Çalışma Prensibi 1

93215-00482
October 2016
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 Shop Manual.
General Information
Function 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 meth-
ods. 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
00 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 .............................................................................................................. 00-6
Recommended lubricants ........................................................................................................................... 00-9
Coolant ..................................................................................................................................................... 00-10
Lubrication chart ........................................................................................................................................00-11
Weight of main components ..................................................................................................................... 00-12
Bolt tightening torque ................................................................................................................................ 00-13
Hose band tightening torque ..................................................................................................................... 00-17
Liquid gasket and screw lock agent .......................................................................................................... 00-18
Cautions regarding welding repair service ................................................................................................ 00-20
03 Measurement for Performance Check ............................................................................................................. 03-1
Cautions on Safety ............................................................................................................................................ 03-2
Standard Measurement Values for Performance Check ................................................................................... 03-3
12 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 ......................................................................................................................................... 12-7
Dust seal ..................................................................................................................................................... 12-8
13 Check & Adjustment Chassis Group ................................................................................................................ 13-1
Linkage Pin ....................................................................................................................................................... 13-2
Liner ............................................................................................................................................................ 13-2
Center Pin ......................................................................................................................................................... 13-5
Adjusting shim ............................................................................................................................................. 13-5
Grease nipple installation direction ............................................................................................................. 13-5
Installing bearing outer ring ......................................................................................................................... 13-5
22 Function & Structure Power Group .................................................................................................................. 22-1
Power Line ........................................................................................................................................................ 22-2
Engine / Transmission ....................................................................................................................................... 22-4
Engine / transmission mount ....................................................................................................................... 22-4
Radiator (S/N 9001~9150) ................................................................................................................................ 22-5
Radiator (S/N 9151~) ........................................................................................................................................ 22-6
Propeller Shaft .................................................................................................................................................. 22-8
Second propeller shaft assembly ................................................................................................................ 22-9
Third propeller shaft assembly .................................................................................................................. 22-10
Axle Assembly ................................................................................................................................................. 22-11
Axle Support .................................................................................................................................................... 22-12
Torque Proportioning Type Differential Gear (TPD) ........................................................................................ 22-14
Function of T.P.D ....................................................................................................................................... 22-17
Operation of T.P.D ..................................................................................................................................... 22-18
Limited Slip Differential (LSD) (option) ............................................................................................................ 22-19
LSD structure ............................................................................................................................................ 22-19
LSD function .............................................................................................................................................. 22-23
LSD operation ........................................................................................................................................... 22-23
23 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
32 Function & Structure Torque Converter and Transmission Group ................................................................... 32-1
Torque Converter .............................................................................................................................................. 32-2
Torque converter structure .......................................................................................................................... 32-2
Power flow path .......................................................................................................................................... 32-2
Torque multiplication ................................................................................................................................... 32-2
Torque Converter (Lock-up) (Option) ................................................................................................................ 32-3
Lock-up clutch structure .............................................................................................................................. 32-4
Lock-up clutch function (only forward) ........................................................................................................ 32-4
Torque Converter Gear Pump ........................................................................................................................... 32-6
Gear pump specifications ........................................................................................................................... 32-6
Gear pump specifications ........................................................................................................................... 32-7
Transmission ..................................................................................................................................................... 32-8
Clutch combination ..................................................................................................................................... 32-8
Planetary gear ............................................................................................................................................. 32-8
Shift lever position ....................................................................................................................................... 32-8
Downshift button operation ......................................................................................................................... 32-8
Gear train and number of teeth ................................................................................................................... 32-9
Clutch Pack ..................................................................................................................................................... 32-12
Power Flow Path in the Transmission ............................................................................................................. 32-13
Forward 1st speed power flow path .......................................................................................................... 32-13
Forward 2nd speed power flow path ......................................................................................................... 32-14
Forward 3rd speed power flow path .......................................................................................................... 32-14
Forward 4th speed power flow path .......................................................................................................... 32-15
Reverse 1st speed power flow path .......................................................................................................... 32-16
Reverse 2nd speed power flow path ......................................................................................................... 32-16
Reverse 3rd speed power flow path ......................................................................................................... 32-17
Hydraulic System Diagram ............................................................................................................................. 32-18
Hydraulic Circuit Diagram ............................................................................................................................... 32-20
Oil Flow ........................................................................................................................................................... 32-22
Oil flow in the torque converter line ........................................................................................................... 32-22
Oil flow to the clutch .................................................................................................................................. 32-22
T/C and T/M Oil Circulation ............................................................................................................................. 32-23
Modulator Valve Unit ....................................................................................................................................... 32-25
Interior schematic (simple explanation) ..................................................................................................... 32-27
Modulator valve function ........................................................................................................................... 32-28
Modulator valve operation ......................................................................................................................... 32-30
Control Valve Assembly .................................................................................................................................. 32-32
Check valve ............................................................................................................................................... 32-34
Clutch solenoid valve assembly ................................................................................................................ 32-35
Clutch valve assembly .............................................................................................................................. 32-39
33 Check & Adjustment Torque Converter and Transmission Group ................................................................... 33-1
Clutch Oil Pressure and Time Lag .................................................................................................................... 33-2
Measuring clutch oil pressure ..................................................................................................................... 33-2
Measuring clutch time lag ........................................................................................................................... 33-4
42 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 (S/N 9001~9300) .............................................................................................................. 42-11
Hydraulic Tank (S/N 9301~) ...................................................................................................................... 42-13
Hydraulic tank specifications ..................................................................................................................... 42-15
Hydraulic oil level check ............................................................................................................................ 42-16
Hydraulic Pump ............................................................................................................................................... 42-17
Loading and pilot and brake pump/Steering pump ................................................................................... 42-17
Loading and pilot and brake pump/Steering pump specifications ............................................................. 42-17
Hydraulic pump principle ........................................................................................................................... 42-18
Hydraulic pump wear plate ....................................................................................................................... 42-19
Hydraulic pump bushing lubrication .......................................................................................................... 42-19
Hydraulic Cylinder ........................................................................................................................................... 42-20
Boom cylinder ........................................................................................................................................... 42-20
Bucket cylinder .......................................................................................................................................... 42-20
Steering cylinder ....................................................................................................................................... 42-21
Hydraulic cylinder specifications ............................................................................................................... 42-22
Loading System .............................................................................................................................................. 42-23
Reducing Valve (for Pilot Pressure) ................................................................................................................ 42-24
Pilot valve (S/N 9001~9250) ........................................................................................................................... 42-25
Pilot valve (S/N 9251~9255) ........................................................................................................................... 42-30
Pilot valve (S/N 9256~) ................................................................................................................................... 42-35
Multiple Control Valve (KML35A/2T003B) ....................................................................................................... 42-40
Multiple control valve specifications .......................................................................................................... 42-41
Multiple control valve main relief valve ..................................................................................................... 42-42
Multiple control valve overload relief valve (with make-up function) ......................................................... 42-44
Multiple control valve make-up valve ........................................................................................................ 42-45
Multiple control valve bucket spool ........................................................................................................... 42-46
Multiple control valve boom spool ............................................................................................................. 42-48
Adapter (Orifice) .............................................................................................................................................. 42-51
Ride Control (OPT) ......................................................................................................................................... 42-52
Ride control hydraulic circuit ..................................................................................................................... 42-52
Ride control operation ............................................................................................................................... 42-53
Ride control valve assembly (Reducing valve circuit) ............................................................................... 42-55
Ride control valve assembly (Accumulator circuit) ................................................................................... 42-58
Accumulator (for ride control) .................................................................................................................... 42-61
Steering System .............................................................................................................................................. 42-62
Orbitrol® ........................................................................................................................................................... 42-63
Orbitrol® structure ..................................................................................................................................... 42-63
Orbitrol® specifications .............................................................................................................................. 42-64
Orbitrol® operation .................................................................................................................................... 42-65
Orbitrol® feed-back mechanism operation ................................................................................................ 42-67

Steering speed and flow rate control ......................................................................................................... 42-68
Hydraulic pump oil amount and steering force .......................................................................................... 42-68
Orbit rotor operation principle .................................................................................................................... 42-69
Steering Valve (KVS32-A4.0/20) ..................................................................................................................... 42-70
Steering valve operation ........................................................................................................................... 42-72
Steering spool variable throttle .................................................................................................................. 42-74
Steering valve flow control spool ............................................................................................................... 42-75
Steering valve main relief valve ................................................................................................................ 42-76
Steering valve overload relief valve .......................................................................................................... 42-78
Steering pilot circuit and its operation ....................................................................................................... 42-80
Stop Valve ....................................................................................................................................................... 42-82
Stop valve function .................................................................................................................................... 42-83
Stop valve operation ................................................................................................................................. 42-83
Reducing Valve (for Orbitrol®) ......................................................................................................................... 42-84

Steering Line Filter .......................................................................................................................................... 42-85
K-Lever (OPT) ................................................................................................................................................. 42-86
Hydraulic circuit ......................................................................................................................................... 42-86
Hydraulic line diagram ............................................................................................................................... 42-87
Hydraulic line ............................................................................................................................................. 42-88
Solenoid valve mount ................................................................................................................................ 42-89
Solenoid valve assembly (1/2) .................................................................................................................. 42-90
Solenoid valve assembly (2/2) .................................................................................................................. 42-91
Efficient Loading System ................................................................................................................................. 42-92
Efficient loading system outline ................................................................................................................. 42-92
Mounting of the ELS valve ........................................................................................................................ 42-93
Mounting of the variable kickout sensor .................................................................................................... 42-94
Efficient loading system operation ............................................................................................................ 42-95
Fan Motor System ........................................................................................................................................... 42-96
Mounting of fan motor ............................................................................................................................... 42-96
Fan Motor Line ................................................................................................................................................ 42-97
Hydraulic circuit (fan motor normal rotation) ............................................................................................. 42-99
Proportional relief valve (S/N 9001~9150) .............................................................................................. 42-101
Proportional relief valve (S/N 9151~) ...................................................................................................... 42-103
Fan motor ................................................................................................................................................ 42-105
Reversing Fan Motor Line (OPT) .................................................................................................................. 42-108
Reversing fan motor function .................................................................................................................. 42-108
Hydraulic circuit (Reverse rotation) ..........................................................................................................42-112
Secondary Steering ........................................................................................................................................42-113
Secondary steering operation ..................................................................................................................42-113
Secondary steering motor and pump .......................................................................................................42-115
43 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 .............................................................................................. 43-9
Hydraulic Cylinder ........................................................................................................................................... 43-14
Cylinder natural drift .................................................................................................................................. 43-14
Stop Valve ....................................................................................................................................................... 43-17
Stop valve adjustment procedure ............................................................................................................. 43-17
52 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 plate ........................................................................................................................ 52-15
Service brake steel plate ........................................................................................................................... 52-16
Service brake piston .................................................................................................................................. 52-17
Service brake pedal stroke adjusting mechanism (S/N 9001~9014) ........................................................ 52-18
Brake circuit air bleeding procedure .......................................................................................................... 52-20
Parking Brake .................................................................................................................................................. 52-22
Parking brake operation ............................................................................................................................ 52-25
Parking brake friction plate ........................................................................................................................ 52-27
Parking brake steel plate ........................................................................................................................... 52-27
Parking brake solenoid valve .................................................................................................................... 52-28
Parking Brake Manual Release ....................................................................................................................... 52-29
Brake Circuit Check Valve ............................................................................................................................... 52-31
Auto Brake ...................................................................................................................................................... 52-32
Auto brake circuit ...................................................................................................................................... 52-32
Auto brake operation set value ................................................................................................................. 52-32
Solenoid valve (for Autobrake circuit) ....................................................................................................... 52-33
Pressure Sensor (for stop lamp and declutch) ................................................................................................ 52-34
Pressure sensor (for declutch) .................................................................................................................. 52-34
Pressure sensor (for stop lamp) ................................................................................................................ 52-34
53 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 ............................................................................................................... 53-9
Parking Brake .................................................................................................................................................. 53-10
Parking brake performance check ............................................................................................................ 53-10
62 Function & Structure Electrical Group .............................................................................................................. 62-1
How to Use Electrical Wiring Diagram .............................................................................................................. 62-2
Utilisation des schémas des câblages électriques (FRANÇAIS) ...................................................................... 62-3
Verwendung des elektrischen Schaltplans (DEUTSCH) ................................................................................... 62-4
Modalità di utilizzo dello schema dei collegamenti elettrici (ITALIANO) ............................................................ 62-5
Cómo utilizar un Diagrama de Alambrado Eléctrico (ESPAÑOL) ..................................................................... 62-6
Como Utilizar o Diagrama de Ligações Eléctricas (PORTUGUÊS) .................................................................. 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 ................................................................................................................................................ 62-13
Engine Start Circuit ......................................................................................................................................... 62-14
Engine start circuit diagram ...................................................................................................................... 62-14
Neutral starter ........................................................................................................................................... 62-15
Starter switch ............................................................................................................................................ 62-16
Battery relay .............................................................................................................................................. 62-17
Alternator I terminal wire ........................................................................................................................... 62-18
Diode unit .................................................................................................................................................. 62-18
Neutral relay .............................................................................................................................................. 62-19
Magnetic switch ........................................................................................................................................ 62-20
Voltage relay ............................................................................................................................................. 62-21
Power Generating/Charging Circuit ................................................................................................................ 62-22
Alternator .................................................................................................................................................. 62-22
ECM (Engine Controller) ................................................................................................................................. 62-23
Function of ECM ....................................................................................................................................... 62-23
Connection diagram .................................................................................................................................. 62-23
Monitor lamp test ...................................................................................................................................... 62-24
Failure diagnosis ....................................................................................................................................... 62-25
Quantum fault code information ................................................................................................................ 62-28
Accelerator pedal ...................................................................................................................................... 62-34
Transmission Control Circuit and Monitor Circuit ............................................................................................ 62-37
Machine control unit (MCU) ...................................................................................................................... 62-37
Machine control unit (MCU) connection diagram (S/N 9001~9350) ......................................................... 62-39
Machine control unit (MCU) connection diagram (S/N 9351~) ................................................................. 62-41
Machine control unit (MCU) function ......................................................................................................... 62-43
Adjustable declutch preset switch ............................................................................................................. 62-52
Monitoring system ..................................................................................................................................... 62-62
Operation monitor lamps ........................................................................................................................... 62-64
Instrument Panel and Switch .......................................................................................................................... 62-65
Instrument panel (S/N 9001~9350) ........................................................................................................... 62-65
Instrument panel (S/N 9351~) ................................................................................................................... 62-66
Instrument panel rear surface ................................................................................................................... 62-67
Gauge circuit ............................................................................................................................................. 62-69
Fuel gauge circuit ...................................................................................................................................... 62-71
MODM ............................................................................................................................................................. 62-72
MODM function ......................................................................................................................................... 62-72
Monitor Changeover .................................................................................................................................. 62-72
Information Monitor ................................................................................................................................... 62-75
Replacement Monitor ................................................................................................................................ 62-79
Fault Log Monitor ...................................................................................................................................... 62-85
Input/Output Monitor ................................................................................................................................. 62-92
Parameter Setting Monitor ........................................................................................................................ 62-96
Specification Setting Monitor ................................................................................................................... 62-105
Electrical Detent Circuit ..................................................................................................................................62-111
Bucket leveler ...........................................................................................................................................62-111
Detent solenoid ....................................................................................................................................... 62-112
Lift kickout & lower kickout ...................................................................................................................... 62-113
Sensor assy ............................................................................................................................................ 62-115
Detent solenoid ....................................................................................................................................... 62-117
Preset height adjustment ........................................................................................................................ 62-117
Diode ............................................................................................................................................................. 62-118
Diode check method ............................................................................................................................... 62-119
Caution for diode check method ............................................................................................................. 62-119
Surge voltage and surge suppression diodes ......................................................................................... 62-121
72 Function & Structure Operator Station Group .................................................................................................. 72-1
Cabin ................................................................................................................................................................. 72-2
Glass ........................................................................................................................................................... 72-3
Wiper mount ................................................................................................................................................ 72-6
Wiper motor ................................................................................................................................................ 72-7
Operator Seat ................................................................................................................................................... 72-9
Steering and Transmission Shift Lever ........................................................................................................... 72-10
Tilt case ......................................................................................................................................................72-11
Column shaft ............................................................................................................................................. 72-12
Shift lever .................................................................................................................................................. 72-12
Air Conditioner ................................................................................................................................................ 72-13
Denso air conditioner components ........................................................................................................... 72-13
Denso air conditioner structure ................................................................................................................. 72-14
Function of cooling mechanism ................................................................................................................ 72-19
Cooling circuit ........................................................................................................................................... 72-22
Electrical circuit ......................................................................................................................................... 72-23
Air conditioner functions of components ................................................................................................... 72-24
Charge of refrigerant ................................................................................................................................. 72-52
Air conditioner troubleshooting ................................................................................................................. 72-69
73 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
92 Drawing & Diagrams ........................................................................................................................................ 92-1
Axle Assembly .................................................................................................................................................. 92-2
Torque Converter and Transmission ................................................................................................................. 92-3
Hydraulic & Brake Circuit (S/N 9001~9250) ...................................................................................................... 92-4
Hydraulic & Brake Circuit (S/N 9251~) .............................................................................................................. 92-5
Brake Circuit ..................................................................................................................................................... 92-6
Electrical Wiring Diagram (1/3) (S/N 9001~9048) ............................................................................................. 92-7
Electrical Wiring Diagram (1/3) (S/N 9049~9250) ........................................................................................... 92-10
Electrical Wiring Diagram (1/3) (S/N 9351~) ................................................................................................... 92-16
Electrical Wiring Diagram ................................................................................................................................ 92-19
Way of looking at connectors .................................................................................................................... 92-19
Electrical wiring diagram abbreviation chart .................................................................................................... 92-21
Electrical Wiring Diagram (CAB) ..................................................................................................................... 92-23
Electrical Connection Diagram (1/2) (S/N 9001~9250) ................................................................................... 92-26
Electrical Connection Diagram (1/2) (S/N 9351~) ........................................................................................... 92-30
Electrical Connection Diagram (2/2) (S/N 9351~) ........................................................................................... 92-31
Electrical Wiring Diagram (Cabin Air Conditioner) .......................................................................................... 92-32
Electrical Circuit Diagram (Cabin Air Conditioner) .......................................................................................... 92-33
Equipment Operation Table (Cabin Air Conditioner) ....................................................................................... 92-34
Electrical Equipment Layout ............................................................................................................................ 92-35
Electrical Equipment Layout (K-Lever) ............................................................................................................ 92-46
Outline of MODM (Machine Operation Diagnostic Module) Operation ........................................................... 92-47
MODM: Input/Output Monitor - Input/Output Signal Correspondence Table ................................................... 92-56
95ZV-2 EU FS 00-1
00 General Information
How to Use Manual ................................................. 00-2

Outline ..................................................................... 00-4
95ZV-2 EU FS 00-2
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 - To remove a heavy unit (20 kg (40 lbs) or more), be
safety. To ensure safety, observe the general cautions sure to use a crane or other lifting device.
described below.
- Just after stopping operation, be careful not to
- This manual is intended for properly trained and directly touch a hot component. You may get burned.
equipped service technicians.
- Contact tire manufacturer's local dealer for tire ser-
- Any work on the machine must be performed by the vicing and changing.
trained personnel only.
- Always store the tools in good condition, and use
- Carefully read this manual to thoroughly understand them properly.
the operation method before you operate or repair
the machine. - Keep the work area clean. Clean up spills immedi-
ately.
- Be sure to wear appropriate clothes and protectors,
such as safety boots, hard hat and goggles. - Avoid the use of flammable solvents and cleaners.
- Place the machine on level and solid ground, and - When working outdoors keep work areas, ladders,
place chocks against the wheels to prevent move- steps, decks and work platforms clear of snow, ice,
ment. and mud.
- Remove the cable from the battery before starting - Use safe work platforms to reach higher areas of the
the service work, and attach a "DO NOT OPERATE!" machine.
tag to the steering wheel.
- Any technician that operates a refrigerant recovery
IMPORTANT and recycling machine must first be certified through
an EPA approved testing program.
If a battery terminal is removed from a machine in More information is available at http://www.epa.gov/
less than 30 seconds after the key is put into the ozone/title6/608/technicians/608certs.html.
“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 start-

ing 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 ade-
quate cribbing under the unit to prevent unexpected
dropping.
95ZV-2 EU FS 00-3
How to Use Manual
Symbols
For safe and effective service work, the following sym-
bols are used for notes and useful information in this
manual.
Symbol Item Description
Shows the condition or procedure that will be useful

Reference
or efficient in doing service work.
Shows the weight of a part or unit. The weight

should be considered in selecting wire rope or cable
Weight
for slinging work or determining the working pos-
ture.
Tightening Shows the tightening torque of a section that should

torque be carefully tightened during assembly work.
Shows the type of coating or adhesive and the coat-

Coating
ing section.
Oil or
Shows the oil or water supply port and the refill
water
amount.
supply
Shows the oil or water drain port and the drain

Drainage
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 per-
formance 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 follow-
ing abbreviation list. Additional abbreviations are listed on page 92-21.
E/G ........... Engine RH ............Right hand side 3rd ............3rd speed

T/C ........... Torque converter LH ............Left hand side 4th ............4th speed
T/M ........... Transmission H ............High M/C ............Machine
SOL ........... Solenoid valve L ............Low min-1 ............RPM
SW ........... Switch GND ............Ground ELS ............Efficient loading system
F ........... Front or Forward OPT ............Option MODM ........Machine operation diag-
A/M ........... Auto/Manual Assy ............Assembly nostic module
B ........... Battery 1st ............1st speed MCU ...........Machine control unit
R ........... Rear or Reverse 2nd ............2nd speed
95ZV-2 EU FS 00-4
Outline
Outline
Layout of main components
3 8
4 9 21 3
5 6 7 8 10 22
18
11
4
16
17
(S/N 9001
~ 9150)
12 20 14 2 15 13 1 19
95V2E00002
95ZV-2 EU FS 00-5
Outline
1. Engine assembly (Cummins QSX-15)

(S/N 9151~) 16 2. Transmission/Torque converter assy
3. Hydraulic pump
4. Multiple (loader) control valve
5. Steering valve
6. Pilot valve (for loading)
7. Transmission control valve
8. Air cleaner
11 9. ELS valve
10. Muffler
11. Radiator
12. Front axle assembly
13. Rear axle assembly
14. 2nd propeller shaft
15. 3rd propeller shaft
16. Hydraulic oil cooler (air-to-oil type)
17. T/C oil cooler
18. Air charge cooler
19. Fuel cooler
22 18
20. Parking brake
21. Combination valve
22. Fan motor
11
17 19
K95V2U00001
95ZV-2 EU FS 00-6
Outline
Inspection and maintenance table

IMPORTANT
Refer to Operation & Maintenance Manual for mainte- Severe application require more frequent mainte-
nance procedures. nance.
Severe conditions include heavy dust, extremely
abrasive material, caustic chemicals, extremely wet
conditions or abnormally hot or cold ambient temper-
atures.
: First time replacement or cleaning only

Operating hours When
Section Item for check
Required
10 50 250 500 1000 1500 2000
Check Engine Oil Level
Check Engine Coolant Level
Check Warning Lamps
Check Exhaust Gas
Drain Water and Sediment from Fuel Filter
Check Fuel Level
Check Drive Belt
Check Crankcase Breather Tube
Check Air Intake System
Check Cooling Fan
Drain Water and Sediment from Fuel Tank
Replace Fuel Filter Cartridge
Replace Engine Oil and Oil Filter Cartridge
Add DCA4 Coolant Additive

Engine
Inspect Automatic Belt Tensioner Pulley
Replace Fuel Tank Breather

Replace Coolant Filter Cartridge (One year or 1500 hours
One year or 1500 hours
whichever comes first.)
Clean Fuel Tank
Check and Adjust Valve Lash Clearance
Check Vibration Damper
Check Engine Compression Pressure
Check Injection Pressure
Clean Crankcase Breather Tube
Clean or Replace Air Cleaner Element

Clean Radiator / Air cooler / Hydraulic oil cooler / Fuel
cooler Fins
Clean or Replace Air Cleaner Element After six cleanings or once a year
Replace Coolant Every 2 years or 3000 hours

95ZV-2 EU FS 00-7
Outline

Operating hours
When
Required
10 50 250 500 1000 1500 2000
Check Transmission Oil Level
Transmission & Replace Transmission Oil Filter Cartridge

Torque
Converter Replace Transmission Oil
Clean or Replace Transmission Breather
Check Tire for Damage, Air and Tread Depth
Greasing (Axle support)
Check Tire Air Pressure
Check Differential Gear Oil
Check Planetary Gear Oil
Greasing (Pillow block bearing unit)
Axle system Check Tightness of Wheel Bolts
Greasing (Differential seals)
Greasing (2nd Propeller Shaft Spline)
Replace Differential Gear Oil
Replace Planetary Gear Oil
Greasing (2nd Propeller Shaft) Every 12000 hours
Greasing (3rd Propeller Shaft) Every 12000 hours
Check Steering Wheel Operation
Steering system Greasing (Steering Cylinder)
Clean Filter for Orbitrol®
Check Service Brake Operation
Check Parking Brake Operation
Check Parking Brake Gear Oil
Brake system Replace Parking Brake Gear Oil
Check Service Brake Disk Wear
Check Brake Accumulator
Clean Filter for Brake Line
Check Hydraulic Oil Level
Greasing
Replace Hydraulic Oil Return Filter
Replace Hydraulic Oil, Clean Filter

Loading system
Replace Filter in the Hydraulic Tank Cap (S/N ~5450)
Replace Filter in the Hydraulic Tank Breather Valve
(S/N 5451~)
Replace Bucket Teeth (option)
Replace Cutting Edge (option)

95ZV-2 EU FS 00-8
Outline

Operating hours
When
Required
10 50 250 500 1000 1500 2000
Adjust and Check Rear View Mirrors
ROPS (Roll Over Protective Structure) Cab
Check Seat Belt Restraint
Greasing (Center Pin)

Chassis
Check Ride Control Accumulator (option)
Replace Seat Belt and Tether
Check Windshield Washer Fluid
Check Bucket Stopper
Check Monitor Panel Operation
Check Horn Operation
Check Back-up Alarm Operation

Electrical
system Check Wiring Harnesses
Check Battery Electrolyte Level
Check or Replace Fuses
Check Drive Belt
Clean Air Conditioner Filter Element
Check Air Conditioner Refrigerant

Air Conditioner
Replace Air Conditioner Filter Elements
Clean Air Conditioner Condenser
Replace Air Conditioner Receiver Dryer Every 3 years or 6000 hours
Others Walk-Around Inspection

95ZV-2 EU FS 00-9
Outline
Recommended lubricants
Refill capacity Ambient Temperature (ºC) Change Interval

Kind of Oil -30 -20 -10 0 10 20 30 40
(Approximate) (Hours)
SAE10W-30
Engine oil 2
Engine 49.2 liter SAE15W-40 500
(CH4 or CI4)
SAE10W
Engine oil (CD) or
Transmission 70 liter ATF 1,000
ATF
1 3 ISO VG32
Hydraulic tank 150 liter Hydraulic oil ISO VG46 2,000
Differential & Front: 100 liter

Planetary Rear: 100 liter Engine oil SAE40 or SAE50
Engine oil (CD) 2,000
Parking brake 3 liter
ASTM D975 No.1
Fuel tank 465 liter Diesel fuel ASTM D975 No.2 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, anti-foam,
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 pumps
every 6,000 hrs operation.
Warning:
When operating in cold ambient temperatures (0 ºF/15 ºC or colder) ISO VG32 or equivalent
hydraulic oil use is recommended. When changing over to cold climate hydraulic oil (i.e. from
thicker ISO VG46 to thinner ISO VG32), brake system bleeding at each wheel hub will be
required to remove thicker oil and prevent delayed reaction of brake application and release.
Differential & Use class API CD engine oil with 5% "Antichatter" additive or friction modifier.
Planetary
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.
95ZV-2 EU FS 00-10
Outline
Diesel Fuel Requirements for diesel fuel

Specifications
Grade No. 1-D Grade No. 2-D
Flash Point ºC. min. 38 52
Water and Sediment % vol. max. 0.05 0.05
Distillation Temperature ºC. 90% vol. recovered max. 288 338
min. 1.3 1.9
Kinematic Viscosity mm2/s at 40ºC
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
Coolant
Coolant specification Recommended mixture of antifreeze
The machine is originally filled with Long Life Coolant (S/N 9001~9150)
(non-Amin type ethylene glycol) which need not be Expected minimum -35ºC -30ºC -25ºC -20ºC -15ºC
replaced for the first two years or 3,000 hours. ambient temperature (-31ºF) (-22ºF) (-13ºF) (-4ºF) (5ºF)
(liter) 54.0 59.8 65.5 71.3 77.0
Pure Water
(gal) (14.3) (15.8) (17.3) (18.8) (20.3)
Do not use Amin type Long Life Coolant in cooling sys-
(liter) 61.0 55.2 49.5 43.7 38.0
tem. It may cause a corrosion against radiator or heater Antifreeze
(gal) (16.1) (14.6) (13.1) (11.6) (10.1)
core.
Mixture Ratio (%) 53 48 43 38 33
If standard antifreeze (not Long Life Coolant) is used for

the replacement, it should be replaced every six (S/N 9151~)
months. Expected minimum -35ºC -30ºC -25ºC -20ºC -15ºC
ambient temperature (-31ºF) (-22ºF) (-13ºF) (-4ºF) (5ºF)
(liter) 47.0 52.0 57.0 62.0 67.0
Pure Water
(gal) (12.4) (13.7) (15.0) (16.4) (17.7)
(liter) 53.0 48.0 43.0 38.0 33.0
Antifreeze
(gal) (14.0) (12.7) (11.4) (10.0) (8.7)
Mixture Ratio (%) 53 48 43 38 33
- 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 -15°C (5°F)) 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.
95ZV-2 EU FS 00-11
Outline
Lubrication chart
DIFF & 2ND PROPELLER HYDRAULIC DIFF & EVERY 12000Hr

GEAR BOX SHAFT TANK GEAR BOX
GO G HO GO EVERY 2000Hr
DIFF TRANSMISSION DIFF
G TO G EVERY 1000Hr
ENGINE OIL PAN
EO EVERY 500Hr
PILLOW UNIT
LINK SYSTEM G GO GO EVERY 250Hr
G EVERY 50Hr
TO HO EO EVERY DAY
G G G G
BUCKET STEERING CYL. CENTER PIN AXLE SUPPORT

G G
2ND PROPELLER 3RD PROPELLER
SHAFT SHAFT
95ZV2-44794-23580 EU
G HO
Grease point Multipurpose grease Hydraulic oil
GO TO
Check and add if necessary Gear oil Engine oil
EO
Oil replacement Engine oil
95ZV-2 EU FS 00-12
Outline
Weight of main components
Item Approx. Approx.

weight weight Remarks
Unit name Part name (kg) (lb)
Bucket 2,750 6,050 GSC bucket
Boom 2,130 4,690
"Z" -Lever 275/pc 605/pc
Link (Bucket to Lever) 60/pc 130/pc
Screen board 175 385
Roof 45 100
Engine room
Radiator guard 195 430
Access panel 35/pc 80/pc
Chassis Hydraulic tank 275 605 Excluding oil
Fuel tank 230 510 Excluding fuel
Floor board 285 630
Cab (ROPS) 600 1,320
Left side 70 155 With handrail
Deck
Right side 50 110 With handrail
Front chassis 2,400 5,280
Rear chassis 2,550 5,610
Counter weight 1,920 4,230
Engine 1,600 3,520 Excluding oil
Radiator assembly 570 1,260 Excluding water and oil
Transmission 1,570 3,460 Excluding oil
Second propeller shaft 90 200
Power line Third propeller shaft 20 45
Front axle assembly 2,000 4,400 Excluding tires and oil
Rear axle assembly 2,030 4,470 Excluding tires and oil (Including axle support)
Front 550 1,210
Differential
Rear 370 820
Multiple control valve 90 200
Pilot valve 5 15
Steering valve 50 110
Orbitrol® 5 15
Hydraulic system Gear pump 35/pc 80/pc Double pump x 2pcs
Fan motor 50 110
Boom cylinder 280/pc 620/pc Excluding oil
Bucket cylinder 135/pc 300/pc Excluding oil
Steering cylinder 50/pc 110/pc Excluding oil
Tire 830/pc 1,830/pc With rim (29.5-25-22PR (L-3)); No Hydro Inflation
Other
Battery 50/pc 110/pc
95ZV-2 EU FS 00-13
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 Bolt strength
Type Nominal Nominal
Pitch 8.8 (8T) 10.9 (11T)
dimension diameter
M8 8 (C) 1.25 26 38
(C) 1.5 53 76
M10 10
(F) 1.25 55 80
(C) 1.75 90 132
M12 12
(F) 1.25 96 142
(C) 2.0 142 206
M14 14
(F) 1.5 152 221
(C) 2.0 216 314
M16 16
(F) 1.5 226 330
(C) 2.5 299 436
M18 18
(F) 1.5 324 476
Metric thread (C) 2.5 417 608
M20 20
(F) 1.5 451 662
(C) 2.5 559 814
M22 22
(F) 1.5 598 878
(C) 3.0 721 1,030
M24 24
(F) 2.0 770 1,128
(C) 3.0 1,030 1,520
M27 27
(F) 2.0 1,128 1,618
(C) 3.5 1,422 2,109
M30 30
(F) 2.0 1,569 2,256
(C) 3.5 1,912 2,844
M33 33
(F) 2.0 2,059 3,040
5/16 05 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
Unified thread 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
1 16 8 UNC 868 1,275
Note: Tighten the bolts according to the above list, unless otherwise specified.
95ZV-2 EU FS 00-14
Outline
(kgf-m)
Pitch 8.8 (8T) 10.9 (11T)
dimension diameter
M8 8 (C) 1.25 2.7 3.9
(C) 1.5 5.4 7.8
M10 10
(F) 1.25 5.6 8.2
(C) 1.75 9.2 13.5
M12 12
(F) 1.25 9.8 14.5
(C) 2.0 14.5 21.0
M14 14
(F) 1.5 15.5 22.5
(C) 2.0 22.0 32.0
M16 16
(F) 1.5 23.0 33.7
(C) 2.5 30.5 44.5
M18 18
(F) 1.5 33.0 48.5
Metric thread (C) 2.5 42.5 62.0
M20 20
(F) 1.5 46.0 67.5
(C) 2.5 57.0 83.0
M22 22
(F) 1.5 61.0 89.5
(C) 3.0 73.5 105.0
M24 24
(F) 2.0 78.5 115.0
(C) 3.0 105.0 155.0
M27 27
(F) 2.0 115.0 165.0
(C) 3.5 145.0 215.0
M30 30
(F) 2.0 160.0 230.0
(C) 3.5 195.0 290.0
M33 33
(F) 2.0 210.0 310.0
5/16 05 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
Unified thread 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
1 16 8 UNC 88.5 130.0
95ZV-2 EU FS 00-15
Outline
(lb-ft)
Pitch 8.8 (8T) 10.9 (11T)
dimension diameter
M8 8 (C) 1.25 19.5 28
(C) 1.5 39 56
M10 10
(F) 1.25 40 59
(C) 1.75 66 97
M12 12
(F) 1.25 70 105
(C) 2.0 105 150
M14 14
(F) 1.5 110 160
(C) 2.0 160 230
M16 16
(F) 1.5 165 245
(C) 2.5 220 320
M18 18
(F) 1.5 235 350
Metric thread (C) 2.5 305 450
M20 20
(F) 1.5 330 490
(C) 2.5 410 600
M22 22
(F) 1.5 440 650
(C) 3.0 530 760
M24 24
(F) 2.0 565 830
(C) 3.0 760 1,120
M27 27
(F) 2.0 830 1,190
(C) 3.5 1,050 1,550
M30 30
(F) 2.0 1,160 1,660
(C) 3.5 1,410 2,100
M33 33
(F) 2.0 1,520 2,240
5/16 05 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
Unified thread 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
1 16 8 UNC 640 940
95ZV-2 EU FS 00-16
Outline
Flanged hexagon bolt
1. Bolt type: Metric thread
2. Bolt strength: 8.8 (8T)
3. Thread pitch: Coarse pitch thread (C)
(N-m)
Type Nominal
Pitch 8.8 (8T)
dimension
M5 0.8 7
M6 1 12
M8 1.25 28
M10 1.5 53
Metric thread
M12 1.75 94
M16 2 231
M20 2.5 441
M24 3 765
(kgf-m)
Type Nominal
Pitch 8.8 (8T)
dimension
M5 0.8 0.7
M6 1 1.2
M8 1.25 2.9
M10 1.5 5.4
Metric thread
M12 1.75 9.6
M16 2 23.5
M20 2.5 45.0
M24 3 78.0
(lb-ft)
Type Nominal
Pitch 8.8 (8T)
dimension
M5 0.8 5.0
M6 1 8.6
M8 1.25 20.9
M10 1.5 38.9
Metric thread
M12 1.75 69.1
M16 2 169.2
M20 2.5 324.0
M24 3 561.6
95ZV-2 EU FS 00-17
Outline
Hose band tightening torque
Low pressure hose

(heat resisting hose) Tightening torque Tightening torque Tightening torque
Hose band
(N-m) (kgf-cm) (lb-ft)
Inner dia. (mm) Outer dia. (mm)
6.3 16.5
7.9 18.5 69002-02200 1.6 16 1.2
9.5 20.5
12.7 24.5 69002-02700
15.9 29.9
69002-03100
19.0 30.0
25.4 38.0 69002-04400
31.8 45.8 69002-05200 4 40 2.9
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 Tightening torque Tightening torque Tightening torque

Hose band
Inner dia. (mm) Outer dia. (mm) (N-m) (kgf-cm) (lb-ft)
6 16.5
8 18.5 69002-02200 1.6 16 1.2
9 20.5
9 22.0 69002-02300
12 24.5
69002-02700
12 26.0
15 29.0
69002-03100
15 30.5
19 32.0
69002-03800
19 34.0
4 40 2.9
25 39.5
69002-04400
25 41.5
32 46.0
69002-05200
32 48.0
38 54.0 69002-05700
50 70.5
69002-07600
50 73.0
To connect the hose to the pipe, tighten the hose band 2~3 mm (1/8 in)
Fix the band
at the following position: avoiding the beading.
Pipe
Hose
Hose band
K50V200002
95ZV-2 EU FS 00-18
Outline
Liquid gasket and screw lock Cautions regarding reassembly

agent To reassemble a screw
Completely remove the hardened lock agent from the

To reassemble the disassembled parts, be sure to use
screw and the threaded hole before reassembling the
the specified liquid gasket or screw lock agent or the
screw.
equivalent according to the following lists:
Code Manufacturer Product name

Note
® A piece of hardened lock agent may be peeled off and
AA01 Loctite Plastic Gasket 568
remain in the component. The remaining piece may
Liquid
AA02 Loctite® Hydraulic sealant cause malfunction during fastener installation.
gasket
AA03 Three Bond Three Bond 1215
AB01 Loctite® Loctite® 262 To bond a plane or to fit a shaft
Screw lock
AB02 Three Bond Three Bond 1327
agent Remove the hardened lock agent using a wire brush or
AB03 Three Bond Three Bond 1374 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.
Cautions regarding parts removal Antiseize Agent
Code Manufacturer Product name

If a screw or shaft to be removed has been locked by
Loctite® 767
one of the above agents, remove the screw or shaft AC01 Loctite®
using a general tool, such as a wrench or puller. (Paste or spray)
If it is difficult to remove the screw or shaft, heat the bolt

to soften the agent (200~250°C) 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.
95ZV-2 EU FS 00-19
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
To avoid a piece of seal tape left in the circuit, leave 1 or

65ZV00002 2 screws from the end of the thread and start threading
it clockwise.
95ZV-2 EU FS 00-20
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 pos-
sible 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 5. To ground the welder, check that the electric current
negative sides from the battery. will not flow through the cylinders.
Cylinder head covers for some models have a low
conductive metal that will cause spark if the welding
IMPORTANT current flows. The spark may damage the cylinder
If a battery terminal is removed from a machine in rod.
less than 30 seconds after the key is put into the
“OFF” position, it can corrupt the ECM program, 6. Calibrate throttle pedal to ECM.
which can disable the engine. Always wait 1 full
minute to be sure to be past this “write to memory (a) Turn the starter switch to "ON".
function” prior to removing battery terminals. (b) Fully depress and release the throttle pedal
three times.
(c) Turn the starter switch to "OFF".
3. Disconnect the connector for MCU (machine con-
troller), ECM (engine controller) and air conditioner.
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 Section to be welded Ground this section.
through the cylinders. (correct grounding)
35C00006
95ZV-2 EU FS 00-21
Outline
7. The weld spattered on the hydraulic cylinders and

on the plated sections of pins will damage the cylin-
ders and pins. There are other parts that may be
damaged by the spatter; hydraulic units, har- Heat-resistant
cloth
nesses, hydraulic hoses, and nylon tubes.
Be sure to mask these units and parts before weld- Section to
ing. Hydraulic hose be welded
Nylon tube Remove
Harness and if
necessary
Hydraulic cylinder wrap
Chassis
35A00005
Plated section (Mask this section.)

(c) Hydraulic hoses, nylon tubes, or harnesses are
easily damaged by the heat during welding. To pro-
tect them from the heat, remove them from the sec-
Pin section with pin tion to be welded to make enough clearance.
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 corro-
sion.
Scrap material, etc.

1m or more
Section to
be welded
1m or more
35C00004
(b) Cover the hydraulic units, electrical units, har-

nesses, hydraulic hoses, nylon tubes, etc. with
heat-resistant cloth (glass wool or canvas) or scrap
material to protect them from spatter.
95ZV-2 EU FS 00-22
MEMO
95ZV-2 EU FS 03-1
03 Measurement for Performance Check
03 Measurement for
Performance Check
Cautions on Safety .................................................. 03-2

Standard Measurement Values for Performance Check
........................................................................... 03-3
95ZV-2 EU FS 03-2
Cautions on Safety
Cautions on Safety
WARNING CAUTION
Unexpected movement of the machine may cause an Touching the fan or the V belt of the engine or the hot
accident resulting in injury or death. area while the engine is running may cause severe
Therefore, to provide repair service with the engine accidents.
running, be sure to observe the following items: Make sure to stop the engine before opening the
- Park the machine on level ground. engine room access panel.
- 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 acci-
dents.
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.
95ZV-2 EU FS 03-3

Measurement conditions
Temperature of torque converter oil: 50~80°C (120~180°F)
Temperature of hydraulic oil: 50~80°C (120~180°F)
Temperature of engine coolant: 50~80°C (120~180°F)
Standard measurement
Item
values for performance check
Remarks
Fuel efficient
System Measurement item Normal
mode
Minimum no-load speed, Low Idle (LI) 850±50 725 in hibernate mode
Maximum no-load speed, High Idle (HI) 2,040±50
Engine speed
(min-1) (rpm) Maximum speed in torque converter stall mode 2,000±100 1,800±100
(S/N 9001~9250) Maximum speed in multiple control valve relief mode 2,010±100 1,670±100
Maximum speed in torque converter stall plus multiple
1,460 +150
- 100 1,250 +150
- 100
control valve relief mode
Engine
Minimum no-load speed, Low Idle (LI) 850±50 725 in hibernate mode
Maximum no-load speed, High Idle (HI) 2,040±50 1,800±50
Engine speed
(min-1) (rpm) Maximum speed in torque converter stall mode 2,020±100 1,800±100
Maximum speed in multiple control valve relief mode 2,010±100 2,010±100
(S/N 9251~)
Maximum speed in torque converter stall plus multiple
1,530 +150
- 100 1,300 +150
- 100
control valve relief mode
Main pressure Idling (LI) 2.4±0.2 (24±2) (341±28)

MPa (kgf/cm2) (psi) Maximum (HI) 3.0±0.2 (31±2) (441±28)
1st speed 2.2±0.2 (22±2) (313±28)
Transmission
Engine speed Idling (LI)

Clutch pressure Except 1st speed 2.4±0.2 (24±2) (341±28)
MPa (kgf/cm2) (psi) 1st speed 2.5±0.2 (25±2) (356±28)
Maximum (HI)
Except 1st speed 2.9±0.2 (30±2) (427±28)
Clutch time lag NeutralForward 1st speed

0.3±0.1 Before wheels move
(sec) (engine speed: 1,500 min-1 (rpm))
95ZV-2 EU FS 03-4
Item
Remarks
Fuel efficient
mode
Cylinder drift
(when boom and Boom cylinder 3 (1/8) or less
bucket are
horizontal and with
no load) Bucket cylinder 4 (5/32) or less
(mm/min) (in/min)
Idling (LI) 23±3.0

Boom rising time
-1
(no load) Engine speed 1,500 min (rpm) 10.5±1.0
(sec)
Maximum (HI) 6.7±0.5
Idling (LI) 5.0±0.5
Full steering time
Engine speed 1,500 min-1 (rpm) 2.4±0.3
(sec)
Full accelerated engine speed 2.4±0.5
20.6±0.5 (210±5)
Loading line main relief pressure (HI)
(2,986±71)
Hydraulic line
Run engine at lowest

23.5±0.5 (240±5)
Loading line overload relief pressure (LI) possible speed while
(3,413±71)
setting
Relief valve setting
20.6±0.5 (210±5)
pressure Steering line main relief pressure (HI)
(2,986±71)
MPa (kgf/cm2) (psi)
24.5 +1.0 +10
0 (250 0 )
Steering line overload relief pressure (LI) possible speed while
(3,555 +1420 )
setting
3.5 (36)
Pilot line reducing pressure (LI) possible speed while
(512)
setting
Engine water temp. <80ºC (180ºF)
T/C oil temp. <110ºC (230ºF) 910 +75
- 200
Fan maximum Hydraulic oil temp. <90ºC (195ºF)
revolution (HI)
min-1 (rpm) Engine water temp. >95ºC (205ºF)
T/C oil temp. >115ºC (240ºF) 1,300 +100
- 50
Hydraulic oil temp. >95ºC (205ºF)
Fan minimum
Engine water temp. <60ºC (140ºF)
revolution (LI) 750 +50
- 200
Engine idle revolution
min-1 (rpm)
95ZV-2 EU FS 03-5
Item
Remarks
Fuel efficient
mode
Shift lever position 2nd speed reverse

Performance of
service brake
Engine speed Maximum (HI) Slowly increase the engine
speed, and check that the
machine does not move at the
Shift lever position 3rd speed reverse maximum engine speed. Before brake check, be
sure to disconnect the
Performance of
cable connector of
parking brake
parking brake solenoid
Engine speed Maximum (HI) valve.
11.8±0.5 (120±5)
Off (Cut-out)
(1,706±71)
Unloader valve
Brake line setting setting pressure
Brake
6.9±1.0 (70±10)
pressure On (Cut-in)
(995±142)
MPa (kgf/cm2) (psi)
Low-pressure alarm switch setting pressure 3.9±0.5 (40±5)

(For brake accumulator circuit) (569±71)
The time from the low-pressure

Accumulator charge
Engine speed (LI) alarm is turned off till the 16
time (sec)
unloading valve cuts off pressure
Run engine 1 minute high idle, then stop the engine.
Repeat stepping on the
(Turn key switch "ON" with engine off.)
Number of brake brake pedal as follows:
Step on the brake pedal and release, and check the at least 10 times
pedal applications On: 5 sec.
number of times until the low-pressure alarm is turned
Off: 5 sec.
on.
Engine: Maximum speed/ Declutch pedal: Quick
Declutch 1/5 slope
release
engagement 15 (6) or less (approx. 11º), unladen,
(Distance the loader rolls back before moving
(cm) (in) 1st speed
forward.)
Note
These are the standard measurement values for the
machines at the time when delivered from the factory.
95ZV-2 EU FS 03-6
MEMO
95ZV-2 EU FS 12-1
12 Function & Structure Chassis Group
12 Function & Structure

Chassis Group
Front Chassis .......................................................... 12-2

Rear Chassis........................................................... 12-5
Center Pin ............................................................... 12-7
95ZV-2 EU FS 12-2
Front Chassis
Front Chassis
Loading linkage
2 8 3 9 4 5
10
7 6
95ZV12001
1. Bucket
2. Link
3. Lever
4. Boom
5. Bucket cylinder
6. Boom cylinder
7. Dump stopper surface
8. Roll-back stopper surface
9. Lever stopper surface
10. Bucket stop plate
(Design differs by manufacturer of the attachment)
95ZV-2 EU FS 12-3
Front Chassis
Even contact both sides
(14’8 13/16”)
4,490 mm
45 º
40 º
270 mm Hinge pin height at

(10.6 in) bucket on ground
Typical bucket dump stopper clearance
(Contact attachment supplier for details on
Typical bucket roll-back stopper adjustment non-standard attachments)
(Contact attachment supplier for details on non-standard To increase clearance increase height of #9
attachments) To reduce clearance decrease height of #9
95V2U12002a
95ZV-2 EU FS 12-4
Front Chassis
Loading linkage pin

mm (in)
1. Bucket - Boom 2. Boom - Lever 3. Boom - Boom cylinder
4. Front chassis - Boom 5. Bucket - Rod 6. Lever - Rod
7. Lever - Bucket cylinder 8. Bucket cylinder - 9. Boom cylinder -

Front chassis Front chassis
10. Front chassis - 11. Steering cylinder -

Steering cylinder Rear chassis
2 7 3 8 4
10 11
1 6 9 K95ZV12003
95ZV-2 EU FS 12-5
Rear Chassis
Rear Chassis
Fuel tank
B 2
7
10
A-Detail
10
(S/N 9151~)
2
4
9 (S/N ~9150)
11
5 6
8
1. Fuel tank
2. Fuel level sensor
3. Fuel tank filler assembly
4. Filter
5. Drain plug
6. Inspection hole cover
7. Gasket (Rubber seal type)
8. Suction pipe
9. Pipe (for vacuum prevention) (S/N ~9150)
10. Breather valve (S/N 9151~)
11. Fuel return pipe B-Detail
95V2E12002
95ZV-2 EU FS 12-6
Rear Chassis
Floor board mount Viscous mount
Floor board
1 1
95ZV12007 4
1. Floor board
2. Rubber cushion
6 8
The floor board is installed on the rear chassis by the
rubber cushion. The instrument panel, control box, 9
7
operator's seat and the air conditioner unit are on the
floor board.
5
K95V2U12001
1. Stud bolt
2. Stud
3. Cushion rubber
(S/N ~9182: HS62) (S/N 9183~: HS70)
4. Case
5. Seal plate
6. Damping plate
7. Silicone oil
8. Plain washer
9. Hexagon head bolt
The floor board is supported by a viscous mount in four

positions so that vibrations, impacts and sounds gener-
ated in the chassis are not transmitted to the inside of
cabin.
95ZV-2 EU FS 12-7
Center Pin
Center Pin
Upper center pin Lower center pin
1
7 6
4
9, 10
Front 3
chassis
Front
5
chassis
6
2
7
Rear
Rear chassis
chassis 5
4
2 Lower
Upper 8, 10 1
95ZV12009 95ZV12010
Upper Lower
1. Center pin 1. Center pin

2. Cover 2. Bearing retainer
3. Bearing cover 3. Bearing assy
4. Sleeve 4. Dust seal
5. Shim 5. Bushing
6. Bearing assy 6. Bolt
7. Dust seal 7. Plate
8. Bolt
9. Bolt
10. Washer
95ZV-2 EU FS 12-8
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.
95ZV-2 EU FS 13-1
13 Check & Adjustment Chassis Group
13 Check & Adjustment

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

Center Pin ............................................................... 13-5
95ZV-2 EU FS 13-2
Linkage Pin
Linkage Pin
WARNING CAUTION
Unexpected movement of the machine may cause an Unexpectedly dropped parts may cause an accident
accident resulting in injury or death. resulting in injury.
Before starting adjustment work, be sure to observe - Before liner insertion, be sure to lift the cylinder
the following items: using a crane to prevent the cylinder from unex-
- Park the machine on level ground. pectedly dropping during liner insertion.
- Apply the parking brake. - Wear protective clothes like work gloves and steel
- Remove the starter key, and attach a "DO NOT toed shoes.
OPERATE!" tag on the cab.
moving.
Liner
3 4 5
1 6
95ZV12004
Adjustment
1 2 3 4 5 6 7
portion
Liner hole Adjustment
110 81 111 91 111 51
diameter (mm) unnecessary
95ZV-2 EU FS 13-3
Linkage Pin
Bucket hinge pin section
Boom Bucket
Bushing Bushing
* *
Hinge pin (#1)
Bolt
Dust seal
Shim Seal retainer assy Shim
95V2E13001
Adjust the clearance (*) to 1.0 mm (0.039 in) or less for

hinge pin (#1).
How to assemble
2. Align the pin holes in the bucket and the boom then
insert the pin.
3. Place the shim between the bucket boss and the

5
seal retainer assy so that the clearance between

.
R122
the boom boss and the seal retainer (* marked) is

less than 1mm.
5
Tighten the bolt for the seal retainer assy.

R5
Shim : 417 N-m (42.5 kgf-m) (307 lb-ft)
90V2E13001 Shim thickness
1.0, 0.5 mm (0.039, 0.020 in)

1. Attach the seal retainer assy to the bushings.
(2 kinds of shim thickness)
(When installing the dust seal to the seal retainer
assy, be sure to check the direction of the dust
seal.)
95ZV-2 EU FS 13-4
Linkage Pin
Adjustment
* *
95ZV12005
Adjust the clearance (*) to 1.2 mm (0.047 in) or less for

#2 ~ #7 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 chas-
sis side while checking that the cylinder is not inclined.
95ZV-2 EU FS 13-5
Center Pin
Center Pin
Adjusting shim Grease nipple installation direc-

tion
1
4
9, 10
3 Grease nipple
Front
Front
chassis
5
6
7 [Upper] [Lower]
Rear
chassis 95ZV13002
2
Upper 8, 10
Install the both grease nipples (for the upper center pin
95ZV12009
and the lower center pin) as illustrated.
The clearance between the front chassis and bearing

cover (3) is 0.75±0.5 mm (0.03±0.02 in) before shim
adjustment.
Installing bearing outer ring
Add shims (5) so that the clearance is 0.1±0.05 mm
(0.004±0.002 in). After that, tighten bolt (9).
: (8): 422 N-m (43.0 kgf-m) (311 lb-ft)

(with lubrication oil)
: (9): 441 N-m (45.0 kgf-m) (326 lb-ft)

Front Rear
3
Center line Split of outer
bearing
95ZV13003
Install bearing outer ring (3) so that the split is perpen-

dicular to the front–rear line of the machine.
95ZV-2 EU FS 13-6
MEMO
95ZV-2 EU FS 22-1
22 Function & Structure Power Group

Power Group
Power Line .............................................................. 22-2

Engine / Transmission............................................. 22-4
Radiator (S/N 9001~9150) ...................................... 22-5
Radiator (S/N 9151~) .............................................. 22-6
Propeller Shaft......................................................... 22-8
Axle Assembly......................................................... 22-11
Axle Support............................................................ 22-12
Torque Proportioning Type Differential Gear (TPD) 22-14
Limited Slip Differential (LSD) (option) .................... 22-19
95ZV-2 EU FS 22-2
Power Line
Power Line
15
95V2U22001
(S/N 9151~) 1. Engine

13 3 2. Torque converter and transmission
3. Radiator
4. 2nd propeller shaft
11 5. 3rd propeller shaft
6. Front axle differential gear
7. Rear axle differential gear
8. Parking brake
9. Air cleaner
10. Muffler
11. Hydraulic oil cooler
12. Torque converter oil cooler
13. Charge air cooler
14. Fuel cooler
15. Precleaner
1 12 14 K95V2U22001
95ZV-2 EU FS 22-3
Power Line
The power output from the engine is transmitted to the

transmission through the torque converter (combined
with the transmission). The speed and direction are
changed according to the engagement of the transmis-
sion 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, fuel cooler and an external
air type hydraulic oil cooler. A parking brake is installed
on the second propeller shaft.
(S/N 9151~)
The torque converter oil cooler is separately mounted
on the chassis.
95ZV-2 EU FS 22-4
Engine / Transmission
Engine / Transmission
Engine / transmission mount
A A
Bracket Transmission side Engine side

Bracket
5 Flywheel
1
4 5
3
6
2 1 7
A-Detail B-Detail
C-Detail
95V2E22002
1. Bushing Bolts are used to connect the engine flywheel housing

2. Sleeve to the torque converter housing, and a spline ring cou-
3. Block pling (7) is used to transmit the engine power to the
4. Washer torque converter. Therefore no thrust load is placed on
5. Washer the engine flywheel or crankshaft.
6. Plate
7. Ring gear Rubber cushions are used to mount the engine and the
transmission on the chassis.
95ZV-2 EU FS 22-5
Radiator (S/N 9001~9150)
Radiator (S/N 9001~9150)
Charge air Coolant IN Charge air

cooler OUT cooler IN
4
B
3
A
C
A
C
7 2
Bypass Fuel cooler IN 5

coolant IN Coolant OUT 6
Hydraulic oil T/C oil Fuel cooler Hydraulic oil T/C oil
cooler OUT cooler OUT OUT cooler IN cooler IN
3 3 8 9
1. Radiator assembly 6. T/C oil cooler
2. Radiator duct 7. Fuel cooler
3. Stay (Bracket) 8. Plate
4. Charge air cooler 9. Bushing-Rubber
5. Hydraulic oil cooler
A-Detail B-Detail C-Detail
K95V2U22002
The radiator incorporates the engine coolant, cooling The fuel cooler and air charge cooler are required to
fin, air charged cooler, and an external air type hydraulic meet engine emission regulations.
oil cooler. For the engine coolant, air charge cooler, fuel
cooler and hydraulic oil cooler, the air-cooling system is Capacity in radiator:
used. For the torque converter oil, the water-cooling Cooling water 70 L (18.5 gal)
system is used. Hydraulic oil 3.4 L (0.9 gal)
Torque converter oil 3.0 L (0.8 gal)
When the coolant is cold enough, the thermostat is Fuel 2.1 L (0.6 gal)
completely closed directing coolant from the bypass line
to the torque converter oil cooler. The coolant flow cools Dry weight 570 kg (1,260 lbs)
the torque converter oil to prevent it from being over-
heated even when the thermostat is closed.
95ZV-2 EU FS 22-6
Radiator (S/N 9151~)
Charge air Coolant

deaerating tank 4
cooler OUT
Hydraulic oil Coolant IN Charge air
cooler IN cooler IN
1
5 3
7
A
C
C
D D
Coolant OUT
Coolant IN
Fuel cooler Fuel cooler 6 7

OUT IN
T/C oil
Hydraulic oil cooler OUT
cooler OUT
Coolant IN (bypass)
T/C oil
6 cooler IN Coolant OUT
D-D Coolant OUT (bypass)
K97V2J22001
1. Radiator assembly 5. Hydraulic oil cooler When the coolant is cold enough, the thermostat is
2. Radiator duct 6. T/C oil cooler completely closed directing coolant from the bypass line
3. Stay (Bracket) 7. Fuel cooler to the torque converter oil cooler. The coolant flow cools
4. Charge air cooler the torque converter oil to prevent it from being over-
heated even when the thermostat is closed.
The radiator incorporates the engine coolant, cooling
fin, air charged cooler, hydraulic oil cooler and an exter- The fuel cooler and air charge cooler are required to
nal air type fuel cooler. For the engine coolant, air meet engine emission regulations.
charge cooler, fuel cooler and hydraulic oil cooler, the
air-cooling system is used. For the torque converter oil,
the water-cooling system is used.
95ZV-2 EU FS 22-7
Radiator mount
3 3 8 9
A-Detail B-Detail C-Detail
95V2E22004
1. —
2. —
3. Stay (Bracket)
4. —
5. —
6. —
7. —
8. Plate
9. Bushing-Rubber
Capacity in radiator:
Cooling water 62 L (16.5 gal)
Hydraulic oil 7 L (1.9 gal)
Torque converter oil 3 L (0.8 gal)
Fuel 2.1 L (0.6 gal)
Dry weight 570 kg (1,260 lbs)

95ZV-2 EU FS 22-8
Propeller Shaft
Propeller Shaft
1 3 4 2
95V2E22005
1. 2nd propeller shaft The engine power is transmitted to the torque converter
2. 3rd propeller shaft (fixed type) and the transmission, and is then transmitted to the sec-
3. Pillow block ond and the third propeller shafts to the front and the
4. Slip joint 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 propel-
ler shaft length.
The third propeller shaft is the fixed type with universal

joints.
95ZV-2 EU FS 22-9
Propeller Shaft
Second propeller shaft assembly
Front differential – Transmission
Grease nipple installation

2 3 1 6 1
angle (a, b, c, d)
d c b a
45
View Z
4 5
2 d
Every 12000 hours greasing
5
Every 2000
hours greasing
Front differential
3
b
1 Transmission
c
1 Every 12000
hours greasing a
95V2U22002
1. Journal spider assy Note

2. Journal spider assy When the bolts are removed always replace them with
3. Propeller shaft assy new bolts. Never reuse the drive line bolts.
4. Pillow block
5. Spline yoke
6. Sleeve yoke assy
95ZV-2 EU FS 22-10
Propeller Shaft
Third propeller shaft assembly
Transmission – Rear differential
Grease nipple installation

1 2 1 angle (a, b)
b a
45
View Z
Rear differential
side
a 1
1 b
Every 12000 hours greasing

Transmission
side
95V2U22003
1. Journal spider assy

2. Propeller shaft
95ZV-2 EU FS 22-11
Axle Assembly
Axle Assembly
1 51
42
41
43
30
24 50
3
7
45 39
45 38 35 6
2 44
12
11
25
28 49 33
54
20 48
46 (S/N 9001
47
19 ~9014) 37
20 32 31
15 23
17 9 16 27
21 26 10
34 2618
16
5 13
14
22
52 40
36 4 35
53 8
29
1. Differential assembly 19. Separation disc 37. Socket bolt

2. Axle housing assembly 20. Friction disc 38. Spring
3. Wheel hub 21. Brake backing plate 39. U-nut
4. Spider (planetary carrier) 22. Plate 40. Bolt
5. Cover 23. Axle nut 41. O-ring
6. Axle shaft 24. Taper roller bearing (inner) 42. Spacer
7. Air bleeder screw 25. Taper roller bearing (outer) 43. Ring
8. Sun gear 26. Needle cage 44. O-ring
9. Disc gear 27. Axle lock plate 45. Plug
10. Planetary gear 28. Separation disc 46. Spring
11. Internal gear 29. Snap ring 47. Sleeve
12. Internal gear hub 30. Floating seal 48. Bushing
13. Snap ring 31. D-ring 49. Socket bolt
14. Planetary pin 32. D-ring 50. Bolt
15. Spring pin 33. O-ring 51. Bolt
16. Wear ring 34. O-ring 52. Bolt
17. Wear ring 35. Magnet plug 53. Socket bolt
18. Piston 36. O-ring 54. Flange bolt
95ZV22010
95ZV-2 EU FS 22-12
Axle Support
Axle Support
Grease pipe
connection port
Grease pipe (PT1/8)
connection port
(PT1/8)
A
Pin
Rear side of (Axle housing)
axle support
9 9
Front
5
4
Front side of 14
axle support 9
A 1 6
View A-A
10 2 3 11
8 11
7 7
13
Groove at
bushing end
10
12 #11 Details
#10 Details
95V2U22005
1. Shaft 8. Lip seal

2. Rear axle support (front) 9. Breather
3. Rear axle support (rear) 10. Bushing
4. Wear ring 11. Bushing
5. Plate 12. Ring
6. Plate 13. Snap ring
7. Lip seal 14. O-ring
95ZV-2 EU FS 22-13
Axle Support
9 (S/N 9032~)
9 (S/N ~9031)
7
6 9 (S/N ~9031)
9 (S/N 9032~)
14
2
4
10
5
7
4
FRONT
12
11
3
8
13
K95V2E22001
1. Shaft 11. Bushing

2. Rear axle support (front) 12. Ring
3. Rear axle support (rear) 13. Snap ring
4. Wear ring 14. O-ring
5. Plate
6. Plate
7. Lip seal
8. Lip seal
9. Breather (S/N 9001~9031)
Fitting (S/N 9032~)
10. Bushing
95ZV-2 EU FS 22-14
Torque Proportioning Type Differential Gear (TPD)

Front differential gear (S/N 9001~9088)
2 1 23
24
3 28
36
29 26
33
35 32
4
31
30
27
5
6 34
7
22
8
9
10
21
25
11
12
13 15
20
14 17 16 18 19
K95V2U22005
95ZV-2 EU FS 22-15
2 1
23
24
29
3
36
K95V2U22003
Front differential gear (S/N 9251~)
2 1
23
29
3
36
K95V2U22004
1. Nut 13. Plate 25. Snap ring

2. Flange yoke 14. Wear ring 26. O-ring
3. Oil seal 15. Side gear 27. O-ring
4. Plug 16. Differential pinion 28. Gear
5. Housing 17. Pin 29. Piston assembly
6. Shim 18. Wear ring 30. Oil seal
7. Taper roller bearing 19. Spider 31. Friction disc
8. Spacer 20. Housing 32. Separation disc
9. Spiral gear set 21. Roller bearing 33. Pin
10. Carrier assembly 22. O-ring 34. Spring pin
11. Taper roller bearing 23. O-ring 35. Spring
12. Adjusting nut 24. O-ring 36. Oil seal (Double lip) (S/N 9066~)
95ZV-2 EU FS 22-16
Rear differential gear
2
3 23
26
4
5 24
6
22
7
10
21
25
11
12
13
14 15
17
16
18 19
20
K95V2U22006
1. Nut 14. Wear ring

2. Flange yoke 15. Side gear
3. Oil seal 16. Differential pinion
4. Trunnion 17. Pin
5. Flange 18. Wear ring
6. Shim 19. Spider
7. Taper roller bearing 20. Housing
8. Spacer 21. Roller bearing
9. Spiral gear set 22. O-ring
10. Carrier assembly 23. O-ring
11. Taper roller bearing 24. O-ring
12. Adjusting nut 25. Snap ring
13. Plate 26. Oil seal (Double lip) (S/N 9066~)
95ZV-2 EU FS 22-17
Function of T.P.D Contact between pinion and side gear
The differential gear used for the machine is the torque T.P.D. Conventional
proportioning type. Compared with the conventional dif- differential
ferential, the torque proportioning differential (T.P.D.)
can reduce tire slippage on sandy or muddy ground.
This prevents some of the reduction in rim - pull and tire

wear caused by tire slippage.
R2
R1
Difference in gear shapes
Shaft center of side gear
95ZV22018
Conventional Conventional differential

differential There is little change in distance from the shaft center of
the side gear.
T.P.D.
The contact point varies as the gear rotates. The dis-
tance between the contact point and the shaft center of
the side gear also varies in the range of R1~R2.
T.P.D. 95ZV22014
Conventional differential
Standard bevel gear
T.P.D.
Special bevel gear
The gear width is 35~50% longer than the conventional
differential.
95ZV-2 EU FS 22-18
Operation of T.P.D
Rotational direction
Pinion
Pinion
Side gear
R2
L R L R2 R1 R L R1 R
R1 R2
[A] [B] [C]

The surface resistance values The surface resistance of the The surface resistance of the
of the right and left wheels are left wheel is low due to sandy right wheel is low.
identical to each other. ground or the like.
95ZV22015
The function of the T.P.D. is as follows: If the surface (slipping occurs), the driving force of the right wheel
resistance values of the right and left wheels differ from will be increased to limit the reduction in the total
each other, engagement position of the pinion gear with amount of the driving force.
the side gears will be automatically shifted to transmit
different torque to the right and left wheels. Different Assuming that the driving torque of the right wheel is TR,
torque in right and left wheels prevents the tires from and that of the left wheel is TL, the relation between TR
slipping. and TL can be expressed as follows:
The number of pinion gear teeth is an odd number, and TR R

the pinion gear operate as follows. ------ = ------1
TL R2
1. When the traction of the right and left wheels are The value obtained from the above formula is referred
identical to each other, the pinion and side gears to as the bias ratio. The limit of the bias ratio is 1.37. In
will be engaged as shown in figure [A]. In this case, other words, until the difference in the surface resis-
the torque arms of both side gears are identical to tance between the right and left tires is increased to
each other (R1 = R2). As a result, identical driving 37%, the pinion gear will be properly engaged with the
force will be applied to both the right and left shifted side gears, and driving force will be properly
wheels. applied to both the side gears to prevent the tires from
slipping.
2. If the left wheel loses traction the engagement posi-
tion between the pinion and side gears will be 3. If the surface resistance of the right wheel is
shifted as shown in figure [B] to quickly rotate (spin) reduced, the engagement position between the pin-
the left wheel. As a result, the torque arms of the ion and side gears will be shifted as shown in figure
both side gears differ from each other (R1> R2), and [C] above. In this case, the right and left sides are
the driving force of the left wheel is small. As a reversed compared with the above description.
result, tire slipping can be reduced.
When the driving force of the left wheel is reduced
95ZV-2 EU FS 22-19
Limited Slip Differential (LSD) (option)
LSD structure
Note
Differential assembly 1. Clutch assembly (2) is built with six plates
as a unit. Do not change this combination.
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
5
Without lining
1
2
2
3
4
Limited Slip Differential
1
2
3
3
2
95V2U22004
1. Differential cage
2. Clutch assembly
3. Side gear
4. Pin
5. Bolt
95ZV-2 EU FS 22-20
2 1 23
24
3
28
38
26
29
33
35 32
4
31
30
27
5
6 34
7
22
8
9 15
10
21
25
11
12
13
20
14 20 17 16 18 19 36 37
K95V2U22007
1. Nut 14. Wear ring 27. O-ring

2. Flange yoke 15. Side gear 28. Gear
3. Oil seal 16. Differential pinion 29. Piston assembly
4. Plug 17. Pin 30. Oil seal
5. Housing 18. Wear ring 31. Friction disc
6. Shim 19. Spider 32. Separation disc
7. Taper roller bearing 20. Housing 33. Pin
8. Spacer 21. Roller bearing 34. Spring pin
9. Spiral gear set 22. O-ring 35. Spring
10. Carrier assembly 23. O-ring 36. Pin
11. Taper roller bearing 24. O-ring 37. Clutch assembly
12. Adjusting nut 25. Snap ring 38. Oil seal (Double lip) (S/N 9066~)
13. Plate 26. O-ring
95ZV-2 EU FS 22-21
2 1
23
24
29
3
38
K95V2U22008
Front differential gear (S/N 9251~)
2 1
23
29
3
38
K95V2U22009
95ZV-2 EU FS 22-22

1
2
3 23
28
5 24
6
22
7
8
15
9
10
21
25
11
12
13
14
17
26 20
16
18 19 20 27
K95V2U22010
1. Nut 15. Side gear

2. Flange yoke 16. Differential pinion
3. Oil seal 17. Pin
4. Trunnion 18. Wear ring
5. Housing 19. Spider
6. Shim 20. Housing
7. Taper roller bearing 21. Roller bearing
8. Spacer 22. O-ring
9. Spiral gear set 23. O-ring
10. Carrier assembly 24. O-ring
11. Taper roller bearing 25. Snap ring
12. Adjusting nut 26. Pin
13. Plate 27. Clutch assembly
14. Wear ring 28. Oil seal (Double lip) (S/N 9066~)
95ZV-2 EU FS 22-23
LSD function LSD operation
Performance comparison between LSD and TPD

LSD
Differential TPD
pinion LSD Differential point 0.4
nge
(bias ratio 2.5) ing ra
LSD clutch p e ra t
L SD O ating
assembly Op e r
T PD
Torque
e
Differential ge rang
cage r an A
n the ran
ge
i he
ins in t
sp n s
t i re spi
re
On
e e ti TPD Differential point 0.73
On (bias ratio 1.37)
Axle shaft 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
Friction ratio between right and left tires
Torque is transferred to the

right and left tires evenly until
the friction ratio between the
right and left tires comes to
Side gear moves 0.4:1. The result is that the
to the left and LSD adds tractive effort.
pushes LSD
clutch. 0.4 1
Side gear
A - Detail
95V2E22014 95V2E22015
LSD (Limited-Slip Differential) is installed between the The following shows operation for the left tire.
side gear and the differential cage in TPD (Torque Pro-
portioning Differential), and increases tractive effort. If A rotating driving force is transmitted from the differen-
the surface traction of the right and left tires differ from tial cage via spider (cross shaft) to the differential pinion
each other during operation, LSD clutch engages and and the side gear.
prevents traction loss.
When the ground surface resistance for the left tire less-
The performance of LSD is shown by using the bias ens, the tapered interface between the differential pin-
ratio. The bias ratio is the ratio between the driving force ion and the left side gear induces a side force. It pushes
of the right and left tires while the differential pinion is the left side gear to the left resulting in frictional engage-
turned. When the bias ratio is larger, it is easier to gain ment with the differential cage, thus impeding free left
traction on the ground surface with less resistance. side gear rotation and gaining traction.
95ZV-2 EU FS 22-24
MEMO
95ZV-2 EU FS 23-1
23 Check & Adjustment Power Group

Power Group
Engine ..................................................................... 23-2

Propeller Shaft......................................................... 23-3
Axle ......................................................................... 23-5
95ZV-2 EU FS 23-2
Engine
Engine
Measuring engine oil pressure
WARNING
Unexpected movement of the machine may cause an Measurement instrument
accident resulting in injury or death.
Therefore, to provide repair service with the engine - Pressure gauge
running, be sure to observe the following items:
- Park the machine on level ground.
- Apply the parking brake. Install position
moving. 1. Location (A)
- Determine the signals between the service men.
- Prohibit any person from walking into dangerous 2. Measuring port: M14 X 1.5
areas.
- Near articulation area of the machine 3. Oil pressure gauge: 1.0 MPa (10 kgf/cm2) (150 psi)
- Under the machine
- Around the engine
- In front of or behind the machine Standard measurement value
Engine speed Service standard

CAUTION 2,040±50 min-1 0.24~0.27 MPa (2.4~2.8 kgf/cm2) (35~40 psi)
Do not touch the fan or V-belt of the engine or high- [Engine coolant temperature 50ºC (120ºF)]
temperature section if the engine is running.
An accident resulting in injury may occur.
(A)
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 revo-
lution.
Measuring engine speed 97ZV23004
Measurement instrument
- Tachometer
Standard measurement value
Low idle (min-1): 850±50
High idle (min-1): 2,040±50

95ZV-2 EU FS 23-3
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 trans-
mission torque and the reaction force. As a result,
the propeller shaft will extremely vibrate, and the ser-
vice 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.
95ZV-2 EU FS 23-4
Propeller Shaft
Propeller shaft tightening torque
Pillow block
2nd propeller shaft (Center bearing) 3rd propeller shaft
Front diff. 1 4 2 3 Rear diff.

Bolt 6
Washer
8 5
(S/N 9301~) K95V2U23005
:
1. 142 N-m (14.5 kgf-m) (105 lb-ft) 1. Screw lock agent (Three Bond 1327)
4. 441 N-m (45.0 kgf-m) (326 lb-ft) 4. Screw lock agent (Loctite® 262)
5. 162 N-m (16.5 kgf-m) (119 lb-ft) 5. —
6. 162 N-m (16.5 kgf-m) (119 lb-ft) 6. —
7. 162 N-m (16.5 kgf-m) (119 lb-ft) 7. —
8. 417 N-m (42.5 kgf-m) (308 lb-ft) 8. Screw lock agent (Loctite® 262)
95ZV-2 EU FS 23-5
Axle
Axle
Axle nut tightening procedure
9 8 7
PT 3/8
Brake oil inlet
2
10
4
5 3
95V2E23002
1. Tighten axle nut (6) with 2,746 N-m (280 kgf-m) :

(2,026 lb-ft) tightening torque to install taper roller 1. 89.7 N-m (9.15 kgf-m) (66 lb-ft)
bearing (7)(8). 2. 417 N-m (42.5 kgf-m) (307 lb-ft)
3. 33.3 N-m (3.40 kgf-m) (25 lb-ft)
2. Loosen axle nut (6). 4. 53.0 N-m (5.40 kgf-m) (39 lb-ft)
5. 86.3 N-m (8.80 kgf-m) (64 lb-ft)
3. Tighten axle nut (6) again with 2,746 N-m (280 kgf-
m) (2,026 lb-ft) tightening torque.
#1, 2, 4, 10: Screw lock agent (Three Bond 1327)
4. Turn wheel hub (9) 2~3 turns back and forth, and
measure the preload applied to section ( part).
Preload of section ( part)

324~363 N (33~37 kgf) (73~81 lbf) 
This is "breakaway" force. The force required to

start the wheel turning.
Note
Use jig to install the floating seal to the axle assembly.
95ZV-2 EU FS 23-6
Axle
Differential gear adjustment procedure

Front differential (S/N 9001~9088)
7 6
(Front differential
preload section)
2
(Rear differential
10 preload section)
5 3
95V2E23003
:
1. 883 N-m (90.0 kgf-m) (651 lb-ft) #2, 3, 4, 5, 7: Screw lock agent (Three Bond 1327)
2. 314 N-m (32.0 kgf-m) (232 lb-ft) #1, 9: Liquid gasket
3. 873 N-m (89.0 kgf-m) (644 lb-ft) (Three Bond 1215 or a locally procured Room
4. 52.5 N-m (5.35 kgf-m) (39 lb-ft) Temperature Vulcanizer (RTV) that does not con-
5. 216 N-m (22.0 kgf-m) (159 lb-ft) tain Acetic Acid)
6. 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)
95ZV-2 EU FS 23-7
Axle
Front differential gear (S/N 9089~9250) Preload adjustment
Measure the preload at the bolt holes of cage (2)(7).

1
Standard preload
7
Front differential:
22~27 N (2.2~2.8 kgf) (5~6 lbf)
Rear differential:
36~45 N (3.7~4.6 kgf) (8~10 lbf)
9
11
If the preload is out of the above range, replace spacer
(10) to adjust the preload to the specified range.
K95V2U23001
Preload is the force required to start the cage moving-

Front differential gear (S/N 9251~) breakaway force.
Note
1 There are 20 types of spacers from 22.10 mm (0.870 in)
to 22.48 mm (0.885 in) in increments of 0.02 mm
(0.0007 in). Thicker spacers reduce preload; thinner
7
spacers increase preload.
9
11
K95V2U23002
10
K95V2U23004
95ZV-2 EU FS 23-8
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
9
Snap ring
Apply grease
when
assembling.
3 mm
Bearing (8) (0.118 in)
3.6 mm
(0.142 in)
11 (S/N 9066~) (double lip)

K85ZV23003 9 (S/N ~9065) (single lip)
K95V2U23003
Note
A snap ring is set to bearing (8) as shown above. Incor- After reassembling the differential assembly, apply
rect installation of bearing (8) may cause the snap ring grease to the grease nipple until the grease comes out
to drop, resulting in a serious mechanical trouble. from the breather.
95ZV-2 EU FS 23-9
Axle
Adjusting tooth contact
Tooth contact Possible cause Adjusting method
A Correct
Loosen the bearing adjuster on the rear

side of ring gear, and tighten the adjuster of 2
Ring gear is too close to the tooth side at the same quantity as loosen-
B
drive pinion ing, so that the ring gear is far apart from
the drive pinion. Check again the backlash
and tooth contact.
2
Ring gear is too far from the
C Do the reverse adjusting as B.
drive pinion
Increase the thickness of shim at the part

of bearing cage being installed and makes 2
Drive pinion is too close to the
D drive pinion apart from the ring gear.
ring gear.
Check again the backlash and tooth con-
tact.
1
Decrease the thickness of shim reverse as

2
D, and makes drive pinion approach the
Drive pinion is too far from the
E ring gear.
ring gear.
Check again the backlash and tooth con-
tact.
1
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.
95ZV-2 EU FS 23-10
Axle
Three types of tooth contact shown below are accept-

able as the best tooth contact.
Tooth contact position and length (rate)
10
1 5 4
Pattern TOP HEEL
A
Pitch line 4~5 10
TOE
BOTTOM
10
2 4 4
Pattern TOP HEEL
B Pitch line 4~5 10
TOE
BOTTOM
10
3 4 3
Pattern TOP HEEL
C TOE 4~5 10
Pitch line
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 pin-
ion as a unit.
Note
Single sale of the bevel gear or the drive pinion is not
possible.
95ZV-2 EU FS 32-1
32 Function & Structure Torque Converter and Transmission Group

Torque Converter and Transmission Group
Torque Converter .................................................... 32-2

Torque Converter (Lock-up) (Option) ...................... 32-3
Torque Converter Gear Pump ................................. 32-6
Transmission ........................................................... 32-8
Clutch Pack ............................................................. 32-12
Power Flow Path in the Transmission ..................... 32-13
Hydraulic System Diagram...................................... 32-18
Hydraulic Circuit Diagram........................................ 32-20
Oil Flow ................................................................... 32-22
T/C and T/M Oil Circulation ..................................... 32-23
Modulator Valve Unit ............................................... 32-25
Control Valve Assembly .......................................... 32-32
95ZV-2 EU FS 32-2
Torque Converter
Torque Converter
Torque multiplication
Torque ratio (t)

Output Input
3
P T 1
95ZV32002
0.5 1.0
Speed ratio (e)
95ZV32003
Torque converter structure If the engine speed/pump impeller speed stays the
same but the turbine impeller speed is reduced due to
The torque converter is between the engine and trans- the transmission load-output torque is increased. This is
mission, and consists of three impellers as shown in the "torque multiplication". Heat is also generated.
figure. The three impellers are pump (P), turbine (T),
and stator (S) impellers. Turbine impeller speed (min –1 ) (rpm)
Speed ratio(e)= ------------------------------------------------------------------------------------------------
-
Pump impeller speed (min – 1 ) (rpm)
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:
pumpturbinestatorpump). Oil is redirected by the
fixed stator impeller back to the pump impeller. When
the turbine impeller rotates, the power will be transmit-
ted to the output shaft.
95ZV-2 EU FS 32-3
Torque Converter (Lock-up) (Option)
(T/M S/N PT315L01-0101~

T/M S/N PT315L04-0105)
4
P T
S
Oil from Lock-up
solenoid valve
1
2
3
(T/M S/N PT315L01-0101~

T/M S/N PT315L04-0100)
(T/M S/N PT315L04-0101~)
(T/M S/N PT315L04-0106~)

95V2U32004
1. Lock-up piston
2. Friction plate
3. Steel plate
4. Turbine shaft
5. Drive cover
95ZV-2 EU FS 32-4
Lock-up clutch structure Lock-up clutch function (only for-

ward)
Lock-up clutch
Output
P T
Input
Oil from S
Lock-up
solenoid
valve
S
Lock-up clutch
P T
95V2E32030
The torque converter is equipped with the lock-up 4

device. 1
2
When the lock-up clutch is engaged, the power from the 3
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
95V2E32028
ground speed can be reached, and less heat is gener-
ated.
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 lockup is activated by the signal from the MCU.
The torque converter oil flows through the oil hole pro-
vided in the center of turbine shaft (4) and the oil hole
provided in drive cover (5), then presses the lock-up pis-
ton onto the pressure plate.
As a result, drive cover (5) is coupled with turbine shaft

(4) to complete the lock-up status.
95ZV-2 EU FS 32-5
Automatic shift (with lock-up solenoid)
Shift up
Speed Shift down
F4L
F4
F3L
3
13.0 11.0 10.0 12.0 15.0 17.0 24.5 26.5 28.0 30.0
(8.1) (6.9) (6.3) (7.5) (9.4)(10.6) (15.3)(16.6) (17.5) (18.8)
Reverse Speed km/h (mile/h) Forward
Automatic shift map (Normal mode) 95V2U32001
3rd → 3rd lock-up 17.0 km/h (10.6 MPH)

Shift Up
4th → 4th lock-up 30.0 km/h (18.8 MPH)
4th lock-up → 4th 28.0 km/h (17.5 MPH)

Shift Down
3rd lock-up → 3rd 15.0 km/h (9.4 MPH)
95ZV-2 EU FS 32-6
Torque Converter Gear Pump

(T/M S/N PT315E01-0101~PT315E02-0195)
A
4 1 10
6
7 2
001A
9
3
Outlet
5
11, 12
Section A-A
Inlet
A
95V2E32002
1. Pump body Gear pump specifications

2. Pump cover
3. Drive gear
4. Driven gear Theoretical
73.6 cm3/rev (4.49 in3/rev)
discharge
5. Needle bearing
Maximum operation
6. Needle bearing pressure
3.4 MPa (35 kgf/cm2) (498 psi)
7. Bearing retainer
Maximum operation
8. Bearing retainer 2,610 min-1 (rpm)
speed
9. Snap ring Approx. 40 L/min (10.5 gpm)
10. Dowel pin Conditions:
11. Bolt Pump speed 830 min-1 (rpm)
Oil temp. 80~100°C (176~212°F)
12. Washer Actual discharge
Oil viscosity 10CST (SAE10W)
Discharge pressure 3.4 MPa
(35 kgf/cm2)
(498 psi)
95ZV-2 EU FS 32-7
(T/M S/N PT315E02-0196~)
6 7 4 12 2
001C
11 Outlet
10
3
8 5
9
1 13
Section A-A
Inlet
A
K95V2U32003
1. Pump body Gear pump specifications

2. Pump cover
3. Drive gear
4. Driven gear Theoretical
73.6 cm3/rev (4.49 in3/rev)
discharge
5. Bushing
Maximum operation
6. Bushing pressure
3.4 MPa (35 kgf/cm2) (498 psi)
7. Plate
Maximum operation
8. Seal 2,610 min-1 (rpm)
speed
9. Backup ring Approx. 40 L/min (10.5 gpm)
10. Oil seal Conditions:
11. Snap ring Pump speed 830 min-1 (rpm)
Oil temp. 80~100°C (176~212°F)
12. Dowel pin Actual discharge
Oil viscosity 10CST (SAE10W)
13. Flange bolt Discharge pressure 3.4 MPa
(35 kgf/cm2)
(498 psi)
95ZV-2 EU FS 32-8
Transmission
Transmission
Clutch combination Shift lever position

Clutch Position of shift
L H R 1 2 3 Function
Speed range lever
F1 Held in 1st speed range for both forward and
1
F2 reverse.
Held in 2nd speed range for both forward and
F3
2 reverse.
F4 Downshift button operation.
(Either 1st or 2nd or
N * * * Held in 3rd speed range for both forward and
3rd) 3
R1 reverse.
R2 Automatic speed change according to shift map

(computer) for 2nd through 4th speeds forward
R3 A
and 2nd through 3rd speeds reverse.
Downshift button operation.
The transmission is equipped with six clutches:
Automatic or manual speed change is available
Forward low range, forward high range, reverse, and depending on the position of the shift lever, as shown in
1st, 2nd and 3rd speeds. Combining the clutches as the table.
shown in the table here provides four forward speeds,
and three reverse speeds for a total of seven speeds. Automatic speed change refers to one where the best
Two clutches must be engaged at the same time to speed range is determined by a computer according to
move the machine. the engine speed and the machine speed detected.
Planetary gear Downshift button operation

This feature permits quick up and down shifting when in
2nd and Automatic.
Ring gear
It operates from 2nd to 1st, and 1st to 2nd.
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.
95ZV-2 EU FS 32-9
Transmission
Gear train and number of teeth
T/C
E/G
2 3 L R
82 82 82 79
22 24 24 27
65
67
1 38 34 34 25 H
63
80
2nd propeller shaft 3rd propeller shaft
95V2E32020
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 Steel plate

Piston stroke Outer Inner Outer Inner Number of
Name of clutch Number Thickness (mm) Number Thickness (mm) return spring
(mm) diameter diameter diameter diameter
of plate New/Wear limit of plate New/Wear limit
(mm) (mm) (mm) (mm)
Low range clutch 5.5±0.5 8 4±0.13 / 3.5 8 6
ø360 ø279 ø426 ø298 3.5±0.1 / 3.3
Reverse clutch 5.5±0.5 8 (Sintered) 8 12
High range clutch 3.0±0.5 4 4±0.1 / 3.4 3 12
ø236 ø159 ø252 ø173 3.2±0.1 / 3.0
1st speed clutch 6.0±0.5 9 (Sintered) 8 12
2nd speed clutch 2.0±0.5 3 4±0.13 / 3.8 3 12
ø360 ø279 ø426 ø298 3.5±0.1 / 3.3
3rd speed clutch 3.0±0.5 4 (Paper) 4 12
95ZV-2 EU FS 32-10
Transmission
Friction plate: mm (in)
For low, reverse clutch
3.0 (0.12)
1
0.6 (0.02)
2
Detail drawing of groove

95V2E32023
1. Plate
2. Facing (sintered)
For 2nd, 3rd speed clutch
2.6 (0.10)
1
1.2 (0.05)
279 +- 00.8 (11.0 +- 00.03 )
2
360 (14.2 )
0.1 (0.004) above

95V2E32024
1. Plate
2. Facing (paper)
For high, 1st speed clutch
2.6 (0.10)
1
159 +- 00.5 (6.26 +- 00.02)
+ 0.25
0.3 - 0.05 (0.01 +- 0.002
0.01
)

95V2E32025
1. Plate
2. Facing (sintered)
95ZV-2 EU FS 32-11
Transmission
Steel plate: mm (in)
For low, reverse, 2nd, 3rd speed clutch
- 1.5 (16.7 - 0.06 )

- 3.0 (11.7 - 0.1 )
+ 0.04
+0
+ 1.0
+0
298
426
95V2E32026
For high, 1st speed clutch
252 +- 00.5 (9.92 +- 0.02

0
)
95V2E32029
95ZV-2 EU FS 32-12
Clutch Pack
Clutch Pack
Inlets for Inlets for

2nd and 3rd reverse and
speed low range
clutch oil clutch oil
28 25 24 20 21 17 16 15 11 12 9 10 8 6
29 5
Inlet of 1st speed

clutch oil
Inlet of high range
clutch oil
Inlet of
lubricating
and
cooling oil
33
7
31 4
32 3
2
30 27 34 26 23 22 35 18 19 14 13 95V2E32003
1. Clutch input shaft 18. Low range ring gear

2. High range clutch drum 19. Low range sun gear
3. Spider 20. 3rd speed clutch piston
4. High range clutch piston 21. 3rd speed planetary gear
5. Friction plate 22. 3rd speed ring gear
6. Steel plate 23. 3rd speed sun gear
7. Piston return spring 24. 2nd speed clutch piston
8. Reverse planetary gear carrier 25. 2nd speed planetary gear
9. Reverse planetary gear 26. 2nd speed ring gear
10. Reverse clutch piston 27. 2nd speed sun gear
11. Friction plate 28. 1st speed clutch drum
12. Steel plate 29. 1st speed clutch piston
13. Anchor pin 30. 1st speed clutch gear
14. Piston return spring 31. Drop gear
15. Reverse ring gear 32. Piston return spring
16. Low range clutch piston 33. Clutch output shaft
17. Low range planetary gear 34. 2nd speed planetary gear carrier
35. Low/3rd speed planetary gear carrier
95ZV-2 EU FS 32-13
Power Flow Path in the Transmission
Forward 1st speed power flow path
Low
range Inlet of low range
21 22 18 17
clutch clutch oil
1st speed clutch 30
Input power
Inlet of 1st speed

clutch oil
Output power
31 33 27 23 19 13
95V2E32004
When first speed forward is selected by the operator or When the 1st speed clutch is engaged, drop gear (31),
the computer, oil is sent from the modulator valve to the 1st speed clutch gear (30), 3rd speed ring gear (22) and
low range clutch and the 1st speed clutch. 3rd speed sun gear (23), 2nd speed sun gear (27)
clutch output shaft (33) form one unit.
When the clutch plates are pressed by the low range
clutch piston, low range ring gear (18) is locked to the As a result, the rotation of the 3rd speed planetary gear
housing by the anchor pins (13). The torque converter (21) around sun gear is output as the rotation of the
rotates the low range sun gear (19) via the clutch input drop gear (31).
shaft (1). This causes low range planetary gears (17) to
rotate around sun gear (19) while rotating on their own
axis. This forces the carrier to rotate. Since the low 3rd speed planetary gear (21)
range planetary carrier and 3rd speed planetary carrier (does not rotate on its own axis)
are one piece, the 3rd speed planetary gears (21) also
rotate around sun gear.
3rd speed ring gear (22) and clutch
output shaft (33) form one unit
95ZV32007
Low range ring gear (18)
Sun gear (19)
The low range planetary decreases the speed of the
Low range planetary gear (17) input shaft but increases torque. The first speed clutch
is used to directly transmit this high torque-low speed to
95ZV32006
the output shaft.
95ZV-2 EU FS 32-14
Forward 2nd speed power flow path
2nd speed
clutch oil Low range Low range clutch oil
2nd speed clutch clutch
Input power
Output power
95V2E32005
Forward 3rd speed power flow path
3rd speed
clutch oil Low range Low range clutch oil
3rd speed clutch clutch
Input power
Output power
95V2E32006
95ZV-2 EU FS 32-15
Forward 4th speed power flow path
2nd speed clutch oil

2nd speed clutch High range clutch
Input power
High range clutch oil
Output power
95V2E32007
95ZV-2 EU FS 32-16
Reverse 1st speed power flow path
Reverse clutch
Reverse clutch oil
1st speed clutch

Input power
1st speed clutch oil
Output power
95V2E32008
Reverse 2nd speed power flow path
Reverse
2nd speed clutch oil clutch oil Reverse clutch
2nd speed clutch

Input power
Output power
95V2E32009
95ZV-2 EU FS 32-17
Reverse 3rd speed power flow path
3rd speed Reverse

3rd speed clutch oil clutch clutch oil Reverse clutch
Input power
Output power
95V2E32010
95ZV-2 EU FS 32-18
Hydraulic System Diagram
35 3
Shift lever
Option
34
12 MCU
LU
10 11
9
15
H 20
2 26
R 22
16 L 24 3 18 1
36 17 21 25 27 19 23
8 7
13 3
28
29
30
33
32
31
2 1
95V2E32011
95ZV-2 EU FS 32-19
1. Transmission oil pan 19. Reverse clutch valve

2. Strainer 20. Low range clutch solenoid valve
3. Torque converter gear pump 21. Low range clutch valve
4. Line filter with bypass valve 22. 1st speed clutch solenoid valve
5. Clutch pressure regulator valve 23. 1st speed clutch valve
6. Modulator valve (1) 24. 2nd speed clutch solenoid valve
7. Relief valve 25. 2nd speed clutch valve
8. T/C inlet relief valve 26. 3rd speed clutch solenoid valve
9. Modulator valve (2) 27. 3rd speed clutch valve
10. Check valve (1) 28. High range clutch
11. Check valve (2) 29. Reverse clutch
12. Pressure sensor 30. Low range clutch
13. Torque converter 31. 1st speed clutch
14. T/C outlet relief valve 32. 2nd speed clutch
15. Oil cooler 33. 3rd speed clutch
16. High range clutch solenoid valve 34. Lock-up clutch solenoid valve (option)
17. High range clutch valve 35. Torque converter (with lock-up clutch) (option)
18. Reverse clutch solenoid valve 36. Check valve
95ZV-2 EU FS 32-20
Hydraulic Circuit Diagram

Neutral position
Modulator valve unit
35 9
34 3.0
12 GA
0.9
10
GP 4K 6K
13
11 5
T P
S
31 P1
22 GB
23 8 30K
1st
9K 7
14
GT 6
29 PR
18
19 36
15 3K
R
28 PH 4
16
17
H
Note
All orifice measurements 3
30 PL ( ø) are in mm.
20
21 P 2
L
1
(PF1/4) Clutch solenoid
valve assembly
32 P2
24 Clutch valve
25 assembly Modulator valve
unit
2nd P
33 P3
26 Lock-up clutch
27 solenoid valve
3rd assembly (option)
Clutch valve Clutch solenoid

assembly valve assembly
95V2E32012
95ZV-2 EU FS 32-21
1. Transmission oil pan 19. Reverse clutch valve

2. Strainer 20. Low range clutch solenoid valve
3. Torque converter gear pump 21. Low range clutch valve
4. Line filter with bypass valve 22. 1st speed clutch solenoid valve
5. Clutch pressure regulator valve 23. 1st speed clutch valve
6. Modulator valve (1) 24. 2nd speed clutch solenoid valve
7. Relief valve 25. 2nd speed clutch valve
8. T/C inlet relief valve 26. 3rd speed clutch solenoid valve
9. Modulator valve (2) 27. 3rd speed clutch valve
10. Check valve (1) 28. High range clutch
11. Check valve (2) 29. Reverse clutch
12. Pressure sensor 30. Low range clutch
13. Torque converter 31. 1st speed clutch
14. T/C outlet relief valve 32. 2nd speed clutch
15. Oil cooler 33. 3rd speed clutch
16. High range clutch solenoid valve 34. Lock-up clutch solenoid valve (option)
17. High range clutch valve 35. Torque converter (with lock-up clutch) (option)
18. Reverse clutch solenoid valve 36. Check valve
Note
The orifice in the clutch valve 19 and 21 is to reduce
shock at clutch engagement.
95ZV-2 EU FS 32-22
Oil Flow
Oil Flow
Oil flow in the torque converter Oil flow to the clutch

line
Oil, regulated to a specified pressure by modulator
valve 1 (6) and clutch pressure regulator valve (5), flows
From torque converter charge pump to torque to each clutch solenoid valve.
converter
Assuming that the transmission is shifted from 1st
Oil from the torque converter gear pump (3) passes speed forward to 1st speed reverse, the reverse clutch
through line filter (4) and enters the modulator valve solenoid is energized, and the clutch oil thus flows into
unit. Since only a small amount of oil flows to the clutch the reverse clutch piston chamber. As the low range
circuit, most of the oil flows to clutch pressure regulator clutch solenoid is de-energized, the oil in the low range
valve (5), forces it open, and passes into the torque con- clutch piston chamber flows through the low range
verter circuit. If the torque converter's inlet pressure clutch solenoid valve and drains into the transmission
exceeds 0.9 MPa (9 kgf/cm2) (128 psi), it forces torque case.
converter inlet relief valve (8) to open, allowing the oil to
escape to the oil pan.
From torque converter to cooling circuit
Return oil from the torque converter flows through outlet

relief valve (14) (set pressure=0.3 MPa (3 kgf/cm2)
(42.7 psi)) in the torque converter housing and to torque
converter cooler (15).
From cooler to lubrication circuit
Oil cooled in the cooler flows to the lubrication paths in

the transmission. This lubricates and cools each bear-
ing and the clutch plates, and then drops into the oil
pan.
95ZV-2 EU FS 32-23
T/C and T/M Oil Circulation
(S/N 9001~9150)
Radiator
Torque converter oil

cooler
Check valve
Clutch solenoid
valve assembly
Modulator
valve unit
Clutch valve
assembly
Lock-up clutch Pilot line

solenoid valve
assembly
(option)
Transmission
oil filter
Transmission
95V2E32022
95ZV-2 EU FS 32-24
(S/N 9151~)
Torque converter
oil cooler
Clutch solenoid
valve assembly
Modulator
valve unit
Clutch valve Pilot line

assembly
Lock-up clutch
solenoid valve
assembly (option)
Transmission
oil filter
Transmission
95V2E32031
95ZV-2 EU FS 32-25
Modulator Valve Unit

(T/M S/N PT315E01-0101~0282)
D GA
A
GP
ø 0.9 orifice ø 3.0 orifice
6
9
GT
F
6
GB
F C
F-F
5 View A
Numbers below also correspond to page 32-20.
1. —
2. — 11 10
3. — C-C
4. —
5. Clutch pressure regulator valve
6. Modulator valve (1)
7. Relief valve (2.9 MPa (30 kgf/cm2) (427 psi))
8. T/C inlet relief valve (0.9 MPa (9 kgf/cm2) (128 psi))
9. Modulator valve (2) (D Solenoid valve) 8
10. Check valve 1 (0.6 MPa (6 kgf/cm2) (85 psi)) D-D
11. Check valve 2 (0.4 MPa (4 kgf/cm2) (57 psi)) K95V2E32001
95ZV-2 EU FS 32-26
(T/M S/N PT315E01-0283~)
D GA
A
GP
6
9
9
GT
F
6
GB
F C
F-F
5
View A
1. —
2. — 11 10
3. — C-C
4. —
5. Clutch pressure regulator valve
6. Modulator valve (1)
7. Relief valve (2.9 MPa (30 kgf/cm2) (427 psi))
8. T/C inlet relief valve (0.9 MPa (9 kgf/cm2) (128 psi))
9. Modulator valve (2) (D Solenoid valve) 8
10. Check valve 1 (0.6 MPa (6 kgf/cm2) (85 psi)) D-D
11. Check valve 2 (0.4 MPa (4 kgf/cm2) (57 psi)) K95V2E32002
95ZV-2 EU FS 32-27
Interior schematic (simple explanation)
11 To clutch solenoid valve
10
0.6 Mpa 0.4 Mpa

(85 psi) (57 psi)
To torque converter
0.9 MPa 2
(9 kgf/cm )
(128 psi) 2.9 MPa
(30 kgf/cm2)
(427 psi)
Drain 8 7 Drain
From pump

9
1. — GA
2. —
3. — 10
4K 6K
4. — To transmission
5. Clutch pressure regulator valve clutch
6. Modulator valve (1) 11 5
7. Relief valve To torque converter
(2.9 MPa (30 kgf/cm2) (427 psi)) GB
8. T/C inlet relief valve 8
30K
(0.9 MPa (9 kgf/cm2) (128 psi))
9K 7
9. Modulator valve (2) (D Solenoid valve)
GT 6
10. Check valve 1
(0.6 MPa (6 kgf/cm2) (85 psi))
11. Check valve 2 Hydraulic circuit From pump
(0.4 MPa (4 kgf/cm2) (57 psi)) GA~GT: gauge port: PT 1/8"
95V2E32014
95ZV-2 EU FS 32-28
When changing direction or speed, the modulation Modulator valve function

mechanism works to reduce the time required for clutch
engagement (time lag), to prevent the shock at clutch
Modulator valve 1
engagement, to improve the work efficiency and durabil-
ity of the power system, and to ensure operator's com-
fort. To clutch solenoid valve
The modulation mechanism controls the clutch oil pres-

sure rising time as follows:
Modulator
valve 2
An electrical signal from the MCU controls the modula-
6 kgf/cm2 4 kgf/cm2
tion operation. For information on the MCU refer to sec-
tion "Electrical Group".
Clutch pressure
regulator valve Modulator
valve 1
Port P
F
f
To torque
converter
9 kgf/cm2
30 kgf/cm2
Drain Drain
From pump
95V2E32015
The modulator valve 1 is a solenoid-operated propor-

tional pressure reducing 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 mag-
netic force (F) are in balance, the spool is stationary,
which generates the specified pressure at port P.
The hydraulic force adjusted by modulator valve 1 acts

on the right end of the clutch pressure regulator valve,
and so the hydraulic force from the pump to the clutch is
also controlled by modulator valve 1.
In other words, when the control pressure from the mod-

ulator valve 1 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 or, above 0.9
MPa (9 kgf/cm2) (128 psi) to the drain port, reducing
clutch oil pressure.
95ZV-2 EU FS 32-29
Modulator valve 2 (D Solenoid valve) Clutch oil pressure control at the time of
engine starting
As mentioned above, the clutch oil pressure is con-
trolled depending on the size of current applied to the
coil of modulator valve 1. Even at a minimum value of
Starter
current, however, the clutch oil pressure is too high for SW Engine
smooth clutch engagement due to the resistance of flow ON start
Clutch oil pressure

across the clutch pressure regulator valve. The modula- Specified
tor valve 2 is used to reduce the clutch oil pressure to pressure
3 sec
appropriate pressure for clutch engagement.
When the modulator valve 2 is energized, the spool

moves to the left and the oil in the clutch circuit is
drained through the ø 0.9 orifice. The oil from the pump
forces open the 0.6 MPa (6 kgf/cm2) (85 psi) and 0.4 0
Time
MPa (4 kgf/cm2) (57 psi) check valve and flows to the 95ZV32010
clutch. The pressure drop due to the check valve allows
a lower minimum clutch oil pressure maintained. This
lower pressure allows some clutch slippage for smooth Just after the engine starting, the clutch oil pressure is
clutch engagement. unstable and the pulse pressure arises.
To prevent the pulse pressure, the current applied to the

modulator valve 1 is kept at a minimum value in 3 sec-
onds after the starter switch is ON.
Pressure sensor
(This program does not work over 3 seconds after the
The shock and the time lag when engaging the clutch starter switch is ON.)
vary by the clutch oil pressure rising time after the com-
pletion of the oil charging into the clutch piston chamber.
In the case that the clutch oil pressure rising time is

early, it causes a large shock. If it is late, it causes a
large time lag.
As the modulator valve 2 is ON during the oil is charging

into the clutch piston chamber, oil flows to the clutch pis-
ton chamber through the check valve 0.6 MPa (6 kgf/
cm2) (85 psi) and 0.4 MPa (4 kgf/cm2) (57 psi).
Oil stops flowing through the check valve at the comple-

tion of the oil charging into the clutch piston chamber.
As a result, since there is no oil pressure drop in the line
to the clutch piston chamber, the clutch oil pressure
rises up to the lowest holding pressure regulated by the
modulator valve 1. The pressure sensor detects this
pressure and transfers the signal to the MCU.
The MCU decides the completion of the oil charging into

the clutch piston chamber and transfers the signal to the
modulator valve 1 to increase the clutch pressure.
95ZV-2 EU FS 32-30
Modulator valve operation Initial oil charging (t1) into the clutch piston
chamber
Modulation chart (Neutral1st forward) When the shift lever is shifted from the neutral to the 1st
speed forward, the low range clutch solenoid valve is
ON
energized and oil under pressure flows into the clutch
Low range clutch OFF piston chamber.
solenoid valve
1st speed clutch ON
The 1st speed clutch solenoid valve remains energized.
solenoid valve
Oil filling After a given time, the control current to the modulator
completed about 400 mA valve 1 is reduced. At the same time, the modulator
Modulator valve 2 is energized and the main clutch oil pressure is
valve 1 Current sharply reduced, concluding the initial oil charging into
(mA) about the chamber.
170 mA
0
The time taken for this initial charging, which depends
ON on the capacity of the clutch piston chamber, is con-
Modulator valve 2
OFF OFF trolled by MCU.
Main pressure
Low pressure holding (t2)
Pressure
MPa (kgf/cm2) P2 P3
P1
To reduce clutch engagement shock, it is necessary to
0 engage the clutch while allowing some slippage of it. To
Low range do this, the current to modulator valve 1 is held low for a
clutch given time. During this time, the clutch piston moves
pressure
Pressure while compressing the piston return spring.
MPa (kgf/cm2)
This low pressure holding time depends on the speed of
0 the engine: longer with lower engine speed, shorter with
higher speed. Modulator 2 is kept energized allowing
t1 t2 t3 t4 some oil to escape to drain.
When shifted Shift completed

This time is also controlled by MCU.
95V2E32019 Pressure rise (t3)
When the clutch piston comes into contact with the

clutch plate and the clutch plates start to transmit power,
t1 Initial
time
charging Changes with combination of
clutches
0~0.12 sec
the control current to modulator valve 1 is gradually
raised. This causes the clutch oil pressure to also grad-
t2 Low pressure
holding time
Changes with engine speed
Less than
0.5 sec ually rise, and the clutch completes engagement while
t3 Pressure rise Changes with combination of
0.3~0.7 sec some slippage occurs. This rise time is also controlled
time clutches by MCU.
t4 Restoration time Changes
clutches
with combination of
0.5~1.3 sec
P1 0.2~0.5 MPa (2~5 kgf/cm2) (28~71 psi)

P2 2.3~2.5 MPa (23~26 kgf/cm2) (327~370 psi)
2.3~2.7 MPa (24~28 kgf/cm2) (341~398 psi)
P3 1st speed
Except 1st speed 2.7~3.1 MPa (28~32 kgf/cm2) (398~455 psi)
- E/G high idle

95ZV-2 EU FS 32-31
Restoration of clutch pressure (t4)
At the completion of clutch engagement, the circuit

opened by modulator 2, which maintained the lower
pressure by draining part of the clutch oil since the initial
charging, is closed. When the power to modulator valve
2 is turned off, the clutch oil pressure is restored to the
specified pressure.
95ZV-2 EU FS 32-32
Control Valve Assembly

T/M S/N:
PT315E01-0101~PT315E02-0100
PT315L01-0101~PT315L02-0100 (Lock-up)
Valve location
Main pressure gauge port 3 Pilot line Check valve
95V2E32016
1. Clutch solenoid valve assembly

2. Clutch valve assembly
3. Lock-up clutch solenoid valve assembly (option)
95ZV-2 EU FS 32-33
T/M S/N:
PT315E02-0101~
PT315L02-0101~ (Lock-up)
Valve location
Pilot line
3
Main pressure gauge port
K95V2U32001
1. Clutch solenoid valve assembly

2. Clutch valve assembly
3. Lock-up clutch solenoid valve assembly (option)
95ZV-2 EU FS 32-34
Check valve
The check valve is designed to maintain the pressure in
the clutch valve circuit, from the pump to the clutch
valves, 0.3 MPa (3.0 kgf/cm2) (43 psi) or more.
If the pressure falls too low during the shift modulation

the clutch valve spool may return to the original position,
as a result, the clutch valves would move to the OFF
position and the clutches would release momentarily.
The check valve prevents this.
95ZV-2 EU FS 32-35
Clutch solenoid valve assembly

T/M S/N:
PT315E01-0101~PT315E02-0221
PT315L01-0101~PT315L03-0100 (Lock-up)
2 6 A 4
PH PL P2 P3 PR P1
3rd P1~PH
1st
L
T
2nd R
H
1 5 3 A-A
A
P1
1st
T
PR
P3
3rd
P2
2nd
PL
L
PH
H
T
P
Hydraulic Diagram
95V2E32017
1. High range clutch solenoid valve

2. Low range clutch solenoid valve
3. Reverse clutch solenoid valve
4. 1st speed clutch solenoid valve
5. 2nd speed clutch solenoid valve
6. 3rd speed clutch solenoid valve
95ZV-2 EU FS 32-36
T/M S/N:
PT315E04-0101~
PT315L03-0101~ (Lock-up)
2 6 A 4
PH PL P2 P3 PR P1
L P1~PH
3rd 1st
T
H R P
2nd
1 5 3 A-A
A
P1
1st
T
PR
P3
3rd
P2
2nd
PL
L
PH
H
T
P
Hydraulic Diagram
K95V2E32002
1. High range clutch solenoid valve

2. Low range clutch solenoid valve
3. Reverse clutch solenoid valve
4. 1st speed clutch solenoid valve
5. 2nd speed clutch solenoid valve
6. 3rd speed clutch solenoid valve
95ZV-2 EU FS 32-37
For high/reverse and speed clutches
After power-off (clutch disengaged status)
5 4
Modulator
1
valve 2
6
Transmission
oil pan C
Clutch valve
3
80ZVE32026
1. Coil
2. Plunger
3. Push rod
4. Spring
5. Spool
6. Manual control push button
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 dis-
engaged.
Under such a condition, pressing the 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 the
spool fully to the right, and disengages the clutch.
95ZV-2 EU FS 32-38
After power-on (Clutch engaged status)
Modulator
valve
Transmission
oil pan C
Clutch valve
80ZVE32027
When the power is supplied to the coil, the magnetic

power attracts the plunger to the left, and the line
between port A and B is opened. Pressure oil flows into
the clutch valve.
95ZV-2 EU FS 32-39
Clutch valve assembly
From clutch From clutch

solenoid valve solenoid valve
(PH, P2, P3, P1) (PL, PR)
A B A A B A
PH PL P2 P3 PR P1
Orifice
PM PM PM PM PM PM
PM PM
PC PC PC PC PC PC
PC PC
T T1 T T1
T T T T T T P
A B A A B A A-A B-B
1 2 5 6 3 4
T1 T
PM
P1
PC
T1 T
PM
PR
PC
T1 T
PM
P3
PC
T1 T
PM
P2
PC
T1 T
PM
PL
PC
T1 T
PM
PH
PC
Hydraulic Diagram
95V2E32018
1. High range clutch valve

2. Low range clutch valve
3. Reverse clutch valve
4. 1st speed clutch valve
5. 2nd speed clutch valve
6. 3rd speed clutch valve
95ZV-2 EU FS 32-40
MEMO
95ZV-2 EU FS 33-1
33 Check & Adjustment Torque Converter and Transmission Group

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

95ZV-2 EU FS 33-2
Clutch Oil Pressure and Time Lag
Measuring clutch oil pressure Gauge port
1. Location:
WARNING
Main pressure
Unexpected movement of the machine may cause an
Therefore, to provide repair service with the engine
moving.
- Prohibit any person from walking into dangerous
areas.
- Under the machine
- Around the engine Lock-up clutch
2nd speed
- In front of or behind the machine H clutch clutch R clutch (option)
3rd speed 1st speed
L clutch clutch clutch
- Pressure gauge
- Tachometer (MODM)
L R 2 3
Transmission oil pressure test port location

95V2E33001
2. Measuring port: PF 1/4
3. Oil pressure gauge: 5 MPa (50 kgf/cm2) (1000 psi)

with 2~3 m (6~10 ft.) hose
Note
Warm-up the engine before measuring the clutch oil
pressure and time lag
95ZV-2 EU FS 33-3
Standard measurement value 9. As the clutch oil pressure rises just after the engine
is started, adjust the engine at high-idling before
2.2±0.2 the pressure measurement.
1st speed (22±2)
Low (313±28)
10. Measure and record the pressure in each speed
idle 2.4±0.2
Except 1st (24±2)
range. (High-idling at the 1st speed, high-idling at
Clutch pressure Engine (341±28) the other speeds)
MPa (kgf/cm2) (psi) speed 2.5±0.2
1st speed (25±2) Note
High (356±28) Change the transmission speed range while keeping
idle 2.9±0.2 the shift lever at the neutral position. Check that the
Except 1st (30±2)
(427±28) pressure instantaneously lowers just after speed
Neutral1st forward speed
change, and then rises to the original pressure again.
Clutch time lag (sec) (engine speed: 0.3±0.1
1,500 min-1 (rpm))
Possible causes for low clutch pressure
Clutch oil pressure measurement proce- Possible cause Solution

dure Malfunctioning modulator valve (1) operation
Inspection &
repair
1. Press the brake pedal, and set and confirm the Inspection &
Malfunctioning modulator valve (2) operation
repair
transmission shift lever is at the neutral position.
Defective MCU Replacement
Disassembly &
2. Set and confirm the parking brake is at the "ON" Oil leakage from clutch
repair
position.
3. Press the brake pedal, and lower the bucket onto

the ground.
4. Stop the engine.
5. Attach the pressure gauge to the pressure mea-

surement port. Place the gauge inside the opera-
tor'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. (Low-idling at the 1st speed, low-idling at the
other speeds)
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.
95ZV-2 EU FS 33-4
Measuring clutch time lag Time lag measurement procedure
1. Press the brake pedal, and set and confirm the

WARNING transmission shift lever is at the neutral position.
2. Set and confirm the parking brake is at the "ON"
position.
To crawl under the machine, be sure to stop the
engine, and block the tires with chocks to prevent
3. Press the brake pedal.
them from moving. Give signals to the person in the
cab during the work.
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.
Stop watch
Do not apply the service brakes.
6. Set the transmission shift lever to the neutral 1st

Standard measurement value speed.
0.3 ± 0.1 sec 7. Keep the engine speed at 1,500 min-1 (rpm).
Note 8. Move the shift lever to the forward position. At the

Neutral 1st forward speed same time, start the stop watch to measure the
at engine speed: 1,500 min-1 (rpm) time required before the machine moves.
Possible causes for clutch time lag
Possible cause Solution

Defective pressure sensor Replacement
Inspection &
repair
Inspection &
repair
Defective MCU Replacement
Disassembly &
Defective clutch
repair
95ZV-2 EU FS 42-1
42 Function & Structure Hydraulic Group

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 ....................................................... 42-17
Hydraulic Cylinder ................................................... 42-20
Loading System ...................................................... 42-23
Reducing Valve (for Pilot Pressure) ........................ 42-24
Pilot valve (S/N 9001~9250) ................................... 42-25
Pilot valve (S/N 9251~9255) ................................... 42-30
Pilot valve (S/N 9256~) ........................................... 42-35
Multiple Control Valve (KML35A/2T003B)............... 42-40
Adapter (Orifice) ...................................................... 42-51
Ride Control (OPT).................................................. 42-52
Steering System ...................................................... 42-62
Orbitrol® ................................................................... 42-63
Steering Valve (KVS32-A4.0/20) ............................. 42-70
Stop Valve ............................................................... 42-82
Reducing Valve (for Orbitrol®) ................................. 42-84
Steering Line Filter .................................................. 42-85
K-Lever (OPT) ......................................................... 42-86
Efficient Loading System......................................... 42-92
Fan Motor System ................................................... 42-96
Fan Motor Line ........................................................ 42-97
Reversing Fan Motor Line (OPT) ............................ 42-108
Secondary Steering ................................................. 42-113
95ZV-2 EU FS 42-2
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 dam-
aged 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.
95ZV-2 EU FS 42-3
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 replace-
ment.
After replacing oil or a part, be sure to observe the fol-

lowing 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 min-

utes or more. Do not operate any hydraulic func-
tions 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.
95ZV-2 EU FS 42-4
Hydraulic Circuit Symbols
Hydraulic lines Pumps & motors
(1)
Working hydraulic
line Fixed
displacement,
Hydraulic pump
(1) Unidirectional (2)
Pilot line
(2) Bidirectional
Drain line
(1)
Lines joining Variable
displacement,
Non-compensating
hydraulic pump (2)
(1) Unidirectional
Flexible line
(2) Bidirectional
(1)
Lines passing Fixed
displacement,
Rotary hydraulic
motor (2)
Line to tank (1) Unidirectional
(Above fluid level) (2) Bidirectional
(1)
Line to tank Variable
(Below fluid level) displacement,
Rotary hydraulic
motor (2)
Hydraulic tank (1) Unidirectional
(Pressurized type) (2) Bidirectional
Fixed restriction
Cylinders
(1)
Rotary joint (1) (2)
(1) one line Single acting
(Unidirectional) cylinder
(2) three line (2) (without spring)
(Bidirectional)
(1) (2)
Single acting
cylinder
(with spring)
(1) (2)
Double acting
cylinder
(single rod)
(1) (2)
Double acting
cylinder
(double rod)
(1) detail symbol

(2) mnemonic symbol
95ZV-2 EU FS 42-5
Operation methods Pressure control valve
Single flow path

Spring valve,
Normally closed
Single flow path

Adjustable spring valve,
Normally open
Control methods
Pressure relief
Lever
valve
Push button
Unloading valve
Pedal or treadle
Mechanical control
Sequence valve
Plunger
Pressure reducing
Spring
valve
Solenoid control
Single acting
solenoid Flow control valve
Double acting
solenoid Flow control valve,
Adjustable non-
compensated
Electric motor
control Pressure
compensated flow
control valve
Unidirectional M
fixed
Bidirectional M
variable
Detent
Flow dividing valve

95ZV-2 EU FS 42-6
Directional control valve Check valve
Two position
Check valve
Two ports
Three position Check valve

Four ports Pilot operated
Four ports with

Shuttle valve
restrictor
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
95ZV-2 EU FS 42-7
Miscellaneous hydraulic symbols
(1)
Hydraulic tank
(1) Vented
(2) Pressurized (2)
Manual shut off

valve
Pressure switch
Accumulator
Electric motor M
Internal
combustion M
Power source
Filter or strainer
Heater
Cooler
Pressure gauge
Temperature
gauge
Flow meter
95ZV-2 EU FS 42-8
Hydraulic System Operation
Hydraulic system operation out- Return oil from the cylinders flows through the valve to
the oil cooler, return filter (12) and into the hydraulic
line tank.
The hydraulic system consists of the following systems:
Even if no hydraulic pump supplies oil to the loading
- Loading system and pilot control circuits due to trouble, or if the engine
is shut off, the boom can be lowered to the ground by
- Steering system the pressure in accumulator (33) in the brake circuit in
case of an emergency.
- Efficient loading system
- Fan motor system

Steering system
- Ride control system (OPT)
The steering system consists of the following compo-
nents.
Loading system - Hydraulic pump (1)

- Steering valve (4)
The loading system consists of the following compo- - Line filter (81)
nents. All numbers base on page 92-4. - Reducing valve (18)
- Orbitrol® (14)
- Hydraulic pump (2) - Stop valve (15)
- Unloader valve (22) - Steering cylinder (8)
- Line filter (81)
- Check valve (32) Oil from pump (1) flows to Orbitrol® (14) through steer-
- Reducing valve (38) ing valve (4), line filter (81) and reducing valve (18). Oil
- Pilot valve (16) to Orbitrol® (14) is reduced to 3.5 MPa (36 kgf/cm2) (512
- Multiple control valve (3) psi) by reducing valve (18).
- Boom cylinders (5)
- Bucket cylinders (6) A small amount of pilot oil supplied from Orbitrol® (14)
controls steering valve (4) to realize steering operations.
Oil from pump (2) flows to pilot valve (16) through
unloader valve (22), line filter (81), check valve (32) and When the steering wheel is turned, oil at a flow rate pro-
reducing valve (38). Oil to pilot valve (16) is reduced to portional to the turning speed is sent from Orbitrol® (14)
3.5 MPa (36 kgf/cm2) (512 psi) by reducing valve (38). and supplied to the oil pack of steering valve (4).
When the pilot control lever is operated, the pilot valve At this time, the pilot pressure is generated. The pilot
line is opened, and the oil pressure is generated pressure strokes the spool of steering valve (4), and
depending on the position of the pilot control lever. supplies hydraulic oil at large flow rate proportional to
the flow rate of the supplied pilot oil to the cylinder line.
The pilot pressure entering the oil pack to multiple con-
trol valve (3) moves the spool against its return spring. The excessive pilot oil flows through steering valve (4)
to the other side of the pilot port.
The spool press-in distance (displacement) depends on
the pilot valve pressure. Shortly before the full turn, stop valve (15) activates, the
pilot circuit is closed.
Oil from the loader pump is then directed through multi-
ple control valve (3) to boom cylinders (5) and bucket
cylinders (6).
95ZV-2 EU FS 42-9
While the steering wheel is not turned, almost all Fan motor system
hydraulic oil from steering pump (1) is sent to the load-
ing line by the action of the flow control spool. The fan motor system consists of the following compo-
nents.
Oil returns from steering cylinders (8) flows through
steering valve (4) and oil cooler or cooler bypass valve - Hydraulic pump (2)
(11). - Unloader valve (22)
- Fan motor (71)
Finally it returns to the tank through return filter (12). - Proportional relief valve (72)
The cooling fan is driven by hydraulic motor (71). The

pressure oil from unloader valve (22) flows into the port
Efficient loading system P of fan motor and then turns fan motor (71).
The efficient loading system consists of the following Three kinds of signals sent from the engine water tem-
components. perature sensor (S/N 9001~9150), ECM (S/N 9151~),
torque converter oil temperature sensor, and hydraulic
- Hydraulic pump (2) oil temperature sensor, are input into the MCU as infor-
- Pressure sensor (49) mation to regulate the maximum fan revolution.
- Relief valve (62)
- Check valve (63) The fan revolution is regulated by proportional relief
- Solenoid valve (64) valve (72). The setting pressure of proportional relief
valve (72) is changed in proportion as the engine revo-
When the ELS switch is turned off, the oil discharged lution and electric current value from MCU.
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. Ride control system (OPT)
On the other hand, the oil discharged from the main Refer to "Ride Control (OPT)" page 42-52 for the infor-
pump (front pump of (2)) opens the check valve, mation.
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 opera-

tion 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.
95ZV-2 EU FS 42-10
Layout of Hydraulic Units
Layout of Hydraulic Units
1 17 14 16 4 5
9 12 3 16 15 2 13 11 6 8 7
10 14
95V2E42001
1. Multiple control valve 10. Boom cylinder

2. Pilot valve 11. Steering cylinder
3. Orbitrol® 12. Reducing valve (steering pilot)
4. Steering valve 13. Reducing valve (loading pilot)
5. Hydraulic pump (for steering) 14. T/C line filter
6. Hydraulic pump (for loading, for pilot and brake) 15. ELS valve
7. Fan motor 16. Secondary steering pump
8. Proportional relief valve (for fan) 17. Stop valve
9. Bucket cylinder
95ZV-2 EU FS 42-11
Hydraulic Tank
Hydraulic Tank
Hydraulic Tank (S/N 9001~9300)

10
Viewed
from top 9
8
13
A-A
3
Outside of As seen from 4

machine chassis out
A
To chassis
15,16
A
14
12
11 11 5 6 95V2E42002
1. Hydraulic tank 11. Drain plug

2. Oil level gauge 12. Inspection port
3. Breather valve (tank cap) 13. Vent pipe (to axle housing) (S/N ~9250)
4. Filter 14. Temperature sensor
5. Suction strainer (loading, pilot & brake) 15. Oil level sensor
6. Suction strainer (steering) 16. Flange bolt
7. Return filter element :11.8 N-m (1.2 kgf-m)
8. Filter bypass valve Don’t use the air tool when tightening.
9. Spring
10. Cover
95ZV-2 EU FS 42-12
Hydraulic Tank
Hydraulic tank breather valve (tank cap) (S/N 9001~9279)
1 2 3 4 5 6
7 7
a
b
c
Viewed from section A
70ZV42005
1. Cover When the pressure inside the hydraulic tank drops

2. Filter element below the outside air pressure, the outside air flows
3. Spring (for exhaust valve) through filter element (2) and to valve assembly (4). The
4. Valve assembly suction valve (b) is then opened to let the air flow into
(a) Exhaust valve the tank.
(b) Suction valve
(c) Air bleeder valve When the air pressure inside the hydraulic tank rises to
5. Spring (for suction valve) a certain point 29 kPa (0.3 kgf/cm2) (4.3 psi), the
6. Key (same as starter key) exhaust valve (a) is lifted (opened) so that the air can
7. Attaching bolts (3 pcs) socket head 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 reduc-

ing the possibility of pump cavitation.
To release the internal pressure from the hydraulic tank,

press downward on cover (1). The 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.

95ZV-2 EU FS 42-13
Hydraulic Tank
Hydraulic Tank (S/N 9301~)
10
Viewed
from top 9
8
13
A-A
3
Outside of As seen from

machine chassis out
A
To chassis
15,16
A
14
12
11 11 5 6 97V2J42001
1. Hydraulic tank 11. Drain plug (Magnet plug)

2. Oil level gauge 12. Inspection port
3. Breather valve (tank cap) 13. Plug
4. — 14. Temperature sensor
5. Suction strainer (loading, pilot & brake) 15. Oil level sensor
6. Suction strainer (steering) 16. Flange bolt
7. Return filter element :11.8 N-m (1.2 kgf-m)
8. Filter bypass valve Don’t use the air tool when tightening.
9. Spring
10. Cover
95ZV-2 EU FS 42-14
Hydraulic Tank
Hydraulic tank breather valve (tank cap) (S/N 9280~)
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).
PUSH Suction valve (b) is then opened to let the air flow into
the tank.
When the air pressure inside the hydraulic tank rises to

1 a certain point 29 kPa (0.3 kgf/cm2) (4.3 psi), Exhaust
6 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

2
to the inside of the tank.
3
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

4 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 reduc-

a
ing the possibility of pump cavitation.
b
5 To release the internal pressure from the hydraulic tank,
K65D2J42001 press down cap (1). Air bleeder valve (b) will be lowered
to release the internal pressure.
1. Cap
The pressure is also applied to the axles.
2. Filter element
3. Spring (for exhaust valve)
4. Valve assembly
(a) Exhaust valve Installing cap
(b) Suction valve (Air bleeder valve)
5. Spring (for suction valve) The cap can be installed in any boom or bucket position.
6. Hex nut
95ZV-2 EU FS 42-15
Hydraulic Tank
Hydraulic tank specifications
Type Semi-closed type

Capacity (at center of oil level sight gauge) L (gal) 150 (40 US gal)
Filtration area (cm2) 25,500
Return filter Filtration particle size (µm) 28
2
Relief valve opening pressure (filter bypass) (MPa) (kgf/cm ) (psi) 0.1±0.02 (1.0±0.2) (14±2.8)
2
Loading Filtration area (cm ) 2,550
Pilot & brake Filtration particle size (µm) 105
Suction strainer
2
Filtration area (cm ) 2,550
Steering
Filtration particle size (µm) 105
2
Suction valve setting pressure (kPa) (kgf/cm ) (psi) 1 (0.01) (0.14)
Discharge valve setting pressure (kPa) (kgf/cm2) (psi) 29 (0.3) (4.3)
Breather valve (oil filling port) Filtration area (cm2) 235
(S/N 9001~9300)
Pushing load before turning cap required for venting pressure,
186.2~215.6 (19~22) (42~48)
removing or installing cap N (kgf) (lb)
Suction valve setting pressure (kPa) (kgf/cm2) (psi) 3.9 (0.04) (0.57)
2
Breather valve (oil filling port) Discharge valve setting pressure (kPa) (kgf/cm ) (psi) 29 (0.3) (4.3)
(S/N 9301~) Filtration area (cm2) 160
95ZV-2 EU FS 42-16
Hydraulic Tank
Hydraulic oil level check
Bucket on ground
Hydraulic tank
Oil level sight gauge

(40 US gal)
150 L
95ZV42010
Before checking the hydraulic oil level, observe the fol-

lowing 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
150 L (40 US gal)
Note
If the oil is at operating temperature 60°C ~ 90°C (140°F
~ 200°F) the oil level may be at or near the top of the oil
level sight gauge.
95ZV-2 EU FS 42-17
Hydraulic Pump
Hydraulic Pump
Loading and pilot and brake pump/Steering pump

5 6 6 2
4
7
8
(S/N 9179~) K95V2U42005
1. Drive gear (front) 5. Oil seal

2. Drive gear (rear) 6. Bushing
3. Driven gear (front) 7. Wear plate (floating type)
4. Driven gear (rear) 8. Damper (S/N 9179~)
Loading and pilot and brake pump/Steering pump specifications

Two types of pump are different in only one place.
Loading and pilot and brake pump has two discharge ports, but steering pump has one because of the common dis-
charge port.
Front Rear
For loading For brake and pilot
Applicable circuit
For steering For steering
Theoretical discharge cm3/rev 80.0 71.3
Maximum operation pressure MPa 20.6±0.5 20.6±0.5
(kgf/cm2) (psi) (210±5) (2,986±71) (210±5) (2,986±71)
Maximum speed min-1 (rpm) 2,500
95ZV-2 EU FS 42-18
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.
95ZV-2 EU FS 42-19
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 volu-
metric efficiency is ensured.
General structure of pressure plate
Rotating gears feed the pressurized oil along the cir-

Suction cumference of the case to the outlet port. The pressur-
ized 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 pres-
sure 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.
Discharge
The high-pressure area in the rear of the pressure plate

is enclosed by the plate seal, backup seal, and isolation
plate.
Discharge
To prevent the gear-sealing area from extremely high
High pressure area pressure due to confined oil, there is a confined oil
bypass groove at the gear-sealing area of the pressure
Backup ring plate.
Hydraulic pump bushing lubrica-

O-ring
tion
The lubrication system uses the oil fed from the pressur-
Suction ized tank.
Part of the oil fed from the inlet port is sent to the bush-
ings to lubricate them. After that, the oil is returned to
Oil groove for
lubricating bearing 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
Suction
oil by:
Starting up a new pump with oil supplied to it.
- Allow new pump to idle (low rpm/no load) for 5 min-

utes.
Confinement
prevention groove - Use the proper viscosity for the coldest possible start
up temperature. Change viscosity if seasonal tem-
perature changes are great (more than 20°C (68°F)).
Discharge
115ZV42006
95ZV-2 EU FS 42-20
Hydraulic Cylinder
Hydraulic Cylinder
1. Piston 11. O-ring 21. Wear ring

2. Piston rod 12. Slipper ring 22. Stop ring
3. Cylinder tube 13. Back ring 23. Bushing
4. Rod cover 14. O-ring 24. —
5. Dust seal 15. Wear ring 25. Bolt
6. Backup ring 16. Piston nut 26. Washer
7. U-packing 17. Stop ring 27. Plug
8. Buffer ring 18. Flange bolt 28. O-ring
9. Bushing 19. — 29. —
10. Backup ring 20. Dust seal 30. Piston packing
Boom cylinder
21 6,7
20,23 16 15 14 12,13 1 2 8 10,11 9 5,17
18
3 4
97ZV42025
: Piston nut (16): 6,669 N-m (680 kgf-m) (4,920 lb-ft)

: Bolt (18): 843 N-m (86 kgf-m) (622 lb-ft)
Bucket cylinder
20 11 6 20
23 16 15 30 15 1 2 3 17 9 10 4 8 7 5 25 23
A
27,28 (Gauge port PF1/4) 30 27,28
5
(Gauge port PF1/4)
A
(S/N 9194~) (S/N 9194~) K95V2E42005
: Piston nut (16): 5,900±300 N-m (602±30.6 kgf-m) (4,353±221 lb-ft)

Bolt (25): 880±90 N-m (89.7±9.2 kgf-m) (649±67 lb-ft) (S/N ~9301)
Bolt (25): 500±65 N-m (50±6.5 kgf-m) (369±48 lb-ft) (S/N 9302~)
95ZV-2 EU FS 42-21
Hydraulic Cylinder
Steering cylinder
20,23 16 15 14 13 12 1 2 3 8 6,7 10,11 9 11 17 5 20,23
22 4
97ZV42027
: Rod cover (4): 1,765 N-m (180 kgf-m) (1,302 lb-ft)

: Piston nut (16): 1,275 N-m (130 kgf-m) (941 lb-ft)
95ZV-2 EU FS 42-22
Hydraulic Cylinder
Hydraulic cylinder specifications

mm (in)
ø190 x ø100 x 953
Inner diameter x rod diameter x stroke
(7.48 x 3.93 x 37.52)
Boom ø100 x 226
Piston rod
cylinder Pin hole (3.93 x 8.90)
(inner diameter x width) ø100 x 228.5
Cylinder
(3.93 x 9.00)
ø160 x ø80 x 605
(6.30 x 3.15 x 23.82)
Bucket ø90 x 100
Piston rod
(inner diameter x width) ø90 x 100
Cylinder
(3.54 x 3.93)
ø90 x ø50 x 600
(3.54 x 1.96 x 23.62)
Steering ø50 x 70
Piston rod
(inner diameter x width) ø50 x 70
Cylinder
(1.97 x 2.75)
95ZV-2 EU FS 42-23
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 Even if no hydraulic pump supplies oil to the loading
lock) and pilot control circuits due to trouble, or if the engine
is shut off, the boom can be lowered to the ground by
Reducing
valve Multiple the pressure in the accumulator in the brake circuit in
Oil packs control Oil packs
case of an emergency.
valve
From steering
From valve
brake line Cooler
P
Return filter
85V2E42004
95ZV-2 EU FS 42-24
Reducing Valve (for Pilot Pressure)
Reducing Valve (for Pilot Pressure)

Pressure adjustment
stud
Locknut
PPDB-LAN
CXCD-XAN CXCD-XAN
Ball
Passage Y
(P) (T)
(TA)
(PARKING)
(ACCR) (ACCF)
(PA)
(Z1) (Z2)
(Z) (PPI)
T Tank
Valve assembly
Note: Valve is shown rotated 180º from normal.

Orifice 2 C
From front brake A

accumulator circuit
Orifice 1 A B
Passage Z
B Plunger T
Hydraulic circuit diagram
Pilot oil circuit 85V2E42005
This valve provides pilot oil pressure to operate the park When the oil pressure on the pilot oil circuit side
brake and loader pilot valve functions. becomes less than the set pressure, the ball moves
down and the pressure at chamber C becomes equiva-
The oil fed from the brake accumulator circuit flows into lent to the pressure on the pilot oil circuit side (B). As a
the pilot oil circuit by way of passage Z. The oil pressure result, the plunger moves down by a spring, opens the
in the pilot oil circuit is applied also on chamber C by passage Z, then introduces the accumulator pressure to
way of orifice 1. the pilot oil circuit side so that the pressure is main-
tained at the specified value.
When the oil pressure in the pilot oil circuit is at or
above the set pressure, the oil in chamber C unseats This pressurized oil is supplied to the multiple control
the ball by way of orifice 2, and escapes to the tank by valve oil pack through the pilot valve and moves the
way of passage Y. As a result, the pressure in chamber multiple control valve spool.
C decreases, then the plunger moves up and closes
passage Z so that the pressure on the pilot oil circuit Set pressure
side does not exceed the set pressure. 3.5 MPa (36 kgf/cm2) (512 psi)
95ZV-2 EU FS 42-25
Pilot valve (S/N 9001~9250)

Float/Down
Raise (Detent)
White (Female)
(for port 3 solenoid)
Roll back (Detent)
Blue (Female)
Dump
From Top
18.20 16.20
White (Male) A B
(for port 4 solenoid) For For
bucket control boom control
A B
(Port 1, 2) (Port 3, 4)
1 2
3 4
From Bottom K115V2U42003

95ZV-2 EU FS 42-26
Roll back Raise

Dump Float
(Detent) (Detent)
(Detent) Down
21 21
20 20
19 19
18 18
2 2
3 4
5
7 9 6
Identifying
Identifying mark
8 mark 8
10 9
10 10 10
11
25 12
13 13 23
22 23 22
To tank port
14
15 16 15 16
14
24 From pump
port
17
Port1 Port2 Port3 Port4

To/from MCV oil packs To/from MCV oil packs
For bucket control For boom control
(Section A-A) (Section B-B) 115V2U42021
1. Lever 14. Spring

2. Push rod 15. Spring
4. Push rod 17. Spool
5. Detent solenoid coil (boom down / float) 18. Detent bushing
6. Detent solenoid coil (boom raise) 19. Spring
7. Detent solenoid coil (bucket level) 20. Detent ring
8. Fixing disc 21. Steel ball (4 pieces per spool)
9. Fixing disc (Identifying mark) 22. Spring seat
10. Push rod 23. Spring seat
11. Spring 24. Casing
12. Plug 25. Spring
13. Spring seat
95ZV-2 EU FS 42-27
Pilot valve function

1
The pilot valve applies oil pressure in proportion to the 21
operating angle of the lever, there-by carrying out 19
20
remote control of the spool in the multiple control valve.
Pilot valve operation (modulated position)
3
Predetent section
10
10
12 12
22 23
14 14
15 16
24
17
Lever is in the neutral position
85V2E42009
The pilot valve has holes of lengthwise direction in

P which the reducing valve is built. The reducing valve
section are consist of spool (17), spring for secondary
Reducing pressure (15)(16), return spring (14) and spring seat
valve (22)(23). Being inserted in plug (12), push rod (10) can
be moved smoothly to change the bending quantity of
Multiple
From
secondary pressure spring (15)(16).
control valve
front brake
Oil pack accumulator
85V2E42008 Return spring (14) contacts casing (24) and spring seat
(22)(23). This spring works on returning push rod (10) to
it’s original position without relation to secondary pres-
sure, 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) close 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 center-
ing springs. There is no oil flow to the cylinder.
95ZV-2 EU FS 42-28
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
21
1 19 tank port. The pump port is opened. It raises the oil
20 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
18
3 maintains a constant pressure to the multiple control
valve.
Predetent section
The oil pressure to the multiple control valve is propor-
10 10 tional 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 load-
25
ing pump to the cylinder is also proportional. Cylinder
13 speed is easily controlled.
22 23
When lever (1) is moved fully forward or back the multi-
15 16
ple control valve spool should also be moved full stroke.
17 17 This allows maximum oil flow to the cylinders for the

fastest cylinder movement.
Lever is shifted from the neutral
In addition, spring seat (13) and spring (25) are installed
85V2E42010 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
When lever (1) is shifted from the neutral, push rod (10)
push rod (10) inside diameter. The inclination of second
and spring seat (23) are pushed down at the same time,
pressure changed by this spring force. Then, to be sure
the value of secondary pressure spring is changed.
the multiple control valve spool is fully stroked, spring
Spool (17) is forced down by the secondary pressure
(25) and spring seat (13) are used. This allow spool (17)
spring (16) and then the tank port is closed and the
to be fully stroked and full pilot pressure will be directed
pump port is opened.
into the oil pack, thus fully stroking the multiple control
valve spool.
As a result, the pressurized oil from the pump flows into
the multiple control valve oil pack. The spool of the mul-
tiple 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 feel-
ing of modulation.
- Spool diameter at tank side is greater than spool

diameter at pump side.
95ZV-2 EU FS 42-29
Pre-detent and detent magnet solenoid

1
21
21 19 20
19
20 3
2
18 3
7
18
3 The figure that fixing
8
disc (8) is absorbed
by the detent
9
solenoid sub (7).
10
T P
P
Actuation of electromagnetic detent
85V2E42012
Actuation of pre-detent
85V2E42011 In addition, the detent magnet works to hold the lever at

it’s position, when the lever is shifted to "Bucket Roll
The pre-detent function is installed in the "Bucket Roll Back" or "Boom Raise" or "Boom Float" position.
Back" or "Boom Float" position that extends the change
of feeling to operator just before electromagnetic detent. Detent magnet section consists of detent solenoid sub
(7), fixing disc (8)(9) and push rod (2)(3).
The pre-detent section consists of detent bush (18),
spring (19), detent ring (20) and steel ball (21). When the circuit for the bucket leveler or the boom kick-
out (option) is turned on, detent solenoid sub (7) is ener-
Push rod (3) installed in the "Bucket Roll Back" or gized and magnetized so that fixing disc (8) of forced up
"Boom Float" position has the notch that steel ball is fit- side (opposite side) is held by magnetic force of detent
ted in. solenoid coil (7).
When push rod (3) is shifted and steel ball run upon the For this reason, lever (1) is held at that position if you
step, operation torque grows big by reactive force of keep the hand away from lever (1).
spring, because the spring is shorted.
Therefore displacement of push rod (10) is maintained,
This extends the change of feeling to operator just and it is the structure that continues generating the sec-
before electromagnetic detent. ond pressure constantly.
When the proximity switch 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.
95ZV-2 EU FS 42-30

Float/Down
Raise (Detent)
White (Female)
Roll back (Detent)
Blue (Female)
Dump
From Top
18.20 16.20
White (Male) A B
(for port 4 solenoid) For For
A B
(Port 1, 2) (Port 3, 4)
1 2
3 4
From Bottom
K115V2U42003
95ZV-2 EU FS 42-31
Roll back Raise

Dump Float
(Detent) (Detent)
(Detent) Down
21 21
20 20
19 19
18 18
2 2
3 4
5
7 9 6
Identifying
Identifying mark
8 mark 8
10 9
10 10 10
11
12
23
22 23 22
To tank port
14
15 16 15 16
14
24 From pump
port
17

(Section A-A) (Section B-B) K92V2E42001
1. Lever 14. Spring

4. Push rod 17. Spool
5. Detent solenoid coil (boom down / float) 18. Detent bushing
6. Detent solenoid coil (boom raise) 19. Spring
7. Detent solenoid coil (bucket level) 20. Detent ring
8. Fixing disc 21. Steel ball (4 pieces per spool)
9. Fixing disc (Identifying mark) 22. Spring seat
11. Spring 24. Casing
12. Plug
13. —
95ZV-2 EU FS 42-32

1
20
3
Predetent section
10
10
12 12
22 23
14 14
15 16
24
17
K92V2E42003

Multiple
From
control valve
front brake
K92V2E42002 Return spring (14) contacts casing (24) and spring seat

95ZV-2 EU FS 42-33

21
18
valve.
Predetent section
speed is easily controlled.
22 23
15 16

K92V2E42004


ing of modulation.

95ZV-2 EU FS 42-34

1
21
19 20
21
19
20 3
2
18 3
7
18
3 8 The figure that fixing
by the detent
9
solenoid sub (7).
10
T P
P
K92V2E42006
K92V2E42005 In addition, the detent magnet works to hold the lever at



95ZV-2 EU FS 42-35
Pilot valve (S/N 9256~)

Float/Down
Raise (Detent)
White (Female)
Roll back (Detent)
Blue (Female)
Dump
(for port 2 solenoid) From Top
18.20 16.20
White (Male)
A B
For For
P T
1 2 2 4
A B
1 2 (Port 1, 2) (Port 3, 4)
3 4
From Bottom
90Z542003
95ZV-2 EU FS 42-36
Roll back Raise

Dump Float
(Detent) (Detent)
(Detent) Down
21 21
20 20
19 19
18 18
2 2
3 4
5
7 9 6
Identifying
Identifying mark
8 mark 8
9
10 10 10 10
11
12
23
22 23 22 16
14
14
15 To tank port
16 15
From pump 24
port
17

(Section A-A) (Section B-B) 90Z542004
1. Lever 13. —
5. Detent solenoid coil (boom down / float) 17. Spool
6. Detent solenoid coil (boom raise) 18. Detent bushing
7. Detent solenoid coil (bucket level) 19. Spring
8. Fixing disc 20. Detent ring
9. Fixing disc (Identifying mark) 21. Steel ball (4 pieces per spool)
11. Spring 23. Spring seat
12. Plug 24. Casing
95ZV-2 EU FS 42-37

1
20
3
Predetent section
10
10
12 12
22 23
14 14
15 16
24
17
90Z542006
T
Multiple
From
control valve
front brake
90Z542005 Return spring (14) contacts casing (24) and spring seat

95ZV-2 EU FS 42-38

21
18
valve.
Predetent section
speed is easily controlled.
22 23
15 16

90Z542007


ing of modulation.

95ZV-2 EU FS 42-39

1
21
19 20
21
19
20 3
2
18 3
7
18
3 8 The figure that fixing
by the detent
9
solenoid sub (7).
10
P
T
P
90Z542009
90Z542008 In addition, the detent magnet works to hold the lever at



95ZV-2 EU FS 42-40
Multiple Control Valve (KML35A/2T003B)
3 8
B2 A2
b2
C C
B1 A1
b1
B B
P T
2
P T
A A
1
10 9 A-A
Bucket Spool Boom Spool

6 6
B1 A1 B2 A2
4 4 5
a1 a2
B-B C-C
95ZV42074
1. Main relief valve

2. Spool (Bucket)
3. Spool (Boom)
4. Overload relief valve (Bucket circuit)
(with make-up valve)
5. Make-up valve (Boom circuit)
6. Load check valve
7. Casing
8. Spring cover
9. Cover
10. Gauge port
95ZV-2 EU FS 42-41
Boom Bucket Multiple control valve specifica-

B2 A2 a2 B1 A1 a1 T tions
Model KML35A/2T003B
20.6 MPa
Main relief valve setting pressure (210 kgf/cm2)
(2,986 psi)
P1
23.5 MPa
Overload relief valve setting pressure (240 kgf/cm2)
(3,413 psi)
Rod side Installed
b2 b1 P Overload Bucket
relief valve Bottom side Installed
Hydraulic line diagram 95ZV42023
installation Rod side Non-installed
point Boom
Bottom side Non-installed
The bucket priority line is used for the multiple control Rod side Installed
valve, and consists of the following units: Make-up Bucket
valve Bottom side Installed
installation Rod side Installed
1. Main relief valve point Boom
Bottom side Non-installed
Relieves the pressure when the working pressure

Note
exceeds the relief setting pressure.
A third spool for an auxiliary function (Log clamps, Side
dump bucket, etc.) is available. If required, the inlet
2. Bucket spool
cover is removed and the third spool is installed. The
inlet cover is reinstalled.
Used for bucket operation, such as roll back, hold-
Priority oil then goes to the third spool function.
ing a tilt angle, and dumping.
3. Boom spool
Used for the boom operation, such as raising, hold-

ing 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".
95ZV-2 EU FS 42-42
Multiple control valve main relief Main relief valve operation

valve
Relief poppet Plunger Orifice 1
Passage B
The main relief valve is installed between the pump and
the control spool. When the cylinder comes to the stroke Tank
end, or if the pressure is above the set pressure, the oil port
fed from the pump will be discharged into the tank
through this valve (main relief valve) to prevent pump
Pump
and pipe damage. A port
Spring
Body
Spring seat
Seat Filter Passage A
95V2E42005
Passage C Passage D
Adjusting screw Tank

port
Pump
A 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 pres-
surized oil in the pump port escapes to the tank port.
95ZV-2 EU FS 42-43
Note Adjusting set pressure

Clogging of the orifice in plunger will cause low pres-
sure. Remove the cap nut. Loosen the lock nut and adjust the
Another possible cause of low pressure is contamina- pressure by the adjusting screw. Turn clockwise the
tion in, or damage to, the seat of relief poppet or adjusting screw to raise the set pressure, or turn coun-
plunger. terclockwise the adjusting screw to lower the set pres-
sure.
After adjustment, be sure to tighten the lock nut.
Set pressure
20.6±0.5 MPa (210±5 kgf/cm2) (2,986±71 psi)
IMPORTANT
Always be certain to tighten locknuts when finished
with adjustment.
Only set pressures in accordance with setting specifi-
cations.
95ZV-2 EU FS 42-44
Multiple control valve overload Overload relief valve operation

relief valve (with make-up func-
When the oil pressure is at the preset valve or less
tion)
(Installed on both the rod and bottom sides of the bucket
Orifice 1 Plunger
circuit) Relief poppet Passage A
Plunger seat
Each overload relief valve (with make-up function) is
installed in the circuit between the cylinder and the con-
trol valve spool. When the spool is in the NEUTRAL
position, if external force on the cylinder becomes too A
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.
Tank Cylinder
Spring port port
Passage B
Seat
95V2E42007
The pressurized oil from the cylinder flows to the cham-

ber 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
Passage C Passage D Plunger

Adjusting screw
Lock nut Tank Cylinder

Body port 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 low-

ers and the plunger is moved to the left. Then the
plunger opens the port to the tank port and the pressur-
ized oil in the cylinder port escapes to the tank port.
95ZV-2 EU FS 42-45
Make-up valve operation Adjusting set pressure
Plunger
Plunger seat
Adjusting screw
Spring
Lock nut Tank Cylinder

Tank Cylinder port
port
port port
Passage E 95V2E42010
95V2E42009
When the overload relief valve on one side of the cylin- Loosen the lock nut and adjust the pressure by the
der port is actuated, the plunger in the control valve is in adjusting screw. Turn clockwise the adjusting screw to
neutral. The port opposite to the one in which high pres- raise the set pressure, or turn counterclockwise the
sure was produced has a greatly reduced pressure. adjusting screw to lower the set pressure.
When the pressure is reduced below the tank pressure,
the make-up valve is opened. After adjustment, be sure to tighten the lock nut.
When the pressure at the cylinder port becomes less Set pressure
than tank pressure, the plunger seat is moved to the 23.5±0.5 MPa (240±5 kgf/cm2) (3,413±71 psi)
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 pas-
sage E. It prevents a vacuum (negative pressure) in the Multiple control valve make-up
cylinder.
valve
Note (Installed on the rod side of the boom circuit)
The make-up valve function is non-adjustable.
The make-up valve is installed in the circuit between the
control spool and boom cylinder.
Extremely quick boom lowering may generate low pres-

sure 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 genera-

tion 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 over-

load relief valve with make-up valve does. Refer to the
description on "overload relief valve" for the makeup
valve operation.
95ZV-2 EU FS 42-46
Multiple control valve bucket spool

Bucket spool operation
1. "Bucket Roll Back" position
D
B1 A1
From pilot valve

Pa1
To pilot valve Spool

Pb1
From pump
95ZV42024
- When the control lever is set to the "Bucket Roll - On the other hand, the oil on the rod side of the
Back" position, the pilot pressure is applied on the bucket cylinder returns from the B1 port to the tank.
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 bot-
tom side of the bucket cylinder, and finally rolls back
the bucket.
95ZV-2 EU FS 42-47
2. "Bucket Dump" position
E D
B1 A1
To pilot valve
Pa1
From pilot valve Spool

Pb1
From pump
95ZV42025
- When the control lever is set to the "Bucket Dump" - Extremely quick dumping generates negative pres-
position, the pilot pressure is applied on the left oil sure (or a void) on the rod side. To prevent genera-
pack (Pb1), the spool moves to the right, and the tion of negative pressure (or a void), the make-up
spool shoulder (C) closes the center bypass line. valve (E) opens so that the oil in the tank port flows
As a result, the oil from the pump opens the load into the rod side of the cylinder.
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.
95ZV-2 EU FS 42-48
Multiple control valve boom spool

Boom spool operation
1. "Boom Raise" position
D
B2 A2
From pilot valve

Pa2
To pilot valve Spool

Pb2
From pump 95ZV42026
- 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.
check valve (D), flows from the A2 port into the bot-
tom 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.
95ZV-2 EU FS 42-49
2. "Boom Down" position
E D
B2 A2
To pilot valve
Pa2

Pb2
C
From pump 95ZV42027
- 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.
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.
95ZV-2 EU FS 42-50
3. "Boom Float" position
B2 A2
To pilot valve
Pa2

Pb2
From pump 95ZV42028
- When the control lever is pushed downward beyond

the "Boom Down" position to the "Boom Float" posi-
tion, 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.
95ZV-2 EU FS 42-51
Adapter (Orifice)
Adapter (Orifice)
O-ring ø1.3 mm
Orifice
Adapter
Installation position Port b2

Multiple
control
valve
80ZV42018
The adapter is installed in the boom lowering line Note

between the pilot valve and the multiple control valve. When the oil is very cold it will pass very slowly through
the orifice. As a result it will take longer than normal for
When the lever is shifted back to the holding position the spool to shift to neutral or holding position.
just after lowering the boom, the boom spool of the mul- Always warm up the oil before beginning normal opera-
tiple control valve is quickly returned to the holding position.
tion 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 return-
ing the pilot oil which was pushing the spool.
95ZV-2 EU FS 42-52
Ride Control (OPT)
Ride Control (OPT)
Ride control hydraulic circuit

4
(16) (18) (15)
(H)
(X)
(Ac) 3
Capacity: 9.5 L
(T) (Ac2) (Ac1) Gas pressure:
(14)
1.96 MPa
(20 kgf/cm2) From multiple
(Ac1) (284.2 psi)
(5) control valve
1
(13) (br)
(R)
Multiple control (P)
valve P line 8.34MPa
(85 kgf/cm2)(1,209 psi)
(11)
Multiple control (T)

valve T line 95V2E42011
1. Valve assy Ride control function

(11) Solenoid valve
(13) Reducing valve Ride control reduces fore and aft pitching motion to the
(14) Check valve machine in roading by using the boom cylinder and
2. Valve assy hydraulic circuit with the accumulator. Ride control can
(15) Selector valve be operated or released by turning the ride control
(16) Solenoid valve switch ON/OFF.
(18) Shuttle valve
3. Accumulator Turn the ride control switch ON, and when the machine
4. Boom cylinder travelling speed reaches more than 7 km/h (4.3 mile/h),
5. Bleeder valve 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.
95ZV-2 EU FS 42-53
Ride Control (OPT)
Ride control operation

Preparation mode (ride control switch is
OFF)
(16) (18) (15)
(H)
(X)
(Ac) 3
Capacity: 9.5 L
(14)
1.96 MPa
(Ac1) (284.2 psi)
(5) control valve
1
(13) (br)
(R)
(85 kgf/cm2)(1,209 psi)
(11)
Multiple control (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 sole-
noid 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.
95ZV-2 EU FS 42-54
Ride Control (OPT)
Running mode (ride control switch is ON)
(16) (18) (15)
(H)
(X)
(Ac) 3
Capacity: 9.5 L
(14)
1.96 MPa
(Ac1) (284.2 psi) control valve
(5)
1
(13) (br)
(R)

(85 kgf/cm2)(1,209 psi) (11)
Multiple control
(T)
The ride control switch is ON, and when the machine Therefore, when the pressure develops at the boom cyl-
travelling speed reaches more than 7 km/h, solenoid inder rod side by pitching motion in roading, oil is
valves (11)(16) come to ON by a signal from the MCU. drained to the tank. When the negative pressure devel-
ops at the boom cylinder rod side, oil from the tank fills
Pressurized oil in the upper part of selector valve (15) is the boom cylinder rod side.
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 cylin-

der 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.
95ZV-2 EU FS 42-55
Ride Control (OPT)
Ride control valve assembly (Reducing valve circuit)

Outline drawing
Pump Tank
2
(T)
(P)
(R)
Boom cylinder
rod side
(Ac1)
Accumulator
4
6
5
1. Block (T)
2. Reducing valve
#2 #3,#4
3. Solenoid
(P)
4. Valve
(R)
5. Check valve
6. Bleeder valve #5
(Ac1)
#6 (br)
Hydraulic circuit
95V2E42012
95ZV-2 EU FS 42-56
Ride Control (OPT)
Reducing valve Check valve
Passage A
Accumulator Bleeder
A valve
Passage B
Passage B
B Poppet
Tank Tank
Orifice 2 Sleeve
Ball
A Reducing valve 95V2E42014
Orifice 1
Pump Oil from the reducing valve pushes the poppet up and
flows to the accumulator circuit.
Passage A
Plunger 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,
Check valve
95V2E42013
and pushes the poppet down with the spring force. As a
result, the oil never flows back.
Oil from the pump flows to the check valve through the
passage A. Also the oil pressure in the check valve cir-
cuit 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)
95ZV-2 EU FS 42-57
Ride Control (OPT)
Solenoid valve
Solenoid
Chamber A
Spring
Orifice
Boom cylinder Sleeve

rod side
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 con-
nected 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 Ω
95ZV-2 EU FS 42-58
Ride Control (OPT)
Ride control valve assembly (Accumulator circuit)

Outline drawing
6 2
X 1
3
4
Tank
Boom cylinder
H bottom side
Reducing
AC1
valve
AC2 AC
6
Accumulator 95V2E42016
1. Block
2. Check valve
3. Solenoid
4. Valve #3,#4
5. Shuttle valve #2
6. Plug (H)
#5
(X)
(Ac1)
(T) (Ac2) (Ac)

Hydraulic circuit 95V2E42017
95ZV-2 EU FS 42-59
Ride Control (OPT)
Shuttle valve Solenoid valve
Movable iron core
Passage A Solenoid
valve
Solenoid
Passage B
Accumulator
Rod
Passage C
Ball Spool
Boom cylinder Passage B
bottom side 95V2E42018
Tank
When the pressure at the accumulator side is higher
than the one at the boom cylinder bottom side, oil flows, Shuttle valve B
pushing the ball down, to the solenoid valve through the
passage A and B.
Passage A
When the boom cylinder bottom pressure is higher, oil Sleeve
A Check
pushes the ball up, and it flows to the solenoid valve valve 95V2E42019
through the passage C and B. The shuttle valve
switches the oil flow direction by selecting higher oil
pressure side. 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 shut down, 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.
Voltage DC 24 V
Current 0.92 A
Resistance 26.2 Ω
95ZV-2 EU FS 42-60
Ride Control (OPT)
Check valve
Passage B
Pressure receive
face E
A
Reducing valve
(sol. valve) Poppet
Passage A
Passage C
Shuttle valve Boom cylinder

bottom side
Pressure receive Passage D

face F
Seat face Sleeve

Accumulator 95V2E42020
When the solenoid valve is not energized, the oil from

the reducing valve flows into the chamber (A) through
the passages A and B. Then the poppet is pushed
down, and the circuit between the accumulator and the
boom cylinder bottom side is closed.
In this time, the boom cylinder bottom pressure applies

to the pressure receive faces E and F. Also the accumu-
lator pressure applies to the bottom side of the poppet.
However the poppet is pushed down because the pres-
sure 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 pop-
pet 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 fluctua-
tions in the boom cylinder bottom side.
95ZV-2 EU FS 42-61
Ride Control (OPT)
Accumulator (for ride control)
7
2 4 1 3
13
10
12
11
9
6
95ZV52058
1. Body 6. Back up ring 11. Gas valve O ring

2. Hydraulic cap 7. Wear ring 12. Gas valve guard
3. Gas cap 8. O-ring 13. Bolt
4. Piston 9. Back up ring
5. V-O ring 10. Gas valve
Accumulator function Accumulator specification
Maximum operation pressure MPa (kgf/cm2)(psi) 20.6 (210)(2,986)

While the ride control operates, the accumulator
absorbs fluctuation of the boom cylinder bottom pres- Nitrogen gas pressure MPa (kgf/cm2) (psi) 1.96 (20) (284)
sure by air cushion function of the nitrogen gas charged Capacity (l) 9.5
in the cylinder.
The cylinder contains N2 (Nitrogen) gas at 1.96 MPa (20

kgf/cm2).
95ZV-2 EU FS 42-62
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 pro-

portional to the turning speed is sent from the Orbitrol®
From and supplied to the oil pack of the steering valve.
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.
Shortly before the full turn, the stop valve activates, the
Stop valve Stop valve pilot circuit is closed.
RH While the steering wheel is not turned, almost all

LH
amount of hydraulic oil from the steering pump is sent to
the loading line by the action of the flow control spool.
Steering valve The pilot oil pressure from the steering pump is limited
by the reducing valve, then supplied to the Orbitrol®.
To loading line
To Orbitrol®
Oil returns from the steering cylinders flows through the
Cooler bypass valve
steering valve and oil cooler or cooler bypass valve.
P Oil cooler Finally it returns to the tank through the return filter.
Reducing
valve
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 opera-
tion.
80ZV42006
95ZV-2 EU FS 42-63
Orbitrol®
Orbitrol®
Orbitrol® is used as a pilot valve, and it operates the Orbitrol® structure
spool of the steering valve by discharging oil, that is in
proportion to rotation amount of the steering wheel, to
the steering valve. 1. Spool 5. Drive shaft
2. Sleeve 6. Centering spring
This Orbitrol® is the closed center and non-load reaction 3. Stator 7. Cross pin
4. Rotor 8. Check valve
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 Valve part
works on P port.
T
6
7 L
Valve
1
R P
2
3
4
Rotor
85V2E42018
95ZV-2 EU FS 42-64
Orbitrol®
- Spool (1) and sleeve (2) as a set form a rotary-type Orbitrol® specifications
directional change-over valve. Spool (1) in this valve
is linked to the steering wheel by means of a spline.
Model ND-K5-D
- When the steering wheel is not being turned, spool Theoretical discharge (cm3/rev) 120
(1) and sleeve (2) are held in the neutral position by Operation pressure MPa (kgf/cm2) (psi) 3.5 (36) (512)
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.
- 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 2
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 func-

tions as a hydraulic motor.
- Rotor (4) rotation is transmitted to the valve part by

means of the connected drive shaft (5), and the
degree of valve opening is regulated depending on
how fast the steering wheel is being turned.
95ZV-2 EU FS 42-65
Orbitrol®
Orbitrol® operation
Neutral
(When the steering wheel is not being turned)
6
T
2
8
L
Oil hole
T R
6 Oil groove
7 L
1
R P
2
70ZV42025
3
4
1. Spool 5. Drive shaft
2. Sleeve 6. Centering spring
3. Stator 7. Cross pin
85V2E42019
- 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.
95ZV-2 EU FS 42-66
Orbitrol®
Turn
(When the steering wheel is being turned)
1
T
6
7 L
T To steering
2 valve Pa port
From steering
R P valve Pb port
L 2
Oil hole 5
1
From reducing valve
R (pump)
Oil groove 3
4
85V2E42020
1. Spool 5. Drive shaft

65ZV42036 2. Sleeve 6. Centering spring
3. Stator 7. Cross pin
- 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.
95ZV-2 EU FS 42-67
Orbitrol®
Orbitrol® feed-back mechanism operation
Spool
Sleeve
Cross pin
Drive shaft
Steering valve
Pa port
Steering valve
Pb port
Stator
Rotor
K80V2J42003
- When an angle of displacement (deviation in circum- - If the turning of the steering wheel stops, the spool
ferential direction) is generated between the spool immediately stops rotating; but, as long as there
and the sleeve through operation of the steering exists an angle of displacement between the spool
wheel, oil from the pump enters the steering valve and the sleeve, oil continues flowing into the
(pilot) and turns the rotor; this oil flows into the steer- Orbitrol®, and the rotor can continue rotating. Due to
ing valve. At this time, the rotor rotation is transmit- this rotation, the sleeve catches up with the spool,
ted to the sleeve by the drive shaft and the cross pin. and closes the hydraulic circuit. Finally, the centering
spring returns the spool and the sleeve to the neutral
- As a result, the sleeve starts rotating slightly behind position and flow of oil is completely stopped.
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.
95ZV-2 EU FS 42-68
Orbitrol®
Steering speed and flow rate con- Hydraulic pump oil amount and
trol steering force
- When there is plenty of oil flowing from the pump,
Low steering speed High steering speed 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.
1
- When the amount of oil from the pump is small, the
3
Small Large
displacement angle of the spool and sleeve reaches
displacement
angle
displacement
angle 2 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 maxi-
mum 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
70ZV42028 harder to turn.
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 regu-

lated by changing the displacement angle of spool
(1) and 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.
95ZV-2 EU FS 42-69
Orbitrol®
Orbit rotor operation principle
Drive shaft (0 rotation) Drive shaft (1/14 rotation) Drive shaft (1/7 rotation)
Rotor center Rotor (rotation)
Locus of rotor center Stator (fixed)

1 1 1
7 2 7 2 7 2
6 3
6 3 6 3
5 4 5 4 5 4
7 2
6 3
5 4
:Flow of high-pressure oil
:Flow of low-pressure oil 70ZV42029
- Inside the rotor there is a stator with 7 internal gears - The rotor makes a 1/6 turn per rotation of the rotor,
that is fixed to the housing and a 6-tooth rotor that is pushing out oil equivalent to 7 chambers. When the
engaged with the stator. rotor rotates once, oil equivalent to 42 chambers (7
chambers x 6 turns) is pushed out.
- Half of the chamber formed by the stator and the
rotor is connected to the high-pressure side and the - For the motor, it has 6 times larger torque or a 1/6
other half to the low-pressure side. reduction effect.
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 dif-
ference).
- When overrunning the power assist capacity of the

rotor 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.
95ZV-2 EU FS 42-70
Steering Valve (KVS32-A4.0/20)
7
ø 3.0 mm (0.118") (G)
PC P
2
3
MR
A A
Pb Pa
B B
5 1 5
T
(F)
P. B.
2
MR
ø 3.0 mm (0.118") A-A
(LC)
B A
4 4
BR AR
Pb Pa
B-B 6
95V2E42021
1. Steering spool
2. Flow control spool
4. Overload relief valve (with make-up valve)
5. Check valve
6. Orifice [ø 0.7 mm] (with filter)
7. Gauge port
95ZV-2 EU FS 42-71
1. Steering spool
AB
AR The movement of the steering spool is controlled by

the oil pressure supplied from the Orbitrol® to the
BR main steering valve oil pack.
Pa Pb
At the center of the spool, there is a variable orifice
with chamfers (throttle grooves). This orifice con-
0.7 T trols the oil flow rate.
RF Also inside the steering spools are check valves
(G) MR P. B.
3.0 which apply a back pressure to oil returning from
Orifice the cylinders.
Pc
P
Hydraulic circuit 95V2E42022 2. Flow control spool
The flow control spool sends oil to the steering line

IMPORTANT depending on the displacement of the steering
Flow control plunger orifice must not be blocked. spool.
Pump damage may result. The excess oil goes to the loading line.
The main relief valve controls the maximum operat-

ing 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-A4.0/20
20.6 MPa
Main relief valve setting pressure (210 kgf/cm2)
(2,986 psi)
24.5 MPa
Overload relief valve setting pressure (250 kgf/cm2)
(3,555 psi)
95ZV-2 EU FS 42-72
Steering valve operation

Neutral position (Steering spool in "Neutral")
Loading circuit
A B
95V2E42023
- In the NEUTRAL position, steering spool (1) closes - When the pump line pressure increases to 0.63 MPa
all the ports to stop flow of the pressurized oil from (6.4 kgf/cm2) (91.4 psi), flow control spool (2) is
the steering pump. The pressure in the pump line, moved to the right due to the pressure difference
therefore, will rise. 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.
95ZV-2 EU FS 42-73
Left turn position
Loading circuit Pump 2
Pilot pressure
Check valve
1
Tank
Variable throttle
95V2E42024
- When steering spool (1) is pushed in to the left, the - During low-speed turning, displacement of steering
pressurized oil from the pump is sent to steering cyl- spool (1) is small. However, since the oil flow rate to
inders through the variable throttle section and the the steering cylinder is reduced at the variable throt-
check valve. The pressurized oil moves the cylinder tle section at the spool center, the pressure differ-
rods and the machine turns to the left. ence 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.
95ZV-2 EU FS 42-74
- For high-speed turning, steering spool (1) is pushed Steering spool variable throttle
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 PB

PA
steering pump is low, therefore the pressure differ-
ence between the front and rear of the throttle sec-
tion 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 differ-
ence between the front and rear of the throttle sec-
tion is increased to activate the flow control spool. As
a result, the excess oil is sent to the loading line. Variable throttle
95V2E42025
When the steering spool is pushed in, the variable throt-

tle is opened, and the pressurized oil from the pump
goes through the variable throttle, the pressure gener-
ated 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 open-

ing 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).
95ZV-2 EU FS 42-75
Steering valve flow control spool
Loading circuit Pump Spring
PA
PB
A B
Variable throttle Steering circuit

Loading circuit Pump
PA
PB
Steering circuit 95V2E42026
When the pump discharge amount is small, the pres-

sure 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 con-
stant in the steering circuit.
95ZV-2 EU FS 42-76
Steering valve main relief valve

When the pressure is at the preset value or
less
Loading circuit Pump Flow control spool
Filter
A
B
Steering spool
Cylinder Tank Cylinder
95V2E42027
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.

95ZV-2 EU FS 42-77
When the pressure exceeds the preset

value
Loading circuit Pump

Flow control spool
A
B
Steering spool
Tank
95V2E42028
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 rela-
tively high, the flow control spool is shifted to the right,
and the oil sent from the pump flows into the loading cir-
cuit.
95ZV-2 EU FS 42-78
Steering valve overload relief

valve
External force
B A
Overload relief valve with

make-up valve
Overload relief valve with Operates as overload
make-up valve relief valve
Operates as
make-up valve
Tank
95V2E42029
Overload relief valves with makeup valve are located in Overload relief function
the circuit between the steering cylinder and the steer-
ing spool on the both sides of the steering cylinder. In this situation, if an external shock (force) is applied to
one side of the cylinder (the bottom side in the figure
While the steering spool is located in the neutral posi- above) causing abnormally high pressure to build up in
tion, the steering cylinder circuits are closed. the circuit, the oil escapes through the valve on side A,
in order to prevent damage to the piping and the cylin-
der.
Makeup function
On the other side of the cylinder (the rod side in the fig-
ure 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 vac-
uum (negative pressure (or void)) from developing in
the circuit.
95ZV-2 EU FS 42-79
Overload relief valve operation Make-up valve operation
C K X K
A
Cylinder
Cylinder
E
D Tank 115ZV42052 Tank 115ZV42054
When the oil pressure is at the preset value or less When the cylinder pressure drops below the tank pres-
sure, sleeve K moves to the right due to the difference
The pressurized oil is sent to the internal space X in the pressure receiving area (G - A) between the left
through the orifice of the piston C. Because the oil pres- side and the right side of sleeve K, and the oil flows
sure is at the preset value or less, the poppet E is from the tank to the cylinder so that the cylinder pres-
closed and the area between the cylinder and the tank sure does not drop below the tank pressure.
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 K X
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 rela-

tively lower than that on the cylinder side, then the pis-
ton C moves to the right and fits in the pilot poppet E.
Because the internal space X leads to the tank, the pop-

pet D moves to the right and the high pressure oil
escapes from the cylinder to the tank.
95ZV-2 EU FS 42-80
Steering pilot circuit and its opera-

tion
From pump
Orbitrol® Reducing valve
To tank
Steering valve
Filter
To tank
Cylinder Cylinder
Stop Stop
valve B A
valve
End cover End cover

Flow amplifier notch
Pilot line Pilot orifice

Tank
K97V2J42006
Oil flow orifice and flows to the end cover on the opposite
side, returning to the tank through the Orbitrol®.
- Oil from the steering pump flows into the steering
valve. The oil flow direction is separated in the steer- - As the amount of oil flowing through the amplifier
ing valve. notch and the pilot orifice increases, the pressure of
The oil is supplied to the Orbitrol® from the steering the oil inside the end cover increases, pushing in the
valve through the reducing valve where the oil pres- steering spool.
sure is reduced. The variable throttle opens, regulating the amount of
oil flowing to the cylinder circuit, depending on flow
- The hydraulic oil from the Orbitrol® first enters the volume, and thus the distance the spool is pushed in.
end cover of the steering valve, then passes through
the steering spool flow amplifier notch and the pilot
95ZV-2 EU FS 42-81
Flow amplifier notch and pilot orifice
Return spring Return spring force Hydraulic force
Pilot pressure
Pilot oil
End cover
Pilot orifice
Flow amplifier notch Flow amp. notch opening

Pilot line K115V2J42005
Pilot orifice
80V2U42006
- 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 flow rises, as the opening of the flow
When pilot oil is sent from the Orbitrol® the oil flows amplifier notch is narrow, the pressure inside the end
through the pilot orifice, the pressure of the oil inside cover is raised higher, pushing the spool in.
the end cover rises, pushing the spool and opening When the spool is pushed in, the opening of the flow
the flow amplifier notch. amplifier notch becomes larger, making it easier for
Then, the oil flows through the flow amplifier notch pilot oil to flow out; thus, the rise in pressure stops
and the pilot orifice. 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.
Return spring force Hydraulic force

Pilot pressure
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.
95ZV-2 EU FS 42-82
Stop Valve
Stop Valve
17.0 mm (S/N ~9257)

14.5 mm (S/N 9258~9300)
16.0 mm (S/N 9301~)
(Full stroke) From Orbitrol®
To steering valve
7 3 8 2 1 6
DR
11 13 10 12 5 4 14 9
3 (S/N 9251~)
K115V2E42003
1. Housing 9. Spring
2. Spool 10. Spacer
B 3. Check valve 11. Boot
4. Plug 12. U-packing
5. Washer 13. Dust seal
6. Plug 14. O-ring
7. Flange
8. Spring
A DR
97ZV42042
95ZV-2 EU FS 42-83
Stop Valve
Stop valve function Stop valve operation
Port A
Port B From
To steering valve Orbitrol®
Stopper
(bolt) Spool
Installed on Check valve

front chassis 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.
B A
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.
95ZV-2 EU FS 42-84
Reducing Valve (for Orbitrol®)
Reducing Valve (for Orbitrol®)
Spring
Sleeve (T)
Tank
Plunger
Passage Z
(A) TS
Pump B
B A
A
Passage Y
(TS) T

(B)
Orbitrol®
90ZV42012
The oil fed from the pump flows into the Orbitrol® circuit This oil is supplied from the Orbitrol® to the steering
by way of passage Y and port A in the plunger. valve pilot port, and moves the spool.
When the oil pressure in the Orbitrol® circuit reaches or Set pressure
exceeds the set pressure (spring force), the plunger is 3.5 MPa (36 kgf/cm2) (512 psi)
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.
95ZV-2 EU FS 42-85
Steering Line Filter
Steering Line Filter
From pump FILTER To reducing

(steering valve) valve
1 3 4 2 5
70ZV42040
1. Case The line filter is integrated into the pilot line of the steer-
2. Nipple ing line, and prevents foreign objects from entering the
3. Strainer pilot line.
4. O-ring
5. O-ring Note
The line filter design shown above is also used for the
brake line.
Front The filter prevents debris from entering the brake accu-
mulator reducing valve assembly.
These filters must be removed, inspected and cleaned
Line filter or replaced every 2,000 hours of operation.
Center pin
center line
Reducing valve Rear

chassis
Installation position for steering pilot line filter

95V2E42032
95ZV-2 EU FS 42-86
K-Lever (OPT)
K-Lever (OPT)
Hydraulic circuit 1
[K-Lever handle]
4
2
R
Horn switch N
3 F
Solenoid valve
95V2U42009
1. K-Lever
2. Arm rest
3. Forward/Reverse changeover switch (on K-Lever)
4. Downshift button (on K-Lever)
When the K-Lever system is turned on, it allows quick

easy steering, directional control, and down shifting on
one joystick type lever. On the other hand, the steering
can be possible by the steering wheel and it overrides
the K-Lever system.
K-Lever switch K-Lever
The transmission forward and reverse (F/R) changeover

switch and the downshift button are built into the K-
Lever. This allows the operator to change the direction
and speed of the machine without releasing the K-
Lever.
Orbitrol®
The K-Lever handle is connected to a potentiometer.
This potentiometer changes the input voltage from 2.5 V

DC down to 0 V DC, or from 2.5 V DC up to 5 V DC and
is interpreted as input voltage at the MCU (machine
control unit). 2.5 V DC is input for no steering action.
Raising or lowering the voltage creates steering input.
Solenoid valve
95V2U42008
95ZV-2 EU FS 42-87
K-Lever (OPT)
Hydraulic line diagram
Solenoid valve assembly
Orbitrol®
A B
X P T
P T
L R
120
L cm3/rev R
Stop valve Stop valve

A A
B B
DR DR
A B
3.5 MPa (512 psi) Pb

at 0 L/min Pa T
B A
P.B.
Steering valve
95 m
G PC P
Reducing valve
95V2U42010
95ZV-2 EU FS 42-88
K-Lever (OPT)
Hydraulic line
From Orbitrol® (R)

Steering valve
(R) (L) Pa Pb
(P) (T) 1
3
2
From Orbitrol® (L)
Orbitrol®
A 2
3
(T)
(P)
1
A
(T)
(R) (L)
(P)
4 2
1
1. High pressure hose 3
2. High pressure hose
View A-A
95V2U42011
95ZV-2 EU FS 42-89
K-Lever (OPT)
Solenoid valve mount
Front
95V2U42012
1. Solenoid valve assembly

2. Orbitrol®
95ZV-2 EU FS 42-90
K-Lever (OPT)
Solenoid valve assembly (1/2)
Front
Orbitrol®
L0 T0
PG2
R0 P0
1
3 B-B
3 3
B
1
T1 L1
2
T
P1 R1 Sol. a A B Sol. b
PG5 X
P
A A
B
4
4 4 PG3 PG4
PG3
L1 L0
R1 R0
PG1 A B
PG4
1. Block A-A
2. Solenoid valve assembly T1
X P T
T0
3. Adapter P1 P0
4. Plug PG5 PG1 PG2
Hydraulic line
95V2U42013
95ZV-2 EU FS 42-91
K-Lever (OPT)
Solenoid valve assembly (2/2)
5 11 13
2 1
4 3 6 14 9 8 10 12 7
95V2U42014
1. Solenoid
2. Socket bolt
DANGER
3. O-ring Always shut the engine off prior to making any adjust-
4. O-ring ments to the spring tensioning screw number 7. Invol-
5. Guide untary movement of the steering can result when this
6. O-ring is misadjusted.
7. Screw (spool centering adjuster)
8. O-ring
9. O-ring
10. Socket bolt
Adjustment method
11. O-ring
12. Nut
13. O-ring If the desired steering speed cannot be achieved
14. Socket bolt through changing the mA or DC V in the MODM, loosen
lock nut number 12 and adjust screw number 7 only
slightly. This is a very sensitive adjustment, and very lit-
tle screw movement is needed to make a significant
change.
Do not over loosen as hazardous involuntary movement

of the steering will take place if this is too loose. It must
be adjusted so as to keep the spool held in the center
position.
95ZV-2 EU FS 42-92
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 drastically shortens the cycle time.
When the ELS switch at the instrument panel is turned

on and excavating, more specifically, the ELS operation
Fast
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.
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 perfor-
When excavating and scooping mance of operating when excavating and scooping.
Switch Steering
Multiple
Boom
Fuel efficient mode switch is also installed at the instru-
control ment panel when operating at the time of fuel saving
pump valve Bucket
valve
driving. If the combination of ELS switch and fuel effi-
cient mode switch is selected properly, it can be able to
Main ELS improve the fuel consumption without reducing the
pump valve operation efficiency.
Hydraulic tank In addition, the height range of the boom that ELS oper-
ates can be set up to the arbitrary height depending on
setting of the variable kickout sensor.
When raising the boom
Multiple
Switch Steering Boom
control
pump valve Bucket
valve The operation condition of ELS
Main ELS The ELS switch ON

pump valve Shift lever Forward position
Machine speed Less than 5 km/h
Hydraulic tank The setting position of the variable kickout sensor
Boom height
is less than it.
Concept of the ELS operation 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 posi-
tion.
When the engine revolution becomes higher than 1,300
min-1, it stops working.
95ZV-2 EU FS 42-93
Mounting of the ELS valve
3 4
ELS valve
(P) (A) Multiple

From main pump
Center pin control valve
center line
(T)
To hydraulic
tank
2 1
Rear chassis
Hydraulic line
P1 P
4
Axle center line Detail of ELS valve section
95V2E42033
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
95ZV-2 EU FS 42-94
Mounting of the variable kickout

sensor
5 8 2
Apply grease
at area
Detail of grease applying
A
Boom
9
4 5,8
2 6
When the boom Chassis
is horizontal
3
1,7
1
Detail of A
85V2E42056
1. The variable kickout sensor

2. Link
3. Plate
4. Plate
5. Shaft
6. Ball bearing
7. O-ring
8. Spring pin
9. Rod
95ZV-2 EU FS 42-95
Efficient loading system operation

While the ELS is not operating While the ELS is operating
3 4 3 4
Multiple
From main pump From main pump
control valve
P line
To hydraulic
tank
2 1 2 1
95V2U42002 95V2U42003
The oil discharged from the switch pump flow into the When the ELS switch is turned on and the ELS opera-
steering valve P port. When the steering wheel is not tion condition set by the MCU is satisfied, the solenoid
turned, this oil is discharged from the steering valve P.B. valve in the ELS valve is energized and the spool is
port. moved.
On the other hand, the oil discharged from the main After that, the setting pressure of relief valve drops to
pump opens the check valve, because cracking pres- the hydraulic tank pressure level.
sure of check valve (3) is less than the setting pressure
of relief valve (2). Therefore, the oil discharged from the main pump
opens relief valve (2) that setting value dropped and all
Cracking pressure of check valve (3) the hydraulic oil from the main pump goes to the
0.2 MPa (2 kgf/cm2) (29 psi) hydraulic tank.
Setting pressure of relief valve (2) But the oil from the steering valve P.B. port cannot flow
20.6 MPa (210 kgf/cm2) (2,987 psi) into relief valve (2) because of check valve (3), and flow
into the multiple control valve P port.
The oil from switch pump and main pump are joined
together 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
Therefore it can be able to operate the boom and force by turning off the main pump and reducing the
bucket at normal speed. pump driving load on engine.
In addition, pressure sensor (4) is installed in the dis- In addition, it becomes easy to operate slightly by
charged side of the main pump and detects oil pressure reducing the quantity of total oil to the loading circuit,
of loading line and sends the signal to the MCU. and is improved the performance of operating when
excavating and scooping.
95ZV-2 EU FS 42-96
Fan Motor System
Fan Motor System
Mounting of fan motor
A T1 L2
(S/N ~9257) (S/N 9258~9301)

A-Detail
T2
In case of using new fan with old frange
Washer x2
(additional parts)
3 (62710-18121)
B
6
19.0 mm
(0.75 in)
2 L2
18.7 mm
Flange bolt x2
3 (alteration parts)
(0.74 in)
1 4 (61802-12040)
Gauge port
(PF3/8)
B-Detail
K95V2E42006
1. Fan motor :
2. Fan (S/N ~9257) T1: 93.7 N-m (9.55 kgf-m) (69 lb-ft)
3. Flange (S/N ~9257) T2: 441~539 N-m (45~55 kgf-m) (326~398 lb-ft)
4. Fan (S/N 9258~)
5. Flange (S/N 9258~9301)
6. Flange (S/N 9302~) L2: With lubrication oil (Engine oil or gear oil)
7. Proportional relief valve
95ZV-2 EU FS 42-97
Fan Motor Line
Fan Motor Line

Fan revolution Engine coolant: High temperature
(min-1) [94ºC (201.2ºF)]
1,300
Stepless
control
range
910
Middle range temperature

(750) [60~80ºC (160~180ºF)]
Low temperature
[below 60ºC (160ºF)]
0
(Hibernate725 800 1,200
(1,115) (1,577)
mode) Engine revolution (min-1) Values inside ( ) are for reference.
Fan revolution * (controlled by MCU)

* To shorten the warm-up time, when the engine water temperature is 60ºC (140ºF) 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. K95V2E42002
Fan motor (1) The cooling fan is driven by the hydraulic motor. The
Cooling fan 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 from the engine water tem-

perature sensor (S/N 9001~9150), ECM (S/N 9151~),
torque converter oil temperature sensor, and hydraulic
oil temperature sensor, are input into the MCU as infor-
mation to regulate the maximum fan revolution.
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.
To return filter
From
unloader
Proportional relief valve (2)
valve
Hydraulic circuit diagram 95V2E42041
Note
Hydraulic oil temperature must be at operating tempera-
ture to do this fan revolution test.
When proportional relief wire is disconnected, fan revo-
lution should go to high speed mode.
95ZV-2 EU FS 42-98
Fan Motor Line
Output current F for control of

Number of the fan revolution
revolutions of Proportional Proportional Proportional
fan (min-1) relief valve [mA] relief valve [mA] relief valve [mA]
About
910 190
F H/D
F T/M
F E/G
1,300 0
0
80 94 ( C) 110 115 ( C) 90 95 ( C)
(176) (201.2) ( F) (230) (239) ( F) (194) (203) ( F)
T E/G T T/M T H/D
The signal of the engine The signal of the torque The signal of the
coolant temperature converter oil temperature hydraulic oil temperature
Control of the fan revolution
95V2E42050
When the input electric current value to proportional In normal condition, fan revolution is regulated by
relief valve (2) is maximum (approximately 190 mA), the engine water temperature. But when the torque con-
fan revolution is minimum value (910 min-1) because verter oil temperature exceeds 110ºC (230ºF) or the
bypass oil amount at proportional relief valve (2) is hydraulic oil temperature exceeds 90ºC (194ºF), in each
increased. When this value is minimum (0 mA), the fan signal input into a MCU from the engine water tempera-
revolution is maximum value (1,300 min-1) because ture, torque converter oil temperature and hydraulic oil
bypass oil amount at proportional relief valve (2) is temperature sensors, the lowest signal in the electric
decreased. current value is chosen (the fan revolution becomes
high to lift the cooling performance), and the control
For example, when the engine water temperature is low, electric current is input into proportional relief valve (2).
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.
When the torque converter oil temperature is below

110ºC (230ºF) and the hydraulic oil temperature is
below 90ºC (194ºF), the fan revolution is controlled only
by engine water temperature.
95ZV-2 EU FS 42-99
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 Brake
Hydraulic oil temp. sensor) circuit
For brake and pilot pump
Unloader valve
Hydraulic tank

95V2E42043
Make-up valve Oil supply is stopped, however the fan is still turning by
the inertial force.
When the pressure oil from the hydraulic pump is sup-
plied to the inlet port P, the pressure in the MA side cir- This condition generates negative pressure at the motor
cuit of the fan motor will increase. The starting torque for inlet port.
the fan motor is generated, and the motor starts to
rotate. The oil in the MB side circuit of the fan motor To prevent generation of negative pressure, make-up
returns to the hydraulic tank via the outlet port T. valve (3) opens so that the oil in the tank port flows into
the fan motor inlet port.
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.
95ZV-2 EU FS 42-100
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 pres-

sure, safety valve (4) relieves the pressurized oil to the
tank port.
95ZV-2 EU FS 42-101
Fan Motor Line
Proportional relief valve (S/N 9001~9150)

The proportional relief valve is installed between the
unloader valve and the fan motor. This valve is the nor-
mally 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 Chamber A Solenoid

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, the
plunger is pressed against the body by the spring 2
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 set-
ting pressure also decreases. Once a constant elec-
tronic signal is given, the pilot poppet is held in a given
potion, holding the setting pressure.
This is maintained by the balance between the elec-

tronic spring 2 force and inlet pressure.
95ZV-2 EU FS 42-102
Fan Motor Line
When the oil pressure exceeds the set point
Plunger Chamber A Solenoid

Body Lock nut
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 pop-
pet 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 counterclock-
wise the adjusting screw to lower the set pressure.
After adjustment, be sure to tighten the lock nut
High pressure set:

18.1±0.5 MPa (185±5 kgf/cm2) (2,625±71 psi)
at 0 mA
95ZV-2 EU FS 42-103
Fan Motor Line
Proportional relief valve (S/N 9151~)
3
5 9
9 (G1) (G1)
T1 P1
10
(P1)
(T1) 4
(G3/8) P2
PG2 (G1)
(PG2) (P2)
1
(T2) (PG1)
T2 PG1
(G1) 2 (G1/4)
2
7 Hydraulic line diagram
8 6
K95V2U42001
1. Block
2. Relief valve
3. Elbow adapter
4. Elbow adapter
5. Adapter
6. Plug
7. Plug (gauge port)
8. Plug
9. Relief valve
10. Solenoid valve
95ZV-2 EU FS 42-104
Fan Motor Line
10 9 2
K95V2U42002
Adjusting set pressure
It is not possible to adjust the set pressure on the

machine. Replace relief valve cartridge (9), if neces-
sary.
: Relief valve (2):

60~70 N-m (6.1~7.1 kgf-m) (44~51 lb-ft)
: Relief valve (9):
35~40 N-m (3.5~4.0 kgf-m) (25~29 lb-ft)
95ZV-2 EU FS 42-105
Fan Motor Line
Fan motor
Port P
B A
B A
Port Tc
Port T
115V2E42030
Fan motor specifications
Displacement capacity 90.3+2 3 3

-0 cm /rev (55.1 in /rev)
Pressure 21.3 MPa (217 kgf/cm2) (3,089 psi)
Rating Speed 1,600 min-1
Flow 144 L/min (38 gal/min)
Continuous variable control with the
Speed
Control method proportional valve (not included in
control
fan motor)
95ZV-2 EU FS 42-106
Fan Motor Line
Fan motor structure
1 2 3 4 5 6
11 9 7 8 13 12 10
A-A
14
P
MA MB
TC
T
17 16 15
B-B
K95V2J42001
1. Output shaft
2. Case 10. Sub bearing
3. Thrust plate 11. Oil seal
4. Piston assy 12. End cover
5. Cylinder block 13. Center spring
6. Valve plate 14. Make-up valve
7. Retainer guide 15. Safety valve
8. Retainer shoe 16. Main spool
9. Main bearing 17. Spring
95ZV-2 EU FS 42-107
Fan Motor Line
Fan motor function and the operation prin- This hydraulic motor is swash plate type axial piston
ciple motor. This converts the power of pressured oil sent
from the hydraulic pump into rotary motion.
Y The oil sent from the hydraulic pump is led into cylinder
block (5) through valve plate (6). This oil is led only onto
F3 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.
ri
The pressure a oil in a half of cylinder block, that is sep-
F3
arated 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)).
This force pushes thrust plate (3) fixed at a certain angle

Y
 for output shaft (1), and it is divided into two compo-
85V2E42043
nent 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 plate (6) separated by Y-Y line linking
a top dead center to a bottom dead center.
F1 D P Resultant force of this torque (T= (F3 x ri)) goes

F3 through a piston as turning force and turns cylinder
F2 block (5).
Because this cylinder block (5) is connected to the out-

put shaft, the output shaft turns, and then torque is
3 5 4 85V2E42044 transmitted.
4
5
Y 6
Supply side
3
Discharge side
Y 85V2E42045
95ZV-2 EU FS 42-108
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
Switch function does not work.
1. Signal of engine water temperature

> 94ºC (201.2ºF)
2. Signal of torque converter oil temperature

> 115ºC (239ºF)
3. Signal of the hydraulic oil temperature

> 95ºC (203ºF)
K70V2J42013
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 sec-

onds, the cooling fan reversal switch turns "OFF" and
the pilot lamp on the switch turns "OFF". Then the cool-
ing 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.
95ZV-2 EU FS 42-109
Reversing fan motor (OPT)
This figure is shown the optional reversing fan motor.
Reversing solenoid
(Electrical connector)
Port P
Gauge port
B (M10 x 1.25)
A
B A
Port Tc
Port T
95V2E42046
Fan motor specifications
Displacement capacity 90.3+2 3 3

-0 cm /rev (55.1 in /rev)
Pressure 21.3 MPa (217 kgf/cm2) (3,089 psi)
Rating Speed 1,600 min-1
Flow 144 L/min (38 gal/min)
Continuous variable control with the
Speed
Control method proportional valve (not included in
control
fan motor)
95ZV-2 EU FS 42-110
Fan motor structure
1 2 3 4 5 6
11 9 7 8 13 12 10
A-A
20
14
P 18
MA MB
19
TC
T
17 16 15
B-B
K95V2J42002
1. Output shaft 11. Oil seal

2. Case 12. End cover
3. Thrust plate 13. Center spring
4. Piston assy 14. Make-up valve
5. Cylinder block 15. Safety valve
6. Valve plate 16. Main spool
7. Retainer guide 17. Spring
8. Retainer shoe 18. Filter (15 µm) (*)
9. Main bearing 19. Selector valve (*)
10. Sub bearing 20. Reversing solenoid (*)
(*) Optional parts for reversing fan motor

95ZV-2 EU FS 42-111
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 85V2E42047
t: sec
F: mA
t FV1 16
t FV2 18
t AR1 1,800
t AR2 60
F VR1 Approx. 190
F VR2 0
95ZV-2 EU FS 42-112
Hydraulic circuit (Reverse rota-

tion)
Fan motor (1)
MB MA
Reverse solenoid (6)
Selector valve (5)
To MCU
Make-up valve (3) (Reversing cooling
fan switch)
Safety valve (4)
MCU
(Engine water temp. sensor
Proportional relief valve (2) T/C oil temp. sensor Brake
Hydraulic oil temp. sensor) circuit
For brake and pilot pump
Unloader valve
Hydraulic tank
Hydraulic line (reverse revolution)

95V2E42047a
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 selec-
tor valve (5) to the left. As a result, the fan motor turns
into reverse.
95ZV-2 EU FS 42-113
Secondary Steering
Secondary Steering
Secondary steering Secondary steering

motor and pump relay
(V4) Pressure sensor
(E7)
(P4) Torque converter
(H8)
(P3)
Hydraulic pump
Check valve
Secondary steering
Steering valve motor and pump
(X3)
Hydraulic circuit
Check valve Electrical circuit
Check valve
K95V2E42004
Secondary steering operation

Machine speed signal
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.
The signal from MCU
With some problems, as the steering hydraulic pressure

to magnetic switch
ON
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 Machine speed
OFF
the magnetic switch. (km/h)
1 2
As a result, the secondary steering motor and pump is

driven. Then it is ready to steer the machine. 85V2E42051
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
95ZV-2 EU FS 42-114
Secondary Steering
Speed sensor
Pilot lamp To steering valve
F13
MCU Pressure
sensor
Check valve
Check valve
G1/2
G1/2
+24 V Secondary G1/2

steering motor G1/2 G3/8
and pump
F5
11.7MPa
(119 kgf/cm2)
(1696 psi)
10
M cm3/rev
G1/2
Check valve
Secondary G1/2
steering relay
+24 V
Secondary
steering motor
and pump
11.7MPa
(119 kgf/cm2)
(1696 psi)
10
M cm3/rev
80.0 71.3
M cm3/rev cm3/rev
Magnetic switch
(on motor and pump)
Steering pump
Hydraulic line
Electrical circuit
Secondary steering circuit

95V2E42036
95ZV-2 EU FS 42-115
Secondary Steering
Secondary steering motor and pump
CW rotation
Magnetic switch
Relief valve
+24 V
Motor Pump 85V2E42052
Customer's power Relief valve

+24 V connection 11.7 MPa
(119.3 kgf/cm2)
Customer's
MCU
connection
M 10
Customer's
ground
connection
Electric/Hydraulic schematic
95V2E42039
Secondary steering motor and pump
Model ND-K2-D
Discharge (cm3/rev) 10
Relief valve setting pressure

11.7 (119.3) (1,696)
MPa (kgf/cm2) (psi)
95ZV-2 EU FS 42-116
MEMO
95ZV-2 EU FS 43-1
43 Check & Adjustment Hydraulic Group

Hydraulic Group
Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

........................................................................... 43-2
Hydraulic Cylinder ................................................... 43-14
Stop Valve ............................................................... 43-17
95ZV-2 EU FS 43-2
Loading/Steering Circuit Relief Valve/Ride Control Circuit

Reducing Valve (OPT)
Loading circuit relief valve setting

pressures CAUTION
Be careful, you may get burned if the high pressure
oil spouts out. To prevent such an accident, be sure
WARNING to release the residual pressure from the pipe, and
Unexpected movement of the machine may cause an open the cap of the hydraulic tank before removing
accident resulting in injury or death. the plug from the pressure measurement port.
Therefore, to provide repair service with the engine
running, be sure to observe the following items: Releasing residual pressure from tank and pipes
- Apply the parking brake. Keep the bottom surface of the bucket horizontal,
- Block the tires with chocks to prevent the tires from and stop the engine when the bucket is approxi-
moving. mately 30 cm (1 ft.) above the ground.
- Prohibit any person from walking into dangerous Tilt down the bucket until it comes in contact with
areas. the ground. Place the bucket control lever in the
- Near articulation areas of the machine roll back position, and then lower the boom.
- Under the machine
- Around the engine Push down on, then open the cap of the hydraulic
- In front of or behind the machine tank to release the residual pressure.
CAUTION
Measurement instruments
Do not touch the fan or V-belt of the engine or a high-
temperature section if the engine is running. An acci-
Pressure gauge
dent resulting in injury may occur.
30 MPa (300 kgf/cm2) (5,000 psi)
access panel of the engine room. Keep all guards in
(for loading line with 3 m (10 ft.) hose)
place.
5 MPa (50 kgf/cm2) (1,000 psi)
engine is stopped.
(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.
Loading line main relief pressure 20.6±0.5

(at maximum speed) MPa (kgf/cm2) (psi) (210±5) (2,986±71)
Loading line overload relief pressure 23.5±0.5
(at idling speed) MPa (kgf/cm2) (psi) (240±5) (3,413±71)
Pilot line MPa (kgf/cm2) (psi) 3.5 (36) (512)
Hydraulic oil temperature: 50±5ºC (120±9ºF)

95ZV-2 EU FS 43-3
Gauge port Valve assembly
Gauge port location Port size

(4)
Main relief pressure (1), (2), (3) (PPI) (Z)
(1), (2), (3)
G (PF) 1/4 with O-ring (Z2) (Z1)
Overload relief
(1), (2), (3) (PA)
pressure (PARKING) ACF (ACCF) (ACCR)
(TA)
Pilot line pressure (4) (T) (P)

(4)
(Reducing valve) G (PF) 3/8 with O-ring
Bucket cylinder Reducing valve

(for pilot)
Note
85V2E43006
North America equipped M/c's
have a quick connector in port
(3) for testing.
(2)
(1)
K97V2J43003
Multiple control valve
Make-up valve
Overload relief
valve
Overload relief Main relief valve

valve
(3)
95ZV43002
95ZV-2 EU FS 43-4
Measuring loading circuit main relief pres- Adjusting main relief pressure
sure
1. Unload the bucket. Cap

Lock nut
Set and confirm the transmission shift lever is neu-
tral position.
3. Set and confirm the parking brake switch to the

"ON" position.
Adjusting
screw
4. Depress the brake pedal.
95ZV43004
5. Lower the boom to the lowest limit.
6. Attach the pressure gauge 30 MPa (300 kgf/cm2) Loosen the lock nut and adjust the pressure by the
(5,000 psi) to the bucket cylinder bottom side (2). adjusting screw.
7. Set the declutch ON/OFF switch to ON. Turn clockwise the adjusting screw to raise the set pres-
Press the brake pedal all the way to the floor. sure, or turn counterclockwise the adjusting screw to
lower the set pressure.
Note
To avoid "fuel saving mode at idle time".
In "fuel saving mode at idle time", not activated promptly
IMPORTANT
and engine may not reach the maximum revolution. At the completion of check and adjustment of main
Press the brake pedal all the way to the floor with the relief valve pressure, be sure to tighten the lock nut.
declutch ON/OFF switch to ON, release this mode.
8. Move the bucket control lever to the roll back posi-

tion. Hold the lever at that position.
9. Increase the engine speed to the maximum, and

measure and record the pressure using the pres-
sure gauge.
95ZV-2 EU FS 43-5
Measuring loading circuit overload relief Adjusting overload relief pressure

pressure
1. Attach the pressure gauge to the port (3).

((1) for the rod side, (2) for the bottom side, (3) for Lock nut
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)) Adjusting screw
1. Lower the boom to the lowest limit.

95ZV43005

tion. Loosen the lock nut and adjust the pressure by the
adjusting screw.
3. Place the shift lever to the forward position.
Turn clockwise the adjusting screw to raise the set pres-
Note sure, or turn counterclockwise the adjusting screw to
Avoid “Hibernate mode” during the measurement. lower the set pressure.
In the “Hibernate mode”, the engine speed is decreased
to 725 min-1 at idling under the following conditions:
- when the transmission shift lever is placed at “N”
IMPORTANT
position, At the completion of check and adjustment of over-
- the engine coolant temperature is higher than 60ºC load relief valve pressure, be sure to reset the main
(140ºF), and relief valve to the original condition.
- 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 posi-

tion and record the pressure.
Bucket cylinder rod side (gauge port (1) or (3))
1. Keep the boom horizontal.
2. Move the bucket control lever to the dump position,

hold and then measure and record the pressure.
95ZV-2 EU FS 43-6
Measuring pilot circuit relief pressure Adjusting pilot line pressure
WARNING
Trapped pressure in brake circuit could cause serious Lock nut
injury when the plug is removed.
Fully release all residual accumulator pressure
before servicing.

Adjusting screw
2. Set the shift lever to the forward position.
Note 90ZVE43004
To avoid "Hibernate mode".
to 725 min-1 at idling under the following conditions: Loosen the lock nut and adjust the pressure by the
- when the transmission shift lever is placed at “N” adjusting screw.
position,
- the engine coolant temperature is higher than 60ºC Turn clockwise the adjusting screw to raise the pilot line
(140ºF), and pressure.
seconds. IMPORTANT
3. Keep the engine speed at low idle (when the brake After the completion of the adjustment of the pilot line
line pressure is normal) and then measure and pressure, be sure to tighten the lock nut.
record the pressure.
95ZV-2 EU FS 43-7
Ride control circuit reducing valve CAUTION

setting pressures (OPT) Be careful, you may get burned if the high pressure
to release the residual pressure from the pipe, and
WARNING
Unexpected movement of the machine may cause an the plug from the pressure measurement port.
Therefore, to provide repair service with the engine Releasing residual pressure from tank and pipes
- Park the machine on level ground. Keep the bottom surface of the bucket horizontal,
- Apply the parking brake. and stop the engine when the bucket is approxi-
- Block the tires with chocks to prevent the tires from mately 30 cm (1 ft.) above the ground.
moving.
- Determine the signals between the service man. Tilt down the bucket until it comes in contact with
- Prohibit any person from walking into dangerous the ground. Place the bucket control lever in the
areas. roll back position, and then lower the boom.
- Under the machine Push down on, then open the cap of the hydraulic
- Around the engine tank to release the residual pressure.
CAUTION Measurement instruments

Pressure gauge
15 MPa (150 kgf/cm2) (3,000 psi)
(for ride control line) with 3 m (10 ft.) hose
place.
Note
For safety, route the gauge to an area where it may be
engine is stopped.
safely read by the person doing the test.
Reference
Ride control line pressure (reducing valve) 8.34±0.3

MPa (kgf/cm2) (psi) (85±3) (1,209±43.5)
Valve assembly
(Accumulator circuit)
Valve assembly
(Reducing valve circuit)
Gauge port
Reducing pressure AC2 G (PF) 1/4 with O-ring
95V2E43002
95ZV-2 EU FS 43-8
Measuring ride control circuit reducing Adjusting reducing valve pressure

pressure
Loosen the lock nut of the reducing valve and adjust the
pressure by the adjusting screw.
X Turn clockwise the adjusting screw to raise the set pres-

sure, or turn counterclockwise the adjusting screw to
T
IMPORTANT
Tank
H
Boom cylinder At the completion of check and adjustment of reduc-
bottom side
ing valve pressure, be sure to tighten the lock nut.
AC1
Reducing
valve
AC
AC2
Plug
Accumulator
Valve assembly (Accumulator circuit)
95V2E43003
Pump Tank Reducing valve

(T)
(P) Lock nut
Adjusting screw
(R)
(Ac1)
Air bleeder nipple
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)
3. Keep the engine speed at low idle and then mea-

sure and record the pressure.
95ZV-2 EU FS 43-9
Steering circuit relief valve setting CAUTION

pressures Be careful, you may get burned if the high pressure
to release the residual pressure from the pipe, and
WARNING
Unexpected movement of the machine may cause an the plug from the pressure measurement port.
Therefore, to provide repair service with the engine Releasing residual pressure from tank and pipes
- Park the machine on level ground. Keep the bottom surface of the bucket horizontal,
- Apply the parking brake. and stop the engine when the bucket is approxi-
- Block the tires with chocks to prevent the tires from mately 30 cm (1 ft.) above the ground.
moving.
- Determine the signals between the service man. Tilt down the bucket until it comes in contact with
- Prohibit any person from walking into dangerous the ground. Place the bucket control lever in the
areas. roll back position, and then lower the boom.
- Under the machine Push down on, then open the cap of the hydraulic
- Around the engine tank to release the residual pressure.
CAUTION 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)
place.
5 MPa (50 kgf/cm2) (1,000 psi)
engine is stopped.
(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.
Steering line main relief pressure

20.6±0.5
(at maximum speed)
(210±5) (2,986±71)
MPa (kgf/cm2) (psi)
Steering line overload relief pressure
24.5 +1.0
0
(at idling speed)
(250 +100 ) (3,555 +1420 )
MPa (kgf/cm2) (psi)
Pilot line 3.5

MPa (kgf/cm2) (psi) (36) (512)

95ZV-2 EU FS 43-10
Gauge port
Main relief pressure

(1), (2) G (PF) 1/4 with O-ring
Overload relief
pressure
Reducing pressure (3) Rc (PT 1/8)
Steering valve
Main relief valve
Overload relief
valve
95ZV43006
95ZV-2 EU FS 43-11
Measuring steering circuit main relief pres- Note

sure Because the stop valve is installed into the steering line,
oil pressure does not reach the set point when the
steering is fully turned.
1. Unload the bucket.
When measuring oil pressure, be sure to apply the artic-
ulation stopper or screw the stopper (bolt) in until the
Set and confirm the transmission shift lever is neu-
front and rear chassis contact each other.
tral position.
3. Set and confirm the parking brake switch to the WARNING

"ON" position.
If the machine begins to move with the articulation
stopper applied, it may cause an accident resulting in
4. Depress the brake pedal.
injury or death.
After the measurement, be sure to disconnect and
store the articulation stopper.
Steering cylinder
(2) Adjusting steering line main pressure
Lock nut
Note
North America equipped (1) Adjusting screw
M/c's have quick
connectors at ports (1)
and (2).
70ZV43007
5. Attach the pressure gauge to the gauge port ((1) or

(2)).
6. Set the declutch ON/OFF switch to ON.

Press the brake pedal all the way to the floor. 95ZV43007
Note Loosen the lock nut and adjust the pressure by the
To avoid "fuel saving mode at idle time". adjusting screw of the main relief valve.
In "fuel saving mode at idle time", not activated promptly
and engine may not reach the maximum revolution. Turn clockwise the adjusting screw to raise the steering
Press the brake pedal all the way to the floor with the line main pressure.
declutch ON/OFF switch to ON, release this mode.
7. In case the pressure gauge is installed to (1), steer

the machine to the left until the front and rear chas-
sis contact each other.
Continue to hold the steering wheel fully turned.
8. Increase the engine speed to high idle, and mea-

sure and record the pressure.
95ZV-2 EU FS 43-12
Measuring steering circuit overload relief Adjusting overload relief pressure

pressure
Lock nut
1. Attach the pressure gauge to the port ((1) for the Adjusting
screw
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.
95ZV43008
Note
Because the stop valve is installed into the steering line,
oil pressure does not reach the set point when the Loosen the lock nut and adjust the pressure by the
steering is fully turned. adjusting screw.
When measuring oil pressure, be sure to apply the artic-
ulation stopper or screw the stopper (bolt) in until the Turn clockwise the adjusting screw to raise the set pres-
front and rear chassis contact each other. sure, or turn counterclockwise the adjusting screw to
4. Place the shift lever to the forward position.
Note
WARNING
Avoid “Hibernate mode” during the measurement. If the machine begins to move with the articulation
In the “Hibernate mode”, the engine speed is decreased stopper applied, it may cause an accident resulting in
to 725 min-1 at idling under the following conditions: injury or death.
- when the transmission shift lever is placed at “N” After the measurement, be sure to disconnect and
position, store the articulation stopper.
- the engine coolant temperature is higher than 60ºC
(140ºF), and
- the engine speed is held at 950 min-1 or less for 10 IMPORTANT
seconds. At the completion of check and adjustment of over-
load relief valve pressure, be sure to reset the main
5. Keep the engine speed at low idle, and measure relief valve to the original condition.
and record the pressure.
Raise the engine speed to 1,000 min-1 if fail to do.
95ZV-2 EU FS 43-13
Measuring pilot circuit relief pressure Adjusting pilot line pressure

(reducing pressure)
Loosen the lock nut and adjust the pressure by the
adjusting screw.
Adjusting screw Turn clockwise the adjusting screw to raise the pilot line
pressure.
Lock nut
IMPORTANT
After the completion of the adjustment of the pilot line
pressure, be sure to tighten the lock nut.
(T)
(A)
(3)
(TS)
(B)
115ZV43007
Gauge port plug width across flat: 5 mm

tion.
3. Set the shift lever to the forward position.
Note
To avoid "Hibernate mode".
to 725 min-1 at idling under the following conditions:
- when the transmission shift lever is placed at “N”
position,
- the engine coolant temperature is higher than 60ºC
(140ºF), and
seconds.
4. Keep the engine speed at low idle and record the

pressure.
5. Hold the bucket control lever at the roll back posi-

tion and record the pressure.
95ZV-2 EU FS 43-14
Hydraulic Cylinder
Hydraulic Cylinder
Cylinder natural drift Measurement procedure
1. Unload the bucket.

WARNING
2. Keep the boom and bucket horizontal.
Standing under the boom or bucket during service
work is dangerous. An accident resulting in injury or 3. Set the parking brake switch to the "ON" position.
death may be caused.
To prevent such an accident, be sure to lock the 4. Lock the boom and bucket control levers using the
boom and bucket control levers in the cab, securely safety lock.
support the boom, and remove the starter key.
In addition, hang a "DO NOT OPERATE!" tag on the 5. Stop the engine.
steering wheel.
6. Mark the cylinder rod at a point 100~150 mm (4~6
in) away from the cylinder head cover.
7. Measure the accurate distance from the cylinder
head cover to the vinyl tape. This is distance "A"
- Scale
mm (in). Measure the distance again 5 minutes
150~300 mm (1 ft.)
later. This is distance "B" mm (in).
- Stop watch
Cylinder drift (mm/min) A – B (mm) (in)
= --------------
- Black vinyl "electrician's" type (in/min) 5 (min)
Note
Warm-up the hydraulic oil before measuring cylinder
drift.
Boom cylinder (mm/min) (in/min) 3 (1/8) or less

Bucket cylinder (mm/min) (in/min) 4 (5/32) or less
95ZV-2 EU FS 43-15
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 cylin-
der rod, the tape may be caught by the rod seal. The
tape will cause oil leakage from the rod seal. To pre-
vent oil leakage, be sure to remove the vinyl tape.
95ZV-2 EU FS 43-16
Hydraulic Cylinder
Possible causes of excessive cylinder drift Boom cylinder
Bucket cylinder
Bucket cylinder Boom cylinder
Boom cylinder rod side flange 95ZV03003
Bucket cylinder rod side flange 95ZV03002

Damaged cylinder piston seal / barrel Disassembly & repair
Oil leakage from multiple control valve
Possible cause Solution Disassembly & repair
boom spool
Damaged cylinder piston seal / barrel Disassembly & repair
Defective multiple control valve overload
Disassembly & repair - Identifying defective part
relief valve
Just like the bucket cylinder, no pressure should be
Oil leakage from multiple control valve applied to the rod side of the boom cylinder when the
Disassembly & repair
bucket spool
weight of the boom is resting on the boom cylinders.
Carefully loosen the split flange (see the arrow) for
- Identifying defective part
the pipe on the cylinder rod side.
Pressure is applied to the bucket cylinder bottom
If the compressed oil spouts from the cylinder, judge
side to support the bucket. There should be no pres-
that the piston seal and/or barrel of the boom cylin-
sure applied to the cylinder rod side.
der is damaged. If the compressed oil spouts from
the pipe side, judge that the piston seal of the other
Keep the boom and bucket horizontal, and stop the
cylinder is defective.
engine. Carefully loosen the split flange (see the
arrow) on the cylinder rod side. If the compressed oil
If no oil spouts from the split flange, judge that oil is
spouts from the cylinder, judge that the piston seal
leaking from the multiple control valve spool.
and/or cylinder barrel is damaged. If the compressed
oil spouts from the hose side, judge that the piston
seal of the other cylinder is defective.
If no compressed oil spouts from the cylinder, judge
that the cause is the defective multiple control over-
load relief valve or oil leakage from the main spool of
multiple control valve.
Note
If only a few drops come out per minute it is considered
normal.
95ZV-2 EU FS 43-17
Stop Valve
Stop Valve
Stop valve adjustment procedure Reference dimension
Front chassis
Stop valve
Stopper (rear chassis)
(bolt)
(L.H, R.H)
Front chassis
Rear chassis
Reference dimension
23~27.5 mm Reference dimension
(0.9~1.1 in) 28~48 mm (1.1~1.9 in)
Stopper (bolt) length Clearance between machine body and stopper 115ZV43005
115ZV43004
Articulation angle ( º) 37 36 35
WARNING Clearance between machine body and 28 38 48
stopper (mm) (in) (1.102) (1.496) (1.890)
When the machine turns, the clearance in the articu- 23 25 27.5
Stopper (bolt) length (mm) (in)
lation area closes. As a result, people may be caught, (0.906) (0.984) (1.083)
leading to a severe accident. To prevent such an
accident, observe the following items strictly when *The target value should be the articulation angle "36º".
adjusting the steering stopper.
- Stop the engine before starting adjustment of the - After adjustment, turn the steering wheel slowly at a
stopper bolt. rate of 5 sec or more per turn, and confirm the clear-
- When confirming the operation after setup, keep ance between the machine body and the stopper.
proper distance from the articulation area of the
machine. - When adjustment is completed, tighten the lock nut
of the stopper (bolt).
The stop valve works when the spool is pushed in 3 mm
(0.118 in). : 90 N-m (9.2 kgf-m) (67 lb-ft)
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.
95ZV-2 EU FS 43-18
MEMO
95ZV-2 EU FS 52-1
52 Function & Structure Brake Group

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............................... 52-29
Brake Circuit Check Valve....................................... 52-31
Auto Brake .............................................................. 52-32
Pressure Sensor (for stop lamp and declutch) ........ 52-34
95ZV-2 EU FS 52-2
Brake System Outline
Brake System Outline

The brake system is the all-hydraulic type, and has two Service brake
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. 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
(Refer to "Hydraulic & Brake Circuit (S/N 9001~9250)" valve (22), and accumulated in accumulator (33) pro-
page 92-4 and "Brake Circuit" page 92-6.) vided 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 pres-

sure
While the brake pedal is not pressed, the internal pres-
sure 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.
95ZV-2 EU FS 52-3
Brake Units Layout
Brake Units Layout

The brake system is the all-hydraulic type, and has two The service brake is the wet disc type. The parking
independent systems consisting of the front system and brake is the spring applied oil pressure released type.
the rear system for enhancing safety.
3 2 1
5 6
95V2E52001
1. Accumulator 4. Brake valve

2. Solenoid valve (for parking) 5. Parking brake
3. Solenoid valve (for auto-brake) 6. Unloader valve
95ZV-2 EU FS 52-4
Unloader Valve
Unloader Valve
(S/N 9001~9048)
To accumulator
6 To tank
B-B
22
24 To fan motor
7
21 23
B
20
8
10
1
19
9 A
Filter
3
18
17 5
Pilot port B
(accumulator 16 4
feedback port)
A-A 15
11 12
From pump
14 2
13 Fan motor port
Pump port A
Accumulator port
T 2
Fan motor port
Pilot port Tank port

(accumulator AC
feedback port)
Rc PP
Tank port
1/8
P
Pilot port Pump port
Accumulator port (accumulator
Hydraulic circuit diagram feedback port) Outline drawing
K115ZV52001
1. Body 9. Plug 17. Spring

2. Spring 10. Plug (gauge port) 18. Spring
3. Spool 11. Governor plunger 19. O-ring
4. O-ring 12. Spring 20. Plug
5. Plug 13. O-ring 21. Adjusting screw
6. Orifice 14. Plug 22. Lock nut
7. Orifice 15. Pilot valve 23. Packing
8. O-ring 16. Spring seat 24. Cap
95ZV-2 EU FS 52-5
Unloader Valve
(S/N 9049~)
To
accumulator
6 To tank
B-B To fan motor
21
22 20
8 7 25 B 10
1
26 19
9 18
17
A
3
16
Filter
4
15
5
12
2 B
Pilot port 11
(accumulator 13
feedback port) A-A From pump
A
Fan motor port
14 Accumulator port
Pump port T 2
Fan motor port

Pilot port AC
(accumulator Tank port
feedback port)
Rc PP
Tank port 1/8
P
Pilot port
Accumulator (accumulator Pump port
port feedback port)
Hydraulic circuit diagram K115ZV52002
1. Body 14. Plug

2. Spring 15. Pilot valve
3. Spool 16. Spring seat
4. O-ring 17. Spring
5. Plug 18. Spring
6. Orifice 19. O-ring
7. Orifice 20. Plug
8. O-ring 21. Adjusting screw
9. Plug 22. Lock nut
10. Plug (gauge port) 23. —
11. Governor plunger 24. —
12. Spring 25. Seat
13. O-ring 26. O-ring
95ZV-2 EU FS 52-6
Unloader Valve
The unloader valve controls the flow rate and the pres- Unloader valve operation
sure of the hydraulic oil sent from the pump to the accu-
mulator. Body (1) is equipped with ports (pump, fan
motor, accumulator, pilot and tank). While the unloader valve is not operating, spool (3) is
pushed back by spring (2) and the pump port to the fan
Spool (3) which opens and closes the pump port to the motor port is closed. Oil flowing from the pump port is
fan motor port, orifice (6) which regulates the flow rate sent to the accumulator port through orifice (6), and the
to the accumulator port with high priority, and the pres- pressure at the accumulator port increases accordingly.
sure governor mechanism which controls the pressure
on the accumulator port side are built in the unloader When an excess flow rate is generated, spool (3) moves
valve. 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 pres-
sure at the accumulator port starts to increase again
(cut-in pressure).
Setting OFF 11.8±0.5 MPa (120±5 kgf/cm2) (1,706±71 psi)

pressure ON 6.9±1.0 MPa (70±10 kgf/cm2) (995±142 psi)
95ZV-2 EU FS 52-7
Valve Unit
Valve Unit
4 Note
Loading line Unloader valve (PI)
pilot valve "Feed back" signal is
acquired from front
brake accumulator.
(PPI) (Z)
(PA) (Z2) (Z1)

Solenoid valve
(Auto brake)
ACF (ACCF) (ACCR)
Unloader valve
(PARKING) (PI)
Wet type "feed back"
parking brake (TA) signal.
(P)
Tank Pump port
(T) (from unloader
valve)
2 3 P=Pump supply
1 T=Tank circuit
PI=Pump feedback to unloader
High pressure (From ACCF circuit)
test ports ACCR=Accumulator circuit-rear
ACCF=Accumulator circuit-front
PPI=Pilot valve
95V2U52002
A B
ACCR
WARNING
P 3 4
A B
ACCF
To parking brake
ACF
PI Rc1/8
1
B
2 Injection Hazard
High pressure test ports contain accu-
P T mulator pressure [11.8 MPa (1,706 psi)]
B PA that can escape from these 2 plugs.
A Depress brake pedal 80~100 times to
Z2
T G1/4 completely discharge the brake accu-
mulators prior to removing these test
ACF T Z PPI TA Z1 plugs.
Rc1/8 G1/2 G1/4 G3/8 G3/8 G1/4 95V2U52003 135ZV52035
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
[3.9±0.5 MPa (40±5 kgf/cm2) (569±71 psi)]
95ZV-2 EU FS 52-8
Valve Unit
Accumulator low pressure sensor
2
A 1 3
View A
1: Power (+)
2: Output (+)
3: Common
(V)
5
0 10 20 30 35 MPa
2
(102) (204) (306) (351) (kgf/cm )
(1422) (2844) (4351) (4991) (psi)
95V2E52095
95ZV-2 EU FS 52-9
Accumulator
Accumulator
7
2 4 1 3
13
10
12
11
9
6
95ZV52058
1. Body The accumulator holds a reserve of pressurized oil for

2. Hydraulic cap the brake circuit prevent disability of the brakes caused
3. Gas cap by a problem with the pump, etc. Two accumulators are
4. Piston provided in the service brake line. Nitrogen gas at 2.94
5. V-O-ring MPa (30 kgf/cm2) (427 psi) is charged in the gas cham-
6. Backup ring ber.
7. Wear ring
8. O-ring One accumulator of the same type is provided also in
9. Backup ring the dry type parking brake line, locate in the front chas-
10. Gas valve sis.
11. Gas valve O-ring
12. Gas valve guard
13. Bolt Accumulator specifications
Maximum operating pressure MPa 11.8±0.5

(kgf/cm2) (psi) (120±5) (1,706±71)
Nitrogen gas charging pressure MPa 2.94±0.1
(kgf/cm2) (psi) (30±1) (427±14)
Nitrogen gas capacity L (gal) 3.0 (0.793)
95ZV-2 EU FS 52-10
Brake Valve
Brake Valve
B 37 38 36 35 39 40
44 46
35
A
31 42 41 43 45 47 48 49 50 52
28
55 A-A
29 34
17 54
53
16
30
15 51
A
18
14 32
Pilot port
19
20
33
23
26
21
25
22 Rear
brake port 24 Tank port
Accumulator
port
10
2
12
Front brake 5
11 port
2
13 Accumulator
port 5
3 Pressure sensor port
B 4
1
8 B-B
9 7 6 95V2E52002
1. Body 12. Body 23. Spring 34. Pedal 45. Boot

2. Spool 13. Spring 24. Case 35. Roller 46. Snap ring
3. Spring seat 14. Cover 25. Snap ring 36. Spacer 47. Shaft
4. Snap ring 15. Oil seal 26. Spring 37. Pedal pin 48. Bolt
5. Plunger 16. Plate 27. — 38. L-pin 49. Washer
6. Spring 17. C-ring 28. Seat 39. Washer 50. Nut
7. Plug 18. Spool input 29. Dust cover 40. Pin 51. Plate
8. O-ring 19. Spring seat 30. Mounting plate 41. Shaft 52. Spring
9. C-ring 20. Pilot piston 31. Pedal bush 42. Spacer 53. Screw
10. Orifice 21. Case 32. Bolt 43. Joint 54. Nut
11. O-ring 22. Spring 33. Spring washer 44. Pin 55. Pedal cover
95ZV-2 EU FS 52-11
Brake Valve
Brake valve performance chart

N
(kgf)
(lbf)
299
(30.5)
300 (67)
(30.6)
Pedal pressing force (F)
(67)
200
(20.4)
(45)
120(12.2)(27)
100
(10.2) 93.3(9.5)(12)
(22)
76.1 67.1
(7.76) (6.84)
(17) (15)
( )
0 3.9 5 7.4 10 15 18.5 19
Pedal stroke
MPa
(kgf/cm2)
(psi) 4.10
(42)
(595)
Output oil pressure (Brake port)
4
(40)
(580)
2
(20)
(290) 0.80
(8.2)
(116)
0.36
(3.7)
(52)
( )
0 3.9 5 7.4 10 15 18.5 19
Pedal stroke
MPa
(kgf/cm2)
(psi) 4.14
(42)
(600)
4
(41)
Output oil pressure (Brake port)
(580)
2
(20)
(290)
0 MPa
0 0.41 2 4 4.55 (kgf/cm2)
(4.2) (20) (41) (46) (psi)
(59) (290) (580) (660)
Pilot oil pressure (pilot port input)
K95V2U52005
95ZV-2 EU FS 52-12
Brake Valve
Brake valve outline While the valve is not operating

B
The brake valve is integrated into the pedal 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 35
depressed, the movement of right side pedal is trans-
mitted 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. 18
Pilot port
23 20
26
22 B1 Rear brake
Accumulator A1
2
13 5
B2 Front brake
Accumulator A2 2
5
6 B
T Tank
Pressure sensor port

B-B 95V2E52003
95ZV-2 EU FS 52-13
Brake Valve
Between spool input (18) and spools (2) in the brake While the valve is operating
valve, springs (22)(23) which convert pedal pressing
force into output oil pressure are installed. When the brake pedal is pressed, spool input (18) and
pilot piston (20) are pushed by way of roller (35).
In addition, two spools (2) are installed for series in the
center of the main body of the brake valve. Plungers (5) Spool input (18) and pilot piston (20) make each spool
which transmit the control oil pressure to spool as the (2) drop down by way of spring (22)(23). When spool (2)
hydraulic reactive force are built in each spool. is pushed down, at first the passage from out-port B1,
B2, and pressure sensor port to the tank port are shut
While the valve is not operating, each spool is returned down.
to the non-operation position by spring (6)(13).
When spool (2) are pushed down further, the passages
As a result, the passages from out-ports B1, B2, and from in-ports A1, A2 to out-ports B1, B2 are opened and
pressure sensor port to tank port are opened, and the pressure oil from the accumulator is sent to the brake
pressure inside the brake piston chamber becomes piston chamber to apply the brake.
equivalent to the pressure in the tank.
Pressure oil of in-ports A1, A2 side act on plunger (5)
In addition, oil sent from the pump is stored in the accu- inside each spool (2) through the orifices and works as
mulator, and sent to the in-ports A1 and A2. But the pas- the hydraulic reactive force to return spool (2) upward.
sages from in-ports A1, A2 to out-ports B1, B2 and
pressure sensor port are shut down by each spool (2), When the sum of hydraulic reactive force and spring
and high pressure oil from the accumulator is main- load (6)(13) becomes balanced with spring load
tained. (22)(23), it returns spool (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). Com-
pressed spring (22)(23) is 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.
95ZV-2 EU FS 52-14
Service Brake
Service Brake
Piston stroke adjuster
(S/N 9001~9014)
Service brake operation
15 16 13
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.
7 6 8 9
Wheel hub 14 When the brake valves are depressed, the pressure oil
in the accumulator enters the disc brake piston chamber
Brake oil for the front and rear wheels, pushes the piston, and
inlet port
generates braking power.
(S/N ~9250)
While the brake pedal is not pressed, the internal pres-
sure 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
12 tank.
Axle housing
1
5
4 2 3 10 11 95ZV52033
1. Internal gear hub

2. Brake piston
3. Piston return spring
4. Steel plate
5. Friction plate
6. Disc gear
7. Axle shaft
8. O-ring (for brake piston)
9. O-ring (for brake piston)
10. O-ring (for gear hub)
11. O-ring (for gear hub)
12. Air bleeder nipple
13. Socket bolt
14. Tolerance ring
15. Sleeve
16. 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.
95ZV-2 EU FS 52-15
Service Brake
Service brake friction plate
6.8 0.1 (0.268 0.004 in)

5.0 0.15 (0.197 0.006 in)
1.2 (0.047 in)
0.65 mm (0.026 in)
400 (15.7 in)

(H)
Detailed drawing of groove
95V2U52004
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.
95ZV-2 EU FS 52-16
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, measure-
ment of wear is disabled.
Therefore, this steel plate should be installed correctly

Upper side
with regard to the tooth location so that the teeth cut-off
Spring pins section is located (or indexed) as shown in the figure.
Internal gear
There is no inside or outside on this plate either. It may

be installed either way.
Upper side
Spring pins
95ZV52034
A brake disc includes three steel plates, and the tooth

pattern of three steel plates differ from each other. Care-
fully install the steel plates.
The steel plate shown in the upper figure should be

installed on the piston side. As to the installation direc-
tion, this steel plate can be installed either side inward
as there is no inward or outward direction.
95ZV-2 EU FS 52-17
Service Brake
Service brake piston
A
5
3 1
3
4 2
6 2
2 4 6
6
A-A
A
95ZV52035
1. Holes for piston return spring

(12 equivalent divisions of circumference)
2. Holes for brake pedal stroke adjustment mecha-
nism (S/N 9001~9014)
(4 equivalent divisions of circumference, M10 x 1.5)
3. Holes for pushing down piston
(4 equivalent divisions of circumference)
4. Holes for removing piston
(2 equivalent divisions of circumference, M10 x 1.5)
5. Holes to drain oil from piston rear side
6. Cooling oil passage
95ZV-2 EU FS 52-18
Service Brake
Service brake pedal stroke adjust- Fig. 2

ing mechanism (S/N 9001~9014)
1.2 mm
(0.047 in)
Piston
Brake stroke
adjusting
mechanism
95ZV52007
When the brake disc is worn and the brake piston is

shifted by approximately 1.2 mm (0.047 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
95ZV52036 time, there is clearance of approximately 1.2 mm (0.047
in) between the sleeve and the socket bolt.
This is the automatic adjuster function which always
offers a constant pedal stroke even if the brake disc is Fig. 3
worn.
Fig. 1 1.2 mm
(0.047 in)
Piston Sleeve Approx.

Tolerance ring
1.2 mm
(0.047 in)
Socket bolt
95ZV52061
Bushing When the brake pedal is released and the hydraulic

115ZV52028 pressure is not applied on the brake piston, the brake
piston is pulled back by the return spring by approxi-
When the brake disk is not worn and the hydraulic pres- mately 1.2 mm (0.047 in), and stopped by the sleeve. In
sure is not applied on the brake piston, the piston is other words, the brake piston return amount is set to
pulled back by the return spring. At that time, there is approximately 1.2 mm (0.047 in) so that a constant
clearance of approximately 1.2 mm (0.047 in) between pedal stroke is always offered. Motions of the sleeve are
the sleeve and the socket bolt. regulated by the tolerance ring (spring). The sleeve is
not moved by the return spring force of the piston.
95ZV-2 EU FS 52-19
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 elas-
tic 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).

95ZV-2 EU FS 52-20
Service Brake
Brake circuit air bleeding proce-

dure WARNING
Unexpected movement of the machine may cause a
severe accident. To prevent such an accident, take
Valve assembly the following safety measures when performing air
Solenoid valve (Brake manifold bleeding with the engine running.
for auto-brake block assembly) - Park the machine on level ground.
- Block the tires with chocks to prevent the wheel
Solenoid valve from moving.
for parking - Determine the signals between the persons related
Hydraulic to this work for engine starting to prevent an acci-
tank
dent.
Step location - When moving up the boom, install a safety column
Hydraulic tank, as seen from top 95V2E52004 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 unsatis-
factory brake modulation.
Perform the following to do this:

Air bleeder nipple
1. Verify that the wheels are securely blocked, and the
articulation lock is in the "locked" position.
2. Charge the accumulator to full pressure, and then,

95V2E52005 shut off the engine.
3. Turn the parking brake solenoid valve release knob

Button counterclockwise, then, back to neutral, five times
(diameter: at five-second intervals between each turn.
approximately
4 mm) 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.
5. Press the auto-brake solenoid valve release button

Solenoid valve Solenoid valve five times at five-second intervals between each
pressure nut
Auto brake solenoid valve turn. Position the knob back to the normal position
95V2E52006
when finished.
6. Close the bleeder nipple and remove the vinyl tube

from the brake valve.
95ZV-2 EU FS 52-21
Service Brake
Bleeding air from brake pipes and axle Bleeding air from parking brake housing
housing hubs
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 pro-

1. Connect a vinyl tube to the air bleeder nipple provided in the axle housing, and place an oil can for
vided in the axle housing, and place an oil can for hydraulic oil recovery.
hydraulic oil recovery. (The air bleeder nipple is equivalent to the one pro-
(The air bleeder nipple is equivalent to the one provided in the brake valve).
vided in the left brake valve).
2. Loosen the air bleeder nipple a little. Turn the park
2. Loosen the air bleeder nipple a little. Press and brake solenoid valve release knob counterclock-
hold the left brake pedal until oil containing no air wise until oil containing no air comes from the air
comes from the air bleeder nipple. After that, bleeder nipple. After that, tighten the air bleeder
tighten the air bleeder nipple. nipple.
Perform this operation for each of the four wheels. : Air bleeder nipple
: Air bleeder nipple 9 N-m (0.9 kgf-m) (6.5 lb-ft)
9 N-m (0.9 kgf-m) (6.5 lb-ft) Position this release knob to the normal position
when finished.
95ZV-2 EU FS 52-22
Parking Brake
Parking Brake
(S/N 9001~9088)
2nd Propeller shaft
13 14 10 9 6 4 5
1
7
17
22
15
8
3
19 2
21
12
11
18
16
20
Front differential assy
K95V2U52002
1. Housing 12. Separation disc

2. Piston 13. Flange nut
3. Housing 14. Nut
4. Spring 15. Gear
5. Spring 16. Housing
6. Head pin 17. Oil seal
7. Bolt 18. Oil seal
8. Straight pin 19. Pin
9. O-ring 20. Spring pin
10. Back-up ring 21. Spring
11. Friction disc 22. Oil seal (Double lip) (S/N 9066~)
95ZV-2 EU FS 52-23
Parking Brake
(S/N 9089~9250)
2nd Propeller shaft

9 6 4 5
1
7
14
15 12
8
3
17 2
19
11
10
16
13
18
K95V2U52001

2. Piston 12. Gear
3. Housing 13. Housing
4. Spring 14. Oil seal (single lip)
5. Spring 15. Oil seal (double lip)
6. Head pin 16. Oil seal (single lip)
7. Bolt 17. Pin
8. Straight pin 18. Spring pin
10. Friction disc
95ZV-2 EU FS 52-24
Parking Brake
(S/N 9251~)
6 9 2nd Propeller shaft 4 5
1
7
14
15 12
8
3
17 2
19
11
10
16
13
18
K95V2U52003

2. Piston 12. Gear
3. Housing 13. Housing
4. Spring 14. Oil seal (single lip)
5. Spring 15. Oil seal (double lip)
6. Housing 16. Oil seal (single lip)
7. Bolt 17. Pin
8. Straight pin 18. Spring pin
10. Friction disc
95ZV-2 EU FS 52-25
Parking Brake
Parking brake operation

(S/N 9001~9088)
(0.197~0.236 in)
13 14 4 5
5~6 mm
7 Brake oil
95V2E52008
(S/N 9089~9250)
A
1
7
Brake oil
K97V2J52008
95ZV-2 EU FS 52-26
Parking Brake
(S/N 9251~)
5
1
4
7 Brake oil
K95V2U52004
The parking brake is the spring applied oil pressure Parking brake wearing check
released type.
Turning on the parking switch turns off the solenoid - To check the wear on parking brake, stop the engine
valve for parking, returns the oil in the brake piston and measure the dimension A.
chamber to the tank, pushes piston (2) with springs A: the dimension from the end face of manual
(4)(5), and makes the brake effective. release bolt (7) to machined surface of housing (1).
Turning off the parking switch turns on the solenoid With new discs and plates this measures
valve for parking, oil flows into the piston chamber, 26.6±1 mm (1.047±0.039 in) (S/N 9001~9250)
pushes piston (2) to the upward over coming spring 42.6±1 mm (1.677±0.039 in) (S/N 9251~)
force (4)(5), and release the brake.
With completely worn out discs, and plates this mea-
sures
22.6±1 mm (0.890±0.039 in) (S/N 9001~9250)
Operation of parking brake 38.6±1 mm (1.520±0.039 in) (S/N 9251~)
Parking switch ON OFF - When the parking brake is operated as emergency

Solenoid valve Power OFF Power ON
around maximum speed out of necessity, check the
wear on parking brake.
Brake piston chamber Oil discharge Oil charge
Parking brake Braking Released
Turning the starter key off works the same as turning the
parking switch "ON".
95ZV-2 EU FS 52-27
Parking Brake
Parking brake friction plate

Five friction plates and five steel plates are assembled
in the parking brake disc.
7.4±0.1 mm (0.291±0.004 in)
5.0±0.1 mm (0.197±0.004 in)

1
0.82 mm (0.032 in) or more

1.0 mm (0.039 in)
ø 330 (13.0 in)

ø 220 (8.7 in)
2
5.7 mm (0.224 in)

95V2E52009
1. Core plate
2. Lining (paper material)
Parking brake steel plate
5.0±0.1 mm (0.197±0.004 in)

m
in) 5 m
6
(14 .D 3
ø 394 (15.5 in)

.4
P.C
ø 220 (8.7 in)
Flatness: 0.5 mm (0.020 in) or less

95V2E52010
95ZV-2 EU FS 52-28
Parking Brake
Parking brake solenoid valve

Spring chamber (brake actuator)
B Solenoid Knob
Reducing P
valve
Manual release
T (counterclockwise
Spool rotation)
Seat Seat
face A face B Tank B
P T
Hydraulic circuit diagram 85V2E52007
Solenoid valve operation Solenoid valve specifications
Voltage DC 24 V
Current 0.92 A
Amp Resistance 26.2 
a
0 a
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.
95ZV-2 EU FS 52-29
Parking Brake Manual Release

If the park brake cannot be released due to an electrical (S/N 9001~9088)
problem, such as a failed park brake solenoid valve coil
or electrical circuit, perform the following operation.
14 4 5
WARNING 13
Sudden accidental movement of the machine could

result in serious injury or death. 1
Before manually operating the parking brake sole-
noid: 7
- 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.
WARNING
If the flange nuts are not returned to the original posi-
tion, the parking brake is disabled and may result in a 95V2E52011
severe accident.
Make sure to return the flange nuts to the original 1. Remove each of two places of lock nuts (14) from
position after manually releasing the parking brake. manual release bolt (7) and tighten flange nuts (13)
alternately 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 you feel
flange nuts (13) are 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 park-
ing brake.
95ZV-2 EU FS 52-30
(S/N 9089~)
Top
Rubber cap
Hose band
A 7
Lock bolt
Flange nut
Detail of A
K97V2J52009
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 park-
ing brake.
95ZV-2 EU FS 52-31
Brake Circuit Check Valve
Brake Circuit Check Valve
Poppet
(P) (T)
(TA)
Pump supply Seat face
(PARKING)
through reducing A (ACCR) (ACCF)
valve (PA)
(Z1) (Z2)
(ACF)
(Z) (PPI)
B (ACCF)
Reducing Accumulator
valve Valve assembly
P=Pump supply
T=Tank circuit
PI=Pump feedback to unloader
A B (from ACCF circuit)
ACCR=Accumulator circuit-rear
ACCF=Accumulator circuit-front
PPI=Pilot valve circuit 85V2E52010
The pressure oil fed from the pump pushes down the
poppet, opens the seat face, and flows into the accumu-
lator 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 accumu-
lator 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 accumula-

tor circuit and another for the rear.
95ZV-2 EU FS 52-32
Auto Brake
Auto Brake
When the traveling direction is switched over between Auto brake operation set value
forward and reverse at a machine speed of 14 km/h
(8.75 mph) or more, the auto brake is applied to protect
the transmission clutches. 1. When the traveling direction is switched over
between forward and reverse at a machine speed
When the machine speed is too high, the auto brake is of 14 km/h (8.75 mph) or more at any speed posi-
applied also to prevent problems caused by excess tion.
speed in the engine and the transmission (over speed-
ing). 2. When the machine speed is too high in each speed
range. Actual speed will vary with tire size.
Set value km/h (mph)

Speed range
F R
Auto brake circuit Approximately 20 Approximately 20
1st
(12.5) (12.5)
Shown in the "released" position
Approximately 22 Approximately 24
2nd
To rear To front (13.75) (15.0)
service brake service brake
Approximately 36 Approximately 36
3rd
(22.5) (22.5)
Approximately 40
4th/A —
(25.0)
From unloader
valve (Pump)
MCU
signal
From reducing
valve (Pump)
95V2E52012
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 the reduc-
ing valve enters the pilot port of left brake valve (23)
through adapter tee (37), 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.
95ZV-2 EU FS 52-33
Auto Brake
Solenoid valve (for Autobrake circuit)

Not activated
Brake valve
B Solenoid
Spool
P
Reducing
valve
T
Tank
Seat face A Seat face B
P T
95V2E52013
When the auto brake actuation signal is not given by the Solenoid specifications
MCU (that is, when the power is not supplied to the
solenoid), the seat face A is closed and the seat face B Voltage DC 24 V
is open. As a result, the brake valve port is connected to Current 0.92 A
the tank, and the auto brake is not applied.
Resistance 26.2 
When the auto brake actuation signal is given by the

MCU (that is, when the power is supplied to the sole-
noid), 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 Amp
from the reducing valve enters the brake valve, and the
brake is applied.
a
0 a
Volt
Varistor
95ZV42079
Note
The varistor (variable resistor) is used for the solenoid
coil to protect the circuit.
95ZV-2 EU FS 52-34
Pressure Sensor (for stop lamp and declutch)

Pressure sensor (for declutch)
Refer to "Electrical Group: "Adjustable declutch preset
switch" page 62-52".
Pressure sensor (for stop lamp)

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 set valve of the MCU (0.51 MPa (5.2
kgf/cm2) (74.0 psi)), the stop lamp turns on.
Pressure sensor for

stop lamp and declutch
Left brake valve
95V2E52014
95ZV-2 EU FS 52-35
Pressure sensor (stop lamp) (S/N 9001~9300)
2
A 1 3
View A
1: Power (+)
2: Output (+)
3: Common
85V2E52012
(V)
5
4
Output voltage
0 1 2 3 4 5 MPa
(10) (20) (30) (40) (50) (kgf/cm2)
(140) (285) (435) (570) (715) (psi)
Pressure
65V2E52003
95ZV-2 EU FS 52-36
Pressure sensor (stop lamp) (S/N 9301~)
GND Vout Vdd
View A
K80V2U52003
(V) 5
3
Output voltage
0 1.08* 4.31* MPa

(11)(157) (44)(625) 5.4 (kgf/cm2)(psi)
(55)(783)
Pressure *: Calibration point

K80V2U52004
95ZV-2 EU FS 53-1
53 Check & Adjustment Brake Group

Brake Group
Brake Circuit Oil Pressure ....................................... 53-2

Service Brake .......................................................... 53-6
Parking Brake.......................................................... 53-10
95ZV-2 EU FS 53-2
Brake Circuit Oil Pressure

Unloader valve setting pressure
WARNING
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. (PPI) (Z)
(Z2) (Z1)
moving.
(PA)
- Determine the signals between the service men.
ACF (ACCF) (ACCR)
(PARKING)
(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.
95ZV-2 EU FS 53-3
Unloader valve setting pressure measure- Unloader valve setting pressure adjustment
ment
(S/N 9001~9048)
24
Measurement instrument 22
21
Fan motor port
Hydraulic pressure gauge:
20 MPa (200 kgf/cm2) (3,000 psi)
Gauge port
ACF port on valve assembly:

Rc (PT) 1/8

Pump port
Cut-out 11.8±0.5 MPa (120±5 kgf/cm2) (1,706±71 psi) Unloader valve
Cut-in 6.9±1.0 MPa (70±10 kgf/cm2) (995±142 psi) 70ZV53001
(S/N 9049~)
Measurement procedure
21 22
1. Lower the boom to the lowest limit, and tilt the Fan motor port
bucket down to the ground.
Then set the parking brake switch to the "ON" posi-
tion.
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. Pump port
: Port plug: 11.3 N-m (1.15 kgf-m) (8.3 lb-ft) Unloader valve
K115ZV53002
4. Start the engine, and keep the speed at low idle.

Measure and record the pressure when the pointer 1. Remove cap nut (24) and loosen lock nut (22).
of the pressure gauge stops rising (cut-out pres-
sure). :
Lock nut (22): 16.7 N-m (1.7 kgf-m) (12.3 lb-ft)
5. Keep the engine at low idle, and repeatedly Cap nut (24): 78.5 N-m (8.0 kgf-m) (57.86 lb-ft)
depress and release the brake pedal to reduce the
accumulator pressure. Measure and record the 2. Adjust the pressure by adjusting screw (21).
pressure when the pointer of the pressure gauge Turn the screw clockwise to raise the pressure.
stops and then starts rising again (cut-in pressure).
Note
Note In a case that the "ON" or "OFF" pressure does not
If the pressure gauge is not available, refer to the pres- match the standard setting pressure, set the "ON" (cut-
sure value displayed on the MODM. in) pressure to the standard setting pressure.
Refer to "Brake Main pressure 1" "Brake Main pressure
2" of MODM "Input/Output Monitor" page 62-92 and 92-
52 for information.
95ZV-2 EU FS 53-4
Brake valve oil pressure Brake valve oil pressure measurement
Hydraulic pressure gauge:

le
10 MPa (105 kgf/cm2) (1,500 psi)

ng
Force
la
da
19
Pe
Gauge port
15
0
Remove air bleeder nipple fitting on the axle housing,

m
m
and then install the pressure gauge to the bleeder posi-

tion.
45
Size of air bleeder port: Rc (PT) 3/8

(In case of the bleeder valve: M10 X 1.0)
85V2E53002
Air bleeder nipple fitting
[59 N-m (6.0 kgf-m) (43 lb-ft)]
85ZVE53001
1. Check to be sure the brake valve is fully released.
2. Press down the brake pedal to check that the oil

pressure rises in proportion to the pedal angle.
3. Release the brake pedal to check that the oil pres-

sure drops to zero in proportion to the pedal angle.
In addition, visually check for brake oil leakage.
Note
If the pressure gauge is not available, refer to the pres-
sure value displayed on the MODM.
Refer to "Brake Pedal Output Oil Pressure" of MODM
"Input/Output Monitor" page 62-92 and 92-52 for infor-
mation.
95ZV-2 EU FS 53-5
Brake valve performance
MPa
(kgf/cm2) 4.10
(psi) (42)
(595)
Output oil pressure (brake port)
4
(40)
(580)
2
(20)
(290) 0.80
(8.2)
(116)
0.36
(3.7)
(52)
0 3.9 5 7.4 10 15 18.5 19
(deg)
Pedal stroke
95V2E53001
Refer to the curve shown in the above figure.
When the measured value does not match the per-

formance curve, check the following points.

Malfunctioning brake valve Repair or replacement
Brake line oil pressure low
Check and repair
(Pump, reducing valve malfunction)
IMPORTANT
After measuring oil pressure, be sure to tighten the
air bleeder valve. Also be sure to bleed air.
95ZV-2 EU FS 53-6
Service Brake
Service Brake
Service brake performance check Method 2
If no test course available as described "Method 1",

Method 1 carry out the following method.
WARNING IMPORTANT
Separate the test course by using rope etc. and keep The following method is easy and simple, however it
persons away from the test course. In addition, post is not an accurate way, because the braking force
persons in several positions near the course to warn and rim-pull may vary on each machine. Confirm
others and avoid an accident while checking the ser- engine & transmission performance via using a stall
vice brake performance. test. See page 03-3.
Reconfirm the brake performance by the method 1 as
soon as possible.
Condition
WARNING
1. Test course Unexpected movement of the machine may cause an
Level, straight, dry and the paved ground. accident resulting in injury or death.
Before starting brake performance check, be sure to
2. Run the machine and depress the brake pedal at observe the following items:
35 km/h (22 mph). - Place the machine on level ground.
Measure and record the braking distance. - Check that there is enough clearance for brake
performance check around the machine.
- During performance check, prohibit any person to
Standard measurement value walking near the machine.
Braking distance 1. Lower the boom to the lowest limit, and roll back
20 m (22 1/4 yard) or shorter the bucket fully until the bucket contacts to the stop-
per.
Possible causes of extremely long braking dis- 2. Set the parking brake switch to the "OFF" position.
tance
3. Set the declutch switch to OFF, and then depress
the brake pedal all the way to the floor.
Low brake line pressure Check and repair
4. Set the shift lever to 2nd reverse speed.
Friction plate wear Check and repair
Brake valve malfunction Check and repair
5. Gradually increase the engine speed. The machine
should not move at the maximum engine speed.
Note
The brake performance check condition and standard
measurement value are based on the law and the regu- Possible cause of machine moving during
lation in Japan. brake performance check
When checking the service brake performance, follow
the law and/or local regulation in your country, state, or Possible cause Solution
province. Low brake line pressure Check and repair
Friction plate wear Check and repair
Brake valve malfunction Check and repair
95ZV-2 EU FS 53-7
Service Brake
Service brake friction plate wear

measurement
Air bleeder nipple
A Slide
calipers
Steel Brake
plate backing
plate
Friction plate
95ZV53004
WARNING
Unexpected movement of machine could cause seri-
Top Internal gear
Oil inlet port ous injury or death. To prevent such an accident,
about 5º observe the following items before checking the
Spring
Spring pin pin brake friction plate wear:
- Stop the engine.
Inner steel Outer steel - Determine the signals between the persons related
plate plate to this work for engine starting to prevent an acci-
dent.
95ZV53005 - Prohibit any person from walking into the danger-
ous area.
IMPORTANT
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.
95ZV-2 EU FS 53-8
Service Brake
Turn the planetary gear so that the oil supply plug is

positioned at ±5º from the top. Check that the teeth of
steel plate are as shown in the figure in page 53-7 (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 25.1 mm (0.988 in).

Note that dimension A is 28.6 mm (1.126 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.
95ZV-2 EU FS 53-9
Service Brake
Cautions on installing brake discs 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
Upper side mechanism by using the following procedure.
Brake piston
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 the
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: 161.90~163.30 mm (6.37~6.43 in)
K97V2J53002 Note
Piston stroke B: 1.20~1.90 mm (0.047~0.075 in)
4. After confirming that the piston is fully retracted

(Dimension A is correct) remove all four bolts.
A
B 5. After finishing the installation work, bleed air com-
Wheel hub pletely from the brake line.
Brake piston
K97V2J53003
95ZV-2 EU FS 53-10
Parking Brake
Parking Brake
Parking brake performance check Method 2
If no test course available as described "Method 1",

Method 1 carry out the following method.
WARNING IMPORTANT
Unexpected movement of the machine may cause an The following method is easy and simple, however it
accident resulting in injury or death. is not an accurate way, because the braking force
Before starting brake performance check, be sure to and rim-pull may vary on each machine.
observe the following items: Confirm engine & transmission performance via stall
- Check that there is enough clearance for brake test. See page 03-3. Reconfirm the brake perfor-
performance check around the machine. mance by the method 1 as soon as possible.
walking near the machine.
WARNING
Condition accident resulting in injury or death.
Before starting brake performance check, be sure to
1. Test course observe the following items:
1/5 slope (Approx. 11º 19') - Place the machine on level ground.
- Check that there is enough clearance for brake
2. Bucket empty performance check around the machine.
3. Parking switch ON walking near the machine.
Standard measurement value 1. Set the parking brake switch to the "ON" position.
No movement on 1/5 slope 2. Disconnect the cable connector of parking brake

solenoid valve.
Possible cause of machine moving during
brake performance check 3. Set the parking brake switch to the “OFF” position.

4. Place the shift lever to the 3rd reverse position.
Wear or breakage of brake disc Check and repair
5. Gradually increase the engine speed. The machine
Parking brake switch malfunction Check and repair
should not move at the maximum speed.
Parking brake solenoid valve malfunction Check and repair
Note IMPORTANT
The brake performance check condition and standard If the machine begins to move with the parking brake
measurement value are based on the law and the regu- applied, the brake discs are worn.
lation in Japan. At the completion of parking brake test, be sure to
When checking the service brake performance, follow connect the connector of electrical line to the sole-
the law and/or local regulation in your country, state, or noid valve again.
province.
Wear or breakage of brake disc Check and repair
Parking brake switch malfunction Check and repair
Parking brake solenoid valve malfunction Check and repair
95ZV-2 EU FS 62-1
62 Function & Structure Electrical Group

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.................................................. 62-14
Power Generating/Charging Circuit......................... 62-22
ECM (Engine Controller) ......................................... 62-23
Transmission Control Circuit and Monitor Circuit .... 62-37
Instrument Panel and Switch................................... 62-65
MODM ..................................................................... 62-72
Electrical Detent Circuit ........................................... 62-111
Diode ....................................................................... 62-118
95ZV-2 EU FS 62-2
How to Use Electrical Wiring Diagram
How to Use Electrical Wiring Diagram

Example
10 6 5 1
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
21
40 39 32 31
40 36 35 31
WIDTH LAMP RIDE CONTROL NEUTRAL BACK LAMP HORN RELAY MCU FAULT
RELAY RELAY RELAY RELAY RELAY
A520 RB RB LgSb YV RL SbP RL LB GW GL B LgW

C201 B611 H133 E214 H610 E220 H128 E219 H127 B501 E218
H129
R R Br Lg G L R Lg G G LgW L
D114 D114 D112 D103 D102 D002 D111 D103 D107 D107 A405 D001
2 1 2 1 2 1 2 1 2 1 2 1
(BLACK) (BLACK) (BLACK) (BLACK) (BLACK) (BLUE)
F5 F0 F6 F7 F8 F9
(1)
(2)
H1
10 6 5 1
D507 A306 F306 A905 A503 D112 E802 E803

OR RO RW RLg YB Br GL GO
C206 A302 F303 E312 E523 G302 E804

PB RBr RY WO SbY BrB WY
C205 F504 F704 F804 E109 G402 A105 E522

PL RB RL GW W BrW WP BrL
E501 C801 A005 B304 E520 E108 F004 E601

WL RG RGy LgG LgL W LgSb BrR
40 36 35 31
(3) 95ZV62001
The address method is used for electrical wiring dia- Example 3

grams. For this method, a symbol is attached to each Checking the other connector terminal where F704 RL
connector and connector terminal in order to easily (item (3)) is connected:
locate the other terminal where the other end of the
cable is connected. 1. F704
Shows that the terminal is connected to the 4th ter-
Example 1 minal of the F7 connector.
Symbol under (or above) connector, such as F6: Check the description in the 4th terminal of the F7
Shows the address of the connector. connector (F704), it shows that the F704 terminal is
connected to H128. This means that the 4th termi-
Example 2 nal of the F7 connector is connected to the 28th ter-
Symbol at the multi-terminal connector, such as 1 and minal of the H1 connector.
10: 2. RL
Shows the terminal number and the numbering direc- Shows the color of the wire "RL" represents that the
tion. insulation color is red, and "L" represents a blue
stripe is on the red insulation.
95ZV-2 EU FS 62-3
Utilisation des schémas des câblages électriques (FRANÇAIS)
Utilisation des schémas des câblages électriques

(FRANÇAIS)
Exemple
10 6 5 1
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
21
40 39 32 31
40 36 35 31
Relais de la lampe Relais du Relais de la lampe Relais de défaillance

d’ écartement contrôle de marche Relais neutre arrière Relais du klaxon du contrôleur

C201 B611 H133 E214 H610 E220 H128 E219 H127 B501 E218
H129
D114 D114 D112 D103 D102 D002 D111 D103 D107 D107 A405 D001
2 1 2 1 2 1 2 1 2 1 2 1
(Noir) (Noir) (Noir) (Noir) (Noir) (Blue)
F5 F0 F6 F7 F8 F9
(1)
(2)
H1
10 6 5 1
D507 A306 F306 A905 A503 D112 E802 E803

C206 A302 F303 E312 E523 G302 E804

C205 F504 F704 F804 E109 G402 A105 E522

E501 C801 A005 B304 E520 E108 F004 E601

40 36 35 31
(3) 95ZV62001
Les schémas des câblages électriques sont basés sur Exemple 3

la méthode de l’adressage. Suivant cette méthode, un Contrôle de la borne du connecteur à laquelle F704 RL
symbole correspond à chaque connecteur et à chaque (point (3)) est connectée:
borne du connecteur de manière à localiser facilement
la borne de connection de l’autre extrémité du câble. 1. F704
Indique que la borne est connectée à la 4ème
Exemple 1 borne du connecteur F7.
Symbole au-dessous (ou au-dessus) du connecteur, Contrôlez la description de la 4ème borne du con-
comme F6: necteur F7 (F704), elle indique que la borne F704
Il indique l’adresse du connecteur. est connectée à H128. Ceci signifie que la 4ème
borne du connecteur F7 est connectée à la 28ème
Exemple 2 borne du connecteur H1.
Symbole sur le connecteur multibornes, comme 1 et 10: 2. RL
Il indique le numéro de la borne et le sens de la Indique la couleur du fil. “RL” signifie que la couleur
numérotation. de l’isolation est rouge, et “L” que la raie bleu est
sur l’isolation rouge.
95ZV-2 EU FS 62-4
Verwendung des elektrischen Schaltplans (DEUTSCH)
Verwendung des elektrischen Schaltplans (DEUTSCH)

Beispiel
10 6 5 1
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
21
40 39 32 31
40 36 35 31
Breitenleuchtenrelais Fahrtsteuerrelais Neutrales Relais Rückleuchtenrelais Hupenrelais Reglerfehlerrelais

C201 B611 H133 E214 H610 E220 H128 E219 H127 B501 E218
H129
D114 D114 D112 D103 D102 D002 D111 D103 D107 D107 A405 D001
2 1 2 1 2 1 2 1 2 1 2 1
(Schwarz) (Schwarz) (Schwarz) (Schwarz) (Schwarz) (Blau)
F5 F0 F6 F7 F8 F9
(1)
(2)
H1
10 6 5 1
D507 A306 F306 A905 A503 D112 E802 E803

C206 A302 F303 E312 E523 G302 E804

C205 F504 F704 F804 E109 G402 A105 E522

E501 C801 A005 B304 E520 E108 F004 E601

40 36 35 31
(3) 95ZV62001
Für den elektrischen Schaltplan wird die Adressenmeth- Beispiel 3

ode verwendet. Damit wird jeder Steckvorrichtung und Überprüfung der anderen Steckvorrichtungsklemme, wo
jeder Anschlußklemme ein Symbol zugeordnet, damit F704 RL (Artikel (3)) angeschlossen ist:
die Klemme, an die das andere Ende des Kabels ange-
schlossen werden muß, leicht gefunden werden kann. 1. F704
Zeigt, daß die Klemme an die vierte Klemme der
Beispiel 1 F7-Steckvorrichtung angeschlossen ist.
Symbol unterhalb (oder oberhalb) der Steckvorrichtung, Überprüfen Sie die Beschreibung in der vierten
wie z. B. F6: Klemme des F7-Steckvorrichtung (F704). Zie gibt
Zeigt die Adresse der Steckvorrichtung an. an, daß die Steckvorrichtung F704 an H128 ange-
schlossen ist. Dies bedeutet, daß die vierte
Beispiel 2 Klemme der F7-Steckvorrichtung an die 28.
Symbol an der Mehrklemmen- Anschlußstelle, wie z. B. Klemme der H1-Steckvorrichtung angeschlossen ist.
1 und 10: 2. RL
Zeigt die Klemmennummer und die Zählrichtung an. Zeigt die Farbe des Kabels an. „ RL ” bedeutet, daß
der lsolierdraht rot ist, und „ L ” bedeutet, daß sich
auf dem roten lsoliermaterial ein blauer Streifen
befindet.
95ZV-2 EU FS 62-5
Modalità di utilizzo dello schema dei collegamenti elettrici (ITALIANO)
Modalità di utilizzo dello schema dei collegamenti elettrici

(ITALIANO)
Esempio
10 6 5 1
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
21
40 39 32 31
40 36 35 31
Relè di larghezza Relè di controllo Relè della lampada Relè del controller
della lampada della guida Relè neutro posteriore Relè del clacson d’ errore

C201 B611 H133 E214 H610 E220 H128 E219 H127 B501 E218
H129
D114 D114 D112 D103 D102 D002 D111 D103 D107 D107 A405 D001
2 1 2 1 2 1 2 1 2 1 2 1
(Nero) (Nero) (Nero) (Nero) (Nero) (Blu)
F5 F0 F6 F7 F8 F9
(1)
(2)
H1
10 6 5 1
D507 A306 F306 A905 A503 D112 E802 E803

C206 A302 F303 E312 E523 G302 E804

C205 F504 F704 F804 E109 G402 A105 E522

E501 C801 A005 B304 E520 E108 F004 E601

40 36 35 31
(3) 95ZV62001
Per gli schemi elettrici si utilizza il metodo degli indirizzi, Esempio 3

in base al quale a ciascun connettore e a ogni suo con- verifica del contatto dell’altro connettore cui è collegato
tatto viene associato un simbolo che permette di identifi- F704 RL (elemento (3)):
care agevolmente il contatto cui è collegata l’altra
estremità del cavo. 1. F704
Indica che il terminale è collegato al contatto n. 4
Esempio 1 del connettore F7.
simbolo al di sopra o al di sotto del connettore, ad Verificare la descrizione del contatto n.4 del con-
esempio F6: nettore F7 (F704): essa mostra che il contatto F704
Mostra l’indirizzo del connettore. è collegato a H128. Ciò indica che il contatto n.4
del connettore F7 è collegato al contatto n. 28 del
Esempio 2 connettore H1.
simbolo presso un connettore a più contatti, ad esempio 2. RL
1 e 10: Indica il colore del cavo: “RL” significa che il colore
Mostra il numero del contatto e il senso di numerazione. dell’isolante è rosso, e “L” rappresenta che una
linea blu è presente sull’isolazione rossa.
95ZV-2 EU FS 62-6
Cómo utilizar un Diagrama de Alambrado Eléctrico (ESPAÑOL)
Cómo utilizar un Diagrama de Alambrado Eléctrico

(ESPAÑOL)
Ejemplo
10 6 5 1
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
21
40 39 32 31
40 36 35 31
Relé de la lámpara Relé de control Relé de la lámpara Relé de fallos

ancha de recorrido Relé neutro trasera Relé de la bocina del controlador

C201 B611 H133 E214 H610 E220 H128 E219 H127 B501 E218
H129
D114 D114 D112 D103 D102 D002 D111 D103 D107 D107 A405 D001
2 1 2 1 2 1 2 1 2 1 2 1
(Negro) (Negro) (Negro) (Negro) (Negro) (Azul)
F5 F0 F6 F7 F8 F9
(1)
(2)
H1
10 6 5 1
D507 A306 F306 A905 A503 D112 E802 E803

C206 A302 F303 E312 E523 G302 E804

C205 F504 F704 F804 E109 G402 A105 E522

E501 C801 A005 B304 E520 E108 F004 E601

40 36 35 31
(3) 95ZV62001
El método de dirección se utiliza para diagrama de Ejemplo 3

alambrado eléctrico. Para este método, se pega un Comprobando el otro terminal de conector donde se
símbolo a cada conector y terminal de conector a fin de conecta F704 RL (ítem (3)):
localizar fácilmente el otro terminal al cual se conecta el
otro extremo del cable. 1. F704
Muestra que el terminal está conectado al terminal
Ejemplo 1 4o del conector F7.
Símbolo debajo (o encima) de conector, tal como F6: Compruebe la descripción en el terminal 4o del
Muestra la dirección del conector. conector F7 (F704). Esto muestra que el terminal
F704 está conectado a H128 y significa que el ter-
Ejemplo 2 minal 4o del conector F7 está conectado al terminal
Símbolo en el conector del multiterminal, tal como 1 y 28o del conector H1.
10: 2. RL
Muestra el número de terminal y la dirección de numer- Muestra el color del alambre “RL” y representa que
ado. el color aislante es rojo, y “L” representa que una
raya azul está en el aislamiento rojo.
95ZV-2 EU FS 62-7
Como Utilizar o Diagrama de Ligações Eléctricas (PORTUGUÊS)
Como Utilizar o Diagrama de Ligações Eléctricas

(PORTUGUÊS)
Exemplo
10 6 5 1
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
21
40 39 32 31
40 36 35 31
Relé de luz Relé de controlo Relé de controlo

de largura de viagem Relé do ponto morto Relé da luz traseira Relé da buzina de falha

C201 B611 H133 E214 H610 E220 H128 E219 H127 B501 E218
H129
D114 D114 D112 D103 D102 D002 D111 D103 D107 D107 A405 D001
2 1 2 1 2 1 2 1 2 1 2 1
(Preto) (Preto) (Preto) (Preto) (Preto) (Azul)
F5 F0 F6 F7 F8 F9
(1)
(2)
H1
10 6 5 1
D507 A306 F306 A905 A503 D112 E802 E803

C206 A302 F303 E312 E523 G302 E804

C205 F504 F704 F804 E109 G402 A105 E522

E501 C801 A005 B304 E520 E108 F004 E601

40 36 35 31
(3) 95ZV62001
O método de endereçamento é utilizado para os diagra- Exemplo 3

mas de ligações eléctricas. Para este método, cada Verificar o outro terminal de conectores, no qual F704
conector e terminal de conector tem um símbolo acop- RL (item (3)) é ligado:
lado para facilitar a localização do outro terminal onde a
outra extremidade do cabo deve ser ligada. 1. F704
Ilustra que o terminal é ligado ao 4o terminal do
Exemplo 1 conector F7.
Símbolo por baixo (ou por cima) do conector, como F6: Verifique a descrição no 4o terminal do conector F7
Indica o endereço do conector. (F704), indica que o terminal F704 está ligado ao
H128. Isto significa que o 4o terminal do conector
Exemplo 2 F7 está ligado ao 28o terminal do conector H1.
Símbolo no conector de multiterminais, como 1 e 10: 2. RL
Indica o número do terminal e a direcção da numer- Indica a cor do fio. “RL” representa que a cor do
ação. isolamento é vermelha e “L” representa uma faixa
azul está no isolamento vermelho.
95ZV-2 EU FS 62-8
Electrical Cable Color Codes
Electrical Cable Color Codes
Color of
stripe Y G Sb Br L W R B O Lg P Gy V
Color of (yellow) (green) (sky blue) (brown) (blue) (white) (red) (black) (orange) (light green) (pink) (grey) (violet)
insulation
Y (yellow) Y YG YSb YBr YL YW YR YB YO YGy YV
G (green) GY G GL GW GR GB GO
Sb (sky blue) SbY SbG Sb SbW SbR SbO SbLg SbP
Br (brown) BrY BrG Br BrL BrW BrR BrB
L (blue) LY LG LBr L LW LR LB LO LLg LP
W (white) WY WG WBr WL W WR WB WO WP WV
R (red) RY RG RBr RL RW R RB RO RLg RGy
B (black) BY BG BL BW BR B BO BLg BP BV
O (orange) OY OG OSb OL OW OR OB O
Lg (light green) LgY LgG LgSb LgBr LgL LgW LgR LgB Lg
P (pink) PG PL PW PB P
Gy (grey) GyY GyG GyL GyW GyR GyB GyO Gy
V (violet) VW VR V
Insulation color
Stripe color
70ZV62001
95ZV-2 EU FS 62-9
Electrical Circuit Symbols
Electrical Circuit Symbols
Name Symbol Name Symbol
Direct current Motor M
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 Pressure switch or

resistor Temperature switch
Inductance or Electromagnetic Negative -positive-negative

coil (NPN) transistor
Positive -negative-positive
Battery or Direct voltage source
(PNP) transistor
95ZV-2 EU FS 62-10
Sensor Mount
Sensor Mount
1 2
5 3 4 7
6 1 5
95V2E62001
1. Machine speed sensor

2. T/C oil temperature sensor
3. Air cleaner sensor
4. E/G coolant temperature sensor (S/N 9001~9150)
5. Hydraulic oil level sensor
6. Hydraulic oil temperature sensor
7. Coolant level alarm sensor
95ZV-2 EU FS 62-11
Fuse
Fuse
The following fuses are provided to protect electrical cir- Fuse box
cuits.
For chassis
Fusible link
70 A x 2, 30 A x 1 Fuse
Fuse No. capacity Protective circuit
(A)
Fuse box LIGHTING
15 fuses x 2 (for chassis and cab) 1 20A
HEAD LIGHT
6 fuses x 1 (for engine controller ECM) 2 15A R. WORK LIGHT SPARE
BOOM KICKOUT
3 10A 30A
(For installation positions, refer to "Electrical Equipment BUCKET LEVELER
Layout".) 4 15A TURN SIGNAL SPARE
PARKING BRAKE
5 30A 20A
MCU (MACHINE)
CAUTION 6 15A F. WORK LIGHT SPARE
Possible burn hazard. Before replacing a fuse, be 7 10A AIR SUS. SEAT (OPT)
15A
sure to turn off the starter switch. 8 15A SPARE
9 15A SPARE SPARE
4WAY FLASHER
IMPORTANT HORN
10 15A 5A
ROOM LAMP
Replace a fuse with the same capacity. RADIO
If a fuse blows immediately after replacement, the 11 10A SPARE
electric system is defective. Locate the defective part, 12 15A PREHEAT
and then repair it.
BUZZER
13 5A MONITOR LAMP
TACHOMETER
14 5A NEUTRAL RELAY
BATTERY RELAY
15 5A
ECM (ENGINE)
For cab
Fuse
(A)
16 5A SPARE
17 5A SPARE SPARE
Fuse box for cab Fuse box for chassis
18 5A R. WIPER / WASHER
20A
19 10A F. WIPER / WASHER
MODM
20 10A SPARE
CIGAR LIGHTER
21 15A SPARE
15A
22 3A DC-DC CONVERTER
23 10A SPARE SPARE
24 10A SPARE
10A
25 20A SPARE
26 5A AIRCON SPARE
27 5A AIRCON
5A
28 10A AIRCON
29 20A AIRCON
90V2E62002 30 20A SPARE
95ZV-2 EU FS 62-12
Fuse
For engine controller (ECM)
Fuse
(A)
31 10A ECM (ENGINE)
32 7.5A SPARE
33 7.5A SPARE
34 7.5A SPARE
35 10A ECM (ENGINE)
36 10A SPARE
Fusible link
Fuse box for ECM K97V2J62001

95ZV-2 EU FS 62-13
Fuse
Fusible link Problems caused by blown fusible link
Fuse Problem (symptom)

Fusible link damaged During engine operation During engine stop
Cover
Fuse - Engine will stop auto- - All the electrical circuit
element matically. will not function.
30A - All the power for all - Engine can not be
electrical circuit will be started.
OFF.
- Horn [and opt. flasher] - The same conditions
will operate. as "During engine oper-
- All the others will not ation".
operate and the - Engine can be started.
70A machine can not be
(1) operated.
- Engine will not stop
automatically but can
Box for fusible link Fusible link be stopped with starter
70ZV62010 switch OFF.
- The machine can be - The same conditions
operated but the batter- as "During engine oper-
(081) (085) (900) 12V 12V 70A
W W
5
[W ] 100 ies can not be charged ation".
30A
(2)
Battery MCU and the batteries will be
(060) (901) ECM (38)
W 5
[W ] discharged soon.
(065) (015) (708)
R1 BR WR
1.25 F15
WR WP
B AC
R2 C 5A WV
(700)
(062) (064) (063)

1.25 1.25
BW G WR
IMPORTANT
F13
F12
F14
5A
15A
5A
(012) (014)
1.25
(013)
Battery relay Starter
BW G (Lg)
70A
(1)
5
B C When replacing fusible link, you may want to discon-
[R ]x6
(910~
915) Magnetic S/W (702) nect the battery negative terminal to avoid arcing out
a circuit and damaging wire.
5 5
[R ] (701) [BW ] Voltage
1.25 relay
RL (703) WG(704)
NR If so, after you reconnect battery, do following:

(013)
F13
(Lg)
(705)
(WG) (707)
WL 1. Turn on key
Charge lamp (706)
WL
1.25 2. Press throttle pedal fully down and up 3 times in
70A
20
B
R
E
I 5~6 seconds.
(2)
Alternator 20
3. Turn off key switch.
(005-a)
(L) ES
F5 M1
M2
100 M1
M Secondary
M2 steering
M pumps (OPT)
Preheat lamp
(720)
(BG) Air heater
15 15
(012)
BW
Heater relay
B ACC’ E
To pilot lamp
Fusible link location 95V2U62010
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.
95ZV-2 EU FS 62-14
Engine Start Circuit
Engine start circuit diagram

Starter switch
B BR ACC R1 R2 C
Preheat
Off
On
Start
MCU
E05 E06 E17 E04 E12
E03 E11 12V 12V
Shift lever F/R position
B18 30A
E24
B12 Fusible link Battery
D11 B11 ECM
D04
F N R F15 Diode unit
F14
5A
5A
1
23A
D12
D05
Battery relay Starter motor
D03
70A
D10
(1)
+24 V B C
Magnetic
switch
Voltage
relay
3 4
2 1
Neutral relay
F13 MCU
+24 V Charge lamp E24
(F5)
* When shift lever is in F/R position: OFF
When shift lever is in N position: ON (2)
R
70A B I
E
Alternator
95V2U62011
95ZV-2 EU FS 62-15
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 neu-
tral (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.
95ZV-2 EU FS 62-16
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 cir-
cuits.
Start
Starts the engine.
Starter switch
Control box Preheat
Preheats the intake air to ensure smooth starting in cold
weather.
Starter switch location

85V2E62002
OFF
35º 30º
Preheat ON
35º
Start
B
C
AC BR
R1
R2
W3 Connection table
W5
B BR AC R1 R2 C
BW R1 BR WR x 2 Preheat
B AC WB x 2 Off
BBG
G R2 C G On
Start
To battery relay
To neutral relay
To heater relay
From battery
1.25
BW WR WR G W5
BG WB WB W3
85V2E62013
95ZV-2 EU FS 62-17
ECM safety features Battery relay

The ECM is equipped with safety functions that are
designed to limit engine revolution (min-1) in certain situ-
ations.
Terminals for coil Moving contact
energizing current
The “zero point” of the pedal is recalibrated every time (4 mm) Main contacts
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.) BR
This permits the ECM to see the signal and set the
engine revolution (min-1) appropriately. Terminals for
main current
Coil for energizing (8 mm)
This function is set to turn “on” 1 second after the key is 95ZV62017
set to the “ON” position, then adjustment is completed in
3 seconds and this function is turned “off”. When the starter switch is placed to the ON position or
the start position, the battery relay is turned on. When
Note the starter switch is set to the OFF position, the alterna-
There is no indication on the instrument panel or MODM tor stops generating power, and the battery relay is
that this function turns either “on” or “off” because there automatically turned off so that the electrical circuits will
is no engine abnormality to call out or indicate. not function.
Effect on the machine If the battery relay was not used, a large amount of cur-
(a) If the throttle pedal is applied while turning the key rent would be directly sent through the starter switch
switch to the start position, the engine maximum when it is turned on. However, use of the battery relay
speed will only increase to 80% of high idle. reduces the amount of current because this relay needs
(b) If the throttle pedal is applied while the engine is only a small amount of current to energize it.
starting, this function will turn “ON” 1 second after
releasing the pedal and engine speed will only
increase 80% of high idle.
Battery relay operation
To avoid these troubles, the following steps are impor-
Starter switch
tant;
1. Wait one second before turning the key from the From AC B
“ON” to the “START” position. charge
circuit Battery relay
2. Do not step on the pedal while the engine is start-
(B)
ing, nor just after the engine starts.
To main (E)
Battery
circuit
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.
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.
95ZV-2 EU FS 62-18
Alternator I terminal wire Diode unit

12V 12V
30A
ECM Battery
(1)
R1 BR F15 WR (2) (3) WP WV:To battery relay
B AC
R2 C 5A
(2)(3): Diode unit WV WR:To starter switch terminal AC (VIA F15) and
WR WP to ECM
Suppression diode WP:To alternator
15A
F12
F14
F13
5A
5A
Charge From
circuit alternator
I terminal Diode storage section
B Neutral
relay 70ZV62017
70V2U62005
Engine motion-active circuit: The diode unit is incorporated in the milky white connec-
tor near the battery relay. It is provided for the following
When the starter switch is turned OFF, the battery relay purpose.
is automatically turned OFF since the command current
from the starter switch terminal AC stops flowing and 1. Diode (2)
the coil is demagnetized. Then the charging circuit from This diode is provided to prevent the roundabout
the alternator is shut down. current from the alternator to the ECM. If this diode
is not provided (or is defective), the ECM does not
However the alternator is still generating power and the turn OFF and the engine cannot be stopped.
load dump surge may be generated. This may damage
the related circuits and equipment. In order to prevent 2. Diode (3)
this trouble, this circuit (1) is provided to hold the battery This diode is provided to prevent the roundabout
relay in the "ON" position. current from the starter switch AC to the alternator I
terminal.
95ZV-2 EU FS 62-19
Neutral relay
1 2
SbP
L
RL
G
4 3
Internal connection dia.

Body black
85V2E62016
Position of shift Between Between Rating DC 24 V

Starting
lever 1 and 2 3 and 4
Operating voltage 16 V or less
F or R Not energized OFF Impossible
Reset voltage 2.4 V or more
N Energized ON Possible Coil resistance 320 
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 neutral relay / magnetic switch / voltage relay
through the starter switch terminal C.
95ZV-2 EU FS 62-20
Magnetic switch
Rating 24 V x 200 A
M C
C C’
M’
M’ C’
70ZV62019
Note
When the neutral relay is magnetized, electric current

flows from the battery to the neutral relay and the mag-
netic 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.
95ZV-2 EU FS 62-21
Voltage relay Note

(S/N 9001~9048) Once the engine is started, the alternator starts generat-
ing electric power.
1 When electric current is supplied from the alternator R

2 3
terminal to the voltage relay, the voltage relay is magne-
tized and is turned OFF.
2
Consequently the magnetic switch turns OFF and no
3 electric current flows to the starter motor terminal C, dis-
engaging the starter motor.
1 4
4
70ZV62020
Voltage relay
Contact point closed 6V
Contact point open 9V
(S/N 9049~)
Blue
K70V2J62005
Voltage relay
Contact point closed 6V
Contact point open 8V
95ZV-2 EU FS 62-22
Power Generating/Charging Circuit
Power Generating/Charging Circuit

Alternator
Engine Mechanical energy supply
The alternator driven by the engine rectifies, with 6

diodes, full waves in three phases of the AC output gen-
erated in the stator coil by the three-phase start connec-
tion (Y connection) into DC output, then supplies it as
Alternator Electrical energy conversion the electric power to the battery and the machine load.
In the electricity generated in the alternator, the voltage

Rotor coil fluctuates depending on the number of revolutions of
excitation current Generated power the engine and the load size if no measures are taken.
IC regulator
To prevent fluctuation, a regulator is integrated so that
Voltage adjustment the voltage supplied to the battery and the load circuit is
For battery relay
For rotor coil always constant.

Adjusted
initial excitation
voltage
operation
For battery relay

operation
Starter
Load circuit operation
switch
Battery charge
<Load>
For rotor coil Battery

initial excitation 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.
95ZV-2 EU FS 62-23
ECM (Engine Controller)
Function of ECM
- Stops the engine.
- Operates the engine.
- Monitors the engine, and diagnoses it for faults.
Connection diagram
B
(081) (031) (730) STOP (013)
W F31 GY (BrR) (LG)
7 6 F13
10A
8 (731) WARNING
(BrB)
B 17 16
(085) (035) (732) MAINTENANCE
W F35 GR (BrW )
18 5
10A
28
(015)
WR (161) W
F15 38 11 (E15)
REMOTE THROTTLE
5 (745)
GY (743) BO
21 7
6 (746)
19 BO
THROTTLE PEDAL
THROTTLE OPENING E
BrW (733)
SENSOR 48 (751)
YV (734) GyR
47 27 EP E/G OIL PRESS.
BLg (735)
49
29
IDLE S/W
30
GyY (736)
OFF IDLE 3 39
40
GyW(737) E
13 50
IDLE
DIAGNOSTIC S/W
S2H
BrG (738)
44 S2L
CAN
RESISTOR S2S
INC/DEC S/W
INC PG (739)
(m) 14
PW (740) B
24 (060)
DEC W
B
S2H
(741) 46 C
BL S2L
9 37 D
S2S
10 36 E
E (YL ) (747)
26 F
AI SbY (209) (Y0 ) (748)
45 27 G
TC Sb (205) A
E 2
E DATA LINK
SbW(203)
(B15) 41 CONNECTOR
SbL (204)
(A34) 23
SC (GL ) (213)
43
(GB ) (214)
20
ECM
E/G ECM connection diagram

95V2E62022
95ZV-2 EU FS 62-24
Monitor lamp test
ON
Key switch Approx.
OFF
2 sec
ON
Engine maintenance lamp Orange
OFF
ON
Engine warning lamp Lights when
abnormality Yellow
OFF
occurs.
ON
Engine stop lamp Red
OFF
95ZV62025
STOP
Engine maintenance lamp

(S/N 9001~9150)
Engine warning lamp
Engine stop lamp

K95V2E62002
When the starter switch is set to ON, three engine mon-

itor 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 corre-

sponding monitor lamp lights.
95ZV-2 EU FS 62-25
Failure diagnosis The diagnosis for the engine failure should be done by
the following steps.
Engine diagnostic switch (option)
Step 1. Starter switch key "OFF"
Step 2. Diagnostic switch "ON"
Diag. switch Inc./Dec. switch
(Part Number: 35010-60130) (Part Number: 35010-60180) Step 3. Starter switch key "ON"
The engine warning lamp flashes with these conditions.

To diagnose the engine failure, convert the flashing pat-
tern to the 3-digit fault code.
The following shows how to convert the flashing pattern

to the 3-digit fault code.
G R R
Note
L W G Y
These code are quickly retrievable with Cummins
Quickcheck hand held analyzers or with the MODM on
the machine.
Cable assembly
(Part Number: 33191-49150) Refer to the "QUANTUM FAULT CODE INFORMA-
70ZV62069 TION" for details.
This switch is used to check the engine failure when any
one of the engine warning lamps is turned on. 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
PREHEAT START
K80V2J62009
ON
OFF
Orange
1 sec 1 sec
ON
OFF
Yellow
0.5 sec
ON
OFF
Red Second
First digit digit Third digit
1 sec 1 sec
Fault code Fault code (continued)
115V2E62008
95ZV-2 EU FS 62-26
Failure diagnostic chart
ON
Key switch
OFF
ON
Diagnostic switch
OFF
[When there is no fault code]

ON
OFF
Orange
ON
Engine warning lamp
OFF
Yellow
ON
Engine stop lamp STOP
OFF
Red
[When there is fault code]
ON
Orange
OFF
1 sec 1 sec
ON
Engine warning lamp
Yellow
OFF
ON
STOP
Engine stop lamp
Red
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
Orange
OFF
1 sec 1 sec
ON
Engine warning lamp
Yellow
OFF
ON
STOP
Engine stop lamp
Red
OFF
1 3 1
Following page explains more.
115V2E62009
95ZV-2 EU FS 62-27
Increment decrement switch (option) - Adjusting the engine idle revolution
When the diagnostic switch is OFF (Starter switch

Diag. switch Inc./Dec. switch key "ON"), the engine idle revolution can be adjusted
(Part Number: 35010-60130) (Part Number : 35010-60180) in 25 rpm by using the increment / decrement switch
(650 rpm  800 rpm  1,000 rpm). Move the incre-
ment / 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
G R
L W
R
G Y
1,000 min-1 (rpm) or to below 650 min-1 (rpm) even
though this switch is moved to "+" or "-".
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 convert-

ing the flashing pattern to 3-digit fault code.
Refer to the "Quantum fault code information" for

details.
95ZV-2 EU FS 62-28
Quantum fault code information Please note that not all are used in the 95ZV-2 machine
application. Refer to Cummins Engine troubleshooting
These codes show the fault codes for the engine failure fault codes list for more information.
displayed on the MODM error log monitor, or checked
by the diagnostic switch (option).
QST30 (135ZV-2)
QSK19 (115ZV-2)
QSC8.3 (80ZV-2)
QSC8.3 (85ZV-2)
QSB4.5 (60ZV-2)
QSB6.7 (70ZV-2)
(70TMV-2)
QSM11 (90ZV-2)
QSM11 (92ZV-2)
QSX15 (95ZV-2)
FAULT
CODE/ DESCRIPTION
LAMP
EG111
Engine Control Module (ECM) - critical internal failure.
Red
EG113
Engine Timing Actuator Circuit - shorted high.
Yellow
EG114
Engine Timing Actuator Circuit - shorted low.
Yellow
EG115 Engine Speed / Camshaft Position Sensor Circuit - lost both of two signals from
Red the magnetic pickup sensor.
EG121 Engine Speed / Position Sensor Circuit - lost one of two signals from the
Yellow magnetic pickup sensor.
EG122
Intake Manifold Pressure Sensor #1 Circuit - shorted high.
Yellow
EG123
Intake Manifold Pressure Sensor #1 Circuit - shorted low.
Yellow
EG124
Intake Manifold Pressure - above normal operation.
Yellow
EG131
Accelerator Pedal Position Sensor Circuit - shorted high.
Red
EG132
Accelerator Pedal Position Sensor Circuit - shorted low.
Red
EG133
Remote Accelerator Pedal Position Sensor Circuit - shorted high.
Red
EG134
Remote Accelerator Pedal Position Sensor Circuit - shorted low.
Red
EG135
Engine Oil Pressure Sensor Circuit - shorted high.
Yellow
EG141
Engine Oil Pressure Sensor Circuit - shorted low.
Yellow
EG143
Engine Oil Pressure Low - warning.
Yellow
EG144 Engine Coolant Temperature Sensor Circuit - voltage above normal or shorted
Yellow high.
EG145 Engine Coolant Temperature Sensor Circuit - voltage below normal or shorted
Yellow low.
EG146
Engine Coolant Temperature High - warning.
Yellow
EG151
Engine Coolant Temperature High - critical.
Red
EG153 Intake Manifold Air Temperature Sensor Circuit - voltage above normal or
Yellow shorted high.
EG154 Intake Manifold Air Temperature Sensor Circuit - voltage below normal or
Yellow shorted low.
EG155
Intake Manifold Air Temperature Sensor High - critical.
Red
EG166
Rack Position Sensor #1 Circuit - shorted high.
Yellow
EG172
Rack Actuator Position #1 Circuit - grounded circuit.
Red
95ZV-2 EU FS 62-29
QST30 (135ZV-2)
QSK19 (115ZV-2)
QSC8.3 (80ZV-2)
QSC8.3 (85ZV-2)
QSB4.5 (60ZV-2)
QSB6.7 (70ZV-2)
(70TMV-2)
QSM11 (90ZV-2)
QSM11 (92ZV-2)
QSX15 (95ZV-2)
FAULT
CODE/ DESCRIPTION
LAMP
EG173
Rack Actuator - mechanically stuck open.
Yellow
EG184
Engine Control Module Identification Input State Error.
Yellow
EG185
Engine Control Module Network Communication Error.
Yellow
EG187
Sensor Supply Voltage #2 Circuit - shorted low.
Yellow
EG212
Engine Oil Temperature Sensor Circuit - shorted high.
Yellow
EG213
Engine Oil Temperature Sensor Circuit - shorted low.
Yellow
EG214
Engine Oil Temperature High - Critical.
Red
EG221
Ambient Air Pressure Sensor Circuit - shorted high.
Yellow
EG222
Ambient Air Pressure Sensor Circuit - shorted low.
Yellow
EG227
Sensor Supply Voltage #2 Circuit - shorted high.
Yellow
EG231
Engine Coolant Pressure Sensor Circuit - shorted high.
Yellow
EG232
Engine Coolant Pressure Sensor Circuit - shorted low.
Yellow
EG233
Engine Coolant Pressure Low - warning.
Yellow
EG234
Engine Speed High - critical.
Red
EG238
Yellow
EG254
Fuel Shutoff Valve Circuit - shorted low.
Red
EG255
Fuel Shutoff Valve Circuit - shorted high.
Yellow
EG259
Fuel Shutoff Valve - stuck open.
Red
EG261
Fuel Temperature High - warning.
Yellow
EG263
Fuel Temperature Sensor Circuit - shorted high.
Yellow
EG265
Fuel Temperature Sensor Circuit - shorted low.
Yellow
EG266 Engine Fuel Temperature - data valid but above normal operational range - most
Red severe level.
EG271
Fuel Control Actuator Circuit - shorted low.
Yellow
EG272
Fuel Control Actuator Circuit - shorted high.
Yellow
EG281
Injection Pump Mechanical System - signal not in range from ECM.
Yellow
EG284 Engine Speed / Position Sensor #1 (Crankshaft) Supply Voltage Circuit - shorted
Yellow low.
EG285
SAE J1939 Data Link Multiplexing PGN Timeout Error.
Yellow
95ZV-2 EU FS 62-30
QST30 (135ZV-2)
QSK19 (115ZV-2)
QSC8.3 (80ZV-2)
QSC8.3 (85ZV-2)
QSB4.5 (60ZV-2)
QSB6.7 (70ZV-2)
(70TMV-2)
QSM11 (90ZV-2)
QSM11 (92ZV-2)
QSX15 (95ZV-2)
FAULT
CODE/ DESCRIPTION
LAMP
EG286
SAE J1939 Data Link Multiplexing Configuration Error.
Yellow
EG287
SAE J1939 Multiplexing Accelerator Pedal Sensor System Error.
Red
EG295
Ambient Air Pressure Sensor Circuit - data incorrect.
Yellow
EG299
Engine stopped not using Starter Switch.
Yellow
EG311
Injector Solenoid Valve Cylinder #1 Circuit - grounded circuit.
Yellow
EG312
Yellow
EG313
Yellow
EG314
Yellow
EG315
Yellow
EG319
Real Time Clock - power Interrupt.
Yellow
EG321
Yellow
EG322
Injector Solenoid Valve Cylinder #1 Circuit - open circuit.
Yellow
EG323
Yellow
EG324
Yellow
EG325
Yellow
EG331
Yellow
EG332
Yellow
EG334
Coolant Temperature Sensor Circuit - data erratic, intermittent, or incorrect.
Yellow
EG341
Engine Control Module - data lost.
Yellow
EG342
Engine Control Module - out of calibration.
Red
EG343
Engine Control Module - warning internal hardware failure.
Yellow
EG346
Engine Control Module - warning software error.
Yellow
EG351
Injector Power Supply.
Yellow
EG352
Yellow
EG378
Fueling Actuator #1 Circuit - open circuit.
Yellow
EG379
Fueling Actuator #1 Circuit - grounded circuit.
Yellow
EG386
Yellow
95ZV-2 EU FS 62-31
QST30 (135ZV-2)
QSK19 (115ZV-2)
QSC8.3 (80ZV-2)
QSC8.3 (85ZV-2)
QSB4.5 (60ZV-2)
QSB6.7 (70ZV-2)
(70TMV-2)
QSM11 (90ZV-2)
QSM11 (92ZV-2)
QSX15 (95ZV-2)
FAULT
CODE/ DESCRIPTION
LAMP
EG387
Accelerator Pedal Position Sensor Supply Voltage Circuit - shorted high.
Yellow
EG394
Timing Actuator #1 Circuit - open circuit.
Yellow
EG395
Timing Actuator #1 Circuit - grounded circuit.
Yellow
EG396
Fueling Actuator #2 Circuit - open circuit.
Yellow
EG397
Fueling Actuator #2 Circuit - grounded circuit.
Yellow
EG398
Timing Actuator #2 Circuit - open circuit.
Yellow
EG399
Timing Actuator #2 Circuit - grounded circuit.
Yellow
EG415
Engine Oil Pressure Low - critical.
Red
EG418
Water in Fuel Indicator High - maintenance.
Yellow
EG419
Intake Manifold Boost Pressure Imbalance.
Yellow
EG423
Fuel Timing Pressure or Timing Actuator Stuck.
Yellow
EG428
Water in Fuel Sensor Circuit - shorted high.
Yellow
EG429
Water in Fuel Sensor Circuit - shorted low.
Yellow
EG431
Accelerator Pedal Idle Validation Circuit - data incorrect.
Yellow
EG432
Accelerator Pedal Idle Validation Circuit - out of calibration.
Red
EG433
Intake Manifold Pressure Sensor Circuit - data incorrect.
Yellow
EG434
Voltage to ECM less than 6 V
Yellow
EG435
Engine Oil Pressure Switch Circuit - data incorrect.
Yellow
EG441
Battery #1 Voltage Low - warning.
Yellow
EG442
Battery #1 Voltage High - warning.
Yellow
EG443
Accelerator Pedal Position Sensor Supply Voltage Circuit - shorted low.
Yellow
EG449
Fuel Pump Delivery Pressure High - warning.
Yellow
EG451
Injector Metering Rail #1 Pressure Sensor Circuit - shorted high.
Yellow
EG452
Injector Metering Rail #1 Pressure Sensor Circuit - shorted low.
Yellow
EG465
Turbocharger #1 Wastegate Control Circuit - shorted high.
Yellow
EG466
Turbocharger #1 Wastegate Control Circuit - shorted low.
Yellow
EG482
Fuel Pressure Low - warning.
Yellow
95ZV-2 EU FS 62-32
QST30 (135ZV-2)
QSK19 (115ZV-2)
QSC8.3 (80ZV-2)
QSC8.3 (85ZV-2)
QSB4.5 (60ZV-2)
QSB6.7 (70ZV-2)
(70TMV-2)
QSM11 (90ZV-2)
QSM11 (92ZV-2)
QSX15 (95ZV-2)
FAULT
CODE/ DESCRIPTION
LAMP
EG483
Injector Metering Rail #2 Pressure Sensor Circuit - shorted high.
Yellow
EG484
Injector Metering Rail #2 Pressure Sensor Circuit - shorted low.
Yellow
EG485
Injector Metering Rail #2 Pressure High - warning.
Yellow
EG486
Injector Metering Rail #2 Pressure Low - warning.
Yellow
EG488
Intake Manifold Temperature High - warning.
Yellow
EG491
Turbocharger #2 Wastegate Control Circuit - shorted high.
Yellow
EG492
Turbocharger #2 Wastegate Control Circuit - shorted low.
Yellow
EG496
Engine Speed / Position Sensor #2 (Camshaft) Supply Voltage.
Yellow
EG524
OEM Alternate Droop Switch Validation - data incorrect.
Yellow
EG527
Auxiliary Input / Output #2 Circuit - shorted high.
Yellow
EG528
OEM Alternate torque validation switch - data incorrect.
Yellow
EG529
Auxiliary Input / Output #3 Circuit - shorted high.
Yellow
EG546
Fuel Delivery Pressure Sensor Circuit - shorted high.
Yellow
EG547
Fuel Delivery Pressure Sensor Circuit - shorted low.
Yellow
EG551
Accelerate Pedal Idle Validation Circuit - shorted low.
Yellow
EG553
Injector Metering Rail #1 Pressure High - warning level.
Yellow
EG554
Fuel Pressure Sensor Error.
Yellow
EG559 Injector Metering Rail #1 Pressure Low - data valid but below normal operational
Yellow range - moderately severe level.
EG596
Electrical Charging System Voltage High - warning level.
Yellow
EG598
Electrical Charging System Voltage Low - critical level.
Red
EG689
Crankshaft Engine Speed Signal Error.
Yellow
EG731
Mechanical Timing Misalignment.
Yellow
EG753 Crankshaft Position Sensor and Camshaft Position Sensor - data erratic,
Yellow intermittent, or in correct.
EG757
Electronic Control Module Data Lost.
Yellow
EG758
Injector Metering Rail #2 Pressure Malfunction.
Yellow
EG778
Engine Speed Sensor (Camshaft) - data erratic, intermittent, or incorrect.
Yellow
EG951
Cylinder Power Imbalance Detected.
None
95ZV-2 EU FS 62-33
QST30 (135ZV-2)
QSK19 (115ZV-2)
QSC8.3 (80ZV-2)
QSC8.3 (85ZV-2)
QSB4.5 (60ZV-2)
QSB6.7 (70ZV-2)
(70TMV-2)
QSM11 (90ZV-2)
QSM11 (92ZV-2)
QSX15 (95ZV-2)
FAULT
CODE/ DESCRIPTION
LAMP
EG1117
Power Lost with Ignition ON - data erratic, intermittent, or incorrect.
None
EG1358 Accelerator Pedal Position Sensor 1 Circuit - voltage above normal or shorted
Yellow high.
EG1359 Accelerator Pedal Position Sensor 1 Circuit - voltage below normal or shorted
Yellow low.
EG1361 Remote Accelerator Pedal Position Sensor 1 Circuit - voltage below normal or
Yellow shorted low.
EG1376 Engine Camshaft Speed / Position Sensor - data erratic, intermittent, or
Orange incorrect.
EG1595 Remote Accelerator Pedal Position Sensor 1 Circuit - voltage above normal or
Yellow shorted high.
EG1597 Engine Control Module Critical Internal Failure - bad intelligent device or
Orange component.
EG1845 Water in Fuel Indicator Sensor Circuit - voltage above normal or shorted to high
Orange source.
EG1846 Water in Fuel Indicator Sensor Circuit - voltage below normal or shorted to low
Orange source.
EG1852 Water in Fuel Indicator - data valid but above normal operational range -
Yellow moderately severe level.
EG1911
Injector Metering Rail 1 Pressure - above normal operating range.
Yellow
EG2185
Yellow
EG2186
Yellow
EG2215 Fuel Pump Delivery Pressure - data valid but below normal operational range -
Yellow moderately severe level.
EG2249
Fuel Pump Delivery Pressure Sensor Circuit - shorted low.
Yellow
EG2261 Fuel Pump Delivery Pressure - data valid but above normal operational range -
Orange least severe level.
EG2262 Fuel Pump Delivery Pressure - data valid but below normal operational range -
Orange least severe level.
EG2265
Fuel Priming Pump Control Signal Circuit - shorted high.
Yellow
EG2266
Fuel Priming Pump Control Signal Circuit - shorted low.
Yellow
EG2311
Fueling Actuator #1 Circuit Error - condition exists.
Yellow
EG2321
Engine Speed Sensor #1 - data erratic, intermittent, or incorrect.
None
EG2322
Engine Speed Sensor #2 - data erratic, intermittent, or incorrect.
None
EG2697 Accelerator Pedal Position Sensor Circuit and Idling Position Detection Switch
Orange Circuit - data erratic, intermittent, or incorrect.
EG2963
Engine Coolant Temperature High - warning.
None
EG2964
Intake Manifold Temperature High - warning.
None
EG2973
Intake Manifold Pressure Sensor Circuit - data erratic, intermittent, or incorrect.
Yellow
(09D20E)
95ZV-2 EU FS 62-34
Accelerator pedal
Pedal
A-Black-APS signal
B-White-APS ground
C-Red-APS supply (5 V)
Throttle pedal
D-Green-Throttle active
Throttle opening E-Blue-Idle active
sensor BrW (733)
48 F-Orange-IVS supply (5 V)
R YV (734)
47
B BLg (735)
49
W E 35
IDLE S/W C
OFF IDLE GyY (736) M
3
G
GyW (737)
13
IDLE L
O
Circuit diagram Note

APS-Acceleration Position Signal
IVS-Idle Validation Switch
Connector
(G) 6 1 (B)
(L) 5 2 (W)
(O) 4 3 (R)
1-Black-APS signal
2-White-APS ground A
3-Red-APS supply (5 V) View A
4-Orange-IVS supply (5 V)
5-Blue-Idle active
6-Green-Throttle active
95V2U62003
Note Pedal Test.

Typical pedal potentiometer resistance at 18ºC (65ºF).
To calibrate a new pedal to the ECM, do the following Wire colors are at the pedal harness with accelerator pedal
within about a 5 or 6 second time frame. unplugged.
- Turn "on" key switch Wire colors  at pedal up position  at pedal down position
- Stroke the pedal fully up and down 3 times. R-B 1,540~2,310 260~390
- Turn "off" the key switch W-B 260~390 1,540~2,310
R-W 2,000~3,000 2,000~3,000
Potentiometer voltage (V)
G-O Open 0
Input 5
L-O 0 Open
Up position 3.75~3.95
Down position 0.55~0.75
95ZV-2 EU FS 62-35
When the accelerator pedal is pressed, the voltage cor-

responding to the pressing angle is input as a signal
from the potentiometer to the ECM (engine controller) to
control the engine revolution.
Pedal Stroke Pedal angle

stop K65V2U62004
17
Installation
angle Note
45 Part “A” is added on S/N 9301 and thereafter and force
28
on pedal is increased from 50 N (5.1 kgf) (11.2 lbf) to 77
N (7.9 kgf) (17.3 lbf).
Pedal Angle
Between terminal 9 (YV-B) and 23 (BLg-W)

Refer to circuit diagram for details.
5V
when plugged in, key "ON"
4
Potentiometer Voltages
0
0 17
Pedal Angle
85V2E62019
95ZV-2 EU FS 62-36
Accelerator pedal installation
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*.
1. Shut off the engine
2. Turn the key to "ON"
3. Fully depress and release the throttle pedal three

times.
4. Turn the key to "OFF".
The throttle pedal and ECM* have now been initialized

or calibrated. The engine may be restarted and retested
for proper performance.
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.
Using the Quantum fault code information section the

following fault codes may indicate a non-initialized throt-
tle pedal:
- 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.
95ZV-2 EU FS 62-37
Transmission Control Circuit and Monitor Circuit
Machine control unit (MCU)
To S5 To S6 To S7 To S8 To S9
85V2E62041
95ZV-2 EU FS 62-38
Connector
MCU
MCU
A 1.2S_SO A16.TT_L A31.1/4_L B12.X_R E 1.SSR_SO E16.SPD E31.TT_SE C 1.2S_SE C16.EP C31.BSL D12.SL_A
A 2.2_SO A17.D_SO A32.SS_L B13.F_SO E 2.FC_SO E17.BATT E32.OT_SE C 2.DSUB2 C17.F C32.EG_M D13.SS_N
A 3.ES_R A18.1_SO A33.3/4_L B14.B_SO E 3.KEY E18.CANL1 E33.OUT_RSE C 3.DSUB4 C18.ASUB1 C33.DD_S D14.KD
A 4.DD_SO A19.EP_L A34.EG_SW1 B15.EG_SW2 E 4.KEY E19.SS_P E34.ET_M C 4.BSL- C19.ASUB2 C34.AFR D15.INCH_S
A 5.3_SO A20.AB_L B 1.H_SO B16.RIN1 E 5.GND E20.CANLO C 5.TT C20.1/2 D 1.PRK D16.OD_SW
A 6.HM A21.A_L B 2.PWM_SO B17.OUT_MD2 E 6.GND E21.TM_M C 6.AC C21.1/8 D 2.AM_SW D17.SH
A 7.LU_SO A22.1/2_L B 3.IP_SO B18.N_R E 7.GND E22.B_SE2 C 7.ET C22.2S D 3.SL_2 D18.SS_SW
A 8.4_SO A23.E_L B 4.R_SO B19.BR_L E 8.GND E23.WT_SE C 8.BL C23.EG_H D 4.SL_R D19.SS_F
A 9.OTH_OUT A24.FR_L B 5.MO_SO B20.CAN_R1 E 9.+5V E24.ALT C 9.BD C24.IP_SW D 5.SL_3 D20.TMP
A10.R_L A25.SC_SW B 6.FR_SO B21.CAN_R2 E10.TGEG E25.RXD1 C10.DSUB1 C25.FR D 6.S_UP D21.INCH
A11.F_L A26.TF_L B 7.SSL_SO B22.DOUT1 E11.KEY E26.TGSP C11.DSUB3 C26.KO_P D 7.S_DOWN D22.KO_S
A12.ST_L A27.AC_L B 8.BSL_SO B23.OUT_FEW E12.KEY E27.INCH_SE C12.DR C27.ES_SE D 8.EG_SW D23.SC
A13.WL_L A28.BP_L B 9.BZ B24.MT E13.CANH1 E28.SC_P C13.BSL+ C28.3/4 D 9.M_SW D24.AR
A14.CW_L A29.N_L B10.BSL_R B25.ET_SE E14.EGR2 E29.CANHO C14.TF C29.1/4 D10.SL_1 D25.SM_SW
A15.ET_L A30.SC_L B11.KO_R B26.TXD1 E15.EGR1 E30.B_SE1 C15.WL C30.DC D11.SL_F D26.SS_R
A1 A2 A3 A4 A5 A6 A7 A8 A9 B1 B2 B3 B4 B5 B6 B7 E1 E2 E3 E4 E5 E6 E7 E8 E9 C1 C2 C3 C4 C5 C6 C7 C8 C9 D1 D2 D3 D4 D5 D6 D7
A10 A11 A12 A13 A14 A15 A16 A17 B8 B9 B10 B11 B12 B13 E10 E11 E12 E13 E14 E15 E16 E17 C10 C11 C12 C13 C14 C15 C16 C17 D8 D9 D10 D11 D12 D13
A18 A19 A20 A21 A22 A23 A24 A25 B14 B15 B16 B17 B18 B19 E18 E19 E20 E21 E22 E23 E24 E25 C18 C19 C20 C21 C22 C23 C24 C25 D14 D15 D16 D17 D18 D19
A26 A27 A28 A29 A30 A31 A32 A33 A34 B20 B21 B22 B23 B24 B25 B26 E26 E27 E28 E29 E30 E31 E32 E33 E34 C26 C27 C28 C29 C30 C31 C32 C33 C34 D20 D21 D22 D23 D24 D25 D26
Connector details
85V2U62009
95ZV-2 EU FS 62-39
Machine control unit (MCU) connection diagram (S/N 9001~9350)
(L) (005-B)
ACC’ TO PARKING S/W
(005)
F5 L2 (L) (005-A)
30A
G (010)
F10
E L x4 (005-A~005-D)
ACC’
E05 E06 E17 E03 E04 E11 E12
(SbP) (145)
WL (707) B18 NR NEUTRAL RELAY
E24
LgW (101)
B12 X MCU FAILURE RELAY
LR (126) BrB (258)
D11 B11 KO LIFT KICKOUT RELAY
LBr (128) L (273)
D04 LOWER KICKOUT RELAY
F N R B10 BS
SHIFT LEVER
OPT
MCU
E
1 YGy (242) SECONDARY STEERING

23A A03 ES
LW (120) MOTOR RELAY COIL
D12
LO (123) (146) LR
D05 B13 F SOLENOID VALVE
LG (122) (147) LB
D03 B01 H SOLENOID VALVE
LY (121)
D10 (148) LBR
B04 R SOLENOID VALVE
YO (232) (141) LY
S/S SHIFT S/W F D19 A18 1ST SPEED SOLENOID VALVE
YW (233)
S/S SHIFT S/W R D26
(LY )
(142) LG
A02 2nd SPEED SOLENOID VALVE
S/S SHIFT YV (231)
D18
SELECTION S/W F5 (LG) 4S (132)(LG)
LB (230)
ARMREST S/W D24 (143) LO
A05 3rd SPEED SOLENOID VALVE
LG (122)
SHIFT UP S/W D06 (LO)
LY (121)
SHIFT DOWN S/W D07 (144) LW
A08 4S 4th INDICATOR RELAY
(YL) (124)
DOWNSHIFT S/W D14 (LW)
YSb (125) LP (149)

SHIFT HOLD S/W D17 A17 D SOLENOID VALVE
WR (170)
LP (168) B14 BRAKE SOLENOID VALVE
DECLUTCH SET-UP D15
(GW)(210) LLg (140)

SLIP CONTROL S/W D23 A07 LU SOLENOID VALVE
LgL (261) RIDE CONTROL
LIFT KICKOUT BrG (255) A04
SET-UP D22 SOLENOID VALVE
LOWER KICKOUT BW (271) GB (267) EFFICIENT LOADING SYSTEM
SET-UP C13 A01
SELECTION SOLENOID VALVE
LOWER KICKOUT S/W C31
GB (278)
B03 PRESS. INC. SOLENOID VALVE
(GB) (277)
PRESS. INC. S/W C24
LgL (225)
B06 REVERSAL FAN SOLENOID VALVE
Lg (222) (154)
REVERSAL FAN S/W C25 (150)
LgR LgR
LgY (223) B05 T/M CONTROL SOLENOID VALVE
AUTO FAN REVERSAL S/W C34 1A
(236)
BR
(Y) (105) E01 S/S SOLENOID VALVE R
RECALL S/W C30
(237)
1A
(R) (106) BL
RESET S/W C12 B07 S/S SOLENOID VALVE L
LLg (165) 1A
D21 (226) (221)
LgB LgB FAN SPEED CONTROL
GO (164) E02
D01 1A SOLENOID VALVE
GyW (200) (013)
C23
GL (265) (Lg)
C22 F13
(GyW ) (260) (LgR) (130)
E F13 C33 A21 AUTO SHIFT INDICATOR LAMP
(GR ) (135)
(013) EP Gy (750) A29 NEUTRAL INDICATOR LAMP
(Lg) E/G OIL PRESS S/W C16 (GyB ) (103)
A14 CENTRAL WARNING LAMP
BrY (181) (LbY) (173)
YO (176) HYD. OIL LEVEL S/W C11 A28 BRAKE OIL PRESS. WARNING LAMP
(GY) (749)
(LgY) (167) A19 E/G OIL PRESS. WARNING LAMP
LgL (182) (GyG) (753)
AIR CLEANER C06 A15 E/G COOLANT TEMP. WARNING LAMP
DECLUTCH S/W DECLUTCH CLOGGING S/W (GyL) (190)
A16 T/M OIL TEMP. WARNING LAMP
(LgW) (192)
(163) E A27 AIR CLEANER WARNING LAMP
ON (SbW) (O ) (241)
A12 STEERING OIL PRESS.
OFF WARNING LAMP
PARKING SOL (162)
LgG ON (005-b)
(L)
F5
OFF
PARKING S/W
FUEL EFFICIENT MODE S/W
EFFICIENT LOADING SYSTEM S/W
RIDE CONTROL S/W

X (LgW) (102)
MCU FAILURE
(LgSb) (112) BZ
WARNING
BUZZER
K95V2E62001
95ZV-2 EU FS 62-40
(SbO) (193)
A26 T/M OIL FILTER WARNING LAMP
SbO (183) (Sb ) (194)
T/M OIL FILTER S/W C14 A13 RADIATOR WATER LEVEL WARNING LAMP
(GY) (169)
A20 AUTO BRAKE INDICATOR LAMP
Sb (184)
RADIATOR WATER LEVEL S/W C15 (OSb) (211) TRACTION CONTROL
A30
YR (405) INDICATOR LAMP (OPT)
FUEL LEVEL F C17 (RL) (235)
A32 REVERSAL FAN
YB (406)
FUEL LEVEL 3/4 C28 INDICATOR LAMP (OPT)
(LgB) (224)
FUEL LEVEL 1/2
YL (407)
C20
A24 S/S INDICATOR LAMP (OPT)
YBr (408) (YR ) (410)
FUEL LEVEL 1/4 C29 A11 FUEL LEVEL F
YG (409) (YB) (411)
FUEL LEVEL 1/8 C21 A33 FUEL LEVEL 3/4
(YL) (412)
A22 FUEL LEVEL 1/2
(YBr) (413)
E A31 FUEL LEVEL 1/4
V (100) (YG) (414)
E09(+5V) A23 FUEL LEVEL E
S/S POTENTIOMETER (OPT) LgBr (104)
G (234) B09 BZ BUZZER
E19
BOOM ANGLE SENSOR
BrR (251) (YB ) (401)
C26 E34 E/G COOLANT TEMP. GAUGE
DECLUTCH SENSOR
(LgR) (166) (BrW) (402)
E27 E21 T/M OIL TEMP. GAUGE
BRAKE OIL PRESS. SENSOR 1
SbY (171) E30 (400)
(WL )
BRAKE OIL PRESS. SENSOR 2 B24 METER OUTPUT (TACHOMETER)
SbY (172) E22
T/M PRESS. SENSOR

YGy (151) C19
EFFICIENT LOADING SYSTEM
PRESS. SENSOR GyB (266)
C01
SECONDARY STEERING
PRESS. SENSOR (OPT) SbR (240)
C27
GyG (754) YSb (403)
E/G COOLANT TEMP. SENSOR B25 A06 HOUR METER DRIVE
GyL (180)
T/M OIL TEMP. SENSOR E31 SbR (208)
B08 AI E/G IDLE SELECTION
(G) (415)
AIR TEMP. PROBE E32 SbP (202)
A09 TC E/G TORQUE SELECTION
GyO (220)
HYD. OIL TEMP. SENSOR E23 SbW (203)
B15 ECM(41) E/G DROOP SELECTION 1
BY (114) SbLg (204)
E07 A34 ECM(23) E/G DROOP SELECTION 2
Y (160) (GW) (212) TRACTION CONTROL
MACHINE SPEED SENSOR E16 A25 SC
SELECTION (OPT)
W (161)
E/G SPEED SENSOR ECM(11) E15 E
(RL)(330)
Y (159) A10 TO BACK-UP LAMP
E08 (RG)(331)
B19 TO BRAKE LAMP
(100)
(E09) V
+5V
YB (115)
(OUT_FEW)B23 FEW
YG (116)
(OUT_RES)E33 RESET
YL (117)
(RXD0)E25 RXD MCU PROGRAM REWRITE
YO (118)
(TXD0)B26 TXD
YBr (119)
E (OUT_MD2)B17 MD2
P (107) GND
DESTINATION SWITCH 1 C02
PL (108) E
DESTINATION SWITCH 2 C03
PG (109) GL (810)
A/M SELECTION D02 (RIN1)B16
PB (110) GR (811) RS232C
ODOMETER SELECTION (DOUT1)B22
D16
PW (111)
TIRE DIA. SELECTION D25 S2H
(CANH0)E29
SPEED SENSOR SELECTION D08 S2L
(CANL0)E20 CAN
S2S
METER SELECTION D09
E MAIN MCU E
K95V2U62002
Note
Refer to Section 92 for the detailed electrical connection
diagram for the MCU including modification information.
95ZV-2 EU FS 62-41
Machine control unit (MCU) connection diagram (S/N 9351~)
TO PARKING S/W
NEUTRAL RELAY
MCU FAILURE RELAY
LIFT KICKOUT RELAY
LOWER KICKOUT RELAY
LEVER
SHIFT
E
SECONDARY STEERING
MOTOR RELAY COIL
F SOLENOID VALVE
H SOLENOID VALVE
R SOLENOID VALVE
1ST SPEED SOLENOID VALVE
S/S SHIFT S/W F
1ST SPEED PL
S/S SHIFT S/W R
2ND SPEED SOLENOID VALVE
S/S SHIFT 2ND SPEED PL
SELECTION S/W
ARMREST S/W 3RD SPEED SOLENOID VALVE
3RD SPEED PL
SHIFT UP S/W
SHIFT DOWN S/W 4TH SPEED SOLENOID VALVE
4TH SPEED PL
DOWNSHIFT S/W
D SOLENOID VALVE
SHIFT HOLD S/W BRAKE SOLENOID VALVE
DECLUTCH SET-UP
LU SOLENOID VALVE
SLIP CONTROL S/W RIDE CONTROL
SOLENOID VALVE
LIFT KICKOUT
SET-UP EFFICIENT LOADING SYSTEM
LOWER KICKOUT SELECTION SOLENOID VALVE
SET-UP PRESS. INC. SOLENOID VALVE
PRESS. INC. S/W REVERSAL FAN SOLENOID VALVE
REVERSAL FAN S/W

AUTO FAN REVERSAL S/W T/M CONTROL SOLENOID VALVE
NEW DECLUTCH SELECTION

S/S SOLENOID VALVE R
NEW ECO MODE SELECTION
S/S SOLENOID VALVE L
FAN SPEED CONTROL

SOLENOID VALVE
E
E/G OIL PRESS.
S/W
HYD. OIL LEVEL
TO S/W SLIP CONTROL INDICATOR LAMP
INSTRUMENT AIR CLEANER
PANEL CLOGGING S/W BRAKE RELAY
DECLUTCH S/W
TO AUTO SHIFT INDICATOR LAMP
INSTRUMENT NEUTRAL INDICATOR LAMP
PANEL T/M OIL FILTER S/W CENTRAL WARNING LAMP
PARKING BRAKE OIL PRESS. WARNING LAMP
SOL RADIATOR WATER
LEVEL S/W E/G OIL PRESS. WARNING LAMP
FUEL LEVEL F E/G COOLANT TEMP. WARNING LAMP
PARKING S/W T/M OIL TEMP. WARNING LAMP
FUEL LEVEL 3/4
AIR CLEANER WARNING LAMP
FUEL LEVEL 1/2
STEERING OIL PRESS.WARNING LAMP
FUEL EFFICIENT MODE S/W FUEL LEVEL 1/4 T/M OIL FILTER WARNING LAMP
FUEL LEVEL 1/8 E/G COOLANT TEMP. GAUGE
AUTO BRAKE INDICATOR LAMP
EFFICIENT LOADING SYSTEM S/W E
RIDE CONTROL S/W

MCU TO
FAILURE INSTRUMENT
PANEL
WARNING
BUZZER : shows OPT.
E
Note
K95V2E62003
95ZV-2 EU FS 62-42
K95V2E62004
Note
95ZV-2 EU FS 62-43
Machine control unit (MCU) function

Forward/reverse (F/R) shifting and speed change
To solenoid valve
for each clutch
F/R clutch solenoid valve

N
F R Solenoid valve
+24 V L for clutch
Shift lever
H Surge
suppression
R diode Modulation
mechanism
(incorporated
in solenoid Clutch Clutch
A valve) valve piston
1
23 1
Speed indicator
lamp Torque converter During energized: Clutch is engaged.
(instrument panel) pump During de-engaged: Clutch is disen-
Downshift +24 V 2
button
Machine with lockup clutch: Lockup clutch piston
MCU 3 To solenoid valve
for each clutch
Machine speed
sensor
LU
E/G
speed ECM Solenoid
sensor valve
Solenoid valve
for clutch
+24 V
Modulation
mechanism
Clutch Clutch
AUTO indicator lamp valve piston
ON when shift lever in A position
Torque converter During energized: Clutch is engaged.

pump During de-engaged: Clutch is disengaged.
95V2U62012
Each clutch has one solenoid valve for transmission Operation error preventive function
control. When electric current flows through the sole- (Simultaneous input of two or more commands)
noid valve, the clutch oil is fed into the clutch piston
chamber through the modulation mechanism and the If both the forward and reverse commands are input at
clutch valve. When the piston operates, the clutch is the same time due to a problem, the transmission is set
engaged. When the current stops flowing through the to the neutral position. In addition, if two or more speed
solenoid valve, the oil is drained from the clutch piston commands are input at the same time, the speed range
chamber through the clutch valve, and the clutch is dis- previously engaged is selected.
engaged.
When the starter switch is at OFF position, if both the
Input detection forward and reverse commands are input at the same
time due to a problem, the engine does not start even if
When the shift lever is set to the F (forward) position, the starter switch is placed in the start position. This is
electric current for input detection signal is sent from the because the neutral relay does not work.
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, the MCU judges the set speed
position of the shift lever in the same way as described
above.
95ZV-2 EU FS 62-44
Shift lever
2 1
Forward F
KNIGHT BEAM CO,LTD

JAPAN
>PAMXD6-G50<
Neutral N
BM51-111
Reverse R
1st speed
2nd speed
3rd speed
Auto
Grounding for speed

change side (B)
3
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 Operator controlled shifting from 2  1  2 in either "2"

2. Grip or "A" is done by momentarily depressing the downshift
3. Connector button on the boom lever.
The shift lever has two direction and four speed posi- Shift lever neutral (N) position
tions; forward and reverse (F and R) and "1", "2", and
"3" speed positions are respectively used for 1st, 2nd, The shift lever has no neutral (N) contact.
and 3rd fixed speeds. The "A" speed position is used for
the variable speed where the 2nd through 4th speed Therefore, if neither the forward nor the reverse (F and
clutches are automatically changed in both the forward R) signal is input, the MCU will judge that the shift lever
and reverse operation. The lockup clutch (OPT) is auto- is at the neutral (N) position.
matically engaged or disengaged in the forward opera-
tion only.
95ZV-2 EU FS 62-45
Operation of solenoid valve Automatic shift
Clutch solenoid valve

Shift up
A 10.8 N-m (1.1 kgf-m) (8 lb-ft) Shift down
Speed
F4
3
+ side
K W E 6 K- 21/ 2
- N
SKM6
G24D
13.0 11.0 0 10.0 12.0 20.5 22.5

– side
Reverse Speed km/h Forward
View from A
Automatic shift map (Normal mode) 95V2E62005
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 3
Coil resistance value Approx. 27 
2
When the input signal is transmitted, the output circuit of
the corresponding solenoid valve is connected to the
13.0 11.0 0 8.5 10.5 18.0 20.0
grounding circuit. As a result, power is supplied to the
solenoid valve and the clutch is engaged. At the same Reverse Speed km/h Forward
time, the speed indicator lamp in the cab lights. Automatic shift map (Fuel efficient mode) 95V2E62006
Note that when the parking brake or the auto brake is When the shift lever is set to A position, the AUTO indi-
actuated or the declutch brake is applied, the forward or cator lamp on the instrument panel will light and one of
reverse (F or R) clutch solenoid valve is turned off and the solenoid valves will be automatically energized
the transmission is set to neutral. according to the machine speed and engine speed. In
addition, the speed indicator lamp will light. The input
signal for automatic shift is controlled by the pulse gen-
erated by the speed sensor and ECM.
95ZV-2 EU FS 62-46
Automatic shift (with lock-up solenoid)
Shift up
Speed
Shift down
F4L
F4
F3L
3
13.0 11.0 10.0 12.0 15.0 17.0 24.5 26.5 28.0 30.0

Automatic shift map (Normal mode) 95V2E62007
Shift up
Speed
Shift down
F4L
F4
F3L
3
13.0 11.0 8.5 10.5 13.0 15.0 22.5 24.5 26.0 28.0
Automatic shift map (Fuel efficient mode) 95V2E62008
95ZV-2 EU FS 62-47
Machine speed sensor
Clearance:
0.4~1.6 mm (0.016~0.063 in)
70V2U62008
Internal resistance * 2.3±0.2 k (25ºC) (77ºF)
* 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.
95ZV-2 EU FS 62-48
Switching from automatic to manual Downshift button operation
Downshift button
LgL SbY GR SbLg SbL GR WL GyG

A502 A507 A701 A608 H718 T103 A806 H136
LY Gy Gy LP LgB WO SbW GL SbP RG

A/M A708 A506 A807 A808 A604 H117 H703 T104 F701 H139
SELECTION H201
RL 0 GyB GyG GyL LP SbR LgBr L BrB LgW LR
B H128 A609 A809 A505 A501 H207 F102 G602 T001 T901 F901 H205
T801
GB LG YGy LgSb LO YSb LLg LW SbP LBr LgL BL
PG H121 A709 E804 H122 A710 A901 H110 A711 F202 H206 E502 E001
H202 H203 H204
S902
1 9 7
1 1
(BLACK)
S4 S5 S6
85V2E62025
The machine has automatic shift cancellation function

for troubleshooting. Connect the coupler (OPT) to S4 80ZVE62017
coupler to cancel the automatic shift function. The mode

will be switched from automatic to manual. Position "A" The downshift button is attached to the boom control
of the shift lever, therefore, is fixed to the 4th speed. 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
Max. voltage DC 24 V
Allowable value
Current 10 mA
The downshift button is of the momentary type. It is

spring loaded to the "OFF" position.
95ZV-2 EU FS 62-49
Modulation at clutch switching
MCU
N Modulator valve (1)

F R Output
B05
Clutch selection
current
+ 24 V control
input signal
Shift lever
1 A
2 3
ON during modulation
Modulator valve (2)
A17
+ 24 V
Pressure sensor
Machine speed sensor
E/G speed sensor
95V2U62016
Modulator valve (2)

Modulator valve (1) Modulator valve (2)
ø 3.0
ø 0.9
To T/M
clutch
To T/C
Modulator valve (1) From pump

95V2U62017 Modulator valve unit hyd. circuit 95V2E62012
The rise time of clutch oil pressure is controlled by mod-

ulator valve (1) and modulator valve (2) to shorten the
IMPORTANT
time lag and reduce shock that occurs when shifting Note orifice placement below MV2.
between forward and reverse, and between gears. Do not mix or lose orifices or transmission failure will
occur!
95ZV-2 EU FS 62-50
Modulator valve (1) [MV1] - Initial charging (t1)
Clutch oil pressure during clutch application is con- The current flow through the coil of MV1 immediately
trolled according to the current passing through the coil after clutch selection is maintained as high as it was
of MV1. before clutch selection (400 mA).
This allows a lot of oil to flow rapidly into the empty
The pressure rises and falls along with the current. clutch piston chamber, reducing the time lag.
- Charging (t2)
Operation of modulator valve (1), (2)
On completion of the initial charging, the current
and clutch pressure change.
through the coil of MV1 is sharply reduced (170 mA).
This reduced current is maintained until the end of
the charging to prevent a sudden pressure rise and
Clutch selection shift shock.
- Completion of the charging

ON
Low clutch OFF The pressure sensor in the line to the clutch piston
solenoid valve chamber sends electrical signal to the MCU.
1st clutch
ON When the charging is completed, due to no pressure
solenoid valve drop in the line, the MCU determines it by the signal
Completion of charging sent from the sensor.
Approx. 400 mA
Modulator valve (1)
Then the MCU sends signal to rise the current
Current flow through the MV1 coil gradually.
(mA) Approx.
170 mA - Pressure rise (t3)
0
ON The clutch oil pressure rises gradually in proportion
Modulator valve (2)
OFF to the current rise.
Note
- If the MV1 coil is damaged or disconnected, the
Main pressure
Pressure P2 P3 clutch oil pressure rises only 0.2~0.5 MPa (28~71
MPa(psi) P1 psi) and the pressure value is not enough to engage
0 the clutch.
- MCU provides the protection program so as to rise
Low clutch the control current again at the time of 0.5 seconds
pressure Pressure after decreasing the MV1 control current when the
MPa(psi) pressure sensor is damaged.
0
t1 t2 t3 t4
95V2E62020
95ZV-2 EU FS 62-51
Modulator valve (2) [MV2]
This valve assists MV1 in controlling (lowering) the

clutch oil pressure.
Unlike MV1, it performs an ON and OFF operation.
Controlling the clutch oil pressure
Modulator valve (2) is energized simultaneously when

the current in MV1 changes from high to low current
flow. It is de-energized some time after the current in
MV1 returns to a higher level and the clutch oil pressure
reaches the specified value.
Note
Modulator valve (2)
If MV2 is damaged or disconnected, the machine will
have severe shift shock during clutch engagement. In
this case, the lowest clutch pressure will be only about
0.7~1.0 MPa (100~142 psi) during charging. The high-
est clutch oil pressure reaches the specified value.
95ZV-2 EU FS 62-52
Adjustable declutch preset switch

200
Clutch OFF
Clutch ON
0 310 510 (kPa)
Declutch sensor
85V2E62028
Declutch selector
Declutch sensor Transmission clutch
switch
More than 510 (kPa) Disengage
ON
Less than 310 (kPa) Engage
Adjustable declutch preset switch is used to change the

angle of the left brake pedal (Declutch pedal) to disen-
gage the transmission clutch.
Pressure sensor for stop lamp With the engine running, step on the left brake pedal
and declutch
Left brake valve (Declutch pedal) up to the desired angle and press the
switch to set the brake pedal (Declutch pedal) angle.
95V2E52014
Switch
70V2U62015
95ZV-2 EU FS 62-53
Back-up alarm
Back-up lights
N
F R
Back-up alarm
Shift lever
+24 V
A10
MCU
1 A
2 3
85V2E62027
When the shift lever is set to the reverse (R) position,

the back-up lamp will light, and the buzzer will sound.
95ZV-2 EU FS 62-54
Parking brake
5A
+ 24V
F13
P Monitor lamp
Parking brake
Parking (ON)
Running (OFF)
Parking
switch
L
ON
OFF H
D01 P
MCU
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 When the power of the solenoid valve is turned on, oil
oil will be fed to the piston chamber of the parking will be fed into the piston chamber, the spring is com-
brake. The piston presses the brake disc with the spring pressed, and the parking brake is released.
force to actuate the parking brake. If the transmission
shift lever is set to the forward or reverse (F or R) posi-
tion, the buzzer will sound and the clutch will not be
engaged.
Parking brake operation
Parking brake solenoid

Parking switch Monitor lamp Buzzer
valve
"Parking" position Sounds when shift lever is
Parking * P No electric power supply
(pulled up) set to F or R
"Running" position
Running Off No buzzer Electric power supply
(pushed in)
*When the parking switch is set to "parking", the forward or reverse clutch is disengaged and set to neutral.
95ZV-2 EU FS 62-55
Solenoid valve for parking brake
Spring chamber (brake actuator)

B Solenoid Knob
Reducing P
valve
Manual release
T (counterclockwise
Spool rotation)
Seat Seat
face A face B Tank 115V2E62020
Rated current 0.92 A
B Resistance 26.2 
P T
95ZV52045
Auto brake
solenoid valve
Valve
assembly
Parking brake
solenoid valve
Hydraulic
tank
Valve location 95V2E62025

95ZV-2 EU FS 62-56
Auto brake
Input side Output side

MCU
Solenoid valve for auto brake
Shift lever position

+24V
selector signal
F R B14
1 23A
Shift lever
Auto brake monitor lamp, buzzer
+24V
A20
Machine
speed
Machine speed Solenoid valve for forward/reverse clutch

B13 L
sensor
B01 H
B04 R
Installation position of solenoid valve for auto brake.

Refer to the description on the solenoid valve for parking brake.
95V2E62015
Shown in the "released" position When the traveling direction is switched over between
To rear
forward and reverse at a machine speed of 14 km/h
To front
service brake service brake (8.75 mph) or more, the auto brake is applied to protect
the transmission clutches.
61 51
When the machine speed is too high, the auto brake is
applied also to prevent troubles caused by excess
23 speed in the engine and the transmission.
PI AR AF When the auto brake signal enters from the MCU to

solenoid valve (36) for auto brake and solenoid valve
(36) is energized and magnetized, the pilot oil from the
PR T PF
reducing valve enters the pilot port of brake valve (23),
and actuates the pilot piston and the spool of the brake
valve.
1.2
1.0
36 When the spool is switched over, the high-pressure oil
From unloader B
valve (Pump) coming from the pump through the unloader valve
enters the front and rear brake piston chambers to apply
the service brake.
P T
At this time, the neutral indicator lamp and the auto
MCU signal
brake indicator lamp on the instrument panel light, and
From reducing
valve (Pump) buzzer sounds. While the auto brake is applied, the for-
ward/reverse clutches of the transmission are disen-
95V2E62016 gaged and kept in the neutral status until the actual
machine speed decreases and reaches the set value.
95ZV-2 EU FS 62-57
When the traveling direction is switched over When machine speed is excessive
between forward and reverse at a machine speed of
14 km/h (8.75 mph) or more Operation chart
(Example: Machine speed excessive in forward direction)
Operation chart Machine speed T/M in neutral

(Example: Shifting from forward to reverse)
ON ON
Machine Machine F solenoid valve
speed: speed:
OFF
Shifting between 3 km/h 2 km/h
forward and reverse (1.9 mph) (1.25 mph)
ON
Speed clutch
Machine speed
solenoid valve
Brake solenoid ON
valve
F solenoid valve ON
OFF OFF
Monitor lamp
OFF Buzzer
Neutral
T/M in neutral ON indicator lamp Service brake operating 115ZV62067
R solenoid valve OFF
ON When the machine speed reaches or exceeds the set

Neutral value, the service brake is applied as in the above case.
indicator lamp OFF OFF When the machine speed drops below the specified
Brake solenoid ON value, the service brake is released.
valve
OFF OFF During service brake application, the transmission is
Monitor lamp
Buzzer placed in neutral.
Service brake operating
95V2E62017
Speed range Set value
1st About 20 km/hr 12.5 mph
2nd About 22 km/hr 13.8 mph
When the traveling direction is switched over between
3rd About 36 km/hr 22.5 mph
forward and reverse at a machine speed 14 km/h (8.75
4th About 40 km/hr 25.0 mph
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 3 km/h (1.9 mph),
the clutch for the opposite direction is engaged. (How-
ever, the brake remains applied until the machine speed
becomes approximately 2 km/h (1.25 mph).
95ZV-2 EU FS 62-58
Auto brake solenoid valve
Brake valve (shuttle valve)
B
Spool Solenoid
P
Reducing
valve
T
Tank
Seat face A Seat face B
P T
95ZV52052
Auto brake
solenoid valve
Valve
assembly
Parking brake
solenoid valve
Hydraulic
tank
Valve location 95V2E62025
Rated current 0.92 A
Resistance 26.2 
95ZV-2 EU FS 62-59
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
If a warning is given as a result of self-diagnosis of

the MCU Body blue
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
1 2
L
MCU replacement
LgW
B
If the monitor lamp lights up under the cause above, it is 4 3
an indication that the MCU's program has malfunctioned
and the MCU assembly must be replaced.
Electrical Chassis side
circuit coupler
When installing a new MCU on the machine, all specifi-
cations must be registered into the MCU through the
85V2E62030
MODM.
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)

95ZV-2 EU FS 62-60
Secondary steering function (OPT)
Speed sensor
Pilot lamp To steering valve
F13
MCU Pressure
sensor
Check valve Check valve

G1/2
G1/2
+24 V G1/2
Secondary
G1/2 G3/8
steering motor
and pump
F5
11.7MPa
(119 kgf/cm2)
(1696 psi)
10
M cm3/rev
G1/2
Check valve
Secondary G1/2
steering relay
+24 V
Secondary
steering motor
and pump
11.7MPa
(119 kgf/cm2)
(1696 psi)
10
M cm3/rev
80.0 71.3
M cm3/rev cm3/rev
Magnetic switch
(on motor and pump)
Steering pump
Hydraulic line
Electrical circuit
95V2E42036
In normal operation, the oil from the steering pump As a result, the secondary steering motor and pump are
flows into the steering valve through the check valve. driven. Then it is ready to steer the machine.
And the signal of the pressure sensor is always sent to
the MCU. Pressure sensor preset value
With some problems, as the steering hydraulic pressure Steering hydraulic pressure
goes down while the engine is running, the pressure ON: at 0.3 MPa (3 kgf/cm2) (44 psi) or lower
sensor signal becomes less than the preset value at the OFF: at 0.4 MPa (4 kgf/cm2) (58 psi) or higher
MCU. In this condition, if the machine speed is more
than 2 km/h, the MCU sends a signal to the magnetic
switch.
95ZV-2 EU FS 62-61
Machine speed signal

The signal from MCU
to magnetic switch
ON
Machine speed
OFF
(km/h)
1 2
85V2E42051
95ZV-2 EU FS 62-62
Monitoring system
If a problem of a unit is detected while the engine is run- When the starter switch is set to ON, all of the monitor
ning, a monitor lamp lights to inform the operator. lamps are lit for 3 seconds and buzzer sounds to check
whether the monitor lamps are normal (not burn out).
For some problems, the buzzer sounds also, and the
central alarm lamp flashes also.
Items to be monitored and operation condition
Monitor lamp
No. Item to be monitored Operation condition Buzzer Lamp test Remarks
Lighting Symbol
color
Machine control unit

1 Defective machine control unit (MCU) —
(MCU)
(red)
Unloader valve accumulator port oil pressure

2 Brake oil pressure is lower than 3.9±0.5 MPa (40±3 kgf/cm2)
(red) (569±71 psi)
While engine running, 0.1 MPa (1.1 kgf/cm2)

3 Engine oil pressure
(16 psi) or less for more than 2 seconds
(red)
101±2ºC or more (214±4ºF or more) for more

4 Engine coolant temperature —
than 2 seconds
(red)
Torque converter oil 120±5ºC or more (248±9ºF or more) for more

5 —
(transmission) temperature than 2 seconds
(red)
Filter resistance: 635±58 mmAq or more (25

6 Clogged air cleaner —
inches H2O) for more than 2 seconds
(red)
Clogged transmission oil Pressure difference at 50±2ºC (122±4ºF) or

7 —
filter more is 0.3 MPa (45±4 psi) or more
(red)
8 Charging condition Defective charge system —

(red)
9 Central alarm For items 1~7, 10 — Flashing type

(red)
When operates, steering pressure is less

Steering oil pressure
10 than 0.4 MPa (4 kgf/cm2) (57 psi).
(option)
(red) Machine speed more than 2 km/h
When engine cooling water level drops

11 Engine cooling water level —
(before start up only)
(red)
(S/N ~9350) F/R: No buzzer
12 Auto brake operation When auto-brake works
sounds
(red)
(S/N 9351~)
95ZV-2 EU FS 62-63
Monitor lamp
No. Item to be monitored Operation condition Buzzer Lamp test Remarks
Lighting Symbol
color
(red)
Hydraulic oil level is low when the engine is
13 Hydraulic oil level
stopped
(red)
14 Engine protection lamp —

(orange)
Any fault in engine detected by ECM

15 Engine warning lamp —
(Engine controller) (2 sec.)
(yellow)
16 Engine stop lamp —

(red)
95ZV-2 EU FS 62-64
Operation monitor lamps
Monitor lamp
No. Monitor item Lighting condition Remarks
Lighting Symbol
color
1 Parking Red When parking brake switch is set to ON
2 Declutch Green When declutch switch is set to ON
When working light (rear) switch is set

3 Working light Green
to ON
When starter switch is in the PREHEAT

4 Preheat Orange
position
Turn signal indicator

5 Green When turn signal lever (left) is actuated
(left)
Turn signal indicator When turn signal lever (right) is

6 Green
(right) actuated
7 High beam Blue When head lamp is set to high beam
When transmission shift lever is set to

8 Auto shift Green
automatic position

9 Neutral Green
neutral position

10 Transmission status Yellow
corresponding gear (1~4)
11 F/R switch indicator Green When F/R selection switch is ON. (OPT)
12 Reversal fan Green When the reversal fan switch is ON. (OPT)
Caution on storage of individual instrument panel

Gauge pointer Pointer axis
IMPORTANT Axis hole

Main body
frame
When storing the instrument panel individually, make Magnet
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. Damper
Meter oil 70ZV62087
95ZV-2 EU FS 62-65
Instrument Panel and Switch
Instrument panel (S/N 9001~9350)
21 20 39 17 9 19 5 18 2 23
1 4 10
11(37)
12
30 26
28 27
13
34
14
35 15
29
16
STOP
40
36
6 33 32 31 24 25(37) 22 7 8 38 3
95V2U62018
1. Tachometer 21. Neutral indicator lamp

2. Engine coolant temperature gauge 22. Transmission status monitor
3. Transmission oil temperature gauge 23. Hour meter
4. Fuel gauge 24. Reversal fan pilot lamp (option)
5. Parking brake indicator lamp 25. Secondary steering warning lamp (option)
6. F/R switch indicator lamp (green) 26. Working light switch (front)
7. Working light indicator lamp (rear) 27. Working light switch (rear)
8. Preheat indicator lamp 28. Fuel efficient mode switch
9. Central warning lamp 29. Selection switch for shift lever or F/R switch
10. Machine control unit (MCU) warning lamp 30. Four-way flasher switch (option)
11. Brake oil circuit warning lamp 31. Engine protection lamp
12. Engine oil pressure warning lamp 32. Engine warning lamp
13. Engine coolant temperature warning lamp 33. Engine stop lamp
14. Transmission oil temperature warning lamp 34. Efficient loading system switch
15. Air cleaner clogging warning lamp 35. Declutch selector switch (S/N 9001~9150)
16. Charge warning lamp 36. Coolant level warning lamp
17. Turn signal indicator lamp (left) 37. Hydraulic oil level warning lamp
18. Turn signal indicator lamp (right) 38. Declutch selector lamp
19. High beam indicator lamp 39. Auto brake indicator lamp
20. Auto shift indicator lamp 40. Transmission oil filter warning lamp
95ZV-2 EU FS 62-66
Instrument panel (S/N 9351~)
22 21 20 17 19 9 5 38 7 18 2
1
12 11(36) 10
4
30 26
28 27
34
29
25(36) 6 24 23 8 37 3 13 14 15 16 35 40 33 32 31
97V2J62003
1. Tachometer 21. Neutral indicator lamp

2. Engine coolant temperature gauge 22. Transmission status monitor
3. Transmission oil temperature gauge 23. Hour meter
4. Fuel gauge 24. Reversal fan pilot lamp (option)
5. Parking brake indicator lamp 25. Secondary steering warning lamp (option)
6. F/R switch indicator lamp (green) 26. Working light switch (front)
7. Working light indicator lamp (rear) 27. Working light switch (rear)
8. Preheat indicator lamp 28. Fuel efficient mode switch
9. Central warning lamp 29. Selection switch for shift lever or F/R switch
10. Machine control unit (MCU) warning lamp 30. Four-way flasher switch (option)
11. Brake oil circuit warning lamp 31. Engine protection lamp
12. Engine oil pressure warning lamp 32. Engine warning lamp
13. Engine coolant temperature warning lamp 33. Engine stop lamp
14. Transmission oil temperature warning lamp 34. Efficient loading system switch
15. Air cleaner clogging warning lamp 35. —
16. Charge warning lamp 36. Coolant level warning lamp
17. Turn signal indicator lamp (left) 37. Hydraulic oil level warning lamp
18. Turn signal indicator lamp (right) 38. Declutch selector lamp
19. High beam indicator lamp 39. Auto brake indicator lamp
20. Auto shift indicator lamp 40. Transmission oil filter warning lamp
95ZV-2 EU FS 62-67
Instrument panel rear surface

(S/N 9001~9350)
CN4
CN1 CN3
1 4 L11 L13 29 48
L12
8P L20 12P 16P
L1 58 57
5 8 L14 L10 35 56
Hour L10 L10
L2 meter
L10 L15 S
L21
L3
L16 E V
L4 S
L17 L10
L5 E V
Engine water
temperature sensor L18
L6 L10 L10
L19
L7 S
CN2
L8 9 18 L22 L23 L24 L25 L26 L27
E V 20P
Transmission oil
L9 temperature sensor 19 28
Layout of connector pins (Instrument panel side)
CN1(8P) CN2(20P) CN3(12P/16P) CN4(2P)

A4 A5 A6 A7 A8
1 2 3 4 9 10 11 12 13 14 15 16 17 18 29 30 31 32 33 34 41 42 43 44 46 47 48 58
5 6 7 8 19 20 22 23 24 25 26 27 28 35 36 37 38 39 40 49 50 53 54 55 56 57
95ZV62124
Pin Lamp Pin Lamp Pin Lamp

Signal Signal Signal
No. No. No. No. No. No.
1 Engine water level alarm L9 21 — — 41 AUTO lamp L20
2 Charge lamp L7 22 — — 42 Auto brake L16
3 Air cleaner clogging alarm L6 23 Fuel level lamp (F) — 43 Converter (+) —
4 T/M oil temperature alarm L5 24 Fuel level lamp (3/4) — 44 Converter (–) —
5 Engine water temperature alarm L4 25 Fuel level lamp (1/2) — 45 — —
6 Engine oil pressure alarm L3 26 Fuel level lamp (1/4) — 46 Declutch lamp L17
7 Brake oil pressure alarm L2 27 Fuel level lamp (E) — 47 — L19
8 MCU failure alarm L1 28 GND (–) — 48 Work lamp L18
9 +24 V power supply — 29 +24 V power supply — 49 Central alarm lamp L14
10 Secondary steering (option) L22 30 — — 50 GND (–) —
11 Reversal fan (option) L23 31 — — 51 — —
12 Engine warning lamp L25 32 — — 52 — —
13 Engine protection lamp L24 33 — — 53 High-beam lamp L12
14 Engine stop lamp L26 34 Neutral L21 54 Turn signal (left) lamp L13
15 — L27 35 +24 V power supply — 55 Turn signal (right) lamp L11
16 E/G water temperature gauge — 36 1st speed indication — 56 — —
17 T/M oil temperature gauge — 37 2nd speed indication — 57 Hour meter (–) —
18 — — 38 3rd speed indication — 58 Hour meter (+) —
19 Instrument panel illumination L10 39 4th speed indication —
20 T/M oil filter clogging alarm L8 40 Parking brake lamp L15
95ZV-2 EU FS 62-68
(S/N 9351~)
CN1 12 1
24 13
E E
S S
V
V
18 1
CN2
36 19
E E
S S
V V
CN1(24P) CN2(36P)
12 11 10 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 80Z562010
Pin Lamp Pin Lamp Pin Lamp

CN1-Signal CN2-Signal CN2-Signal
No. No. No. No. No. No.
1 Secondary steering (option) 25 1 Reversal fan (option) 24 19 Fuel level lamp (3/4) 4
2 — — 2 — — 20 — —
3 — — 3 F/R switch (option) 6 21 T/C (T/M) oil temperature gauge 3
4 — — 4 — — 22 — —
5 — — 5 Preheat lamp 8 23 Engine water temperature alarm 35
6 4th speed indication 22 6 Declutch lamp 37 24 Charge lamp 16
7 3rd speed indication 22 7 Auto brake 38 25 Air cleaner clogging alarm 15
8 2nd speed indication 22 8 Central alarm lamp 9 26 T/C (T/M) oil temperature alarm 14
9 1st speed indication 22 9 Neutral indication 21 27 Engine water temperature alarm 13
10 GND (–) — 10 Turn signal (left) lamp 17 28 Engine oil pressure alarm 12
11 Backup battery — 11 AUTO lamp 20 29 — —
12 +24 V power supply — 12 T/M oil filter clogging alarm 40 30 Brake alarm 11
13 Tachometer 1 13 Instrument panel illumination — 31 — —
14 Parking brake lamp 5 14 High-beam lamp 19 32 — —
15 — — 15 Work lamp 7 33 E/G stop lamp 33
16 — — 16 Turn signal (right) lamp 18 34 E/G warning lamp 32
17 — — 17 — — 35 E/G protection lamp 31
18 — — 18 Controller failure alarm 10 36 — —
19 — —
20 Hour meter 23
21 Fuel level lamp (E) 4
22 Fuel level lamp (1/2) 4
23 Fuel level lamp (1/4) 4
24 Engine water temperature gauge 2
95ZV-2 EU FS 62-69
Gauge circuit
Sensors respectively detect the temperature and fuel
level, and then convert them into electric signals. The
signals are transmitted to the corresponding gauges
Controller
that indicate the transmitted values.
Note
If a gauge is removed from the panel, the resistance
Grounding S Power supply between the terminals will differ from the standard value
24V
shown in the table.
E V
15V (S/N ~9350)
13V (S/N 9351~)
Viewed from rear surface of instrument panel

K90ZV62016
(S/N ~9350)
Gauge Engine water temperature T/C, T/M oil temperature
110ºC(230ºF)
97ºC(206ºF) 100ºC(212ºF)
100ºC(212ºF) 120ºC(248ºF)
35ºC(95ºF) 103ºC(217ºF)
50ºC(122ºF)
125ºC(257ºF)
Indication
White Red White Red
Resistance between
120~125 75~80
S and E ()
Resistance between
120~125 85~90
S and V ()
Resistance between
170~190 130~150
E and V ()
(S/N 9351~)
Gauge Engine water temperature T/C, T/M oil temperature
67C° 125C°
(152.6°F) 56C°
102C° (257°F)
50C° (132.8°F)
(215.6°F)
(122°F)
Indication
White
White
Red Red
Resistance between
80~95 80~95
S and E ()
Resistance between
26~30 26~30
S and V ()
Resistance between
106~126 106~126
E and V ()
95ZV-2 EU FS 62-70
Temperature sensor
(For engine water temperature (S/N 9001~9150),
torque converter oil temperature and hydraulic oil
temperature)
115V2E62023
Temperature of 80 90 100 120

detection part (ºC) [176ºF] [194ºF] [212ºF] [248ºF]
Resistance (k) 6.2~6.9 4.7~5.2 3.6~3.9 2.1~2.4
95ZV-2 EU FS 62-71
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 transmit-
MCU
Level ted to the MCU, electrically processed, then only one
sensor lamp corresponding to the gauge level lights on the
C14 instrument panel.
C15
YR (405)
Indicator
FUEL LEVEL F
YB (406)
C17
lamps +24V Float switch switching and indicator lamp lighting status
FUEL LEVEL 3/4 C28
YL (407)
FUEL LEVEL 1/2 C20 Indicator lamp
YBr (408) Float switch
FUEL LEVEL 1/4 C29 ◎ : Flashing ● : Lit
FUEL LEVEL 1/8
YG (409) ○ : ON × : OFF
C21
A11
(YR ) (410)
(YB) (411)
FUEL LEVEL F – : Extinguished
E A33 FUEL LEVEL 3/4
A22
(YL) (412)
FUEL LEVEL 1/2 E 1/4 1/2 3/4 F E 1/4 1/2 3/4 F
(YBr) (413)
A31 FUEL LEVEL 1/4
A23
(YG) (414)
FUEL LEVEL E F or more × × × × × – – – – ●
Actual fuel level

From F to 3/4 × × × × ○ – – – ● –
From 3/4 to 1/2 × × × ○ ○ – – ● – –
From 1/2 to 1/4 × × ○ ○ ○ – ● – – –
A
From 1/4 to E × ○ ○ ○ ○ ● – – – –
E or less ○ ○ ○ ○ ○ ◎ – – – –
Any other pattern – – – – –
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
1L
less.
2L
Float switch
3L
F
4L
ON
5L
3/4
L
ON
1/2
ON
1/4
ON
1/8
ON
Fuel level sensor

(Brown) (Black) 3/4
E (Yellow) (White) 1/2
1/8 (Green) (Red) 1/4
View A K115V2E62003
95ZV-2 EU FS 62-72
MODM
MODM
(Machine Operation Diagnostic Module) Monitor Changeover
Replacement Fault log

[ ]button [ ]button monitor monitor
Information Input/Output
monitor monitor
Display window [ (step back)] [ (step forward)] Specification Parameter

button button setting monitor setting monitor
90ZV-262001
Change over the monitor using the following procedure:

MODM function
When the starter switch is ON, the MODM software ver-
The MODM has the following functions: sion displays for 3 seconds.
- Information monitor
Displays outside air temperature, machine speed 80V2U62001

and engine speed, engine coolant temperature,
transmission oil temperature, hydraulic oil tempera-
ture and miles driven etc. After this, machine information screen displays informa-
tion relative to the machine function.
- Replacement monitor
Allows check of the replacement time for the parts

and oil periodically replaced, allows setting of the 80V2U62002
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.

95ZV-2 EU FS 62-73
MODM
Changing display from one function to next From Information monitor to Replacement
monitor:
Press both the [ (step back)] button and [ (step
forward)] button at the same time to change over the Press both the [ (step back)] and [ (step for-
monitor mode in sequence "Information monitor  ward)] buttons at the same time.
Replacement monitor  Fault log monitor  Input/Out-
put monitor  Parameter setting monitor  Specifica- Display should now appear as shown below.
tion setting monitor Information monitor".
However the monitor mode can not be changed in

reverse such as "Information monitor  Specification 90ZV-262034
setting monitor  Parameter setting monitor ....."
The display will not be changed to the next monitor By pressing the [ (step forward)] button or [
when you hold the buttons. (step back)] button you may then continue to navigate
through the items that should be replaced at given ser-
For the display sequence, refer to "Outline of MODM vice intervals.
(Machine Operation Diagnostic Module) Operation"
page 92-47. From Replacement monitor to Fault log moni-
tor:
Press both the [ (step back)] and [ (step for-

ward)] buttons at the same time.
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.
95ZV-2 EU FS 62-74
MODM
From Fault log monitor to Input/Output moni- From Specification setting monitor to Informa-
tor: tion monitor:
Press both the [ (step back)] and [ (step for- Press both the [ (step back)] and [ (step for-
ward)] buttons at the same time. ward)] buttons at the same time.
80V2U62004 80V2U62002
With the shift lever in "Neutral" and "Automatic", the While in default temperature screen, the password input
screen should appear as above. screen can be seen by simultaneously pressing the [ ]
and [ ] buttons. When the password input is finished,
This screen shows the "Input and Output" signal data. fuel consumption can be seen. Pressing [ ] button tog-
gles between metric and US values.
From Input/Output monitor to Parameter set-
ting monitor:

80V2U62005
Display should appear similar to above.
This screen shows "Parameter settings" and may be

used to make changes in an already validated parame-
ter.
From Parameter setting monitor to Specifica-

tion setting monitor:

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 invali-
date a given parameter; effectively turning ON or OFF
the function of an option.
95ZV-2 EU FS 62-75
MODM
Information Monitor 1. Outside air temperature

(Refer to page 92-49)
Information monitor display

90ZV-262024
The following items are displayed:

The monitor displays the current outside air temperature
When the starter switch is ON, the software version dis- when the starter switch is ON.
plays for 3 seconds, then shows default screen.
Press the [ ] button to change over the display unit
from "ºC" to "ºF". Press the [ ] button again to return
the display unit from "ºF" to "ºC".
90ZV-262024
2. Machine speed and engine speed
To toggle between metric standard values (ºC, MPa,
Press the [ (step forward)] button and release.
km/h, etc.) and US standards (ºF, PSI, MPH, etc.), press
the [ ] button.
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 This indicates the actual machine speed and engine

revolutions. This is useful for determining items like shift
mapping patterns in relationship to speed range selec-
When the password input is finished, you will now be at
tion.
the screen shown below.
For speed to be accurate, the correct tire size must be
entered into the main MCU via this MODM unit.
80V2U62007 Press the [ ] button to change the display unit from

"km/h" to "mph"
To leave this screen, press the [ ] and [ ] buttons
Press the [ ] button again to return the display unit
simultaneously again.
from "mph" to "km/h".
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 tempera-
ture" 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 92-47 and 92-49.
95ZV-2 EU FS 62-76
MODM
3. Current engine coolant temperature and 4. Current transmission oil temperature and
maximum engine coolant temperature maximum transmission oil temperature
recorded (which can be reset) recorded (which can be reset)
Press the [ (step forward)] button and release. 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 temper- The monitor displays the current transmission oil tem-
ature in the "EG COOLANT" line and maximum engine perature in the "TC OIL" line and maximum transmis-
coolant temperature for the day in the "MAX" line. This sion oil temperature for the day in the "MAX" line. This
self resets daily at 24:00 (12:00 Midnight). self resets daily at 24:00 (12:00 Midnight).
Even if the engine is stopped once and then started Even if the engine is stopped once and then started
again, if the time is before 24:00, the monitor displays again, if the time is before 24:00, the monitor displays
the maximum engine coolant temperature recorded on the maximum transmission oil temperature recorded on
the day. the day.
The maximum engine coolant temperature is automati- The maximum transmission oil temperature is automati-
cally reset everyday at 24:00, whether the engine starter cally reset everyday at 24:00, whether the engine starter
switch is turned on or off. switch is turned on or off.
Immediately after reset, the engine coolant temperature Immediately after reset, the transmission oil tempera-
at the time of reset is displayed as the maximum engine ture at the time of reset is displayed as the maximum
coolant temperature. In other words, the current engine transmission oil temperature. In other words, the current
coolant temperature is equivalent to the maximum transmission oil temperature is equivalent to the maxi-
engine coolant temperature. mum transmission oil temperature.
To manually reset, press the [ ] button to reset the To manually reset, press the [ ] button to reset the
maximum engine coolant temperature. Immediately maximum transmission oil temperature. Immediately
after reset, the engine coolant temperature at the time after reset, the transmission oil temperature at the time
of reset is displayed as the maximum engine coolant of reset is displayed as the maximum transmission oil
temperature. temperature.
Press the [ ] button to change over the display unit Press the [ ] button to change over the display unit
from "ºC" to "ºF". Press the [ ] button again to return from "ºC" to "ºF". Press the [ ] button again to return
the display unit from "ºF" to "ºC". the display unit from "ºF" to "ºC".
95ZV-2 EU FS 62-77
MODM
5. Current hydraulic oil temperature and max- 6. Odometer (total miles driven) and trip
imum hydraulic oil temperature recorded meter (which can be reset)
(which can be reset)
90ZV-262029
90ZV-262028

The monitor displays the total number of miles that
The monitor displays the current hydraulic oil tempera- machine is operated in top line and miles for operator
ture in the "HYD OIL" line and maximum hydraulic oil selected time frame the trip meter in lower line. This
temperature for the day in the "MAX" line. This self logs miles in forward and reverse.
resets daily at 24:00 (12:00 Midnight).
Press the [ ] button to reset the trip meter displayed in
Even if the engine is stopped once and then started lower line.
again, if the time is before 24:00, the monitor displays
the maximum hydraulic oil temperature recorded on the Press the [ ] button to change over the display unit
day. from "km" to "mile". Press the [ ] button again to return
the display unit from "mile" to "km".
The maximum hydraulic oil temperature is automatically
reset everyday at 24:00, whether the engine starter 7. Number of cycles and cycle time
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. 90ZV-262030
To manually reset, press the [ ] button to reset the You will now be at the screen shown above.
maximum hydraulic oil temperature. Immediately after
reset, the hydraulic oil temperature at the time of reset The monitor displays the number of cycles in the upper
is displayed as the maximum hydraulic oil temperature. line and the time required for one cycle (moving forward
and backward twice) in the lower line.
Press the [ ] button to change over the display unit
from "ºC" to "ºF". Press the [ ] button again to return This can be used to determine comparative production
the display unit from "ºF" to "ºC". 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.
95ZV-2 EU FS 62-78
MODM
8. Hydraulic system oil pressure Unit conversion and language selection

Press the [ (step forward)] button and release. Select the unit and language using the [ ] button.
Unit conversion (for traveling distance, temper-

ature and pressure)
80V2U62008
Press the [ ] button once to change the display unit.

You will now be at the screen shown above. Press the [ ] button again to return to the previous dis-
play unit.
The monitor displays the unloader pressure of the effi-
cient loading system (ELS). Language selection
Press the [ ] button to change over the display unit Press and hold the [ ] button for 3 seconds or longer to
from "MPa" to "psi". Press the [ ] button again to return get language selection screen.
the display unit from "psi" to "MPa".
9. Voltage
80V2U62009
English is selected as the initial setting.

90ZV-262032
Japanese, French, German, Italian, Spanish, Turkish,

You will now be at the screen shown above. Dutch and English can also be selected.
Shows complete electrical system voltage as is seen at Press the [ (step forward)] button or [ (step
the battery level. back)] button to view the language selections.
Note For returning to the information monitor after selecting

If voltage drops below 27 V DC, the hibernate mode the desired language, press and hold the [ ] button for
(lowers RPM’s to conserve fuel) will not work. 2 seconds or longer.
For returning to the information monitor without select-

10. Hour meter (total operating hours) and trip ing another language, press the [ ] button.
meter (which can be reset)
Refer to "Main Menu" page 92-48.
90ZV-262033
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.
95ZV-2 EU FS 62-79
MODM
Replacement Monitor 2. Fuel filter

(Refer to page 92-50) 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
The display window displays remaining time until next
monitor.
replacement of fuel filter cartridge.
Note
If an exclamation mark shows before the numbers that
90ZV-262034 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 70V2U62018
engine oil sulfur content is less than 0.5%. If engine oil
sulfur content exceeds 0.5%, this interval must be cut in
Note
half.
Make sure to set the replacement interval (timer reset)
whenever the fuel filter is replaced.
Note
If an exclamation mark shows before the numbers that
It may be necessary to change this filter more fre-
indicate hours, this shows how many hours overdue the
quently, depending on fuel cleanness.
filter is.
80V2U62079
Note
whenever the engine oil filter is replaced.
95ZV-2 EU FS 62-80
MODM
3. Coolant filter (80ZV-2 ~ 135ZV-2 only) 4. Torque converter and transmission filter
80V2U62011 80V2U62012
The display window displays remaining time until next The display window displays remaining time until next
replacement of the engine coolant filter cartridge. replacement of the torque converter and transmission
filter cartridge.
Note
If an exclamation mark shows before the numbers that Note
indicate hours, this shows how many hours overdue the If an exclamation mark shows before the numbers that
filter is. indicate hours, this shows how many hours overdue the
filter is.
70V2U62019
70V2U62020
Note
Make sure to set the replacement interval (timer reset) Note
whenever the coolant filter is replaced. Make sure to set the replacement interval (timer reset)
whenever the torque converter and transmission filter is
It may be necessary to change this filter more fre- replaced.
quently, depending on engine coolant condition.
It may be necessary to change this filter more fre-
quently, depending on transmission oil cleanness.
95ZV-2 EU FS 62-81
MODM
5. Hydraulic return filter 6. Engine oil
80V2U62013 80V2U62014
replacement of hydraulic return filter. replacement of engine oil.
Note Note
If an exclamation mark shows before the numbers that If an exclamation mark shows before the numbers that
indicate hours, this shows how many hours overdue the indicate hours, this shows how many hours overdue the
hydraulic return filter change is. oil change is.
Ex. "!12 h" indicates that it is 12 hours overdue. Ex. "!12 h" indicates that it is 12 hours overdue.
70V2U62021 70V2U62022
Note Note
Make sure to set the replacement interval (timer reset) Make sure to set the replacement interval (timer reset)
whenever the hydraulic return filter is replaced. 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.
95ZV-2 EU FS 62-82
MODM
7. Torque converter and transmission oil 8. Axle oil
80V2U62015 80V2U62016
replacement of torque converter and transmission oil. replacement of both front and rear axle and planetary
unit oils.
Note
If an exclamation mark shows before the numbers that Note
indicate hours, this shows how many hours overdue the If an exclamation mark shows before the numbers that
oil change is. indicate hours, this shows how many hours overdue the
oil change is.
70V2U62023
70V2U62024
Note
Make sure to set the replacement interval (timer reset) Note
whenever torque converter and transmission oil is Make sure to set the replacement interval (timer reset)
replaced. whenever axle oil is replaced.
It may be necessary to change this oil more frequently, It may be necessary to change this oil more frequently,
depending on work site conditions, oil sampling results depending on work site conditions, oil sampling results
and oil cleanness. and oil cleanness.
95ZV-2 EU FS 62-83
MODM
9. Hydraulic oil Replacement interval set (timer reset)

Press the [ (step forward)] button and release. When the machine is shipped, the standard replace-
ment interval is set as the initial setting.
Press and hold the [ ] button for 2 seconds or more on

80V2U62017
the replacement monitor screen to display the timer
reset screen.
You will now be at the screen shown above. The timer reset screen displays the standard replace-
ment interval.
The display window displays remaining time until next
replacement of hydraulic oil. For setting the standard replacement interval, press the
[ ] button.
Note
If an exclamation mark shows before the numbers that Then, the standard replacement interval is set, and it
indicate hours, this shows how many hours overdue the returns to the replacement monitor screen again.
oil change is.
70V2U62025
Note
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.
95ZV-2 EU FS 62-84
MODM
Example: Engine oil Replacement interval pop-up
When the remaining time until the next replacement

interval reaches " 0 " (or 0 hours), the replacement pop-
90ZV-262037 up appears and flashes in the display window.
For setting the replacement interval other than the stan-

dard 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 contin-
uously. It means that "100", "200", "300" hours ..... is
added in 100 hour increments.
90ZV-262039
When the [ (step back)] button is pressed and held

for 2 seconds or more, "100" hours is subtracted contin- When two or more replacement pop-ups occur at the
uously in the same manner. same time, the corresponding items flash in turn.
After setting the replacement interval, press and hold After the remaining time for the next replacement
the [ ] button for 2 seconds or more. reaches " 0 ", the corresponding pop-up appears up to
three times when the starter switch is ON.
The replacement interval is reset, and the display
returns to the replacement monitor screen again. (The MODM software version is displayed for 3 sec-
onds, 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) proce-
dure above.
95ZV-2 EU FS 62-85
MODM
Display language Fault Log Monitor

The same language selected in the information monitor
is used as the display language for the replacement Start from key ON. Press the [ (step back)] button
monitor. and [ (step forward)] button together twice to get to
this point.
For selecting the display language, it is necessary to
return to the information monitor.
The display language can be selected only on the infor-

mation monitor screen.
Fault log history check
1. Active faults
For returning from the replacement monitor to the infor-
mation monitor, change the monitor in turn as described Up to 100 machine faults and 100 engine faults can be
in the sequence "Replacement monitor [ ][ ] recorded in fault log (200 total).
(pressing them at the same time)  Fault log monitor
[ ][ ] (pressing them at the same time)  Input/ Failure codes that begin with CN are machine faults.
Output monitor [ ][ ] (pressing them at the same (CN=Chassis fault #)
time)  Parameter setting monitor [ ][ ] (pressing
them at the same time)  Specification setting monitor Failure codes that begin with EN are engine faults.
[ ][ ] (pressing them at the same time)  Infor- (EN=Engine fault #)
mation monitor".
What is shown
For the display sequence, refer to "Outline of MODM The following list of items are shown. Fault descriptor,
(Machine Operation Diagnostic Module) Operation" fault code number, date of occurrence and hour-minute-
page 92-47. second of occurrence. Examples shown below.
This shows fault CN321. This is caused by an engine

coolant temperature fault (open circuit). Note descrip-
tions.
Fault descriptor Fault code
Date Time in 24:00 hour scale

July 20, 2006 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.

95ZV-2 EU FS 62-86
MODM
2. Inactive faults (Checking history ) Selection of machine fault log and engine
fault log
Again, up to 100 machine faults and 100 engine faults
can be recorded in the fault log (200 faults total).
You can toggle between viewing the engine faults or
machine faults.
Failure codes that begin with CN are machine faults.
Failure codes that begin with EN are engine faults. Machine fault
What is shown When the machine fault log screen is displayed, press
The following list of items are shown. Order of occur- and hold the [ (step forward)] button for 2 seconds
rences, fault code number, date, hour-minute-second, or more to display the engine fault log screen which
and frequency of occurrence. Examples shown below. shows the latest engine fault code.
This shows fault CN321. This is caused by an engine

coolant temperature fault (open circuit). Note descrip-
tions.
80V2U62022
Order of occurrences A=Active fault Engine fault

100 total 01~00 Fault code number 002 is qty of occurrences
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.

July 20, 2006 3:27:32 80V2U62023
80V2U62020
The machine fault log screen and engine fault log

This shows fault EG146. This is caused by an engine screen can be distinguished as follows:
coolant temperature fault (overheat condition). Note
descriptions. Displayed fault code:
CN ..... Machine fault log screen
EG ..... Engine fault log screen
Order of occurrences A=Active fault
100 total 01~00 Fault code number 016 is qty of occurrences

July 25, 2006 1:31:38
80V2U62021
..... If still active, shows "A" before fault number.

95ZV-2 EU FS 62-87
MODM
Machine fault log navigation Clear fault log

Clear inactive fault log
When two or more fault codes are recorded, press the
[ (step forward)] button to display the next latest Fault codes can be cleared by pressing the [ ] button
fault code. and holding it for more than 2 seconds while in the
engine fault mode, or in the machine fault mode
Press the [ (step back)] button to display the fault screens.
code in chronological order.
Note
When pressing the [ ] button to clear a fault code,
password entry is required on the 95ZV-2 S/N 9254 and
Engine fault log navigation thereafter.
The password must be acquired from the Kawasaki Ser-
When two or more fault codes are recorded, press the vice Representative and is not for general public use as
[ (step forward)] button to display the next latest it can cause troubles if the necessary troubleshooting
fault code. information is deleted. If you have the password, write it
in the value entry blanks provided below.
Press the [ (step back)] button to display the fault
code in chronological order. DO NOT GIVE THIS PASSWORD OUT TO CUSTOM-
ERS OR END USERS!
Press and hold the [ ] button for 2 seconds or more to

clear the entire fault log.
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 mem-

ory, 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.
95ZV-2 EU FS 62-88
MODM
Clear active fault log (error pop up) (S/N

9001~9166)
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.
95ZV-2 EU FS 62-89
MODM
Failure code (Input side)
Code Failure Detection condition (In case of)

Shift lever F & R contact ON at the same time
CN121 Shift lever F & R switch malfunction
Failure continues for more than 3 seconds
Shift lever any of more than two 1•2•3•A contact ON at the same time
CN122 Shift lever 1•2•3•A switch malfunction (1) Failure continues for more than 3 seconds (30 seconds from program ver.
100915)
All 1•2•3•A signal OFF continues for more than 3 seconds (30 seconds
CN123 Shift lever 1•2•3•A switch malfunction (2)
from program ver. 100915)
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
Shift-up switch & shift-down switch contact ON at the same time
CN143 Shift-up switch & shift-down switch malfunction
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
T/M oil pressure switch malfunction
CN151 Signal OFF continues for more than 10 seconds during engine running
(This applies to the model 115ZV-2/135ZV-2 only)
T/M oil pressure sensor malfunction T/M pressure below 294 kPa (3.0 kgf/cm2) (43 psi) continues for more than
CN152
(This applies to the model 95ZV-2 only) 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
No E/G speed sensor input for more than 3 seconds when E/G speed sen-
CN163 E/G speed sensor 1 (ECM output) malfunction (1)
sor selection is OFF (Input circuit is disconnected)
Input value is more than 3,000 min-1 for more than 3 seconds when E/G
CN164 E/G speed sensor 1 (ECM output) malfunction (2)
speed sensor selection is OFF
E/G speed sensor 2 (Sensor output) malfunction No E/G speed sensor input for more than 3 seconds when E/G speed sen-
CN165
(1) sor selection is ON (Input circuit is disconnected)
E/G speed sensor 2 (Sensor output) malfunction Input value is more than 3,000 min-1 for more than 3 seconds when E/G
CN167
(2) 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
Secondary steering oil pressure sensor
CN251 Voltage is lower than 0.2 V for more than 3 seconds
malfunction (1)
Secondary steering oil pressure sensor
CN252 Voltage is larger than 4.6 V for more than 3 seconds
malfunction (2)
Oil pressure sensor detects secondary steering oil pressure below
CN254 Low secondary steering oil pressure 306 kPa (3.1 kgf/cm2) (44 psi) for more than 3 seconds during engine run-
ning
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
Efficient loading system hydraulic oil pressure sen-
CN271 Voltage is lower than 0.2 V for more than 3 seconds
sor malfunction (1)
Efficient loading system hydraulic oil pressure sen-
CN272 Voltage 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
95ZV-2 EU FS 62-90
MODM
Code Failure Detection condition (In case of)

CN351 Hydraulic oil temperature sensor malfunction (1) Input voltage is larger than 3.56 V for more than 3 seconds
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
Brake oil pressure sensor 1 detects pressure below 4,081 kPa (41.6 kgf/
CN412 Abnormal brake oil pressure (1)
cm2) (592 psi) for more than 1 second during engine running
Brake oil pressure sensor 2 detects pressure below 4,081 kPa for (41.6
CN413 Abnormal brake oil pressure (2)
kgf/cm2) (592 psi) more than 1 second during engine running
Brake oil pressure difference switch is in abnormal condition for more than
CN414 Abnormal brake oil pressure difference
1 second
CN415 Abnormal brake oil amount Brake oil amount switch is in abnormal condition for more than 1 second
Engine oil pressure switch is OFF for more than 2 seconds during engine
CN421 Abnormal engine oil pressure
running
CN431 Abnormal engine coolant temperature (1) Engine coolant temperature switch is ON for more than 2 seconds
Engine coolant temperature sensor is in 101 deg. C (214 deg. F) condition
CN432 Abnormal engine coolant temperature (2)
for more than 2 seconds
CN451 Abnormal T/M oil temperature (1) T/M oil temperature switch is ON for more than 2 seconds
T/M oil temperature sensor is in 122 deg. C (252 deg. F) condition for more
CN452 Abnormal T/M oil temperature (2)
than 2 seconds
Hydraulic oil temperature sensor is in 100 deg. C (212 deg. F) condition for
CN461 Abnormal hydraulic oil temperature
more than 2 seconds
30 minutes after starter switch is ON, T/M oil filter switch is ON for more
CN471 Clogged T/M oil filter 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
Radiator cooling water level switch is OFF for more than 2 seconds when
CN491 Abnormal cooling water level in radiator
the engine is off.
CN496 Abnormal hydraulic oil level Hydraulic oil level switch is in abnormal condition for more than 30 seconds
Abnormal brake disc oil temperature
CN497 Brake disc oil temperature switch is ON for more than 1 second
(This applies to the model 135ZV-2 only)
Abnormal disc wear
CN498 Brake disc wear switch is ON for more than 1 second
(This applies to the model 135ZV-2 only)
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 32±1 V
Voltage is lower than 22±0.5 V for more than 10 seconds during engine
CN913 Abnormal MCU voltage (2)
running
(CN_In 10K01)
Fuel level display table

Note
Input Output
This table applies to the 95/115/135ZV-2 units.
1/8 1/4 1/2 3/4 F E 1/4 1/2 3/4 F
x x x x x — — — —
x x x x — — — —
x x x — — — —
x x — — — —
x — — — —
— — — —
Other than above — — — — —
: No input signal given : Lamp on : Lamp flashing
x : Input signal given — : Lamp off
95ZV-2 EU FS 62-91
MODM
Failure code (Output side)
Code Failure Detection condition

CN512 F solenoid valve malfunction 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
Speed change control solenoid valve malfunction
CN536 Speed change control solenoid valve is short-circuited
(1)
Speed change control solenoid valve malfunction
CN537 Speed change control solenoid valve is disconnected
(2)
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
Efficient loading system selection solenoid valve Efficient loading system selection solenoid valve is short-circuited or dis-
CN681
malfunction connected
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
(CN_Out 10F24)
Failure code (Engine)
Refer to "Quantum fault code information" page 62-28.

95ZV-2 EU FS 62-92
MODM
Input/Output Monitor By pressing the [ (step forward)] button, you will

arrive at a window as shown below.
Input/Output monitor display

80V2U62026
1. Input signal monitor
This is because in window 2, it shows the parking brake
From a position of turning on the key switch, press both as being released and the corresponding slot would
the [ (step back)] and [ (step forward)] buttons have a 1 in that place. In other words, the parking brake
simultaneously 3 times, you will arrive at the screen coil has been energized and the slot has a 1 in it indicat-
shown below. ing that it is energized and the parking brake is
released.
Now press the [ (step forward)] button once. You

80V2U62025 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)

Nothing in this case is activated, so all of the slots are
This monitor displays the ON/OFF status of the shift occupied with the number 0.
lever, setting switches, pressure switches, etc.
There are seven input groups from INPUT 1 to INPUT 7. 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 corre-

sponding item number. 80V2U62028
When input signal is OFF, "0" is displayed under corre- The screen indicates that ride control and ELS are acti-
sponding item number. vated, or the switch for each one is energized.
Refer to "MODM: Input/Output Monitor - Input/Output Now press the [ (step forward)] button once. You
Signal Correspondence Table" page 92-56. will arrive at the screen shown below.
As shown in table of section "MODM: Input/Output Mon-
itor - 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
95ZV-2 EU FS 62-93
MODM
Now press the [ (step forward)] button once. You 2. Current output monitor
will arrive at the screen shown below.
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.
80V2U62030
Note
The [ (step back)] or [ (step forward)] button
This indicates that there are no inputs happening in this must be held for 2 seconds or more with each change. If
situation. not, it will not move to next item.
Now press the [ (step forward)] button once. You If the feature is set to "Invalid" in specification setting,
will arrive at the screen shown below. the following items will be skipped.
- STEERING PRESS - SP7 (EMG steering)
- BOOM ANGLE - SP15 (Lift kickout)

80V2U62031
This indicates that there are inputs for a full fuel tank,
the machine is equipped with an optional reversing fan,
90ZV-262019
and the switch for the fan is in the "ON" or energized
position.
This area is called the "Current Output Monitor". As
Now press the [ (step forward)] button once. You seen, it first shows actual front brake circuit pressure.
will arrive back the screen shown below.
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.

80V2U62032
Again, in review, note the following:

- This monitor displays the ON/OFF status of the shift following screen is seen.
lever, setting switches, pressure switches, etc.
- There are seven input groups from INPUT 1 to

INPUT 7.
80V2U62033
- Each group has eight items from item 0 to the item 7.

- When input signal is ON, "1" is displayed under cor- following screen is seen.
responding item number.
- When input signal is OFF, "0" is displayed under cor-

responding item number.
80V2U62034
For more clarification, refer to "MODM: Input/Output

Monitor - Input/Output Signal Correspondence Table".
95ZV-2 EU FS 62-94
MODM
Next, by pressing the [ (step forward)] button, the 3. Output signal monitor (D1~D6)
following screen is seen.
This monitor displays the ON/OFF status of the trans-
mission forward/backward solenoid valves, speed range
solenoid valves, indicator lamps and warning lamps on
the instrument panel, etc.
80V2U62035
There are six output groups from OUTPUT 1 to OUT-

Note PUT 6.
Brake main pressure 1 is accumulator oil pressure for
rear accumulator which serves only the rear brake cir- Each group has eight items from item 0 to 7.
cuit. Brake main pressure 2 is accumulator oil pressure
for front accumulator which serves the front brake circuit When output signal is ON, "1" is displayed under corre-
and all pilot derived pressures; these are pilot oil pres- sponding item number.
sure for the pilot control valves, auto brake, park brake
release, etc. The actual real-time pressures are shown When output signal is OFF, "0" is displayed under corre-
in these fields. sponding item number.
Next, by pressing the [ (step forward)] button, the Refer to "MODM: Input/Output Monitor - Input/Output
following screen is seen. Signal Correspondence Table" page 92-56.
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

80V2U62036
Output Monitor" part of the "Input and Output Monitor"
section.
This shows the 2nd speed solenoid coil and the forward
All of the aforementioned screens can be seen in coil outputs have been applied, as the transmission is in
reverse order by using the [ (step back)] button. forward and automatic.
Holding this button in for longer than 2 seconds will take
you to the input signal monitor screen section. 1st, 3rd, 4th, reverse, high, and autobrake solenoid coils
are not energized and show no application signal.
Next press the [ (step forward)] button to show the

following screen.
80V2U62037
Again, note that all values except the last are 0, and
only the brake lamp output is in the "ON" position.
95ZV-2 EU FS 62-95
MODM
Next press the [ (step forward)] button to show the 4. Electric current output monitor
following screen.
This indicates the milliampere (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.

80V2U62042
following screen.
This current output will vary as demands for fan revolu-

tions change, according to amount of heat that is being
generated. This heat must be discharged to cool the
80V2U62039
system that is heating back down.
Note that the place under slot 5 is occupied by a 1, as When the machine systems are cold and the machine is
MCU failure relay should be energized by MCU if MCU in warm up mode, the mA level will be higher than when
passes software logic test at MCU boot-up that occurs the machine has worked for a time and has become
with the key in the "ON" position. heat saturated.
Next press the [ (step forward)] button to show the Note

following screen. Disconnecting the fan solenoid wire will increase the
fan’s 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
80V2U62040
with work.
Note that the place under slot 1 is occupied by a 1, as Refer to fault code table for the chassis side for more
the unit is in automatic shift mode and the dash lamp detail.
should be illuminated to indicate this. Also the place
under slot 7 is occupied by a 1, as the unit is full of fuel.

following screen.
80V2U62041
Note that this shows no input signal at this time.

95ZV-2 EU FS 62-96
MODM
Parameter Setting Monitor 1. Shift inhibitor

(Refer to page 92-53) From turning on key switch which would default to
screen shown below.
Parameter setting monitor display
This monitor allows check of parameters that are cur-

rently set.
80V2U62002
Value levels to set parameter for items like ride control,

tire ratios, date/time clock (used to log faults), declutch Pressing both the [ (step forward)] and [ (step
pressures, secondary steering, detent values sensor, back)] buttons simultaneously, 4 times once after
etc. another, arrive at the screen shown below.
Note
If the feature is set to "Invalid" in specification setting
view, the following items will be skipped in the parame-
80V2U62005
ter setting monitor view.
- RIDE CONTROL - SP5 (Ride control) The transmission changes the speed range automati-
cally according to the machine speed. If the machine
- EMG STEERING - SP7 (EMG steering) speed sensor is disconnected when the machine is run-
ning high, the machine speed is suddenly reduced
- K-LEVER - SP8 (K-Lever) because of that the transmission is automatically shifted
to the low range. As a result, the operator becomes very
- TRACTION CONTROL - SP11 (Traction control) unstable condition by rapid deceleration. This device
prevents the above.
- 2 STAGE - SP13 (Efficient loading system)
By pressing the [ (step forward)] button, you will
- BOOM SOFT LAND - SP14 (Lower kickout) arrive at a window as shown below.
- KICK OUT - SP15 (Lift kickout)
80V2U62043
95ZV-2 EU FS 62-97
MODM
2. Ride control Press the [ (step forward)] button to add "1" to a

numerical value.
will arrive at the screen shown below. Note
Value for "ON" must be 1 km/hr or more greater than
"OFF".
The numerical value will increase as you press the [

80V2U62044
(step forward)] button as follows;
The screen should appear similar to what is shown. This 0  1  2 ..... 9  0  1  2 .....
shows the speed at which ride control turns on and per-
mits the base end oil to work against the accumulator Press the [ (step back)] button to subtract "1" from a
piston. numerical value.
Now press the [ (step forward)] button once. You The number then decreases as follows;
will arrive at the screen shown below.
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 val-
80V2U62045
ues and return to the parameter setting screen.
The screen should appear similar to what is shown. This Press the [ ] button to return to the parameter setting
shows the speed at which ride control turns off and does screen without changing parameter values.
not permit the base end oil to work against the accumu-
lator 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 sec-
ond).
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, press-
ing [ ] 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.
95ZV-2 EU FS 62-98
MODM
3. Meter division ratio 4. Tachograph
Next, by pressing the [ (step forward)] button, the Next, by pressing the [ (step forward)] button, the
following screen is seen. following screen is seen.
80V2U62046 80V2U62048
The screen should appear similar to what is shown. This Next, by pressing the [ (step forward)] button, the
is the speed division ratio for the smaller tire. This per- following screen is seen.
mits the speed reading to be accurate when equipped
with smaller tires.

80V2U62049
5. Secondary steering
80V2U62047 Next, by pressing the [ (step forward)] button, the

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. 80V2U62050
Note
The screen should appear similar to what is shown and
indicates the engagement speed.
Tire size
Model
Small size (B) Large size (A)
When this option is on the machine, this screen will per-
65ZV-2 17.5 20.5
mit the technician to see the engagement speeds. This
70ZV-2 20.5 23.5 will engage when the machine loses power to the
80ZV-2 20.5 23.5 engine, or if the steering pump were to fail and hydraulic
85ZV-2 23.5 26.5 system pressure falls below 0.4 MPa (4 kgf/cm2) (57
90ZV-2 23.5 26.5 psi) as long as the machine speed is above 2 km/h, and
92ZV-2 26.5 26.5 it disengages when the speed falls below 1 km/h.
95ZV-2 26.5 29.5
115ZV-2 29.5 35/65 Next, by pressing the [ (step forward)] button, the
Note that the 1/12 ratio is the small size (B), and the 1/
11 ratio is the large size (A).
80V2U62051
95ZV-2 EU FS 62-99
MODM
6. K-Lever (stick steering) Review the following screens that are able to be seen
by pressing the [ (step forward)] button. (A setting
Next, by pressing the [ (step forward)] button, the 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 moni-

80V2U62057
tor display.
i=Signal intensity (or mA)
Review the following screens that are able to be seen
by pressing the [ (step forward)] button. (A setting A Type
shown.)
Solenoid valve Current (mA) Solenoid valve

LH side RH side
imax
i2
80V2U62053
80V2U62054
i1
V=Voltage
Potentio-
meter (V)
The screen should appear similar to what is shown and 2.5
0 V1 V1 5
indicates the K-Lever mA signal strength or intensity.
V2 V2
Vmax Vmax
Note
The default setting for K-Lever is to the "A" type. 80V2U62077
The voltage settings are displayed in the MODM moni-

tor display. 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
95ZV-2 EU FS 62-100
MODM
B Type 7. Traction control

Solenoid valve
LH side
Current (mA) Solenoid valve
RH side
imax
i3
i2
80V2U62058
This indicates parameter of 1.0 second when in forward

i1 and 1st (F1) gear before traction control will engage. If
time of engagement for F1 is less than 1 second, it is
Potentio-
meter (V) looked at as not permanent; software will not respond to
2.5 signal as it is considered to be inconsequential. This
0 V1 V1 5
helps avoid erratic machine function.
V2 V2
V3 V3
Vmax Vmax Next, by pressing the [ (step forward)] button, the
80V2U62078 following screen is seen.
Initial set values
K-LEVER V1 0.25 V 80V2U62059
K-LEVER V2 1.0 V
K-LEVER V3 2.0 V This stands for Dual Stage for slip control. This parame-
ter is not used in USA production and should be disre-
K-LEVER i1 290 mA
garded. (It would have set a given hydraulic system
K-LEVER i2 400 mA pressure value to indicate that machine was excavating
K-LEVER i3 450 mA and MCU logic for traction control would take into
account this additional parameter.)
K-LEVER imax 470 mA

Note following screen is seen.
Type A and B are switched on the specification setting
monitor. (Refer to page 62-106)
In case of type A, screen changes as follows.

80V2U62060
V1  V2  Vmax  i1  i2  imax
This stands for Inching slip control feature and is not
In case of type B, screen changes as follows. used. This parameter is not used in USA production and
should be disregarded. (If it were used, declutch (or
V1  V2  V3  i1  i2  i3  imax 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).)
95ZV-2 EU FS 62-101
MODM
80V2U62061 80V2U62065
This is time inching. This is time frame in lsc above. This stands for Slip Control time; data is provided in
seconds of time. When the set time for starting slippage
Next, by pressing the [ (step forward)] button, the begins, traction control engages and makes adjust-
following screen is seen. ments accordingly.
8. Declutch
80V2U62062 Next, by pressing the [ (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.
80V2U62066
This is brake circuit pressure; at this pressure, the
declutch circuit will put the transmission to neutral posi-
tion, 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.

80V2U62064
This stands for Slip Control intensity; indicates acceler-

ated slipping velocity of traction control. The value is
indicated in km/h per 0.1 second. Each 1/10th of a sec-
ond the velocity is cut back by engine rpm reduction so
slippage will not occur, and this provides reduced tire
slippage.
95ZV-2 EU FS 62-102
MODM
9. Efficient loading system (ELS) 10. Engine power control
Next, by pressing the [ (step forward)] button, the Temperature

80V2U62067
80V2U62070
This is the voltage at the rotary sensor wire that returns
signal to MCU. This signal from the rotary sensor deter-
mines the boom height position. If the boom is high, the The screen should appear similar to what is shown.
unloader valve solenoid coil at the ELS control valve will
not be energized, and the ELS will not operate to unload This is the temperature at which hibernate mode will
the loading pump. 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 Next, by pressing the [ (step forward)] button, the
senses 2.5 V or less. following screen is seen.
Typical voltage for the rotary sensor is as shown in

graphic below (approximate values).
65V2E62024
Approximate voltage values

The screen should appear similar to what is shown.
Boom fully up=4.8 V
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 V DC, 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
95ZV-2 EU FS 62-103
MODM
11. Lower kickout (for return to dig) 13. Calendar (Date and time)
80V2U62072 90ZV-262022
The screen should appear similar to what is shown; volt- The screen should appear similar to what is shown.
age 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)

80V2U62073
The screen should appear similar to what is shown; volt-

age 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 dam-

age caused by the mass of the boom, bucket, and link-
age moving up rapidly with the boom cylinders
extending and causing the pistons to hit the boom cylin-
der heads.
95ZV-2 EU FS 62-104
MODM
Parameter change Press the [ (step forward)] button to add "1" to a

numerical value. The numerical value will increase as
The parameter values can be changed when the both you press the [ (step forward)] button as follows.
conditions below are satisfied:
0  1  2 ..... 9  0
The engine is stopped (starter switch is ON).
The parking switch is ON. 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 specifica- 9  8  7..... 0  9
tion setting monitor. (Refer to page 92-53)
After changing parameter values, press and hold the
[ ] button for 2 second or more to finalize the input val-
Ride control setting 1 ues and return to the parameter setting screen.
Press the [ ] button to return to the parameter setting

screen without changing parameter values.
The date & time sequence reads as shown.

When the corresponding item is set to "INVALID", the
parameter screen is not displayed. (It is skipped to the
DATE YY / MM / DD
next screen.)
TIME hh : mm : ss
Calendar Y=year
M=month
D=day
90ZV-262022
h=hour
m=minute
Changing date and clock values: s=second
These values can be changed by doing the following. Example:
Press and hold the [ ] button for 2 seconds or more on DATE 06 / 07 / 12 = July 12, 2006
the parameter setting screen to display the parameter TIME 20 : 15 : 11 = 8:15:11 pm
change screen.
Note
The cursor flashes in a 1-second cycle (flashes on for Failure to enter the values correctly will make the clock
0.5 second). give the wrong time, and the date to read incorrectly in
all of the dependent functions, such as fault code mes-
Press the [ ] button to move the cursor. sages, etc.
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 [ ] but-
ton will move it to the left end in the upper line. The cur-
sor 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
95ZV-2 EU FS 62-105
MODM
Specification Setting Monitor 1. Specification setting display

(Refer to page 92-54 and 92-55) This monitor allows check of the specifications currently
set.
Specification setting monitor display
When attaching an optional unit, change the specifica-
From turning on key switch which would default to tion setting to make the corresponding function valid.
screen shown below.
It is necessary to log with the correct password for
changing the specification setting.
If no password is entered, only the initial specification

80V2U62002
setting monitor can be seen, and is shown the program
number that is designed for that particular machine
Pressing both the [ (step forward)] and [ (step model.
back)] buttons simultaneously, 5 times once after
another, arrive at the screen shown below.
80V2U62074
80V2U62074
When you are at this point, press the [ (step for-
ward)] button for over 2 seconds will take you to the fol-
lowing 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 CUSTOM-

ERS OR END USERS !
IT IS FOR TRAINED KAWASAKI SERVICE PERSON-

NEL ONLY ! SERIOUS DAMAGE TO MACHINE MAY
RESULT BY USING INAPPROPRIATE ENTRY VAL-
UES.
95ZV-2 EU FS 62-106
MODM
2. Password entry and changing settings Every time the [ (step back)] button is pressed, the
displayed content is changed "FR switch  Wheel type
Note  Kickout  ..." in sequence.
To make changes to entry settings, engine must be
"OFF", and key switch in "ON" position with parking The following items can now be selected as "VALID" or
brake applied. Otherwise changes will not happen. "INVALID" by pressing and holding the [ ] button for 2
seconds or longer, and then selecting the [ (step for-
ward)] or the [ (step back)] button to choose
"VALID" or "INVALID" as required.
90ZV-262023
When finished, press and hold the [ ] button for 2 sec-
onds or longer to accept the change.
The password is a numerical password.
If you need to return without making a selection, press
Press the [ (step forward)] button to add "1" to a the [ ] button, and you will return to the previous
numerical value. screen without making a change of selection.
The numerical value will increase as you press the [ - Selection switch shift (shift lever or F/R switch)
(step forward)] button as follows; Valid/Invalid
0  1  2  3  4  5 ..... 9  0  1  2  3  - Shift hold

4  5 ..... etc. Valid/Invalid
Press the [ ] button to change the cursor position to - Ride control

continue password entry. When finished, press the [ ] Valid/Invalid
button for longer than 2 seconds to get to the following
screen. - Secondary steering
Valid/Invalid
- K-Lever (Stick steering)

A Type/B Type/Invalid
80V2U62075
- Hydraulic pressure increase

Every time the [ (step forward)] button is pressed Valid/Invalid
and held for 2 seconds, the displayed contents are
changed over "All setting reset  Specification group 1 - Traction control
 Specification group 2  All setting reset" in Valid/Invalid
sequence.
- Tachograph
Every time the [ (step back)] button is pressed and Valid/Invalid
held for 2 seconds, the displayed contents are changed
over "All setting reset  Specification group 2  Speci- - Efficient loading system (ELS)
fication group 1  All setting reset" in sequence. Valid/Invalid
For the display sequence, refer to "Outline of MODM - Lower kickout

(Machine Operation Diagnostic Module) Operation" Valid/Invalid
page 92-47.
- Lift kickout (variable)
Specification group 1 Valid/Invalid
Every time the [ (step forward)] button is pressed, - Wheel type

the displayed content is changed "FR switch  Shift A type (Big wheel)/B type (Small wheel)
hold  Ride control  ..." in sequence.
95ZV-2 EU FS 62-107
MODM
Specification group 2 - Engine oil pressure sensor (for communication and

monitor control)
Every time the [ (step forward)] button is pressed, Valid/Invalid
the displayed content is changed "Downshift button 
Auto brake  Engine speed  ..." in sequence. - Brake pressure differential switch
Valid/Invalid
Every time the [ (step back)] button is pressed, the
displayed content is changed "Downshift button  - Brake oil level
Brake oil level  Brake oil differential sw  ..." in Valid/Invalid
sequence.
Use the table on page 62-110 to do this.
The following items can now be selected as "VALID" or
"INVALID" by pressing and holding the [ ] button for 2 You may exit back to the default screen when finished
seconds or longer, and then selecting the [ (step for- by pressing the [ (step forward)] and [ (step
ward)] or the [ (step back)] button to choose back)] buttons simultaneously.
"VALID" or "INVALID" as required.
When finished, press and hold the [ ] button for 2 sec-

WARNING
onds or longer to accept the change. Changing the systems parameters to non factory set-
tings will render the monitor ineffective. This can lead
If you need to return without making a selection, press to warranty claims that will not be covered by the fac-
the [ ] button, and you will return to the previous tory warranty.
screen without making a change of selection. DO NOT VALIDATE OPTIONS OR SETTINGS THAT
DO NOT APPLY !
- 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 con-

trol)
Valid/Invalid
- Engine coolant temperature sensor (for monitor con-

trol)
Net/Sensor
- Engine oil pressure switch (for monitor control)

Valid/Invalid
95ZV-2 EU FS 62-108
MODM
All setting reset Allows batch deletion or batch reset of information mon-
itor, replacement monitor or fault log monitor.
Specified
Item Comment
Parameter
Information monitor
Kick down (downshift button) SP1 Always valid
Selection switch shift Optional When this is performed, the following items will be reset.
SP2
(shift lever or F/R switch) (EU valid)
Shift hold SP3 Always invalid
- Maximum engine coolant temperature
Autobrake SP4 Valid 92~135ZV-2
Ride control SP5 Option - Maximum transmission oil temperature
Engine speed SP6 Sensor
Secondary steering SP7

Option - Maximum hydraulic oil temperature
(EU always valid)
K-Lever SP8 Option - Number of cycles
Engine curve SP9 Output
Hydraulic pressure increase
SP10 Option - Cycle time
(power up)
Traction control SP11 Valid 92~135ZV-2 - Trip meter (for hour meter)
Tachograph SP12 Always invalid
Valid
Efficient loading system (ELS) SP13 Replacement monitor
(Option on 65/70ZV-2)
Lower kickout SP14 Always valid
Lift kickout SP15 Always valid - Engine oil filter timer
Cooling fan SP16 A type
- Fuel filter timer
Torque converter oil tempera-
SP17 Invalid
ture switch
Engine coolant temperature - Coolant filter timer
SP18 Invalid
switch
Engine coolant temperature - Torque converter line filter timer
SP19 Net
sensor
Engine oil pressure switch SP20 Always valid - Hydraulic oil return filter timer
Engine oil pressure sensor SP21 Invalid
Brake pressure differential - Engine oil timer
SP22 50/60ZV-2 only
switch
Brake oil level SP23 50/60ZV-2 only - Torque converter and transmission oil timer
Wheel type SP24 A or B type
- 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.
95ZV-2 EU FS 62-109
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.
95ZV-2 EU FS 62-110
MODM
Default position of specification setting monitor
(EU)
OPTION EITHER 65ZV-2 70ZV-2
ITEM 80ZV-2 85ZV-2 90ZV-2 92ZV-2 95ZV-2 115ZV-2
VALID OR INVALID 65TMV-2 70TMV-2
Kick down
Valid/Invalid
(downshift button)
Selection switch shift
(shift lever or F/R Valid/Invalid
switch)
Shift hold Valid/Invalid x x x x x x x x
Autobrake Valid/Invalid x x x x x   
Ride control Valid/Invalid x x x x x x x x
Engine speed Net/Sensor Sensor Sensor Sensor Sensor Sensor Sensor Sensor Sensor
Secondary steering Valid/Invalid
K-Lever Valid/Invalid x x x x x x x x
Engine curve Output/Net/Invalid Output Output Output Output Output Output Output Output
Hydraulic pressure
Valid/Invalid x x x x x x x x
increase (power up)
Traction control Valid/Invalid x x x x x x x
Tachograph Valid/Invalid x x x x x x x x
Efficient loading sys-
Valid/Invalid x x
tem (ELS)
Lower kickout Valid/Invalid
Lift kickout Valid/Invalid
Cooling fan A type/B type/Invalid A type A type A type A type A type A type A type A type
Torque converter oil
temperature switch
Engine coolant tem-
perature switch
Engine coolant tem-
Net/Sensor Net Net Net Net Net Net Net Net
perature sensor
Engine oil pressure
Valid/Invalid
switch
Engine oil pressure
sensor
Brake pressure differ-
Invalid/Nc/No x x x x x x x x
ential switch
Brake oil level Invalid/Nc/No x x x x x x x x
Wheel type A or B type A type B type A type B type A type A type A type A type
=Valid x=Invalid
 Auto brake is always valid on 92/95/115ZV-2 units.  Pilot operated hydraulics for K-Lever on 115/135ZV-2.
Items that are not shaded in table are available options.

95ZV-2 EU FS 62-111
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
Detent 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.
Multiple control valve

Bucket leveler
Adjusting rod (detected object)
Connector
Proximity switch Bucket cylinder
85V2E62007
Proximity switch
Adjusting the clearance
Proximity switch +24V

LED Br 1
Switch Coil for detent
main B 2 inside the pilot
circuit L
3
valve
+24V
Detection part
Operation indicator lamp (LED)
1(Br)
Detected View Z
object
3(L) 2(B)
5±2 mm (0.197±0.079 in) 85ZV62015
Adjust the clearance between the sensor and the

adjusting plate to 5±2 mm (0.197±0.079 in). In this con-
dition, the operation indicator lamp (LED) is on, and the
circuit between the switches (2) – (3) is on.
95ZV-2 EU FS 62-112
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 62±3 
95ZV-2 EU FS 62-113
Lift kickout & lower kickout
Location
A
5
3
Detail A
6
85V2E62008
1. Rotary sensor assy

2. Rod
3. Link
4. Cover
5. Cover
6. Boom
95ZV-2 EU FS 62-114
Lift kickout
When the boom control lever is placed at "Raise" posi-

tion 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.
Lower kickout
When the boom control lever is placed at "Float" posi-

tion 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.
95ZV-2 EU FS 62-115
Sensor assy
4 4 2
2 3
5
1
A-A Detail of grease applying
1
A A
30
Position sensor detail
85V2E62009
1. Position sensor
2. Link
3. Plate
4. Shaft
5. Ball bearing
95ZV-2 EU FS 62-116
A B C
View A A
Position sensor detail
CCW
70T2U62008
Resistance 5 k ± 1 k
Electrical rotation 128º (Theoretical)
Mechanical rotation 180º
Clockwise stop 90º from elect. center
Spring return To clockwise end of rotation
70T2U62009
95ZV-2 EU FS 62-117
Detent solenoid Preset height adjustment
Lever position: Lever position:

Lower kickout side Lift kickout side
Push rod Push rod Switch 85V2E62047
Detent Detent
(Upper) (Lower)
solenoid solenoid
(for lift) (for lower)
Fixing Fixing Hold Hold
disc disc
Reset Reset
85V2E62017
65V2E62018
Two detent solenoids are installed in the pilot valve
boom side.
1. Lift kickout preset height
One is for the lift kickout and another is for the lower
Raise the boom to the desired position and press
kickout.
the left side of the kickout control switch located on
the console box to set the boom height for the lift
Voltage DC 24 V
kickout.
Coil resistance 62±3 
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.
95ZV-2 EU FS 62-118
Diode
Diode
Symbols Open circuit, failed in open position.
Snap!
+24V
Switch
+ Solenoid
[Anode] [Cathode]
Surge voltage
(forward direction) Diode

Current flow
(backward direction)
Current flows while the diode is disconnected.
(The solenoid is energized, however the surge voltage
is not absorbed. This damages electrical parts.)
70ZV62051 70T2U62011
Normal A diode is an electronic part which makes the current

flow in one direction.
Current flow
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.
+24V
Switch
Solenoid
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.
Diode
Current flows while the diode is normal Some electrical parts, as solenoid valves, buzzers,
(The solenoid is energized.) 70ZV62052 relays, all equipped with electromagnetic coils may gen-
erate a surge voltage caused by counter electromotive
force when the power is turned off. This surge voltage
Short-circuit, failed in closed position.
may cause malfunction of equipment.
Diodes are provided to prevent such a malfunction.
+24V However, if a diode is damaged and short-circuited (or

Switch fails closed) in its inside, electronic parts may be
Solenoid harmed.
Therefore, if a malfunction occurs in electrical equip-

Diode ment, electrical connection diagrams should be referred
to first, to determine and repair the cause. If a diode is
Current flows through the diode with smaller resistance. provided in the electrical equipment, the diode should
The solenoid is not energized. be checked for damage.
95ZV62074
95ZV-2 EU FS 62-119
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
Coil
about 300  or smaller, the continuity is detected.
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 12V
Diode check mode
30A
ECM Battery
(1)
R1 BR F15 WR (2) (3) WP
B AC
R2 C 5A
(2)(3): Diode unit
Suppression diode
15A
F12
F14
F13
5A
5A
R1
Charge From
circuit alternator
I terminal
B Neutral
relay
70V2U62005
Forward check
Continuity is detected in the status shown in the figure.
Normal Continuity is not detected when tester terminals are
connected in opposite way.
Continuity is not detected in either way Disconnection
Abnormal
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 Judgement

Continuity (voltage value) Over level Normal
Over level Over level Open circuit
0 volt 0 volt Short-circuit
95ZV-2 EU FS 62-120
Diode
Resistance check mode
Analog type tester
R1>0 R2=
0 0
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
0 0 Short-circuit
95ZV-2 EU FS 62-121
Diode
Surge voltage and surge suppres- Fig. 3

sion diodes
Fig. 1 Surge suppression
diode
Electromagnetic field
forms when switch closes. Coil
Current direction
Coil
Voltage
Battery
Current
Switch or
Current [A]
Voltage [V]
transistor
Time [sec] K70V2J62006
Load When the surge voltage was generated, it causes to

115ZVE62032
increase wear on the switch points.
Some electrical parts such as solenoid valves are During the coil is being activated by the transistor, when
equipped with a coil. the excruciating high voltage is loaded on the transistor,
the transistor may be broken.
When a coil is energized, an electromagnetic field is
formed. See fig. 1. In order to absorb this surge voltage, connect the diode
parallel to the coil in the reverse direction against the
Fig. 2 power supply.
Snap!
When the switch opens, the When the switch is off, the same amount of electric cur-
field collapses across the rent, that was flown till now, flows through the diode.
coil windings.
Coil
Voltage This electric current is attenuated gradually and finally it
Battery
Current reaches zero. That means no surge voltage is gener-

ated in the circuit.
Current [A]
Voltage [V]
ON OFF This diode is called as flywheel diode.

Time [sec]
Surge voltage
Load
115ZVE62033
When the solenoid coil is de-energized, the field col-

lapses across the coil. The collapse of this electromag-
netic field across the solenoid coil generates an
unregulated voltage surge. See fig. 2.
This can damage transistors, contacts, and other elec-

tronic parts. (See connection diagram.)
95ZV-2 EU FS 62-122
MEMO
95ZV-2 EU FS 72-1
72 Function & Structure Operator Station Group

Operator Station Group
Cabin ....................................................................... 72-2

Operator Seat.......................................................... 72-9
Steering and Transmission Shift Lever.................... 72-10
Air Conditioner ........................................................ 72-13
95ZV-2 EU FS 72-2
Cabin
Cabin
B
A A
3
7
5
6
1
2
A-A
4
B-B
85V2E72001
The cabin equipped with the ROPS (Roll Over Protec-

tive Structure) is provided as standard.
1. Door (left side)

2. Front wiper
3. Window washer jet nozzle
4. Outside air suction port (air conditioner)
5. Antenna
6. Sun visor
7. Rear view mirror
95ZV-2 EU FS 72-3
Cabin
Glass
70V2E72001
1. Front glass
2. Front side glass
3. Rear glass
95ZV-2 EU FS 72-4
Cabin
1. Part number 32011-21690 2. Part number 32011-21700
Clear glass Clear glass

(Outside) Laminate: 0.76 mm (Outside) Laminate: 0.76 mm
T=3.0 T=3.0
Green glass Green glass

(Inside) (Inside)
T=3.0 T=3.0
A-A A-A
(mm)
327.5
(mm)
0
R2
R3
953
A
A
1195
A
1149
R3
R53
96
R3
4- 299.5
R3
0
52.5
646.5 699
70V2E72002 70V2E72003
Note Note
This glass must comply with ECE REG43. This glass must comply with ECE REG43.
95ZV-2 EU FS 72-5
Cabin
3. Part number 32011-21500
(mm)
1262.5
R2 4
4 R2
848
T=6.0
0 R3
R3 0
1325.5
70V2E72004
Note
This glass must comply with ECE REG43.
95ZV-2 EU FS 72-6
Cabin
Wiper mount
Front wiper
5
714 (Along surface)
Wipin
g ang
le 56º
ace)
2
ng surf
1
lo
R750(A
2
1 3
97ZV72004
1. Wiper motor 4. Intermittent wiper relay

2. Wiper arm 5. Washer jet nozzle
3. Wiper blade
Rear wiper
3
50
R5
450
2 106
97ZV72005
1. Wiper motor 3. Wiper blade

2. Wiper arm 4. Washer jet nozzle
95ZV-2 EU FS 72-7
Cabin
Wiper motor
Front
Cabin
(Automatic stop position)

12
159200 589
24V
100
3 4 5 6
80
(B
ø5 the
115
re
a
70
rh
60
ol
e)
.2
(3º 10')
±0
5.6
R8
Wipin
g angl
e 56º 22
Ro
tati
ng
dire
cti on
(-1) AVS0.85 W
(-2) AVS0.85 L
(+) AVS0.85 R
(S) AVS0.85 Y
(+) AVS0.85 R
MOTOR ( L1~L3=3.7µH
C1~C3=0.2µF )
1
Circuit breaker
M
L3
L2 L1
C3
C2 C1
R R Y B L W
Washer motor 24 V
OFF
LOW
HIGH
SWITCH
Circuit diagram
2 7
97ZV72100
Wiper motor (front) specifications

1. Wiper motor assembly
2. Link assembly Nominal torque 23.5 N-m (2.4 kgf-m)
3. Washer Rated voltage DC 24 V
4. Nut Rotating speed Load: Low 46±4 min-1
5. Cap 1.0 N-m (0.1 kgf-m) High 68±7 min-1
6. Nut Low ≧ 32 min-1
Rotating speed Load:
7. Crank arm 4.0 N-m (0.4 kgf-m) High ≧ 42 min-1
No-load starting voltage (Minimum) ≦ 16 V
Automatic stopping voltage (Maximum) ≧ 32 V
No-load current ≦2A
Locked rotor current ≦ 15 A
95ZV-2 EU FS 72-8
Cabin
Rear
Wiping angle: 106º±3º

Automatic stop
position
L(+)
LB (+1) Y(S)
Cabin
AVS0.85 LB
(+1)
AVS0.85 L
(+)
1 AVS0.85 WB
AVS0.85 Y
( )
MOTOR (S)
(Circuit breaker) WB
M
2 3 4 5 6
LB Y L
Cabin Tightening torque:
+1 S + Pantagraph arm 6.4~9.3 N-m (0.6~0.9 kgf-m)
OFF
24V
ON
SWITCH
Circuit diagram (motor stop position)
K97V2J72001
1. Wiper motor Wiper motor (rear) specifications

2. Washer
3. Packing Nominal torque 12 N-m (1.2 kgf-m)
4. Nut Rated voltage DC 24 V
5. Cap Rotating speed Load: Speed 38±5 min-1
6. Nut 0.6 N-m (0.6 kgf-m) Current 2 A or less
Rotating speed Speed 40±5 min-1
No load Current 1 A or less
Starting voltage 16 V or less
Locked rotor current 7 A or less
95ZV-2 EU FS 72-9
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

3
1. Sit on the seat.
2. Turn handle (4) to adjust seat height.

Clockwise to raise seat.
2 Anti-Clockwise to lower seat.
1 3. Check ride indicator (5) shows green.

If red, readjust seat height.
Within the green band of the ride indicator there is 75

6 mm of height adjustment for any driver.
Note
The seat is designed so that it is unnecessary to make
any adjustment for the driver weight.
95ZV OM EU SEAT
4
5 Up-stop height adjustment control (europe specifi-
cation)
85V2E72003
To adjust the up-stop height, rotate handwheel (6) clock-

wise to raise the seat unseated, rotate it counterclock-
1. Reclining adjustment lever
wise to lower the seat unseated.
2. Back-and-forth adjustment lever
3. Arm rest height adjuster
4. Height and Weight adjuster
5. Ride indicator
6. 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.
95ZV-2 EU FS 72-10
Steering and Transmission Shift Lever
Tilt quantity
56 56
Operator
stand 7
8 95ZVE72009
1. Steering wheel Handle tilt

2. Transmission shift lever 56 mm in each direction from the center
3. Turn signal indicator and head lamp high/low selec-
tor lever Handle slide
4. Handle tilt adjustment lever 85 mm upward and downward
5. Gas spring
6. Column shaft assembly Note
7. Lower column shaft - Install gas spring (5) with its rod side facing down-
8. Orbitrol® ward as shown in the figure above.
- Install lower column shaft (7), together with the
Tilt case (1~6) can select the optimal position in the fol- Orbitrol®, from the underside of the operator stand.
lowing range:
95ZV-2 EU FS 72-11
Tilt case
1
1
4 Lock 6
release
position
2 7
2
5
4
Operator
stand
9
Operator
270 (355 when slid)
stand
Slide quantity
Lock position
85
10 3
97ZV72017
1. Column shaft assembly : (6): 21.5 N-m (2.2 kgf-m)

2. Bracket : (7): 49 N-m (5.0 kgf-m)
3. Bracket : (8): 54 N-m (5.5 kgf-m)
4. Handle tilt adjustment lever : (10) (inside): 31.9 N-m (3.3 kgf-m)
5. Bolt : (10) (outside): 89.1 N-m (9.1 kgf-m)
6. Nut
(double-start thread, tapered in lever mounting
area)
7. Nut
8. Nut
9. Bushing
10. Nut
95ZV-2 EU FS 72-12
Column shaft
Grease
charged Adhesive
4 applied
3 1
8
8
10 9
2
11 7
6
5
Waterproof seal 13
11
11
8
12 B-B
A-A
97ZV72018
1. Column tube Shift lever

2. Column shaft
3. Column bushing Refer to "Electrical Group 62".
4. Bushing
5. Terminal (male)
6. Ball bearing
7. C-shaped snap ring
8. U-shaped joint
9. Serrated shaft
10. Tube
11. Transmission shift lever installation positioning hole
12. Wiring output port
13. Bolt
: (13): 25 N-m (2.5 kgf-m)

95ZV-2 EU FS 72-13
Air Conditioner
Air Conditioner
Denso air conditioner components
4
1-1
1-2
5
1
7
9
2 10 12
11 14
6
8 13
97ZV72020
1. Air conditioner assembly Air conditioner specifications (system per-

1-1 Cooling unit assembly formance)
1-2 Blower assembly
2. Air distributor assembly
Cooling system performance
3. Recirculating air filter
4. Control panel
Cooling capacity 4.65 kw (15,881 BTU) ± 10%
5. Condenser assembly
Air quantity 550 m3/h (720 yd3/h) ± 10%
6. Compressor assembly
7. Receiver drier
8. Receiver drier bracket Power consumption 345 W (14.4 amps) ± 10%
9. Joint
10. Drain hoses Heating system performance
11. Relay
12. Thermistor* (inside air sensor) Heat radiation quantity 5.2 kw (17,759 BTU) ± 10%
13. Thermistor* (outside air sensor) Air quantity 380 m3/h (500 yd3/h) ± 10%
14. Solar sensor (insolation sensor) Rated voltage DC 24 V
Power consumption 170 W (7.1 amps) ± 10%
* or thermal resistor (Difference in temperature: 65ºC, water flow rate: 6 L/min)
95ZV-2 EU FS 72-14
Air Conditioner
Denso air conditioner structure

Cooling unit
37
14
57
51
38
13
25 2
50
49
24
9
24
23
11 6
5 8
15
3 17
16
12
97ZV72021
95ZV-2 EU FS 72-15
Air Conditioner
1. Cooling unit case (rear) 20. — 39. —

2. Cooling unit case (front) 21. — 40. —
3. — 22. — 41. —
4. Evaporator core 23. Power integrated circuit 42. —
5. Heater core assembly 43. —
6. Expansion valve 24. Servo motor (A/M, air mixing) 44. —
7. — 25. Servo motor (mode) 45. —
8. Tube 26. — 46. —
9. De-icing sensor 27. — 47. —
(thermal resistor) 28. — 48. —
10. — 29. — 49. Lever (face, front)
11. Door (upper) 30. — 50. Control lever (face, front)
12. Door (lower) 31. — 51. Door (S/A) (face, front)
13. Door (foot) 32. — 52. —
14. Damper (vent) 33. — 53. —
15. Pressure switch (triple) 34. — 54. —
16. Liquid tube 35. — 55. —
17. Suction tube 36. — 56. —
18. — 37. Lever (face, door) 57. Thermo sensor (water temperature)
19. — 38. Lever (foot, door)
95ZV-2 EU FS 72-16
Air Conditioner
Heater and accessories Air distributor (hood & defroster selection

box)
13
3
6
6 4 9
7
2
7
2
1
97ZV72024
11
17 10
1. Air damper case
2. Air damper case
3. —
4. —
5. —
6. Control lever
7. Door
97ZV72023 8. —
9. Control lever
1. Blower case
10. —
2. Blower case
11. —
3. Air damper case
12. —
4. Air damper case
13. Servo motor actuator (AY, inside/outside air)
5. Blower & blower motor
6. Servo motor
7. Door
8. —
9. —
10. Bracket
11. Pipe (for cooling motor)
12. —
13. —
14. —
15. —
16. —
17. Relay
95ZV-2 EU FS 72-17
Air Conditioner
Air compressor (with magnetic clutch)
2-1
2 2-2
2-3
2-6
2-8
5~7
2-7
85V2U72001
1. Compressor 3. —
2. Magnetic clutch assembly 4. —
2-1 Magnetic stator coil 5. Plate washer
2-2 Magnetic clutch pulley 6. Plate washer
2-3 Clutch hub 7. Plate washer
2-6 Plate washer
2-7 Snap ring
2-8 Snap ring
Condenser unit
3
1
4
3 2
12
10 95V2U72001
1. Condenser core 7. Cover

2. Blower assembly 8. —
3. Condenser bracket 9. —
4. Condenser bracket 10. Wire harness
5. — 11. —
6. — 12. Resistor
95ZV-2 EU FS 72-18
Air Conditioner
Control unit
Control
amplifier
Control panel
97ZV72027
Control panel
Temperature Vent mode

OFF switch Blower switches setting switches selector switch AUTO switch
Inside/outside air Liquid crystal display Air conditioner

selector switches (LCD) unit ON/OFF switch 97ZV72028
95ZV-2 EU FS 72-19
Air Conditioner
Function of cooling mechanism 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
Principle of cooling
agent. A down tube in the receiver drier is submerged
into the heavier liquid that is now at the bottom of the
Expansion
receiver drier. This tube will permit passage of only the
Indoor valve heavier liquid that is at the bottom of the receiver drier.
Expansion Condenser
Then the high-pressure liquid passes through the ther-
Evaporator
mal expansion valve that provides a restriction or throt-
Evaporation Releases
Condensation heat to the tles the flow of refrigerant. This restriction reduces the
outside. pressure of the liquid refrigerant thus reducing its boiling
Deprives heat point. The expansion valve also meters the amount of
Compression Refrigerant
of the adjacent
area.
refrigerant to the evaporator, by modulating the valve
from wide open to closed, which varies with the heat
Compressor
load. The expansion valve separates the high-pressure
Basic cooling cycle side from the low-pressure side.
97ZV72029
The refrigerant is now at the evaporator. Temperatures

in the evaporator are cold enough to cause the ambient
Function and operation of air conditioning sys- air to cool when blown through it. This causes conden-
tem sation to happen. The fan-charged air that rushes
through the evaporator is now going to shed its humid-
Very often, things are much simpler than they may ity. This humidity, or condensed water, is routed through
appear. This is also the case with an air conditioning some tubing to be discharged to the outside of the cab
system. Gas when compressed often heats as a result as waste water that falls to the ground. The refrigerant
of molecular compression, and when decompressed it is now on its way back to the compressor. It is still under
cools. Some gases are more prone to heat or cool to a pressure when compared to the atmospheric air pres-
greater degree when undergoing these changes than sure. However, because it is drawn along by the refrig-
are others. We use these natural laws to make an air erant compressor suction, we now say that is in the
conditioning system work. Another factor to take into suction side (low-pressure side) of the circuit.
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 tempera-

tures, imagine that you can very quickly make the refrig-
erant 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 con-
verted into a liquid at this point, while still in the con-
denser. This is why it is called the condenser, as it has
condensed the gas into a liquid. As a liquid that may still
95ZV-2 EU FS 72-20
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 --> liq-
uid --> gas ...", and carries heat from the low tempera-
ture side (inside the cab) to the high temperature side
(outside the cab) while changing its status.
There are many types of refrigerants. This air condi-

tioner 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 CH2FCF3

Molecular weight 102.03
Boiling point -26.19ºC (-15ºF)
Critical temperature 101.14ºC (214ºF)
4.1 MPa (41.45 kgf/cm2)
Critical pressure
(595 psi)
Critical density 511 kg/m3 (0.073 lbs)
Density of saturated liquid
1,206 kg/m3 (595 psi)
(at 25ºC/77ºF)
Specific volume of saturated vapor
0.0310 m3/kg
(at 25ºC or 77ºF)
197.54 KJ/kg (186 BTU)
Latent heat of evaporation (at 0ºC/32ºF)
(47.19 kcal/kg)
Combustibility Noncombustible
Ozone decomposition modulus 0
95ZV-2 EU FS 72-21
Air Conditioner
Refrigerant characteristics Generally, fluid (which is the generic name for com-
pressed / condensed non-gas liquid) has following prop-
erties.
100
(212)
1. When the temperature of gas at a certain pressure

Refrigerant temperature (ºC) (ºF)
80
(176)
decreases, the gas starts to condense and change
60
(140)
into liquid at a certain temperature. For each sub-
stance (liquid), this temperature is fixed at a given
40
(104)
35
pressure. This temperature determined by a given
(95)
20
pressure is called the "saturated temperature".
(68)
15
(59)
0
2. On the contrary when the temperature is deter-
mined, the pressure at which liquefication starts is
(
20
4) fixed. This pressure is called the "saturated pres-
(
30
22)
sure".
0 3.6 5 8 10 15 20 25 30 35
2
40 (kgf/cm ) The figure on the left shows the relationship
353 490 785 981 1,471 1,961 2,452 2,942 3,432 3,923 (kPa)
51 71 114 142 213 284 355 426 497 568 (psi) between the saturated temperature and the satu-
Gauge pressure (kgf/cm2G) rated pressure of refrigerant R134a.
Relationship between saturated pressure At the temperature and the pressure below at the
and saturated temperature of R134a 85V2U72002
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 25ºC (77ºF), the refrigerant should
change (be evaporated) from liquid into gas at a tem-
perature lower than 25ºC (77ºF). 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 con-

densed to liquid, the refrigerant is cooled down by out-
side air of about 35ºC (95ºF) 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.
95ZV-2 EU FS 72-22
Air Conditioner
Cooling circuit The figure on the left shows the cooling circuit of the air
conditioner.
In this circuit diagram, the area which cools down the air
inside the cab is the evaporator. The cooling circuit uti-
lizes the fact that the refrigerant absorbs heat (latent
heat of evaporation) from the adjacent area when evap-
orated, and cools down the air inside the cab. The area
Inside cab where the refrigerant is evaporated is the evaporator.
Pressure bulb
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 refriger-
Evaporator Expansion valve
ant (wet evaporation refrigerant with low degree of dry-
Blower ness) is supplied into the evaporator.
Inside engine room

For example, in order to cool down the air to 15ºC
(59ºF), the refrigerant can absorb the latent heat of
evaporation from the air only when it is evaporated at a
Compressor Cooling fan temperature lower than 15ºC (59ºF). It can be seen from
the figure in the previous page that the pressure of the
Pressure switch
refrigerant inside the evaporator should be 353 kPa (3.6
kgf/cm2G) (51 psi) or less to realize it. And in order to
Receiver dryer keep sufficient cooling effect, the supplied refrigerant
quantity should be adjusted so that the refrigerant sup-
Condenser plied to the evaporator is completely evaporated inside
the evaporator into dry vapor or gas.
Structure of cooling circuit
Accordingly, the cooling circuit should be constructed to
85V2U72003
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 expan-
sion 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 com-
pressor and heat change (heat radiation) of the con-
denser, which acts to change the state of the gas to
liquid.
95ZV-2 EU FS 72-23
Air Conditioner
Electrical circuit
Control schematic drawing
Outside air
sensor Input signals Input signals
Set temperature, room temperature,
water temperature, air temperature Insolation sensor
after evaporator Outside air sensor
Insolation e = Inside air temperature - Set temperature Set temperature

sensor correction
Freeze sensor
Water temperature
sensor
Blower voltage/temperature control/blow-off servo motor position determination
Inside air
Blower
Water temperature (ºC)
Warm-up control
sensor 55
voltage
BLC
Temperature 25
control
servo HOT
Blower motor COOL

Blow-off
Temperature servo FACE
control servo B/I
FLOOR
Y value
Blow-off servo
Compressor ON-OFF
ON
3 4
Freeze sensor temperature (ºC)
95ZVE72018
95ZV-2 EU FS 72-24
Air Conditioner
Air conditioner functions of com-

ponents
Control panel
Name and function of each part on control
panel
(3) Temperature (4) Vent mode selector

(1) OFF switch Indicator lamps (2) Blower switches setting switches switch (5) AUTO switch
(6) Inside/outside air selector switches (7) Liquid crystal Indicator lamps (8) Air conditioner
display (LCD) unit ON/OFF switch
97ZV72036
- (1) OFF switch - (2) Blower switches
This switch stops the operation of the blower and the These switches change over the air flow quantity in
air conditioner. six steps.
When OFF switch (1) is pressed, the set tempera- The air flow quantity is displayed on the LCD unit.
ture and the air blow quantity displayed on LCD unit When the switch is pressed, the air flow quantity
(7) as well as the indicator lamps above AUTO increases.
switch (5) and air conditioner ON/OFF switch (8) When the switch is pressed, the air flow quantity
turned "off", and operation is stopped. decreases.
In the automatic mode, the air flow quantity is auto-
matically 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 "high"

95ZV-2 EU FS 72-25
Air Conditioner
- (3) Temperature setting switches
These switches set the temperature inside the cab in

the range from 18.0ºC (65ºF) to 32.0ºC (90ºF).
When the switch is pressed, the set temperature
increases.
When the switch is pressed, the set temperature
decreases.
Usually, set the temperature to 23~25.0ºC
(72~77ºF).
Display on the LCD unit and the function
Display on LCD unit Set temperature

18.0ºC (65ºF) Maximum cooling
18.5~31.5ºC Temperature inside cab is controlled so that
(65~95ºF) set temperature is realized.
32.0ºC (90ºF) 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 posi-
tions.
In the automatic mode, the vent mode is automati-
cally changed over.
Display on Vent positions

Vent mode Remarks
LCD unit (A) (B) (C) (D)
Face (blow-off to upper portion of

body mainly during cooling) ○ ○
Face & foot ○ ○ ○
Foot
(blow-off to feet mainly during heating) ○
This mode is not

Foot & defroster ○ ○ ○ selected in automatic
mode.
This mode is not
Defroster ○ ○ selected in automatic
mode.
- (5) AUTO switch
This switch automatically changes over the air blow When the automatic mode is changed over to the
quantity, the vent mode and the inside/outside air in manual mode, the indicator lamp above AUTO
accordance with the set temperature. switch (5) is extinguished. In the manual mode, the
When AUTO switch (5) is pressed, the indicator air blow quantity, the vent mode and the inside/out-
lamp above it lights. side air can be changed over by manipulating each
Usually, press this switch, set the temperature by switch.
using temperature setting switches (3), and use the
air conditioner in the automatic mode.
95ZV-2 EU FS 72-26
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 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.
Outside air entry
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 the OFF switch (1) is pressed, the set temper-
ature 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 (cool-

ing 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 con-
ditioner is turned off and the indicator lamp is extin-
guished.
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.)
95ZV-2 EU FS 72-27
Air Conditioner
Operating method 2. Stopping the automatic operation
Normal use
1. Automatic operation (1) OFF switch
Set temperature (3) Temperature setting (5) AUTO switch

switches
97ZV72041
Air flow quantity (8) Air conditioner

ON/OFF switch Press OFF switch (1). Then, the set temperature and
the air flow quantity displayed on the LCD unit are extin-
97ZV72040
guished, the indicator lamps above AUTO switch (5)
and air conditioner ON/OFF switch (8) are extinguished,
(a) Set AUTO switch (5) to ON. Confirm that the set and the operation is stopped.
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/out-
side air to realize the set temperature.
Note
When the vent mode is set to or
in the automatic operation, if the engine water tem-
perature is low, the air flow quantity is restricted to
prevent blow-off of cold air.
95ZV-2 EU FS 72-28
Air Conditioner
3. Manual operation 4. Stopping the manual operation
(2) Blower switches (3) Temperature (4) Vent mode

setting switches selector switch
(1) OFF switch
(6) Inside/outside air selector switch (8) Air conditioner

ON/OFF switch
97ZV72042 97ZV72041
(a) Press blower switches (2), and adjust the air flow Press OFF switch (1). Then, the set temperature and
quantity. the air flow quantity displayed on the LCD unit are extin-
Confirm that the set temperature and the air flow guished, the indicator lamps above AUTO switch (5)
quantity are displayed on the LCD unit. and air conditioner ON/OFF switch (8) are extinguished,
and the operation is stopped.
(b) Set to ON air conditioner ON/OFF switch (8). Con-
firm 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.
95ZV-2 EU FS 72-29
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 (5) AUTO switch
(6) Inside/outside (3) Temperature

air selector switch setting switches
(6) Inside/outside (3) Temperature
air selector switch 97ZV72045
setting switches
97ZV72044
(a) Press blower switches (2), and adjust the air flow
quantity.
(a) Press blower switches (2), and adjust the air flow Confirm that the set temperature and the air flow
quantity. quantity are displayed on the LCD unit.
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.
(b) Press vent mode selector switch (4), and display
the vent mode on the LCD unit. (c) Set outside air introduction selector switch (6).
(c) Set to ON air conditioner ON/OFF switch (8). Con- (d) Press temperature setting switches (3), and display
firm that the indicator lamp above the switch lights. the set temperature "32.0" (maximum heating sta-
tus) on the LCD unit.
(d) Arbitrarily set blower switches (2), temperature set-
ting switches (3) and inside/outside air selector Adjust the louver at each vent position so that air flow
switches (6). reaches the windows.
Then, the air conditioner realizes the bi-level operation When defogging the windows or dehumidifying the air
in which cold air is blown to the head and hot air is inside the cab in rainy season, set air conditioner ON/
blown to the feet. OFF switch (8) to ON.
95ZV-2 EU FS 72-30
Air Conditioner
Other functions 3. Failure code deletion
Self-diagnosis function After completing the inspection and/or the repair,

delete the failure codes memorized in the com-
Each sensor and equipment used in the air conditioner puter.
can be diagnosed for failure. 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 sec-
(1) OFF switch onds or more.
<Display on the LCD unit and the failure mode>
Display Failure mode

E- No failure
E11 Wire breakage in inside air sensor
(6) Inside/outside E12 Short-circuit in inside air sensor
air selector (3) Temperature setting switches E13 Wire breakage in outside air sensor
switches Press and hold both the " " and " "
switches together E14 Short-circuit in outside air sensor
(for 3 seconds or more). 97ZV72035
E15 Wire breakage in water temperature sensor
E16 Short-circuit in water temperature sensor
1. Press the OFF switch to stop the operation. E18 Short-circuit in insolation sensor
(The set temperature and the air flow quantity dis- E21 Wire breakage in vent sensor
played on the LCD are extinguished.) E22 Short-circuit in vent sensor
E43 Abnormality in vent damper
2. When both temperature setting switches " " and
E44 Abnormality in air mixing damper
" " (3) are pressed and held together for 3 sec-
E45 Abnormality in inside/outside air
onds or more, the failure mode is displayed on the
E51 Abnormality in refrigerant pressure
LCD unit.
(a) If two or more failure are detected, the displayed Celsius-Fahrenheit selector function for the set tem-
contents can be scrolled through by pressing either perature display
one of temperature levels (3) " " or " ".
While the blower is operating, press and hold both tem-
(b) Press OFF switch (1) again to finish the self diag- perature setting switches (3) " " and " " together
nosis function and return to the normal display. for 5 seconds or more to change over the unit of the dis-
played value between Celsius and Fahrenheit. How-
ever, the unit type (C or F) itself is not displayed.
Only the set value is displayed.
Value displayed on LCD unit

Celsius (ºC) 18.0~32.0
Fahrenheit (ºF) 65~90
95ZV-2 EU FS 72-31
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
air
Air mixing damper B (completely closed)
[In the case of maximum heating]

Air mixing damper A (completely closed)
Blower motor
Co
ld
ir
a ir
ta
Ho
Inside/outside air selection damper
Air mixing damper A Inside
air
Outside
air
Air mixing damper B (completely opened) 80ZVE72002
Fan
During maximum cooling, the air mixing damper B is
completely closed, and the air mixing damper A is com-
pletely opened. As a result, the air cooled by the evapo-
Blower motor rator does not go through the heater radiator but is
blown off.
Heater radiator Evaporator
Air mixing damper B During maximum heating, the air mixing damper A is
completely closed, and the air mixing damper B is com-
pletely opened. As a result, all the air which has gone
through the evaporator goes through the heater radia-
80ZVE72001 tor, then the warmed air is blown off.
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.
95ZV-2 EU FS 72-32
Air Conditioner
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
Evaporator between the target and the refrigerant in the evaporator.
(5)
(7)
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
(4) between the refrigerant and the air.
(2)
By cooling, the moisture contained in the air condenses,
(8) (1)
changes into water drops, and adheres to the outside of
the evaporator. If these water drops are frozen, the cool-
(6) ing effect deteriorates. To prevent this, attention should
be paid also to proper drainage of condensed water.
The refrigerant quantity supplied to the evaporator is

(3) 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
Refrigerant flow inside evaporator ( ) evaporator should be minimal.
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 Symptom Cause Action

Both high pressure and low pressure are low,
- Joint portion of supply area - Tightening
Gas leak and air bubbles can be seen through sight
- Cracks in evaporator main body - Repair/replacement
glass.
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
- Blockage in filter
Freezing Air quantity is small, and low pressure is low. (Evaporator is not preforming - Cleaning/replacement
inadequately.)
95ZV-2 EU FS 72-33
Air Conditioner
Expansion valve (box type) Expansion valve operation
(Evaporator) Diaphragm
Evaporator
Spring
Temperature
sensing rod
Diaphragm
Temperature sensing rod
Needle valve (To compressor)

(From receiver) Needle valve
Structural drawing of box type expansion valve From receiver To compressor

(High pressure) (Low pressure)
97ZV72049 97ZV72050
The expansion valve offers the following two functions. The temperature sensing rod detects the temperature of
the refrigerant, and transfers the detected temperature
1. By injecting the liquid refrigerant at high tempera- to the refrigerant gas chamber.
ture and high pressure which has gone through the
receiver from a small hole, the expansion valve The gas pressure changes in accordance with the
expands dramatically the liquid refrigerant into mist detected temperature, the temperature sensing rod
refrigerant at low temperature and low pressure. directly connected to the diaphragm is moved, then the
needle valve opening is adjusted.
2. Promptly in accordance with the vaporized status of
the refrigerant inside the evaporator, the expansion - When the temperature at the exit of the evaporator is
valve adjusts the refrigerant quantity. low or when cooling load is small, following occurs.
In order to ensure that the evaporator offers its full
performance, the liquid refrigerant should be kept in The gas pressure inside the diaphragm chamber
a state in which it deprives heat of the adjacent becomes low, the volume decreases, the temperature
area and its evaporation is always completed at the sensing rod moves to the right, and the needle valve is
exit of the evaporator. closed.
To realize this, the expansion valve automatically
adjusts the refrigerant quantity in accordance with - When the temperature at the exit of the evaporator is
fluctuation of the temperature inside the cab (cool- high or when cooling load is great, following occurs.
ing load) and fluctuation of the rotation speed of the
compressor. The gas pressure inside the diaphragm chamber
The expansion valve consists of a needle valve, a becomes high, the volume increases, the temperature
diaphragm and a temperature sensing rod. sensing rod moves to the left, the needle valve is
The temperature sensing rod detects the tempera- opened, and more quantity of refrigerant is supplied to
ture of the refrigerant which has gone through the the evaporator.
evaporator, and transfers the detected temperature
to the refrigerant gas chamber located in the upper
portion of the diaphragm chamber.
95ZV-2 EU FS 72-34
Air Conditioner
Troubleshooting the expansion valve

Blocked expansion Both high pressure and low pressure are low,
valve or defective and air bubbles cannot be seen through sight - Expansion valve - Cleaning/adjustment or replacement
adjustment (too closed) glass.
Defective adjustment Low pressure is too high, and compressor
- Expansion valve - Adjustment or replacement
(too open) head is cold.
Cooling is disabled during operation. Frosting
Freezing caused by is not detected in evaporator. Both high - Replace receiver tank, evacuate air,
- Expansion valve
moisture pressure and low pressure are low, and air then charge gas again.
bubbles cannot be seen through sight glass.
95ZV-2 EU FS 72-35
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 radia-
tor, the air receives heat from the heater radiator fins
and is warmed.
The hot water inside the heater radiator is forcedly cir-

culated by the engine water pump.
Troubleshooting the heater radiator

- Joint portion of supply area
Water leak Water leaks from heater core. - Repair/replacement
- Cracks in heater core main body
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
95ZV-2 EU FS 72-36
Air Conditioner
Servo motor
3 2 1
5 4
1
2
6
3
4
5 M
7
6
7
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 deter-
mined 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 posi-
tion 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

Motor is locked - Motor
- Servo motor does not rotate. - Repair/replacement
(disabled). - Control unit
- Indicator lamps of temperature setting
switches do not light in accordance with - Fixed plate
Contact is contacting
preset pattern. - Moving contact - Repair/replacement
poorly.
- Servo motor does not stop in accordance - Control unit
with preset pattern.
95ZV-2 EU FS 72-37
Air Conditioner
Blower motor assembly Blower motor assembly specifications
Voltage DC 24 V
Fan Blower motor
Number of rotations of motor 3,100 min-1
Power consumption 225 W (9.4 amps) ± 10%
Fan outer diameter ø150 (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

- Blower motor
Blower motor operation is defective. Air is not blown at all. - Repair/replacement
- Control unit
BLC (blower linear control)
85V2U72004
97ZV72054
This resistor changes over the air quantity of the blower

motor.
Troubleshooting the blower linear control

- BLC
Wire in BLC is broken. Air quantity does not change. - Replacement
- Control unit
- Blower motor
Blower motor operation is defective. Air is not blown at all. - Repair/replacement
- Control unit
95ZV-2 EU FS 72-38
Air Conditioner
De-icing sensor (Thermistor (or thermal resis- Evaporator

tor))
Appearance of thermistor
8,000
7,000
6,000
Thermistor
Resistance ()
5,000
4,000 Heater radiator 97ZV72056
3,000
2,000
The thermistor mounted on the blowoff port side of the
1,000 evaporator detects the temperature of the air cooled by
0
10 5 0 5 10 15 20 25 30
the evaporator, and transmits it as a signal to the control
(14) (23) (32) (41) (50) (59) (68) (77) (86) amplifier.
Temperature (ºC) (ºF)
Characteristics curve between temperature
and resistance of thermistor 85V2U72005 If the air at the vent is 3ºC (37ºF) or less, the control
amplifier turns off the compressor clutch relay. If the air
at the blowoff port becomes 4ºC (39ºF) or more, the
The thermistor, a kind of semi-conductor, offers the
control amplifier turns on the compressor clutch relay
characteristics as shown in the curve on the above.
again to restart cooling.
When the temperature becomes high, its resistance
Because the air temperature at the vent is detected and
becomes small. When the temperature becomes low, its
the compressor clutch relay is turned on and off accord-
resistance becomes large.
ingly, freezing of the evaporator is prevented.
Troubleshooting the thermistor

Cable in thermistor is broken. Compressor clutch does not work.
- Thermistor - Replacement
Thermistor is short-circuited. Air not blowing.
*Note
For temperature reference between ºC and ºF please
see references below.
Temp ºC Temp ºF
-10ºC 14ºF
0ºC 32ºF
10ºC 50ºF
20ºC 68ºF
25ºC 77ºF
30ºC 86ºF
95ZV-2 EU FS 72-39
Air Conditioner
Water temperature sensor Foot/defroster selection box
Air conditioner unit
Foot
Def
97ZV72057 97ZV72059
This sensor detects the temperature of the engine cool- This selection box changes over the vent positions
ing water flowing into the heater core, and feeds it back between the foot side and the defroster side.
to the control panel.
When the vent mode selector switch (MODE) on the
This sensor is installed on the rear side of the heater control panel is pressed, the servo motor in this selec-
core, and can be taken out when being pulled out. tion box changes over the vent selection damper to the
foot side or the defroster side by way of a link and lever.
Temperature Resistance value
-30ºC (-22ºF) 91.4 k
25ºC (77ºF) 5 k
100ºC (212ºF) 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

0ºC (32ºF) 16.45 k
25ºC (77ºF) 5 k
95ZV-2 EU FS 72-40
Air Conditioner
Compressor and magnetic clutch Compressor specifications

Compressor
Piston
Discharge valve
6 1 Discharge valve
74
3
10
5 Suction valve
Suction valve
Diagonal plate
8
Suction/compression action 97ZV72061
Model 10S150
2 9 Cylinder diameter ø32 (1.26")
11
Stroke 20.8 mm (0.82")
97ZV72060
Number of cylinders 10
Cylinder capacity 167.3 cm3 (10.21"3)
Maximum allowable number of rotations 6,000 min-1
1. Compressor 7. Coil
2. Magnetic clutch 8. Bearing Lubricating oil ND-OIL8
3. Rotor 9. Shaft Lubricating oil quantity 180 cm3 (11"3) [6 oz]
4. Stator 10. Dust proof cover
5. Hub 11. Pressure relief valve
6. Pulley
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 temper-
ature 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 cylin-
ders) 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 com-

pression stroke, the other one is in the vacuum stroke.
The compressor is lubricated by the compressor oil con-

tained 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 sei-
zure, 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.
95ZV-2 EU FS 72-41
Air Conditioner
Magnetic clutch Magnet clutch specifications
Model L50T
S
Voltage DC 24 V
Pulled Power consumption 40 W (1.67 amps)
force
Stator Drive belt V-ribbed belt (six ribs)
Switch Air gap 0.5±0.15 mm (0.020" ± 0.006")
Iron piece
(rotor)
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 com-
pressor.
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.
95ZV-2 EU FS 72-42
Air Conditioner
Troubleshooting the compressor and magnetic

clutch

- Compressor temperature is abnormally high.
- High pressure is abnormally low, and low
pressure is abnormally high.
Suction or exhaust valve is - Air bubbles cannot be seen through sight - Suction or exhaust valve - Repair/replacement
damaged. * glass.
- Abnormal sounds are made while clutch is
turned on.
Clutch draw voltage is low. - Stator coil - Replacement
- Wiring on main body - Repair
Power is not supplied to
- Control amplifier - Replacement
stator coil.
- Pressure switch - Replacement
- Compressor does not rotate.
Gap between hub and rotor (Air in cab does not become cool enough.) - Magnetic clutch - Replacement
is large.
Compressor main body is
defective - Shaft, piston - Repair/replacement
(seized, etc.).
Clutch bearing is damaged. - Clutch bearing - Replacement
Contact or slippage caused
- Abnormal sounds are made while clutch is
by too small gap between - Magnetic clutch - Replacement
turned off.
hub and rotor.
V belt is slack. - V belt - Adjustment/replacement
Compressor main body is - Internal compressor trou-
- Abnormal sounds are made while clutch is - Repair/replacement
defective. ble
turned on.
V belt is slack. - V belt - Adjustment/replacement
* This can be the result of "liquid charging". Do not liquid charge as a compressor cannot compress liquid; this will damage it.
95ZV-2 EU FS 72-43
Air Conditioner
Condenser unit Condenser fan motor
The condenser fan motor used to cool down the con-

denser is mounted on the condenser together with a fan
Condenser
shroud.
Blower assembly Condenser specifications

Resistor
Voltage DC 24 V
Power consumption 80 W (3.4 amps) x 10%
Cover
Air quantity 1,750±10 m3/Hr (61,800"3/Hr)
Number of rotations of motor 2,200 min-1 (rpm)
Fan motor
95V2U72002
Each condenser unit consists of a condenser, a con-

denser 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 (70ºC, 1,618 kPa (16.5 kgf/cm2)) (158ºF (235
psi)) sent from the compressor, and change it into liquid
refrigerant during passing tubes.
95ZV-2 EU FS 72-44
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

Heat radiation quantity is
- Blockage or crushed fins - Clean or replace condenser
insufficient due to blockage*. Both high pressure and low pressure are
abnormally high, and air does not become
Rotation of condenser fan cool enough. - Fan motor - Repair or replace motor
motor is defective.
High pressure is abnormally high, low
pressure is abnormally low, and air does not
Blockage / condenser airflow - Internal to condenser fins - Clean or replace condenser
become cool enough.
Air bubbles can be seen through sight glass.
Both high pressure and low pressure are
- Leaks at joints - Tightening
Gas leak abnormally low, and air bubbles can be seen
- Cracks in main body - Repair or replacement
through sight glass.
* It is important to check the fan blades also as these can become bent or packed with dirt, making them ineffective.
95ZV-2 EU FS 72-45
Air Conditioner
Receiver dryer Desiccant
If moisture is present inside the cooling circuit, the com-

pressor valve and oil may deteriorate, metal parts within
the circuit may corrode, or moisture may be frozen
Refrigerant inlet inside expansion valve which may clog the circuit. To
Refrigerant outlet prevent such failure, synthetic zeolite (drying agent) is
positioned inside the air conditioner and acts as a desic-
cant 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
Desiccant Strainer
be replaced.
Desiccant specifications
Capacity 550 cm3

Receiver tube Desiccating agent Synthetic zeolite
Desiccating agent capacity 290 g
Receiver tank
IMPORTANT
If parts of the cooling circuit are removed and left for
a long time for repair or another reason, the desiccant
97ZV72065 absorbs moisture contained in the air and loses its
absorption performance, and the receiver dryer
should be replaced. To prevent this, after parts are
The receiver dryer consists of a receiver tank, desic-
removed, all openings should be plugged.
cant, 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 fluc-
tuation 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 cir-
cuit.
In addition, the receiver tank stores a reserve of refriger-

ant 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.
95ZV-2 EU FS 72-46
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 consid-

erably clogged (in this case, the high pressure
increases and the low pressure decreases), the entire
receiver dryer should be replaced.
Troubleshooting the receiver tank

- At first, air in cab will cool down, but after a
Icing - Desiccating agent in receiver - Replacement of receiver dryer
short time no longer will cool properly.
- High pressure is excessively high, low pres-
Blockage in strainers sure is excessively low, and air does not - Blockage in strainers - Replacement of receiver dryer
become cool enough*.
*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.
95ZV-2 EU FS 72-47
Air Conditioner
Sight glass Pressure switches
Sight glass Terminal
Receiver joint Contact area
Receiver dryer
97ZV72066 97ZV72067
This sight glass is installed on the receiver joint located The pressure switch detects the pressure on the high
on the top of the receiver dryer. Only through this sight pressure side of the cooling circuit, and stops the com-
glass, the refrigerant quantity inside the circuit can be pressor when detecting any abnormality so that damage
visually checked. of the equipment in the cooling circuit can be prevented.
There are three types of pressure switches, high pres-

WARNING sure type, medium pressure type and low pressure
Possible freezing of eye tissue. type, which function as shown in the table below.
Always wear protective eyewear when doing a visual
inspection.
95ZV-2 EU FS 72-48
Air Conditioner
Switching pressure Switch operation Causes of abnormal

Switch Function
kPa (kgf/cm2) (psi) confirmation method pressure
Pressure switch coupler

2,550 3,136 A
When pressure between Heat radiation of condenser
compressor and expansion (26) (32) is insufficient due to clogging
High valve becomes abnormally (370) (455) in condenser or defective
pressure high, this switch shuts down ON C D rotation of condenser fan*.
switch power supplied to compressor
magnetic clutch to protect *A damaged fan blade would
OFF B
circuit. produce a similar symptom.
Check conductivity
between A and B.
When detecting fluctuation of

pressure between compressor 1,519
and expansion valve, this (15.5)
switch gives a signal to control (220)
Medium amplifier about whether to ON Check conductivity between C and D
pressure rotate condenser fan motor at in pressure switch coupler shown
switch low speed or high speed. above.
While this switch is ON, fan OFF
motor rotates at high speed. 1,225
While this switch is OFF, fan (12.5)
motor rotates at low speed. (178)
When pressure between

compressor and expansion 226
valve becomes abnormally low (2.3)
due to refrigerant leak, this (33)
Low switch shuts down power ON Check conductivity between A and B
Refrigerant leak from a part
pressure supplied to compressor in pressure switch coupler shown
of circuit.
switch magnetic clutch to prevent above.
seizure of compressor caused OFF
by insufficient compressor oil 196
which decreased together with (2.0)
refrigerant. (28)
Troubleshooting the pressure switch

- Condenser fan motor does not change its speed - Medium pressure
Insufficient cooling - Replacement
(to high speed). switch
- Even when abnormal high pressure (3,136 kPa (32 kgf/cm2)
(455 psi)) occurs, compressor does not turn off. - High or low pres-
Gas leak - Replacement
- Even when gas (refrigerant) has run short, compressor does sure switch*
not turn off.
*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.
95ZV-2 EU FS 72-49
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

0 compressor service valve releases the refrigerant to the
atmosphere when abnormal high pressure occurs.
Pressure
28.1 35.0 42.4 (kgf/cm2 ) IMPORTANT
2,756 3,430 4,158 (kPa)
400 500 600 (psi) When the refrigerant quantity inside the cooling cir-
cuit is correct, the pressure switch always remains
Characteristics drawing of ON even if the compressor is stopped because the
relief valve operation refrigerant pressure is approximately 588 kPa (6.0
kgf/cm2) (85 psi) as far as the outside air temperature
97ZV72069a
is around 25ºC (77ºF).
When the outside air temperature becomes 0ºC
(32ºF) 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.
Pressure relief valve 97ZV72070

95ZV-2 EU FS 72-50
Air Conditioner
Relay A Relay B
(Condenser fan, condenser fan high, compressor (Evaporator fan motor, low/high)
clutch)
97ZV72072 97ZV72099
Relay A specifications Relay B specifications
Rated voltage DC 24 V Rated voltage DC 24 V

Rated current 16 A Rated current 11 A
Rated coil current 0.1 A Rated coil current 0.075 A
Troubleshooting the relay

- Blower motor does not rotate at all. - Blower motor main
- Blower motor remains rotating. relay
- Blower motor does not rotate at high speed. - Blower motor Hi
- Blower motor remains rotating at high speed. relay
- Blower motor does not rotate at medium speed Me2. - Blower motor Me2
- Blower motor speed does not change from Me2 to Me1. relay
- Blower motor does not rotate at medium speed Me1. - Blower motor Me1
Coil wire is broken. - Blower motor speed does not change from Me1 to low speed. relay
- Replacement
Contact is melted down.
- Both condenser fans do not rotate.
- Condenser fan relay
- Both condenser fans remain rotating.
- When condenser fan is at high pressure, it does not rotate at
high speed. - Condenser fan relay
- When condenser fan is at low pressure, it remains rotating at 1
high speed.
- Compressor magnetic clutch does not turn on. - Compressor clutch
- Compressor magnetic clutch remains ON. relay
95ZV-2 EU FS 72-51
Air Conditioner
Refrigerant hose
WARNING
Burst hazard
These hoses operate at high pressure for HVAC sys-
Outer layer tems and must not be replaced with substandard
hoses.
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.
95ZV-2 EU FS 72-52
Air Conditioner
Charge of refrigerant
WARNING
WARNING Serious accidents may occur during storage and
transportation of a service can.
Serious accidents may occur in the refrigerant charg- Observe the following contents.
ing work. - A service can accommodates high pressure gas in
Observe the following contents. the saturated liquid status. If the temperature rises,
- Only trained or experienced specialists having suf- the pressure may increase drastically and the can
ficient knowledge on the contents of the work may burst. Keep the temperature of the service
should be allowed to perform the refrigerant charg- can at 40ºC (104ºF) or less.
ing work. Make sure to keep the can away from hot objects
- If the refrigerant comes into contact with your eyes, or fire.
you may lose your eyesight. Make sure to wear - During storage, make sure to avoid direct sunlight,
protective goggles. and store the can in a dark and cool place.
- The refrigerant in the liquid status is at low temper- - Inside the closed cab (including trunk), the air tem-
ature (approximately -30ºC (-22ºF)). If it splashes perature may rise considerably due to solar heat,
on your skin, you may suffer from frostbite. Pay etc., and may become dangerously temperature
close attention when handling it. even in winter if the closed cab is exposed to direct
- If the refrigerant (Refrigerant R134a) touches a hot sunlight. Never put the can inside the cab.
object (approximately +400ºC or more), it decom- - If the service can suffer from flaws, dents and
poses and generates harmful substances. deformations, its strength deteriorates. Never hit or
Never release the refrigerant in a room where ven- drop it. And never throw or drop a package of cans
tilation is bad and there is a hot object or a fire while loading or unloading it.
(such as in the presence of a stove). - Keep the can away from the reach of children.
- In order to protect the environment, do not release
the gaseous refrigerant to the atmosphere.
IMPORTANT
CAUTION - It is prohibited by law to reuse service cans. Never
reuse them.
Serious accidents may occur during the refrigerant - Pay close attention so that air and dusts do not
charging work. enter into the cooling circuit.
Observe the following contents. - Never charge the refrigerant excessively.
- When warming a service can to charge the refrig- - The air conditioner is so designed as to be used
erant, make sure to open the low pressure valves with Refrigerant R134a. Never charge any other
of the service can and the gauge manifold, then refrigerant such as Freon R12.
warm it with hot water of 40ºC (104ºF) or less (tem- - If the compressor oil (ND-OIL 8) adheres to the
perature at which you feel warm when putting your painting face or the resin area, the painting may
hand into it). peel off or the resin may be damaged. If so, wipe it
Never warm the can with boiling water or overheat off soon.
it with open fire. If the can is treated in such a way, - Tighten the piping at the specified torque.
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.
95ZV-2 EU FS 72-53
Air Conditioner
Work procedure Charging procedure
The refrigerant charging process is mainly divided into 1. Charge the system with the required amount of gas
"refrigerant evacuation procedure" and "gas charging by weight, and check for leaks by letting the HVAC
procedure" as shown below. system sit static and permit pressure to equalize.
2. Check the system pressure in comparison to the
ambient temperature. If acceptable, go to next step
Refrigerant evacuation procedure (3).
3. Turn on the engine, run at 1,200~1,500 rpm.
The "refrigerant evacuation process"* eliminates mois- 4. Turn on the HVAC air condition system, making
ture present inside the cooling circuit. If the moisture sure that the heat is off and A/C is set with fan on
remains inside the circuit, it may cause varied problems high.
even if its quantity is extremely small: The moisture may 5. Let the HVAC system run on coldest setting until all
freeze inside the expansion valve during operation, and parts are cold saturated; this should take about 30
may block the circuit or generate oxidation. To prevent minutes or more.
such problems, the refrigerant containing air inside the 6. Check the temperature that is coming from the
cooling circuit should be evacuated, and the moisture vents of the HVAC system inside the cab. Check
inside the circuit should be boiled and evaporated so the performance in the operating pressure and tem-
that all moisture is eliminated before pure refrigerant is perature chart.
recharged into the circuit. 7. Either remove or install more refrigerant depending
upon the findings.
*May be referred to as "air evacuation procedure" since it contains air
which also contains water that can cause system damage as noted.
Observe the work procedure and cautions shown below,
and charge the refrigerant correctly.
Gas charging procedure
The system should operate within about 5% of the
The "gas charging procedure" charges the refrigerant parameters. Be sure that the condenser is clear, evapo-
as gas into the circuit while in a vacuum state. The gas rator is clean and the fans are all working as they should
charging process not only affects the cooling ability of with good airflow in the system.
the air conditioner but also affects the system compo-
nent life.* Note
If the inside of the cab become cold during the charging
If the refrigerant is charged too quickly or in a liquid process, the compressor magnetic clutch turns off and
state, pressure inside the circuit may become extremely system charging is disabled.
high and the cooling ability may deteriorate. If the refrig-
erant charging volume is too low, the lubricating oil for When charging, completely open the cab doors.
the compressor may not circulate smoothly and com-
pressor pistons may seize and lock up the compressor. This will keep the system from turning off and on.
Because the gas charging process involves high pres-

sure gas, it is extremely dangerous if it is not done cor-
rectly.
Observe the work procedure shown below and the cau-

tions, and charge the refrigerant correctly.
*Note
Liquid charging destroys a compressor. Never permit
entry of liquid refrigerant.
95ZV-2 EU FS 72-54
Air Conditioner
Charging procedure chart
Start evacuation.
20~30 min -750 mmHg (-30" Hg) or less

Refrigerant If too little vacuum, repair leaking
evacuation Stop evacuation.
connection*
process *It is possible that system may need pressurized
Leave system untouched for 5 min. and tested for leaks.
Check pressure. Stop when gage indicates excessive pressure

(air entry)
When gage indicates a normal value
Charge refrigerant gas. Charge gaseous refrigerant until gauge pressure

reaches 98 kPa (1 kgf/cm2) (14 psi). Check for leaks.
Check for gas leak.

Gas Note
charging A full charge should be about 2±0.1 lbs (900±50 g) of
process
refrigerant.
Charge refrigerant.
As a general guideline, with engine off and HVAC

system static, the pressure in the system should be
Check for gas leak. about 85 psi (588 kPa) (6.0 kgf/cm2) with the pres-
sure has equalized between the low and high pres-
sure side.
Performance test
95ZVE72042
95ZV-2 EU FS 72-55
Air Conditioner
Refrigerant charging tools Charging hose and quick connectors

Recovery and recycling unit
Gauge manifold*
Low pressure
charging hose High pressure
(blue) charging hose
95ZV72024
(red)
Quick connector
(Lo)
It is against Federal Regulations* in the United States to
release refrigerant to atmosphere. A recovery and recy-
cling unit must be used to capture the refrigerant so as
not to release it into the atmosphere.
Center charging hose
(green or yellow)
*Refer to section 609 of the clean air act at www.epa.gov.
Quick connector
(Hi)
It is used for the following;
1. Recover the refrigerant. 97ZV72077

2. Filter the refrigerant.
3. Measure the refrigerant weight.
These different colored hoses are used to evacuate the
4. Remove trapped non compressible gases (air).
air and charge the gas. (The colors may be different
5. Measure the refrigerant to install in system by
depending on the manufacturer.)
weight.
6. Measure the pressure of the refrigerant in system.
Red hose
7. Measure ambient temperature.
Connects the high pressure valve of the gauge manifold
8. View bubbles in system if there are any.
and the high pressure charging valve (with "H" mark on
its cap) of compressor outlet hose.
Read and understand the Operation Manual for the
recovery and recycling machine.
Blue hose
Connects the low pressure valve of the gauge manifold
IMPORTANT and the low pressure charging valve (with "L" mark on
Only use a vacuum pump if the system is already its cap) of the compressor inlet hose.
open to atmosphere and refrigerant has completely
left the system. 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.

95ZV-2 EU FS 72-56
Air Conditioner
Leak detector Gauge manifold
Many recovery and recycling units are equipped with a

gauge manifold, which is very similar to the gauge man-
ifolds 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

recycling unit.
85V2U72007
Low pressure High pressure
gauge 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 High pressure
valve
Low pressure
charging hose Center valve High pressure
mounting nipple Center charging charging hose
hose mounting mounting nipple
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 vac-
uum.
3. Boiling action, perhaps due to pressure changes.
95ZV-2 EU FS 72-57
Air Conditioner
Cautions on handling of quick connector and Precautions

charging valve
When discharging the refrigerant, use a quick connec- Quick connector

tor.
1. Connecting the quick connector.
Screwdriver, etc.
Sleeve "Click" sound (OK)
Valve pin
(A)
Spring
Charging valve Charging valve
97ZV72082
97ZV72080
IMPORTANT
Slide the sleeve upward, push the quick connector If you push the valve pin with a considerable force
against the charging valve, press and hold securely [294 kPa (3 kgf/cm2) (43 psi)] with a screwdriver, etc.,
part (A) until a click is heard, then slide the sleeve the spring may come off and the refrigerant may leak.
downward. Never do this.
IMPORTANT
- Push quick connector against charging valve verti-
cally.
- If refrigerant remains inside the charging hose, the
quick connector may not be easily connected.
2. Disconnecting the quick connector
(A)
(B)
97ZV72081
While pressing and holding the part (A) of the quick

connector, slide sleeve upward to disconnect quick
connector.
95ZV-2 EU FS 72-58
Air Conditioner
Refrigerant charging procedure Valve setting

Lo Hi
Air evacuation work
Closed Closed
High pressure valve
WARNING
If hoses are connected incorrectly, serious accidents Low pressure valve
may occur.
Observe the following.
(red)
- Never confuse connection of hose to the high pres-
(blue)
sure side and the low pressure side of the gauge
(green)
manifold.
(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
With system "OFF";

(a) Close both the high pressure (Hi) valve and the low
pressure (Lo) valve of the gauge manifold.
95ZV72024
(b) Connect the charging hose.

It is against Federal Regulations* in the United States to
release refrigerant to atmosphere. A recovery and recy- Red hose
cling unit must be used to capture the refrigerant so as To be connected between the high pressure (Hi)
not to release it into the atmosphere. valve of the gauge manifold and the high pressure
charging valve.
*Refer to section 609 of the clean air act at www.epa.gov.
Blue hose
1. Connecting the gauge manifold To be connected between the low pressure (Lo)
valve of the gauge manifold and the low pressure
CAUTION charging valve of the compressor.
Close both low and high pressure valve, as seen in Yellow or green hose
"a" below. 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 con-
nected, a vacuum condition cannot take place.
95ZV-2 EU FS 72-59
Air Conditioner
2a. Evacuating the system with a vacuum pump 2b. Evacuating the system with a recycling and recove-
ry unit.
When pulling a vacuum with a vacuum pump on a sys-
tem that has been open due to replacing major compo-
nents.
Valve setting
After air evacuation Valve setting
Lo Hi for 30 minutes Lo Hi
OpenedOpened Closed Closed
High pressure valve
Low pressure valve

95ZV72024
(red)
(blue)
Each manufacture of recycling and recovery units pro-
(green) vide operating instructions for their units. Read, under-
stand and closely follow operating instructions as
provided.
(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 evac-

uate until the degree of vacuum becomes -750 mm
Hg (-30" Hg) for about 20~30 minutes.
(c) After finishing evacuation, close both the high pres-

sure 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.
95ZV-2 EU FS 72-60
Air Conditioner
3. Checking for leaks after vacuum has been drawn Refrigerant charging process
This section describes a static charging procedure with

Valve setting Leave for 10 minutes or more
as per EPA regulations
the engine in "OFF" and compressor not turning.
Lo Hi
Pointer of low
Closed Closed pressure gauge Do not run engine until high and low pressures are
moves toward "0".
Low pressure gauge equal so that no damage is done to the compressor.
0
0 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
Moves atmosphere. Use of a recovery and recycle unit is best.
toward "0". Carefully follow instructions with recovery unit.
Tighten connection areas
of piping.
97ZV72085
Valve setting
Lo Hi
After a vacuum has been pulled on system; Closed Closed
Leave the circuit for 5 minutes or more with H and L

valves of gauge manifold closed. Then, make sure that Open the
service can-
the needle of each gauge does not move. ister valve.
Red
Blue (low) (high)
If the needle of the gauge moves toward "0", a leak has
occurred somewhere in the circuit. Tighten the connec-
tion areas of the piping, evacuate the system again, Service
Charging hose canister
then make sure that there is no leaks. R134a
(green or yellow) 97ZV72086
IMPORTANT
Make sure to tighten the connection areas of the pip-
IMPORTANT
ing at a specified tightening torque. Never purge or vent refrigerant to atmosphere. (EPA)
For the tightening torque, refer to the volume "Mainte-
nance Standard".
95ZV-2 EU FS 72-61
Air Conditioner
1. Charging the refrigerant from the high pressure

Valve setting After 1~1.5 service Valve setting side with the engine in the "OFF“ position.
Lo Hi cans are charged Lo Hi
OpenedOpened Closed Closed
(a) After evacuation, disconnect the charging hose
(green or yellow) of gauge manifold from vacuum
pump, and connect it to the service canister.
High pressure valve
(b) Purging air from lines

Low pressure
valve Open the service canister valve very slightly with
low and high pressure manifold valves closed.
(red) 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
(blue)
lines, as air is discharged by the refrigerant pres-
(green) (Hi)
sure. EPA says that release of this tiny bit of air that
is very small is ok.
(Lo)
Charging valve
on high pressure (c) WITH ENGINE "OFF"; Open tank canister valve
side 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 ser-
Compressor
(stopped) vice cans. If using scale, add one to one and a half
Service can valve lbs.)
(opened charge
R134a closed)
95ZVE72052 (d) After charging, close the low and high pressure
valves of the gauge manifold and the service can
valve.
WARNING
If the refrigerant were changed from the high pres- 2. Check for gas leak with a leak detector
sure side, the refrigerant would flow in reverse direc-
tion and the can and the hose may be burst if you Check for gas leak in the circuit using a leak tester,
start the engine and operate the compressor. Never etc. If a leak is detected, repair leak as required. If
start the engine in this condition. located at connections, tighten the connection area.
IMPORTANT
IMPORTANT
Make sure to tighten the connection areas of the pip-
If you charge refrigerant with refrigerant canister ing at a specified tightening torque.
placed upside down liquid will exit canister, refriger- For the tightening torque, refer to the volume "Mainte-
ant is sucked into the compressor in a liquid state. nance Standard". Do not overtighten or it will worsen.
This will damage the compressor. Charge only with
refrigerant gas.
95ZV-2 EU FS 72-62
Air Conditioner
3. Charging the refrigerant - low pressure side - e/g (c) Start the engine, and increase the number of rota-
"ON". tions to approximately 1,500 min-1(rpm).
Charge the refrigerant (d) On the control panel, set the fan speed to high and
Valve setting until air bubbles seen Valve setting set the air flow volume to maximum cold, and set
through the sight glass
Lo Hi disappear. Lo Hi the vent port temperature switches to the coldest
Opened Closed Closed Closed
status.
(e) Open the low pressure valve of the gauge manifold

High pressure valve
and service canister valve to charge the refrigerant.
When air bubbles seen through the sight glass of
Low pressure the receiver dryer disappear, charge the refrigerant
valve further more by 150~250 g.
(red)
IMPORTANT
When replacing service canister while charging
refrigerant, connect the line as described earlier so
(blue) (green) (Hi)
as to not have air in the line.
(Lo)
Charging valve (f) After charging, close the low pressure valve of the
on high pressure gage manifold and the service can valve. Then,
side stop the engine.
Compressor Refrigerant quantity to be charged (guideline)

(On-load) 900±50 g (2.0±0.1 lb)
Service can valve
(opened charge
R134a closed) Refrigerant
Sight glass situation
95ZVE72052 quantity
Gas bubbles are few.
(When the number of rpm’s of the
Proper engine is gradually increased from the
idle status to 1,500 min-1, gas bubbles
Sight glass disappear.)
Gas bubbles are not seen in the flow at

all. System is over-pressurized.
Too much (In this case, both the high pressure
Receiver joint and the low pressure are high, and the
cooling ability is deteriorated.)
Many gas bubbles are seen in the flow.

Receiver dryer Insufficient
(Gas bubbles visibly seen constantly.)
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.
95ZV-2 EU FS 72-63
Air Conditioner
4. Guidelines to determine quantities of refrigerant 5. Disconnecting the gauge manifold

charge
Use the following table to determine the refrigerant

charge quantity.
Item Criteria
(A)
Doors Completely open
Temperature control switches Maximum cooling
Blower speed High
Inside/outside air selection Inside air (B)
Number of rotations of engine 1,500 min-1

Air conditioner switch ON
1,862 kPa (19 kgf/cm2) (270 psi)
Pressure on high pressure side 97ZV72081
or less
After inspecting the refrigerant charge, disconnect

IMPORTANT the charging hose from the high and low pressure
- If outside air temperature is high (40ºC/104ºF or charging valves using the following procedure.
more) or if the pressure on the high pressure side
is 1,862 kPa (19 kgf/cm2) (270 psi) or more when (a) While pressing and holding part (A) of the quick
the judgement condition above is set, perform the connector, slide sleeve upward and disconnect the
following so that the pressure becomes 1,862 kPa quick connector.
(19 kgf/cm2) (270 psi) or less, then check the
refrigerant quantity. (b) Attach a cap to each of the high and low pressure
- Close the doors completely, and set the charging valves.
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 refriger-
ant quantity is extremely low, lubricant in the com-
pressor 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 cir-
cuit may become abnormally high (which is dan-
gerous). Never do this.
95ZV-2 EU FS 72-64
Troubleshooting using the gauge manifold Condition

Normal status After warming up the engine, check the pressure under
the following condition.
- Doors
<Low pressure side> <High pressure side>
Completely open
215~275 kPa 1,470~1,765 kPa
(2.2~2.8 kgf/cm2) (15~18 kgf/cm2) - Inside/outside air selection
(31~40 psi) (213~255 psi)
Inside air
- Number of rotations of engine

1,500 min-1
- Temperature at suction port of air conditioner

30~35ºC (86~95ºF)
- Blower speed
High
- Temperature control switches

Maximum cooling
97ZV72091
Pressure values indicated by gauges in the normal status
A/C suction port temperature Pressure Pressure value by gauge

High pressure side 1,000~1,215 kPa (10.2~12.4 kgf/cm2) (145~176 psi)
20~25ºC (68~77ºF)
Low pressure side 127~167 kPa (1.3~1.7 kgf/cm2) (18~24 psi)
25~30ºC (77~86ºF)
30~35ºC (86~95ºF)
35~40ºC (95~104ºF)
95ZV-2 EU FS 72-65
Air Conditioner
When the refrigerant charge quantity is insuffi- When the refrigerant does not circulate (due to
cient clogging in the cooling circuit)
<Low pressure side> <High pressure side> <Low pressure side> <High pressure side>
49~98 kPa 686~981 kPa Negative value 490~588 kPa
(0.5~1.0 kgf/cm2) (7~10 kgf/cm2) (5~6 kgf/cm2)
(7~14 psi) (100~144 psi) (71~85 psi)
97ZV72092 97ZV72093
Symptom Cause Inspection/action point Symptom Cause Inspection/action point

- Pressure is low on - Refrigerant - Find and repair - If cooling circuit is Clogging in - Inspect receiver
both low and high quantity is leaks. completely blocked, cooling circuit dryer, expansion
pressure sides. insufficient. needle on low pres- valve, etc. (Temper-
- Repair leak. Add sure side indicates a ature is different
- Gas bubbles go - Gas is refrigerant. vacuum immedi- between IN and
through sight glass leaking. ately. OUT of failing part.)
continuously. - If pressure indicated
by gage is around - If cooling circuit is - After finishing work,
- Temperature of "0", detect and partially blocked, evacuate system
blown air is not cold. repair leaks, vac- needle on low pres- and recharge.
uum system and sure side slowly
recharge. indicates a vacuum.
95ZV-2 EU FS 72-66
Air Conditioner
When the moisture has entered into the cooling When the compression in compressor is defec-
circuit. tive.

392~588 kPa 686~981 kPa
Abnormal status 686~981 kPa
(4~6 kgf/cm2) (7~10 kgf/cm2)
Vacuum (7~10 kgf/cm2)
(57~85 psi) (100~144 psi)
(100~144 psi)
Normal status
215~275 kPa 1,470~1,765 kPa
(2.2~2.8 kgf/cm2) (15~18 kgf/cm2)
(31~40 psi) (213~255 psi)
97ZV72095
Symptom Cause Inspection/action point

- Pressure on low Compressor is - Review 2nd symp-
97ZV72094 pressure side is defective. tom.
unusually high, and
pressure on high - If pressure in com-
Symptom Cause Inspection/action point pressure side is pressor is low, com-
unusually low. pressor will not build
- Air conditioner oper- Expansion valve - Inspect expansion much heat due to
ates normally for a is frozen due to valve, replace if - Shortly after air con- lack of pressure.
while after startup, entry of needed. ditioner turns off,
but pressure on low moisture. pressure becomes - Replace compres-
pressure side indi- - Replace receiver equal between high sor.
cates a vacuum dryer. pressure side and
value later. low pressure side. - After finishing work,
- After finishing work, evacuate system
evacuate system and recharge.
completely and
recharge.
95ZV-2 EU FS 72-67
Air Conditioner
When there is too much refrigerant or cooling When air has entered into the cooling circuit
in the condenser is insufficient
<Low pressure side> <High pressure side> <Low pressure side> <High pressure side>
245~343 kPa 1,961~2,452 kPa 245~294 kPa 1,961~2,452 kPa
(2.5~3.5 kgf/cm2) (20~25 kgf/cm2) (2.5~3.0 kgf/cm2) (20~25 kgf/cm2)
(35~50 psi) (284~355 psi) (35~43 psi) (284~355 psi)
97ZV72096 97ZV72097
Symptom Cause Inspection/action point Symptom Cause Inspection/action point

- Pressure is high on - Refrigerant - Check and correct - Pressure is high on Air has entered - Refrigerant is bad.
both low pressure quantity is refrigerant charge both low pressure system.
side and high pres- too much. pressure. side and high pres-
sure side. sure side.
- Plugged or - Inspect and repair
- Even when engine bent con- condenser fins. - Low pressure pip- - Evacuate system
rpm’s (min-1) are denser fins. ing is not cold. completely.
reduced, gas bub- - Repair or replace
bles cannot be seen - Bad fan fan or fan motor - Gas bubbles go - Replace refrigerant.
at all in sight glass. motor or fan through sight glass.
blade. - Inspect and repair
- Air in cab does not evaporator fins.
become cool - Heat trans-
enough. fer does not
occur in
evaporator
has plugged
fins
95ZV-2 EU FS 72-68
Air Conditioner
When the expansion valve is opened too much

294~392 kPa 1,961~2,452 kPa
(3.0~4.0 kgf/cm2) (20~25 kgf/cm2)
(43~57 psi) (284~355 psi)
97ZV72098
Symptom Cause Inspection/action point

- Pressure is high on Expansion valve - Temperature sens-
both low pressure is defective. ing rod may be
side and high pres- sticking.
sure side.
- Inspect expansion
- Condensation forms valve. Check temp
on low pressure in and out of valve
side pipes. to determine if it is
operating correctly.
Thermal expansion valve
To and from evaporator Diaphragm
Spring
Temperature sensing rod
Needle valve Compressor return

From receiver dryer
97ZV72049
95ZV-2 EU FS 72-69
Air Conditioner
Air conditioner troubleshooting  Error code table
Display Failure mode

Fault diagnosis procedure
E- No failure
E11 Wire breakage in inside air sensor
E12 Short-circuit in inside air sensor
Hearing check E13 Wire breakage in outside air sensor
E14 Short-circuit in outside air sensor
Error code check ∗ E15 Wire breakage in water temperature sensor

E16 Short-circuit in water temperature sensor
E18 Short-circuit in insolation sensor
Phenomenon check
E21 Wire breakage in vent sensor
E22 Short-circuit in vent sensor
Basic check E43 Abnormality in vent damper
E44 Abnormality in air mixing damper
In accordance with fault phenomenon
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 Electrical system

check check
- Pressure check
- Gas leak check
Repair/check
End
80V2E01012
95ZV-2 EU FS 72-70
Air Conditioner
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.
<Trouble shooting charts>
Clogged inner air filter Clean the filter.

Clogged outer air filter Clean the filter.
Existence of obstacle at vicinity of suction port Remove the obstacle.
Normal rotation Deformed or damaged blower Replace the blower with a new one.
Frosting in evaporator Stop the air compressor, to melt the ice.
Examine the cause before taking the corrective measure. See A-1 .
Blower motor Adhesion of dust to surface of evaporator Clean the surface of evaporator.
rotation
Decreased supply voltage Check the battery charging system.

Battery terminal contact failure Correct the contact failure.
Slow rotation
Blower motor rotation failure Replace the blower motor with a new one.
Air flow rate
BLC failure Replace the BLC with a new one.
failure
Blower is rotated only
when the fan switch is Operation of BLC over-voltage protective function Examine the cause of over-voltage before taking the corrective measure.
selected to High-speed ∗ Examine the cause before taking the corrective measure,and then replace
position. Blown fuse the fuse with that of the same capacity. See B-1 .
Blower motor
rotation Blower main relay failure Replace the blower main relay with a new one.
failure Blower motor failure Replace the blower motor with a new one.
Rotation failure Interference of blower with case Correct the interference.
for all modes Blower switch failure Replace the panel with a new one.
Body earth failure Earth the body securely.
Without
Wiring failure, disconnected connector Check the wiring.
diagnostic
display Operation of BLC protective function due Replace the motor with a new one.
to locked motor
Normal pressure Mixing of outside air Close the window and door.
Adjust the inside/outside air changeover damper.
Disengaged A/M link Re-set the link.
Compressor
normal rotation
Too high pressure at low-pressure side(approx. 294kPa[3kgf/cm2] or over) See C-2 .
Too low pressure at high-pressure side(Pressure is not increased to approx. 981kPa[10kgf/cm2] or over) See C-3 .
Pressure error Too low pressure at low-pressure side(Pressure is decreased to approx. 49kPa[0.5kgf/cm2] or less See C-4 .
Cooling failure
Normal air High pressure both at high-pressure side and low-pressure side See C-5 .
flow rate Low pressure both at high-pressure side and low-pressure side Insufficient refrigerant.
Broken or slipped belt Replace the V-belt with a new one.

Compressor Compressor failure (locking) Replace the compressor with a new one.
rotation failure Magnet clutch failure Repair the magnet switch, or replace it with a new one. See D-1 .
Clutch engagement failure due to Check the wiring. See D-2 .
electrical system failure
Wiring failure, disconnection, disengaged connector Check the wiring.
With diagnostic display:
E44 (A/M servo motor Servomotor failure Replace the servo motor with a new one.
error) Blocked foreign matter Remove the foreign matter.
Operation of high-pressure cut

function See C-1 .
With diagnostic display:
E51 (refrigerant high/
Operation of low-pressure cut
lower pressure error) See C-3 .
function
80V2E01013
95ZV-2 EU FS 72-71
Air Conditioner
Air Conditioner
Magnet clutch circuit failure Check the clutch circuit. Replace the clutch relay with a new one.
Voltage applied to Thermister(frosting sensor) wiring failure Check the short-circuit. Correction
magnet clutch
95ZV-2 EU FS 72-72
Thermister(frosting sensor) characteristic failure Check for characteristic. Replace the thermister(frosting sensor) with a new one.
Adjustment failure of gap between the thermister(frosting sensor) and evaporator Adjust the gap (12 ± 5 mm) (0.5 ± 0.2 in).
A-1
12 ± 5 mm
(0.5 ± 0.2 in)
Voltage not applied
to magnet clutch Magnet clutch failure Replace the magnet clutch
with a new one. Thermister
(frosting sensor)
Evaporator
Locked blower motor Replace the blower motor with a new one.
B-1 Erroneous wiring Perform the checking, referring to the wiring diagram.
Sort-circuit wiring Check the wiring.
Unusually high outside air temperature

Insufficiently cooled condenser Clogging of dust or mud, etc. in fin. Clean(Washing with water) the fin.
C-1
Over-filled refrigerant Discharge the refrigerant to proper level.
Mixing of air during refrigerating cycle Fully discharge the refrigerant, and execute the
evacuation, and fill the refrigerant again to
proper level.

Compressor failure Broken head gasket
C-2 Broken suction valve Replace the compressor with a new one.
Foreign matter caught by suction valve
Excessively opened expansion valve Valve failure Replace the valve with a new one.
Contact failure in Correction
pressure needle valve
85V2U72008
Unusually low outside air temperature
Limited refrigerant Limited amount of refrigerant filled Fill the refrigerant to proper level.
Gas leakage Perform the leak test and repair the location of
failure before filling the refrigerant.
C-3
Compressor failure Swash plate shoe seizure
Locked piston Replace the compressor with a new one.
Suction/discharge valve failure
Expansion valve failure Clogged valve(mixing of foreign matter) Replace the valve with a new one.
Relieved gas from pressure needle valve Replace the valve with a new one.
Clogging(mixing of moisture content) due to frozen valve Execute the evacuation fully after replacing the
valve and receiver with a new one respectively.
Unusually low outside air temperature

Limited refrigerant Limited amount of refrigerant filled Fill the refrigerant to proper level.
Gas leakage Perform the leak test and repair the location of
failure before filling the refrigerant.
Clogging during refrigerating cycle Clogged receiver & drier Replacement

C-4 Clogging due to foreign matter in the course of piping Replacement
Expansion valve failure Clogged valve(mixing of foreign matter) Replace the valve with a new one.
Relieved gas from pressure needle valve Replace the valve with a new one.
Temporary clogging(mixing of moisture content) Execute the evacuation fully after replacing the
due to frozen valve valve and receiver with a new one respectively.
Frosted evaporator to A-1
Insufficiently cooled condenser Clogging of dust or mud, etc. in fin. Clean(washing with water) the fin.
C-5
80V2E01015
95ZV-2 EU FS 72-73
Air Conditioner
Air Conditioner
95ZV-2 EU FS 72-74
Disconnected stator coil Replacement

Excessive air gap between rotor and stator Repair or replacement
Slipped clutch Slippage due to broken key or key insertion failure Replace the key with a new one.
Stained clutch surface due to oil Remove the oil.
D-1
Rare-short in coil Replacement
Battery voltage drop Re-charging

Foreign matter caught between rotor and stator Disassembling/repair
Air conditioner switch failure Replace the control panel with a new one.
Blower switch failure Replace the control panel with a new one.
Compressor clutch relay failure Replacement
D-2
Thermo-sensor failure Replacement
High/low-pressure switch failure Replacement
High-pressure error Excessively high pressure [2452 kPa(25kgf/cm2)or over] C-1
2
Excessively low pressure [981 kPa(10kgf/cm )or lower] C-4
80V2E01016
Insufficient Same as "Cooling failure"
wind force
Heating failure
Low water temperature
Normal wind
force
The air is mixed in hot-water circuit. Discharge the air.

Clogged or bent piping Repair or replacement
Normal water Excessively low outside air temperature
temperature
Limited engine cooling water Fill the coolant to proper level.
Broken heater core Replace the heater core with a
new one.
Note: Do not fail to check that the pump pressure is normal, and that the heater hose is not connected with
IN side and OUT side reversed.
The temperature
controller LED is Disengaged temperature controller link Re-set the link.
operated properly. Foreign matter caught Remove the foreign matter.
The temperature
Wiring failure, disconnection, disconnected connector Check the wiring.
controller LED is not
operated properly. Servo motor failure Replacement
Leakage of water in
Clogged drain hole Cleaning
operator's cab
85V2U72009
95ZV-2 EU FS 72-75
Air Conditioner
Air Conditioner
Without diagnostic display

Disengaged link Re-set the link.
95ZV-2 EU FS 72-76
(blow-off servo motor normal)
Blow-off changeover Wiring failure, disconnection, disconnected connector Check the wiring.
failure
With diagnostic display: E43
Servo motor failure Replacement
(blow-off servo motor abnormal)
Foreign matter caught Remove the foreign matter.
Without diagnostic display

Disengaged link Re-set the link.
(inside air/outside air servo motor normal)
Outside air/inside air Wiring failure, disconnection, disconnected connector Re-check the wiring
changeover failure
Servo motor failure Replacement
(inside air/outside air servo motor abnormal)
Foreign matter caught Remove the foreign matter.

Disconnected harness, disengaged connector Re-check the wiring.
(disconnected inside air sensor)
Disconnected inside air sensor Replacement
Room temperature With diagnostic display: E12

Short-circuit harness Check the wiring.
higher or lower than (short-circuit inside air sensor)
setting temperature
Short-circuit inside air sensor Replacement
Without diagnostic display Perform the checking in

Cooling failure, heating failure accordance with the paragraph
(without inside air sensor error)
"Cooling failure/heating failure".
80V2E01018
95ZV-2 EU FS 73-1
73 Check & Adjustment Operator Station Group

Operator Station Group
Air Conditioner ........................................................ 73-2

95ZV-2 EU FS 73-2
Air Conditioner
Air Conditioner
Adjustment of lubricating oil

quantity when components of air WARNING
conditioner are replaced In order to protect the environment, do not release
refrigerant to atmosphere when removing compo-
nents from air conditioner system. It not illegal to do
so.
IMPORTANT
- When replacing components of the air conditioner,
if the lubricant oil quantity is too small, the com-
pressor may seize. And if the lubricating oil quan-
tity 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).
Fig. 1
97ZV73002 - 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 Tightening torque

Pipe size or bolt size
area N-m (kgf-cm) (lb-ft)
ø8 pipe 14.7 (150) (7)
Nut type
1/2 pipe 24.5 (250) (18)
(Fig. 2)
Fig. 2
97ZV73003 5/8 pipe 34.3 (350) (25)
M6 bolt in receiver (4T) 6.9 (70) (5)

Block joint
(Fig. 3) Any M6 bolt other than
11.8 (120) (9)
above (6T)
Fig. 3 97ZV73004
95ZV-2 EU FS 73-3
Air Conditioner
When the compressor is replaced Torque values
New compressor 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 Example

remaining (B)
inside circuit Suppose that the oil quantity (A) removed from the com-
A A pressor to be replaced is 100 cm3. See figure 1.
Fig. 1 Oil quantity remaining inside circuit (B)

97ZV73005
= 180 cm3 - (100 + 20) = 60 cm3
Remove 60 cm3 from the new compressor to avoid

To avoid overloading the circuit;
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 system’s 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.
95ZV-2 EU FS 73-4
Air Conditioner
When the evaporator is replaced When the condenser is replaced
Quantity of lubricating oil lost by replacement of con-

denser is approximately 40 cm3 (1.35 oz).
1
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)
When the receiver dryer is replaced

Evaporator
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.
: (1): 7 N-m (0.7 kgf-m) (5 lb-ft)

: (2): 15 N-m (1.5 kgf-m) (11 lb-ft)
97ZV73006
Quantity of lubricating oil lost by replacement of evapo-

rator 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)

95ZV-2 EU FS 73-5
Air Conditioner
Adjustment of air gap (between 1. Remove the front cover of the magnetic clutch.
hub and rotor) in compressor 2. Measure dimension A between rotor end face and
magnetic clutch 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 Reference plane Standard (normal dimension) of air gap (A - B)
0.50±0.15 mm (0.020±0.006 in)
Air gap
0.50±0.15 mm (0.020±0.006 in)
A (OFF status) If the obtained value does not agree with the crite-
Position while magnetic ria, loosen the head bolt, remove the hub, and
clutch is ON
adjust the air gap by adjusting the thickness of the
B (ON status) washer plate between the hub and the shaft.
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 perform-

ing this work.
95ZV-2 EU FS 73-6
Air Conditioner
Compressor V-belt adjustment
Compressor
V-belt
Belt
tensioner
K95V2U73001
No adjustment is necessary.
The belt tension is automatically adjusted by the belt
tensioner installed on the engine.
95ZV-2 EU FS 73-7
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
Note
Cleaning When replacing the receiver dryer, do not release the
Once every 2 weeks or when required. refrigerant into the atmosphere.
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 fil-
ter.
Replacement
Once each year or when required.
When air flow volume is so small as to affect air move-

ment 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 move-

ment even after the filter has been cleaned, or when the
air filter has been cleaned 6 times, replace it.
95ZV-2 EU FS 73-8
MEMO
INDEX
A Brake System Outline ....................................................... 52-2
Accelerator pedal ............................................................62-34 Brake Units Layout ........................................................... 52-3
Accelerator pedal installation ..........................................62-36 Brake Valve .................................................................... 52-10
Accumulator ......................................................................52-9 Brake valve oil pressure ................................................... 53-4
Accumulator (for ride control) .........................................42-61 Brake valve oil pressure measurement ............................ 53-4
Accumulator function ......................................................42-61 Brake valve outline ......................................................... 52-12
Accumulator low pressure sensor .....................................52-8 Brake valve performance ................................................. 53-5
Adapter (Orifice) .............................................................42-51 Brake valve performance chart ...................................... 52-11
Adjustable declutch preset switch ...................................62-52 Bucket cylinder ............................................................... 42-20
Adjusting set pressure ....................................................42-43 Bucket hinge pin section .................................................. 13-3
Adjusting shim ..................................................................13-5 Bucket leveler ............................................................... 62-111
Adjusting tooth contact .....................................................23-9 Bucket spool operation ................................................... 42-46
Adjustment ........................................................................13-4
Adjustment method .........................................................42-91 C
Adjustment of air gap (between hub and rotor) in Cabin ................................................................................ 72-2
compressor magnetic clutch .........................................73-5 Caution for diode check method ................................... 62-119
Adjustment of axle internal pressure ................................52-2 Cautions on Hydraulic Parts Replacement ....................... 42-3
Adjustment of lubricating oil quantity when components Cautions on installing brake discs .................................... 53-9
of air conditioner are replaced ......................................73-2 Cautions on Safety ........................................................... 03-2
Air compressor (with magnetic clutch) ............................72-17 Cautions regarding parts removal .................................. 00-18
Air Conditioner ...................................................... 72-13, 73-2 Cautions regarding reassembly ...................................... 00-18
Air conditioner functions of components .........................72-24 Cautions regarding welding repair service ..................... 00-20
Air conditioner specifications (system performance) ......72-13 Center Pin ............................................................... 12-7, 13-5
Air conditioner troubleshooting .......................................72-69 Changing display from one function to next ................... 62-73
Air conditioner unit ..........................................................72-31 Charge of refrigerant ...................................................... 72-52
Air distributor (hood & defroster selection box) ...............72-16 Check valve .....................................32-34, 42-6, 42-56, 42-60
Air filters ............................................................................73-7 Clear active fault log (error pop up) (S/N 9001~9166)
All setting reset .............................................................62-108 .................................................................................... 62-88
Alternator ........................................................................62-22 Clear fault log ................................................................. 62-87
Alternator I terminal wire .................................................62-18 Clutch combination ........................................................... 32-8
Auto Brake ......................................................................52-32 Clutch Oil Pressure and Time Lag ................................... 33-2
Auto brake ......................................................................62-56 Clutch oil pressure control at the time of engine starting
Auto brake circuit ............................................................52-32 .................................................................................... 32-29
Auto brake operation set value .......................................52-32 Clutch oil pressure measurement procedure ................... 33-3
Automatic shift ................................................................62-45 Clutch Pack .................................................................... 32-12
Automatic shift (with lock-up solenoid) ................. 32-5, 62-46 Clutch solenoid valve assembly ..................................... 32-35
Axle ...................................................................................23-5 Clutch specifications ......................................................... 32-9
Axle Assembly ...................................................... 22-11, 92-2 Clutch valve assembly .................................................... 32-39
Axle nut tightening procedure ...........................................23-5 Column shaft .................................................................. 72-12
Axle Support ...................................................................22-12 Compressor and magnetic clutch ................................... 72-40
Compressor V-belt adjustment ......................................... 73-6
B Condenser unit .................................................... 72-17, 72-43
Back-up alarm .................................................................62-53 Connection diagram ....................................................... 62-23
Battery relay ....................................................................62-17 Connector ....................................................................... 62-38
Battery relay operation ....................................................62-17 Continuity check mode ................................................. 62-119
Bearing installation ...........................................................23-8 Control panel .................................................................. 72-24
Bleeding air from brake pipes and axle housing hubs Control schematic drawing ............................................. 72-23
....................................................................................52-21 Control unit ..................................................................... 72-18
Bleeding air from parking brake housing ........................52-21 Control Valve Assembly ................................................. 32-32
Bolt tightening torque ......................................................00-13 Coolant ........................................................................... 00-10
Boom cylinder .................................................................42-20 Coolant specification ...................................................... 00-10
Boom spool operation .....................................................42-48 Cooling circuit ................................................................. 72-22
Brake Circuit .....................................................................92-6 Cooling unit .................................................................... 72-14
Brake circuit air bleeding procedure ...............................52-20 Cylinder natural drift ....................................................... 43-14
Brake Circuit Check Valve ..............................................52-31 Cylinders .......................................................................... 42-4
Brake Circuit Oil Pressure ................................................53-2
D Engine fault log navigation .............................................62-87
Denso air conditioner components ................................. 72-13 Engine Start Circuit ......................................................... 62-14
Denso air conditioner structure ...................................... 72-14 Engine start circuit diagram ............................................ 62-14
Detent solenoid ............................................... 62-112, 62-117 Equipment Operation Table (Cabin Air Conditioner) ......92-34
Differential gear adjustment procedure ............................ 23-6
Diode ............................................................................ 62-118 F
Diode check method .................................................... 62-119 Failure diagnosis ............................................................ 62-25
Diode check mode ....................................................... 62-119 Failure diagnostic chart ..................................................62-26
Diode unit ....................................................................... 62-18 Fan motor ..................................................................... 42-105
Directional control valve ................................................... 42-6 Fan motor function and the operation principle ............ 42-107
Display language ............................................................ 62-85 Fan Motor Line ............................................................... 42-97
Downshift button operation ................................... 32-8, 62-48 Fan motor specifications ............................................... 42-105
Dust seal .......................................................................... 12-8 Fan motor structure ...................................................... 42-106
Fan Motor System .......................................................... 42-96
E Fan motor system .............................................................42-9
ECM (Engine Controller) ................................................ 62-23 Fault diagnosis procedure .............................................. 72-69
ECM safety features ....................................................... 62-17 Fault log history check .................................................... 62-85
Efficient Loading System ................................................ 42-92 Fault Log Monitor ............................................................ 62-85
Efficient loading system ................................................... 42-9 Flanged hexagon bolt .....................................................00-16
Efficient loading system operation ................................. 42-95 Floor board ....................................................................... 12-6
Efficient loading system outline ...................................... 42-92 Floor board mount ............................................................ 12-6
Electrical Cable Color Codes ........................................... 62-8 Flow amplifier notch and pilot orifice .............................. 42-81
Electrical circuit .............................................................. 72-23 Flow control valve .............................................................42-5
Electrical Circuit Diagram (Cabin Air Conditioner) ......... 92-33 Flushing Hydraulic Circuit ................................................. 42-2
Electrical Circuit Symbols ................................................. 62-9 For high/reverse and speed clutches ............................. 32-37
Electrical Connection Diagram (1/2) (S/N 9001~9250) Forward 1st speed power flow path ................................ 32-13
.................................................................................... 92-26 Forward 2nd speed power flow path .............................. 32-14
Electrical Connection Diagram (1/2) (S/N 9251~9350) Forward 3rd speed power flow path ...............................32-14
.................................................................................... 92-28 Forward 4th speed power flow path ...............................32-15
Electrical Connection Diagram (1/2) (S/N 9351~) .......... 92-30 Forward/reverse (F/R) shifting and speed change ......... 62-43
Electrical Connection Diagram (2/2) (S/N 9001~9250) Friction plate: mm (in) .....................................................32-10
.................................................................................... 92-27 Front Chassis ...................................................................12-2
Electrical Connection Diagram (2/2) (S/N 9251~9350) Front wiper ........................................................................72-6
.................................................................................... 92-29 Fuel gauge circuit ...........................................................62-71
Electrical Connection Diagram (2/2) (S/N 9351~) .......... 92-31 Fuel tank ...........................................................................12-5
Electrical Detent Circuit ................................................ 62-111 Function of ECM ............................................................. 62-23
Electrical Equipment Layout ........................................... 92-35 Function of T.P.D ............................................................ 22-17
Electrical Equipment Layout (K-Lever) ........................... 92-46 Fuse ................................................................................ 62-11
Electrical Wiring Diagram ............................................... 92-19 Fuse box .........................................................................62-11
Electrical Wiring Diagram (1/3) (S/N 9001~9048) ............ 92-7 Fusible link ......................................................................62-13
Electrical Wiring Diagram (1/3) (S/N 9049~9250) .......... 92-10
Electrical Wiring Diagram (1/3) (S/N 9251~9350) .......... 92-13 G
Electrical Wiring Diagram (1/3) (S/N 9351~) .................. 92-16 Gauge circuit .................................................................. 62-69
Electrical Wiring Diagram (2/3) (S/N 9001~9048) ............ 92-8 Gear pump specifications ........................................32-6, 32-7
Electrical Wiring Diagram (2/3) (S/N 9049~9250) .......... 92-11 Gear train and number of teeth ........................................ 32-9
Electrical Wiring Diagram (2/3) (S/N 9251~9350) .......... 92-14 Glass ................................................................................72-3
Electrical Wiring Diagram (2/3) (S/N 9351~) .................. 92-17 Grease nipple installation direction ................................... 13-5
Electrical Wiring Diagram (3/3) (S/N 9001~9048) ............ 92-9
Electrical Wiring Diagram (3/3) (S/N 9049~9250) .......... 92-12
Electrical Wiring Diagram (3/3) (S/N 9251~9350) .......... 92-15 H
Electrical Wiring Diagram (3/3) (S/N 9351~) .................. 92-18 Heater and accessories ..................................................72-16
Electrical Wiring Diagram (CAB) .................................... 92-23 Hexagon bolt .................................................................. 00-13
Electrical Wiring Diagram (Cabin Air Conditioner) Hose band tightening torque ..........................................00-17
(S/N 5301~) ............................................................... 92-32 How to assemble .............................................................. 13-3
Electrical wiring diagram abbreviation chart ................... 92-21 How to Use Electrical Wiring Diagram ..............................62-2
Engine .............................................................................. 23-2 How to Use Manual ..........................................................00-2
Engine / Transmission ...................................................... 22-4 How to wind a seal tape ................................................. 00-19
Engine / transmission mount ............................................ 22-4 Hydraulic & Brake Circuit (S/N 9001~9250) ..................... 92-4
Engine diagnostic switch (option) ................................... 62-25 Hydraulic & Brake Circuit (S/N 9251~) ............................. 92-5
Hydraulic circuit ..............................................................42-86
Hydraulic circuit (fan motor normal rotation) ...................42-99 Loading linkage pin .......................................................... 12-4
Hydraulic circuit (Reverse rotation) ...............................42-112 Loading System .............................................................. 42-23
Hydraulic Circuit Diagram ...............................................32-20 Loading system ................................................................ 42-8
Hydraulic Circuit Symbols .................................................42-4 Loading/Steering Circuit Relief Valve/Ride Control
Hydraulic Cylinder ............................................... 42-20, 43-14 Circuit Reducing Valve (OPT) ...................................... 43-2
Hydraulic cylinder specifications .....................................42-22 Lock-up clutch function (only forward) .............................. 32-4
Hydraulic line ..................................................................42-88 Lock-up clutch structure ................................................... 32-4
Hydraulic line diagram ....................................................42-87 Lower center pin ............................................................... 12-7
Hydraulic lines ..................................................................42-4 Lower kickout ............................................................... 62-114
Hydraulic oil level check .................................................42-16 LSD function ................................................................... 22-23
Hydraulic Pump ..............................................................42-17 LSD operation ................................................................ 22-23
Hydraulic pump bushing lubrication ................................42-19 LSD structure ................................................................. 22-19
Hydraulic pump oil amount and steering force ...............42-68 Lubrication chart ............................................................. 00-11
Hydraulic pump principle ................................................42-18
Hydraulic pump wear plate .............................................42-19
M
Hydraulic System Diagram .............................................32-18
Machine control unit (MCU) ............................................ 62-37
Hydraulic System Operation .............................................42-8
Machine control unit (MCU) connection diagram
Hydraulic system operation outline ...................................42-8
(S/N 9001~9350) ....................................................... 62-39
Hydraulic Tank ................................................................42-11
Machine control unit (MCU) connection diagram
Hydraulic Tank (S/N 9001~9300) ...................................42-11
(S/N 9351~) ............................................................... 62-41
Hydraulic Tank (S/N 9301~) ...........................................42-13
Machine control unit (MCU) failure warning ................... 62-59
Hydraulic tank breather valve (tank cap) (S/N 9001~9279)
Machine control unit (MCU) function .............................. 62-43
....................................................................................42-12
Machine fault log navigation ........................................... 62-87
Hydraulic tank breather valve (tank cap) (S/N 9280~) ....42-14
Machine speed sensor ................................................... 62-47
Hydraulic tank specifications ..........................................42-15
Magnetic switch .............................................................. 62-20
Main relief valve operation ............................................. 42-42
I Make-up valve ................................................................ 42-99
Increment decrement switch (option) ..............................62-27 Make-up valve operation ..................................... 42-45, 42-79
Information Monitor .........................................................62-75 Measurement procedure .................................................. 53-8
Information monitor display .............................................62-75 Measuring clutch oil pressure ........................................... 33-2
Input/Output Monitor .......................................................62-92 Measuring engine oil pressure ......................................... 23-2
Input/Output monitor display ...........................................62-92 Measuring engine speed .................................................. 23-2
Inspection and maintenance table ....................................00-6 Measuring loading circuit main relief pressure ................. 43-4
Installing bearing outer ring ..............................................13-5 Measuring loading circuit overload relief pressure ........... 43-5
Instrument panel (S/N 9001~9350) .................................62-65 Measuring pilot circuit relief pressure ............................... 43-6
Instrument panel (S/N 9351~) .........................................62-66 Measuring pilot circuit relief pressure
Instrument Panel and Switch ..........................................62-65 (reducing pressure) .................................................... 43-13
Instrument panel rear surface .........................................62-67 Measuring ride control circuit reducing pressure .............. 43-8
Interior schematic (simple explanation) ..........................32-27 Measuring steering circuit main relief pressure .............. 43-11
Items to be monitored and operation condition ...............62-62 Measuring steering circuit overload relief pressure ........ 43-12
Miscellaneous hydraulic symbols ..................................... 42-7
MODM ............................................................................ 62-72
K
MODM function .............................................................. 62-72
K-Lever (OPT) ................................................................42-86
MODM: Input/Output Monitor - Input/Output Signal
Correspondence Table .............................................. 92-56
L Modulation at clutch switching ........................................ 62-49
Layout of Hydraulic Units ................................................42-10 Modulator valve 1 ........................................................... 32-28
Layout of main components ..............................................00-4 Modulator valve 2 (D Solenoid valve) ............................. 32-29
Left turn position .............................................................42-73 Modulator valve function ................................................ 32-28
Lift kickout .....................................................................62-114 Modulator valve operation .............................................. 32-30
Lift kickout & lower kickout ............................................62-113 Modulator Valve Unit ...................................................... 32-25
Limited Slip Differential (option) ......................................22-19 Monitor Changeover ....................................................... 62-72
Liner ..................................................................................13-2 Monitor lamp test ............................................................ 62-24
Linkage Pin .......................................................................13-2 Monitoring system .......................................................... 62-62
Liquid gasket and screw lock agent ................................00-18 Mounting of fan motor .................................................... 42-96
Loading and pilot and brake pump/Steering pump .........42-17 Mounting of the ELS valve ............................................. 42-93
Loading and pilot and brake pump/Steering pump Mounting of the variable kickout sensor ......................... 42-94
specifications ..............................................................42-17 Multiple Control Valve (KML35A/2T003B) ...................... 42-40
Loading circuit relief valve setting pressures ....................43-2 Multiple control valve boom spool .................................. 42-48
Loading linkage .................................................................12-2 Multiple control valve bucket spool ................................. 42-46
Multiple control valve main relief valve ........................... 42-42 Power Flow Path in the Transmission ............................32-13
Multiple control valve make-up valve ............................. 42-45 Power Generating/Charging Circuit ................................ 62-22
Multiple control valve overload relief valve (with Power Line ........................................................................22-2
make-up function) ...................................................... 42-44 Pre-detent and detent magnet solenoid
Multiple control valve specifications ............................... 42-41 ............................................................. 42-29, 42-34, 42-39
Preload adjustment ........................................................... 23-7
Preparation mode (ride control switch is OFF) ............... 42-53
N
Preset height adjustment .............................................. 62-117
Neutral ............................................................................ 42-65
Pressure control valve ...................................................... 42-5
Neutral position (Steering spool in "Neutral") ................. 42-72
Pressure relief valve ....................................................... 72-49
Neutral relay ................................................................... 62-19
Pressure sensor ............................................................. 32-29
Neutral starter ................................................................ 62-15
Pressure sensor (for Declutch) .......................................52-36
Pressure sensor (for declutch) .......................................52-34
O Pressure Sensor (for stop lamp and declutch) ............... 52-34
Oil Flow .......................................................................... 32-22 Pressure sensor (for stop lamp) .....................................52-34
Oil flow in the torque converter line ................................ 32-22 Pressure switches .......................................................... 72-47
Oil flow to the clutch ....................................................... 32-22 Principle of cooling ......................................................... 72-19
Oil seal installation ........................................................... 23-8 Propeller Shaft .........................................................22-8, 23-3
Operation methods ........................................................... 42-5 Propeller shaft phase ........................................................ 23-3
Operation monitor lamps ................................................ 62-64 Propeller shaft tightening torque .......................................23-4
Operation of parking brake ............................................. 52-26 Proportional relief valve (S/N 9001~9150) .................... 42-101
Operation of T.P.D ......................................................... 22-18 Proportional relief valve (S/N 9151~) ............................ 42-103
Operator Seat ................................................................... 72-9 Proportional relief valve operation ................................ 42-101
Orbit rotor operation principle ......................................... 42-69 Proximity switch ............................................................ 62-111
Orbitrol® .......................................................................... 42-63 Pumps & motors ............................................................... 42-4
Orbitrol® feed-back mechanism operation ..................... 42-67 Purpose of flushing ........................................................... 42-2
Orbitrol® operation .......................................................... 42-65
Orbitrol® specifications ................................................... 42-64 Q
Orbitrol® structure ........................................................... 42-63
Quantum fault code information .....................................62-28
Outline .............................................................................. 00-4
Outline of MODM (Machine Operation
Diagnostic Module) Operation ................................... 92-47 R
Overload relief valve operation ........................... 42-44, 42-79 Radiator (S/N 9001~9150) ................................................ 22-5
Radiator (S/N 9151~) ........................................................ 22-6
Rear Chassis .................................................................... 12-5
P
Rear wiper ........................................................................72-6
Parameter change ........................................................ 62-104
Receiver dryer .......................................................72-45, 73-7
Parameter Setting Monitor ............................................. 62-96
Recommended lubricants ................................................. 00-9
Parameter setting monitor display .................................. 62-96
Recommended mixture of antifreeze .............................. 00-10
Parking Brake ...................................................... 52-22, 53-10
Reducing valve ............................................................... 42-56
Parking brake ........................................................ 52-2, 62-54
Reducing Valve (for Orbitrol®) ........................................ 42-84
Parking brake clearance adjustment .............................. 53-10
Reducing Valve (for Pilot Pressure) ...............................42-24
Parking brake friction plate ............................................. 52-27
Refrigerant ......................................................................72-20
Parking Brake Manual Release ...................................... 52-29
Refrigerant characteristics .............................................. 72-21
Parking brake operation ................................................. 52-25
Refrigerant charging procedure ...................................... 72-58
Parking brake performance check ................................. 53-10
Refrigerant charging tools .............................................. 72-55
Parking brake solenoid valve ......................................... 52-28
Refrigerant hose ............................................................. 72-51
Parking brake steel plate ................................................ 52-27
Relay A ........................................................................... 72-50
Parts to be replaced periodically ...................................... 73-7
Relay B ........................................................................... 72-50
Pilot valve (S/N 9001~9250) .......................................... 42-25
Replacement interval pop-up ..........................................62-84
Pilot valve (S/N 9251~9255) .......................................... 42-30
Replacement interval set (timer reset) ............................62-83
Pilot valve (S/N 9256~) .................................................. 42-35
Replacement Monitor .....................................................62-79
Pilot valve function ................................... 42-27, 42-32, 42-37
Replacement time check ................................................62-79
Resistance check mode ............................................... 62-120
.............................................................. 42-27, 42-32, 42-37
Reverse 1st speed power flow path ...............................32-16
Planetary gear .................................................................. 32-8
Reverse 2nd speed power flow path .............................. 32-16
Possible causes for clutch time lag .................................. 33-4
Reverse 3rd speed power flow path ...............................32-17
Possible causes for low clutch pressure and
Reversing fan control chart ........................................... 42-111
clutch time lag .............................................................. 33-3
Reversing fan motor (OPT) .......................................... 42-109
Possible causes of excessive cylinder drift .................... 43-16
Reversing fan motor function ........................................ 42-108
Power flow path ................................................................ 32-2
Reversing Fan Motor Line (OPT) ..................................42-108 Steering spool variable throttle ....................................... 42-74
Ride Control (OPT) .........................................................42-52 Steering System ............................................................. 42-62
Ride control circuit reducing valve setting Steering system ................................................................ 42-8
pressures (OPT) ...........................................................43-7 Steering Valve (KVS32-A4.0/20) .................................... 42-70
Ride control function .......................................................42-52 Steering valve flow control spool .................................... 42-75
Ride control hydraulic circuit ...........................................42-52 Steering valve main relief valve ...................................... 42-76
Ride control operation .....................................................42-53 Steering valve operation ................................................. 42-72
Ride control system (OPT) ...............................................42-9 Steering valve overload relief valve ................................ 42-78
Ride control valve assembly (Accumulator circuit) .........42-58 Stop Valve ........................................................... 42-82, 43-17
Ride control valve assembly (Reducing valve circuit) .....42-55 Stop valve adjustment procedure ................................... 43-17
Rotor part ........................................................................42-64 Stop valve function ......................................................... 42-83
Running mode (ride control switch is ON) ......................42-54 Stop valve operation ....................................................... 42-83
Surge voltage and surge suppression diodes .............. 62-121
Switching from automatic to manual .............................. 62-48
S
Symbols ............................................................................ 00-3
Safety precautions ............................................................00-2
Screw lock agent application procedure .........................00-19
Second propeller shaft alignment .....................................23-3 T
Second propeller shaft assembly ......................................22-9 T/C and T/M Oil Circulation ............................................ 32-23
Secondary Steering ......................................................42-113 The operation condition of ELS ...................................... 42-92
Secondary steering function (OPT) ................................62-60 Third propeller shaft assembly ....................................... 22-10
Secondary steering motor and pump ............................42-115 Tilt case .......................................................................... 72-11
Secondary steering operation .......................................42-113 Time lag measurement procedure ................................... 33-4
Selection of machine fault log and engine fault log ........62-86 Tolerance ring ................................................................ 52-19
Sensor assy ..................................................................62-115 Torque Converter ............................................................. 32-2
Service Brake ....................................................... 52-14, 53-6 Torque Converter (Lock-up) (Option) ............................... 32-3
Service brake ....................................................................52-2 Torque Converter and Transmission ................................ 92-3
Service brake friction plate .............................................52-15 Torque Converter Gear Pump ................................. 32-5, 32-6
Service brake friction plate wear measurement ................53-7 Torque Converter structure .............................................. 32-2
Service brake operation ..................................................52-14 Torque multiplication ........................................................ 32-2
Service brake pedal stroke adjusting mechanism Torque Proportioning Type Differential Gear (TPD) ....... 22-14
(S/N 9001~9014) ........................................................52-18 Transmission .................................................................... 32-8
Service brake performance check ....................................53-6 Transmission Control Circuit and Monitor Circuit ........... 62-37
Service brake piston .......................................................52-17 Troubleshooting using the gauge manifold .................... 72-64
Service brake steel plate ................................................52-16 Turn ................................................................................ 42-66
Shift lever ........................................................................72-12
Shift lever forward/reverse (F/R) position .......................62-15
U
Shift lever neutral (N) position ........................................62-15
Unit conversion and language selection ......................... 62-78
Shift lever position ............................................................32-8
Unloader Valve ................................................................. 52-4
Shuttle valve ...................................................................42-59
Unloader valve operation ................................................. 52-6
Sight glass ......................................................................72-47
Unloader valve setting pressure ....................................... 53-2
Solenoid specifications ...................................................52-33
Unloader valve setting pressure measurement ................ 53-3
Solenoid valve .................................................... 42-57, 42-59
Upper center pin ............................................................... 12-7
Solenoid valve (for Autobrake circuit) .............................52-33
Solenoid valve assembly (1/2) ........................................42-90
Solenoid valve assembly (2/2) ........................................42-91 V
Solenoid valve mount .....................................................42-89 Valve part ....................................................................... 42-63
Solenoid valve operation ................................................52-28 Valve Unit ......................................................................... 52-7
Solenoid valve specifications ..........................................52-28 Viscous mount .................................................................. 12-6
Specification Setting Monitor ........................................62-105 Voltage relay .................................................................. 62-21
Specification setting monitor display .............................62-105
Standard Measurement Values for Performance
Check ...........................................................................03-3
W
Starter switch ..................................................................62-16 Way of looking at connectors ......................................... 92-19
Steel plate: mm (in) .........................................................32-11 Weight of main components ........................................... 00-12
Steering and Transmission Shift Lever ...........................72-10 When the compressor is replaced .................................... 73-3
Steering circuit relief valve setting pressures ...................43-9 When the condenser is replaced ...................................... 73-4
Steering cylinder .............................................................42-21 When the evaporator is replaced ..................................... 73-4
Steering Line Filter ..........................................................42-85 When the pressure exceeds the preset value ................ 42-77
Steering pilot circuit and its operation .............................42-80 When the pressure is at the preset value or less ........... 42-76
Steering speed and flow rate control ..............................42-68 While the ELS is not operating ....................................... 42-95
While the ELS is operating ............................................. 42-95
While the valve is not operating ..................................... 52-12
While the valve is operating ........................................... 52-13
While the valve is releasing ............................................ 52-13
Wiper motor ...................................................................... 72-7
Wiper mount ..................................................................... 72-6
Work procedure .............................................................. 72-53
MEMO
Maintenance Log
Date Machine hours Service performed

Notes

Çalışma Prensibi 1

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93215-00482

Orbitrol® structure ..................................................................................................................................... 42-63

Orbitrol® specifications .............................................................................................................................. 42-64

Orbitrol® operation .................................................................................................................................... 42-65

Orbitrol® feed-back mechanism operation ................................................................................................ 42-67

Reducing Valve (for Orbitrol®) ......................................................................................................................... 42-84

How to Use Manual ................................................. 00-2

How to Use Manual

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

- Be sure to release the internal pressure before you

- Be sure to apply the articulation stopper before start-

- While supporting the bottom of the chassis using a

- When the boom or bucket is raised or when a unit is

Symbol Item Description

Shows the condition or procedure that will be useful

Shows the weight of a part or unit. The weight

Tightening Shows the tightening torque of a section that should

Shows the type of coating or adhesive and the coat-

Shows the oil or water drain port and the drain

E/G ........... Engine RH ............Right hand side 3rd ............3rd speed

Layout of main components

1. Engine assembly (Cummins QSX-15)

Inspection and maintenance table

: First time replacement or cleaning only

Check Engine Oil Level

Check Engine Coolant Level

Check Warning Lamps

Check Exhaust Gas

Drain Water and Sediment from Fuel Filter

Check Fuel Level

Check Drive Belt

Check Crankcase Breather Tube

Check Air Intake System

Check Cooling Fan

Drain Water and Sediment from Fuel Tank

Replace Fuel Filter Cartridge

Replace Engine Oil and Oil Filter Cartridge

Add DCA4 Coolant Additive

Replace Fuel Tank Breather

Check and Adjust Valve Lash Clearance

Check Vibration Damper

Check Engine Compression Pressure

Check Injection Pressure

Clean Crankcase Breather Tube

Clean or Replace Air Cleaner Element

Replace Coolant Every 2 years or 3000 hours

: First time replacement or cleaning only

Check Transmission Oil Level

Transmission & Replace Transmission Oil Filter Cartridge

Clean or Replace Transmission Breather

Check Tire for Damage, Air and Tread Depth

Greasing (Axle support)

Check Tire Air Pressure

Check Differential Gear Oil

Check Planetary Gear Oil

Greasing (Pillow block bearing unit)

Axle system Check Tightness of Wheel Bolts

Greasing (Differential seals)

Greasing (2nd Propeller Shaft Spline)

Replace Differential Gear Oil

Replace Planetary Gear Oil

Greasing (2nd Propeller Shaft) Every 12000 hours

Greasing (3rd Propeller Shaft) Every 12000 hours