump)

29

MCU
signal

37

1. When the traveling direction is switched over


between forward and reverse at a machine speed
of 12 km/h (7.5 mph) or more while the shift lever is
set to position A.
2. When the machine speed is too high in each speed
range. Actual speed will vary with tire size.
Speed range

Shown in the "released" position


To rear
service brake

Auto brake operation set value

1.6 MPa
(16 kgf/cm2)
(230 psi)

From unloader valve

115V2E52012

When the auto brake signal enters from the MCU to the
solenoid valve for auto brake, solenoid valve (29) is
energized and magnetized. The pilot oil from unloader
valve (22) enters the pilot port of left brake valve (23)
through reducing valve (37) (setting pressure: 1.6 MPa
(16 kgf/cm2) (230 psi)), and actuates the pilot piston and
the spool of the brake valve.
When the spool is moved over, the high-pressure oil
coming from the pump through the unloader valve
enters the front and rear brake piston chambers to apply
the service brake.

Set value km/h (mph)


F

1st

Approximately 13
(8.125)

Approximately 12
(7.5)

2nd

Approximately 22
(13.75)

Approximately 24
(15.0)

3rd

Approximately 36
(22.5)

Approximately 36
(22.5)

4th/A

Approximately 39
(24.375)

52-34
Function & Structure Brake Group
Auto Brake

Reducing valve (for Autobrake circuit)

Orifice 1

Plunger

Orifice 2
Pilot oil circuit
Z

Seat face A

From unloader
valve

Brake valve

B
Seat face B

Tank

T
Spool

Reducing valve
(for autobrake)
Passage Y

Hydraulic circuit diagram

Solenoid valve
(for autobrake)

115V2U52004

This reducing valve provides pilot oil pressure to operate the auto brake.
The oil fed from the unloader valve circuit flows into the
pilot oil circuit by way of passage Z. The oil pressure in
the pilot oil circuit is applied also on chamber C by way
of orifice 1.
When the oil pressure in the pilot oil circuit is at or
above the set pressure, the oil in chamber C unseats
the ball by way of orifice 2, and escapes to the tank by
way of passage Y.

As a result, the pressure in chamber C decreases, then


the plunger moves down and closes passage Z so that
the pressure on the pilot oil circuit side does not exceed
the set pressure.
When the oil pressure on the pilot oil circuit side
becomes less than the set pressure, the ball moves up
and the pressure at chamber C becomes equivalent to
the pressure on the pilot oil circuit side (B). As a result,
the plunger moves up by a spring, opens the passage Z,
then introduces the unloader pressure to the pilot oil circuit side so that the pressure is maintained at the specified value.

52-35
115ZV-2 Function & Structure Brake Group
Auto Brake
When the solenoid valve for auto brake is energized
and magnetized, this pressurized oil is supplied to the
brake valve through the solenoid valve for auto brake
and brake is applied.
Set pressure
1.3 MPa (13 kgf/cm2) (185 psi)

Solenoid valve (for Autobrake circuit)


When the auto brake actuation signal is not given by the
MCU (that is, when the power is not supplied to the
solenoid), the seat face A is closed and the seat face B
is open. As a result, the brake valve port is connected to
the tank, and the auto brake is not applied.
When the auto brake actuation signal is given by the
MCU (that is, when the power is supplied to the solenoid), the spool is pushed to the upward, the seat face A
is open, and the seat face B is closed. As a result, the
oil from the reducing valve enters the brake valve, and
the brake is applied.

Solenoid specifications
Voltage

DC 24 V

Current

0.92 A

Resistance

26.2

Amp

a
0

Volt

Varistor
95ZV42079

Note
The varistor (variable resistor) is used for the solenoid
coil to protect the circuit.

52-36
Function & Structure Brake Group
Pressure Sensor (for stop lamp and declutch)

Pressure Sensor (for stop lamp and declutch)


Pressure sensor (for stop lamp)

Left brake valve

Pressure sensor for stop lamp


and declutch

115V2E52007

This pressure sensor that set valve is controlled by the


MCU is installed between the brake valve and the front
brake.
When the brake pedal is depressed and the pressure
increases to the setting of the MCU (0.26 MPa (2.5 kgf/
cm2) (35 psi)), the stop lamp turns on.

52-37
115ZV-2 Function & Structure Brake Group
Pressure Sensor (for stop lamp and declutch)

View A
1: Power (+)
2: Output (+)
3: Common

85V2E52012

(V)
5
4
3
2
1
0

1
(10)
(140)

2
(20)
(285)

3
(30)
(435)

4
(40)
(570)

5
(50)
(715)

MPa
(kgf/cm2)
(psi)

65V2E52003

Pressure sensor (for Declutch)


Refer to "Electrical Group: Adjustable declutch preset
switch".

52-38
Function & Structure Brake Group

MEMO

53-1
115ZV-2 Check & Adjustment Brake Group

Check & Adjustment


Brake Group
Brake Circuit Oil Pressure ....................................... 53-2
Service Brake .......................................................... 53-6
Parking Brake.......................................................... 53-9

53-2
heck & Adjustment Brake Group
Brake Circuit Oil Pressure

Brake Circuit Oil Pressure


WARNING
Unexpected movement of the machine may cause an
accident resulting in injury or death. Therefore, to
provide repair service with the engine running, be
sure to observe the following items:
- Park the machine on level ground.
- Apply the parking brake.
- Block the tires with chocks to prevent the tires from
moving.
- Determine the signals between the service men.

Unloader valve setting pressure

(PPI)

(Z2)

(Z)

(Z1)

(PA)

ACF
(PARKING)

(ACCF)

(ACCR)

(TA)

(T)

(P)

ACF port

Valve assembly
85V2E53001

WARNING

Injection Hazard
Depress brake pedal 80~100 times
to completely discharge the brake
accumulators prior to removing
these test plugs.
135ZV52035

Brake line main pressure is regulated by the unloader


valve.

53-3
115ZV-2 Check & Adjustment Brake Group
Brake Circuit Oil Pressure

Unloader valve setting pressure measurement

Unloader valve setting pressure adjustment


(S/N 9001~9050)

24

Measurement instrument
Hydraulic pressure gauge
20 MPa (200 kgf/cm2) (3,000 psi)

22

21

Fan motor port

Gauge port
ACF port on valve assembly: Rc (PT) 1/8

Standard measurement value


Cut-out
Cut-in

Pump port

11.80.5 MPa (1205 kgf/cm2) (1,70671 psi)


2

6.91.0 MPa (7010 kgf/cm ) (995142 psi)

Unloader valve
70ZV53001

Measurement procedure
1. Lower the boom to the lowest limit, and tilt the
bucket down to the ground.
Then set the parking brake switch to the "ON" position.

(S/N 9051~)

21

22
Fan motor port

2. Stop the engine. Repeatedly depress and release


the brake pedal till you feel light brake to discharge
accumulator pressure.
3. Remove one of the ACF port plug on the valve
assembly and attach the pressure gauge to the
port.
: Port plug: 11.3 N-m (1.15 kgf-m) (8.3 lb-ft)
4. Start the engine, and keep the speed at low idle.
Measure and record the pressure when the pointer
of the pressure gauge stops rising (cut-out pressure).
5. Keep the engine at low idle, and repeatedly
depress and release the brake pedal to reduce the
accumulator pressure. Measure and record the
pressure when the pointer of the pressure gauge
stops and then starts rising again (cut-in pressure).
Note
If the pressure gauge is not available, refer to the pressure value displayed on the MODM.
Refer to "Brake Main pressure 1" "Brake Main pressure
2" of MODM "Input/Output Monitor" page 62-85 and 9245 for information.

Pump port
Unloader valve

K115ZV53002

1. Remove cap nut (24) and loosen lock nut (22).


2. Adjust the pressure by adjusting screw (21).
Turn the screw clockwise to raise the pressure.
Note
In a case that the "ON" or "OFF" pressure does not
match the standard setting pressure, set the "ON" (cutin) pressure to the standard setting pressure.
: Lock nut (22): 16.7 N-m (1.7 kgf-m) (12.3 lb-ft)
: Cap nut (24): 78.5 N-m (8.0 kgf-m) (57.86 lb-ft)

53-4
Check & Adjustment Brake Group
Brake Circuit Oil Pressure

Brake valve oil pressure

Measurement procedure
1. Check to be sure the brake valve is fully released.

Force

3. Release the brake pedal to check that the oil pressure drops to zero in proportion to the pedal angle.
In addition, visually check for brake oil leakage.

19

Pe

da

la
ng

le

2. Press down the brake pedal to check that the oil


pressure rises in proportion to the pedal angle.

15
0
m
m

45

Note
If the pressure gauge is not available, refer to the pressure value displayed on the MODM.
Refer to "Brake Pedal Output Oil Pressure" of MODM
"Input/Output Monitor" page 62-85 and 92-45 for information.
85V2E53002

Brake valve oil pressure measurement


Measurement instrument
Hydraulic pressure gauge
10 MPa (105 kgf/cm2) (1,500 psi)

Gauge port
Remove air bleeder nipple fitting on the axle housing,
and then install the pressure gauge to the bleeder position.
Size of air bleeder port: Rc (PT) 3/8
(In case of the bleeder valve: M10 X 1.0)

Air bleeder nipple fitting


[59 N-m (6.0 kgf-m) (43 lb-ft)]

85ZVE53001

53-5
115ZV-2 Check & Adjustment Brake Group
Brake Circuit Oil Pressure

Brake valve performance

Output oil pressure (brake port)

MPa
(kgf/cm2)
(psi)
4
(40)
(580)

4.90
(50.0)
(711)

2
(20)
(290)
1.57
(16.0)
(229)

0.36
(3.7)
(52)

( )
0

10

3.9 5

15

Pedal stroke

18.5 19
K115V2U53001

Refer to the curve shown in the above figure.


When the measured value does not match the performance curve, check the following points.
Possible cause
Malfunctioning brake valve

Solution
Repair or replacement

Brake line oil pressure low


(Pump, reducing valve malfunction)

Check and repair

Blown brake seals

Repair

Lost plugs in axle or hub

Repair

IMPORTANT
After measuring oil pressure, be sure to tighten the
air bleeder valve. Also be sure to bleed air.

53-6
Check & Adjustment Brake Group
Service Brake

Service Brake
Service brake performance check

Method 2

Method 1

If no test course available as described "Method 1",


carry out the following method.

IMPORTANT

WARNING
Separate the test course by using rope etc. and keep
persons away from the test course. In addition, post
persons in several positions near the course to warn
others and avoid an accident while checking the service brake performance.
Condition
1. Test course
Level, straight, dry and the paved ground.
2. Run the machine and depress the brake pedal at
35 km/h (22 mph).
Measure and record the braking distance.
Standard measurement value
Braking distance
20 m (22 1/4 yard) or shorter
Possible causes of extremely long braking distance
Possible cause

Solution

Low brake line pressure

Check and repair

Friction plate wear

Check and repair

Brake valve malfunction

Check and repair

Note
The brake performance check condition and standard
measurement value are based on the law and the regulation in Japan.
When checking the service brake performance, follow
the law and/or local regulation in your country, state, or
province.

The following method is easy and simple, however it


is not an accurate way, because the braking force
and rim-pull may vary on each machine. Confirm
engine & transmission performance via using a stall
test. See page 03-3.
Reconfirm the brake performance by the method 1 as
soon as possible.

WARNING
Unexpected movement of the machine may cause an
accident resulting in injury or death.
Before starting brake performance check, be sure to
observe the following items:
- Place the machine on level ground.
- Check that there is enough clearance for brake
performance check around the machine.
- During performance check, prohibit any person to
walking near the machine.
1. Lower the boom to the lowest limit, and roll back
the bucket fully until the bucket contacts to the stopper.
2. Set the parking brake switch to the "OFF" position.
3. Set the declutch switch to OFF, and then depress
the brake pedal all the way to the floor.
4. Set the shift lever to 2nd reverse speed.
5. Gradually increase the engine speed. The machine
should not move at the maximum engine speed.
Possible cause of machine moving during brake
performance check.
Possible cause

Solution

Low brake line pressure

Check and repair

Friction plate wear

Check and repair

Brake valve malfunction

Check and repair

53-7
115ZV-2 Check & Adjustment Brake Group
Service Brake

Service brake friction plate wear measurement


A

Air bleeder nipple

200 mm
slide caliper

Slide
caliper

Steel plate

Brake
backing
plate
Friction plate
115ZV53002

IMPORTANT
Oil inlet port
Spring pin

Inner steel
plate

Internal gear

Top
about
2.5

Spring pin

Outer steel
plate

After inserting calipers, do not rotate the wheels. If


the wheels are rotated, the calipers may be caught
and broken by the reduction gear. In this case, the
reduction gear must be disassembled.

Measurement procedure

115ZV53003

WARNING
Unexpected movement of machine could cause serious injury or death. To prevent such an accident,
observe the following items before checking the
brake friction plate wear:
- Park the machine on level ground.
- Apply the parking brake.
- Stop the engine.
- Determine the signals between the persons related
to this work for engine starting to prevent an accident.
- Prohibit any person from walking into the dangerous area.

Turn the planetary gear so that the oil supply plug is


positioned at 2.5 from the top. Check that the teeth of
steel plate are as shown (only one section of the plate
circumference is as shown in the figure).
Insert calipers to the inner steel plate to measure the
dimension A.
Note
During measurement, be sure the service brake is
applied.
The wear limit for dimension A is 35.2 mm (1.386 in).
Note that dimension A is 40.4 mm (1.590 in) when the
plate is new and unused.
Note
To aid quick measurement on the front axle-raise the
front of the machine so the front tires clear the ground
by about 25 mm (1 in). This allows easy rotation of the
wheel to align the gear teeth.

53-8
Check & Adjustment Brake Group
Service Brake

Cautions on installing brake discs

Upper side

When only the friction plates or the steel plates are to be


replaced, if the brake piston and brake stroke adjusting
mechanism are installed as they are, the brake may
drag and the brake discs may seize.
Push back the brake piston and brake stroke adjusting
mechanism by using the following procedure.
1. Loosen the axle housing air bleeder nipple.
2. Insert bolts into four holes for pushing back the
brake piston, then tighten the four bolts evenly. The
piston should return evenly.
Bolt size for pushing brake piston back (4 required)
M10 x 1.5 - 45~50 (1.8~1.97 in) (Fully threaded)

For pushing down


brake piston

3. After pushing back the piston, confirm dimension A


from the piston end face to the wheel hub end face.

IMPORTANT
Wheel bearings must be adjusted correctly to get an
accurate measurement for dimension A. Dimension
should be equal at top and bottom.
A: 186.85~188.25 mm (7.356~7.411 in)
115V2E53001

Note:
Piston stroke B:
1.45~4.35 mm (0.057~0.171 in)
4. After confirming that the piston is fully retracted
(Dimension A is correct) remove all four bolts.

A
B

Wheel hub

Brake piston

115V2E53002

5. After finishing the installation work, bleed air completely from the brake line.

53-9
115ZV-2 Check & Adjustment Brake Group
Parking Brake

Parking Brake
Parking brake performance check

Method 2

Method 1

If no test course available as described "Method 1",


carry out the following method.

IMPORTANT

WARNING
Unexpected movement of the machine may cause an
accident resulting in injury or death.
Before starting brake performance check, be sure to
observe the following items:
- Check that there is enough clearance for brake
performance check around the machine.
- During performance check, prohibit any person to
walking near the machine.

1. Test course
1/5 slope (Approx. 11 19')
2. Bucket empty
3. Parking switch ON

1. Set the parking brake switch to the "ON" position.

Standard measurement value

2. Disconnect the cable connector of parking brake


solenoid valve.

No movement on 1/5 slope


Possible cause of machine moving during brake
performance check
Possible cause

WARNING
Unexpected movement of the machine may cause an
accident resulting in injury or death.
Before starting brake performance check, be sure to
observe the following items:
- Place the machine on level ground.
- Check that there is enough clearance for brake
performance check around the machine.
- During performance check, prohibit any person to
walking near the machine.

Condition

Wear or breakage of brake disc

The following method is easy and simple, however it


is not an accurate way, because the braking force
and rim-pull may vary on each machine.
Confirm engine & transmission performance via stall
test. See page 03-3. Reconfirm the brake performance by the method 1 as soon as possible.

Solution
Check and repair

Parking brake switch malfunction

Check and repair

Parking brake solenoid valve malfunction

Check and repair

Note
The brake performance check condition and standard
measurement value are based on the law and the regulation in Japan.
When checking the service brake performance, follow
the law and/or local regulation in your country, state, or
province.

3. Set the parking brake switch to the OFF position.


4. Place the shift lever to the 3rd reverse position.
5. Gradually increase the engine speed. The machine
should not move at the maximum speed.

IMPORTANT
If the machine begins to move with the parking brake
applied, the brake discs are worn.
At the completion of parking brake test, be sure to
connect the connector of electrical line to the solenoid valve again.
Possible cause

Solution

Wear or breakage of brake disc

Check and repair

Parking brake switch malfunction

Check and repair

Parking brake solenoid valve malfunction

Check and repair

53-10
Check & Adjustment Brake Group

MEMO

62-1
115ZV-2 Function & Structure Electrical Group

Function & Structure


Electrical Group
How to Use Electrical Wiring Diagram .................... 62-2
Electrical Cable Color Codes .................................. 62-8
Electrical Circuit Symbols........................................ 62-9
Sensor Mount .......................................................... 62-10
Fuse ........................................................................ 62-11
Engine Start Circuit.................................................. 62-13
Power Generating/Charging Circuit......................... 62-21
ECM (Engine Controller) ......................................... 62-22
Transmission Control Circuit and Monitor Circuit .... 62-35
Instrument Panel and Switch................................... 62-60
MODM ..................................................................... 62-65
Electrical Detent Circuit ........................................... 62-104
Diode ....................................................................... 62-110

62-2
Function & Structure Electrical Group
How to Use Electrical Wiring Diagram

How to Use Electrical Wiring Diagram


Example
10

10 9

20 19 18 17 16

15 14 13 12 11
21

40 39

32 31

40

36

35

31

WIDTH LAMP
RELAY

BACK LAMP
RELAY

HORN RELAY

RB
B611

LgSb YV
H133 E214

RL SbP
H610 E220

RL
LB
H128 E219

GW GL
H127 B501

R
R
D114 D114

Br
Lg
D112 D103

G
L
D102 D002

R
Lg
D111 D103

G
G
D107 D107

RB

A520
C201
H129

RIDE CONTROL NEUTRAL


RELAY
RELAY

(BLACK)

F5

(BLACK)

F0

(BLACK)

F6

(BLACK)

F7

LgW
E218

LgW
L
A405 D001
1

(BLACK)

F8

MCU FAULT
RELAY

(BLUE)

F9

(1)
(2)

H1

10
D507 A306 F306
OR RO RW

40

A905
RLg

5
A503
YB

1
D112 E802 E803
Br
GL GO

C206 A302 F303 E312


PB RBr RY WO

E523 G302
SbY BrB

C205 F504 F704 F804


RB
RL GW
PL

E109 G402 A105 E522


W BrW WP BrL

E501 C801 A005 B304


WL RG RGy LgG

36

E520 E108 F004


LgL
W LgSb

35

E804
WY

E601
BrR

31

(3)

The address method is used for electrical wiring diagrams. For this method, a symbol is attached to each
connector and connector terminal in order to easily
locate the other terminal where the other end of the
cable is connected.
Example 1
Symbol under (or above) connector, such as F6:
Shows the address of the connector.
Example 2
Symbol at the multi-terminal connector, such as 1 and
10:
Shows the terminal number and the numbering direction.

95ZV62001

Example 3
Checking the other connector terminal where F704 RL
(item (3)) is connected:
1. F704
Shows that the terminal is connected to the 4th terminal of the F7 connector.
Check the description in the 4th terminal of the F7
connector (F704), it shows that the F704 terminal is
connected to H128. This means that the 4th terminal of the F7 connector is connected to the 28th terminal of the H1 connector.
2. RL
Shows the color of the wire "RL" represents that the
insulation color is red, and "L" represents a blue
stripe is on the red insulation.

62-3
115ZV-2 Function & Structure Electrical Group
Utilisation des schmas des cblages lectriques (FRANAIS)

Utilisation des schmas des cblages lectriques


(FRANAIS)
Exemple
10

10 9

20 19 18 17 16

15 14 13 12 11
21

40 39

32 31

40

36

35

31

Relais de la lampe
d cartement

Relais du
contrle de marche

Relais neutre

Relais de la lampe
arrire

Relais du klaxon

RB
B611

LgSb YV
H133 E214

RL SbP
H610 E220

RL
LB
H128 E219

GW GL
H127 B501

R
R
D114 D114

Br
Lg
D112 D103

G
L
D102 D002

R
Lg
D111 D103

G
G
D107 D107

RB

A520
C201
H129

(Noir)

F5

(Noir)

F0

(Noir)

F6

(Noir)

F7

LgW
E218

LgW
L
A405 D001
1

(Noir)

F8

Relais de dfaillance
du contrleur

(Blue)

F9

(1)
(2)

H1

10
D507 A306 F306
OR RO RW

40

A905
RLg

5
A503
YB

1
D112 E802 E803
Br
GL GO

C206 A302 F303 E312


PB RBr RY WO

E523 G302
SbY BrB

C205 F504 F704 F804


RB
RL GW
PL

E109 G402 A105 E522


W BrW WP BrL

E501 C801 A005 B304


WL RG RGy LgG

36

E520 E108 F004


LgL
W LgSb

35

E804
WY

E601
BrR

31

(3)

Les schmas des cblages lectriques sont bass sur


la mthode de ladressage. Suivant cette mthode, un
symbole correspond chaque connecteur et chaque
borne du connecteur de manire localiser facilement
la borne de connection de lautre extrmit du cble.
Exemple 1
Symbole au-dessous (ou au-dessus) du connecteur,
comme F6:
Il indique ladresse du connecteur.
Exemple 2
Symbole sur le connecteur multibornes, comme 1 et 10:
Il indique le numro de la borne et le sens de la
numrotation.

95ZV62001

Exemple 3
Contrle de la borne du connecteur laquelle F704 RL
(point (3)) est connecte:
1. F704
Indique que la borne est connecte la 4me
borne du connecteur F7.
Contrlez la description de la 4me borne du connecteur F7 (F704), elle indique que la borne F704
est connecte H128. Ceci signifie que la 4me
borne du connecteur F7 est connecte la 28me
borne du connecteur H1.
2. RL
Indique la couleur du fil. RL signifie que la couleur
de lisolation est rouge, et L que la raie bleu est
sur lisolation rouge.

62-4
Function & Structure Electrical Group
Verwendung des elektrischen Schaltplans (DEUTSCH)

Verwendung des elektrischen Schaltplans (DEUTSCH)


Beispiel
10

10 9

20 19 18 17 16

15 14 13 12 11
21

40 39

32 31

40

36

35

31

Breitenleuchtenrelais

Fahrtsteuerrelais

Neutrales Relais

Rckleuchtenrelais

Hupenrelais

RB
B611

LgSb YV
H133 E214

RL SbP
H610 E220

RL
LB
H128 E219

GW GL
H127 B501

R
R
D114 D114

Br
Lg
D112 D103

G
L
D102 D002

R
Lg
D111 D103

G
G
D107 D107

RB

A520
C201
H129

(Schwarz)

F5

(Schwarz)

F0

(Schwarz)

F6

(Schwarz)

F7

Reglerfehlerrelais

LgW
L
A405 D001
1

(Schwarz)

F8

LgW
E218

(Blau)

F9

(1)
(2)

H1

10

6
D507 A306 F306
OR RO RW

40

A905
RLg

5
A503
YB

1
D112 E802 E803
GL GO
Br

C206 A302 F303 E312


PB RBr RY WO

E523 G302
SbY BrB

C205 F504 F704 F804


PL
RB
RL GW

E109 G402 A105 E522


W BrW WP BrL

E501 C801 A005 B304


WL RG RGy LgG

36

E520 E108 F004


LgL
W LgSb

35

E804
WY

E601
BrR

31

(3)

Fr den elektrischen Schaltplan wird die Adressenmethode verwendet. Damit wird jeder Steckvorrichtung und
jeder Anschluklemme ein Symbol zugeordnet, damit
die Klemme, an die das andere Ende des Kabels angeschlossen werden mu, leicht gefunden werden kann.
Beispiel 1
Symbol unterhalb (oder oberhalb) der Steckvorrichtung,
wie z. B. F6:
Zeigt die Adresse der Steckvorrichtung an.
Beispiel 2
Symbol an der Mehrklemmen- Anschlustelle, wie z. B.
1 und 10:
Zeigt die Klemmennummer und die Zhlrichtung an.

95ZV62001

Beispiel 3
berprfung der anderen Steckvorrichtungsklemme, wo
F704 RL (Artikel (3)) angeschlossen ist:
1. F704
Zeigt, da die Klemme an die vierte Klemme der
F7-Steckvorrichtung angeschlossen ist.
berprfen Sie die Beschreibung in der vierten
Klemme des F7-Steckvorrichtung (F704). Zie gibt
an, da die Steckvorrichtung F704 an H128 angeschlossen ist. Dies bedeutet, da die vierte
Klemme der F7-Steckvorrichtung an die 28.
Klemme der H1-Steckvorrichtung angeschlossen ist.
2. RL
Zeigt die Farbe des Kabels an. RL bedeutet, da
der lsolierdraht rot ist, und L bedeutet, da sich
auf dem roten lsoliermaterial ein blauer Streifen
befindet.

62-5
115ZV-2 Function & Structure Electrical Group
Modalit di utilizzo dello schema dei collegamenti elettrici (ITALIANO)

Modalit di utilizzo dello schema dei collegamenti elettrici


(ITALIANO)
Esempio
10

10 9

20 19 18 17 16

15 14 13 12 11
21

40 39

32 31

40

36

35

31

Rel di larghezza
della lampada

Rel di controllo
della guida

Rel neutro

Rel della lampada


posteriore

Rel del clacson

RB
B611

LgSb YV
H133 E214

RL SbP
H610 E220

RL
LB
H128 E219

GW GL
H127 B501

R
R
D114 D114

Br
Lg
D112 D103

G
L
D102 D002

R
Lg
D111 D103

G
G
D107 D107

RB

A520
C201
H129

(Nero)

F5

(Nero)

F0

(Nero)

F6

(Nero)

F7

LgW
E218

LgW
L
A405 D001
1

(Nero)

F8

Rel del controller


d errore

(Blu)

F9

(1)
(2)

H1

10
D507 A306 F306
OR RO RW

40

A905
RLg

5
A503
YB

1
D112 E802 E803
Br
GL GO

C206 A302 F303 E312


PB RBr RY WO

E523 G302
SbY BrB

C205 F504 F704 F804


RB
RL GW
PL

E109 G402 A105 E522


W BrW WP BrL

E501 C801 A005 B304


WL RG RGy LgG

36

E520 E108 F004


LgL
W LgSb

35

E804
WY

E601
BrR

31

(3)

Per gli schemi elettrici si utilizza il metodo degli indirizzi,


in base al quale a ciascun connettore e a ogni suo contatto viene associato un simbolo che permette di identificare agevolmente il contatto cui collegata laltra
estremit del cavo.
Esempio 1
simbolo al di sopra o al di sotto del connettore, ad
esempio F6:
Mostra lindirizzo del connettore.
Esempio 2
simbolo presso un connettore a pi contatti, ad esempio
1 e 10:
Mostra il numero del contatto e il senso di numerazione.

95ZV62001

Esempio 3
verifica del contatto dellaltro connettore cui collegato
F704 RL (elemento (3)):
1. F704
Indica che il terminale collegato al contatto n. 4
del connettore F7.
Verificare la descrizione del contatto n.4 del connettore F7 (F704): essa mostra che il contatto F704
collegato a H128. Ci indica che il contatto n.4
del connettore F7 collegato al contatto n. 28 del
connettore H1.
2. RL
Indica il colore del cavo: RL significa che il colore
dellisolante rosso, e L rappresenta che una
linea blu presente sullisolazione rossa.

62-6
Function & Structure Electrical Group
Cmo utilizar un Diagrama de Alambrado Elctrico (ESPAOL)

Cmo utilizar un Diagrama de Alambrado Elctrico


(ESPAOL)
Ejemplo
10

10 9

20 19 18 17 16

15 14 13 12 11
21

40 39

32 31

40

36

35

31

Rel de la lmpara
ancha

Rel de control
de recorrido

Rel neutro

Rel de la lmpara
trasera

Rel de la bocina

RB
B611

LgSb YV
H133 E214

RL SbP
H610 E220

RL
LB
H128 E219

GW GL
H127 B501

R
R
D114 D114

Br
Lg
D112 D103

G
L
D102 D002

R
Lg
D111 D103

G
G
D107 D107

RB

A520
C201
H129

(Negro)

F5

(Negro)

F0

(Negro)

F6

(Negro)

F7

LgW
E218

LgW
L
A405 D001
1

(Negro)

F8

Rel de fallos
del controlador

(Azul)

F9

(1)
(2)

H1

10
D507 A306 F306
OR RO RW

40

A905
RLg

5
A503
YB

1
D112 E802 E803
Br
GL GO

C206 A302 F303 E312


PB RBr RY WO

E523 G302
SbY BrB

C205 F504 F704 F804


RB
RL GW
PL

E109 G402 A105 E522


W BrW WP BrL

E501 C801 A005 B304


WL RG RGy LgG

36

E520 E108 F004


LgL
W LgSb

35

E804
WY

E601
BrR

31

(3)

El mtodo de direccin se utiliza para diagrama de


alambrado elctrico. Para este mtodo, se pega un
smbolo a cada conector y terminal de conector a fin de
localizar fcilmente el otro terminal al cual se conecta el
otro extremo del cable.
Ejemplo 1
Smbolo debajo (o encima) de conector, tal como F6:
Muestra la direccin del conector.
Ejemplo 2
Smbolo en el conector del multiterminal, tal como 1 y
10:
Muestra el nmero de terminal y la direccin de numerado.

95ZV62001

Ejemplo 3
Comprobando el otro terminal de conector donde se
conecta F704 RL (tem (3)):
1. F704
Muestra que el terminal est conectado al terminal
4o del conector F7.
Compruebe la descripcin en el terminal 4o del
conector F7 (F704). Esto muestra que el terminal
F704 est conectado a H128 y significa que el terminal 4o del conector F7 est conectado al terminal
28o del conector H1.
2. RL
Muestra el color del alambre RL y representa que
el color aislante es rojo, y L representa que una
raya azul est en el aislamiento rojo.

62-7
115ZV-2 Function & Structure Electrical Group
Como Utilizar o Diagrama de Ligaes Elctricas (PORTUGUS)

Como Utilizar o Diagrama de Ligaes Elctricas


(PORTUGUS)
Exemplo
10

10 9

20 19 18 17 16

15 14 13 12 11
21

40 39

32 31

40

36

35

31

Rel de luz
de largura

Rel de controlo
de viagem

Rel do ponto morto

Rel da luz traseira

Rel da buzina

RB
B611

LgSb YV
H133 E214

RL SbP
H610 E220

RL
LB
H128 E219

GW GL
H127 B501

R
R
D114 D114

Br
Lg
D112 D103

G
L
D102 D002

R
Lg
D111 D103

G
G
D107 D107

RB

A520
C201
H129

(Preto)

F5

(Preto)

F0

(Preto)

F6

(Preto)

F7

LgW
E218

LgW
L
A405 D001
1

(Preto)

F8

Rel de controlo
de falha

(Azul)

F9

(1)
(2)

H1

10
D507 A306 F306
OR RO RW

40

A905
RLg

5
A503
YB

1
D112 E802 E803
Br
GL GO

C206 A302 F303 E312


PB RBr RY WO

E523 G302
SbY BrB

C205 F504 F704 F804


RB
RL GW
PL

E109 G402 A105 E522


W BrW WP BrL

E501 C801 A005 B304


WL RG RGy LgG

36

E520 E108 F004


LgL
W LgSb

35

E804
WY

E601
BrR

31

(3)

O mtodo de endereamento utilizado para os diagramas de ligaes elctricas. Para este mtodo, cada
conector e terminal de conector tem um smbolo acoplado para facilitar a localizao do outro terminal onde a
outra extremidade do cabo deve ser ligada.
Exemplo 1
Smbolo por baixo (ou por cima) do conector, como F6:
Indica o endereo do conector.
Exemplo 2
Smbolo no conector de multiterminais, como 1 e 10:
Indica o nmero do terminal e a direco da numerao.

95ZV62001

Exemplo 3
Verificar o outro terminal de conectores, no qual F704
RL (item (3)) ligado:
1. F704
Ilustra que o terminal ligado ao 4o terminal do
conector F7.
Verifique a descrio no 4o terminal do conector F7
(F704), indica que o terminal F704 est ligado ao
H128. Isto significa que o 4o terminal do conector
F7 est ligado ao 28o terminal do conector H1.
2. RL
Indica a cor do fio. RL representa que a cor do
isolamento vermelha e L representa uma faixa
azul est no isolamento vermelho.

62-8
Function & Structure Electrical Group
Electrical Cable Color Codes

Electrical Cable Color Codes


Color of
stripe
Color of
insulation

Y
G
(yellow) (green)

(sky blue)

Sb

Br
(brown)

L
(blue)

W
(white)

R
(red)

B
O
(black) (orange)

YSb

YBr

YL

YW

YR

YB

YO

GL

GW

GR

GB

GO

SbW

SbR

Y (yellow)

YG

G (green)

GY

Sb (sky blue)

SbY

SbG

Br (brown)

BrY

BrG

Br

BrL

BrW

BrR

BrB

L (blue)

LY

LG

LBr

LW

LR

W (white)

WY

WG

WBr

WL

R (red)

RY

RG

RBr

RL

B (black)

BY

BG

O (orange)

OY

OG

OSb

Lg (light green)

LgY

LgG

LgSb

P (pink)
Gy (grey)

GyY

Sb

Lg

(light green)

P
(pink)

SbO

SbLg

SbP

LB

LO

LLg

LP

WR

WB

WO

RW

RB

RO

RLg

BL

BW

BR

BO

BLg

OL

OW

OR

OB

LgL

LgW

LgR

LgB

PG

PL

PW

GyG

GyL

GyW

GyR

VW

VR

LgBr

V (violet)

Insulation color
Stripe color

70ZV62001

V
(violet)

YGy

YV

WP

WV
RGy

BP

BV

Lg

PB
GyB

Gy
(grey)

P
GyO

Gy
V

62-9
115ZV-2 Function & Structure Electrical Group
Electrical Circuit Symbols

Electrical Circuit Symbols


Name

Symbol

Name

Direct current

Motor

Alternating current

Equipment

Conductor (General)

Fuses

Branching connection

Lamp

Conductors (Connected)

Rectifiers

Conductors (Not connected)

Mechanical coupling

Terminal

Relay contact ("a" contact)

Ground

Relay contact ("b" contact)

Resistance or Resistor

Switch

Variable resistance or Variable


resistor

Pressure switch or
Temperature switch

Inductance or Electromagnetic
coil

Negative -positive-negative
(NPN) transistor

Battery or Direct voltage source

Positive -negative-positive
(PNP) transistor

Symbol

62-10
Function & Structure Electrical Group
Sensor Mount

Sensor Mount
1

6
3

1
For air conditioner

1.
2.
3.
4.
5.
6.
7.
8.

Machine speed sensor


T/C oil temperature sensor
Air cleaner sensor
E/G coolant temperature sensor (S/N 9001~9050)
Hydraulic oil level sensor
Hydraulic oil temperature sensor
Coolant level alarm sensor
Cold starter temperature switch

8
A-Detail

115V2E62001

62-11
115ZV-2 Function & Structure Electrical Group
Fuse

Fuse
The following fuses are provided to protect electrical circuits.
Fusible link
70 A x 2, 30 A x 1
Fuse box
15 fuses x 2 (for chassis and cab)
6 fuses x 1 (for engine controller ECM)
(For installation positions, refer to "Electrical Equipment
Layout".)

CAUTION
Possible burn hazard. Before replacing a fuse, be
sure to turn off the starter switch.

IMPORTANT
Replace a fuse with the same capacity.
If a fuse blows immediately after replacement, the
electric system is defective. Locate the defective part,
and then repair it.

Fuse box
For chassis
Fuse No.

Fuse
capacity
(A)

20A

15A

R. WORK LIGHT

10A

BOOM KICKOUT
BUCKET LEVELER

15A

TURN SIGNAL

30A

PARKING BRAKE
MCU (MACHINE)

15A

F. WORK LIGHT

10A

AIR SUS. SEAT (OPT)

15A

SPARE

15A

SPARE

10

15A

4WAY FLASHER
HORN
ROOM LAMP
RADIO

11

10A

SPARE

12

15A

COLD STARTER

13

5A

BUZZER
MONITOR
(MCU)

14

5A

NEUTRAL RELAY

15

5A

BATTERY RELAY
ECM (ENGINE)

Protective circuit
LIGHTING
HEAD LIGHT
SPARE
30A
SPARE
20A
SPARE
15A
SPARE
5A

For cab

Fuse box for cab

Fuse box for chassis

90V2E62002

Fuse No.

Fuse
capacity
(A)

16

5A

SPARE

17

5A

SPARE

Protective circuit

18

5A

R. WIPER / WASHER

19

10A

F. WIPER / WASHER

20

10A

MODM

21

15A

SPARE

22

3A

DC-DC CONVERTER

23

10A

SPARE

24

10A

SPARE

25

20A

AIRCON

26

5A

SPARE

27

5A

SPARE

28

10A

SPARE

29

20A

AIRCON

30

20A

SPARE

SPARE
20A
SPARE
15A
SPARE
10A
SPARE
5A

62-12
Function & Structure Electrical Group
Fuse

Fusible link

Problems caused by blown fusible link


Fusible link

Cover

Box for fusible link

(081) (085)
W
W

Fusible link

(900)
[W5]

30A

(060) (901)
W [W5]

TO MCU

During engine stop

30A

- All the electrical circuit


will not function.
- Engine can not be
started.

70A
(1)

- Horn [and opt. flasher]


will operate.
- All the others will not
operate and the
machine can not be
operated.
- Engine will not stop
automatically but can
be stopped with starter
switch OFF.

70A
(2)

- The machine can be


operated but the batteries can not be charged
and the batteries will be
discharged soon.

- The same conditions


as "During engine operation".
- Engine can not be
started.

- The same conditions


as "During engine operation".

IMPORTANT

5A

5A

(013)
(Lg)

BATTERY
RELAY

70A

(1)

STARTER

When replacing fusible link, you may want to disconnect the battery negative terminal to avoid arcing out
a circuit and damaging wire.
If so, after you reconnect battery, do following:
1. Turn on key
2. Press throttle pedal fully down and up 3 times in
5~6 seconds.
3. Turn off key switch.

B C

[R5] x 6
(910~
915)
[R5] (701)

MAGNETIC
(702)
S/W
5
[BW ]

RL1.25 (703)

WG(704)

VOLTAGE
RELAY

NR
(013)
(Lg)

F13

(705)
(WG)

(707)
WL

CHARGE LAMP
20

70A

(2)

F5

(706)
WL1.25
R

ALTERNATOR
(005-a)
ES
(L)

20

M1
M2

M1

100

M2

(062)
(012)
BW F12 BW
15A
B

During engine operation

WV
(700)

(063)
WR1.25
F13

F14
(014)
G1.25

12V

Problem (symptom)
- Engine will stop automatically.
- All the power for all
electrical circuit will be
OFF.

70ZV62010

(708)
WP

5A

Fuse
element

BATTERY

ECM(H)
(065)
(015)
WR1.25 F15 WR

R1 BR
B AC
R2 C

(064)
G1.25

12V

100

Fuse
damaged

ACC

SECONDARY
STEERING PUMP
SECONDARY
STEERING PUMP

M
M

THERMO

(722) SWITCH (721)


(BrR)
BrB

COLD
STARTER
SWITCH

ETHER KIT

TO PILOT LAMP

Fusible link location

K115V2U62001

The fusible link is located in the box as shown in the


above figures. If excessive current flows through the
starter switch or the electric line downstream of the
starter switch due to shortcircuit, the fuse element will
be blown to protect the circuit. The condition of the fuse
element can be seen through the transparent cover.
Determine the cause before replacing the fusible link.
For replacement of a fusible link, remove 2 bolts and
pull it up.

62-13
115ZV-2 Function & Structure Electrical Group
Engine Start Circuit

Engine Start Circuit


Engine start circuit diagram
Starter switch
Off
On
Start

B BR ACC R1 R2 C

MCU

23A

B12

Fusible link

12V

Battery

ECM

B11

Diode unit

F15
5A

D12
D05
D03
D10

(1)

D04

30A

+24 V

70A

F N R

D11

12V

B18

5A

Shift lever

E04
E12
E03
E11

F14

E24

Shift lever F/R position

E05 E06 E17

Battery
relay

Starter motor
B C

Magnetic
switch
3

Neutral relay

* When shift lever is in F/R position: OFF


When shift lever is in N position: ON

Voltage
relay

MCU
E24

F13

Charge lamp

+24 V
(F5)
(2)
70A

R
E

Alternator

115V2E62033

62-14
Function & Structure Electrical Group
Engine Start Circuit

Neutral starter
To prevent the machine from unexpected movement at
engine start up, the machine is so designed that the
engine can start only while the shift lever is in the neutral (N) position.

Shift lever neutral (N) position


When the starter switch is turned to the ON position
while the shift lever is located in the N position, the coil
actuation circuit of the neutral relay is connected to the
ground of the MCU unit and the contact of the neutral
relay is switched over to ON.
When the starter switch is turned to the START position,
the start command current flows from the starter switch
terminal C to the neutral relay, the magnetic switch and
the voltage relay. As a result, the magnetic switch turns
ON, the starting current flows in the starter motor, and
the engine starts.

Shift lever forward/reverse (F/R) position


While the shift lever is located in the F or R position, the
power is not supplied to the neutral relay coil, and the
main contact is OFF. As a result, the starting current
from the starter switch terminal C does not flow in the
magnetic switch, and the engine does not start.

62-15
115ZV-2 Function & Structure Electrical Group
Engine Start Circuit

Starter switch

Off
Enables insertion and removal of the starter key.
All the electrical circuits (except the horn and hazard
flasher [OPT.]) will be turned off.
On
Supplies power to the charge, lamp, and monitor circuits.
Start
Starts the engine.

Starter switch

Control box

Starter switch location

85V2E62002

OFF

AC

30

ON

35
Start

BR

R1

R2

BW WR WR
BG WB WB

AC

WB x 2

On

R2

Start

W5
W3

R2

Off

1.25

R1

To neutral relay

BBG
G

WR x 2

R1 BR

BR AC

To battery relay

BW

From battery

Connection table

W3
W5

115V2E62004

62-16
Function & Structure Electrical Group
Engine Start Circuit

The ECM is equipped with safety functions that are


designed to limit engine revolution (min-1) in certain situations.
The zero point of the pedal is recalibrated every time
the key switch is turned to the ON position, so that the
pedal operation positions are consistent. (Pedal angle
relative to engine revolution (min-1) point.)
This permits the ECM to see the signal and set the
engine revolution (min-1) appropriately.
This function is set to turn on 1 second after the key is
set to the ON position, then adjustment is completed in
3 seconds and this function is turned off.
Note
There is no indication on the instrument panel or MODM
that this function turns either on or off because there
is no engine abnormality to call out or indicate.
Effect on the machine
(a) If the throttle pedal is applied while turning the key
switch to the start position, the engine maximum
speed will only increase to 80% of high idle.
(b) If the throttle pedal is applied while the engine is
starting, this function will turn ON 1 second after
releasing the pedal and engine speed will only
increase 80% of high idle.
To avoid these troubles, the following steps are important;
1. Wait one second before turning the key from the
ON to the START position.
2. Do not step on the pedal while the engine is starting, nor just after the engine starts.
These safety features protect engine parts from high
speed damage due to low oil pressure while the engine
is cold and oil is beginning to circulate through the
engine.

Battery relay

Terminals for coil


energizing current
(4 mm)

Moving contact
Main contacts

BR

Coil for energizing

Terminals for
main current
(8 mm)

95ZV62017

When the starter switch is placed to the ON position or


the start position, the battery relay is turned on. When
the starter switch is set to the OFF position, the alternator stops generating power, and the battery relay is
automatically turned off so that the electrical circuits will
not function.
If the battery relay was not used, a large amount of current would be directly sent through the starter switch
when it is turned on. However, use of the battery relay
reduces the amount of current because this relay needs
only a small amount of current to energize it.

Battery relay operation


Starter switch
From
charge
circuit

AC

Battery relay
(B)

To main
circuit

(E)

Battery

ECM safety features

Suppression
diode

85V2E62014

Battery relay
Rated voltage

DC 24 V

Minimum operating voltage

20 V or less

Release voltage

9 V or less

When current flows from the starter switch terminal AC,


the coil will be energized, and the moving contact will
lower to close the main contact. As a result, current will
flow from the battery to the main circuit.

62-17
115ZV-2 Function & Structure Electrical Group
Engine Start Circuit

Alternator I terminal wire


12V

Diode unit
12V

30A

ECM
F15

R1 BR
B AC
R2 C

WR

(2) (3)

WP

Battery
(1)

(2)(3): Diode unit

5A

WV

Charge
circuit

WR WP

5A

5A

F13

F14

Suppression diode

WV:To battery relay


WR:To starter switch terminal AC (VIA F15) and
to ECM
WP:To alternator

Neutral
relay

From
alternator
I terminal

Diode storage section


70ZV62017

115V2E62005

Engine motion-active circuit: (1)


When the starter switch is turned OFF, the battery relay
is automatically turned OFF since the command current
from the starter switch terminal AC stops flowing and
the coil is demagnetized. Then the charging circuit from
the alternator is shut down.
However the alternator is still generating power and the
load dump surge may be generated. This may damage
the related circuits and equipment. In order to prevent
this trouble, this circuit (1) is provided to hold the battery
relay in the "ON" position.

The diode unit is incorporated in the milky white connector near the battery relay. It is provided for the following
purpose.
1. Diode (2)
This diode is provided to prevent the roundabout
current from the alternator to the ECM. If this diode
is not provided (or is defective), the ECM does not
turn OFF and the engine cannot be stopped.
2. Diode (3)
This diode is provided to prevent the roundabout
current from the starter switch AC to the alternator I
terminal.

62-18
Function & Structure Electrical Group
Engine Start Circuit

SbP

RL

Neutral relay

Internal connection dia.

Body black

85V2E62016

Position of shift
lever

Between
1 and 2

Between
3 and 4

Starting

F or R

Not energized

OFF

Impossible

Energized

ON

Possible

The structures of the neutral relay, engine idle selection


relay, engine torque selection relay, engine oil pressure
switch relay, horn relay, width lamp relay and the head
lamp relay are identical to each other.
Note
The illustrations show the de-energized condition.
When the shift lever is in the N position while the starter
switch is kept at the start position, the neutral relay is
magnetized and electric current flows from the battery
to the magnetic switch / voltage relay through the starter
switch terminal C.

Rating

DC 24 V

Operating voltage

16 V or less

Reset voltage

2.4 V or more

Coil resistance

320

62-19
115ZV-2 Function & Structure Electrical Group
Engine Start Circuit

Magnetic switch

Rating 24V x 200A

M
C

C
M

70ZV62019

Note
The illustrations show the de-energized condition.
When the neutral relay is magnetized, electric current
flows from the battery to the magnetic switch through
the starter switch terminal C. It magnetizes the magnetic
switch.
On the other hand since the battery relay is already ON
at this time, electric current flows from the battery to the
starter motor terminal C through the battery relay and
the magnetic switch, engaging the starter motor to start
engine.

62-20
Function & Structure Electrical Group
Engine Start Circuit

Voltage relay

Note
The illustrations show the de-energized condition.

(S/N 9001~9006)

Once the engine is started, the alternator starts generating electric power.
1

When electric current is supplied from the alternator R


terminal to the voltage relay, the voltage relay is magnetized and is turned OFF.
Consequently the magnetic switch turns OFF and no
electric current flows to the starter motor terminal C, disengaging the starter motor.

70ZV62020

Voltage relay
Contact point closed

6V

Contact point open

9V

(S/N 9007~)
Blue

K70V2J62005

Voltage relay
Contact point closed

6V

Contact point open

8V

62-21
115ZV-2 Function & Structure Electrical Group
Power Generating/Charging Circuit

Power Generating/Charging Circuit


Engine

Mechanical energy supply

Alternator

Rotor coil
excitation current

Electrical energy conversion

<Load>

For rotor coil


initial excitation

Battery

Load circuit operation

Starter
switch

Voltage adjustment

Battery charge

For battery relay


operation

Adjusted
voltage

IC regulator

For battery relay


operation

The alternator driven by the engine rectifies, with 6


diodes, full waves in three phases of the AC output generated in the stator coil by the three-phase start connection (Y connection) into DC output, then supplies it as
the electric power to the battery and the machine load.
In the electricity generated in the alternator, the voltage
fluctuates depending on the number of revolutions of
the engine and the load size if no measures are taken.

Generated power

For rotor coil


initial excitation

Alternator

70ZV62021

The power generating/charging device and the charging


circuit consisting of an alternator, regulator, battery, etc.
generate and supply the power required to all electrical
units of the machine.

To prevent fluctuation, a regulator is integrated so that


the voltage supplied to the battery and the load circuit is
always constant.

62-22
Function & Structure Electrical Group
ECM (Engine Controller)

ECM (Engine Controller)


Function of ECM
- Stops the engine.
- Operates the engine.
- Monitors the engine, and diagnoses it for faults.

Connection diagram

16 PIN

(081)
W

(085)
W

10A

B
(015)
WR

F15

E
10A

J
K
L

H
23 PIN

GR (742)
GY (743)
BG (744)
(A25)

(GW) (212)

THROTTLE PEDAL
THROTTLE OPENING
SENSOR

YV (734)

GyY (736)
GyW(737)

IDLE

(741)
BL

(745)
BO

20

16

21
22

17
18

(730)
(BrR)

STOP

(731)
(BrB)

WARNING

(013)
(Lg)

F13

(732) MAINTENANCE
(BrW)

9
10
11
(161) W

(E15)

S2H
S2L

INC/DEC S/W
INC

PG (739)

(m)

PW (740)

DEC

31
BrG (738)

E/G OIL PRESS.

EP

DIAGNOSTIC S/W

(751)
GyR

31 PIN
BrW (733)
BLg (735)

IDLE S/W
OFF IDLE

AI

SbY (209)

TC

Sb (205)

DC

SbW(207)
RLg (206)

CAN

S2S
23

RESISTOR

24
14
12
13

B
9 PIN
C
D
E
F

S2H

(060)
W

B
C

S2L

S2S

(YL) (747)

(Y0) (748)

G
A
E

E/G ECM connection diagram

DATA LINK
CONNECTOR

115V2E62006

62-23
115ZV-2 Function & Structure Electrical Group
ECM (Engine Controller)

Monitor lamp test


ON

Key switch

Approx.
2 sec

OFF
ON

Engine maintenance lamp

Orange

OFF
ON

Engine warning lamp

Lights when
abnormality
occurs.

OFF
ON

Engine stop lamp

Red

OFF

95ZV62025

20

10

30

0
x100min

Yellow

-1

STOP

Engine maintenance lamp


Engine warning lamp
Engine stop lamp
115V2E62007

When the starter switch is set to ON, three engine monitor lamps (engine protection, engine warning and
engine stop) are lit for approximately 2 seconds.
After that, if there is an abnormality in a circuit, a corresponding monitor lamp lights.

62-24
Function & Structure Electrical Group
ECM (Engine Controller)

Failure diagnosis

The diagnosis for the engine failure should be done by


the following steps.

Engine diagnostic switch (option)


Diag. switch
(Part Number: 35010-60130)

Step 1. Starter switch key "OFF"


Step 2. Diagnostic switch "ON"
Step 3. Starter switch key "ON"

Inc./Dec. switch
(Part Number: 35010-60180)

The engine warning lamp flashes with these conditions.


To diagnose the engine failure, convert the flashing pattern to the 3-digit fault code.
The following shows how to convert the flashing pattern
to the 3-digit fault code.
G R
L W

Note
These code are quickly retrievable with Cummins
Quickcheck hand held analyzers or with the MODM on
the machine.

R
G Y

Cable assembly
(Part Number : 33191-49150)
70ZV62069

This switch is used to check the engine failure when any


one of the engine warning lamps is turned on.

Refer to the "QUANTUM FAULT CODE INFORMATION" for details.


The following steps show how to finish the diagnosis for
the engine failure.
Step 1. Diagnostic switch "OFF"
Step 2. Starter switch key "OFF"

OFF

ON

START

95ZV62028

ON
OFF
Orange
1 sec

1 sec

Yellow

Red

ON
OFF

ON
OFF

0.5 sec
Second
digit

First digit
1 sec

Third digit
1 sec

Fault code

Fault code (continued)


115V2E62008

62-25
115ZV-2 Function & Structure Electrical Group
ECM (Engine Controller)

Failure diagnostic chart


ON

Key switch

OFF
ON

Diagnostic switch

OFF

[When there is no fault code]


ON

Engine maintenance lamp


Orange

ON

Engine warning lamp


Yellow

Engine stop lamp

OFF

OFF
ON

STOP

Red

OFF

[When there is fault code]


ON

Engine maintenance lamp


Orange

1 sec

1 sec

ON

Engine warning lamp


Yellow

Engine stop lamp

OFF

STOP

Red

OFF
ON
OFF

100's digit

1 sec

10's digit

1 sec

1's digit

Fault code
[Example: Failure code 131]
Accelerator pedal position sensor
circuit-shorted high.
ON

Engine maintenance lamp


Orange

1 sec

1 sec

ON

Engine warning lamp


Yellow

Engine stop lamp

OFF

STOP

Red

OFF
ON
OFF

Following page explains more.


115V2E62009

62-26
Function & Structure Electrical Group
ECM (Engine Controller)

Increment decrement switch (option)


Diag. switch
(Part Number: 35010-60130)

G R
L W

- Adjusting the engine idle revolution

Inc./Dec. switch
(Part Number : 35010-60180)

R
G Y

Cable assembly
(Part Number : 33191-49150)
70ZV62069

The switch is used for;


1. Checking the history of the engine failures
2. Adjusting the engine idle revolution
- Checking the history of the engine failures
When the diagnostic switch is ON (Starter switch key
"ON"), the lights will continue to flash the same fault
code until the system is advanced to the next active
fault code. To go to the second fault code, move the
increment / decrement switch to "+", then release it.
You can also go back to the previous fault code by
moving the switch to "-", then releasing it. To check
the third or fourth fault code, move the switch to "+",
then release it when all active fault codes have been
viewed. Moving the switch to "-" will go back to the
first fault code.
Refer to the section of the diagnostic switch for converting the flashing pattern to 3-digit fault code.
Refer to the "Quantum fault code information" for
details.

When the diagnostic switch is OFF (Starter switch


key "ON"), the engine idle revolution can be adjusted
in 25 rpm by using the increment / decrement switch
(650 rpm 800 rpm 1,000 rpm). Move the increment / decrement switch to "+", then release it, to
increase the engine idle revolution to 1,000 min-1
(rpm).
To decrease the engine idle revolution, move this
switch to "-", then release it. As a result the engine
idle revolution is adjusted as 650 min-1 (rpm).
The engine idle revolution is not changed to over
1,000 min-1 (rpm) or to below 650 min-1 (rpm) even
though this switch is moved to "+" or "-".

62-27
115ZV-2 Function & Structure Electrical Group
ECM (Engine Controller)

Quantum fault code information


These codes show the fault codes for the engine failure
displayed on the MODM error log monitor, or checked
by the diagnostic switch (option).

DESCRIPTION
ZW550

FAULT
CODE/
LAMP

Please note that not all are used in the ZW550


machine application. Refer to Cummins Engine troubleshooting fault codes list for more information.

EG111
Red

Engine Control Module (ECM) - critical internal failure.

EG113
Yellow

Engine Timing Actuator Circuit - shorted high.

EG114
Yellow

Engine Timing Actuator Circuit - shorted low.

EG115
Red

Engine Speed / Camshaft Position Sensor Circuit - lost both of two signals from
the magnetic pickup sensor.

EG121
Yellow

Engine Speed / Position Sensor Circuit - lost one of two signals from the
magnetic pickup sensor.

EG122
Yellow

Intake Manifold Pressure Sensor #1 Circuit - shorted high.

EG123
Yellow

Intake Manifold Pressure Sensor #1 Circuit - shorted low.

EG124
Yellow

Intake Manifold Pressure - above normal operation.

EG131
Red

Accelerator Pedal Position Sensor Circuit - shorted high.

EG132
Red

Accelerator Pedal Position Sensor Circuit - shorted low.

EG133
Red

Remote Accelerator Pedal Position Sensor Circuit - shorted high.

EG134
Red

Remote Accelerator Pedal Position Sensor Circuit - shorted low.

EG135
Yellow

Engine Oil Pressure Sensor Circuit - shorted high.

EG141
Yellow

Engine Oil Pressure Sensor Circuit - shorted low.

EG143
Yellow

Engine Oil Pressure Low - warning.

EG144
Yellow

Engine Coolant Temperature Sensor Circuit - voltage above normal or shorted


high.

EG145
Yellow

Engine Coolant Temperature Sensor Circuit - voltage below normal or shorted


low.

EG146
Yellow

Engine Coolant Temperature High - warning.

EG151
Red

Engine Coolant Temperature High - critical.

EG153
Yellow

Intake Manifold Air Temperature Sensor Circuit - voltage above normal or


shorted high.

EG154
Yellow

Intake Manifold Air Temperature Sensor Circuit - voltage below normal or


shorted low.

EG155
Red

Intake Manifold Air Temperature Sensor High - critical.

EG166
Yellow

Rack Position Sensor #1 Circuit - shorted high.

EG172
Red

Rack Actuator Position #1 Circuit - grounded circuit.

62-28
Function & Structure Electrical Group
ECM (Engine Controller)

FAULT
CODE/
LAMP

ZW550

DESCRIPTION

EG173
Yellow

Rack Actuator - mechanically stuck open.

EG184
Yellow

Engine Control Module Identification Input State Error.

EG185
Yellow

Engine Control Module Network Communication Error.

EG187
Yellow

Sensor Supply Voltage #2 Circuit - shorted low.

EG212
Yellow

Engine Oil Temperature Sensor Circuit - shorted high.

EG213
Yellow

Engine Oil Temperature Sensor Circuit - shorted low.

EG214
Red

Engine Oil Temperature High - Critical.

EG221
Yellow

Ambient Air Pressure Sensor Circuit - shorted high.

EG222
Yellow

Ambient Air Pressure Sensor Circuit - shorted low.

EG227
Yellow

Sensor Supply Voltage #2 Circuit - shorted high.

EG231
Yellow

Engine Coolant Pressure Sensor Circuit - shorted high.

EG232
Yellow

Engine Coolant Pressure Sensor Circuit - shorted low.

EG233
Yellow

Engine Coolant Pressure Low - warning.

EG234
Red

Engine Speed High - critical.

EG238
Yellow

Sensor Supply Voltage #3 Circuit - shorted low.

EG254
Red

Fuel Shutoff Valve Circuit - shorted low.

EG255
Yellow

Fuel Shutoff Valve Circuit - shorted high.

EG259
Red

Fuel Shutoff Valve - stuck open.

EG261
Yellow

Fuel Temperature High - warning.

EG263
Yellow

Fuel Temperature Sensor Circuit - shorted high.

EG265
Yellow

Fuel Temperature Sensor Circuit - shorted low.

EG266
Red

Engine Fuel Temperature - data valid but above normal operational range - most
severe level.

EG271
Yellow

Fuel Control Actuator Circuit - shorted low.

EG272
Yellow

Fuel Control Actuator Circuit - shorted high.

EG281
Yellow

Injection Pump Mechanical System - signal not in range from ECM.

EG284
Yellow

Engine Speed / Position Sensor #1 (Crankshaft) Supply Voltage Circuit - shorted


low.

EG285
Yellow

SAE J1939 Data Link Multiplexing PGN Timeout Error.

62-29
115ZV-2 Function & Structure Electrical Group
ECM (Engine Controller)

FAULT
CODE/
LAMP

ZW550

DESCRIPTION

EG286
Yellow

SAE J1939 Data Link Multiplexing Configuration Error.

EG287
Red

SAE J1939 Multiplexing Accelerator Pedal Sensor System Error.

EG295
Yellow

Ambient Air Pressure Sensor Circuit - data incorrect.

EG299
Yellow

Engine stopped not using Starter Switch.

EG311
Yellow

Injector Solenoid Valve Cylinder #1 Circuit - grounded circuit.

EG312
Yellow

Injector Solenoid Valve Cylinder #5 Circuit - grounded circuit.

EG313
Yellow

Injector Solenoid Valve Cylinder #3 Circuit - grounded circuit.

EG314
Yellow

Injector Solenoid Valve Cylinder #6 Circuit - grounded circuit.

EG315
Yellow

Injector Solenoid Valve Cylinder #2 Circuit - grounded circuit.

EG319
Yellow

Real Time Clock - power Interrupt.

EG321
Yellow

Injector Solenoid Valve Cylinder #4 Circuit - grounded circuit.

EG322
Yellow

Injector Solenoid Valve Cylinder #1 Circuit - open circuit.

EG323
Yellow

Injector Solenoid Valve Cylinder #5 Circuit - open circuit.

EG324
Yellow

Injector Solenoid Valve Cylinder #3 Circuit - open circuit.

EG325
Yellow

Injector Solenoid Valve Cylinder #6 Circuit - open circuit.

EG331
Yellow

Injector Solenoid Valve Cylinder #2 Circuit - open circuit.

EG332
Yellow

Injector Solenoid Valve Cylinder #4 Circuit - open circuit.

EG334
Yellow

Coolant Temperature Sensor Circuit - data erratic, intermittent, or incorrect.

EG341
Yellow

Engine Control Module - data lost.

EG342
Red

Engine Control Module - out of calibration.

EG343
Yellow

Engine Control Module - warning internal hardware failure.

EG346
Yellow

Engine Control Module - warning software error.

EG351
Yellow

Injector Power Supply.

EG352
Yellow

Sensor Supply Voltage #1 Circuit - shorted low.

EG378
Yellow

Fueling Actuator #1 Circuit - open circuit.

EG379
Yellow

Fueling Actuator #1 Circuit - grounded circuit.

EG386
Yellow

Sensor Supply Voltage #1 Circuit - shorted high.

62-30
Function & Structure Electrical Group
ECM (Engine Controller)

FAULT
CODE/
LAMP

ZW550

DESCRIPTION

EG387
Yellow

Accelerator Pedal Position Sensor Supply Voltage Circuit - shorted high.

EG394
Yellow

Timing Actuator #1 Circuit - open circuit.

EG395
Yellow

Timing Actuator #1 Circuit - grounded circuit.

EG396
Yellow

Fueling Actuator #2 Circuit - open circuit.

EG397
Yellow

Fueling Actuator #2 Circuit - grounded circuit.

EG398
Yellow

Timing Actuator #2 Circuit - open circuit.

EG399
Yellow

Timing Actuator #2 Circuit - grounded circuit.

EG415
Red

Engine Oil Pressure Low - critical.

EG418
Yellow

Water in Fuel Indicator High - maintenance.

EG419
Yellow

Intake Manifold Boost Pressure Imbalance.

EG423
Yellow

Fuel Timing Pressure or Timing Actuator Stuck.

EG428
Yellow

Water in Fuel Sensor Circuit - shorted high.

EG429
Yellow

Water in Fuel Sensor Circuit - shorted low.

EG431
Yellow

Accelerator Pedal Idle Validation Circuit - data incorrect.

EG432
Red

Accelerator Pedal Idle Validation Circuit - out of calibration.

EG433
Yellow

Intake Manifold Pressure Sensor Circuit - data incorrect.

EG434
Yellow

Voltage to ECM less than 6 V

EG435
Yellow

Engine Oil Pressure Switch Circuit - data incorrect.

EG441
Yellow

Battery #1 Voltage Low - warning.

EG442
Yellow

Battery #1 Voltage High - warning.

EG443
Yellow

Accelerator Pedal Position Sensor Supply Voltage Circuit - shorted low.

EG449
Yellow

Fuel Pump Delivery Pressure High - warning.

EG451
Yellow

Injector Metering Rail #1 Pressure Sensor Circuit - shorted high.

EG452
Yellow

Injector Metering Rail #1 Pressure Sensor Circuit - shorted low.

EG465
Yellow

Turbocharger #1 Wastegate Control Circuit - shorted high.

EG466
Yellow

Turbocharger #1 Wastegate Control Circuit - shorted low.

EG482
Yellow

Fuel Pressure Low - warning.

62-31
115ZV-2 Function & Structure Electrical Group
ECM (Engine Controller)

FAULT
CODE/
LAMP

ZW550

DESCRIPTION

EG483
Yellow

Injector Metering Rail #2 Pressure Sensor Circuit - shorted high.

EG484
Yellow

Injector Metering Rail #2 Pressure Sensor Circuit - shorted low.

EG485
Yellow

Injector Metering Rail #2 Pressure High - warning.

EG486
Yellow

Injector Metering Rail #2 Pressure Low - warning.

EG488
Yellow

Intake Manifold Temperature High - warning.

EG491
Yellow

Turbocharger #2 Wastegate Control Circuit - shorted high.

EG492
Yellow

Turbocharger #2 Wastegate Control Circuit - shorted low.

EG496
Yellow

Engine Speed / Position Sensor #2 (Camshaft) Supply Voltage.

EG524
Yellow

OEM Alternate Droop Switch Validation - data incorrect.

EG527
Yellow

Auxiliary Input / Output #2 Circuit - shorted high.

EG528
Yellow

OEM Alternate torque validation switch - data incorrect.

EG529
Yellow

Auxiliary Input / Output #3 Circuit - shorted high.

EG546
Yellow

Fuel Delivery Pressure Sensor Circuit - shorted high.

EG547
Yellow

Fuel Delivery Pressure Sensor Circuit - shorted low.

EG551
Yellow

Accelerate Pedal Idle Validation Circuit - shorted low.

EG553
Yellow

Injector Metering Rail #1 Pressure High - warning level.

EG554
Yellow

Fuel Pressure Sensor Error.

EG559
Yellow

Injector Metering Rail #1 Pressure Low - data valid but below normal operational
range - moderately severe level.

EG596
Yellow

Electrical Charging System Voltage High - warning level.

EG598
Red

Electrical Charging System Voltage Low - critical level.

EG689
Yellow

Crankshaft Engine Speed Signal Error.

EG731
Yellow

Mechanical Timing Misalignment.

EG753
Yellow

Crankshaft Position Sensor and Camshaft Position Sensor - data erratic,


intermittent, or in correct.

EG757
Yellow

Electronic Control Module Data Lost.

EG758
Yellow

Injector Metering Rail #2 Pressure Malfunction.

EG778
Yellow

Engine Speed Sensor (Camshaft) - data erratic, intermittent, or incorrect.

EG951
None

Cylinder Power Imbalance Detected.

62-32
Function & Structure Electrical Group
ECM (Engine Controller)

DESCRIPTION
ZW550

FAULT
CODE/
LAMP

EG1117
None

Power Lost with Ignition ON - data erratic, intermittent, or incorrect.

EG1358
Yellow

Accelerator Pedal Position Sensor 1 Circuit - voltage above normal or shorted


high.

EG1359
Yellow

Accelerator Pedal Position Sensor 1 Circuit - voltage below normal or shorted


low.

EG1361
Yellow

Remote Accelerator Pedal Position Sensor 1 Circuit - voltage below normal or


shorted low.

EG1376
Orange

Engine Camshaft Speed / Position Sensor - data erratic, intermittent, or


incorrect.

EG1595
Yellow

Remote Accelerator Pedal Position Sensor 1 Circuit - voltage above normal or


shorted high.

EG1597
Orange

Engine Control Module Critical Internal Failure - bad intelligent device or


component.

EG1845
Orange

Water in Fuel Indicator Sensor Circuit - voltage above normal or shorted to high
source.

EG1846
Orange

Water in Fuel Indicator Sensor Circuit - voltage below normal or shorted to low
source.

EG1852
Yellow

Water in Fuel Indicator - data valid but above normal operational range moderately severe level.

EG1911
Yellow

Injector Metering Rail 1 Pressure - above normal operating range.

EG2185
Yellow

Sensor Supply Voltage #4 Circuit - shorted high.

EG2186
Yellow

Sensor Supply Voltage #4 Circuit - shorted low.

EG2215
Yellow

Fuel Pump Delivery Pressure - data valid but below normal operational range moderately severe level.

EG2249
Yellow

Fuel Pump Delivery Pressure Sensor Circuit - shorted low.

EG2261
Orange

Fuel Pump Delivery Pressure - data valid but above normal operational range least severe level.

EG2262
Orange

Fuel Pump Delivery Pressure - data valid but below normal operational range least severe level.

EG2265
Yellow

Fuel Priming Pump Control Signal Circuit - shorted high.

EG2266
Yellow

Fuel Priming Pump Control Signal Circuit - shorted low.

EG2311
Yellow

Fueling Actuator #1 Circuit Error - condition exists.

EG2321
None

Engine Speed Sensor #1 - data erratic, intermittent, or incorrect.

EG2322
None

Engine Speed Sensor #2 - data erratic, intermittent, or incorrect.

EG2697
Orange

Accelerator Pedal Position Sensor Circuit and Idling Position Detection Switch
Circuit - data erratic, intermittent, or incorrect.

EG2963
None

Engine Coolant Temperature High - warning.

EG2964
None

Intake Manifold Temperature High - warning.

EG2973
Yellow

Intake Manifold Pressure Sensor Circuit - data erratic, intermittent, or incorrect.

(09D20E)

62-33
115ZV-2 Function & Structure Electrical Group
ECM (Engine Controller)

Accelerator pedal

Pedal
A-Black-APS signal
B-White-APS ground
C-Red-APS supply (5 V)
D-Green-Throttle active
E-Blue-Idle active
F-Orange-IVS supply (5 V)

Throttle pedal
Throttle
opening sensor

BrW (733)
R

YV (734)

BLg (735)

W
IDLE S/W
OFF IDLE

GyY (736)
G
GyW (737)

IDLE

L
BL (741)

20
21
22

35

E
C
M

10
11

Note
APS-Acceleration Position Signal
IVS-Idle Validation Switch

Circuit diagram

Connector
(G) 6
(L) 5
(O) 4

1-Black-APS signal
2-White-APS ground
3-Red-APS supply (5 V)
4-Orange-IVS supply (5 V)
5-Blue-Idle active
6-Green-Throttle active

1 (B)
2 (W)
3 (R)

View A

115V2E62010

Note
To calibrate a new pedal to the ECM, do the following
within about a 5 or 6 second time frame.
- Turn "on" key switch
- Stroke the pedal fully up and down 3 times.
- Turn "off" the key switch
Potentiometer voltage (V)
Input

Up position

3.75~3.95

Down position

0.55~0.75

Pedal Test.
Typical pedal potentiometer resistance at 18C (65F).
Wire colors are at the pedal harness with accelerator pedal
unplugged.
Wire colors

at pedal up position

at pedal down position

R-B

1,540~2,310

260~390

W-B

260~390

1,540~2,310

R-W

2,000~3,000

2,000~3,000

G-O

Open

L-O

Open

62-34
Function & Structure Electrical Group
ECM (Engine Controller)
When the accelerator pedal is pressed, the voltage corresponding to the pressing angle is input as a signal
from the potentiometer to the ECM (engine controller) to
control the engine revolution.

Pedal
stop

Stroke

Throttle pedal sends electrical signal to the engine


ECM*. When the throttle pedal or the ECM* is replaced
or when the battery cable is disconnected the throttle
pedal must be calibrated, or "initialized", with the ECM*.
Failure to initialize the throttle pedal will result in a fault
code warning light, and a possible power deration.
When a new throttle pedal or ECM* is installed or when
the battery cable is re-connected or a fault code (listed
below) is indicated follow these steps within a time
frame of about 5 or 6 seconds to initialize the throttle
pedal with the ECM*.

Pedal angle

17

Installation
angle
45

Accelerator pedal installation

1. Shut off the engine


28

2. Turn the key to "ON"


3. Fully depress and release the throttle pedal three
times.

Pedal Angle

4. Turn the key to "OFF".

5V
Potentiometer Voltages
when plugged in, key "ON"

The throttle pedal and ECM* have now been initialized


or calibrated. The engine may be restarted and retested
for proper performance.

Between terminal 9 (YV-B) and 23 (BLg-W)


Refer to circuit diagram for details.

If the problem continues disconnect the wiring harness


connector at the throttle pedal and inspect both sides.
The pins and sockets should be clean, dry and straight.
If there is a problem correct it, reconnect the connector,
follow the steps above and retest.

4
3
2

Using the Quantum fault code information section the


following fault codes may indicate a non-initialized throttle pedal:

1
0

17

0
Pedal Angle

85V2E62019

Fault Code 132


Fault Code 134
Fault Code 287
Fault Code 431
Fault Code 432
Fault Code 443

If the problem is not corrected contact your Cummins


Engine distributor for assistance.
*Engine Control Module; Computer that controls engine
functions, and monitors engine faults.

62-35
115ZV-2 Function & Structure Electrical Group
Transmission Control Circuit and Monitor Circuit

Transmission Control Circuit and Monitor Circuit


Machine control unit (MCU)

To S5

To S6

To S7

To S8

To S9

85V2E62041

62-36
Function & Structure Electrical Group
Transmission Control Circuit and Monitor Circuit

Connector

MCU

To S5

To S6

To S7

To S8

To S9

MCU

A1

A2

A3

A4

A5

A6

A7

A8

A9

A10

A11

A12

A13

A14

A15

A16

A17

A18

A19

A20

A21

A22

A23

A24

A25

A26

A27

A28

A29

A30

A31

To S5

A32

B12.X_R
B13.F_SO
B14.B_SO
B15.EG_SW2
B16.RIN1
B17.OUT_MD2
B18.N_R
B19.BR_L
B20.CAN_R1
B21.CAN_R2
B22.DOUT1
B23.OUT_FEW
B24.MT
B25.ET_SE
B26.TXD1

A31.1/4_L
A32.FR_L
A33.3/4_L
A34.EG_SW1
B 1.H_SO
B 2.PWM_SO
B 3.IP_SO
B 4.R_SO
B 5.MO_SO
B 6.FR_SO
B 7.SSL_SO
B 8.BSL_SO
B 9.BZ
B10.BSL_R
B11.KO_R

A16.TT_L
A17.D_SO
A18.1_SO
A19.EP_L
A20.AB_L
A21.A_L
A22.1/2_L
A23.E_L
A24.SS_L
A25.SC_SW
A26.TF_L
A27.AC_L
A28.BP_L
A29.N_L
A30.SC_L

A 1.2S_SO
A 2.2_SO
A 3.ES_R
A 4.DD_SO
A 5.3_SO
A 6.HM
A 7.LU_SO
A 8.4_SO
A 9.OTH_OUT
A10.R_L
A11.F_L
A12.ST_L
A13.WL_L
A14.CW_L
A15.ET_L

A33

A34

B1

B2

B3

B4

B5

B6

B7

B8

B9

B10

B11

B12

B13

B14

B15

B16

B17

B18

B19

B20

B21

B22

B23

B24

To S6

B25

B26

E1

E31.TT_SE
E32.OT_SE
E33.OUT_RSE
E34.ET_M

E16.SPD
E17.BATT
E18.CANL1
E19.SS_P
E20.CANLO
E21.TM_M
E22.B_SE2
E23.WT_SE
E24.ALT
E25.RXD1
E26.TGSP
E27.INCH_SE
E28.SC_P
E29.CANHO
E30.B_SE1

E 1.SSR_SO
E 2.FC_SO
E 3.KEY
E 4.KEY
E 5.GND
E 6.GND
E 7.GND
E 8.GND
E 9.+5V
E10.TGEG
E11.KEY
E12.KEY
E13.CANH1
E14.EGR2
E15.EGR1

E2

E3

E4

E5

E6

E7

E8

E9

E10

E11

E12

E13

E14

E15

E16

E17

E18

E19

E20

E21

E22

E23

E24

E25

E26

E27

E28

E29

E30

E31

E32

E33

To S7
Connector details

E34

C16.EP
C17.F
C18.ASUB1
C19.ASUB2
C20.1/2
C21.1/8
C22.2S
C23.EG_H
C24.IP_SW
C25.FR
C26.KO_P
C27.ES_SE
C28.3/4
C29.1/4
C30.DC

C 1.2S_SE
C 2.DSUB2
C 3.DSUB4
C 4.BSLC 5.TT
C 6.AC
C 7.ET
C 8.BL
C 9.BD
C10.DSUB1
C11.DSUB3
C12.DR
C13.BSL+
C14.TF
C15.WL

C1

C2

C3

C4

C5

C6

C7

C8

C9

C10

C11

C12

C13

C14

C15

C16

C17

C18

C19

C20

C21

C22

C23

C24

C25

C26

C27

C28

C29

C30

C31

To S8

C32

D12.SL_A
D13.SS_N
D14.KD
D15.INCH_S
D16.OD_SW
D17.SH
D18.SS_SW
D19.SS_F
D20.TMP
D21.INCH
D22.KO_S
D23.SC
D24.AR
D25.SM_SW
D26.SS_R

C31.BSL
C32.EG_M
C33.DD_S
C34.AFR
D 1.PRK
D 2.AM_SW
D 3.SL_2
D 4.SL_R
D 5.SL_3
D 6.S_UP
D 7.S_DOWN
D 8.EG_SW
D 9.M_SW
D10.SL_1
D11.SL_F

C33

C34

D1

D2

D3

D4

D5

D6

D7

D8

D9

D10

D11

D12

D13

D14

D15

D16

D17

D18

D19

D20

D21

D22

D23

D24

D25

D26

To S9
115V2E62028

62-37
115ZV-2 Function & Structure Electrical Group
Transmission Control Circuit and Monitor Circuit

MCU connection diagram

ACC

(L) (005-b)
F5

(005)
L2

TO PARKING S/W

(L) (005-a)

30A
G (010)

F10

E
ACC

LX4 (005-A~005-D)
E05 E06 E17
WL (707)

E03

E04

E11

E12
B18

E24

B12
LR (126)

23A

LW (120)
LG (122)
LY (121)
YO (232)
YW (233)

S/S SHIFT S/W R


S/S SHIFT
SELECTION S/W (OPT)

YV (231)
F5

LB (230)

ARMREST S/W (OPT)

LG (122)

SHIFT UP S/W (OPT)

LY (121)

SHIFT DOWN S/W (OPT)

(YL) (124)

DOWNSHIFT BUTTON

YSb (125)

SHIFT HOLD S/W (OPT)

LP (168)

DECLUTCH SET-UP

(GW) (210)

TRACTION
CONTROL S/W
LIFT KICKOUT
SET-UP

BrG (255)
BW (271)

LOWER KICKOUT SET-UP

(GB) (277)

PRESSURE INTENSIFYING
S/W (OPT)
REVERSAL FAN S/W (OPT)

Lg (222)

AUTO FAN REVERSAL


S/W (OPT)

LgY (223)

RECALL S/W
RESET S/W

(Y)

(105)

(R)

(106)

LLg (165)
GO (164)

F13

GyW (200)

(013)
(Lg)

GL (265)

YO(176)

(GyW ) (260)

(LgY) (167)

DECLUTCH S/W
ON

PARKING SOL

HYD. OIL LEVEL S/W

(163)
(SbW)

OFF
ON

(162)
LgG

E/G OIL PRESS S/W

DECLUTCH

AIR CLEANER
CLOGGING S/W
(005-b)
(L)

OFF

D04

B10

D12
D05
D03
D10
D19
D26

D18
D24
D06
D07
D14
D17

A03
B13
B01
B04
A18

EP

A02

(273)

MCU FAILURE RELAY

KO

LIFT KICKOUT RELAY


LOWER KICKOUT RELAY

BS

A05

A08

A17
B14
A07

D23

A04

D22

A01
B03

Gy (750)
BrY (181)
LgL (182)

B06
C24
B05
C25
C34
C30
C12

L SOLENOID VALVE

(147) LB

H SOLENOID VALVE

(148) LBr

R SOLENOID VALVE

(141) LY

1ST SPEED SOLENOID VALVE

(142) LG

2ND SPEED SOLENOID VALVE

4S (132)(LG)

(143) LO

3RD SPEED SOLENOID VALVE

E01
B07
E02

(144) LW

A21

C22

A29

C33

A14

C16

A28
A19

C06

A15
A16
A27

D SOLENOID VALVE

WR (170)

BRAKE SOLENOID VALVE

LLg (140)

LU SOLENOID VALVE (OPT)

LgL (261)

RIDE CONTROL
SOLENOID VALVE

GB (267)

EFFICIENT LOADING SYSTEM


SELECTION SOLENOID VALVE

GB (278)

PRESSURE INTENSIFYING
SOLENOID VALVE (OPT)

LgL (225)
(154)
LgR
(236)
BR
(237)
BL
(226)
LgB

REVERSAL FAN SOLENOID VALVE


(OPT)

(150)
LgR

SPPC SOLENOID VALVE

1A

S/S SOLENOID VALVE R (OPT)

1A
1A

S/S SOLENOID VALVE L (OPT)


(221)
LgB

1A

D01
C23

4TH INDICATOR RELAY

4S

(LW)
LP (149)

D21

C11

SECONDARY STEERING
MOTOR RELAY COIL

ES

(LO)

D15

C13

YGy (242)
(146) LR

(LG)

A12
F5

BrB (258)

NEUTRAL RELAY

NR

(LY)

C31

LOWER KICKOUT S/W

B11

LgW (101)

OPT

LO (123)

S/S SHIFT S/W F

D11

MACHINE CONTROL UNIT (MCU)

SHIFT LEVER

F N R

LBr (128)

E/G DROOP
SELECTION 1
(SbP) (145)

(LgR) (130)
(GR) (135)
(GyB) (103)
(LgY) (173)
(Gy)

(749)

(GyG) (753)
(GyL) (190)
(LgW) (192)
(O)

(241)

F13

(013)
(Lg)

FAN SPEED CONTROL SOLENOID


VALVE
AUTO SHIFT INDICATOR LAMP
NEUTRAL INDICATOR LAMP
CENTRAL WARNING LAMP
BRAKE OIL PRESS. WARNING LAMP
E/G OIL PRESS. WARNING LAMP
E/G COOLANT TEMP. WARNING LAMP
T/M OIL TEMP. WARNING LAMP
AIR CLEANER WARNING LAMP
STEERING OIL PRESS.
WARNING LAMP

PARKING S/W

FUEL EFFICIENT MODE S/W

EFFICIENT LOADING SYSTEM S/W

RIDE CONTROL S/W


X

MCU
FAILURE

(LgW) (102)
(LgSb)

WARNING
BUZZER

(112)

BZ

K115V2E62001

62-38
Function & Structure Electrical Group
Transmission Control Circuit and Monitor Circuit

(152)
PB
SbO (183)

T/M OIL FILTER S/W

Sb (184)

RADIATOR WATER
LEVEL S/W
FUEL LEVEL F

YR (405)
YB (406)

FUEL LEVEL 3/4

YL (407)

FUEL LEVEL 1/2

YBr (408)

FUEL LEVEL 1/4

YG (409)

FUEL LEVEL 1/8

D20
C14
C15
C17
C28
C20
C29
C21

E
V (100)

S/S POTENTIOMETER (OPT)

G (234)

BOOM ANGLE SENSOR

BrR (251)

DECLUTCH SENSOR

(LgR) (166)

BRAKE OIL
PRESS. SENSOR 1
BRAKE OIL
PRESS. SENSOR 2

E09 (+5V)

E19
C26
E27

A26
A13

MACHINE CONTROL UNIT (MCU)

(153)
P

T/M ACC. LIMIT S/W

A20
A30
A32
A24
A11
A33
A22
A31
A23
B09

E34
E21

SbY (171) E30


B24

(SbO) (193)
(Sb)

T/M OIL FILTER WARNING LAMP


RADIATOR COOLANT LEVEL WARNING LAMP
AUTO BRAKE INDICATOR LAMP

(194)

(GY) (169)
(OSb) (211)

TRACTION CONTROL INDICATOR LAMP

(RL) (235)

REVERSAL FAN INDICATOR LAMP (OPT)

(LgB) (224)

S/S INDICATOR LAMP (OPT)

(YR) (410)

FUEL LEVEL F
FUEL LEVEL 3/4
FUEL LEVEL 1/2
FUEL LEVEL 1/4
FUEL LEVEL E

(YB) (411)
(YL)

(412)

(YBr) (413)
(YG) (414)
LgBr (104)

BUZZER RELAY

BZ

(YB) (401)

E/G COOLANT TEMP. GAUGE

(BrW) (402)

T/M OIL TEMP. GAUGE


METER OUTPUT
(TACHOMETER)

(WL)(400)

SbY (172) E22


E10

EFFICIENT LOADING SYSTEM


OIL PRESS. SENSOR

GyB (266)

SECONDARY STEERING
PRESS. SENSOR

C01
E26

SbR (240)
GyG (754)

E/G COOLANT TEMP. SENSOR

GyL (180)

T/M OIL TEMP. SENSOR

(G) (415)

OUTSIDE AIR TEMP. SENSOR

GyO (220)

HYD. OIL TEMP. SENSOR

BY (114)
Y (160)

MACHINE SPEED SENSOR


E/G SPEED SENSOR

ECM(31)

W (161)
Y (159)

(420)
OSb (+)

()

(421)
OB (+)

()

B25

A06

E31

B08

E32

A09

E23

B15

E07

A34

E16

A25

E15
A10

E08

B19

(OUT_FEW)B23
(OUT_RES)E33
(RXD0)E25
(TXD0)B26
(OUT_MD2)B17

E
P (107)
PL (108)
PG (109)
PB (110)

YSb (403)
SbR

(208)

SbP

(202)

SbW (203)

HOUR METER DRIVE

(RIN1)B16

D02

D08

E/G TORQUE SELECTION

TC

E/G DROOP SELECTION 1

F5

DC

E/G DROOP SELECTION 2

(LB) (138)

TO BACK-UP LAMP

(RG) (331)

YB
YG
YL
YO
YBr

TRACTION CONTROL SELECTION

ECM(O)

TO BRAKE LAMP
(100)
V

(115)
(116)
(117)
(118)
(119)

+5V
FEW
RESET
RXD
TXD
MD2
GND

MCU PROGRAM REWRITE

C03
D16

E/G IDLE SELECTION

AI

(GW) (212)

C02

D25

(DOUT1)B22

GL (810)

S2H
S2L
S2S

(CANH0)E29
(CANL0)E20

MAIN MCU

RS232C

GR (811)

D09
E

TACHOGRAPH MACHINE SPEED (OPT)

C27

(E09)

DESTINATION SWITCH 1
DESTINATION SWITCH 2
A/MSELECTION
ODMETER SELECTION
TIRE DIA. SELECTION
SPEED SENSOR SELECTION
METER SELECTION

TACHOGRAPH E/G SPEED (OPT)

CAN

K115V2E62002

62-39
115ZV-2 Function & Structure Electrical Group
Transmission Control Circuit and Monitor Circuit

Machine control unit (MCU) function


Forward/reverse (F/R) shifting and speed change
To solenoid valve
for each clutch

F/R clutch solenoid valve

+24 V

Shift lever

Modulation
mechanism

Surge
suppression
diode
(incorporated
in solenoid
valve)

R
1

23

A
1

Downshift
button

MCU

Machine speed
sensor

+24 V

Solenoid valve
for clutch

Clutch
valve

Speed indicator
lamp
(instrument panel)

Torque
converter
pump

Direct charge
valve

Clutch
piston

During energized: Clutch is engaged.


During de-engaged: Clutch is disengaged.
Lockup clutch
piston

Machine with lockup clutch:

To solenoid valve
for each clutch

LU

ECM
Modulation
mechanism

Engine speed
sensor

Solenoid
valve

Solenoid valve
for clutch

+24 V

ON when shift lever in A position

Clutch
valve

AUTO indicator lamp

Direct charge
valve

Torque
converter
pump

Clutch
piston

During energized: Clutch is engaged.


During de-engaged: Clutch is disengaged.

115V2E62013

Each clutch has one solenoid valve for transmission


control. When electric current flows through the solenoid valve, the clutch oil is fed into the clutch piston
chamber through the modulation mechanism and the
clutch valve. When the piston operates, the clutch is
engaged. When the current stops flowing through the
solenoid valve, the oil is drained from the clutch piston
chamber through the clutch valve, and the clutch is disengaged.
Input detection
When the shift lever is set to the F (forward) position,
electric current for input detection signal is sent from the
MCU to the grounding circuit via shift lever contact F.
The MCU, therefore, judges that the shift lever is set to
the F (forward) position. There is no shift lever contact
for the R (reverse) input circuit and electric current will
not flow.
For the speed change by the shift-up/shift-down signal,
the MCU judges the set speed in the same way as
described above.

Operation error preventive function


(Simultaneous input of two or more commands)
If both the forward and reverse commands are input at
the same time due to a problem, the transmission is set
to the neutral position. In addition, if two or more speed
commands are input at the same time, the speed range
previously engaged is selected.
When the starter switch is at OFF position, if both the
forward and reverse commands are input at the same
time due to a problem, the engine does not start even if
the starter switch is placed in the start position. This is
because the neutral relay does not work.

62-40
Function & Structure Electrical Group
Transmission Control Circuit and Monitor Circuit
Shift lever

KNIGHT BEAM CO,LTD


BM51-111
JAPAN
>PAMXD6-G50<

Forward F

Neutral N

Reverse R

1st speed
2nd speed

Auto

3rd speed

Grounding for
speed change side (B)
1st speed (GW)

2nd speed (GL)

Auto (G)

3rd speed (GY)

F (GR)

Unused

R (GB)

Grounding for
F/R side (B)

70ZV62025

1. Bracket assembly
2. Grip
3. Connector
The shift lever has two direction and four speed positions; forward and reverse (F and R) and "1", "2", and
"3" speed positions are respectively used for 1st, 2nd,
and 3rd fixed speeds. The "A" speed position is used for
the variable speed where the 2nd through 4th speed
clutches are automatically changed in both the forward
and reverse operation. The lockup clutch (OPT) is automatically engaged or disengaged in the forward operation only.

Operator controlled shifting from 2 1 2 in either "2"


or "A" is done by momentarily depressing the downshift
button on the boom lever.
Shift lever neutral (N) position
The shift lever has no neutral (N) contact.
Therefore, if neither the forward nor the reverse (F and
R) signal is input, the MCU will judge that the shift lever
is at the neutral (N) position.

62-41
115ZV-2 Function & Structure Electrical Group
Transmission Control Circuit and Monitor Circuit

Automatic shift

Operation of solenoid valve


Clutch solenoid valve

Shift up

10.8 N-m (1.1 kgf-m) (8 lb-ft)

Shift down

Speed
F4

+ side

SKM6
G24D

K W E 6 K- 21/
N
12.0 10.0

side

Reverse

View from A

10.0 11.0

17.0 19.0

Speed km/h

Forward

Automatic shift map (Normal mode)

115V2E62014

35 N-m (3.6 kgf-m) (26 lb-ft)


Shift up
80ZV62012

Shift down

F4
Solenoid valve (with built-in diode)
Rated voltage

DC 24 V

Coil resistance value

Approx. 27

3
2

When the input signal is transmitted, the output circuit of


the corresponding solenoid valve is connected to the
grounding circuit. As a result, power is supplied to the
solenoid valve and the clutch is engaged. At the same
time, the speed indicator lamp in the cab lights.
Note that when the parking brake or the auto brake is
actuated or the declutch brake is applied, the forward or
reverse (F or R) clutch solenoid valve is turned off and
the transmission is set to neutral.

11.5 9.5

Reverse

9.5 10.5

Speed km/h

16.5 18.5

Forward

Automatic shift map (Fuel efficient mode)

115V2E62015

When the shift lever is set to A position, the AUTO indicator lamp in the cab will light and one of the solenoid
valves will be automatically energized according to the
machine speed. In addition, the speed indicator lamp
will light. The input signal for automatic shift is controlled
by the pulse generated by the speed sensor.

62-42
Function & Structure Electrical Group
Transmission Control Circuit and Monitor Circuit

Automatic shift (with lock-up solenoid)


Shift up
Shift down

Speed

F4L
F4
F3L
3
2
12.0 10.0

Reverse

10.0 11.0

13.5 15.5

20.5 21.5

26.5 28.5

Forward
Speed km/h
Automatic shift map (Normal mode)
115V2E62016

Shift up
Shift down

Speed

F4L
F4
F3L
3
2
11.5 9.5

Reverse

9.5 10.5

12.0 14.0

20.0 22.0

24.0 26.0

Forward
Speed km/h
Automatic shift map (Fuel efficient mode) 115V2E62017

62-43
115ZV-2 Function & Structure Electrical Group
Transmission Control Circuit and Monitor Circuit

Machine speed sensor


Machine speed sensor

115V2E62026

39 N-m (4.0 kgf-m) (29 lb-ft)

Clearance adjustment
0.45~1.6 mm (0.018~0.063 in)
115V2E62018

Internal resistance *

2.30.2 k (25C) (77F)

* Internal resistance changes greatly with temperature. At lower temperature the resistance is lower. At operating temperature the resistance increases.
If resistance is 0 or the speed sensor is defective.

The detector is adjacent to the transmission output


gear. The pulse voltage is transmitted to the MCU.
Note
To prevent electronic "noise" from other sources that
may corrupt signal, "twist" the wire from sensor all the
way to the MCU.

IMPORTANT
Make sure to apply the correct torque value when
replacing the sensor. Shims help to set clearance
between sensor & gear but over-torque can change
clearance.

62-44
Function & Structure Electrical Group
Transmission Control Circuit and Monitor Circuit

Downshift button operation


Downshift button

80ZVE62017

The downshift button is attached to the boom control


lever.
In any operation mode, pressing the downshift button
during 2nd speed operation shifts the 2nd speed to the
1st speed. After that, if the downshift button is pressed
again, the speed is changed from the 1st to the 2nd, or
to move the shift lever to neutral or to the opposite
direction, the speed will be changed to the 2nd again.
Note that when the speed is shifted, the transmission
status monitor lamp on the instrument panel changes
from the 2nd gear to the 1st gear or from the 1st gear to
the 2nd gear.
Downshift button

YL
BY

70ZV62031

Allowable value

Max. voltage

DC 24 V

Current

10 mA

The downshift button is of the momentary type. It is


spring loaded to the "OFF" position.

62-45
115ZV-2 Function & Structure Electrical Group
Transmission Control Circuit and Monitor Circuit

Modulation at clutch switching


MCU

Clutch selection
input signal

F
Shift lever

2 3

Output
current
control

+ 24 V

Modulator valve

B05

T/M accumulator
limit switch
Machine speed sensor
E/G speed sensor

ECM

115V2E62024

To T/C
ACC2

ACC1

P3

P2
PG

10

0.007 MPa
(0.07 kgf/cm2)
(0.1 psi)

0.39 ~ 2.65 MPa


(4 ~ 27 kgf/cm2)
(56.8 ~ 384 psi)

PG

Drain (T/M side)

P4

PG

To T/C return line

30L/min

4.0
0.88 MPa
(9 kgf/cm2)
(128 psi)

P5

To T/M lubrication line

34

To T/M solenoid
valves

PG
Drain (T/M side)

PM

P1

PG

Drain (T/M side)

From pump
115V2E62025

The rise time of clutch oil pressure is controlled by modulator valve (proportional relief valve) (6) to shorten the
time lag and reduce shock that occurs when shifting
between forward and reverse, and between gears.

62-46
Function & Structure Electrical Group
Transmission Control Circuit and Monitor Circuit

Modulator valve operation

Initial oil charging (t1) into the clutch piston


chamber
When the shift lever is shifted from the neutral to the 1st
speed forward, the low range clutch solenoid valve is
energized and oil in the accumulator flows into the
empty clutch piston chamber first.

Modulation chart (Neutral1st forward)


ON

Then, oil under pressure flows into the clutch piston


chamber. After a given time, the control current to the
modulator valve is reduced. Accordingly the main clutch
oil pressure is reduced, concluding the initial oil charging into the clutch chamber.

Low range clutch OFF


solenoid valve
ON

1st speed clutch


solenoid valve

Modulator
valve

Oil filling completed Engagement


(clutch) (Acc.)
completed

The time taken for this initial charging, which depends


on the capacity of the clutch piston chamber, is controlled by a MCU.

Current
(mA)

Main
pressure

Pressure
MPa
(kgf/cm2)
(psi)

Low range
clutch
Pressure
pressure
MPa
(kgf/cm2)
(psi)

Clutch piston chamber filling (t2)

P1

P2

The holding pressure in this time depends on the speed


of the engine: lower pressure with lower engine speed,
higher pressure with higher engine speed.
This time is also controlled by the MCU.

0
t2
t1

t3

When shifted

Accumulator filling (t3)

t4

Shift completed

115V2E32023

t1

Initial charging
time

Changes with combination of


clutches

0~0.12 sec

t2

Low pressure
holding time

Changes with engine speed

Less than
0.5 sec

t3

Pressure rise
time

Changes with combination of


clutches

0.3~0.7 sec

t4

Restoration time

Changes with combination of


clutches

0.5~1.3 sec

P1

0.5~1.5 MPa (6~15 kgf/cm2) (85~213 psi)

P2

2.6~2.9 MPa (27~30 kgf/cm2) (384~427 psi)

- E/G high idle

To reduce clutch engagement shock, it is necessary to


engage the clutch while allowing some slippage of it. To
do this, the current to the modulator valve is held low for
a given time. The torque converter gear pump fills the
oil both into the accumulator and into the clutch piston
chamber. During this time, the clutch piston moves
while compressing the piston return spring.

The pump continues to fill the oil into the accumulator.


At the same time the clutch oil pressure is raised slowly.
This prevents the clutch engagement shock caused by
a rapid pressure rise.

Pressure rise (t4)


Since the accumulator is completely accumulated at the
start point of t4, the limit switch is turned ON, sending
the signal to the MCU. At that point, the clutch piston
comes into contact with the clutch plate and the clutch
plates start to transmit power. The MCU recognizes that
the accumulator is at the full accumulation by this signal, and gradually increases the driving current to the
modulator valve.
Then, the hydraulic pressure for the clutch will consequently increases to complete the clutch engagement.

62-47
115ZV-2 Function & Structure Electrical Group
Transmission Control Circuit and Monitor Circuit

Adjustable declutch preset switch


200

Clutch OFF

Clutch ON

310

510

(kPa)

Declutch sensor
85V2E62028

Declutch selector
switch
ON

Declutch sensor

Transmission clutch

More than 510 (kPa)

Disengage

Less than 310 (kPa)

Engage

Adjustable declutch preset switch is used to change the


angle of the left brake pedal (Declutch pedal) to disengage the transmission clutch.

Left brake valve

Pressure sensor for stop lamp


and declutch

95V2E52014

Switch

115V2U62019

With the engine running, step on the left brake pedal


(Declutch pedal) up to the desired angle and press the
switch to set the brake pedal (Declutch pedal) angle.

62-48
Function & Structure Electrical Group
Transmission Control Circuit and Monitor Circuit

Back-up alarm

Back-up lights

Shift lever

Back-up alarm
MCU

+24 V

2 3

A10

85V2E62027

When the shift lever is set to the reverse (R) position,


the back-up lamp will light, and the buzzer will sound.

62-49
115ZV-2 Function & Structure Electrical Group
Transmission Control Circuit and Monitor Circuit

Parking brake

5A
F13

+ 24V

Monitor lamp

Parking brake

Parking (ON)
Running (OFF)
Parking
switch

ON
OFF
MCU

D01

30A
F5
+ 24V

95V2E62014

The parking brake solenoid valve activates the parking


brake.
Parking switch ON:

Parking switch OFF:

When the power of the solenoid valve is turned off, no


oil will be fed to the piston chamber of the parking
brake. The piston presses the brake disc with the spring
force to actuate the parking brake. If the transmission
shift lever is set to the forward or reverse (F or R) position, the buzzer will sound and the clutch will not be
engaged.

When the power of the solenoid valve is turned on, oil


will be fed into the piston chamber, the spring is compressed, and the parking brake is released.

Parking brake operation


Parking switch

Monitor lamp

Buzzer

Parking brake solenoid


valve

Parking *

"Parking" position
(pulled up)

Sounds when shift lever is


set to F or R

No electric power supply

Running

"Running" position
(pushed in)

Off

No buzzer

Electric power supply

*When the parking switch is set to "parking", the forward or reverse clutch is disengaged and set to neutral.

62-50
Function & Structure Electrical Group
Transmission Control Circuit and Monitor Circuit
Solenoid valve for parking brake
Spring chamber (brake actuator)
B

Reducing
valve

Solenoid

Knob

T
Seat
face A

Manual release
(counterclockwise
rotation)

Spool

Seat
face B Tank

115V2E62020

Solenoid specifications
Rated voltage

Hydraulic circuit diagram


95ZV52045

Valve assembly
(Brake manifold block assembly)
Front

Solenoid valve
for auto brake

Solenoid
valve for
parking
115V2E62021

DC 24 V

Rated current

0.92 A

Resistance

26.2

62-51
115ZV-2 Function & Structure Electrical Group
Transmission Control Circuit and Monitor Circuit

Auto brake

Input side

1 23A

+24V

Machine speed

Shift lever

Shift lever position


selector signal

Machine speed
sensor

Output side

MCU

Solenoid valve for auto brake

B14

Auto brake monitor lamp, buzzer

+24V

A20
B13

B01

B04

Solenoid valve for forward/reverse clutch

Installation position of solenoid valve for auto brake.


Refer to the description on the solenoid valve for parking brake.

95V2E62015

When the traveling direction is switched over between


forward and reverse at a machine speed of 12 km/h (7.5
mph) or more, the auto brake is applied to protect the
transmission clutches.

Shown in the "released" position


To rear service
brake

To front
service brake

23

When the machine speed is too high, the auto brake is


applied also to prevent troubles caused by excess
speed in the engine and the transmission.

From unloader
valve (Pump)

When the auto brake signal enters from the MCU to


solenoid valve (29) for auto brake and solenoid valve
(29) is energized and magnetized, the pilot oil from
unloader valve (22) enters the pilot port of left brake
valve (23) through reducing valve (37) (setting pressure:
1.3 MPa (13 kgf/cm2) (185 psi)), and actuates the pilot
piston and the spool of the brake valve.

29

MCU
signal

37

When the spool is switched over, the high-pressure oil


coming from the pump through the unloader valve
enters the front and rear brake piston chambers to apply
the service brake.

1.3 MPa
(13 kgf/cm2)
(185 psi)

From unloader valve

K115V2U52001

At this time, the neutral indicator lamp and the auto


brake indicator lamp on the instrument panel light, and
buzzer sounds. While the auto brake is applied, the forward/reverse clutches of the transmission are disengaged and kept in the neutral status until the actual
machine speed decreases and reaches the set value.

62-52
Function & Structure Electrical Group
Transmission Control Circuit and Monitor Circuit
When the traveling direction is switched over
between forward and reverse at a machine speed of
12 km/h (7.5 mph) or more

When machine speed is excessive


Operation chart
(Example: Machine speed excessive in forward direction)

Operation chart
(Example: Shifting from forward to reverse)
Machine
speed
5 km/h
Shifting between
forward and reverse (3.12 mph)

Machine
speed

Machine
speed
2 km/h
(1.25 mph)

F solenoid valve

Brake solenoid
valve
Monitor lamp OFF

OFF

R solenoid valve

Buzzer
Neutral
indicator lamp

ON

ON
OFF

Service brake operating

115ZV62067

OFF

When the machine speed reaches or exceeds the set


value, the service brake is applied as in the above case.
When the machine speed drops below the specified
value, the service brake is released.

ON
Neutral
indicator lamp OFF
Brake solenoid
valve
OFF
Monitor lamp
Buzzer

ON

Speed clutch
solenoid valve

ON

T/M in neutral

ON

ON
OFF

Machine
speed

F solenoid valve

T/M in neutral

OFF
ON
OFF

During service brake application, the transmission is


placed in neutral.

Service brake operating


95V2E62017

When the traveling direction is switched over between


forward and reverse at a machine speed 12 km/h (7.5
mph) or more at any speed position, the power of the
solenoid valve for auto brake turns on and the service
brake is applied until the machine speed is reduced to 2
km/h (1.25 mph). At the same time, the power of all
solenoid valves for forward/reverse clutches is turned
off, and the transmission is set to the neutral position.
When the machine speed reaches 5 km/h (3.12 mph),
the clutch for the opposite direction is engaged. (However, the brake remains applied until the machine speed
becomes approximately 2 km/h (1.25 mph).

Speed range

Set value km/h (mph)


F

1st

Approximately 13
(8.125)

Approximately 12
(7.5)

2nd

Approximately 22
(13.75)

Approximately 24
(15.0)

3rd

Approximately 36
(22.5)

Approximately 36
(22.5)

4th/A

Approximately 39
(24.375)

62-53
115ZV-2 Function & Structure Electrical Group
Transmission Control Circuit and Monitor Circuit
Auto brake solenoid valve

Seat face A

Pilot oil circuit


From unloader
valve

Brake valve

B
Seat face B

Tank

T
Spool

Reducing valve
(for autobrake)

Hydraulic circuit diagram

Solenoid valve
(for autobrake)

115V2E52006

Valve assembly
(Brake manifold block assembly)

Solenoid valve
for auto brake

Solenoid
valve for
parking
115V2E62021

Solenoid specifications
Rated voltage

DC 24 V

Rated current

0.92 A

Resistance

26.2

62-54
Function & Structure Electrical Group
Transmission Control Circuit and Monitor Circuit

Machine control unit (MCU) failure warning


Should the MCU stop working due to the following
cause, a dash mounted monitor lamp lights up to give
warning.
MCU failure monitor lamp

MCU replacement
If the monitor lamp lights up under the cause above, it is
an indication that the MCU's program has malfunctioned
and the MCU assembly must be replaced.

Electrical
circuit

LgW

The MCU has a self-diagnosis function incorporated in


it, and if the computer program becomes abnormal due
to abuse or defect, a dangerous condition may occur,
the monitor lamp lights up and all the outputs from the
MCU are turned OFF.

LgW

Body blue

If a warning is given as a result of self-diagnosis of


the MCU

Chassis side
coupler

When installing a new MCU on the machine, all specifications must be registered into the MCU through the
MODM.

85V2E62030

Rating

DC 24 V

Operation voltage

16 V or less

Reset voltage

2.4 V or more

Coil resistance

320

MCU fault relay (Normally closed)

62-55
115ZV-2 Function & Structure Electrical Group
Transmission Control Circuit and Monitor Circuit

Secondary steering function (OPT)

Speed sensor

Pilot lamp
F13

MCU

To steering valve
Pressure
sensor

Check valve

Check valve
G1/2
G1/2

+24 V

Secondary
steering motor
and pump

G1/2
G1/2

F5

16
cm3/rev

G3/8

11.7MPa
(119 kgf/cm2)
(1696 psi)

G1/2

Check valve

Secondary
steering relay

G1/2

+24 V

Secondary
steering motor
and pump
11.7MPa
(119 kgf/cm2)
(1696 psi)

16
cm3/rev

M
Magnetic switch
(on motor and pump)

90.7 90.7
cm3/rev cm3/rev

Steering pump

Hydraulic line
Electrical circuit

115V2E42025

In normal operation, the oil from the steering pump


flows into the steering valve through the check valve.
And the signal of the pressure sensor is always sent to
the MCU.
With some problems, as the steering hydraulic pressure
goes down while the engine is running, the pressure
sensor signal becomes less than the preset value at the
MCU. In this condition, if the machine speed is more
than 2 km/h, the MCU sends a signal to the magnetic
switch.

As a result, the secondary steering motor and pump are


driven. Then it is ready to steer the machine.
Pressure sensor preset value
Steering hydraulic pressure
ON: at 0.3 MPa (3 kgf/cm2) (44 psi) or lower
OFF: at 0.4 MPa (4 kgf/cm2) (58 psi) or higher

62-56
Function & Structure Electrical Group
Transmission Control Circuit and Monitor Circuit

The signal from MCU


to magnetic switch

Machine speed signal

ON

Machine speed

OFF

(km/h)

85V2E42051

62-57
115ZV-2 Function & Structure Electrical Group
Transmission Control Circuit and Monitor Circuit

Monitoring system
If a problem of a unit is detected while the engine is running, a monitor lamp lights to inform the operator.
For some problems, the buzzer sounds also, and the
central alarm lamp flashes also.
When the starter switch is set to ON, all of the monitor
lamps are lit for 3 seconds and buzzer sounds to check
whether the monitor lamps are normal (not burn out).

Items to be monitored and operation condition


No.

Item to be monitored

Machine control unit (MCU)

Brake oil pressure

Engine oil pressure

Engine coolant temperature

Torque converter oil


(transmission) temperature

Clogged air cleaner

Clogged transmission oil


filter

Charging condition

Central alarm

10

Steering oil pressure

11

Engine cooling water level

12

Auto brake operation

Monitor lamp
Lighting
color

(red)

(red)

(red)

(red)

(red)

(red)

(red)

(red)

(red)

(red)

Symbol

Operation condition

Defective machine control unit (MCU)

Lamp test

Remarks

Unloader valve accumulator port oil pressure


is lower than 3.90.5 MPa (403 kgf/cm2)
(56971 psi)
While engine running, 0.1 MPa (1.1 kgf/cm 2)
(16 psi) or less for more than 2 seconds
1012C or more (2144F or more) for more
than 2 seconds

1205C or more (2489F or more) for more


than 2 seconds

Filter resistance: 63558 mmAq or more (25


inches H2O) for more than 2 seconds

Pressure difference at 502C (1224F) or


more
0.3 MPa (454 psi) or more

Defective charge system

For items 1~7, 10

Flashing type

When operates steering pressure is less than


0.4 MPa (4 kgf/cm2) (57 psi), machine speed
is more than 2 km/h.
When engine cooling water level drops
(before start up only)

(red)

Buzzer

When auto-brake works

F/R: No buzzer
sounds

62-58
Function & Structure Electrical Group
Transmission Control Circuit and Monitor Circuit

No.

Item to be monitored

13

Hydraulic oil level

Monitor lamp
Lighting
color

(red)

Symbol

Operation condition

Buzzer

Lamp test

Hydraulic oil level is low when the engine is


stopped

(red)
14

Engine protection lamp

15

Engine warning lamp

16

Engine stop lamp

(orange)

(yellow)

(red)

Any fault in engine detected by ECM


(Engine controller)

(2 sec.)

Remarks

62-59
115ZV-2 Function & Structure Electrical Group
Transmission Control Circuit and Monitor Circuit

Operation monitor lamps


Monitor lamp

No.

Monitor item

Parking

Red

Declutch

Green

When declutch switch is set to ON

Working light

Green

When working light (rear) switch is set


to ON

K-Lever indicator

Green

When K-Lever system is ON.

Turn signal indicator (left)

Green

When turn signal lever (left) is actuated

Turn signal indicator (right)

Green

When turn signal lever (right) is


actuated

High beam

Blue

When head lamp is set to high beam

Auto shift

Green

When transmission shift lever is set to


automatic position

Neutral

Green

When transmission shift lever is set to


neutral position

10

Transmission status

Yellow

When transmission shift lever is set to


corresponding gear (1~4)

11

Reversal fan

Green

When the reversal fan switch is ON.

Lighting
color

Symbol

Lighting condition

Remarks

When parking brake switch is set to ON

Caution on storage of individual instrument panel

IMPORTANT

Gauge pointer

Pointer axis
Axis hole

When storing the instrument panel individually, make


sure that the panel face (transparent face) faces
upward.
If the panel face faces below the vertical direction, the
damper oil may leak from meter pointer axis holes.
Meter

Damper
oil

Main body
frame

Magnet
70ZV62039

62-60
Function & Structure Electrical Group
Instrument Panel and Switch

Instrument Panel and Switch


Instrument panel

21

20

6 17

19 5 18

23

10

11(37)

12

30

26

28

27
13

34
14
35

15
36
16
38

STOP

39

29

33

32

31

24

25
(37)

22 8

115V2E62022

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

Tachometer
Engine coolant temperature gauge
Transmission oil temperature gauge
Fuel gauge
Parking brake indicator lamp
Auto brake indicator lamp
Declutch selector lamp
Working light indicator lamp (rear)
Central warning lamp
Machine control unit (MCU) warning lamp
Brake oil circuit warning lamp
Engine oil pressure warning lamp
Engine coolant temperature warning lamp
Transmission oil temperature warning lamp
Air cleaner clogging warning lamp
Charge warning lamp
Turn signal indicator lamp (left)
Turn signal indicator lamp (right)
High beam indicator lamp
Auto shift indicator lamp

21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.

Neutral indicator lamp


Transmission status monitor
Hour meter
Reversal fan pilot lamp (option)
Secondary steering warning lamp (option)
Working light switch (front)
Working light switch (rear)
Fuel efficient mode switch
F/R switch indicator lamp (option)
Four-way flasher switch (option)
Engine protection lamp
Engine warning lamp
Engine stop lamp
Efficient loading system switch
Cold start (ether injection) switch
Selection switch for shift lever or F/R switch
(option)
37. Hydraulic oil level warning lamp
38. Transmission oil filter warning lamp
39. Coolant level warning lamp

62-61
115ZV-2 Function & Structure Electrical Group
Instrument Panel and Switch

Instrument panel rear surface

1
L1
L2

CN1

8P

CN4
L11

4
58 57

Hour
meter

L10

L6

L19

L7

L8

Transmission oil
temperature sensor

L9

E
L10

L18

L10

L10

56
L10

L21

L17

Engine water
temperature sensor

48

16P

35

L16

L4

12P
L10

L15

CN3

29

L20

L14

L10

L3

L5

L13

L12

CN2

L22

18

L23

L24

L25

L26

L27

20P
19

28

Layout of connector pins (Instrument panel side)


CN1(8P)

CN2(20P)

A5

A6

A7

9 10 11 12 13 14 15 16 17 18

29 30 31 32 33 34

41 42 43 44

35 36 37 38 39 40

49 50

3 4

6 7

19 20

CN3(12P/16P)

22 23 24 25 26 27 28

CN4(2P)
A8

A9
46 47 48

58

53 54 55 56

57
115V2E62027

Pin
No.
1

Signal
Engine water level alarm

Lamp
No.

Pin
No.

Signal

Lamp
No.

Pin
No.

L9

21

41

Lamp
No.

AUTO lamp

L20
L16

Charge lamp

L7

22

42

Auto brake

Air cleaner clogging alarm

L6

23

Fuel level lamp (F)

43

Converter (+)

T/M oil temperature alarm

L5

24

Fuel level lamp (3/4)

44

Converter ()

Engine water temperature alarm

L4

25

Fuel level lamp (1/2)

45

Engine oil pressure alarm

L3

26

Fuel level lamp (1/4)

46

Brake oil pressure alarm

L2

27

Fuel level lamp (E)

47

MCU failure alarm

L1

28

GND ()

48

Work lamp

L18

+24 V power supply

49

Central alarm lamp

L14

50

GND ()

+24 V power supply

29

10

Secondary steering

L22

30

Signal

Declutch lamp

L17

L19

11

Reversal fan (option)

L23

31

51

12

Engine warning lamp

L25

32

52

13

Engine protection lamp

L24

33

14

Engine stop lamp

L26

34

Neutral

53

High-beam lamp

L12

L21

54

Turn signal (left) lamp

L13

Turn signal (right) lamp

L11

15

L27

35

+24 V power supply

55

16

E/G water temperature gauge

36

1st speed indication

56

17

T/M oil temperature gauge

37

2nd speed indication

57

Hour meter ()

58

Hour meter (+)

18

38

3rd speed indication

19

Instrument panel illumination

L10

39

4th speed indication

20

T/M oil filter clogging alarm

L8

40

Parking brake lamp

L15

62-62
Function & Structure Electrical Group
Instrument Panel and Switch

Gauge circuit

Controller

Power supply
24V

Grounding

15V

Viewed from rear surface of instrument panel


K90ZV62016

Sensors respectively detect the temperature and fuel


level, and then convert them into electric signals. The
signals are transmitted to the corresponding gauges
that indicate the transmitted values.
Note
If a gauge is removed from the panel, the resistance
between the terminals will differ from the standard value
shown in the table.
Gauge

Engine water temperature


97C(206F)
35C(95F)

100C(212F)
103C(217F)

T/C, T/M oil temperature


110C(230F)
100C(212F)

120C(248F)

50C(122F)

125C(257F)

Indication

White

Red

Red

White

Resistance between
S and E ()

120~125

75~80

Resistance between
S and V ()

120~125

85~90

Resistance between
E and V ()

170~190

130~150

62-63
115ZV-2 Function & Structure Electrical Group
Instrument Panel and Switch
Temperature sensor
(For engine water temperature (S/N 9001~9050),
torque converter oil temperature and hydraulic oil
temperature)

2
1

115V2E62023

Temperature of
detection part (C)

80
[176F]

90
[194F]

100
[212F]

120
[248F]

Resistance (k)

6.2~6.9

4.7~5.2

3.6~3.9

2.1~2.4

62-64
Function & Structure Electrical Group
Instrument Panel and Switch

Fuel gauge circuit

The level sensor provided inside the fuel tank is


equipped with five float switches. When the oil level
becomes low, the contact of the corresponding float
switches turns on. The float switch signals are transmitted to the MCU, electrically processed, then only one
lamp corresponding to the gauge level lights on the
instrument panel.

MCU

Level
sensor
C14

Indicator
+24V
lamps

C15
YB (406)

FUEL LEVEL 3/4

YL (407)

FUEL LEVEL 1/2

YBr (408)

FUEL LEVEL 1/4

YG (409)

FUEL LEVEL 1/8

C17
C28

Float switch switching and indicator lamp lighting status

C20

C21

(YR ) (410)

A11
A22
A31

FUEL LEVEL F
FUEL LEVEL 3/4
FUEL LEVEL 1/2
FUEL LEVEL 1/4
FUEL LEVEL E

(YB) (411)

A33

(YL) (412)
(YBr) (413)

A23

(YG) (414)

Indicator lamp
: Flashing : Lit
: Extinguished

Float switch
: ON : OFF

C29

Actual fuel level

YR (405)

FUEL LEVEL F

1/4 1/2 3/4

F or more

From F to 3/4

From 3/4 to 1/2

From 1/2 to 1/4

From 1/4 to E

E or less

Any other pattern

1L

Example of failure:
When the wire of the "1/2" float switch is broken, the indicator
lamps for "1/4" and "E" do not light even if the fuel amount
becomes 1/2 or less.
2L
3L

Float switch

1/4 1/2 3/4

4L

5L

ON

3/4
ON
1/2
ON
1/4
ON
1/8
ON
Fuel level sensor

(Black) 3/4

(Brown)

(White) 1/2

E (Yellow)

(Red) 1/4

1/8 (Green)
View A

K115V2E62003

62-65
115ZV-2 Function & Structure Electrical Group
MODM

MODM
Monitor Changeover

(Machine Operation Diagnostic Module)

[ ]button

Display window

]button

[ (step back)] [ (step forward)]


button
button

Replacement
monitor

Fault log
monitor

Information
monitor

Input/Output
monitor

Specification
setting monitor

Parameter
setting monitor

90ZV-262001

MODM function
The MODM has the following functions:

Change over the monitor using the following procedure:


When the starter switch is ON, the MODM software version displays for 3 seconds.

- Information monitor
Displays outside air temperature, machine speed
and engine speed, engine coolant temperature,
transmission oil temperature, hydraulic oil temperature and miles driven etc.

80V2U62001

After this, machine information screen displays information relative to the machine function.

- Replacement monitor
Allows check of the replacement time for the parts
and oil periodically replaced, allows setting of the
replacement interval, and displays the replacement
pop-ups.
- Fault log monitor
Allows check of previous errors, and displays active
errors.
- Input/Output monitor
- Parameter setting monitor
Allows check and change of the parameter setting.
- Specification setting monitor
Allows check and change of the specification setting.

80V2U62002

62-66
Function & Structure Electrical Group
MODM

Changing display from one function to next


Press both the [
(step back)] button and [
(step
forward)] button at the same time to change over the
monitor mode in sequence "Information monitor
Replacement monitor Fault log monitor Input/Output monitor Parameter setting monitor Specification setting monitor Information monitor".

From Information monitor to Replacement


monitor:
Press both the [
(step back)] and [
ward)] buttons at the same time.
Display should now appear as shown below.

However the monitor mode can not be changed in


reverse such as "Information monitor Specification
setting monitor Parameter setting monitor ....."
The display will not be changed to the next monitor
when you hold the buttons.
For the display sequence, refer to "Outline of MODM
(Machine Operation Diagnostic Module) Operation"
page 92-40.

(step for-

90ZV-262034

By pressing the [
(step forward)] button or [
(step back)] button you may then continue to navigate
through the items that should be replaced at given service intervals.

From Replacement monitor to Fault log monitor:


Press both the [
(step back)] and [
ward)] buttons at the same time.

(step for-

70V2U62016

Display should appear as shown.


(Example: Downshift button malfunction)
This screen shows fault logs or inactive fault codes and
provides a chronological date and time line of when they
occurred.
By pressing the [
(step forward)] button or [
(step back)] button you may then continue to navigate
through inactive codes.
Up to 100 are stored. In the upper left corner you will
notice a numerical sequence of number between
01~00. This represents faults 1~100 as they have been
logged.

62-67
115ZV-2 Function & Structure Electrical Group
MODM

From Fault log monitor to Input/Output monitor:

From Specification setting monitor to Information monitor:

Press both the [


(step back)] and [
ward)] buttons at the same time.

Press both the [


(step back)] and [
ward)] buttons at the same time.

(step for-

80V2U62004

With the shift lever in "Neutral" and "Automatic", the


screen should appear as above.
This screen shows the "Input and Output" signal data.

From Input/Output monitor to Parameter setting monitor:


Press both the [
(step back)] and [
ward)] buttons at the same time.

(step for-

80V2U62005

Display should appear similar to above.


This screen shows "Parameter settings" and may be
used to make changes in an already validated parameter.

From Parameter setting monitor to Specification setting monitor:


Press both the [
(step back)] and [
ward)] buttons at the same time.

(step for-

70V2U62017

Display should appear similar to above.


This screen shows "Specification settings" and may be
used to make changes in a MODM to validate or invalidate a given parameter; effectively turning ON or OFF
the function of an option.

(step for-

80V2U62002

While in default temperature screen, the password input


screen can be seen by simultaneously pressing the [ ]
and [ ] buttons. When the password input is finished,
fuel consumption can be seen. Pressing [ ] button toggles between metric and US values.

62-68
Function & Structure Electrical Group
MODM

Information Monitor

1. Outside air temperature

(Refer to page 92-42)

Information monitor display

90ZV-262024

The following items are displayed:


When the starter switch is ON, the software version displays for 3 seconds, then shows default screen.

90ZV-262024

To toggle between metric standard values (C, MPa,


km/h, etc.) and US standards (F, PSI, MPH, etc.), press
the [ ] button.

The monitor displays the current outside air temperature


when the starter switch is ON.
Press the [ ] button to change over the display unit
from "C" to "F". Press the [ ] button again to return
the display unit from "F" to "C".

2. Machine speed and engine speed


Press the [

(step forward)] button and release.

To get fuel consumption data, press the [ ] and [ ]


buttons simultaneously and release, as seen below.

90ZV-262025

You will now be at the screen shown above.


90ZV-262023

When the password input is finished, you will now be at


the screen shown below.

This indicates the actual machine speed and engine


revolutions. This is useful for determining items like shift
mapping patterns in relationship to speed range selection.
For speed to be accurate, the correct tire size must be
entered into the main MCU via this MODM unit.

80V2U62007

To leave this screen, press the [ ] and [ ] buttons


simultaneously again.
Every time the [
(step forward)] button is pressed,
the displayed contents are changed "Machine speed
and engine speed Engine coolant temperature
Transmission oil temperature Hydraulic oil temperature" in sequence.
Every time the [
(step back)] button is pressed, the
displayed contents are changed over in sequence "Hour
meter Voltage Boom cylinder oil pressure
Cycle".
For the display sequence, refer to "Outline of MODM
(Machine Operation Diagnostic Module) Operation"
page 92-40 and 92-42.

Press the [ ] button to change the display unit from


"km/h" to "mph"
Press the [ ] button again to return the display unit
from "mph" to "km/h".

62-69
115ZV-2 Function & Structure Electrical Group
MODM

3. Current engine coolant temperature and


maximum engine coolant temperature
recorded (which can be reset)
Press the [

(step forward)] button and release.

4. Current transmission oil temperature and


maximum transmission oil temperature
recorded (which can be reset)
Press the [

(step forward)] button and release.

90ZV-262026

90ZV-262027

You will now be at the screen shown above.

You will now be at the screen shown above.

The monitor displays the current engine coolant temperature in the "EG COOLANT" line and maximum engine
coolant temperature for the day in the "MAX" line. This
self resets daily at 24:00 (12:00 Midnight).

The monitor displays the current transmission oil temperature in the "TC OIL" line and maximum transmission oil temperature for the day in the "MAX" line. This
self resets daily at 24:00 (12:00 Midnight).

Even if the engine is stopped once and then started


again, if the time is before 24:00, the monitor displays
the maximum engine coolant temperature recorded on
the day.

Even if the engine is stopped once and then started


again, if the time is before 24:00, the monitor displays
the maximum transmission oil temperature recorded on
the day.

The maximum engine coolant temperature is automatically reset everyday at 24:00, whether the engine starter
switch is turned on or off.

The maximum transmission oil temperature is automatically reset everyday at 24:00, whether the engine starter
switch is turned on or off.

Immediately after reset, the engine coolant temperature


at the time of reset is displayed as the maximum engine
coolant temperature. In other words, the current engine
coolant temperature is equivalent to the maximum
engine coolant temperature.

Immediately after reset, the transmission oil temperature at the time of reset is displayed as the maximum
transmission oil temperature. In other words, the current
transmission oil temperature is equivalent to the maximum transmission oil temperature.

To manually reset, press the [ ] button to reset the


maximum engine coolant temperature. Immediately
after reset, the engine coolant temperature at the time
of reset is displayed as the maximum engine coolant
temperature.

To manually reset, press the [ ] button to reset the


maximum transmission oil temperature. Immediately
after reset, the transmission oil temperature at the time
of reset is displayed as the maximum transmission oil
temperature.

Press the [ ] button to change over the display unit


from "C" to "F". Press the [ ] button again to return
the display unit from "F" to "C".

Press the [ ] button to change over the display unit


from "C" to "F". Press the [ ] button again to return
the display unit from "F" to "C".

62-70
Function & Structure Electrical Group
MODM

5. Current hydraulic oil temperature and maximum hydraulic oil temperature recorded
(which can be reset)
Press the [

(step forward)] button and release.

6. Odometer (total miles driven) and trip


meter (which can be reset)
Press the [

(step forward)] button and release.

90ZV-262029
90ZV-262028

You will now be at the screen shown above.


The monitor displays the current hydraulic oil temperature in the "HYD OIL" line and maximum hydraulic oil
temperature for the day in the "MAX" line. This self
resets daily at 24:00 (12:00 Midnight).
Even if the engine is stopped once and then started
again, if the time is before 24:00, the monitor displays
the maximum hydraulic oil temperature recorded on the
day.
The maximum hydraulic oil temperature is automatically
reset everyday at 24:00, whether the engine starter
switch is turned on or off.
Immediately after reset, the hydraulic oil temperature at
the time of reset is displayed as the maximum hydraulic
oil temperature. In other words, the current hydraulic oil
temperature is equivalent to the maximum hydraulic oil
temperature.
To manually reset, press the [ ] button to reset the
maximum hydraulic oil temperature. Immediately after
reset, the hydraulic oil temperature at the time of reset
is displayed as the maximum hydraulic oil temperature.
Press the [ ] button to change over the display unit
from "C" to "F". Press the [ ] button again to return
the display unit from "F" to "C".

You will now be at the screen shown above.


The monitor displays the total number of miles that
machine is operated in top line and miles for operator
selected time frame the trip meter in lower line. This
logs miles in forward and reverse.
Press the [ ] button to reset the trip meter displayed in
lower line.
Press the [ ] button to change over the display unit
from "km" to "mile". Press the [ ] button again to return
the display unit from "mile" to "km".

7. Number of cycles and cycle time


Press the [

(step forward)] button and release.

90ZV-262030

You will now be at the screen shown above.


The monitor displays the number of cycles in the upper
line and the time required for one cycle (moving forward
and backward twice) in the lower line.
This can be used to determine comparative production
data between operators and between working sites.
Press the [ ] button to reset both the number of cycles
and the cycle time.
After reset, the monitor displays newly the number of
cycles in the upper line and the time required for one
cycle in the lower line.

62-71
115ZV-2 Function & Structure Electrical Group
MODM

Unit conversion and language selection

8. Hydraulic system oil pressure


Press the [

(step forward)] button and release.

80V2U62008

Select the unit and language using the [ ] button.

Unit conversion (for traveling distance, temperature and pressure)


Press the [ ] button once to change the display unit.
Press the [ ] button again to return to the previous display unit.

You will now be at the screen shown above.


The monitor displays the unloader pressure of the efficient loading system (ELS).
Press the [ ] button to change over the display unit
from "MPa" to "psi". Press the [ ] button again to return
the display unit from "psi" to "MPa".

Language selection
Press and hold the [ ] button for 3 seconds or longer to
get language selection screen.

9. Voltage
Press the [

80V2U62009

(step forward)] button and release.


You will now be at the screen shown above.
90ZV-262032

English is selected as the initial setting.

You will now be at the screen shown above.

Japanese, French, German, Italian, Spanish, Turkish,


Dutch and English can also be selected.

Shows complete electrical system voltage as is seen at


the battery level.

Press the [
(step forward)] button or [
back)] button to view the language selections.

Note
If voltage drops below 27 V DC, the hibernate mode
(lowers RPMs to conserve fuel) will not work.

For returning to the information monitor after selecting


the desired language, press and hold the [ ] button for
2 seconds or longer.

10. Hour meter (total operating hours) and trip


meter (which can be reset)
Press the [

(step forward)] button and release.

90ZV-262033

You will now be at the screen shown above.


The monitor displays total operating hours in upper line,
and trip meter hours in lower line.
Press the [ ] button to reset the trip meter displayed in
the lower line.

(step

For returning to the information monitor without selecting another language, press the [ ] button.
Refer to "Main Menu" page 92-41.

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Function & Structure Electrical Group
MODM

Replacement Monitor

2. Fuel filter

(Refer to page 92-43)

Press the [

(step forward)] button and release.

Replacement time check


1. Engine oil filter

80V2U62010

Press both the [


(step forward)] and [
(step
back)] buttons simultaneously to change over the
screen from the information monitor to the replacement
monitor.

90ZV-262034

You will now be at the screen shown above.

You will now be at the screen shown above.


The display window displays remaining time until next
replacement of fuel filter cartridge.
Note
If an exclamation mark shows before the numbers that
indicate hours, this shows how many hours overdue the
filter is.
Ex. "!12 h" indicates that it is 12 hours overdue.

The display window first displays the remaining time


until next replacement of the engine oil filter cartridge.
This interval is based on using low sulfur fuel and when
engine oil sulfur content is less than 0.5%. If engine oil
sulfur content exceeds 0.5%, this interval must be cut in
half.
Note
If an exclamation mark shows before the numbers that
indicate hours, this shows how many hours overdue the
filter is.
Ex. "!12 h" indicates that it is 12 hours overdue.

80V2U62079

Note
Make sure to set the replacement interval (timer reset)
whenever the engine oil filter is replaced.

70V2U62018

Note
Make sure to set the replacement interval (timer reset)
whenever the fuel filter is replaced.
It may be necessary to change this filter more frequently, depending on fuel cleanness.

62-73
115ZV-2 Function & Structure Electrical Group
MODM

3. Coolant filter (80ZV-2 ~ 135ZV-2 only)


Press the [

(step forward)] button and release.

4. Torque converter and transmission filter


Press the [

(step forward)] button and release.

80V2U62011

80V2U62012

You will now be at the screen shown above.

You will now be at the screen shown above.

The display window displays remaining time until next


replacement of the engine coolant filter cartridge.

The display window displays remaining time until next


replacement of the torque converter and transmission
filter cartridge.

Note
If an exclamation mark shows before the numbers that
indicate hours, this shows how many hours overdue the
filter is.
Ex. "!12 h" indicates that it is 12 hours overdue.

Note
If an exclamation mark shows before the numbers that
indicate hours, this shows how many hours overdue the
filter is.
Ex. "!12 h" indicates that it is 12 hours overdue.

70V2U62019
70V2U62020

Note
Make sure to set the replacement interval (timer reset)
whenever the coolant filter is replaced.
It may be necessary to change this filter more frequently, depending on engine coolant condition.

Note
Make sure to set the replacement interval (timer reset)
whenever the torque converter and transmission filter is
replaced.
It may be necessary to change this filter more frequently, depending on transmission oil cleanness.

62-74
Function & Structure Electrical Group
MODM

5. Hydraulic return filter


Press the [

6. Engine oil

(step forward)] button and release.

Press the [

(step forward)] button and release.

80V2U62013

80V2U62014

You will now be at the screen shown above.

You will now be at the screen shown above.

The display window displays remaining time until next


replacement of hydraulic return filter.

The display window displays remaining time until next


replacement of engine oil.

Note
If an exclamation mark shows before the numbers that
indicate hours, this shows how many hours overdue the
hydraulic return filter change is.

Note
If an exclamation mark shows before the numbers that
indicate hours, this shows how many hours overdue the
oil change is.

Ex. "!12 h" indicates that it is 12 hours overdue.

Ex. "!12 h" indicates that it is 12 hours overdue.

70V2U62021

Note
Make sure to set the replacement interval (timer reset)
whenever the hydraulic return filter is replaced.

70V2U62022

Note
Make sure to set the replacement interval (timer reset)
whenever engine oil is replaced.
It may be necessary to change this oil more frequently,
depending on work site conditions, oil sampling results
and oil cleanness.

62-75
115ZV-2 Function & Structure Electrical Group
MODM

7. Torque converter and transmission oil


Press the [

(step forward)] button and release.

8. Axle oil
Press the [

(step forward)] button and release.

80V2U62015

80V2U62016

You will now be at the screen shown above.

You will now be at the screen shown above.

The display window displays remaining time until next


replacement of torque converter and transmission oil.

The display window displays remaining time until next


replacement of both front and rear axle and planetary
unit oils.

Note
If an exclamation mark shows before the numbers that
indicate hours, this shows how many hours overdue the
oil change is.
Ex. "!12 h" indicates that it is 12 hours overdue.

Note
If an exclamation mark shows before the numbers that
indicate hours, this shows how many hours overdue the
oil change is.
Ex. "!12 h" indicates that it is 12 hours overdue.

70V2U62023
70V2U62024

Note
Make sure to set the replacement interval (timer reset)
whenever torque converter and transmission oil is
replaced.

Note
Make sure to set the replacement interval (timer reset)
whenever axle oil is replaced.

It may be necessary to change this oil more frequently,


depending on work site conditions, oil sampling results
and oil cleanness.

It may be necessary to change this oil more frequently,


depending on work site conditions, oil sampling results
and oil cleanness.

62-76
Function & Structure Electrical Group
MODM

Replacement interval set (timer reset)

9. Hydraulic oil
Press the [

(step forward)] button and release.

80V2U62017

You will now be at the screen shown above.


The display window displays remaining time until next
replacement of hydraulic oil.
Note
If an exclamation mark shows before the numbers that
indicate hours, this shows how many hours overdue the
oil change is.
Ex. "!12 h" indicates that it is 12 hours overdue.

70V2U62025

Note
Make sure to set the replacement interval (timer reset)
whenever hydraulic oil is replaced.
It may be necessary to change this oil more frequently,
depending on work site conditions, oil sampling results
and oil cleanness.

When the machine is shipped, the standard replacement interval is set as the initial setting.
Press and hold the [ ] button for 2 seconds or more on
the replacement monitor screen to display the timer
reset screen.
The timer reset screen displays the standard replacement interval.
For setting the standard replacement interval, press the
[ ] button.
Then, the standard replacement interval is set, and it
returns to the replacement monitor screen again.

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115ZV-2 Function & Structure Electrical Group
MODM

Replacement interval pop-up

Example: Engine oil

90ZV-262037

When the remaining time until the next replacement


interval reaches " 0 " (or 0 hours), the replacement popup appears and flashes in the display window.

For setting the replacement interval other than the standard replacement interval, follow the procedure below:
90ZV-262038

+50
+100 (2 seconds or more)
50
100 (2 seconds or more)
Press the [
(step forward)] button once to add "50"
hours. Press the [
(step forward)] button twice to
add "100" hours. Press the [
(step forward)] button
three times to add "150" hours. "50" hours is added
every time the [
(step forward)] button is pressed.
Every time the [
(step back)] button is pressed, "50"
hours is subtracted.
When the [
(step forward)] button is pressed and
held for 2 seconds or more, "100" hours is added continuously. It means that "100", "200", "300" hours ..... is
added in 100 hour increments.
When the [
(step back)] button is pressed and held
for 2 seconds or more, "100" hours is subtracted continuously in the same manner.
After setting the replacement interval, press and hold
the [ ] button for 2 seconds or more.
The replacement interval is reset, and the display
returns to the replacement monitor screen again.

90ZV-262039

When two or more replacement pop-ups occur at the


same time, the corresponding items flash in turn.
After the remaining time for the next replacement
reaches " 0 ", the corresponding pop-up appears up to
three times when the starter switch is ON.
(The MODM software version is displayed for 3 seconds, and then the replacement pop-up flashes.)
When the [
(step forward)] button, [
(step back)]
button, [ ] button or [ ] button is pressed, it returns to
the previous screen again.
After replacing the corresponding filter or oil, return to
the timer reset screen and set the replacement interval.
Refer to the replacement interval set (timer reset) procedure above.

62-78
Function & Structure Electrical Group
MODM

Display language
The same language selected in the information monitor
is used as the display language for the replacement
monitor.
For selecting the display language, it is necessary to
return to the information monitor.
The display language can be selected only on the information monitor screen.
For returning from the replacement monitor to the information monitor, change the monitor in turn as described
in the sequence "Replacement monitor [
][
]
(pressing them at the same time) Fault log monitor
[
][
] (pressing them at the same time) Input/
Output monitor [
][
] (pressing them at the same
time) Parameter setting monitor [
][
] (pressing
them at the same time) Specification setting monitor
[
][
] (pressing them at the same time) Information monitor".
For the display sequence, refer to "Outline of MODM
(Machine Operation Diagnostic Module) Operation"
page 92-40.

Fault Log Monitor


(Refer to page 92-44)
Start from key ON. Press the [
(step back)] button
and [
(step forward)] button together twice to get to
this point.

Fault log history check


1. Active faults
Up to 100 machine faults and 100 engine faults can be
recorded in fault log (200 total).
Failure codes that begin with CN are machine faults.
(CN=Chassis fault #)
Failure codes that begin with EN are engine faults.
(EN=Engine fault #)
What is shown
The following list of items are shown. Fault descriptor,
fault code number, date of occurrence and hour-minutesecond of occurrence. Examples shown below.
This shows fault CN321. This is caused by an engine
coolant temperature fault (open circuit). Note descriptions.

Fault descriptor

Date
July 20, 2006

Fault code

Time in 24:00 hour scale


3:27:32 PM
80V2U62018

This shows fault EG146. This is caused by an engine


coolant temperature fault (overheat condition).

80V2U62019

Fault codes are split into input and output signals.

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115ZV-2 Function & Structure Electrical Group
MODM

2. Inactive faults (Checking history )


Again, up to 100 machine faults and 100 engine faults
can be recorded in the fault log (200 faults total).
Failure codes that begin with CN are machine faults.

Selection of machine fault log and engine


fault log
You can toggle between viewing the engine faults or
machine faults.

Failure codes that begin with EN are engine faults.

Machine fault

What is shown
The following list of items are shown. Order of occurrences, fault code number, date, hour-minute-second,
and quantity of occurrence. Examples shown below.

When the machine fault log screen is displayed, press


and hold the [
(step forward)] button for 2 seconds
or more to display the engine fault log screen which
shows the latest engine fault code.

This shows fault CN321. This is caused by an engine


coolant temperature fault (open circuit). Note descriptions.

Order of occurrences
100 total 01~00
Fault code number

A=Active fault
002 is qty of occurrences

80V2U62022

Engine fault
When the engine fault log screen is displayed, press
and hold the [
(step back)] button for 2 seconds or
more to display the machine fault log screen which
shows the latest machine fault code.

Date
July 20, 2006

Time in 24:00 hour scale


3:27:32

80V2U62023
80V2U62020

This shows fault EG146. This is caused by an engine


coolant temperature fault (overheat condition). Note
descriptions.

Order of occurrences
100 total 01~00
Fault code number

Date
July 25, 2006

A=Active fault
016 is qty of occurrences

Time in 24:00 hour scale


1:31:38
80V2U62021

..... If still active, shows "A" before fault number.

The machine fault log screen and engine fault log


screen can be distinguished as follows:
Displayed fault code:
CN ..... Machine fault log screen
EG ..... Engine fault log screen

62-80
Function & Structure Electrical Group
MODM

Machine fault log navigation


When two or more fault codes are recorded, press the
[
(step forward)] button to display the next latest
fault code.
Press the [
(step back)] button to display the fault
code in chronological order.

Clear fault log


Clear inactive fault log
Fault codes can be cleared by pressing the [ ] button
and holding it for more than 2 seconds while in the
engine fault mode, or in the machine fault mode
screens.
Press and hold the [ ] button for 2 seconds or more to
clear the entire fault log.

Engine fault log navigation


When two or more fault codes are recorded, press the
[
(step forward)] button to display the next latest
fault code.
Press the [
(step back)] button to display the fault
code in chronological order.

When there are two or more fault codes recorded, all


fault codes recorded are cleared by performing the clear
fault log operation once.
Press the [ ] button not to clear the fault log and to
return to the machine fault log screen again.
Note
To clear engine fault codes, you must be in the engine
fault screen.
To clear machine fault codes, you must be in the
machine fault screen.
Individual faults cannot be cleared only one at a time. All
engine or machine faults are cleared at once.
Note any fault codes prior to erasing them from memory, in case you need that information later.
After engine fault codes (EGXXX) or machine fault
codes (CNXXX) have been cleared, the buzzer will
sound to alert that the code has been erased from
memory. If you do not hear the buzzer, the fault codes
have not been erased from memory history.

62-81
115ZV-2 Function & Structure Electrical Group
MODM

Clear active fault log (error pop up)


When a fault occurs, the corresponding fault code is
forcibly displayed on the screen.
When two or more active faults occur, up to 5 fault
codes each are displayed repeatedly. (Up to total 10
fault codes for CN and EG errors together)
For deleting the displayed fault codes, press one of the
[
(step forward)] button, [
(step back)] button,
[ ] button or [ ] button.

80V2U62024

Then, the screen displayed before the active fault codes


appears again.
Active fault codes are displayed repeatedly when the
starter switch is ON and will continue to display until the
cause of each fault code is eliminated.
If there is a fault that has been erased, and the cause is
not repaired, the fault will quickly reappear in the screen
due to being active.
It will continue to reappear until the underlying cause of
the fault is eliminated.

62-82
Function & Structure Electrical Group
MODM

Failure code (Input side)


Code

Failure

Detection condition (In case of)

CN121

Shift lever F & R switch malfunction

Shift lever F & R contact ON at the same time


Failure continues for more than 3 seconds

CN122

Shift lever 123A switch malfunction (1)

Shift lever any of more than two 123A contact ON at the same time
Failure continues for more than 3 seconds

CN123

Shift lever 123A switch malfunction (2)

All 123A signal OFF continues for more than 3 seconds

CN141

Shift-up switch malfunction

Switch is ON for more than 10 seconds

CN142

Shift-down switch malfunction

Switch is ON for more than 10 seconds

CN143

Shift-up switch & shift-down switch malfunction

Shift-up switch & shift-down switch contact ON at the same time


Failure continues for more than 3 seconds

CN145

Kick-down switch malfunction

Switch is ON for more than 10 seconds

CN146

Shift hold switch malfunction

Switch is ON for more than 10 seconds

CN151

T/M oil pressure switch malfunction


(This applies to the model 115ZV-2/135ZV-2 only)

Signal OFF continues for more than 10 seconds during engine running

CN161

Machine speed sensor malfunction (1)

Input circuit is disconnected for more than 3 seconds

CN162

Machine speed sensor malfunction (2)

Input value is over 70 km/h (44 mile/h) for more than 3 seconds

CN163

E/G speed sensor 1 (ECM output) malfunction (1)

No E/G speed sensor input for more than 3 seconds when E/G speed sensor selection is OFF (Input circuit is disconnected)

CN164

E/G speed sensor 1 (ECM output) malfunction (2)

Input value is more than 3,000 min-1 for more than 3 seconds when E/G
speed sensor selection is OFF

CN165

E/G speed sensor 2 (Sensor output) malfunction


(1)

No E/G speed sensor input for more than 3 seconds when E/G speed sensor selection is ON (Input circuit is disconnected)

CN167

E/G speed sensor 2 (Sensor output) malfunction


(2)

Input value is more than 3,000 min-1 for more than 3 seconds when E/G
speed sensor selection is ON

CN213

Inching sensor malfunction (1)

Voltage is lower than 0.2 V for more than 3 seconds

CN214

Inching sensor malfunction (2)

Voltage is larger than 4.6 V for more than 3 seconds

CN232

S/S potentiometer malfunction (1)

Voltage is lower than 0.1 V for more than 3 seconds

CN234

S/S potentiometer malfunction (2)

Voltage is larger than 4.9 V for more than 3 seconds

CN236

S/S shift switch (F & R contact) malfunction

Failure continues for more than 3 seconds

CN251

Secondary secondary steering oil pressure sensor


malfunction(1)

Voltage is lower than 0.2 V for more than 3 seconds

CN252

Secondary steering oil pressure sensor malfunction (2)

Voltage is larger than 4.6 V for more than 3 seconds

CN254

Low secondary steering oil pressure

Oil pressure sensor detects secondary steering oil pressure below


306 kPa (3.1 kgf/cm2) (44 psi) for more than 3 seconds during engine running

CN262

Kickout potentiometer malfunction (1)

Voltage is lower than 0.2 V for more than 3 seconds

CN263

Kickout potentiometer malfunction (2)

Voltage is larger than 4.6 V for more than 3 seconds

CN271

Efficient loading system hydraulic oil pressure senVoltage is lower than 0.2 V for more than 3 seconds
sor malfunction (1)

CN272

Efficient loading system hydraulic oil pressure senVoltage is larger than 4.6 V for more than 3 seconds
sor malfunction (2)

CN312

Brake oil pressure sensor 1 malfunction (1)

Voltage is lower than 0.2 V for more than 3 seconds

CN313

Brake oil pressure sensor 1 malfunction (2)

Voltage is larger than 4.6 V for more than 3 seconds

CN315

Brake oil pressure sensor 2 malfunction (1)

Voltage is lower than 0.2 V for more than 3 seconds

CN316

Brake oil pressure sensor 2 malfunction (2)

Voltage is larger than 4.6 V for more than 3 seconds

CN321

E/G coolant temperature sensor malfunction (1)

Input voltage is larger than 3.56 V for more than 3 seconds

CN323

E/G coolant temperature sensor malfunction (2)

Input voltage is lower than 0.263 V for more than 3 seconds

CN341

T/M oil temperature sensor malfunction (1)

Input voltage is larger than 3.56 V for more than 3 seconds

CN342

T/M oil temperature sensor malfunction (2)

Input voltage is lower than 0.263 V for more than 3 seconds

CN351

Hydraulic oil temperature sensor malfunction (1)

Input voltage is larger than 3.56 V for more than 3 seconds

62-83
115ZV-2 Function & Structure Electrical Group
MODM
Code

Failure

Detection condition (In case of)

CN352

Hydraulic oil temperature sensor malfunction (2)

Input voltage is lower than 0.263 V for more than 3 seconds

CN381

Fuel level sensor malfunction

Input signal corresponds to "any other pattern" in fuel level indication table

CN391

Air temperature probe malfunction (1)

Input voltage is larger than 4.35 V for more than 3 seconds

CN392

Air temperature probe malfunction (2)

Input voltage is lower than 0.13 V for more than 3 seconds

CN412

Abnormal brake oil pressure (1)

Brake oil pressure sensor 1 detects pressure below 4,081 kPa (41.6 kgf/
cm2) (592 psi) for more than 1 second during engine running

CN413

Abnormal brake oil pressure (2)

Brake oil pressure sensor 2 detects pressure below 4,081 kPa for (41.6
kgf/cm2) (592 psi) more than 1 second during engine running

CN414

Abnormal brake oil pressure difference

Brake oil pressure difference switch is in abnormal condition for more than
1 second

CN415

Abnormal brake oil amount

Brake oil amount switch is in abnormal condition for more than 1 second

CN421

Abnormal engine oil pressure

Engine oil pressure switch is OFF for more than 2 seconds during engine
running

CN431

Abnormal engine coolant temperature (1)

Engine coolant temperature switch is ON for more than 2 seconds

CN432

Abnormal engine coolant temperature (2)

Engine coolant temperature sensor is in 101 deg. C (214 deg. F) condition


for more than 2 seconds

CN451

Abnormal T/M oil temperature (1)

T/M oil temperature switch is ON for more than 2 seconds

CN452

Abnormal T/M oil temperature (2)

T/M oil temperature sensor is in 122 deg. C (252 deg. F) condition for more
than 2 seconds

CN461

Abnormal hydraulic oil temperature

Hydraulic oil temperature sensor is in 100 deg. C (212 deg. F) condition for
more than 2 seconds

CN471

Clogged T/M oil filter

30 minutes after starter switch is ON, T/M oil filter switch is ON for more
than 2 seconds when T/M oil temperature sensor detects oil temperature
more than 60 deg. C (140 deg. F)

CN481

Clogged air cleaner element

Air cleaner switch is ON for more than 2 seconds

CN491

Abnormal cooling water level in radiator

Radiator cooling water level switch is OFF for more than 2 seconds when
the engine is off.

CN496

Abnormal hydraulic oil level

Hydraulic oil level switch is in abnormal condition for more than 30 seconds

CN801

CAN disconnect

CAN line is disconnected

CN802

Abnormal engine coolant temperature (CAN)

No engine coolant temperature data received for more than 3 seconds

CN912

Abnormal MCU voltage (1)

Voltage is larger than 301 V

Abnormal MCU voltage (2)

Voltage is lower than 220.5 V for more than 10 seconds during engine
running

CN913

Fuel level display table


Input

Output

1/8

1/4

1/2

3/4

x
x

1/4

1/2

3/4

Other than above


: No input signal given
x : Input signal given

: Lamp on
: Lamp off

Note
This table applies to ZW550 units.

: Lamp flashing

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Function & Structure Electrical Group
MODM

Failure code (Output side)


Code
CN512

Failure
F solenoid valve malfunction

Detection condition
F solenoid valve is short-circuited or disconnected

CN514

R solenoid valve malfunction

R solenoid valve is short-circuited or disconnected

CN516

1st solenoid valve malfunction

1st solenoid valve is short-circuited or disconnected

CN518

2nd solenoid valve malfunction

2nd solenoid valve is short-circuited or disconnected

CN521

3rd solenoid valve malfunction

3rd solenoid valve is short-circuited or disconnected

CN524

4th solenoid valve malfunction

4th solenoid valve is short-circuited or disconnected

CN526

D solenoid valve malfunction

D solenoid valve is short-circuited or disconnected

CN528

H solenoid valve malfunction

H solenoid valve is short-circuited or disconnected

CN531

LU solenoid valve malfunction

LU solenoid valve is short-circuited or disconnected

CN534

Auto-brake solenoid valve malfunction

Auto-brake solenoid valve is short-circuited or disconnected

CN536

Speed change control solenoid valve malfunction


(1)

Speed change control solenoid valve is short-circuited

CN537

Speed change control solenoid valve malfunction


(2)

Speed change control solenoid valve is disconnected

CN621

S/S solenoid valve R malfunction (1)

S/S solenoid valve R is short-circuited

CN622

S/S solenoid valve R malfunction (2)

S/S solenoid valve R is disconnected

CN623

S/S solenoid valve L malfunction (1)

S/S solenoid valve L is short-circuited

CN624

S/S solenoid valve L malfunction (2)

S/S solenoid valve L is disconnected

CN631

Pressure increase solenoid valve malfunction

Pressure increase solenoid valve is short-circuited or disconnected

CN641

Ride control solenoid valve malfunction

Ride control solenoid valve is short-circuited or disconnected

CN681

Efficient loading system selection solenoid valve


malfunction

Efficient loading system selection solenoid valve is short-circuited or disconnected

CN693

Lower kickout relay malfunction (1)

Lower kickout relay (coil) is short-circuited

CN694

Lower kickout relay malfunction (2)

Lower kickout relay (coil) is disconnected

CN712

Cooling fan solenoid valve malfunction (1)

Cooling fan solenoid valve is short-circuited

CN713

Cooling fan solenoid valve malfunction (2)

Cooling fan solenoid valve is disconnected

CN721

Hour meter drive malfunction

Hour meter drive is short-circuited

Failure code (Engine)


Refer to "Quantum fault code information" page 62-27.

62-85
115ZV-2 Function & Structure Electrical Group
MODM

Input/Output Monitor

By pressing the [
(step forward)] button, you will
arrive at a window as shown below.

(Refer to page 92-45)

Input/Output monitor display


80V2U62026

1. Input signal monitor


From a position of turning on the key switch, press both
the [
(step back)] and [
(step forward)] buttons
simultaneously 3 times, you will arrive at the screen
shown below.

80V2U62025

This is because in window 2, it shows the parking brake


as being released and the corresponding slot would
have a 1 in that place. In other words, the parking brake
coil has been energized and the slot has a 1 in it indicating that it is energized and the parking brake is
released.
Now press the [
(step forward)] button once. You
will arrive at the screen shown below.

This is the beginning of the section for input and output


signal display.
80V2U62027

Input signal monitor (D1~D7)


This monitor displays the ON/OFF status of the shift
lever, setting switches, pressure switches, etc.
There are seven input groups from INPUT 1 to INPUT 7.

Nothing in this case is activated, so all of the slots are


occupied with the number 0.
Now press the [
(step forward)] button once. You
will arrive at the screen shown below.

Each group has eight items from item 0 to 7.


When input signal is ON, "1" is displayed under corresponding item number.

80V2U62028

When input signal is OFF, "0" is displayed under corresponding item number.

The screen indicates that ride control and ELS are activated, or the switch for each one is energized.

Refer to "MODM: Input/Output Monitor - Input/Output


Signal Correspondence Table" page 92-49.

Now press the [


(step forward)] button once. You
will arrive at the screen shown below.

As shown in table of section "MODM: Input/Output Monitor - Input/Output Signal Correspondence Table" that
follows, the selection below reflects that forward and
automatic have been selected by the shift lever.

80V2U62029

This indicates that the engine is running as the place for


alternate neutral voltage under slot 3 is occupied by a 1.
80V2U62025

62-86
Function & Structure Electrical Group
MODM
Now press the [
(step forward)] button once. You
will arrive at the screen shown below.

80V2U62030

2. Current output monitor


Every time the [
(step forward)] button is pressed
and held for 2 seconds, the displayed contents are
changed. First item seen is as shown below.

This indicates that there are no inputs happening in this


situation.

Note
The [
(step back)] or [
(step forward)] button
must be held for 2 seconds or more with each change. If
not, it will not move to next item.

Now press the [


(step forward)] button once. You
will arrive at the screen shown below.

If the feature is set to "Invalid" in specification setting,


the following items will be skipped.
- STEERING PRESS - SP7 (EMG steering)

80V2U62031

This indicates that there are inputs for a full fuel tank,
the machine is equipped with an optional reversing fan,
and the switch for the fan is in the "ON" or energized
position.
Now press the [
(step forward)] button once. You
will arrive back the screen shown below.

- BOOM ANGLE - SP15 (Lift kickout)

90ZV-262019

This area is called the "Current Output Monitor". As


seen, it first shows actual front brake circuit pressure.
Next, by pressing the [
(step forward)] button, the
following screen is seen if equipped with secondary
steering.

80V2U62025

You have completely reviewed all of the input signals.


Again, in review, note the following:
- This monitor displays the ON/OFF status of the shift
lever, setting switches, pressure switches, etc.

80V2U62032

Next, by pressing the [


following screen is seen.

- There are seven input groups from INPUT 1 to


INPUT 7.
- Each group has eight items from item 0 to the item 7.
- When input signal is ON, "1" is displayed under corresponding item number.
- When input signal is OFF, "0" is displayed under corresponding item number.
For more clarification, refer to "MODM: Input/Output
Monitor - Input/Output Signal Correspondence Table".

(step forward)] button, the

80V2U62033

Next, by pressing the [


following screen is seen.

(step forward)] button, the

80V2U62034

62-87
115ZV-2 Function & Structure Electrical Group
MODM
Next, by pressing the [
following screen is seen.

(step forward)] button, the

80V2U62035

Note
Brake main pressure 1 is accumulator oil pressure for
rear accumulator which serves only the rear brake circuit. Brake main pressure 2 is accumulator oil pressure
for front accumulator which serves the front brake circuit
and all pilot derived pressures; these are pilot oil pressure for the pilot control valves, auto brake, park brake
release, etc. The actual real-time pressures are shown
in these fields.
Next, by pressing the [
following screen is seen.

(step forward)] button, the

3. Output signal monitor (D1~D6)


This monitor displays the ON/OFF status of the transmission forward/backward solenoid valves, speed range
solenoid valves, indicator lamps and warning lamps on
the instrument panel, etc.
There are six output groups from OUTPUT 1 to OUTPUT 6.
Each group has eight items from item 0 to 7.
When output signal is ON, "1" is displayed under corresponding item number.
When output signal is OFF, "0" is displayed under corresponding item number.
Refer to "MODM: Input/Output Monitor - Input/Output
Signal Correspondence Table" page 92-49.
Next, by pressing the [
(step forward)] button for 2
seconds or longer will show the following screen.

90ZV-262019

You have now navigated through the entire "Current


Output Monitor" part of the "Input and Output Monitor"
section.
All of the aforementioned screens can be seen in
reverse order by using the [
(step back)] button.
Holding this button in for longer than 2 seconds will take
you to the input signal monitor screen section.

80V2U62036

This shows the 2nd speed solenoid coil and the forward
coil outputs have been applied, as the transmission is in
forward and automatic.
1st, 3rd, 4th, reverse, high, and autobrake solenoid coils
are not energized and show no application signal.
Next press the [
following screen.

(step forward)] button to show the

80V2U62037

Again, note that all values except the last are 0, and
only the brake lamp output is in the "ON" position.

62-88
Function & Structure Electrical Group
MODM
Next press the [
following screen.

(step forward)] button to show the

4. Electric current output monitor


This indicates the milliamps (mA) of electric current that
are being sent to the fan solenoid valve from the MCU.

80V2U62038

Press the [
(step forward)] button for 2 seconds or
longer to show the following screen.

All values are at 0 as there are no outputs needed in this


scenario.
Next press the [
following screen.

(step forward)] button to show the

80V2U62039

Note that the place under slot 5 is occupied by a 1, as


MCU failure relay should be energized by MCU if MCU
passes software logic test at MCU boot-up that occurs
with the key in the "ON" position.
Next press the [
following screen.

(step forward)] button to show the

80V2U62040

Note that the place under slot 1 is occupied by a 1, as


the unit is in automatic shift mode and the dash lamp
should be illuminated to indicate this. Also the place
under slot 7 is occupied by a 1, as the unit is full of fuel.
Next press the [
following screen.

(step forward)] button to show the

80V2U62041

Note that this shows no input signal at this time.

80V2U62042

This current output will vary as demands for fan revolutions change, according to amount of heat that is being
generated. This heat must be discharged to cool the
system that is heating back down.
When the machine systems are cold and the machine is
in warm up mode, the mA level will be higher than when
the machine has worked for a time and has become
heat saturated.
Note
Disconnecting the fan solenoid wire will increase the
fans revolutions to full speed, and will set a CN713 fault
code. This will reside in the system fault code memory
until it is cleared. If you disconnect the solenoid coil, you
must remember to clear this fault code when finished
with work.
Refer to fault code table for the chassis side for more
detail.

62-89
115ZV-2 Function & Structure Electrical Group
MODM

Parameter Setting Monitor


(Refer to page 92-46)

Parameter setting monitor display


This monitor allows check of parameters that are currently set.
Value levels to set parameter for items like ride control,
tire ratios, date/time clock (used to log faults), declutch
pressures, secondary steering, detent values sensor,
etc.
Note
If the feature is set to "Invalid" in specification setting
view, the following items will be skipped in the parameter setting monitor view.
- RIDE CONTROL - SP5 (Ride control)
- EMG STEERING - SP7 (EMG steering)
- K-LEVER - SP8 (K-Lever)
- TRACTION CONTROL - SP11 (Traction control)
- 2 STAGE - SP13 (Efficient loading system)
- BOOM SOFT LAND - SP14 (Lower kickout)

1. Shift inhibitor
From turning on key switch which would default to
screen shown below.

80V2U62002

Pressing both the [


(step forward)] and [
(step
back)] buttons simultaneously, 4 times once after
another, arrive at the screen shown below.

80V2U62005

The transmission changes the speed range automatically according to the machine speed. If the machine
speed sensor is disconnected when the machine is running high, the machine speed is suddenly reduced
because of that the transmission is automatically shifted
to the low range. As a result, the operator becomes very
unstable condition by rapid deceleration. This device
prevents the above.
By pressing the [
(step forward)] button, you will
arrive at a window as shown below.

- KICK OUT - SP15 (Lift kickout)


80V2U62043

62-90
Function & Structure Electrical Group
MODM

2. Ride control
Now press the [
(step forward)] button once. You
will arrive at the screen shown below.

80V2U62044

The screen should appear similar to what is shown. This


shows the speed at which ride control turns on and permits the base end oil to work against the accumulator
piston.
Now press the [
(step forward)] button once. You
will arrive at the screen shown below.

80V2U62045

The screen should appear similar to what is shown. This


shows the speed at which ride control turns off and does
not permit the base end oil to work against the accumulator piston.
Changing ride control on/off speed values:
These values can be changed for machines that are
equipped with this option by doing the following.
Press and hold the [ ] button for 2 seconds or more on
the parameter setting screen to display the parameter
change screen. The cursor flashes in a 1-second cycle
(flashes on for 0.5 second and flashes off for 0.5 second).
Press the [ ] button to move the cursor. The cursor
moves to the right. When the cursor reaches the right
end in the upper line, pressing [ ] button will move it to
the left end in the lower line.
When the cursor reaches the right end in the line, pressing [ ] button moves it to the left end in the line. The
cursor skips digits which can not be changed.
Cursor movement:
Moving to the right Right end in the upper line
Left end in the lower line Right end in the lower
line Left end in the upper line.

Press the [
(step forward)] button to add "1" to a
numerical value.
Note
Value for "ON" must be 1 km/hr or more greater than
"OFF".
The numerical value will increase as you press the [
(step forward)] button as follows;
0 1 2 ..... 9 0 1 2 .....
Press the [
(step back)] button to subtract "1" from a
numerical value.
The number then decreases as follows;
9 8 7 ..... 0 9 8 7 .....
After changing parameter values, press and hold the
[ ] button for 2 second or more to finalize the input values and return to the parameter setting screen.
Press the [ ] button to return to the parameter setting
screen without changing parameter values.

62-91
115ZV-2 Function & Structure Electrical Group
MODM

3. Meter division ratio


Next, by pressing the [
following screen is seen.

4. Tachograph
(step forward)] button, the

Next, by pressing the [


following screen is seen.

80V2U62046

The screen should appear similar to what is shown. This


is the speed division ratio for the smaller tire. This permits the speed reading to be accurate when equipped
with smaller tires.
Next, by pressing the [
following screen is seen.

(step forward)] button, the

80V2U62048

Next, by pressing the [


following screen is seen.

(step forward)] button, the

(step forward)] button, the

80V2U62049

5. Secondary steering
80V2U62047

Next, by pressing the [


following screen is seen.

The screen should appear similar to what is shown. This


is the speed division ratio for the larger tire. This permits
the speed reading to be accurate when equipped with
larger tires.
Note
Model
ZW550

29.5

80V2U62050

The screen should appear similar to what is shown and


indicates the engagement speed.

Tire size
Small size (B)

(step forward)] button, the

Large size (A)


35/65

Note that the 1/12 ratio is the small size (B), and the 1/
11 ratio is the large size (A).

When this option is on the machine, this screen will permit the technician to see the engagement speeds. This
will engage when the machine loses power to the
engine, or if the steering pump were to fail and hydraulic
system pressure falls below 0.4 MPa (4 kgf/cm2) (57
psi) as long as the machine speed is above 2 km/h, and
it disengages when the speed falls below 1 km/h.
Next, by pressing the [
following screen is seen.

(step forward)] button, the

80V2U62051

62-92
Function & Structure Electrical Group
MODM

6. K-Lever (stick steering)


Next, by pressing the [
following screen is seen.

(step forward)] button, the

Review the following screens that are able to be seen


by pressing the [
(step forward)] button. (A setting
shown.)

80V2U62055
80V2U62052

The screen should appear similar to what is shown and


indicates the K-Lever voltage.

80V2U62056

Note
The default setting for K-Lever is to the "A" type.
The voltage settings are displayed in the MODM monitor display.
Review the following screens that are able to be seen
by pressing the [
(step forward)] button. (A setting
shown.)

80V2U62057

i=Signal intensity (or mA)


A Type

Solenoid valve
LH side

Solenoid valve
RH side

Current (mA)

imax
i2

80V2U62053

80V2U62054

i1

V=Voltage
The screen should appear similar to what is shown and
indicates the K-Lever mA signal strength or intensity.
Note
The default setting for K-Lever is to the "A" type.
The voltage settings are displayed in the MODM monitor display.

Potentiometer (V)

V1
V2
Vmax

2.5
V1

5
V2
Vmax
80V2U62077

Initial set values


K-LEVER V1

0.25 V

K-LEVER V2

2.0 V

K-LEVER Vmax

2.4 V

K-LEVER i1

290 mA

K-LEVER i2

450 mA

K-LEVER imax

470 mA

62-93
115ZV-2 Function & Structure Electrical Group
MODM

7. Traction control

B Type

Solenoid valve
LH side

Next, by pressing the [


following screen is seen.

Solenoid valve
RH side

Current (mA)

imax

(step forward)] button, the

i3

i2
80V2U62058

i1
Potentiometer (V)

V1
V2
V3

2.5
V1

5
V2
V3

Vmax

Vmax
80V2U62078

This indicates parameter of 1.0 second when in forward


and 1st (F1) gear before traction control will engage. If
time of engagement for F1 is less than 1 second, it is
looked at as not permanent; software will not respond to
signal as it is considered to be inconsequential. This
helps avoid erratic machine function.
Next, by pressing the [
following screen is seen.

(step forward)] button, the

Initial set values


K-LEVER V1

0.25 V

K-LEVER V2

1.0 V

K-LEVER V3

2.0 V

K-LEVER i1

290 mA

K-LEVER i2

400 mA

K-LEVER i3

450 mA

K-LEVER imax

470 mA

Note
Type A and B are switched on the specification setting
monitor. (Refer to page 62-99)

80V2U62059

This stands for Dual Stage for slip control. This parameter is not used in USA production and should be disregarded. (It would have set a given hydraulic system
pressure value to indicate that machine was excavating
and MCU logic for traction control would take into
account this additional parameter.)
Next, by pressing the [
following screen is seen.

(step forward)] button, the

In case of type A, screen changes as follows.


80V2U62060

V1 V2 Vmax i1 i2 imax
In case of type B, screen changes as follows.
V1 V2 V3 i1 i2 i3 imax

This stands for Inching slip control feature and is not


used. This parameter is not used in USA production and
should be disregarded. (If it were used, declutch (or
inching circuit) sensor would signal MCU to know brake
circuit pressure & deactivate traction control if the brake
circuit pressure was over a given value for a given time
frame (See "ti" below; ti is also not used).)

62-94
Function & Structure Electrical Group
MODM
Next, by pressing the [
following screen is seen.

(step forward)] button, the

Next, by pressing the [


following screen is seen.

80V2U62061

This is time inching. This is time frame in lsc above.


Next, by pressing the [
following screen is seen.

(step forward)] button, the

(step forward)] button, the

80V2U62065

This stands for Slip Control time; data is provided in


seconds of time. When the set time for starting slippage
begins, traction control engages and makes adjustments accordingly.

8. Declutch
80V2U62062

Next, by pressing the [


following screen is seen.

(step forward)] button, the

This stands for Slip Control velocity, or ground speed


regulation for traction control "ON"; speed has to be at
or below this setting to activate traction control.
Next, by pressing the [
following screen is seen.

(step forward)] button, the

This is brake circuit pressure; at this pressure, the


declutch circuit will put the transmission to neutral position, and delete the forward or reverse clutch output. IS
stands for Inching Sensor.
80V2U62063

This stands for Slip Control engine, or engine speed


regulation for traction control "ON"; rpm speed has to be
at or above this setting to activate traction control.
Next, by pressing the [
following screen is seen.

80V2U62066

(step forward)] button, the

80V2U62064

This stands for Slip Control intensity; indicates accelerated slipping velocity of traction control. The value is
indicated in km/h per 0.1 second. Each 1/10th of a second the velocity is cut back by engine rpm reduction so
slippage will not occur, and this provides reduced tire
slippage.

62-95
115ZV-2 Function & Structure Electrical Group
MODM

9. Efficient loading system (ELS)


Next, by pressing the [
following screen is seen.

10. Engine power control

(step forward)] button, the

Temperature
Next, by pressing the [
following screen is seen.

(step forward)] button, the

80V2U62067

This is the voltage at the rotary sensor wire that returns


signal to MCU. This signal from the rotary sensor determines the boom height position. If the boom is high, the
unloader valve solenoid coil at the ELS control valve will
not be energized, and the ELS will not operate to unload
the loading pump.

80V2U62070

The screen should appear similar to what is shown.


This is the temperature at which hibernate mode will
engage.

DS=Dual Stage (or ELS)

TWni=Temperature Water normal idle.

on="on". (Thus the term "DSon".)

Voltage

This indicates that the dual stage system is on when it


senses 2.5 V or less.

Next, by pressing the [


following screen is seen.

(step forward)] button, the

Typical voltage for the rotary sensor is as shown in


graphic below (approximate values).
65V2E62024

Approximate voltage values


Boom fully up=4.8 V

The screen should appear similar to what is shown.


This is the voltage at which hibernate mode is changed
to normal operation mode forcibly.
Vni=Voltage normal idle.
If the voltage is less than 26.7 VDC, hibernate low idle
will not engage. This is so battery will stay charged.

80V2U62068

Bucket can be in any orientation

Boom fully down=0.40 V


Carry level

80V2U62069

62-96
Function & Structure Electrical Group
MODM

11. Lower kickout (for return to dig)

13. Calendar (Date and time)

Next, by pressing the [


following screen is seen.

Next, by pressing the [


following screen is seen.

(step forward)] button, the

80V2U62072

The screen should appear similar to what is shown; voltage will vary.
When lowering, position can be set to make the detent
system stop bucket prior to hitting the ground. The MCU
will recognize this only when value is 2.50 V or less. If it
is greater than 2.50 V, MCU ignores the signal.

12. Lift kickout (for boom raise)


Next, by pressing the [
following screen is seen.

(step forward)] button, the

80V2U62073

The screen should appear similar to what is shown; voltage will vary.
Ks=Kickout set point
When raising boom, position can be set to make the
detent system stop the boom prior to the piston hitting
the cylinder head. The MCU will recognize this only
when value is 4.20 V or more. If it is less than 4.20 V,
MCU ignores the signal.
This feature protects boom cylinders from inertial damage caused by the mass of the boom, bucket, and linkage moving up rapidly with the boom cylinders
extending and causing the pistons to hit the boom cylinder heads.

(step forward)] button, the

90ZV-262022

The screen should appear similar to what is shown.

62-97
115ZV-2 Function & Structure Electrical Group
MODM

Parameter change
The parameter values can be changed when the both
conditions below are satisfied:
The engine is stopped (starter switch is ON).
The parking switch is ON.

Press the [
(step forward)] button to add "1" to a
numerical value. The numerical value will increase as
you press the [
(step forward)] button as follows.
0 1 2 ..... 9 0
Press the [
(step back)] button to subtract "1" from a
numerical value. The number decreases as follows.

A parameter value can be changed, however, only when


the corresponding item is set to "VALID" in the specification setting monitor. (Refer to page 92-46)
Ride control setting 1

9 8 7..... 0 9
After changing parameter values, press and hold the
[ ] button for 2 second or more to finalize the input values and return to the parameter setting screen.
Press the [ ] button to return to the parameter setting
screen without changing parameter values.

When the corresponding item is set to "INVALID", the


parameter screen is not displayed. (It is skipped to the
next screen.)

The date & time sequence reads as shown.


DATE
TIME

YY / MM / DD
hh : mm : ss

Y=year
M=month
D=day

Calendar

90ZV-262022

Changing date and clock values:


These values can be changed by doing the following.
Press and hold the [ ] button for 2 seconds or more on
the parameter setting screen to display the parameter
change screen.
The cursor flashes in a 1-second cycle (flashes on for
0.5 second).
Press the [ ] button to move the cursor.
The cursor moves to the right. When the cursor reaches
the right end in the upper line, pressing [ ] button will
move it to the left end in the lower line. When the cursor
reaches the right end in the lower line, pressing [ ] button will move it to the left end in the upper line. The cursor skips digits which cannot be changed.
Cursor movement:
Moving to the right Right end in the upper line
Left end in the lower line Right end in the lower
line Left end in the upper line

h=hour
m=minute
s=second
Example:
DATE
TIME

06 / 07 / 12 = July 12, 2006


20 : 15 : 11 = 8:15:11 pm

Note
Failure to enter the values correctly will make the clock
give the wrong time, and the date to read incorrectly in
all of the dependent functions, such as fault code messages, etc.

62-98
Function & Structure Electrical Group
MODM

Specification Setting Monitor


(Refer to page 92-47 and 92-48)

Specification setting monitor display


From turning on key switch which would default to
screen shown below.

80V2U62002

Pressing both the [


(step forward)] and [
(step
back)] buttons simultaneously, 5 times once after
another, arrive at the screen shown below.

1. Specification setting display


This monitor allows check of the specifications currently
set.
When attaching an optional unit, change the specification setting to make the corresponding function valid.
It is necessary to log with the correct password for
changing the specification setting.
If no password is entered, only the initial specification
setting monitor can be seen, and is shown the program
number that is designed for that particular machine
model.

80V2U62074

80V2U62074

When you are at this point, press the [


(step forward)] button for over 2 seconds will take you to the following screen.

90ZV-262023

The asterisk symbol will have a flashing _ underscore


below it, indicating that it is ready to have a password
entered into it to permit login access to change variable
parameters.
The login access code must be acquired from the
Kawasaki Service Representative and is not for general
public use as it can cause machine troubles if the wrong
parameters are inserted.
If you have the password, write it in the place value
entry blanks provided below.
_ _ _ _
DO NOT GIVE THIS PASSWORD OUT TO CUSTOMERS OR END USERS !
IT IS FOR TRAINED KAWASAKI SERVICE PERSONNEL ONLY ! SERIOUS DAMAGE TO MACHINE MAY
RESULT BY USING INAPPROPRIATE ENTRY VALUES.

62-99
115ZV-2 Function & Structure Electrical Group
MODM

2. Password entry and changing settings


Note
To make changes to entry settings, engine must be
"OFF", and key switch in "ON" position with parking
brake applied. Otherwise changes will not happen.

90ZV-262023

The password is a numerical password.


Press the [
(step forward)] button to add "1" to a
numerical value.

Every time the [


(step back)] button is pressed, the
displayed content is changed "FR switch Wheel type
Kickout ..." in sequence.
The following items can now be selected as "VALID" or
"INVALID" by pressing and holding the [ ] button for 2
seconds or longer, and then selecting the [
(step forward)] or the [
(step back)] button to choose
"VALID" or "INVALID" as required.
When finished, press and hold the [ ] button for 2 seconds or longer to accept the change.
If you need to return without making a selection, press
the [ ] button, and you will return to the previous
screen without making a change of selection.

The numerical value will increase as you press the [


(step forward)] button as follows;

- Selection switch shift (shift lever or F/R switch)


Valid/Invalid

0 1 2 3 4 5 ..... 9 0 1 2 3
4 5 ..... etc.

- Shift hold
Valid/Invalid

Press the [ ] button to change the cursor position to


continue password entry. When finished, press the [ ]
button for longer than 2 seconds to get to the following
screen.

- Ride control
Valid/Invalid

80V2U62075

Every time the [


(step forward)] button is pressed
and held for 2 seconds, the displayed contents are
changed over "All setting reset Specification group 1
Specification group 2 All setting reset" in
sequence.
Every time the [
(step back)] button is pressed and
held for 2 seconds, the displayed contents are changed
over "All setting reset Specification group 2 Specification group 1 All setting reset" in sequence.
For the display sequence, refer to "Outline of MODM
(Machine Operation Diagnostic Module) Operation"
page 92-40.
Specification group 1
Every time the [
(step forward)] button is pressed,
the displayed content is changed "FR switch Shift
hold Ride control ..." in sequence.

- Secondary steering
Valid/Invalid
- K-Lever (Stick steering)
A Type/B Type/Invalid
- Hydraulic pressure increase
Valid/Invalid
- Traction control
Valid/Invalid
- Tachograph
Valid/Invalid
- Efficient loading system (ELS)
Valid/Invalid
- Lower kickout
Valid/Invalid
- Lift kickout (variable)
Valid/Invalid
- Wheel type
A type (Big wheel)/B type (Small wheel)

62-100
Function & Structure Electrical Group
MODM
Specification group 2
Every time the [
(step forward)] button is pressed,
the displayed content is changed "Downshift button
Auto brake Engine speed ..." in sequence.
Every time the [
(step back)] button is pressed, the
displayed content is changed "Downshift button
Brake oil level Brake oil differential sw ..." in
sequence.
The following items can now be selected as "VALID" or
"INVALID" by pressing and holding the [ ] button for 2
seconds or longer, and then selecting the [
(step forward)] or the [
(step back)] button to choose
"VALID" or "INVALID" as required.
When finished, press and hold the [ ] button for 2 seconds or longer to accept the change.
If you need to return without making a selection, press
the [ ] button, and you will return to the previous
screen without making a change of selection.
- Kick-down (downshift button)
Valid/Invalid
- Auto brake
Valid/Invalid
- Engine speed
Communication/Sensor
- E/G curve selection
Communication/Output/Invalid
- Cooling fan
Valid/A type/B type
- Transmission oil temperature switch (for monitor
control)
Valid/Invalid
- Engine coolant temperature switch (for monitor control)
Valid/Invalid
- Engine coolant temperature sensor (for monitor control)
Valid/Invalid
- Engine oil pressure switch (for monitor control)
Valid/Invalid

- Engine oil pressure sensor (for communication and


monitor control)
Valid/Invalid
- Brake pressure differential switch
Valid/Invalid
- Brake oil level
Valid/Invalid
Use the table on page 62-103 to do this.
You may exit back to the default screen when finished
by pressing the [
(step forward)] and [
(step
back)] buttons simultaneously.

WARNING
Changing the systems parameters to non factory settings will render the monitor ineffective. This can lead
to warranty claims that will not be covered by the factory warranty.
DO NOT VALIDATE OPTIONS OR SETTINGS THAT
DO NOT APPLY !

62-101
115ZV-2 Function & Structure Electrical Group
MODM

All setting reset


Item

Allows batch deletion or batch reset of information monitor, replacement monitor or fault log monitor.
Specified
Parameter

Comment

Information monitor

Kick down (downshift button)

SP1

Always valid

Selection switch shift


(shift lever or F/R switch)

SP2

Optional

Shift hold

SP3

Always lnvalid

Autobrake

SP4

Valid

Ride control

SP5

Option

Engine speed

SP6

Sensor

Secondary steering

SP7

Option
(EU always valid)

- Maximum hydraulic oil temperature


- Number of cycles

When this is performed, the following items will be reset.


- Maximum engine coolant temperature
- Maximum transmission oil temperature

K-Lever

SP8

Option

Engine curve

SP9

Output

Hydraulic pressure increase


(power up)

SP10

Option

- Cycle time

Traction control

SP11

Valid

Tachograph

SP12

Always invalid

- Trip meter (for hour meter)

Efficient loading system (ELS) SP13

Valid

Lower kickout

SP14

Always valid

Lift kickout

SP15

Always valid

Cooling fan

SP16

A type

Torque converter oil temperature switch

SP17

Invalid

- Fuel filter timer

Engine coolant temperature


switch

SP18

Invalid

- Coolant filter timer

Engine coolant temperature


sensor

SP19

Sensor

- Torque converter line filter timer

Engine oil pressure switch

SP20

Always valid

Engine oil pressure sensor

SP21

Sensor (INVALID)

- Hydraulic oil return filter timer

Brake pressure differential


switch

SP22

Invalid

- Engine oil timer

Brake oil level

SP23

Invalid

Wheel type

SP24

A or B type

Replacement monitor
- Engine oil filter timer

- Torque converter and transmission oil timer


- Axle gear oil timer
- Hydraulic oil timer
After timers are reset, each of them is automatically set
to the standard initial set value.

Fault log monitor


- The machine fault log is deleted.
- The engine fault log is deleted.
Note
This can be reset with engine running. It will retain reset
results.

62-102
Function & Structure Electrical Group
MODM

All setting reset procedure (Start at screen


shown)

80V2U62075

Press and hold the [ ] button for 2 seconds or more to


display the all setting reset execution screen.
See example below.

80V2U62076

When executing the all setting reset function, press and


hold the [ ] button for 2 seconds or more. Then, the all
setting reset function is executed, and the specification
setting screen appears again.
Press the [ ] button to return to the specification setting
screen without executing the all setting reset function.

62-103
115ZV-2 Function & Structure Electrical Group
MODM

Default position of specification setting monitor


ITEM

OPTION EITHER
VALID OR INVALID

ZW550

Kick down
(downshift button)

Valid/Invalid

Selection switch shift


(shift lever or F/R
switch)

Valid/Invalid

Shift hold

Valid/Invalid

Autobrake

Valid/Invalid

Ride control

Valid/Invalid

Engine speed

Net/Sensor

Sensor

Secondary steering

Valid/Invalid

K-Lever

Valid/Invalid

x
x

Engine curve

Output/Net/Invalid

Hydraulic pressure
increase (power up)

Valid/Invalid

Traction control

Valid/Invalid

Tachograph

Valid/Invalid

Efficient loading system (ELS)

Valid/Invalid

Lower kickout

Valid/Invalid

Lift kickout

Valid/Invalid

Cooling fan

A type/B type/Invalid

Torque converter oil


temperature switch

Valid/Invalid

Engine coolant temperature switch

Valid/Invalid

Engine coolant temperature sensor

Net/Sensor

Sensor

Engine oil pressure


switch

Valid/Invalid

Engine oil pressure


sensor

Valid/Invalid

Brake pressure differential switch

Invalid/Nc/No

Brake oil level

Invalid/Nc/No

Wheel type

A or B type

=Valid x=Invalid
* Auto brake is always valid on ZW550 units.

Output
x

A type

x
A type

** Pilot operated hydraulics for K-Lever on ZW550.

Items that are not shaded in table are addable options.

62-104
Function & Structure Electrical Group
Electrical Detent Circuit

Electrical Detent Circuit


Bucket leveler
After dumping, if the control lever is set to the "rollback"
position, the control lever will be held at that position
until the bucket is tilted to the set angle. This is because
the detent solenoid in the pilot valve is energized so that
the fixing disc connected to the push rod is held by the
magnetic force. When the bucket is positioned at the set
angle, the rod will retract from the proximity switch. The
proximity switch is turned off and the detent solenoid in
the pilot valve is de-energized and demagnetized. The
control lever is automatically returned to the neutral
position by the spring. As a result, the bucket is set to
the selected digging angle automatically.

Detent

Multiple control valve

Bucket leveler

Adjusting rod (detected object)

Proximity switch

Connector
Bucket cylinder

85V2E62007

Proximity switch
Adjusting the clearance
Proximity switch
Switch
main
circuit

LED

+24V

Br 1

Coil for detent


inside pilot
valve

B 2
L
3
+24V

Detection part
Operation indicator lamp (LED)
Detected
object

1(Br)

View Z

52 mm (0.1970.079 in)

3(L)

Adjust the clearance between the sensor and the


adjusting plate to 52 mm (0.1970.079 in). In this condition, the operation indicator lamp (LED) is on, and the
circuit between the switches (2) (3) is on.

2(B)
85ZV62015

62-105
115ZV-2 Function & Structure Electrical Group
Electrical Detent Circuit

Detent solenoid

Push rod

Detent
solenoid
Fixing
disc

85V2E62035

Three detent solenoids are installed in the pilot valve.


One detent solenoid, for the bucket leveler, is installed
in the pilot valve bucket side.
Two detent solenoids, for the boom kickout and float,
are installed in the pilot valve boom side.
Voltage

DC 24 V

Coil resistance

623

62-106
Function & Structure Electrical Group
Electrical Detent Circuit

Lift kickout & lower kickout


Location

4
A
5

3
1
Detail A

1.
2.
3.
4.
5.
6.

Rotary sensor
Rod
Link
Cover
Cover
Boom

85V2E62008

Lift kickout

Lower kickout

When the boom control lever is placed at "Raise" position and the boom reaches at the preset height, the lift
kickout automatically releases the detent and returns
the boom control lever to "Hold" position. The detent
function and the units are the same way as those of the
bucket leveler.

When the boom control lever is placed at "Float" position and the boom reaches at the preset height, the
lower kickout automatically releases the detent and
returns the boom control lever to "Hold" position. The
detent function and the units are the same way as those
of the bucket leveler.

62-107
115ZV-2 Function & Structure Electrical Group
Electrical Detent Circuit

Sensor assy
4

5
A-A

Detail of grease applying

A
30
Position sensor detail

85V2E62009

1.
2.
3.
4.
5.

Position sensor
Link
Plate
Shaft
Ball bearing

62-108
Function & Structure Electrical Group
Electrical Detent Circuit

A B C

View A

A
Position sensor detail

CCW

70T2U62008

70T2U62009

Resistance

5 k 1 k

Electrical rotation

128 (Theoretical)

Mechanical rotation

180

Clockwise stop

90 from elect. center

Spring return

To clockwise end of rotation

62-109
115ZV-2 Function & Structure Electrical Group
Electrical Detent Circuit

Detent solenoid

Lever position:
Lower kickout side

Preset height adjustment

Lever position:
Lift kickout side

Push rod

Push rod

Detent
solenoid
(for lift)
Fixing
disc

Detent
solenoid
(for lower)
Fixing
disc

Switch

115V2E62019

(Upper)

(Lower)

Hold

Hold

Reset

Reset

85V2E62017

Two detent solenoids are installed in the pilot valve


boom side.
One is for the lift kickout and the other is for the lower
kickout.
Voltage

DC 24 V

Coil resistance

623

65V2E62018

1. Lift kickout preset height


Raise the boom to the desired position and press
the left side of the kickout control switch located on
the console box to set the boom height for the lift
kickout.
2. Lower kickout preset height
Lower the boom to the desired position and press
the right side of the kickout control switch located
on the console box to set the boom height for the
lower kickout.

62-110
Function & Structure Electrical Group
Diode

Diode
Open circuit, failed in open position.

Symbols

+24V

[Anode]

[Cathode]

Surge voltage

(forward direction)

Current flow

Switch
Solenoid

(backward direction)

70ZV62051

Normal

Diode

Current flows while the diode is disconnected.


(The solenoid is energized, however the surge voltage
is not absorbed. This damages electrical parts.)
70T2U62011

A diode is an electronic part which makes the current


flow in one direction.
Current flow

+24V

Switch
Solenoid

Diode

Current flows while the diode is normal


(The solenoid is energized.)

70ZV62052

Short-circuit, failed in closed position.

The + side is called "anode", and the - side is called


"cathode". The current can flow only in the direction
from the anode to the cathode.
When a diode is connected in the current flow direction,
it is called forward direction. When a diode is connected
in the current non-flow direction, it is called backward
direction.
Some electrical parts, as solenoid valves, buzzers,
relays, all equipped with electromagnetic coils may generate a surge voltage caused by counter electromotive
force when the power is turned off. This surge voltage
may cause malfunction of equipment.
Diodes are provided to prevent such a malfunction.

+24V

Switch
Solenoid

Diode

Current flows through the diode with smaller resistance.


The solenoid is not energized.
95ZV62074

However, if a diode is damaged and short-circuited (or


fails closed) in its inside, electronic parts may be
harmed.
Therefore, if a malfunction occurs in electrical equipment, electrical connection diagrams should be referred
to first, to determine and repair the cause. If a diode is
provided in the electrical equipment, the diode should
be checked for damage.

62-111
115ZV-2 Function & Structure Electrical Group
Diode

Diode check method

Caution for diode check method


Continuity check mode
When checking the continuity by continuity check mode
of volt-ohm-ammeter, only in case that the resistance is
about 300 or smaller, the continuity is detected.

Coil

If the continuity check mode of volt-ohm-ammeter is


used to check the continuity of diode with 500~600 ,
no continuity is detected both ways.

+
Analog type tester

Use a volt-ohm-ammeter with diode mode for checking


diode continuity.
95ZV62129

12V

Diode check mode

12V

30A

ECM
F15

R1 BR
B AC
R2 C

WR

(2) (3)

WP

Battery
(1)

(2)(3): Diode unit

5A

Charge
circuit

R1

5A

5A

F13

F14

Suppression diode

Neutral
relay

From
alternator
I terminal

115V2E62005

Normal
Abnormal

Forward check

Continuity is detected in the status shown in the figure.


Continuity is not detected when tester terminals are connected in opposite way.
Continuity is not detected in either way Disconnection
Continuity is detected in either way

Short-circuit

Note
When the circuit tester is the digital (number indication)
type, exchange the positions of the terminals of the
tester during the check. Some solenoid coils contain
diodes inside the solenoid coil pack.
Backward check
85V2E62036

Forward check

Backward check

Continuity (voltage value)

Over level

Judgement
Normal

Over level

Over level

Open circuit

0 volt

0 volt

Short-circuit

62-112
Function & Structure Electrical Group

Resistance check mode


Analog type tester

R1>0

R2=

Forward check

Backward check
Digital type tester

R1>0

R2=

R1

Forward check

Backward check

Forward check

Backward check

Judgement

R (0<R<)

Normal

Open circuit

Short-circuit

62-113
115ZV-2 Function & Structure Electrical Group
Diode

Surge voltage and surge suppression diodes

Fig. 3

Fig. 1

Surge suppression
diode

Coil

Current
Switch or
transistor
Time [sec]

Load
115ZVE62032

Some electrical parts such as solenoid valves are


equipped with a coil.
When a coil is energized, an electromagnetic field is
formed. See fig. 1.
Fig. 2

Battery

Coil

When the switch opens, the


field collapses across the coil
windings.
Voltage

Voltage [V]
Current [A]

K70V2J62006

When the surge voltage was generated, it causes to


increase wear on the switch points.
During the coil is being activated by the transistor, when
the excruciating high voltage is loaded on the transistor,
the transistor may be broken.
In order to absorb this surge voltage, connect the diode
parallel to the coil in the reverse direction against the
power supply.
When the switch is off, the same amount of electric current, that was flown till now, flows through the diode.
This electric current is attenuated gradually and finally it
reaches zero. That means no surge voltage is generated in the circuit.

Current

Load

Coil

Voltage

Voltage [V]
Current [A]

Current direction

Battery

Electromagnetic field forms


when switch closes.

This diode is called as flywheel diode.

ON
OFF
Time [sec]

Surge voltage
115ZVE62033

When the solenoid coil is de-energized, the field collapses across the coil. The collapse of this electromagnetic field across the solenoid coil generates an
unregulated voltage surge. See fig. 2.
This can damage transistors, contacts, and other electronic parts. (See connection diagram.)

62-114
Function & Structure Electrical Group
Diode

72-1
115ZV-2 Function & Structure Operator Station Group

Function & Structure


Operator Station Group
Cabin ....................................................................... 72-2
Operator Seat.......................................................... 72-10
Steering and Transmission Shift Lever.................... 72-11
Air Conditioner ........................................................ 72-14
Troubleshooting....................................................... 72-70

72-2
Function & Structure Operator Station Group
Cabin

Cabin
Mounting drawing
2

Floor board

Rear chassis

The cabin equipped with the ROPS (Roll Over Protective Structure) is provided as standard.
1. Cabin
2. ROPS

115V2E72001

72-3
115ZV-2 Function & Structure Operator Station Group
Cabin
Outline drawing

AB
3

7
6

1.
2.
3.
4.
5.
6.
7.
8.

B-B

Door (left side)


Front wiper
Window washer jet nozzle
Outside air suction port (air conditioner)
Antenna
Sun visor
Rear view mirror
ROPS

A-A

K115V2J72002

72-4
Function & Structure Operator Station Group
Cabin

Glass

70V2E72001

1. Front glass
2. Front side glass
3. Rear glass

72-5
115ZV-2 Function & Structure Operator Station Group
Cabin

1. Part number KC3201121690

Clear glass
(Outside)

2. Part number KC3201121700

Clear glass
(Outside)

Laminate: 0.76 mm

T=3.0

Laminate: 0.76 mm

T=3.0

Green glass
(Inside)

Green glass
(Inside)

T=3.0

T=3.0

A-A

A-A

(mm)

327.5
(mm)
R3

953

R2

96

R3

299.5
52.5

0
R3

R3

4-

R53

1149

1195

699

646.5

70V2E72002

Note
This glass must comply with ECE REG43.

70V2E72003

Note
This glass must comply with ECE REG43.

72-6
Function & Structure Operator Station Group
Cabin

3. Part number KC3201121500

(mm)
1262.5

R2

R2

848

0
R3

T=6.0

R3

1325.5

70V2E72004

Note
This glass must comply with ECE REG43.

72-7
115ZV-2 Function & Structure Operator Station Group
Cabin

Wiper mount
Front wiper

714 (Along surface)

Wipin
g ang

le 56

long su
rf

ace)

R750(A

1
4

4
97ZV72004

1. Wiper motor
2. Wiper arm
3. Wiper blade

4. Intermittent wiper relay


5. Washer jet nozzle

Rear wiper

4
3

97ZV72005

1. Wiper motor
2. Wiper arm

3. Wiper blade
4. Washer jet nozzle

72-8
Function & Structure Operator Station Group
Cabin

Wiper motor
Front
Cabin

(Automatic stop position)


12

159200 589
24V

100

e)
ol
rh
5 the
a
re

(B

115

80
70

0
5.6
R8

(3 10')

.2

60

Wipin
g

angle

22

56

Ro

tati
ng

dire
cti

on

(-1) AVS0.85 W

(-2) AVS0.85 L

(+) AVS0.85 R

(S) AVS0.85 Y

(+) AVS0.85 R

( L1~L3=3.7H
C1~C3=0.2F )

MOTOR
Circuit breaker
L3

Washer motor

L1

L2

C3

C2
R

C1
L

24 V

SWITCH

OFF
LOW
HIGH

Circuit diagram

97ZV72100

1.
2.
3.
4.
5.
6.
7.

Wiper motor assembly


Link assembly
Washer
Nut
Cap
Nut
Crank arm

Wiper motor (front) specifications


Nominal torque

23.5 N-m (2.4 kgf-m)

Rated voltage

DC 24 V

Rotating speed Load:


1.0 N-m (0.1 kgf-m)

Low

464 min-1

High

Rotating speed Load:


4.0 N-m (0.4 kgf-m)

High

687 min-1
> 32 min-1
=
> 42 min-1
=
< 16 V
=
> 32 V
=
<2A
=
< 15 A
=

Low

No-load starting voltage (Minimum)


Automatic stopping voltage (Maximum)
No-load current
Locked rotor current

72-9
115ZV-2 Function & Structure Operator Station Group
Cabin
Rear

Wiping angle: 1063

Automatic stop
position

LB (+1)

Y(S)

L(+)

Cabin

AVS0.85 LB
(+1)
AVS0.85 L
(+)

MOTOR
(Circuit breaker)

AVS0.85 WB
( )

AVS0.85 Y
(S)

WB

M
2
LB

+1

L
+

Cabin

Pantagraph arm

Tightening torque:
6.4~9.3 N-m (0.6~0.9 kgf-m)

OFF
ON

24V

SWITCH
Circuit diagram (motor stop position)

K97V2J72001

1.
2.
3.
4.
5.
6.

Wiper motor
Washer
Packing
Nut
Cap
Nut

Wiper motor (rear) specifications


Nominal torque

12 N-m (1.2 kgf-m)

Rated voltage
Rotating speed Load:
0.6 N-m (0.6 kgf-m)
Rotating speed
No load

DC 24 V
Speed

385 min-1

Current

2 A or less

Speed

405 min-1

Current

1 A or less

Starting voltage

16 V or less

Locked rotor current

7 A or less

72-10
Function & Structure Operator Station Group
Operator Seat

Operator Seat
Armrests
Rotate control knob (3) to select desired angle. Pivot up
and parallel with backrest when not in use.
Combined height and weight adjuster

1. Sit on the seat.


2. Turn handle (4) to adjust seat height.
Clockwise to raise seat.
Anti-Clockwise to lower seat.

2
1

3. Check ride indicator (5) shows green.


If red, readjust seat height.
Within the green band of the ride indicator there is 75
mm of height adjustment for any driver.

95ZV OM EU SEAT

Note
The seat is designed so that it is unnecessary to make
any adjustment for the driver weight.
Up-stop height adjustment control (europe specification)

85V2E72003

1.
2.
3.
4.
5.
6.

Reclining adjustment lever


Back-and-forth adjustment lever
Arm rest height adjuster
Height and Weight adjuster
Ride indicator
Handwheel

Seat adjustment
Adjust the seat for comfort and so that the pedals may
be pushed fully down when the operator's back is fully
back.
Reclining
Move adjustment lever (1) forward and hold, select
backrest angle, release adjustment lever.
Forward/Backward
Lift lever (2) up and hold, slide seat to desired position,
release lever.

To adjust the up-stop height, rotate handwheel (6) clockwise to raise the seat unseated, rotate it counterclockwise to lower the seat unseated.

72-11
115ZV-2 Function & Structure Operator Station Group
Steering and Transmission Shift Lever

Steering and Transmission Shift Lever


Tilt quantity
56

56

4
5
4
6

Operator
stand

1. Steering wheel
2. Transmission shift lever
3. Turn signal indicator and head lamp high/low selector lever
4. Handle tilt adjustment lever
5. Gas spring
6. Column shaft assembly
7. Lower column shaft
8. Orbitrol
Tilt case (1~6) can select the optimal position in the following range:

95ZVE72009

Handle tilt
56 mm in each direction from the center
Handle slide
85 mm upward and downward
Note
- Install gas spring (5) with its rod side facing downward as shown in the figure above.
- Install lower column shaft (7), together with the
Orbitrol, from the underside of the operator stand.

72-12
Function & Structure Operator Station Group
Steering and Transmission Shift Lever

Tilt case
8

1
1

4
2

Lock
release
position

6
7

2
5
4
Operator
stand

Slide quantity
85

Lock position

270 (355 when slid)

9
Operator
stand

10

97ZV72017

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Column shaft assembly


Bracket
Bracket
Handle tilt adjustment lever
Bolt
Nut
(double-start thread, tapered in lever mounting
area)
Nut
Nut
Bushing
Nut

: (6): 21.5 N-m (2.2 kgf-m)


: (7): 49 N-m (5.0 kgf-m)
: (8): 54 N-m (5.5 kgf-m)
: (10) (inside): 31.9 N-m (3.3 kgf-m)
: (10) (outside): 89.1 N-m (9.1 kgf-m)

72-13
115ZV-2 Function & Structure Operator Station Group
Steering and Transmission Shift Lever

Column shaft
Grease
charged

Adhesive
applied

1
8

11
5

10

6
Waterproof seal

13
11

11

12

B-B

A-A

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

Column tube
Column shaft
Column bushing
Bushing
Terminal (male)
Ball bearing
C-shaped snap ring
U-shaped joint
Serrated shaft
Tube
Transmission shift lever installation positioning hole
Wiring output port
Bolt
: (13): 25 N-m (2.5 kgf-m)

Shift lever
Refer to "Electrical Group 62".

97ZV72018

72-14
Function & Structure Operator Station Group
Air Conditioner

Air Conditioner
Air conditioner components

1-1

3
1-2

12

10

11

14

13

97ZV72020

1. Air conditioner assembly


1-1 Cooling unit assembly
1-2 Blower assembly
2. Air distributor assembly
3. Recirculating air filter
4. Control panel
5. Condenser assembly
6. Compressor assembly
7. Receiver drier
8. Receiver drier bracket
9. Joint
10. Drain hoses
11. Relay
12. Thermistor* (inside air sensor)
13. Thermistor* (outside air sensor)
14. Solar sensor (insolation sensor)
* or thermal resistor

Air conditioner specifications (system performance)


Cooling system performance
Cooling capacity

4.65 kw (15,881 BTU) 10 %

Air quantity

550 m3/h (720 yd3/h) 10 %

Rated voltage

DC 24 V

Power consumption

345 W (14.4 amps) 10 %

Heating system performance


Heat radiation quantity

5.2 kw (17,759 BTU) 10 %

Air quantity

380 m3/h (500 yd3/h) 10 %

Rated voltage

DC 24 V

Power consumption

170 W (7.1 amps) 10 %

(Difference in temperature: 65C, water flow rate: 6 L/min)

72-15
115ZV-2 Function & Structure Operator Station Group
Air Conditioner

Denso air conditioner structure


Cooling unit
37
14

57

51

38
13
25

50
49

24

9
24

23
6

11

5
15
4

17

3
16
12

97ZV72021

72-16
Function & Structure Operator Station Group
Air Conditioner

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.

Cooling unit case (rear)


Cooling unit case (front)

Evaporator core
Heater core
Expansion valve

Tube
De-icing sensor
(thermal resistor)

Door (upper)
Door (lower)
Door (foot)
Damper (vent)
Pressure switch (triple)
Liquid tube
Suction tube

20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.

Power integrated circuit


assembly
Servo motor (A/M, air mixing)
Servo motor (mode)

Lever (face, door)


Lever (foot, door)

39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.

Lever (face, front)


Control lever (face, front)
Door (S/A) (face, front)

Thermo sensor (water temperature)

72-17
115ZV-2 Function & Structure Operator Station Group
Air Conditioner

Heater and accessories

Air distributor (hood & defroster selection


box)
13
3

2
5
1
1

97ZV72024

11
17

10

97ZV72023

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.

Blower case
Blower case
Air damper case
Air damper case
Blower & blower motor
Servo motor
Door

Bracket
Pipe (for cooling motor)

Relay

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

Air damper case


Air damper case

Control lever
Door

Control lever

Servo motor actuator (AY, inside/outside air)

72-18
Function & Structure Operator Station Group
Air Conditioner

Air compressor (with magnetic clutch)

2-1
2

2-2

2-3
2-6

2-8

5~7

2-7
1
85V2U72001

1. Compressor
2. Magnetic clutch assembly
2-1 Magnetic stator coil
2-2 Magnetic clutch pulley
2-3 Clutch hub
2-6 Plate washer
2-7 Snap ring
2-8 Snap ring

3.
4.
5.
6.
7.

Plate washer
Plate washer
Plate washer

Condenser unit
3
1

4
2

12

10

1.
2.
3.
4.
5.
6.

Condenser core
Blower assembly
Condenser bracket
Condenser bracket

7.
8.
9.
10.
11.
12.

95V2U72001

Cover

Wire harness

Resistor

72-19
115ZV-2 Function & Structure Operator Station Group
Air Conditioner

Control unit

Control
amplifier

Control panel

97ZV72027

Control panel
OFF switch

Inside/outside air
selector switches

Blower switches

Temperature
setting switches

Liquid crystal display


(LCD) unit

Vent mode
selector switch

AUTO switch

Air conditioner
ON/OFF switch

97ZV72028

72-20
Function & Structure Operator Station Group
Air Conditioner

Function of cooling mechanism


Principle of cooling
Indoor

Evaporator

Expansion
valve
Expansion
Evaporation
Condensation

Deprives heat
of the adjacent
area.

Condenser
Releases
heat to the
outside.

Compression Refrigerant
Compressor
Basic cooling cycle

97ZV72029

Function and operation of air conditioning system


Very often, things are much simpler than they may
appear. This is also the case with an air conditioning
system. Gas when compressed often heats as a result
of molecular compression, and when decompressed it
cools. Some gases are more prone to heat or cool to a
greater degree when undergoing these changes than
are others. We use these natural laws to make an air
conditioning system work. Another factor to take into
consideration is that we enhance the natural effects of
hot and cold in these refrigerants by manipulating the
gas temperature while it is undergoing the heating or
cooling process.
Note
HFC 134A is a very effective "vehicle" to carry away
heat.
Explanation of function of air conditioning unit.
As an example of manipulating refrigerant temperatures, imagine that you can very quickly make the refrigerant intensely hot. This is done by use of a
compressor, as we just mentioned in paragraph one.
If you course the heated refrigerant that just came from
the compressor through a condenser that will cool it
while it is very hot and in a compressed gaseous state,
you will make it shed some of its heat that it gained in
the compression process. This refrigerant then is converted into a liquid at this point, while still in the condenser. This is why it is called the condenser, as it has
condensed the gas into a liquid. As a liquid that may still

contain some minor gas fractions, it is routed into the


receiver drier. There it dries the refrigerant by use of a
material we term a "desiccant", which means drying
agent. A down tube in the receiver drier is submerged
into the heavier liquid that is now at the bottom of the
receiver drier. This tube will permit passage of only the
heavier liquid that is at the bottom of the receiver drier.
Then the high-pressure liquid passes through the thermal expansion valve that provides a restriction or throttles the flow of refrigerant. This restriction reduces the
pressure of the liquid refrigerant thus reducing its boiling
point. The expansion valve also meters the amount of
refrigerant to the evaporator, by modulating the valve
from wide open to closed, which varies with the heat
load. The expansion valve separates the high-pressure
side from the low-pressure side.
The refrigerant is now at the evaporator. Temperatures
in the evaporator are cold enough to cause the ambient
air to cool when blown through it. This causes condensation to happen. The fan-charged air that rushes
through the evaporator is now going to shed its humidity. This humidity, or condensed water, is routed through
some tubing to be discharged to the outside of the cab
as waste water that falls to the ground. The refrigerant
is now on its way back to the compressor. It is still under
pressure when compared to the atmospheric air pressure. However, because it is drawn along by the refrigerant compressor suction, we now say that is in the
suction side (low-pressure side) of the circuit.

72-21
115ZV-2 Function & Structure Operator Station Group
Air Conditioner

Refrigerant
A liquid object which circulates inside cooling circuit and
transmits heat is called "refrigerant". The refrigerant
changes repeatedly its state, from "liquid --> gas --> liquid --> gas ...", and carries heat from the low temperature side (inside the cab) to the high temperature side
(outside the cab) while changing its status.
There are many types of refrigerants. This air conditioner adopts refrigerant R134a which does not contain
chlorine and does not destroy the ozone layer.

IMPORTANT
Make sure to use the specified refrigerant (R134a). If
any other refrigerant is used, following problems may
occur:
- The air does not become cool enough.
- The equipment may be damaged.
And never mix R134a with any other refrigerant.
Chemical formula
Molecular weight

CH2FCF3
102.03

Boiling point

-26.19C (-15F)

Critical temperature

101.14C (214F)

Critical pressure

4.1 MPa (41.45 kgf/cm2)


(595 psi)

Critical density

511 kg/m3 (0.073 lbs)

Density of saturated liquid


(at 25C/77F)

1,206 kg/m3 (595 psi)

Specific volume of saturated vapor


(at 25C or 77F)
Latent heat of evaporation (at 0C/32F)
Combustibility
Ozone decomposition modulus

0.0310 m3/kg
197.54 KJ/kg (186 BTU)
(47.19 kcal/kg)
Noncombustible
0

72-22
Function & Structure Operator Station Group
Air Conditioner

Refrigerant characteristics

Generally, fluid (which is the generic name for compressed / condensed non-gas liquid) has following properties.

Refrigerant temperature (C) (F)

100
(212)

1. When the temperature of gas at a certain pressure


decreases, the gas starts to condense and change
into liquid at a certain temperature. For each substance (liquid), this temperature is fixed at a given
pressure. This temperature determined by a given
pressure is called the "saturated temperature".

80
(176)
60
(140)
40
(104)
35
(95)
20
(68)
15
(59)
0

20
4)

30
22)
0

8 10
3.6 5
353 490 785 981
51 71 114 142

15
1,471
213

20
1,961
284

25
2,452
355

30
2,942
426

35
3,432
497

Gauge pressure (kgf/cm2G)


Relationship between saturated pressure
and saturated temperature of R134a

2
40 (kgf/cm )
3,923 (kPa)
568
(psi)

85V2U72002

2. On the contrary when the temperature is determined, the pressure at which liquefication starts is
fixed. This pressure is called the "saturated pressure".
The figure on the left shows the relationship
between the saturated temperature and the saturated pressure of refrigerant R134a.
At the temperature and the pressure below at the
lower right side of the curve, the refrigerant is liquid.
At the temperature and the pressure above at the
upper left side of the curve, the refrigerant is gas.
Suppose that the air conditioner is used in mid summer.
When evaporated, the refrigerant absorbs the heat of
evaporation from the air inside the cab.
Accordingly, in order to cool down the air inside the cab
to approximately 25C (77F), the refrigerant should
change (be evaporated) from liquid into gas at a temperature lower than 25C (77F). From the figure, it can
be seen that the refrigerant R134a can sufficiently cool
down the air inside the cab at a pressure above the
atmospheric pressure. (If used refrigerant requires a
pressure below the atmospheric pressure to cool down
the air to the necessary temperature, air enters into the
circuit and the ability of the cooler is diminished.)
In the process at which the vaporized refrigerant is condensed to liquid, the refrigerant is cooled down by outside air of about 35C (95F) so that it can condense.
Accordingly, as is seen from the figure, the refrigerant
can be liquefied at the pressure of 785 kPa (8.0 kgf/
cm2G) (114 psi) or more.

72-23
115ZV-2 Function & Structure Operator Station Group
Air Conditioner

Cooling circuit

The figure on the left shows the cooling circuit of the air
conditioner.

Inside cab

Pressure bulb

Expansion valve

Evaporator
Blower

Inside engine room

Compressor

Cooling fan
Pressure switch
Receiver dryer

Condenser
Structure of cooling circuit
85V2U72003

In this circuit diagram, the area which cools down the air
inside the cab is the evaporator. The cooling circuit utilizes the fact that the refrigerant absorbs heat (latent
heat of evaporation) from the adjacent area when evaporated, and cools down the air inside the cab. The area
where the refrigerant is evaporated is the evaporator.
The "cooling" effect can be obtained only when the air to
be cooled down is continuously fed to the area around
the evaporator by the blower fan and the liquid refrigerant (wet evaporation refrigerant with low degree of dryness) is supplied into the evaporator.
For example, in order to cool down the air to 15C
(59F), the refrigerant can absorb the latent heat of
evaporation from the air only when it is evaporated at a
temperature lower than 15C (59F). It can be seen from
the figure in the previous page that the pressure of the
refrigerant inside the evaporator should be 353 kPa (3.6
kgf/cm2G) (51 psi) or less to realize it. And in order to
keep sufficient cooling effect, the supplied refrigerant
quantity should be adjusted so that the refrigerant supplied to the evaporator is completely evaporated inside
the evaporator into dry vapor or gas.
Accordingly, the cooling circuit should be constructed to
reduce the pressure inside the evaporator and supply
proper quantity of refrigerant into the evaporator so that
the evaporator can cool down the air sufficiently.
The supplied refrigerant quantity is adjusted by the
expansion valve. The pressure inside the evaporator is
kept at a low value by the closing action of the expansion valve and the suction action of the compressor.
The compressor works as a pump which circulates the
refrigerant. The refrigerant in the dry vapor status
returns into liquid by the compression action of the compressor and heat change (heat radiation) of the condenser, which acts to change the state of the gas to
liquid.

72-24
Function & Structure Operator Station Group
Air Conditioner

Electrical circuit
Control schematic drawing

Outside air
sensor

Input signals

Input signals

Set temperature, room temperature,


water temperature, air temperature
after evaporator

Insolation sensor
Outside air sensor

e = Inside air temperature - Set temperature

Insolation
sensor

Set temperature
correction

Freeze sensor

Water temperature
sensor

55

BLC
Temperature
control
servo
HOT

Temperature
control servo

Blower motor

Blow-off
servo

25

Warm-up control

Blower
voltage

Water temperature (C)

Blower voltage/temperature control/blow-off servo motor position determination

Inside air
sensor

COOL
FACE
B/I
FLOOR

Y value

Blow-off servo
Compressor ON-OFF
ON
3

Freeze sensor temperature (C)

95ZVE72018

72-25
115ZV-2 Function & Structure Operator Station Group
Air Conditioner

Air conditioner functions of components


Control panel
Name and function of each part on control
panel
(1) OFF switch

Indicator lamps

(2) Blower switches

(6) Inside/outside air selector switches

(3) Temperature
setting switches

(7) Liquid crystal


display (LCD) unit

- (1) OFF switch


This switch stops the operation of the blower and the
air conditioner.
When OFF switch (1) is pressed, the set temperature and the air blow quantity displayed on LCD unit
(7) as well as the indicator lamps above AUTO
switch (5) and air conditioner ON/OFF switch (8)
turned "off", and operation is stopped.

(4) Vent mode selector


switch

Indicator lamps

(5) AUTO switch

(8) Air conditioner


ON/OFF switch

97ZV72036

- (2) Blower switches


These switches change over the air flow quantity in
six steps.
The air flow quantity is displayed on the LCD unit.
When the
switch is pressed, the air flow quantity
increases.
When the
switch is pressed, the air flow quantity
decreases.
In the automatic mode, the air flow quantity is automatically changed over.
Display on the LCD unit and the air blow quantity
Display on LCD unit

Air blow quantity


Air quantity "low"
Air quantity "medium 1"
Air quantity "medium 2"
Air quantity "medium 3"
Air quantity "medium 4"
Air quantity "high"

72-26
Function & Structure Operator Station Group
Air Conditioner
- (3) Temperature setting switches
These switches set the temperature inside the cab in
the range from 18.0C (65F) to 32.0C (90F).
When the
switch is pressed, the set temperature
increases.
When the
switch is pressed, the set temperature
decreases.
Usually, set the temperature to 23~25.0C
(72~77F).
Display on the LCD unit and the function
Display on LCD unit

Set temperature

18.0C (65F)

Maximum cooling

18.5~31.5C
(65~95F)

Temperature inside cab is controlled so that


set temperature is realized.

32.0C (90F)

Maximum heating

- (4) Vent mode selector switch


This switch changes over the vent mode.
When vent mode selector switch (4) is pressed, the
vent mode displayed on LCD unit (7) is changed
over, and air is blown from the displayed vent positions.
In the automatic mode, the vent mode is automatically changed over.
Display on
LCD unit

Vent mode

Vent positions
(A)

(B)

Face (blow-off to upper portion of


body mainly during cooling)

Face & foot

Foot
(blow-off to feet mainly during heating)

(C)

(D)

Remarks

Foot & defroster

Defroster

This mode is not


selected in automatic
mode.

This mode is not


selected in automatic
mode.

- (5) AUTO switch


This switch automatically changes over the air blow
quantity, the vent mode and the inside/outside air in
accordance with the set temperature.
When AUTO switch (5) is pressed, the indicator
lamp above it lights.
Usually, press this switch, set the temperature by
using temperature setting switches (3), and use the
air conditioner in the automatic mode.

When the automatic mode is changed over to the


manual mode, the indicator lamp above AUTO
switch (5) is extinguished. In the manual mode, the
air blow quantity, the vent mode and the inside/outside air can be changed over by manipulating each
switch.

72-27
115ZV-2 Function & Structure Operator Station Group
Air Conditioner
- (6) Inside/outside air selector switches
These switches change over inside air circulation
and outside air entry.
When an either switch is pressed, the indicator lamp
above it lights to indicate the selected air flow status.
In the automatic mode, outside air introduction and
inside air circulation are automatically changed over.
Inside air recirculation

Outside air entry

The outside air is shut down, and the air


inside the cab is circulated.
Press this switch to rapidly cool or heat the
air inside the cab or when the outside air is
dirty.
The outside air enters the cab.
Press this switch to introduce clean air into
the cab or defog the windows.

- (7) Liquid crystal display (LCD) unit


This LCD unit indicates the set temperature, the air
flow quantity and the vent mode during operation.
When OFF switch (1) is pressed, the set temperature and the air flow quantity are extinguished and
the operation is stopped.
- (8) Air conditioner ON/OFF switch
This switch turns on and off the air conditioner (cooling or dehumidification/heating).
When this switch (8) is pressed, the air conditioner is
turned on and the indicator lamp above the switch
lights. When this switch is pressed again, the air conditioner is turned off and the indicator lamp is extinguished.
However, the air conditioner is turned on only while
the blower is operating (that is, while the air blow
quantity is displayed on the LCD unit.)

72-28
Function & Structure Operator Station Group
Air Conditioner

Operating method

2. Stopping the automatic operation

Normal use
1. Automatic operation

Set temperature

(1) OFF switch

(3) Temperature setting


switches

(5) AUTO switch

97ZV72041

Air flow quantity

(8) Air conditioner


ON/OFF switch
97ZV72040

(a) Set AUTO switch (5) to ON. Confirm that the set
temperature and the air flow quantity are displayed
on the LCD unit, and that the indicator lamps above
AUTO switch (5) and the air conditioner ON/OFF
switch (8) are lit.
(b) Adjust temperature setting switches (3), and set
arbitrary temperature.
The air conditioner automatically changes over the
air flow quantity, the vent mode and the inside/outside air to realize the set temperature.
Note
When the vent mode is set to
or
in the automatic operation, if the engine water temperature is low, the air flow quantity is restricted to
prevent blow-off of cold air.

Press OFF switch (1). Then, the set temperature and


the air flow quantity displayed on the LCD unit are extinguished, the indicator lamps above AUTO switch (5)
and air conditioner ON/OFF switch (8) are extinguished,
and the operation is stopped.

72-29
115ZV-2 Function & Structure Operator Station Group
Air Conditioner
3. Manual operation

(2) Blower switches

(3) Temperature
setting switches

(6) Inside/outside air selector switch

4. Stopping the manual operation

(4) Vent mode


selector switch

(1) OFF switch

(8) Air conditioner


ON/OFF switch
97ZV72042

(a) Press blower switches (2), and adjust the air flow
quantity.
Confirm that the set temperature and the air flow
quantity are displayed on the LCD unit.
(b) Set to ON air conditioner ON/OFF switch (8). Confirm that the indicator lamp above the switch lights.
(c) Adjust temperature setting switches (3), and set
arbitrary temperature.
(d) Press vent mode selector switch (4), and select
arbitrary vent mode.
(e) Press an either inside/outside air selector switch (6)
to select inside air circulation or outside air entry.

97ZV72041

Press OFF switch (1). Then, the set temperature and


the air flow quantity displayed on the LCD unit are extinguished, the indicator lamps above AUTO switch (5)
and air conditioner ON/OFF switch (8) are extinguished,
and the operation is stopped.

72-30
Function & Structure Operator Station Group
Air Conditioner
Other uses

2. Defroster operation

1. Head cooling, feet heating (bi-level) operation


(2) Blower switches

(4) Vent mode selector switch

(4) Vent mode selector switch


(2) Blower switches

(6) Inside/outside
air selector switch

(5) AUTO switch

(6) Inside/outside
air selector switch
(3) Temperature
setting switches
97ZV72044

(a) Press blower switches (2), and adjust the air flow
quantity.
Confirm that the set temperature and the air flow
quantity are displayed on the LCD unit.
(b) Press vent mode selector switch (4), and display
the vent mode
on the LCD unit.
(c) Set to ON air conditioner ON/OFF switch (8). Confirm that the indicator lamp above the switch lights.
(d) Arbitrarily set blower switches (2), temperature setting switches (3) and inside/outside air selector
switches (6).
Then, the air conditioner realizes the bi-level operation
in which cold air is blown to the head and hot air is
blown to the feet.

(3) Temperature
setting switches
97ZV72045

(a) Press blower switches (2), and adjust the air flow
quantity.
Confirm that the set temperature and the air flow
quantity are displayed on the LCD unit.
(b) Press vent mode selector switch (4), and display
the vent mode
or
on the LCD unit.
(c) Set outside air introduction selector switch (6).
(d) Press temperature setting switches (3), and display
the set temperature "32.0" (maximum heating status) on the LCD unit.
Adjust the louver at each vent position so that air flow
reaches the windows.
When defogging the windows or dehumidifying the air
inside the cab in rainy season, set air conditioner ON/
OFF switch (8) to ON.

72-31
115ZV-2 Function & Structure Operator Station Group
Air Conditioner

Other functions

3. Failure code deletion

Self-diagnosis function
Each sensor and equipment used in the air conditioner
can be diagnosed for failure.

(1) OFF switch

After completing the inspection and/or the repair,


delete the failure codes memorized in the computer.
If not removed, the failure codes memorized in the
computer continue to display on the LCD whenever
diagnosing. To delete the failure codes, press and
hold both air intake control switches (6) for 3 seconds or more.
<Display on the LCD unit and the failure mode>
Display
EE11

(6) Inside/outside
air selector
switches

(3) Temperature setting switches


Press and hold both the " " and " "
switches together
97ZV72035
(for 3 seconds or more).

1. Press the OFF switch to stop the operation.


(The set temperature and the air blow quantity displayed on the LCD are extinguished.)
2. When the both temperature setting switches " "
and " " (3) are pressed and held together for 3
seconds or more, the failure mode is displayed on
the LCD unit.
(a) If two or more failure are detected, the displayed
contents can be scrolled through by pressing either
one of the temperature levels (3) " " or " ".
(b) Press OFF switch (1) again to finish the self diagnosis function and return to the normal display.

Failure mode
No failure
Wire breakage in inside air sensor

E12

Short-circuit in inside air sensor

E13

Wire breakage in outside air sensor

E14

Short-circuit in outside air sensor

E15

Wire breakage in water temperature sensor

E16

Short-circuit in water temperature sensor

E18

Short-circuit in insolation sensor

E21

Wire breakage in vent sensor

E22

Short-circuit in vent sensor

E43

Abnormality in vent damper

E44

Abnormality in air mixing damper

E45

Abnormality in inside/outside air

E51

Abnormality in refrigerant pressure

Celsius-Fahrenheit selector function for the set temperature display


While the blower is operating, press and hold both temperature setting switches (3) " " and "
" together
for 5 seconds or more to change over the unit of the displayed value between Celsius and Fahrenheit. However, the unit type (C or F) itself is not displayed.
Only the set value is displayed.
Value displayed on LCD unit
Celsius (C)

18.0~32.0

Fahrenheit (F)

65~90

72-32
Function & Structure Operator Station Group
Air Conditioner

Air conditioner unit

Air mixing damper

[In the case of maximum cooling]


Air mixing damper A (completely opened)
Heater coil
Evaporator coil

Cold air
Co
ld

a ir

Air mixing damper B (completely closed)


[In the case of maximum heating]
Air mixing damper A (completely closed)

Ho
t

air

Blower motor
Inside/outside air selection damper
Air mixing damper A

air

Inside
air

Outside
air

Fan

Blower motor
Heater radiator

Co
ld

Evaporator
Air mixing damper B

80ZVE72001

The air conditioner unit has the cooling, heating and air
blowing functions to perform conditioning of the air
inside the cab, and consists of an evaporator which
cools down the air, a heater radiator which warms the
air and a blower motor which blows the air.
The temperature in the vent position is adjusted when
the opening/closing position of the air mixing damper is
so controlled that the cooled air while passing through
the evaporator and the warmed air while passing
through the heater radiator are mixed.
The air mixing damper is controlled by the servo motor
for air mixing assembled in the unit.

Air mixing damper B (completely opened)

80ZVE72002

During maximum cooling, the air mixing damper B is


completely closed, and the air mixing damper A is completely opened. As a result, the air cooled by the evaporator does not go through the heater radiator but is
blown off.
During maximum heating, the air mixing damper A is
completely closed, and the air mixing damper B is completely opened. As a result, all the air which has gone
through the evaporator goes through the heater radiator, then the warmed air is blown off.

72-33
115ZV-2 Function & Structure Operator Station Group
Air Conditioner

Evaporator

(7)

(5)

Evaporator

The evaporator is an important heat exchanger which


evaporates liquid refrigerant set to low temperature and
low pressure by an expansion valve, utilizes its latent
heat, and absorbs heat from air (target) inside the cab.
Accordingly, heat should be smoothly transmitted
between the target and the refrigerant in the evaporator.

(4)

For this purpose, fins are provided on the air side of the
evaporator to extend the heat transmission area on the
air side so that heat can be smoothly transmitted
between the refrigerant and the air.

(2)

By cooling, the moisture contained in the air condenses,


changes into water drops, and adheres to the outside of
the evaporator. If these water drops are frozen, the cooling effect deteriorates. To prevent this, attention should
be paid also to proper drainage of condensed water.

(8) (1)

(6)

The refrigerant quantity supplied to the evaporator is


adjusted by the expansion valve described next. In
order to ensure that the refrigerant quantity is accurately
adjusted, pressure drop of the refrigerant inside the
evaporator should be minimal.

(3)

Refrigerant flow inside evaporator (


From expansion valve(1) to (8)
Compressor

Accordingly, reduction of pressure drop is an element to


enhance the performance of the evaporator.
97ZV72048

Troubleshooting the evaporator


Item
Gas leak

Symptom
Both high pressure and low pressure are low,
and air bubbles can be seen through sight
glass.

Cause
- Joint portion of supply area
- Cracks in evaporator main body

Action
- Tightening
- Repair/replacement

Blockage in circuit

Both high pressure and low pressure are low.

- Blockage inside

- Cleaning/replacement

Blockage in fins

Air quantity is small. (Filters may be clogged.)

- Blockage in fins

- Cleaning

Freezing

Air quantity is small, and low pressure is low.

- Blockage in filter
(Evaporator is not preforming
inadequately.)

- Cleaning/replacement

72-34
Function & Structure Operator Station Group
Air Conditioner

Expansion valve (box type)

(Evaporator)

Expansion valve operation

Diaphragm

Evaporator

Spring
Temperature
sensing rod
Diaphragm

Temperature sensing rod


Needle valve (To compressor)
(From receiver)

Needle valve
From receiver
(High pressure)

Structural drawing of box type expansion valve


97ZV72049

The expansion valve offers the following two functions.


1. By injecting the liquid refrigerant at high temperature and high pressure which has gone through the
receiver from a small hole, the expansion valve
expands dramatically the liquid refrigerant into mist
refrigerant at low temperature and low pressure.
2. Promptly in accordance with the vaporized status of
the refrigerant inside the evaporator, the expansion
valve adjusts the refrigerant quantity.
In order to ensure that the evaporator offers its full
performance, the liquid refrigerant should be kept in
a state in which it deprives heat of the adjacent
area and its evaporation is always completed at the
exit of the evaporator.
To realize this, the expansion valve automatically
adjusts the refrigerant quantity in accordance with
fluctuation of the temperature inside the cab (cooling load) and fluctuation of the rotation speed of the
compressor.
The expansion valve consists of a needle valve, a
diaphragm and a temperature sensing rod.
The temperature sensing rod detects the temperature of the refrigerant which has gone through the
evaporator, and transfers the detected temperature
to the refrigerant gas chamber located in the upper
portion of the diaphragm chamber.

To compressor
(Low pressure)

97ZV72050

The temperature sensing rod detects the temperature of


the refrigerant, and transfers the detected temperature
to the refrigerant gas chamber.
The gas pressure changes in accordance with the
detected temperature, the temperature sensing rod
directly connected to the diaphragm is moved, then the
needle valve opening is adjusted.
- When the temperature at the exit of the evaporator is
low or when cooling load is small, following occurs.
The gas pressure inside the diaphragm chamber
becomes low, the volume decreases, the temperature
sensing rod moves to the right, and the needle valve is
closed.
- When the temperature at the exit of the evaporator is
high or when cooling load is great, following occurs.
The gas pressure inside the diaphragm chamber
becomes high, the volume increases, the temperature
sensing rod moves to the left, the needle valve is
opened, and more quantity of refrigerant is supplied to
the evaporator.

72-35
115ZV-2 Function & Structure Operator Station Group
Air Conditioner
Troubleshooting the expansion valve
Item

Symptom

Cause

Action

Both high pressure and low pressure are low,


Blocked expansion
and air bubbles cannot be seen through sight
valve or defective
adjustment (too closed) glass.

- Expansion valve

- Cleaning/adjustment or replacement

Defective adjustment
(too open)

Low pressure is too high, and compressor


head is cold.

- Expansion valve

- Adjustment or replacement

Freezing caused by
moisture

Cooling is disabled during operation. Frosting


is not detected in evaporator. Both high pressure and low pressure are low, and air bubbles
cannot be seen through sight glass.

- Expansion valve

- Replace receiver tank, evacuate air,


then charge gas again.

72-36
Function & Structure Operator Station Group
Air Conditioner

Heater radiator coil

Fin

Heater core

97ZV72051

The heater radiator utilizes the engine cooling water as


the heat source. When going through the heater radiator, the air receives heat from the heater radiator fins
and is warmed.
The hot water inside the heater radiator is forcedly circulated by the engine water pump.
Troubleshooting the heater radiator
Item

Symptom

Cause

Action

Water leaks from heater core.

- Joint portion of supply area


- Cracks in heater core main body

- Repair/replacement

Blockage in circuit

Air inside cab does not become warm.

- Blockage inside heater radiator

- Replacement

Blockage in fins

Air quantity is small.

- Blockage in fins

- Cleaning

Water leak

72-37
115ZV-2 Function & Structure Operator Station Group
Air Conditioner

5 4

3 2 1

Servo motor

1
2
4

5
6

97ZV72052

When a switch on the control panel is pressed, the


power is applied from the control panel on terminal (6)
or (7) of the servomotor. (The rotating direction is determined by the terminal on which the power is applied.)
A variable resistor is provided inside the servo motor.
As the motor rotates, the resistance of this resistor
changes accordingly.
When the 5 V voltage is supplied from the control panel
to this variable resistor, the control panel detects the
variable resistor position based on the electric potential
difference. When the variable resistor reaches the position specified by each switch, the power supplied to the
motor is stopped.
Note
If the power is directly applied on terminals of the motor,
the output shaft of the motor may be damaged or wire
breakage may occur in the motor coil. Do not directly
drive terminals of the motor.
Troubleshooting the servo motor
Item
Motor is locked
(disabled).
Contact is contacting
poorly.

Symptom

Cause

Action

- Servo motor does not rotate.

- Motor
- Control unit

- Repair/replacement

- Indicator lamps of temperature setting


switches do not light in accordance with
preset pattern.
- Servo motor does not stop in accordance
with preset pattern.

- Fixed plate
- Moving contact
- Control unit

- Repair/replacement

72-38
Function & Structure Operator Station Group
Air Conditioner

Blower motor assembly

Blower motor assembly specifications

Fan

Blower motor

Voltage

DC 24 V

Number of rotations of motor

3,100 min-1

Power consumption

225 W (9.4 amps) 10 %

Fan outer diameter

150 (5.9")

Note
This unit can be bench tested with 24 V DC by using
normal test methods. Determine if excessive amperage
is required to turn it. It is controlled by the speed control
(BLC) below.
Air

Air

97ZV72053

The blower motor assembly consists of a DC motor


and a fan, and blows air.
Troubleshooting the blower motor
Item
Blower motor operation is defective.

Symptom
Air is not blown at all.

Cause
- Blower motor
- Control unit

Action
- Repair/replacement

BLC (blower linear control)

85V2U72004

97ZV72054

This resistor changes over the air quantity of the blower


motor.
Troubleshooting the blower linear control
Item

Symptom

Cause

Action

Wire in BLC is broken.

Air quantity does not change.

- BLC
- Control unit

- Replacement

Blower motor operation is defective.

Air is not blown at all.

- Blower motor
- Control unit

- Repair/replacement

72-39
115ZV-2 Function & Structure Operator Station Group
Air Conditioner

De-icing sensor (Thermistor (or thermal resistor))

Evaporator

Appearance of thermistor
8,000
7,000

Resistance ()

6,000

Thermistor

5,000

Heater radiator

4,000

97ZV72056

3,000
2,000
1,000
0

10
(14)

5
(23)

0
(32)

5
(41)

10
(50)

15
(59)

20
(68)

25
(77)

30
(86)

Temperature (C) (F)


Characteristics curve between temperature
85V2U72005
and resistance of thermistor

The thermistor, a kind of semi-conductor, offers the


characteristics as shown in the curve on the above.
When the temperature becomes high, its resistance
becomes small. When the temperature becomes low, its
resistance becomes large.

The thermistor mounted on the blowoff port side of the


evaporator detects the temperature of the air cooled by
the evaporator, and transmits it as a signal to the control
amplifier.
If the air at the vent is 3C (37F) or less, the control
amplifier turns off the compressor clutch relay. If the air
at the blowoff port becomes 4C (39F) or more, the
control amplifier turns on the compressor clutch relay
again to restart cooling.
Because the air temperature at the vent is detected and
the compressor clutch relay is turned on and off accordingly, freezing of the evaporator is prevented.

Troubleshooting the thermistor


Item

Symptom

Cable in thermistor is broken.

Compressor clutch does not work.

Thermistor is short-circuited.

Air not blowing.

*Note
For temperature reference between C and F please
see references below.
Temp C
-10C
0C
10C
20C
25C
30C

Temp F
14F
32F
50F
68F
77F
86F

Cause
- Thermistor

Action
- Replacement

72-40
Function & Structure Operator Station Group
Air Conditioner

Water temperature sensor

Foot/defroster selection box

Air conditioner unit

Foot
Def
97ZV72057

This sensor detects the temperature of the engine cooling water flowing into the heater core, and feeds it back
to the control panel.
This sensor is installed on the rear side of the heater
core, and can be taken out when being pulled out.
Temperature

Resistance value

-30C (-22F)

91.4 k

25C (77F)

5 k

100C (212F)

0.321

Inside air temperature sensor

97ZV72058

This sensor detects the air temperature inside the cab,


and feeds it back to the control panel.
This sensor is installed in the inside are suction port,
and can be taken out when the clamp is removed.
Temperature

Resistance value

0C (32F)

1.645 k

25C (77F)

5 k

97ZV72059

This selection box changes over the vent positions


between the foot side and the defroster side.
When the vent mode selector switch (MODE) on the
control panel is pressed, the servo motor in this selection box changes over the vent selection damper to the
foot side or the defroster side by way of a link and lever.

72-41
115ZV-2 Function & Structure Operator Station Group
Air Conditioner

Compressor and magnetic clutch

Compressor specifications

Compressor

Piston

Discharge valve

Discharge valve

74

10

Suction valve
Diagonal plate

Suction/compression action

11
97ZV72060

1.
2.
3.
4.
5.
6.

Suction valve

Compressor
Magnetic clutch
Rotor
Stator
Hub
Pulley

7.
8.
9.
10.
11.

Coil
Bearing
Shaft
Dust proof cover
Pressure relief valve

The compressor is driven by the V belt from the engine


by way of the magnetic clutch. The compressor draws in
and compresses the gaseous refrigerant at low temperature and low pressure which deprived heat of the air
inside the cab in the evaporator and was vaporized to
make the gaseous refrigerant be at high temperature
and high pressure, then feeds it to the circuit on the high
pressure side again. Five pairs of pistons (with ten cylinders) reciprocate in the same direction with the shaft in
accordance with rotations of the shaft.
Accordingly, when one piston of a pair is in the compression stroke, the other one is in the vacuum stroke.
The compressor is lubricated by the compressor oil contained in the gaseous refrigerant and the oil splashed by
the diagonal plate.
Accordingly, if the refrigerant quantity decreases, the
compressor will seize from oil starvation. To prevent seizure, a pressure switch is provided in the circuit so that
the power supplied to the magnetic clutch is shut down
and the compressor is protected when the refrigerant
quantity decreases.

97ZV72061

Model

10S150

Cylinder diameter

32 (1.26")

Stroke

20.8 mm (0.82")

Number of cylinders

10

Cylinder capacity

167.3 cm3 (10.21"3)

Maximum allowable number of rotations

6,000 min-1

Lubricating oil

ND-OIL8

Lubricating oil quantity

180 cm3 (11"3) [6 oz]

72-42
Function & Structure Operator Station Group
Air Conditioner

Magnetic clutch

Magnet clutch specifications


Model
S

Pulled
force
Switch
Iron piece
(rotor)

Stator

Power
supply
Magnetic
force
N

Principle of magnetic clutch

97ZV72062

The magnetic clutch controls mechanical connection


between the engine and the compressor. When the
engine is rotating and the air conditioner ON/OFF switch
is ON, if the temperature inside the cab reaches or
exceeds the temperature set by the temperature setting
switches, the magnetic clutch stops or drives the compressor.

Suction face

Pulley
Stator coil

Hub

Rotor

Stator
Ball bearing

Magnet clutch
97ZV72063

The hub of the magnetic clutch is fitted onto the shaft of


the compressor. While the compressor is not driven, the
hub is separated from the rotor and only the pulley is
rotating. When the air conditioner switch is set to ON,
the current flows in the stator coil, the stator works as a
magnet and engages the hub, then the compressor
rotates together with the pulley.
When the current applied on the stator coil is set to OFF,
the hub is not immediately separated but rotates
together with the pulley because the pulley has residual
magnetism. Accordingly, clearance is provided between
the hub and pulley so that they are not in close contact
with each other during disengagement. This clearance
is called air gap.

L50T

Voltage

DC 24 V

Power consumption

40 W (1.67 amps)

Drive belt

V-ribbed belt (six ribs)

Air gap

0.50.15 mm (0.020" 0.006")

72-43
115ZV-2 Function & Structure Operator Station Group
Air Conditioner
Troubleshooting the compressor and magnetic
clutch
Item

Symptom

Suction or exhaust valve is


damaged. *

- Compressor temperature is abnormally high.


- High pressure is abnormally low, and low
pressure is abnormally high.
- Air bubbles cannot be seen through sight
glass.

Cause

Action

- Suction or exhaust valve

- Repair/replacement

Clutch draw voltage is low.

- Stator coil

- Replacement

Power is not supplied to


stator coil.

- Wiring on main body


- Control amplifier
- Pressure switch

- Repair
- Replacement
- Replacement

- Magnetic clutch

- Replacement

Compressor main body is


defective
(seized, etc.).

- Shaft, piston

- Repair/replacement

Clutch bearing is damaged.

- Clutch bearing

- Replacement

- Magnetic clutch

- Replacement

V belt is slack.

- V belt

- Adjustment/replacement

Compressor main body is


defective.

- Internal compressor trouble

- Repair/replacement

- V belt

- Adjustment/replacement

- Abnormal sounds are made while clutch is


turned on.

Gap between hub and rotor


is large.

Contact or slippage caused


by too small gap between
hub and rotor.

V belt is slack.

- Compressor does not rotate.


(Air in cab does not become cool enough.)

- Abnormal sounds are made while clutch is


turned off.

- Abnormal sounds are made while clutch is


turned on.

* This can be the result of "liquid charging". Do not liquid charge as a compressor cannot compress liquid; this will damage it.

72-44
Function & Structure Operator Station Group
Air Conditioner

Condenser unit

Condenser fan motor


The condenser fan motor used to cool down the condenser is mounted on the condenser together with a fan
shroud.

Condenser
Blower assembly
Resistor
Cover

Fan motor
95V2U72002

Each condenser unit consists of a condenser, a condenser fan motor and a resistor. Two condenser units
are arranged in series with the piping.
The condenser units cool down the gaseous refrigerant
at high temperature and high pressure sent from the
compressor, and change it into liquid refrigerant.

Condenser
The condenser consisting of tubes and fins cools down
the gaseous refrigerant at high temperature and high
pressure (70C, 1,618 kPa (16.5 kgf/cm2)) (158F (235
psi)) sent from the compressor, and change it into liquid
refrigerant during passing tubes.

Condenser specifications
Voltage

DC 24 V

Power consumption

80 W (3.4 amps) x 10 %

Air quantity

1,75010 m3/Hr (61,800"3/Hr)

Number of rotations of motor

2,200 min-1 (rpm)

72-45
115ZV-2 Function & Structure Operator Station Group
Air Conditioner

Resistor
The resistor controls rotation of the condenser fan motor
in two steps in accordance with a command given by
the fan control pressure switch (medium pressure
switch).
Resistor specifications
Resistance

4.0

Troubleshooting the condenser unit


Item

Symptom

Heat radiation quantity is


insufficient due to blockage*. Both high pressure and low pressure are
abnormally high, and air does not become
Rotation of condenser fan
cool enough.
motor is defective.

Cause

Action

- Blockage or crushed fins

- Clean or replace condenser

- Fan motor

- Repair or replace motor

Blockage / condenser airflow

High pressure is abnormally high, low pressure is abnormally low, and air does not
become cool enough.
Air bubbles can be seen through sight glass.

- Internal to condenser fins

- Clean or replace condenser

Gas leak

Both high pressure and low pressure are


abnormally low, and air bubbles can be seen
through sight glass.

- Leaks at joints
- Cracks in main body

- Tightening
- Repair or replacement

* It is important to check the fan blades also as these can become bent or packed with dirt, making them ineffective.

72-46
Function & Structure Operator Station Group
Air Conditioner

Receiver dryer

Desiccant

Refrigerant inlet
Refrigerant outlet

Desiccant

If moisture is present inside the cooling circuit, the compressor valve and oil may deteriorate, metal parts within
the circuit may corrode, or moisture may be frozen
inside expansion valve which may clog the circuit. To
prevent such failure, synthetic zeolite (drying agent) is
positioned inside the air conditioner and acts as a desiccant suitable to the circuit so that it absorbs moisture
entering the circuit during installation or refrigerant
charging.
When the expansion valve is often frozen by moisture
(icing), the desiccating agent does not have enough
absorption ability. When this happens, the receiver must
be replaced.

Strainer

Desiccant specifications
Receiver tube

Receiver tank

97ZV72065

The receiver dryer consists of a receiver tank, desiccant, strainers, and a receiver tube.

Receiver tank
In the air conditioner, the number of rotations of the
compressor changes and the proper refrigerant quantity
in the cooling circuit fluctuates in accordance with fluctuation of the number of revolution of the engine.
The receiver tank receives such fluctuation. When the
cooling circuit does not require much refrigerant, the
receiver stores temporarily excess refrigerant. When the
cooling circuit requires much refrigerant, the receiver
tank supplies refrigerant from its receiver tube to the circuit.
In addition, the receiver tank stores a reserve of refrigerant in order to take balance of charging of the refrigerant
and respond to any minute leaks of the refrigerant
caused by permeation through rubber hoses.

Capacity

550 cm3

Desiccating agent

Synthetic zeolite

Desiccating agent capacity

290 g

IMPORTANT
If parts of the cooling circuit are removed and left for
a long time for repair or another reason, the desiccant
absorbs moisture contained in the air and loses its
absorption performance, and the receiver dryer
should be replaced. To prevent this, after parts are
removed, all openings should be plugged.

72-47
115ZV-2 Function & Structure Operator Station Group
Air Conditioner

Strainers
If dusts enter the circuit, the expansion valve may be
clogged, the compressor may be damaged, and the
cooling function may be deteriorated.
Strainers are provided to prevent dusts from flowing with
in the refrigerant.
The strainers cannot be cleaned. When they are considerably clogged (in this case, the high pressure
increases and the low pressure decreases), the entire
receiver dryer should be replaced.
Troubleshooting the receiver tank
Item

Symptom

Cause

Action

Icing

- At first, air in cab will cool down, but after a


short time no longer will cool properly.

- Desiccating agent in receiver

- Replacement of receiver dryer

Blockage in strainers

- High pressure is excessively high, low pressure is excessively low, and air does not
become cool enough*.

- Blockage in strainers

- Replacement of receiver dryer

*A means to test this is to check the temperature between the inlet and outlet of receiver dryer. If it drops more than it should the dryer is
plugging and should be replaced.

72-48
Function & Structure Operator Station Group
Air Conditioner

Sight glass

Pressure switches

Sight glass

Terminal

Receiver joint

Contact area

Receiver dryer

97ZV72066

This sight glass is installed on the receiver joint located


on the top of the receiver dryer. Only through this sight
glass, the refrigerant quantity inside the circuit can be
visually checked.

WARNING
Possible freezing of eye tissue.
Always wear protective eyewear when doing a visual
inspection.

97ZV72067

The pressure switch detects the pressure on the high


pressure side of the cooling circuit, and stops the compressor when detecting any abnormality so that damage
of the equipment in the cooling circuit can be prevented.
There are three types of pressure switches, high pressure type, medium pressure type and low pressure
type, which function as shown in the table below.

72-49
115ZV-2 Function & Structure Operator Station Group
Air Conditioner

Switch

Switching pressure
kPa (kgf/cm2) (psi)

Function

Switch operation
confirmation method

Causes of abnormal
pressure

Pressure switch coupler

High
pressure
switch

When pressure between


compressor and expansion
valve becomes abnormally
high, this switch shuts down
power supplied to compressor
magnetic clutch to protect
circuit.

ON

2,550
(26)
(370)

3,136
(32)
(455)

D
B

OFF

Heat radiation of condenser


is insufficient due to clogging
in condenser or defective
rotation of condenser fan*.
*A damaged fan blade would
produce a similar symptom.

Check conductivity
between A and B.

Medium
pressure
switch

When detecting fluctuation of


pressure between compressor
and expansion valve, this
switch gives a signal to control
amplifier about whether to
rotate condenser fan motor at
low speed or high speed.
While this switch is ON, fan
motor rotates at high speed.
While this switch is OFF, fan
motor rotates at low speed.

Low
pressure
switch

When pressure between


compressor and expansion
valve becomes abnormally low
due to refrigerant leak, this
switch shuts down power
supplied to compressor
magnetic clutch to prevent
seizure of compressor caused
by insufficient compressor oil
which decreased together with
refrigerant.

1,519
(15.5)
(220)

ON
OFF
1,225
(12.5)
(178)

Check conductivity between C and D


in pressure switch coupler shown
above.

226
(2.3)
(33)

ON

Check conductivity between A and B


in pressure switch coupler shown
above.

OFF

Refrigerant leak from a part


of circuit.

196
(2.0)
(28)

Troubleshooting the pressure switch


Item
Insufficient cooling

Gas leak

Symptom

Cause

Action

- Condenser fan motor does not change its speed


(to high speed).

- Medium pressure
switch

- Replacement

- Even when abnormal high pressure (3,136 kPa (32 kgf/cm2)


(455 psi)) occurs, compressor does not turn off.
- Even when gas (refrigerant) has run short, compressor does
not turn off.

- High or low pressure switch*

- Replacement

*If abnormally high pressure occurs while the high pressure switch is non-functioning, the equipment in the cooling circuit may be damaged.
The pressure relief valve releases the refrigerant to the atmosphere in order to prevent equipment or personnel damage.

72-50
Function & Structure Operator Station Group
Air Conditioner

Pressure relief valve

Flow rate
(L/min)
113

Gas discharge route while valve is operating


97ZV72071

This valve mounted on the high pressure side of the


compressor service valve releases the refrigerant to the
atmosphere when abnormal high pressure occurs.

Pressure
28.1
2,756
400

35.0
3,430
500

42.4
4,158
600

(kgf/cm2 )
(kPa)
(psi)

Characteristics drawing of
relief valve operation
97ZV72069a

Pressure relief valve

97ZV72070

IMPORTANT
When the refrigerant quantity inside the cooling circuit is correct, the pressure switch always remains
ON even if the compressor is stopped because the
refrigerant pressure is approximately 588 kPa (6.0
kgf/cm2) (85 psi) as far as the outside air temperature
is around 25C (77F).
When the outside air temperature becomes 0C
(32F) or less, the pressure switch for low pressure
detection turns off even if the refrigerant quantity is
proper because the refrigerant pressure becomes
196 kPa (2.0 kgf/cm2) (28 psi) or less. As a result, the
compressor does not work.
It means that the pressure switch for low pressure
detection functions also as a thermostat which
detects the outside air temperature.

72-51
115ZV-2 Function & Structure Operator Station Group
Air Conditioner

Relay A

Relay B

97ZV72072

Relay A specifications

97ZV72099

Relay B specifications

Rated voltage

DC 24 V

Rated voltage

Rated current

16 A

Rated current

DC 24 V
11 A

Rated coil current

0.1 A

Rated coil current

0.075 A

Troubleshooting the relay


Item

Coil wire is broken.


Contact is melted down.

Symptom

Cause

- Blower motor does not rotate at all.


- Blower motor remains rotating.

- Blower motor main


relay

- Blower motor does not rotate at high speed.


- Blower motor remains rotating at high speed.

- Blower motor Hi
relay

- Blower motor does not rotate at medium speed Me2.


- Blower motor speed does not change from Me2 to Me1.

- Blower motor Me2


relay

- Blower motor does not rotate at medium speed Me1.


- Blower motor speed does not change from Me1 to low speed.

- Blower motor Me1


relay

- Both condenser fans do not rotate.


- Both condenser fans remain rotating.

- Condenser fan relay

- When condenser fan is at high pressure, it does not rotate at


high speed.
- When condenser fan is at low pressure, it remains rotating at
high speed.

- Condenser fan relay


1

- Compressor magnetic clutch does not turn on.


- Compressor magnetic clutch remains ON.

- Compressor clutch
relay

Action

- Replacement

72-52
Function & Structure Operator Station Group
Air Conditioner

Refrigerant hose

WARNING
Burst hazard
These hoses operate at high pressure for HVAC systems and must not be replaced with substandard
hoses.

Outer layer
Reinforcing layer

Use only OEM replacement hoses or hoses of the


same rating as OEM replacement hoses.
Mouth ring
Inner layer
Intermediate layer

97ZV72073

White line and "R134a" indication

97ZV72074

As shown in the figure on the above, the refrigerant


hose consists of the outer layer, the reinforcing layer,
the intermediate layer and the inner layer, and the
mouth ring is crimped.
Region

Material

Outer layer

Ethylene propylene rubber

Reinforcing layer

Polyester

Intermediate layer

Chlorinated butyl rubber

Inner layer

Nylon

The mouth ring of this hose is changed and the symbol


"R134a" is indicated on this hose as shown in the figure
on the right.

IMPORTANT
Never use any other hose or any other refrigerant.
Otherwise, refrigerant may leak.

72-53
115ZV-2 Function & Structure Operator Station Group
Air Conditioner

Charge of refrigerant
WARNING
Serious accidents may occur in the refrigerant charging work.
Observe the following contents.
- Only trained or experienced specialists having sufficient knowledge on the contents of the work
should be allowed to perform the refrigerant charging work.
- If the refrigerant comes into contact with your eyes,
you may lose your eyesight. Make sure to wear
protective goggles.
- The refrigerant in the liquid status is at low temperature (approximately -30C (-22F)). If it splashes
on your skin, you may suffer from frostbite. Pay
close attention when handling it.
- If the refrigerant (Refrigerant R134a) touches a hot
object (approximately +400C or more), it decomposes and generates harmful substances.
Never release the refrigerant in a room where ventilation is bad and there is a hot object or a fire
(such as in the presence of a stove).
- In order to protect the environment, do not release
the gaseous refrigerant to the atmosphere.

CAUTION
Serious accidents may occur during the refrigerant
charging work.
Observe the following contents.
- When warming a service can to charge the refrigerant, make sure to open the low pressure valves
of the service can and the gauge manifold, then
warm it with hot water of 40C (104F) or less (temperature at which you feel warm when putting your
hand into it).
Never warm the can with boiling water or overheat
it with open fire. If the can is treated in such a way,
it may burst.
- When charging the refrigerant after having started
the engine, never open the high pressure (Hi)
valve. If it is opened, the high pressure gas may
flow in the reverse direction, and the service can
and the hose may burst.

WARNING
Serious accidents may occur during storage and
transportation of a service can.
Observe the following contents.
- A service can accommodates high pressure gas in
the saturated liquid status. If the temperature rises,
the pressure may increase drastically and the can
may burst. Keep the temperature of the service
can at 40C (104F) or less.
Make sure to keep the can away from hot objects
or fire.
- During storage, make sure to avoid direct sunlight,
and store the can in a dark and cool place.
- Inside the closed cab (including trunk), the air temperature may rise considerably due to solar heat,
etc., and may become dangerously temperature
even in winter if the closed cab is exposed to direct
sunlight. Never put the can inside the cab.
- If the service can suffer from flaws, dents and
deformations, its strength deteriorates. Never hit or
drop it. And never throw or drop a package of cans
while loading or unloading it.
- Keep the can away from the reach of children.

IMPORTANT
- It is prohibited by law to reuse service cans. Never
reuse them.
- Pay close attention so that air and dusts do not
enter into the cooling circuit.
- Never charge the refrigerant excessively.
- The air conditioner is so designed as to be used
with Refrigerant R134a. Never charge any other
refrigerant such as Freon R12.
- If the compressor oil (ND-OIL 8) adheres to the
painting face or the resin area, the painting may
peel off or the resin may be damaged. If so, wipe it
off soon.
- Tighten the piping at the specified torque.

72-54
Function & Structure Operator Station Group
Air Conditioner

Work procedure
The refrigerant charging process is mainly divided into
"refrigerant evacuation procedure" and "gas charging
procedure" as shown below.

Refrigerant evacuation procedure


The "refrigerant evacuation process"* eliminates moisture present inside the cooling circuit. If the moisture
remains inside the circuit, it may cause varied problems
even if its quantity is extremely small: The moisture may
freeze inside the expansion valve during operation, and
may block the circuit or generate oxidation. To prevent
such problems, the refrigerant containing air inside the
cooling circuit should be evacuated, and the moisture
inside the circuit should be boiled and evaporated so
that all moisture is eliminated before pure refrigerant is
recharged into the circuit.
*May be referred to as "air evacuation procedure" since it contains air
which also contains water that can cause system damage as noted.

Gas charging procedure


The "gas charging procedure" charges the refrigerant
as gas into the circuit while in a vacuum state. The gas
charging process not only affects the cooling ability of
the air conditioner but also affects the system component life.*
If the refrigerant is charged too quickly or in a liquid
state, pressure inside the circuit may become extremely
high and the cooling ability may deteriorate. If the refrigerant charging volume is too low, the lubricating oil for
the compressor may not circulate smoothly and compressor pistons may seize and lock up the compressor.
Because the gas charging process involves high pressure gas, it is extremely dangerous if it is not done correctly.
Observe the work procedure shown below and the cautions, and charge the refrigerant correctly.
*Note
Liquid charging destroys a compressor. Never permit
entry of liquid refrigerant.

Charging procedure
1. Charge the system with the required amount of gas
by weight, and check for leaks by letting the HVAC
system sit static and permit pressure to equalize.
2. Check the system pressure in comparison to the
ambient temperature. If acceptable, go to the next
step (3).
3. Turn on the engine, run at 1,200~1,500 rpm.
4. Turn on the HVAC air condition system, making
sure that the heat is off and A/C is set with fan on
high.
5. Let the HVAC system run on coldest setting until all
parts are cold saturated; this should take about 30
minutes or more.
6. Check the temperature that is coming from the
vents of the HVAC system inside the cab. Check
the performance in the operating pressure and temperature chart.
7. Either remove or install more refrigerant depending
upon the findings.
Observe the work procedure and cautions shown below,
and charge the refrigerant correctly.
The system should operate within about 5% of the
parameters. Be sure that the condenser is clear, evaporator is clean and the fans are all working as they should
with good airflow in the system.
Note
If the inside of the cab become cold during the charging
process, the compressor magnetic clutch turns off and
system charging is disabled.
When charging, completely open the cab doors.
This will keep the system from turning off and on.

72-55
115ZV-2 Function & Structure Operator Station Group
Air Conditioner

Charging procedure chart


Start evacuation.
20~30 min
Refrigerant
evacuation
process

Stop evacuation.

-750 mmHg (-30" Hg) or less


If too little vacuum, repair leaking
connection*

Leave system untouched for 5 min.


Check pressure.

*It is possible that system may need pressurized


and tested for leaks.

Stop when gage indicates excessive pressure


(air entry)

When gage indicates a normal value


Charge refrigerant gas.

Gas
charging
process

Check for gas leak.

Charge refrigerant.

Check for gas leak.

Performance test

Charge gaseous refrigerant until gauge pressure


reaches 98 kPa (1 kgf/cm2) (14 psi). Check for leaks.

Note
A full charge should be about 20.1 lbs (90050 g) of
refrigerant.
As a general guideline, with engine off and HVAC
system static, the pressure in the system should be
about 85 psi (588 kPa) (6.0 kgf/cm2) with the pressure has equalized between the low and high pressure side.
95ZVE72042

72-56
Function & Structure Operator Station Group
Air Conditioner

Refrigerant charging tools

Charging hose and quick connectors

Recovery and recycling unit

Gauge manifold*

Low pressure
charging hose
(blue)
95ZV72024

It is against Federal Regulations* in the United States to


release refrigerant to atmosphere. A recovery and recycling unit must be used to capture the refrigerant so as
not to release it into the atmosphere.
*Refer to section 609 of the clean air act at www.epa.gov.

It is used for the following;


1.
2.
3.
4.
5.

Recover the refrigerant.


Filter the refrigerant.
Measure the refrigerant weight.
Remove trapped non compressible gases (air).
Measure the refrigerant to install in system by
weight.
6. Measure the pressure of the refrigerant in system.
7. Measure ambient temperature.
8. View bubbles in system if there are any.
Read and understand the Operation Manual for the
recovery and recycling machine.

IMPORTANT
Only use a vacuum pump if the system is already
open to atmosphere and refrigerant has completely
left the system.

High pressure
charging hose
(red)

Quick connector
(Lo)

Center charging hose


(green or yellow)
Quick connector
(Hi)

97ZV72077

These different colored hoses are used to evacuate the


air and charge the gas. (The colors may be different
depending on the manufacturer.)
Red hose
Connects the high pressure valve of the gauge manifold
and the high pressure charging valve (with "H" mark on
its cap) of compressor outlet hose.
Blue hose
Connects the low pressure valve of the gauge manifold
and the low pressure charging valve (with "L" mark on
its cap) of the compressor inlet hose.
Green or yellow hose
Connects the center valve of the gauge manifold and
the vacuum pump (or the service can valve).
*Gauge manifold may be used with vacuum pump or recovery unit.

72-57
115ZV-2 Function & Structure Operator Station Group
Air Conditioner

Gauge manifold

Leak detector

Many recovery and recycling units are equipped with a


gauge manifold, which is very similar to the gauge manifolds that were used for earlier application refrigerant
handling systems.
Typically, the low pressure side hose color is blue, the
charging hose color is yellow (may be light green), and
the high pressure side hose color is red.
These are generally integrated into the recovery and
recling unit.
85V2U72007

Low pressure
gauge

High pressure
gauge

A leak detector find areas where refrigerant traces are


leaking and sounds an alarm to alert the technician of
areas of leakage.
Gauge manifold

Low pressure
valve
Low pressure
charging hose
Center valve
mounting nipple Center charging
hose mounting
nipple

High pressure
valve
High pressure
charging hose
mounting nipple
97ZV72078

It is used to evacuate the air and charge the gas, and


equipped with a high pressure gauge, a low pressure
gage, plus valves and hose mounting nipples as shown
in the figure on the above.
Some gauge manifolds are equipped with sight glasses.
These are used to check for bubbles in the refrigerant.
Excessive flow of bubbles may indicate:
1. Low pressure.
2. Leak to atmosphere (air ingestion) when in vacuum.
3. Boiling action, perhaps due to pressure changes.

72-58
Function & Structure Operator Station Group
Air Conditioner

Cautions on handling of quick connector and


charging valve
When discharging the refrigerant, use a quick connector.

Precautions
Quick connector

1. Connecting the quick connector.

Screwdriver, etc.
Sleeve

"Click" sound (OK)

Valve pin

(A)
Spring

Charging valve

Charging valve

97ZV72082
97ZV72080

Slide the sleeve upward, push the quick connector


against the charging valve, press and hold securely
part (A) until a click is heard, then slide the sleeve
downward.

IMPORTANT
- Push the quick connector against the charging
valve vertically.
- If refrigerant remains inside the charging hose, the
quick connector may not be easily connected.
2. Disconnecting the quick connector

Sleeve

"Click" sound (OK)

(A)

(B)

97ZV72081

While pressing and holding the part (A) of the quick


connector, slide sleeve upward to disconnect quick
connector.

IMPORTANT
If you push the valve pin with a considerable force
[294 kPa (3 kgf/cm2) (43 psi)] with a screwdriver, etc.,
the spring may come off and the refrigerant may leak.
Never do this.

72-59
115ZV-2 Function & Structure Operator Station Group
Air Conditioner

Refrigerant charging procedure

Valve setting
Lo
Hi
Closed Closed

Air evacuation work

High pressure valve

WARNING
If hoses are connected incorrectly, serious accidents
may occur.
Observe the following.
- Never confuse connection of hose to the high pressure side and the low pressure side of the gauge
manifold.

Low pressure valve


(red)
(blue)
(green)

(Hi)

Recovery and recycling unit

(Lo)
Charging valve
on high pressure
side (located on
receiver dryer)
Vacuum pump shown
Compressor (stopped)

A refrigerant recycle and recovery unit


may be used.

95ZVE72045

95ZV72024

It is against Federal Regulations* in the United States to


release refrigerant to atmosphere. A recovery and recycling unit must be used to capture the refrigerant so as
not to release it into the atmosphere.
*Refer to section 609 of the clean air act at www.epa.gov.

1. Connecting the gauge manifold

CAUTION
Close both low and high pressure valve, as seen in
"a" below.

With system "OFF";


(a) Close both the high pressure (Hi) valve and the low
pressure (Lo) valve of the gauge manifold.
(b) Connect the charging hose.
Red hose
To be connected between the high pressure (Hi)
valve of the gauge manifold and the high pressure
charging valve.
Blue hose
To be connected between the low pressure (Lo)
valve of the gauge manifold and the low pressure
charging valve of the compressor.
Yellow or green hose
To be connected between center valve of gauge
manifold and recovery unit (equipped with vacuum
pump).

IMPORTANT
Connect quick connectors to both the high pressure
and low pressure sides before starting air evacuation.
The check valve of a quick connector cannot hold
vacuum status. If a side of quick connector is not connected, a vacuum condition cannot take place.

72-60
Function & Structure Operator Station Group
Air Conditioner
2a. Evacuating the system with a vacuum pump
When pulling a vacuum with a vacuum pump on a system that has been open due to replacing major components.

2b. Evacuating the system with a recycling and recovery unit.

After air evacuation Valve setting


Lo
Hi
Lo
Hi
for 30 minutes
Closed Closed
OpenedOpened
Valve setting

High pressure valve

Low pressure valve


95ZV72024

(red)
(blue)

(green)

(Hi)
(Lo)
Charging valve
on high
pressure side
Vacuum pump (operating)
Compressor (stopped)

(stopped)
95ZVE72046

(a) Open both the high pressure (High) valve and the
low pressure (Low) valve of the gauge manifold.
(b) Turn on the switch of the vacuum pump, and evacuate until the degree of vacuum becomes -750 mm
Hg (-30" Hg) for about 20~30 minutes.
(c) After finishing evacuation, close both the high pressure valve and the low pressure valve of the gauge
manifold. Then, turn off the switch of the vacuum
pump.

IMPORTANT
If you stop the vacuum pump before closing each
valve of the gauge manifold, refrigerant from vacuum
unit and tank is released to the atmosphere. It is
important to first close both high and low side valves.

Each manufacture of recycling and recovery units provide operating instructions for their units. Read, understand and closely follow operating instructions as
provided.

72-61
115ZV-2 Function & Structure Operator Station Group
Air Conditioner
3. Checking for leaks after vacuum has been drawn
Valve setting

Leave for 10 minutes or more


as per EPA regulations
Lo
Hi
Pointer of low
Closed Closed
pressure gauge
moves toward "0".
Low pressure gauge
0

Moves
toward "0".

Tighten connection areas


of piping.
97ZV72085

After a vacuum has been pulled on system;

Refrigerant charging process


This section describes a static charging procedure with
the engine in "OFF" and compressor not turning.
Do not run engine until high and low pressures are
equal so that no damage is done to the compressor.
The illustrations below show use of a gauge manifold
assembly. This is not the preferred method in the USA
due to EPA regulations against purging refrigerant to
atmosphere. Use of a recovery and recycle unit is best.
Carefully follow instructions with recovery unit.
Valve setting
Lo
Hi
Closed Closed

Leave the circuit for 5 minutes or more with H and L


valves of gauge manifold closed. Then, make sure that
the needle of each gauge does not move.
If the needle of the gauge moves toward "0", a leak has
occurred somewhere in the circuit. Tighten the connection areas of the piping, evacuate the system again,
then make sure that there is no leaks.

IMPORTANT
Make sure to tighten the connection areas of the piping at a specified tightening torque.
For the tightening torque, refer to the volume "Maintenance Standard".

Blue (low)

Red
(high)

Open the
service canister valve.

Charging hose

(green or yellow)

R134a

Service
canister
97ZV72086

IMPORTANT
Never purge or vent refrigerant to atmosphere. (EPA)

72-62
Function & Structure Operator Station Group
Air Conditioner

Valve setting
Lo
Hi
OpenedOpened

1. Charging the refrigerant from the high pressure


side with the engine in the "OFF position.

Valve setting

After 1~1.5 service


cans are charged

Lo
Hi
Closed Closed

High pressure valve

(a) After evacuation, disconnect the charging hose


(green or yellow) of gauge manifold from vacuum
pump, and connect it to the service canister.
(b) Purging air from lines

Low pressure
valve
(red)

(blue)

(green)

(Lo)

(Hi)

Charging valve
on high pressure
side

Compressor
(stopped)
R134a

Service can valve


(opened charge
closed)
95ZVE72052

WARNING
If the refrigerant were changed from the high pressure side, the refrigerant would flow in reverse direction and the can and the hose may be burst if you
start the engine and operate the compressor. Never
start the engine in this condition.

IMPORTANT
If you charge refrigerant with refrigerant canister
placed upside down liquid will exit canister, refrigerantis sucked into the compressor in a liquid state.
This will damage the compressor. Charge only with
refrigerant gas.

Open the service canister valve very slightly with


low and high pressure manifold valves closed.
Open both high and low side valves so that lines
are charged. Connect lines to HVAC system. A
small amount of trapped air will escape from the
lines, as air is discharged by the refrigerant pressure. EPA says that release of this tiny bit of air that
is very small is ok.
(c) WITH ENGINE "OFF"; Open tank canister valve
and charge the gaseous refrigerant until gauge
pressure read 98 kPa (1 kgf/cm2) (14 psi). (This
should take about one to one and half one lb service cans. If using scale, add one to one and a half
lbs.)
(d) After charging, close the low and high pressure
valves of the gauge manifold and the service can
valve.
2. Check for gas leak with a leak detector
Check for gas leak in the circuit using a leak tester,
etc. If a leak is detected, repair leak as required. If
located at connections, tighten the connection area.

IMPORTANT
Make sure to tighten the connection areas of the piping at a specified tightening torque.
For the tightening torque, refer to the volume "Maintenance Standard". Do not overtighten or it will worsen.

72-63
115ZV-2 Function & Structure Operator Station Group
Air Conditioner
3. Charging the refrigerant - low pressure side - e/g
"ON".
Valve setting
Lo
Hi
Opened Closed

Charge the refrigerant


until air bubbles seen
through the sight glass
disappear.

(c) Start the engine, and increase the number of rotations to approximately 1,500 min-1(rpm).
(d) On the control panel, set the fan speed to high and
set the air flow volume to maximum cold, and set
the vent port temperature switches to the coldest
status.

Valve setting
Lo
Hi
Closed Closed

High pressure valve

Low pressure
valve

(e) Open the low pressure valve of the gauge manifold


and service canister valve to charge the refrigerant.
When air bubbles seen through the sight glass of
the receiver dryer disappear, charge the refrigerant
further more by 150~250 g.

IMPORTANT

(red)

(blue)

(green)

(Lo)

(Hi)

Charging valve
on high pressure
side

Compressor
(On-load)
R134a

Service can valve


(opened charge
closed)
95ZVE72052

When replacing service canister while charging


refrigerant, connect the line as described earlier so
as to not have air in the line.
(f)

After charging, close the low pressure valve of the


gage manifold and the service can valve. Then,
stop the engine.
Refrigerant quantity to be charged (guideline)
90050 g (2.00.1 lb)

Refrigerant
quantity

Proper

Gas bubbles are few.


(When the number of rpms of the
engine is gradually increased from the
idle status to 1,500 min-1, gas bubbles
disappear.)

Too much

Gas bubbles are not seen in the flow at


all. System is over-pressurized.
(In this case, both the high pressure
and the low pressure are high, and the
cooling ability is deteriorated.)

Insufficient

Many gas bubbles are seen in the flow.


(Gas bubbles visibly seen constantly.)

Sight glass

Receiver joint

Receiver dryer

97ZV72066

(a) Make sure that the high and low pressure valves of
the gauge manifold and service canister valve are
closed.
(b) If the inside of the cab becomes cold during the
charging process, the compressor magnetic clutch
turns off and system charging is disabled.
When charging, completely open the cab doors.
This will keep the system from turning off and on.

Sight glass situation

72-64
Function & Structure Operator Station Group
Air Conditioner
4. Guidelines to determine quantities of refrigerant
charge
Use the following table to determine the refrigerant
charge quantity.
Item

Criteria

Doors

Completely open

Temperature control switches

Maximum cooling

Blower speed

High

Inside/outside air selection

Inside air

Number of rotations of engine

1,500 min-1

Air conditioner switch

ON

Pressure on high pressure side

1,862 kPa (19 kgf/cm2) (270 psi)


or less

IMPORTANT
- If outside air temperature is high (40C/104F or
more) or if the pressure on the high pressure side
is 1,862 kPa (19 kgf/cm2) (270 psi) or more when
the judgement condition above is set, perform the
following so that the pressure becomes 1,862 kPa
(19 kgf/cm2) (270 psi) or less, then check the
refrigerant quantity.
- Close the doors completely, and set the
blower fan to the low speed (by pressing
the Lo switch).
- Use a shaded area or a place indoors
away from sunlight.
- If you turn on the air conditioner while the refrigerant quantity is extremely low, lubricant in the compressor may be insufficient and a failure such as
seizure of the compressor may occur. Never do
this.
- If the refrigerant quantity is over charged, cooling
may be insufficient or the pressure inside the circuit may become abnormally high (which is dangerous). Never do this.

5. Disconnecting the gauge manifold

Sleeve

"Click" sound (OK)

(A)

(B)

97ZV72081

After inspecting the refrigerant charge, disconnect


the charging hose from the high and low pressure
charging valves using the following procedure.
(a) While pressing and holding part (A) of the quick
connector, slide sleeve upward and disconnect the
quick connector.
(b) Attach a cap to each of the high and low pressure
charging valves.

72-65
115ZV-2 Function & Structure Operator Station Group
Air Conditioner

Troubleshooting using the gauge manifold


Normal status

<Low pressure side>


215~275 kPa
(2.2~2.8 kgf/cm2)
(31~40 psi)

Condition
After warming up the engine, check the pressure under
the following condition.
- Doors
Completely open

<High pressure side>


1,470~1,765 kPa
(15~18 kgf/cm2)
(213~255 psi)

- Inside/outside air selection


Inside air
- Number of rotations of engine
1,500 min-1
- Temperature at suction port of air conditioner
30~35C (86~95F)
- Blower speed
High
- Temperature control switches
Maximum cooling

97ZV72091

Pressure values indicated by gauges in the normal status


A/C suction port temperature
20~25C (68~77F)
25~30C (77~86F)
30~35C (86~95F)
35~40C (95~104F)

Pressure

Pressure value by gauge

High pressure side

1,000~1,215 kPa

Low pressure side

127~167 kPa

High pressure side

1,215~1,470 kPa

Low pressure side

167~215 kPa

High pressure side

1,470~1,784 kPa

Low pressure side

215~275 kPa

High pressure side

1,784~2,146 kPa

Low pressure side

275~353 kPa

(10.2~12.4 kgf/cm 2) (145~176 psi)


(1.3~1.7 kgf/cm 2)

(18~24 psi)

(12.4~15.0 kgf/cm 2) (176~213 psi)


(1.7~2.2 kgf/cm 2)

(24~31 psi)

(15.0~18.2 kgf/cm 2) (213~258 psi)


(2.2~2.8 kgf/cm 2)

(31~40 psi)

(18.2~21.9 kgf/cm 2) (258~310 psi)


(2.8~3.6 kgf/cm 2)

(40~51 psi)

72-66
Function & Structure Operator Station Group
Air Conditioner

When the refrigerant charge quantity is insufficient


<Low pressure side>
49~98 kPa
(0.5~1.0 kgf/cm2)
(7~14 psi)

<High pressure side>


686~981 kPa
(7~10 kgf/cm2)
(100~144 psi)

When the refrigerant does not circulate (due to


clogging in the cooling circuit)
<Low pressure side>
Negative value

<High pressure side>


490~588 kPa
(5~6 kgf/cm2)
(71~85 psi)

97ZV72092

Symptom

Cause

- Pressure is low on
both low and high
pressure sides.

- Refrigerant
quantity is
insufficient.

- Gas bubbles go
through sight glass
continuously.

- Gas is
leaking.

- Temperature of
blown air is not cold.

Inspection/action point
- Find and repair
leaks.
- Repair leak. Add
refrigerant.
- If pressure indicated
by gage is around
"0", detect and
repair leaks, vacuum system and
recharge.

97ZV72093

Symptom

Cause

Inspection/action point

- If cooling circuit is
completely blocked,
needle on low pressure side indicates a
vacuum immediately.

Clogging in cooling circuit

- Inspect receiver
dryer, expansion
valve, etc. (Temperature is different
between IN and
OUT of failing part.)

- If cooling circuit is
partially blocked,
needle on low pressure side slowly
indicates a vacuum.

- After finishing work,


evacuate system
and recharge.

72-67
115ZV-2 Function & Structure Operator Station Group
Air Conditioner

When the moisture has entered into the cooling


circuit.
<Low pressure side>
Abnormal status
Vacuum
Normal status
215~275 kPa
(2.2~2.8 kgf/cm2)
(31~40 psi)

When the compression in compressor is defective.


<Low pressure side>
392~588 kPa
(4~6 kgf/cm2)
(57~85 psi)

<High pressure side>


686~981 kPa
(7~10 kgf/cm2)
(100~144 psi)

<High pressure side>


686~981 kPa
(7~10 kgf/cm2)
(100~144 psi)

1,470~1,765 kPa
(15~18 kgf/cm2)
(213~255 psi)

97ZV72095

Symptom
97ZV72094

Symptom

Cause

- Air conditioner operates normally for a


while after startup,
but pressure on low
pressure side indicates a vacuum
value later.

Expansion valve
is frozen due to
entry of moisture.

Inspection/action point
- Inspect expansion
valve, replace if
needed.
- Replace receiver
dryer.
- After finishing work,
evacuate system
completely and
recharge.

- Pressure on low
pressure side is
unusually high, and
pressure on high
pressure side is
unusually low.
- Shortly after air conditioner turns off,
pressure becomes
equal between high
pressure side and
low pressure side.

Cause
Compressor is
defective.

Inspection/action point
- Review 2nd symptom.
- If pressure in compressor is low, compressor will not build
much heat due to
lack of pressure.
- Replace compressor.
- After finishing work,
evacuate system
and recharge.

72-68
Function & Structure Operator Station Group
Air Conditioner

When there is too much refrigerant or cooling


in the condenser is insufficient
<Low pressure side>
245~343 kPa
(2.5~3.5 kgf/cm2)
(35~50 psi)

When air has entered into the cooling circuit


<Low pressure side>
245~294 kPa
(2.5~3.0 kgf/cm2)
(35~43 psi)

<High pressure side>


1,961~2,452 kPa
(20~25 kgf/cm2)
(284~355 psi)

<High pressure side>


1,961~2,452 kPa
(20~25 kgf/cm2)
(284~355 psi)

97ZV72097

97ZV72096

Symptom
- Pressure is high on
both low pressure
side and high pressure side.
- Even when engine
rpms (min-1) are
reduced, gas bubbles cannot be seen
at all in sight glass.
- Air in cab does not
become cool
enough.

Cause

Inspection/action point

- Refrigerant
quantity is
too much.

- Check and correct


refrigerant charge
pressure.

- Plugged or
bent condenser fins.

- Inspect and repair


condenser fins.

- Bad fan
motor or fan
blade.
- Heat transfer does not
occur in
evaporator
has plugged
fins

- Repair or replace
fan or fan motor
- Inspect and repair
evaporator fins.

Symptom
- Pressure is high on
both low pressure
side and high pressure side.

Cause
Air has entered
system.

Inspection/action point
- Refrigerant is bad.

- Low pressure piping is not cold.

- Evacuate system
completely.

- Gas bubbles go
through sight glass.

- Replace refrigerant.

72-69
115ZV-2 Function & Structure Operator Station Group
Air Conditioner

When the expansion valve is opened too much


<Low pressure side>
294~392 kPa
(3.0~4.0 kgf/cm2)
(43~57 psi)

<High pressure side>


1,961~2,452 kPa
(20~25 kgf/cm2)
(284~355 psi)

97ZV72098

Symptom

Cause

Inspection/action point

- Pressure is high on
both low pressure
side and high pressure side.

Expansion valve
is defective.

- Temperature sensing rod may be


sticking.
- Inspect expansion
valve. Check temp
in and out of valve
to determine if it is
operating correctly.

- Condensation forms
on low pressure
side pipes.

Thermal expansion valve

To and from evaporator

Diaphram

Spring

Temperature sensing rod


Needle valve Compressor return
From receiver dryer

97ZV72049

72-70
Function & Structure Operator Station Group
Troubleshooting

Troubleshooting
Air conditioner

Error code table

Fault diagnosis procedure

Display
E-

Hearing check
Error code check
Phenomenon check

Failure mode
No failure

E11

Wire breakage in inside air sensor

E12

Short-circuit in inside air sensor

E13

Wire breakage in outside air sensor

E14

Short-circuit in outside air sensor

E15

Wire breakage in water temperature sensor

E16

Short-circuit in water temperature sensor

E18

Short-circuit in insolation sensor

E21

Wire breakage in vent sensor

Basic check

E22

Short-circuit in vent sensor

E43

Abnormality in vent damper

In accordance with fault phenomenon

E44

Abnormality in air mixing damper

E45

Abnormality in inside/outside air

E51

Abnormality in refrigerant pressure

1) Control mechanism
2) V-belt
3) Sight glass
4) Piping connection

Refrigerant cycle
check
- Pressure check
- Gas leak check

Electrical system
check

Repair/check
End

80V2E01012

72-71
115ZV-2 Function & Structure Operator Station Group
Troubleshooting
Basic check
1. Check of control mechanism
Operate the switch arranged on the control panel,
to check that it is operable smoothly and securely.
2. Check of V-belt
Check that the V-belt is tensioned properly, and that
it is not damaged.
3. Check of refrigerant level through sight glass
When the air bubble is observed a lot through sight
glass, the refrigerant is probably insufficient.
In such a case, therefore, perform the checking
with using a gauge manifold.

Sight glass

Receiver joint

Receiver drier

95ZVE01003

4. Check of piping connection


At the piping connection where the oil stain is seen,
there is probably a refrigerant leakage.
In such a case, remove the stain, and then check
for gas leakage.

Cooling failure

Normal air
flow rate

With diagnostic display:


E51 (refrigerant high/
lower pressure error)

With diagnostic display:


E44 (A/M servo motor
error)

Without
diagnostic
display

Air flow rate


failure

<Trouble shooting charts>

Pressure error

Normal pressure

Rotation failure
for all modes

Blower is rotated only


when the fan switch is
selected to High-speed
position.

Slow rotation

Operation of low-pressure
function

Operation of high-pressure cut


function

Compressor
normal rotation
failure

Compressor
normal rotation

Blower motor
rotation
failure

Blower motor
rotation

Normal rotation

Close the window and door.


Adjust the inside/outside air changeover damper.
Re-set the link.

Servomotor failure
Blocked foreign matter

Wiring failure, disconnection, disengaged connector

Magnet clutch failure


Clutch engagement failure due to
electrical system failure

Broken or slipped belt


Compressor failure(locking)

Insufficient refrigerant.

Check the wiring.


Replace the servo motor with a new one.
Remove the foreign matter.

Replace the V-belt with a new one.


Replace the compressor with a new one.
Repair the magnet switch, or replace it with a new one.
Check the wiring.

High pressure both at high-pressure side and low-pressure side


Low pressure both at high-pressure side and low-pressure side

Too low pressure at high-pressure side(Pressure is not increased to approx. 981kPa[10kgf/cm2] or over)
Too low pressure at low-pressure side(Pressure is decreased to approx. 49kPa[0.5kgf/cm2] or less

See C-3 .

See C-1 .

See D-2 .

See D-1 .

See C-4 .
See C-5 .

See C-2 .
See C-3 .

Examine the cause before taking the corrective measure,and then replace
the fuse with that of the same capacity.
See B-1 .
Replace the blower main relay with a new one.
Replace the blower motor with a new one.
Correct the interference.
Replace the panel with a new one.
Earth the body securely.
Check the wiring.
Replace the motor with a new one.

Too high pressure at low-pressure side(approx. 294kPa[3kgf/cm2] or over)

Disengaged A/M link

Mixing of outside air

Blown fuse
Blower main relay failure
Blower motor failure
Interference of blower with case
Blower switch failure
Body earth failure
Wiring failure, disconnected connector
Operation of BLC protective function due
to locked motor

Operation of BLC over-voltage protective function

See A-1 .

Examine the cause of over-voltage before taking the corrective measure.

Check the battery charging system.


Correct the contact failure.
Replace the blower motor with a new one.
Replace the BLC with a new one.

Decreased supply voltage


Battery terminal contact failure
Blower motor rotation failure
BLC failure

Adhesion of dust to surface of evaporator

Deformed or damaged blower


Frosting in evaporator

Clean the filter.


Clean the filter.
Remove the obstacle.
Replace the blower with a new one.
Stop the air compressor, to melt the ice.
Examine the cause before taking the corrective measure.
Clean the surface of evaporator.

Clogged inner air filter


Clogged outer air filter
Existence of obstacle at vicinity of suction port

72-72
Function & Structure Operator Station Group
Troubleshooting

80V2E01013

C-2

C-1

B-1

A-1

Voltage not applied


to magnet clutch

Voltage applied to
magnet clutch
Check for characteristic.

Thermister(frosting sensor) characteristic failure

Clogging of dust or mud, etc. in fin.

Excessively opened expansion valve

Replace the valve with a new one.


Correction

Contact failure in
pressure needle valve

Replace the compressor with a new one.

Valve failure

Foreign matter caught by suction valve

Broken suction valve

Discharge the refrigerant to proper level.

Over-filled refrigerant
Broken head gasket

Fully discharge the refrigerant, and execute the


evacuation, and fill the refrigerant again to
proper level.

Mixing of air during refrigerating cycle

Compressor failure

Discharge the refrigerant to proper level.

Over-filled refrigerant

Insufficiently cooled condenser

Clean(Washing with water) the fin.

Check the wiring.

Unusually high outside air temperature

Perform the checking, referring to the wiring diagram.

Evaporator

Sort-circuit wiring

Replace the blower motor with a new one.

Replace the magnet clutch


with a new one.
Thermister
(frosting sensor)

12 5 mm
(0.5 0.2 in)

Adjust the gap (12 5 mm) (0.5 0.2 in).

Replace the thermister(frosting sensor) with a new one.

Correction

Replace the clutch relay with a new one.

Erroneous wiring

Locked blower motor

Magnet clutch failure

Adjustment failure of gap between the thermister(frosting sensor) and evaporator

Check the short-circuit.

Check the clutch circuit.

Thermister(frosting sensor) wiring failure

Magnet clutch circuit failure

72-73
115ZV-2 Function & Structure Operator Station Group
Troubleshooting

85V2U72008

C-5

C-4

C-3

Over-filled refrigerant

Clogging of dust or mud, etc. in fin.

Discharge the refrigerant to proper level.

Clean(washing with water) the fin.

Execute the evacuation fully after replacing the


valve and receiver with a new one respectively.

Temporary clogging(mixing of moisture content)


due to frozen valve

Insufficiently cooled condenser

Replace the valve with a new one.

Relieved gas from pressure needle valve

to A-1

Replace the valve with a new one.

Replacement

Replacement

Clogged valve(mixing of foreign matter)

Clogging due to foreign matter in the course of piping

Clogged receiver & drier

Perform the leak test and repair the location of


failure before filling the refrigerant.

Gas leakage

Execute the evacuation fully after replacing the


valve and receiver with a new one respectively.

Clogging(mixing of moisture content) due to frozen valve

Fill the refrigerant to proper level.

Replace the valve with a new one.

Relieved gas from pressure needle valve

Limited amount of refrigerant filled

Replace the valve with a new one.

Clogged valve(mixing of foreign matter)

Suction/discharge valve failure

Locked piston

Replace the compressor with a new one.

Perform the leak test and repair the location of


failure before filling the refrigerant.

Gas leakage

Swash plate shoe seizure

Fill the refrigerant to proper level.

Limited amount of refrigerant filled

Frosted evaporator

Expansion valve failure

Clogging during refrigerating cycle

Limited refrigerant

Unusually low outside air temperature

Expansion valve failure

Compressor failure

Limited refrigerant

Unusually low outside air temperature

72-74
Function & Structure Operator Station Group
Troubleshooting

80V2E01015

D-2

D-1

C-4

Replacement

High/low-pressure switch failure

Excessively low pressure [981 kPa(10kgf/cm )or lower]

Replacement

Thermo-sensor failure

C-1

Replacement

Excessively high pressure [2452 kPa(25kgf/cm2)or over]

Replace the control panel with a new one.

Compressor clutch relay failure

High-pressure error

Replace the control panel with a new one.

Blower switch failure

Re-charging

Battery voltage drop

Air conditioner switch failure

Replacement

Rare-short in coil

Disassembling/repair

Remove the oil.

Foreign matter caught between rotor and stator

Replace the key with a new one.

Stained clutch surface due to oil

Repair or replacement
Slippage due to broken key or key insertion failure

Excessive air gap between rotor and stator

Slipped clutch

Replacement

Disconnected stator coil

72-75
115ZV-2 Function & Structure Operator Station Group
Troubleshooting

80V2E01016

Leakage of water in
operator's cab

Heating failure

Normal wind
force

Insufficient
wind force

Fill the coolant to proper level.


Replace the heater core with a
new one.

Limited engine cooling water


Broken heater core

Replacement

Cleaning

Check the wiring.

Servo motor failure

Remove the foreign matter.

Foreign matter caught

Wiring failure, disconnection, disconnected connector

Re-set the link.

Disengaged temperature controller link

IN side and OUT side reversed.

The temperature
controller LED is not
operated properly.

Clogged drain hole

Repair or replacement

Clogged or bent piping


Excessively low outside air temperature

Discharge the air.

The air is mixed in hot-water circuit.

Note: Do not fail to check that the pump pressure is normal, and that the heater hose is not connected with

The temperature
controller LED is
operated properly.

Normal water
temperature

Low water temperature

Same as "Cooling failure"

72-76
Function & Structure Operator Station Group
Troubleshooting

85V2U72009

setting temperature

higher or lower than

Room temperature

changeover failure

Outside air/inside air

failure

Blow-off changeover

(without inside air sensor error)

Without diagnostic display

(short-circuit inside air sensor)

With diagnostic display: E12

(disconnected inside air sensor)

With diagnostic display: E11

(inside air/outside air servo motor abnormal)

With diagnostic display: E45

(inside air/outside air servo motor normal)

Without diagnostic display

(blow-off servo motor abnormal)

With diagnostic display: E43

(blow-off servo motor normal)

Without diagnostic display

Cooling failure, heating failure

Short-circuit inside air sensor

Perform the checking in


accordance with the paragraph
"Cooling failure/heating failure".

Replacement

Check the wiring.

Replacement

Disconnected inside air sensor


Short-circuit harness

Re-check the wiring.

Remove the foreign matter.

Foreign matter caught

Disconnected harness, disengaged connector

Replacement

Re-check the wiring

Wiring failure, disconnection, disconnected connector


Servo motor failure

Re-set the link.

Remove the foreign matter.

Foreign matter caught

Disengaged link

Replacement

Check the wiring.

Wiring failure, disconnection, disconnected connector


Servo motor failure

Re-set the link.

Disengaged link

72-77
115ZV-2 Function & Structure Operator Station Group
Troubleshooting

80V2E01018

72-78
Function & Structure Operator Station Group

MEMO

73-1
115ZV-2 Check & Adjustment Operator Station Group

Check & Adjustment


Operator Station Group
Air Conditioner ........................................................ 73-2

73-2
Check & Adjustment Operator Station Group
Air Conditioner

Air Conditioner
Adjustment of lubricating oil
quantity when components of air
conditioner are replaced

WARNING
In order to protect the environment, do not release
refrigerant to atmosphere when removing components from air conditioner system. It not illegal to do
so.

IMPORTANT

Fig. 1

97ZV73002

- When replacing components of the air conditioner,


if the lubricant oil quantity is too small, the compressor may seize. And if the lubricating oil quantity is too much, the cooling ability may lessen.
Use the correct amount of compressor lube oil.
- When connecting a joint, apply compressor oil
(ND-OIL 8) on the O ring before tightening (Fig. 1).
- If the compressor oil (ND-OIL 18) is applied to
paint, paint may peel or otherwise be damaged. If it
gets on a painted surface, quickly wipe it off.
- Tighten the piping, etc. at the recommended
torque.
Tightening torque table
Connection
area

Nut type
(Fig. 2)
Fig. 2

97ZV73003

Block joint
(Fig. 3)

Fig. 3

97ZV73004

Pipe size or bolt size

Tightening torque
N-m (kgf-cm) (lb-ft)

8 pipe

14.7 (150) (7)

1/2 pipe

24.5 (250) (18)

5/8 pipe

34.3 (350) (25)

M6 bolt in receiver (4T)

6.9 (70) (5)

Any M6 bolt other than


above (6T)

11.8 (120) (9)

73-3
115ZV-2 Check & Adjustment Operator Station Group
Air Conditioner

When the compressor is replaced


New compressor

Torque values

Old compressor to be replaced

Compressor mounting bolt


29 N-m (3.0 kgf-m) (22 lb-ft)
Hose block joint on high pressure side
12 N-m (1.2 kgf-m) (9 lb-ft)
Hose block joint on low pressure side
12 N-m (1.2 kgf-m) (9 lb-ft)

Oil quantity
remaining
inside circuit

Example
(B)

Suppose that the oil quantity (A) removed from the compressor to be replaced is 100 cm3. See figure 1.

A
Fig. 1
97ZV73005

To avoid overloading the circuit;


1. Remove the oil from the removed (old) compressor,
measure and record the oil quantity. (Approximately
20 cm3 (0.7 oz) of oil cannot be removed, and
remains inside the compressor.)................ A cm3
2. The compressor can hold about 180 cm3 (6.1 oz; or
0.76 cup) of oil. Determine the systems remaining
oil quantity using the following equation.
Oil quantity remaining inside circuit is:
= 180 cm3 - (Oil quantity A discharged; see fig. 1.
from removed compressor + 20 cm3)
3. Drain as much oil from the compressor as the
quantity remaining inside the refrigerant circuit.
When finished, mount the new compressor.
Compressor lubricating oil
ND-OIL 8 (Nihon Denso oil 8; Polyalkalene glycol
(PAG) oil)

IMPORTANT
- Oil (180 cm3; or 0.76 cup) required for the cooling
circuit is sealed inside a new compressor.
Prior to replacing the compressor, excess oil
should be drained from the new compressor.
- The compressor oil can come to absorb moisture.
Seal the compressor immediately after adjusting
the oil quantity with a plastic cap.
- Never use ester based oil. Use only PAG oil.

Oil quantity remaining inside circuit (B)


= 180 cm3 - (100 + 20) = 60 cm3
Remove 60 cm3 from the new compressor to avoid
overloading the circuit.

73-4
Check & Adjustment Operator Station Group
Air Conditioner

When the evaporator is replaced

When the condenser is replaced


Quantity of lubricating oil lost by replacement of condenser is approximately 40 cm3 (1.35 oz).

When replacing the condenser core, add 40 cm3 (1.35


oz) of compressor oil (ND-OIL 8) to a new condenser.
: (1): 25 N-m (2.5 kgf-m) (18 lb-ft)
: (2): 15 N-m (1.5 kgf-m) (11 lb-ft)

Evaporator

When the receiver dryer is replaced


Quantity of lubricating oil lost by replacement of receiver
dryer is approximately 20 cm3 (0.7 oz).

Expansion valve

The amount of oil loss by replacement of the receiver


dryer is within the allowable range, and adding oil is not
needed if this is the first replacement of the condenser
core.
At the next time the dryer is replaced and from then on,
add 20 cm3 (0.7 oz) of compressor oil (ND-OIL 8) to a
new receiver dryer.

97ZV73006

Quantity of lubricating oil lost by replacement of evaporator core is approximately 40 cm3 (1.35 oz).
When replacing the evaporator, add 40 cm3 (1.35 oz) of
compressor oil (ND-OIL 8) to a new evaporator.
: (1): 12 N-m (1.2 kgf-m) (9 lb-ft)

: (1): 7 N-m (0.7 kgf-m) (5 lb-ft)


: (2): 15 N-m (1.5 kgf-m) (11 lb-ft)

73-5
115ZV-2 Check & Adjustment Operator Station Group
Air Conditioner

Adjustment of air gap (between


hub and rotor) in compressor
magnetic clutch

1. Remove the front cover of the magnetic clutch.


2. Measure dimension A between rotor end face and
hub end face while magnetic clutch is "OFF".
3. Apply the battery voltage directly on the connector
of the magnetic clutch, and measure the size of B in
the same way as step 2 above. Note the difference.

Position while magnetic


clutch is OFF

A (OFF status)
Position while magnetic
clutch is ON

Reference plane
Air gap
0.500.15 mm (0.0200.006 in)

B (ON status)

Hub
Head bolt
Washer plate

Rotor

95ZVE73002

WARNING
Shut off the engine to do this procedure.
If you try to adjust air gap while engine is "ON", a
serious accidents would occur.
Turn starter switch "OFF", stop rotation of engine tag
out unit, pull out starter key, then start adjustment.
Use a "Do Not Start" tag on the machine when performing this work.

Standard (normal dimension) of air gap (A - B)


0.500.15 mm (0.0200.006 in)
If the obtained value does not agree with the criteria, loosen the head bolt, remove the hub, and
adjust the air gap by adjusting the thickness of the
washer plate between the hub and the shaft.

73-6
Check & Adjustment Operator Station Group
Air Conditioner

Compressor V-belt adjustment

Bracket
Bracket

Air conditioner
compressor

Plate

V-belt

Adjusting nut

Bracket mounting
nut
Bolt

115V2E73001

Belt adjustment procedure

Belt adjustment value

1. Loosen four bracket mounting nut.


: Bracket mounting nut:
53.0 N-m (5.4 kgf-m) (39 lb-ft)

2. Loosen the adjusting nut.


Turn the adjusting nut clockwise to adjust the Vbelt.
Turn the adjusting nut counter clockwise to loosen
the V-belt.
3. After the adjustment, tighten the bracket mounting
nut securely.

85V2E73002

Adjust the V-belt tension so that the belt tension at A


part is 35388 N (369 kgf) by using tension gauge.
Note
The V-belt tension should be 559108 N (5711 kgf)
when the belt is replaced with new one.

73-7
115ZV-2 Check & Adjustment Operator Station Group
Air Conditioner

Parts to be replaced periodically

Receiver dryer

Air filters

Replacement
Once every 3 years or 6,000 hours

Air filter for outside air


Cleaning
Once every 2 weeks or when required.
However, if the operating environment is severe (with
much sand, dust, etc.) and the air filter is easily clogged,
clean it more frequently.
To clean, blow filter with compressed air of 196~294
kPa (2~3 kgf/cm2) (28~43 psi) mainly from inside of filter.
Replacement
Once each year or when required.
When air flow volume is so small as to affect air movement even after the filter has been cleaned, or when the
air filter has been cleaned 20 times, replace it.

Air filters for inside air


Cleaning
Once each month
However, if the air filters are easily clogged, clean them
more frequently.
To clean, blow filter with compressed air of 196~294
kPa (2~3 kgf/cm2) (28~43 psi) mainly from inside of the
filter.
Replacement
Once every 3 years
When air flow volume is so small as to affect air movement even after the filter has been cleaned, or when the
air filter has been cleaned 6 times, replace it.

Note
When replacing the receiver dryer, do not release the
refrigerant into the atmosphere.

73-8
Check & Adjustment Operator Station Group

MEMO

80-1
115ZV-2 Function & Structure Supplement

Function & Structure


Supplement
Foreword ................................................................. 80-2
Quick Coupler .......................................................... 80-3
Power boost circuit .................................................. 80-7
Short Boom (OPT)................................................... 80-15
Limited Slip Differential (LSD) ................................. 80-17

80-2
93216-00520
August 2009

93216-00520
August 2009

Foreword
The purpose of this supplemental manual is to provide information about the following features:
- Quick Coupler for the easier installation of attachment
- Power Boost Switch to increase the hydraulic oil pressure to assist heavy loading work
- Short Boom (option) to increase the unit strength of the bucket
- Limited Slip Differential to increase tractive effort.
Refer to the 115ZV-2 Shop Manual, Function and Structure (Manual No. 93216-00460) for the other information.

80-3
115ZV-2 Function & Structure Supplement
Quick Coupler

01-2
Function & Structure Supplement
Quick Coupler

Quick Coupler
Hydraulic line and electrical circuit

2,13
3

Main switch

10

11
B
12

K115V2E01004

1.
2.
3.
4.
5.
6.
7.

Solenoid valve assembly


High pressure hose
High pressure hose
High pressure hose
Oil pipe
Elbow adapter
Elbow adapter

8.
9.
10.
11.
12.
13.

Adapter
Plug
Cable assy
Cable assy
Cable assy
Spiral tube

80-4
Function & Structure Supplement
Quick Coupler

01-3
115ZV-2 Function & Structure Supplement
Quick Coupler

9
T

7
P

8
8
5

Details of A

B-B

K115V2E01005

Fuse box

Main switch
R5

R5

R5
RL RG LR LW YR YW

Br

WR

RL RG LR
W R
Y
R1.25 R
G

Br

LW YR YW
L
G Br

10

WR
O

12

13

R5

L Lg0.5

R5

R5

R5

R5

G1.25 WR

BW

11

R5

14

15

YW
LR

YR
RG

LW
RL

WR

BW
G

W
W

10
C-C

Power connector for option

Lock cylinder
Lock when cylinder extends.
Release when cylinder shortens.

Solenoid valve

Left

SOL A

B
1
W
2
R
3

De-energized

7
4
5
6

10
W
R
G

W
G

Energize SOL B

Right

WR

Main switch
Energize SOL A

SOL B
12

11
G
W

G
W
Floor board

To tank
From control valve
(bucket cylinder bottom
circuit)

Yellow tape

B (Release)

A (Fix)

Hydraulic circuit
Electrical circuit
K115V2E01006

80-5
115ZV-2 Function & Structure Supplement
Quick Coupler

01-4
115ZV-2 Function & Structure Supplement
Quick Coupler

Solenoid valve

SOLENOID a

SOLENOID b
A

SOL. a

SOL. b
P

T3

T2

9
T1

b
P

Hydraulic symbol
K92V2E01004

1.
2.
3.
4.
5.
6.
7.
8.
9.

Casing
Spool
Washer
Spacer
Spring
Screw
Solenoid
O-ring
O-ring

:
T1: 6.4 0.5 N-m (0.65 0.05 kgf-m)
T2: 44.1 4.9 N-m (4.50 0.50 kgf-m)
(Width across flats: 17 mm)
T3: 7.8 0.5 N-m (0.80 0.05 kgf-m)

80-6
Function & Structure Supplement
Quick Coupler

01-5
115ZV-2 Function & Structure Supplement
Quick Coupler

Solenoid valve specifications


Maximum hydraulic oil pressure

P, A, B port

31.5 MPa (320 kgf/cm2)

T port

15.7 MPa (160 kgf/cm2)

Maximum oil flow amount

70 L/min

Rated voltage

DV 24 V

Rated current

1.1 A

80-7
115ZV-2 Function & Structure Supplement
Power boost circuit

80-7
Function & Structure Supplement
Power
Power boost
boost circuit
circuit

Power boost circuit


5

DOWN UP

B2
A2

19

b2

TS
G1/4
1.3
B1

TS
G1/4

DUMP RAISE

23.5 0.5 MPa


(240 5 kgf/cm2) a2

A1

23.5 0.5 MPa


(240 5 kgf/cm2) a1

b1

Relief valve

From pump line

P
TS

Solenoid valve

(b1) 1
DUMP

2 (a1)
RAISE

(b2) 3
DOWN

4 (a2)
UP

16
A

From
reducing
valve

TB

To tank

95

To tank
From
reducing
valve

K115V2E01001

80-8
Function & Structure Supplement
Power boost circuit

01-7
115ZV-2 Function & Structure Supplement
Power boost circuit

Power boost
switch

K115V2E01002

During heavy loading work, when the power boost


switch is pressed, the solenoid valve is energized and
the pilot pressure from the reducing valve acts on the
relief valve piston of multiple control valve (3).
It increases the relief set pressure from the normal preset value 20.6 MPa (210 kgf/cm2) to 22.7 MPa (230 kgf/
cm2) for 5 seconds. The 5 seconds time limit is controlled by the MCU.
While increasing the main pressure, the lifting force and
the digging force are increased.

80-9
115ZV-2 Function & Structure Supplement
Power boost circuit

01-8
115ZV-2 Function & Structure Supplement
Power boost circuit

Multiple control valve main relief valve (MRV) (2 stage relief)


The main relief valve is installed between the pump port
and the cylinder port.
If the pressure is above the preset value as the cylinder
comes to the stroke end, etc., the oil fed from the pump
is discharged into the tank through this main relief valve
to prevent the pump and pipes from being damaged.

Multiple
control
valve

Relief valve

K115V2E01007

PL

T
7

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

11

Plunger
Spring seat
Filter
Seat
Poppet
Piston
Adapter plug
Spring
Lock nut (High pressure side)
Lock nut (Low pressure side)
Adapter plug

10

135ZV42064

80-10
Function & Structure Supplement
Power boost circuit

01-9
115ZV-2 Function & Structure Supplement
Power boost circuit

Multiple control valve main relief valve


(MRV) operation

Multiple control valve main relief valve


(MRV) adjusting set pressure
Low pressure setting

8
T

Loosen lock nut (10), and screw in adapter plug (11) to


increase the set pressure.
Loosen adapter plug (11) to decrease the set pressure.

High pressure setting


Loosen lock nut (9), and screw in adapter plug (7) to
increase the set pressure.
Loosen adapter plug (7) to decrease the set pressure.

T
5

135ZV42065

When the oil pressure is lower than the set point


- The pressure of the pump port acts on poppet (5) via
the orifice in the center of plunger (1), the orifice in
spring seat (2) and filter (3). Poppet (5) is pressed
onto seat (4) by spring (8).
When the oil pressure exceeds the set point
- When the pressure of the pump port exceeds the
force of spring (8), poppet (5) opens and the oil in
the chamber on the left side of plunger (1) escapes
into the tank port. As a result, the pressure in the
chamber on the left side drops drastically, plunger
(1) moves to the left, and the pressurized oil in the
pump port escapes into the tank port.
When the pressure intensifying switch is depressed
- When the pressure intensifying switch is depressed,
piston (6) is shifted to the right by the pressure from
the pressure intensifying solenoid valve via the port
PL of adapter plug (7), and spring (8) is compressed
by the dimension A. By this motion, the pressure of
the relief (high pressure side) setting increases.

Note
When setting pressures, low side pressure must be
adjusted before adjusting high side pressure.
When adjusting low side pressures, high side must be
rechecked and reset.

IMPORTANT
At the completion of check and adjustment of main
relief valve pressure, be sure to tighten the lock nut.

80-11
Function & Structure Supplement

80-11
Function & Structure Supplement

Measuring loading circuit overload relief


pressure

Adjusting overload relief pressure

1. Attach the pressure gauge to the gauge port.


Lock nut

2. Adjust the main relief valve pressure to 24.5 MPa


(250 kgf/cm2) (3,560 psi), so the pressure is above
the overload relief pressure.

Adjusting screw
T
PL

11

Overload relief valve


95ZV43005

Loosen the lock nut and adjust the pressure by the


adjusting screw.

10
Main relief valve
K115V2E01003

Note
Loosen lock nut (10), and screw in adapter plug (11) to
raise the main relief valve pressure.

Bucket cylinder bottom side


1. Lower the boom to the lowest limit.
2. Move the bucket control lever to the roll back position.
3. Keep the engine speed at low idle.
4. Hold the bucket control lever at the roll back position and record the pressure.

1. Bucket cylinder rod side


1. Keep the boom horizontal.
2. Move the bucket control lever to the dump position,
hold and then measure and record the pressure.

Turn clockwise the adjusting screw to raise the set pressure, or turn counterclockwise the adjusting screw to
lower the set pressure.

IMPORTANT
At the completion of check and adjustment of overload relief valve pressure, be sure to reset the main
relief valve to the original condition.

80-12
Function & Structure Supplement
Power boost circuit

01-11
115ZV-2 Function & Structure Supplement
Power boost circuit

Hydraulic line
Multiple control valve

Relief valve

Solenoid valve

Combination valve mount

K115V2E01009

80-13
115ZV-2 Function & Structure Supplement
Power boost circuit

01-12
115ZV-2 Function & Structure Supplement
Power boost circuit

Electrical cable

To control box

Ground
Power boost switch
Floor harness

Solenoid valve

Cable assy (1)

Cable assy (2)

K115V2E01010

80-14
Function & Structure Supplement
Power boost circuit

01-13
115ZV-2 Function & Structure Supplement
Power boost circuit

Electrical connection diagram


Switch

Floor harness
B

277
000 GB
B 278
GB

C24

Cable assy (1)

MCU

Y
1

Solenoid valve
B

Cable assy (2)

Ground
K115V2E01011

80-15
115ZV-2 Function & Structure Supplement
Short Boom (OPT)

01-14
115ZV-2 Function & Structure Supplement
Short Boom (OPT)

Short Boom (OPT)


Bucket cylinder

Short boom

K115V2E01008

80-16
Function & Structure Supplement
Short Boom (OPT)

01-15
115ZV-2 Function & Structure Supplement
Short Boom (OPT)

Bucket cylinder

12,13,14
7,8 11 15
24

1 2

23

5 16,17 4 20 18,19

25,26

21

9,10
K115V2E01012

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

Cylinder tube
Piston rod
Piston
Rod cover
Bushing
Bushing
Piston nut
Stop ring
Bolt
Washer
Wear ring
Back ring
Slipper ring
Back-up ring
O-ring

16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.

O-ring
Back-up ring
U-packing
Back-up ring
Buffer ring
Dust seal
Dust seal
Set screw
Wear ring
Plug
O-ring

:Piston nut (7): 8,820 N-m (900 kgf-m) (6,510 lb-ft)


:Bolt (9): 1,270 N-m (130 kgf-m) (940 lb-ft)

Bucket cylinder specifications


Inner diameter x rod diameter x stroke

mm (in)
225 x 120 x 719
(8.86 x 4.72 x 28.31)

Piston rod

100 x 120
(3.93 x 4.72)

Cylinder

100 x 120
(3.93 x 4.72)

Pin hole (inner diameter x width)

80-17
115ZV-2 Function & Structure Supplement
Limited Slip Differential (LSD)

01-16
115ZV-2 Function & Structure Supplement
Limited Slip Differential (LSD)

Limited Slip Differential (LSD)


LSD gear structure
Note
1. Clutch assembly (2) is built with six plates
as a unit. Do not change this combination.

Differential assembly

2. When installing clutch assembly (2), make


sure of the direction of plates (surfaces with
lining and surface without lining).
With lining

Differential cage

Side gear

Without lining

1
2

3
4

Limited Slip Differential


1

2
3
3
2
4

95V2U22004

1.
2.
3.
4.
5.

Differential cage
Clutch assembly
Side gear
Pin
Bolt

80-18
Function & Structure Supplement
Limited Slip Differential (LSD)

01-17
115ZV-2 Function & Structure Supplement
Limited Slip Differential (LSD)

Front differential gear (S/N 9001~9050)

23

24

28

3
29

26
33
35

32

31

30

27

5
6

34

22

8
9
10

17
21

25
15
38

11
12
13

14

37

16 18 19

20
K115V2E01013

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Nut
Flange yoke
Oil seal
Plug
Housing
Shim
Taper roller bearing
Spacer
Spiral gear set
Carrier assembly

11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

Taper roller bearing


Adjusting nut
Plate
Wear ring
Side gear
Differential pinion
Pin
Wear ring
Spider
Housing

21.
22.
23.
24.
25.
26.
27.
28.
29.
30.

Roller bearing
O-ring
O-ring
O-ring
Snap ring
O-ring
O-ring
Gear
Piston assembly
Oil seal

31.
32.
33.
34.
35.
36.
37.
38.

Friction disc
Separation disc
Pin
Spring pin
Spring

Clutch assembly
Pin

80-19
Function & Structure Supplement

01-18
115ZV-2 Function & Structure Supplement

Front differential gear (S/N 9051~9100)

29

3
36

K115V2U22002

Front differential gear (S/N 9101~)

29

3
36

K115V2U22003

1.
2.
3.
29.
36.

Nut
Flange yoke
Oil seal
Piston assembly
Oil seal (Double lip) (S/N 9051~)

80-20
Function & Structure Supplement
Limited Slip Differential (LSD)

01-19
115ZV-2 Function & Structure Supplement
Limited Slip Differential (LSD)

Rear differential gear


1

22

31
23

28

24

8
21
6
9

20

10

27
26

11
7

25

13

12
18
30

17

19

14
32
16

1.
2.
3.
4.
5.
6.
7.
8.

Nut
Flange yoke
Oil seal
Trunnion
Housing
Taper roller bearing
Taper roller bearing
Sleeve

9.
10.
11.
12.
13.
14.
15.
16.

Spiral gear set


Carrier assembly
Adjusting nut
Lock plate
Straight pin
Wear ring
Wear ring
Differential pinion

15

17.
18.
19.
20.
21.
22.
23.
24.

29

Side gear
Spider
Housing assy
Roller bearing
O-ring
O-ring
O-ring
Shim

K115V2E01014

25.
26.
27.
28.
29.
30.
31.

O-ring
Pin
Snap ring
Bolt
Bolt
Bolt
Oil seal (Double lip)
(S/N 9051~)
32. Clutch assembly

80-21
115ZV-2 Function & Structure Supplement
Limited Slip Differential (LSD)

01-20
115ZV-2 Function & Structure Supplement
Limited Slip Differential (LSD)

LSD function

LSD operation
LSD performance
Differential
pinion

LSD Differential point 0.6


(bias ratio 1.75)
Torque

LSD clutch
assembly
Differential
cage

ir
et
On

Axle shaft

Side gear

Side gear moves


to the left and
pushes LSD
clutch.

0.1

s
pin
es

he
nt

atin
Oper
LSD

ge
ran

ge

0.2
0.3
0.4
0.5
0.6
0.7
0.8
Friction ratio between right and left tires

0.6

g ran

0.9

Torque is transferred to the


right and left tires evenly until
the friction ratio between the
right and left tires comes to
0.6:1. The result is that the
LSD adds tractive effort.

A - Detail
95V2E22014

K115V2E01015

LSD (Limited-Slip Differential) is installed between the


side gear and the differential cage, and increases tractive effort. If the surface traction of the right and left tires
differ from each other during operation, LSD clutch
engages and prevents traction loss.

The following shows operation for the left tire.

The performance of LSD is shown by using the bias


ratio. The bias ratio is the ratio between the driving force
of the right and left tires while the differential pinion is
turned. When the bias ratio is larger, it is easier to gain
traction on the ground surface with less resistance.

When the ground surface resistance for the left tire lessens, the tapered interface between the differential pinion and the left side gear induces a side force. It pushes
the left side gear to the left resulting in frictional engagement with the differential cage, thus impeding free left
side gear rotation and gaining traction.

A rotating driving force is transmitted from the differential cage via spider (cross shaft) to the differential pinion
and the side gear.

80-22
Function & Structure Supplement

MEMO

Maintenance Log
Date

Machine hours

Service performed

Date

Machine hours

Service performed

Date

Machine hours

Service performed

Date

Machine hours

Service performed

Notes