AAA-S85C3V00-012 (93211-00071)
WHEEL LOADER SHOP MANUAL
85 Z
Powered by CUMMINS M11-C Engine. SERIAL NUMBERS 85C3-5501 and up.
General Information Functions & Structure
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 Functions and structure Note: ① For Troubleshooting and Measurement for Performance Check, refer to the 85ZⅣ -2 Shop Manual AAA-S85C3V01-012 (93211-00081). ② For Disassembly and reassembly and Service standard, refer to the 85ZⅣ -2 Shop Manual AAA-S85C3V14-012 (93211-00091) ③ For the engine, refer to the engine Shop Manual provided by the engine manufacturer. The purpose of this manual is to provide information on the product and the correct maintenance and repair methods. Please read this manual to ensure correct troubleshooting and good repair service. This manual will be periodically reviewed and revised for more satisfactory content. If you have any opinion or requests, please inform us.
（1）
Safety Precautions The most important point in providing repair service is safety. To ensure safety, observe the general cautions described below.
・ This manual is intended for properly trained and equipped service technicians. ・ Any work on the machine must be performed by the trained personnel only. ・ Carefully read this manual to thoroughly understand the operation method before you operate or repair the machine. ・ Be sure to wear appropriate clothes and protectors, such as safety boots, hard hat and goggles. ・ Place the machine on a level and solid ground, and place chocks against the wheels to prevent movement. ・ Remove the cable from the battery before starting the service work, and attach a "DO NOT OPERATE!" tag to the steering wheel. ・ Be sure to release the internal pressure before you remove a pipe, such as the hydraulic oil, air, or engine coolant pipe. ・ Be sure to apply the articulation stopper before starting work. ・ While supporting the bottom of the chassis using a jack, be sure to support the chassis using the blocks. ・ When the boom or bucket is raised or when a unit is lifted by a crane, be sure to place a stand or adequate cribbing under the unit to prevent unexpected dropping. ・ Do not start to work in an enclosed area if adequate ventilation is not provided. ・ To remove a heavy unit (20kg (40 lbs) or more), be sure to use a crane or other lifting tool. ・ Just after stopping operation, be careful not to directly touch a hot component. You may get burned. ・ Contact tire manufacturer's local dealer for tire servicing and changing. ・ Always store the tools in good condition, and use them properly. ・ Keep the work area clean. Clean up spills immediately. ・ Avoid the use of flammable solvents and cleaners. ・ When working outdoors keep work areas, ladders, steps, decks and work platforms clear of snow, ice, and mud. ・ Use safe work platforms to reach higher areas of the machine.
（2）
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.
（3）
Symbols For safe and effective service work, the following symbols are used for notes and useful information in this manual. Symbol
Item Reference
Description Shows the condition or procedure that will be useful or efficient in doing service work. Shows the weight of a part or unit. The weight
Weight
should be considered in selecting wire rope or cable for slinging work or determining the working posture.
Shows the tightening torque of a section that Tightening should be carefully tightened during assembly torque work.
Coating
l
Oil or water supply
Drainage
Shows the type of coating or adhesive and the coating section.
Shows the oil or water supply port and the refill amount.
Shows the oil or water drain port and the drain amount.
IMPORTANT If the specified conditions are not satisfied or the specified procedure is not observed, there is a strong possibility that the product will be damaged or the performance of the product will be reduced. The message shows the preventive measures.
（4）
Outline ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 00-1 Chassis Group ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 12-1 Power Group ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 22-1 Torque Converter & Transmission Group ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 32-1 Hydraulic Group ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-1 Brake Group ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-1 Electrical Group ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-1
OUTLINE 00 Layout of Main Components ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 00-2 Recommended Lubricants ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 00-3 Lubrication Chart ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 00-4 Weight of Main Components ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 00-5 Hexagon Bolt Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 00-6 Flanged Hexagon Bolt Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 00-9 Hose Band Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 00-10 Liquid Gasket and Screw Lock Agent ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 00-11 Cautions regarding Welding Repair Service ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 00-12
00-1
85Z Ⅳ -2
Layout of Main Components
Outline 00
Layout of Main Components 7
4
5
3
2
8
1
9
15
10
6
16
11
13
7
14
12 85V0001
1. Engine assembly (Cummins M11-C) 2. Transmission / Torque converter assy 3. Hydraulic pump (3 section type) 4. Multiple (loader) control valve 5. Steering valve 6. Pilot valve (for loading) 7. Transmission control valve 8. Air cleaner
9. Muffler 10. Radiator 11. Front axle assembly 12. Rear axle assembly 13. 2nd propeller shaft 14. 3rd propeller shaft 15. Hydraulic oil cooler 16. T / C oil cooler (lower tank of radiator)
00-2
85Z Ⅳ -2
Recommended Lubricants
Outline 00
Recommended Lubricants Ambient Temperature Kind of Oil
Capacity
Engine
Engine oil (CE)
39 liter (10gal.)
Transmission
Engine oil (CD) Mobil TRANS HD-10 ATF
38 liter (10gal.)
Hydraulic system
Hydraulic oil
130 liter (34gal.)
Differential & Planetary
Gear Lubricant
‐２２° −４° １４° ３２° ５０° ６８° ８６°Ｆ ‐３０°‐２０°−１０° ０°Ｃ １０° ２０° ３０°
SAE 10W-30 SAE 15W-40 SAE 10W Mobil TRANS HD-10 Multi-Purpose ATF ISO VG46 ISO VG32
Front : 65 liter (17gal.)
MOBIL TRANS HD-50
Rear : 70 liter (8.5gal.)
Change Interval (Hours) 250
1,000
2,000 2,000
SAE 80W
Steering gear box
Gear oil (GL-5)
0.4liter (0.1gal.)
SAE 90
2,000
SAE 140
Brake
Engine oil
2.4 liter (0.6gal.)
Fuel tank
Diesel fuel
300 liter (79gal.)
MOBIL DELVAC 1 ASTM D975 No.2 ASTM D975 No.1
-daily
Engine Use oil that meets engine oil classification "CE" (MIL-L-2104C). Transmission
Use engine oil classification "CD" (MIL-L-2104C), Mobil TRANS HD-10, Multi-purpose Automatic Transmission Fluid. Never mix engine oil, Mobil TRAMS HD-10 and/or ATF.
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. Differential & Planetary Brake
Use Mobil TRANS HD-50 or equivalent.
Use engine oil Mobil DELVAC 1 only.
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 a needle bearing.
00-3
85Z Ⅳ -2
Lubrication Chart
Outline 00
Lubrication Chart
Front differential gear and gear box
Hydraulic oil
Rear differential gear and gear box Every 2000 hours
Transmission Engine oil pan
Every 1000 hours Every 250 hours
Linkage Center pin
Every 50 hours Daily
Brake oil reservoir tank
Bucket
Steering cylinder
Axle support
2nd propeller shaft
3rd propeller shaft ９０ＺⅣ０００３
○・ ・ ・ ・ ・ ・ ・ ・Oil supply
・ ・ ・ ・ ・ ・ ・ ・Multipurpose grease G・
・ ・ ・ ・ ・ ・Hydraulic oil HO・
△・ ・ ・ ・ ・ ・ ・ ・Check and additional oil supply
GO・ ・ ・ ・ ・ ・ ・Gear oil
TO・ ・ ・ ・ ・ ・ ・Engine oil
EO・ ・ ・ ・ ・ ・ ・Engine oil
BO・ ・ ・ ・ ・ ・ ・Engine oil
□・ ・ ・ ・ ・ ・ ・ ・Oil replacement
00-4
85Z Ⅳ -2
Weight of Main Components
Outline 00
Weight of Main Components
Part name
Approx. Weight (kg)
Approx. Weight (lb)
Bucket
1440
3170
GSN bucket
Boom
1250
2750
Standard
" Z " -Lever
360
790
Link (Bucke to Lever)
70
155
305
670
Including air cleaner and condenser
265
580
Excluding air cleaner and condenser
Hydraulic tank
150
330
Excluding oil
Fuel tank
150
330
Excluding fuel
Deck
40
90
Including hand rail
Cab and floor board
900
1980
Including ope. board, instrument panel and control box
Front chassis
1680
3700
Bare chassis
Rear chassis
1360
3000
Bare chassis
Counter weight
1100
2430
Standard
Engine
1000
2200
Excluding oil
Radiator
200
440
Excluding water and oil
Transmission
880
1940
Excluding oil
Second propeller shaft
55
120
Third propeller shaft
10
22
Air cleaner
18
40
Exhaust silencer (Muffler)
23
50
Front axle assembly
1300
2870
Excluding tires and oil
Rear axle assembly
1700
3750
Excluding tires and oil (Including axle support)
Differential
178
390
Multiple control valve
54
120
Steering valve
22
48
Hydraulic
Gear pump
49
107
system
Boom cylinder
200/pc
440/pc
Excluding oil
Bucket cylinder
215
475
Excluding oil
Steering cylinder
38/pc
85/pc
Excluding oil
Tire
510/pc
1125/pc
With rim (23.5-25-16PR); No Hydro Inflation
Air conditioner unit
83
185/pc
(In cab portion)
Battery
40/pc
90/pc
Item Unit name
Remarks
Engine room assembly Chassis
Power line
Other
00-5
85Z Ⅳ -2
Hexagon Bolt Tightening Torque
Outline 00
Hexagon Bolt Tightening Torque (0) Bolt type: 6 1 0 0 1 - 1 2 0 3 0 (1) Thread type: Metric thread=0 (5) (4) (0) (1) ( 2 ) ( 3 ) Unified thread=2 (2) Bolt strength: 4〜11 T (3) Thread pitch: Metric thread: Coarse pitch thread (C), fine pitch thread (F) Unified thread: Coarse pitch thread (UNC), fine pitch thread (UNF) (4) Diameter: 12 → 12mm Metric ; 12 → 12/16 → 3/4 inch Unified (5) Length: 030=30mm (Length is always given in mm for metric or unified bolts.) Bolt size Type
Nominal dimension
Nominal dia.
Pitch
M8
8
(C) 1.25
9
26
38
(C) 1.5
19
53
76
(F) 1.25
20
55
80
(C) 1.75
32
90
132
(F) 1.25
34
96
142
(C) 2.0
51
142
206
(F) 1.5
54
152
221
(C) 2.0
76
216
314
(F) 1.5
80
226
330
(C) 2.5
103
299
436
(F) 1.5
113
324
476
(C) 2.5
147
417
608
(F) 1.5
162
451
662
(C) 2.5
196
559
814
(F) 1.5
211
598
878
(C) 3.0
255
721
1,030
(F) 2.0
270
770
1,128
(C) 3.0
373
1,030
1,520
(F) 2.0
397
1,128
1,618
(C) 3.5
510
1,422
2,109
(F) 2.0
549
1,569
2,256
(C) 3.5
686
1,912
2,844
M10 M12 M14 M16
Metric thread
Unified thread
(N-m)
Bolt strength
10 12 14 16
4.6 (4T)
8.8 (8T)
10.9T (11T)
M18
18
M20
20
M22
22
M24
24
M27
27
M30
30
M33
33
(F) 2.0
736
2,059
3,040
5/16
05
18 UNC
9
25
35
3/8
06
16 UNC
16
44
65
7/16
07
14 UNC
25
71
103
1/2
08
13 UNC
36
103
147
9/16
09
12 UNC
52
147
216
5/8
10
11 UNC
72
201
294
3/4
12
10 UNC
127
358
525
7/8
14
9 UNC
196
554
809
1
16
16 UNC
309
868
1,275
★ :Tighten the bolts according to the above list, unless otherwise specified.
00-6
85Z Ⅳ -2
Hexagon Bolt Tightening Torque
Outline 00
(kgf-m) Bolt size Type
Nominal dia.
Pitch
4.6 (4T)
8.8 (8T)
10.9T (11T)
M8
8
(C) 1.25
0.9
2.7
3.9
M10
10
(C) 1.5
1.9
5.4
7.8
(F) 1.25
2.0
5.6
8.2
M12
12
(C) 1.75
3.3
9.2
13.5
(F) 1.25
3.5
9.8
14.5
M14
14
(C) 2.0
5.2
14.5
21.0
(F) 1.5
5.5
15.5
22.5
M16
16
(C) 2.0
7.8
22.0
32.0
(F) 1.5
8.2
23.0
33.7
(C) 2.5
10.5
30.5
44.5
(F) 1.5
11.5
33.0
48.5
(C) 2.5
15.0
42.5
62.0
(F) 1.5
16.5
46.0
67.5
(C) 2.5
20.0
57.0
83.0
(F) 1.5
21.5
61.0
89.5
(C) 3.0
26.0
73.5
105.0
(F) 2.0
27.5
78.5
115.0
(C) 3.0
38.0
105.0
155.0
(F) 2.0
40.5
115.0
165.0
(C) 3.5
52.0
145.0
215.0
(F) 2.0
56.0
160.0
230.0
(C) 3.5
70.0
195.0
290.0
(F) 2.0
75.0
210.0
310.0
M18 Metric thread
M20 M22 M24
Unified thread
Bolt strength
Nominal dimension
18 20 22 24
M27
27
M30
30
M33
33
5/16
05
18 UNC
0.9
2.5
3.6
3/8
06
16 UNC
1.6
4.5
6.6
7/16
07
14 UNC
2.6
7.2
10.5
1/2
08
13 UNC
3.7
10.5
15.0
9/16
09
12 UNC
5.3
15.0
22.0
5/8
10
11 UNC
7.3
20.5
30.0
3/4
12
10 UNC
13.0
36.5
53.5
7/8
14
9 UNC
20.0
56.5
82.5
1
16
16 UNC
31.5
88.5
130.0
★ :Tighten the bolts according to the above list, unless otherwise specified.
00-7
85Z Ⅳ -2
Hexagon Bolt Tightening Torque
Outline 00
(lb-ft.) Bolt size Type
Nominal dia.
Pitch
4.6 (4T)
8.8 (8T)
10.9T (11T)
M8
8
(C) 1.25
6.5
19.5
28
M10
10
(C) 1.5
13.7
39
56
(F) 1.25
14.5
40
59
M12
12
(C) 1.75
23
66
97
(F) 1.25
25
70
105
M14
14
(C) 2.0
37
105
150
(F) 1.5
39
110
160
M16
16
(C) 2.0
56
160
230
(F) 1.5
59
165
245
(C) 2.5
76
220
320
(F) 1.5
83
235
350
(C) 2.5
105
305
450
(F) 1.5
120
330
490
(C) 2.5
145
410
600
(F) 1.5
155
440
650
(C) 3.0
190
530
760
(F) 2.0
200
565
830
(C) 3.0
275
760
1120
(F) 2.0
295
830
1190
(C) 3.5
375
1050
1550
(F) 2.0
405
1160
1660
(C) 3.5
505
1410
2100
(F) 2.0
540
1520
2240
M18 Metric thread
M20 M22 M24
Unified thread
Bolt strength
Nominal dimension
18 20 22 24
M27
27
M30
30
M33
33
5/16
05
18 UNC
6.5
18.0
26
3/8
06
16 UNC
11.5
32
47
7/16
07
14 UNC
18.8
52
76
1/2
08
13 UNC
26
76
105
9/16
09
12 UNC
38
110
160
5/8
10
11 UNC
52
150
215
3/4
12
10 UNC
94
265
385
7/8
14
9 UNC
145
410
595
1
16
16 UNC
225
640
940
★ :Tighten the bolts according to the above list, unless otherwise specified.
00-8
Flanged Hexagon Bolt Tightening Torque
85Z Ⅳ -2
Outline 00
Flanged Hexagon Bolt Tightening Torque 1.Bolt Type
Metric thread
2.Bolt strength
4〜8T
3.Thread pitch
Coarse pitch thread(C)
(N-m) Bolt size Type
Metric thread
Bolt strength
Nominal dimension
Pitch
M5
0.8
4
7
M6
1
7
12
M8
1.25
15
28
M10
1.5
28
53
M12
1.75
50
94
M16
2
−
231
M20
2.5
−
441
M24
3
−
765
4.8 (4T)
8.8 (8T)
(kgf-m) Bolt size Type
Metric thread
Bolt strength
Nominal dimension
Pitch
4.8 (4T)
8.8 (8T)
M5
0.8
0.4
0.7
M6
1
0.7
1.2
M8
1.25
1.5
2.9
M10
1.5
2.9
5.4
M12
1.75
5.1
9.6
M16
2 2.5
− −
23.5
M20 M24
3
−
78.0
45.0
(lb-ft) Bolt size Type
Metric thread
Bolt strength
Nominal dimension
Pitch
4.8 (4T)
8.8 (8T)
M5
0.8
2.9
5.0
M6
1
5.0
8.6
M8
1.25
10.8
20.9
M10
1.5
20.9
38.9
M12
1.75
36.7
69.1
M16
2
−
169.2
M20
2.5
−
324.0
M24
3
−
561.6
00-9
85Z Ⅳ -2
Hose Band Tightening Torque
Outline 00
Hose Band Tightening Torque Low pressure hose (heat resisting hose)
Hose band
Tightening torque
Tightening torque
Tightening torque
(N-m)
(kgf-cm)
(lb-ft)
1.6
16
1.2
4
40
2.9
Tightening torque (N-m)
Tightening torque (kgf-cm)
Tightening torque (lb-ft)
1.6
16
1.2
4
40
2.9
Inner dia.(mm) Outer dia.(mm) 6.3
16.5
HH022W
7.9
18.5
HH022W
9.5
20.5
HH022W
12.7
24.5
HH027W
15.9
29.9
HH031W
19.0
30.0
HH031W
25.4
38.0
HH044W
31.8
45.8
HH052W
38.1
52.1
HH057W
50.8
67.8
HH071W
60.5
76.0
HH082W
75.5
93.0
HH095W
Low pressure hose Inner dia.(mm) Outer dia.(mm)
Hose band
6
16.5
HH022W
8
18.5
HH022W
9
20.5
HH022W
9
22.0
HH023W
12
24.5
HH027W
12
26.0
HH027W
15
29.0
HH031W
15
30.5
HH031W
19
32.0
HH038W
19
34.0
HH038W
25
39.5
HH044W
25
41.5
HH044W
32
46.0
HH052W
32
48.0
HH052W
38
54.0
HH057W
50
70.5
HH076W
50
73.0
HH076W
To connect the hose to the pipe, tighten the hose band at the following position: Hose
Hose band Center of pipe protrusion 10〜20mm
00-10
Pipe
85Z Ⅳ -2
Liquid Gasket and Screw Lock Agent
Outline 00
Liquid Gasket and Screw Lock Agent To reassemble the disassembled parts, be sure to use the specified liquid gasket or screw lock agent of the equivalent according to the following lists:
Liquid Gasket Code
Manufacturer
Product name
ＡＡ０１
Loctite ®
Plastic Gasket 568
ＡＡ０２
Loctite ®
Hydraulic sealant
ＡＡ０３
Three Bond
Three Bond 1215
Code
Manufacturer
Product name
ＡＢ０１
Loctite ®
Loctite ® 262
ＡＢ０２
Three Bond
Three Bond 1327
ＡＢ０３
Three Bond
Three Bond 1374
Screw Lock Agent
・ Cautions regarding parts removal
・ Cautions regarding reassembly
If a screw or shaft to be removed has been locked by one of the above agents, remove the screw or shaft using a general tool, such as a wrench or puller. If it is difficult to remove the screw or shaft, heat the bolt to soften the agent (200 to 250 ℃ ) using a soldering iron or gas torch. Caution:If there is a seal near the screw or shaft to be removed, carefully use the heating method for removal, to avoid damage to the seal. If heat has been used to remove the bolt a new bolt should be used during reassembly.
To reassembly a screw: Completely remove the hardened lock agent from the screw and the threaded hole before reassembling the screw. Note: A piece of hardened lock agent may be peeled off and remain in the component. The remaining piece may cause malfunction during fastener installation.
To bond a plane or to fit a shaft: Remove the hardened lock agent using a wire brush or the like, and polish the surface using sand paper. Use of a loctite primer like Locquic ® Primer T cleans threads and speeds curing time.
Antiseize Agent Code
Manufacturer
ＡＣ０１
Loctite ®
Product name Loctite ® 767 (Paste or spray)
00-11
Caution Regarding Welding Repair Service
85Z Ⅳ -2
Outline 00
Cautions Regarding Welding Repair Service If welding is needed to repair the chassis, observe the following precautions to protect the hydraulic cylinders, hydraulic units, gear sets, and electrical units from possible damage.
Cautions: 1. Remove the ground terminal from the battery. 2. The controller circuit breaker should be turned "OFF" . 3. Ground the welder near the section to be welded. 4. To ground the welder, check that the electric current will not flow through the cylinders. Cylinder head covers for some models have a low-conductive metal that will cause spark if the welding current flows. The spark may damage the cylinder rod. Example 1:
Section to be welded Do not ground this section. Electric current may flow through the cylinders. Ground this section. (correct grounding)
Example 2:
Do not ground this section. Electric current may flow through the cylinders.
Section to be welded
Ground this section. (correct grounding)
00-12
Caution Regarding Welding Repair Service
85Z Ⅳ -2
5. The weld spattered on the hydraulic cylinders and on the plated sections of pins will damage the cylinders and pins. There are other parts that may be damaged by the spatter; hydraulic units, harnesses, hydraulic hoses, and nylon tubes.
Outline 00
Be sure to mask these units and parts before welding.
a)Plated section Cover the plated sections with heat-resistant cloth, such as glass wool or canvas . Note: The weld spattered on the plated sections causes corrosion.
Hydraulic cylinder
Plated section (Mask this section.)
Pin section with pin temporarily inserted Pin
Plated section (Mask this section.)
b)Cover the hydraulic units, electrical units, harnesses, hydraulic hoses, nylon tubes, etc. with heat-resistant cloth (glass wool or canvas) or scrap material to protect them from spatter. 1m or more
Scrap material, etc.
Section to be welded
1
1m or more
c) Hydraulic hoses, nylon tubes, or harnesses are easily damaged by the heat during welding. To protect them from the heat, remove them from the section to be welded to make enough clearance.
Section to be welded Hydraulic hose Nylon tube Harness
Remove and if necessary wrap Chassis
00-13
CHASSIS GROUP 12 Front Chassis ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 12-2 Rear Chassis ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 12-4 Center Pin ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 12-5 Clearance Adjustment for Pin Section ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 12-6 Center Pin ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 12-7
12-1
85Z Ⅳ -2
Front Chassis
CHASSIS 12
Front Chassis Loading system
5
4
3 9
10
1
2
8
6
7
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 attachement) Even contact both sides
4063 41〜43 °
A 50 °
A=5 ± 2mm
Typical bucket dump stopper clearance (Contact attachment supplier for details on non-standard attachments) To increase clearance increase height of #9 To reduce clearance decrease height of #9
260
Typical bucket roll-back stopper adjustment (Contact attachment supplier for details on non-standard attachments)
12-2
85Z Ⅳ -2
Front Chassis
CHASSIS 12
Construction of loading system pin sections 1. Bucket - Boom
2. Boom - Lever
3. Boom - Boom cylinder
φ７０ φ１３０
4. Front chassis - Boom
φ９０
6. Lever - Rod
5. Bucket - Rod
φ９０ φ９０
φ１００
8. Bucket cylinder Front chassis
7. Lever - Bucket cylinder
φ１００
φ９０
φ１００
10. Front chassis Steering cylinder
9. Boom cylinder Front chassis
11. Steering cylinder Rear chassis
φ５０
８ ７
４
９
２
５ １０
３ ６
１１
１
12-3
85Z Ⅳ -2
Rear Chassis
CHASSIS 12
Rear Chassis Fuel tank
７
３ １
２
４
１２
８
６
５
1. Fuel tank 2. Fuel level sensor 3. Fuel tank filler assembly 4. Filter 5. Drain cock/Plug 6. Inspection hole cover 7. Gasket (Rubber seal type) 8. Suction pipe ８５Ｋ１２００１
12-4
85Z Ⅳ -2
Center Pin
CHASSIS 12
Center Pin 4
7
9
3 11
5 6 Front chassis
10
Upper 1. Center pin 2. Cover 3. Bearing cover 4. Washer 5. Shim 6. Bearing assy 7. Dust seal 8. Bolt 9. Bolt 10. Washer 11. Grease nipple
Rear chassis
1
2 8
Upper 6 5
7
4
8
Lower 1. Center pin 2. Bearing retainer 3. Bearing assy 4. Dust seal 5. Bushing 6. Bolt 7. Plate 8. Grease nipple
2
3
5 Front chassis
1 Lower
Rear chassis ９０ＺⅣ１２０５
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.
Dust seal
Seal position
12-5
85Z Ⅳ -2
Clearance Adjustment for Pin Section
CHASSIS 12
Clearance Adjustment for Pin Section WARNING
CAUTION
Unexpected movement of the machine may cause an accident resulting in injury or death. Before starting adjustment work, be sure to observe the following items: ・ Park the machine on level ground. ・Apply the parking brake. ・ Remove the starter key, and hang a "DO NOT OPERATE!" tag on the steering wheel. ・ Block the tires with chocks to prevent the tires from moving.
Unexpectedly dropped parts may cause an accident resulting in injury. ・ Before liner insertion, be sure to lift the cylinder using a crane to prevent the cylinder from unexpectedly dropping during liner insertion. ・ Wear protective clothes like work gloves and steel toed shoes.
4
3
5
2
7
6
1
Adjustment portion
1
2
3
4
5
6
7
Liner hole dia. (mm)
71
91
131
101
101
Adjustment unnecessary
51
Adjustment
※
Adjust the clearance to 1.2mm or less between the bosses using a liner of 1mm thickness. For the steering cylinder, be sure to adjust the clearance on the rear chassis side first and then on the front chassis side while checking that the cylinder is not inclined.
12-6
※
Center Pin
85Z Ⅳ -2
CHASSIS 12
Center Pin Adjusting Shim(#5) The clearance between the front chassis and bearing cover (#3) is 0.75 ± 0.5mm before shim adjustment. Add shims so that the clearance is 0.1 ± 0.05mm.
〔Ｕｐｐｅ ｒ ｓｅｃ ｔ ｉ ｏｎ〕 14 3 5
#12・ ・476N-m (48.5kgf-m) (351lb-ft) #14・ ・216N-m (22.0kgf-m) (159lb-ft)
Rear chassis
Front chassis
12
Installing bearing cover(#3) Install the bearing cover so that the grease nipple mounting hole is positioned at the specified angle as shown in the right figure. Front
3 22.5 ° Grease hole
Installing bearing outer ring(#9)
〔Ｌｏｗｅ ｒ ｓｅｃ ｔ ｉ ｏｎ〕
16
Install the bearing outer ring so that the split is perpendicular to the front-rear line of the machine.
Rear chassis
9
Front chassis
Front
Rear
9 Split of outer bearing
Grease nipple installation direction 22.5 °
12-7
POWER GROUP 22 Outline of Power Line ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 22-2 Engine Mount ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 22-3 Radiator Mount ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 22-4 Propeller Shaft ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 22-5 Axle Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 22-7 Rear Axle Support ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 22-11 Differential Gear ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 22-13 Fuel Control ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 22-18 Engine Oil Pressure ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 22-19
22-1
85Z Ⅳ -2
Outline of Power Line
POWER 22
Outline of 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 transmission clutches. The power is then transmitted through the second and third propeller shafts to the differential gears of front and rear axles. Finally the power is transmitted through the axles to the planetary gears, and tires to move the machine.
On the fan side of the engine, there is a radiator. The radiator incorporates engine coolant, torque converter oil cooler, and an external air type hydraulic oil cooler. On the second propeller shaft side of the transmission, a parking brake is installed.
2
9
10
1
13
3 11
12 15 14
6
1. Engine 2. Torque converter and transmission 3. Radiator 4. 2nd propeller shaft 5. 3rd propeller shaft 6. Front axle differential gear 7. Rear axle differential gear 8. Parking brake
16
8
4
5
7
８５ＺⅣ ＵＳ２２０１
9. Air cleaner 10. Muffler 11. Hydraulic oil cooler 12. Transmission oil cooler(bottom tank of radiator) 13. Precleaner 14. Planetary gears 15. Rear axle support(trunnion type) 16. Axle shaft
22-2
85Z Ⅳ -2
Engine Mount
POWER 22
Engine Mount Bolts are used to connect the engine flywheel housing to the transmission housing, and a spline ring coupling is used to transmit the engine power to the transmission. Therefore no thrust load is placed on the engine flywheel or crank shaft.
Rubber cushions are used to mount the engine and the transmission on the chassis.
８５Ｖ２２００１
1. Rubber cushion 2. Ring gear 3. O-ring
①
1
A-A Section B
８５ＺⅣ ＵＳ２２０３
② ８５ＺⅣ
③
Engine flywheel housing
Flywheel
④ T/C
2 3 ８５ＺⅣ２２−００３
Engine -to- transmission connection section
22-3
① 417N-m (42.5kgf-m) (307 lb-ft) ② 417N-m (42.5kgf-m) (307 lb-ft) ③ 53N-m (5.35kgf-m) (39 lb-ft) ④ 44N-m (4.50kgf-m) (33 lb-ft)
85Z Ⅳ -2
Radiator Mount
POWER 22
Radiator Mount The radiator incorporates the engine coolant, torque converter oil cooler, and an external air type hydraulic oil cooler. For the engine coolant and hydraulic oil, the air-cooling system is used. For the torque converter oil, the water-cooling system is used. The torque converter oil cooler is in the radiator lower tank.
When the coolant is cold enough, the thermostat is completely closed directing coolant from the bypass line to the torque converter oil cooler. The coolant flow cools the torque converter oil to prevent it from being overheated even when the thermostat is closed
2
1
4 C
3
7 C A B
B A 6 5
Viewed from rear
9
② ① 8
Coolant inlet
①
A-A
B-B
Coolant inlet
C-C Hydraulic oil inlet Torque converter oil inlet Coolant outlet
８５ＺⅣ ＵＳ２２０５
Hydraulic oil inlet Coolant bypass line inlet Torque converter oil outlet
. 1. Radiator assembly(three piece type) 2. Fan guard 3. Stay(Bracket) 4. Coolant inlet hose 5. Coolant outlet hose 6. Coolant bypass hose 7. Thermostat 8. Rubber cushion 9. Coolant drain pipe and plug
① 230N-m (23.5kgf-m) (170 lb-ft) With liquid adhesive Loctite 262 ② 49N-m (5.0kgf-m) (36 lb-ft)
Coolant drain Hydraulic oil outlet Torque converter oil inlet Coolant outlet
l Capacity in radiator: Cooling water 36 l Hydraulic oil 3.5 l Torque converter oil 1.7 l
Dry weight 200kg 22-4
85Z Ⅳ -2
Propeller Shaft
POWER 22
Propeller Shaft The engine power transmitted to the torque converter, the transmission and is then transmitted to the second and the third propeller shafts to the front and the rear axle.
For the second propeller shaft, the universal joint and slip joint type spline shaft are used for smooth power transmission at any steering angle or change in propeller shaft length. The third propeller shaft is the fixed type with universal joints.
1
② ①
②
2
①
Front axle
Rear axle ８５Ｖ２２００２
3
③
4
1. 2nd propeller shaft 2. 3rd propeller shaft(fixed type) 3. Center bearing 4. Slip joint
①142N-m (14.5kgf-m) (105 lb-ft) With liquid adhesive Three bond 1327 ②83N-m (8.5kgf-m) (61 lb-ft) With liquid adhesive Three bond 1327 ③216N-m (22.0kgf-m) (159 lb-ft)
22-5
85Z Ⅳ -2
Propeller Shaft
POWER 22
・Adjusting yoke direction (phase) at reinstallation Adjust the yokes of the second and third propeller shafts to the same direction (phase). Second propeller shaft
Third propeller shaft
Front differential
Transmission
・ 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.
Rear differential
When the propeller shaft is articulated due to machine steering, differences in the yoke phases (directions) will cause unbalance between the transmission torque and the reaction force. As a result, the propeller shaft extremely vibrates, and the service life of the shaft will be shortened.
・ Adjusting yoke directions (second propeller shaft)
Top view Differential side
(C)
(B)
Side view
・ As misalignment may produce an abnormal noise, be sure to align points (A), (B), and (C) of the yokes when reassembling the propeller shaft. ・ To align the points (A), (B), and (C), insert spacer or shim into the pillow block section.
22-6
(A)
Transmission side
85Z Ⅳ -2
Axle Assembly
Axle Assembly
POWER 22
(S/N 85C3-5501〜5600)
Construction Front axle assembly The only difference between the front and rear axles is the differential housing (1) and axle housing (2). Other parts are the same as the rear axle assembly.
11
17
28
14
12
27
2
①
1
4 25
15
26
3
⑤ 9 8 5
16 PT3/8 Brake oil inlet
18
③ 24 10
④
7
13 ⑥
② 23
22
1. Differential assembly 2. Axle housing assembly 3. Wheel hub 4. Spider(planetary carrier) 5. Cover 6. Axle shaft 7. Air bleeder screw 8. Sun gear 9. Disc gear 10. O-ring(2)
21
20
29
19
6
11. Planetary gear(4) 12. Internal gear 13. Return spring(8) 14. Snap ring 15. Planetary pin(4) 16. Oil seal 17. Washer(16) 18. Washer 19. O-ring 20. O-ring
ｋｇｍ
①132N-m (13.5kgf-m) (98lb-ft) With liquid adhesive Three bond 1327 ②86N-m (8.8kgf-m) (64lb-ft) ③53N-m (5.4kgf-m) (39lb-ft) With liquid adhesive Three bond 1327 ④90N-m (9.2kgf-m) (67lb-ft) ⑤216N-m (22.0kgf-m) (159lb-ft) With liquid adhesive Three bond 1327 ⑥33N-m (3.4kgf-m) (25lb-ft) Note :For details on service brake components refer to Section 52.
22-7
21. Steel plate(2) 22. Brake friction disc(2) 23. Brake retainer 24. Axle washer(lock plate) 25. Axle nut 26. Taper roller bearing(inner) 27. Taper roller bearing(outer) 28. Needle bearing(8) 29. Brake piston
85Z Ⅳ -2
Axle Assembly
POWER 22
1
②
16 3
26
7
2
27 10
6
29
28 11 13 20 19
25
24
22
17 22 23 14 4
15
8
12 5
21 18
9 21
① 85V22003
1. Differential assembly 2. Axle housing assembly 3. Wheel hub 4. Spider(planetary carrier) 5. Cover 6. Axle shaft 7. Air bleeder screw 8. Sun gear 9. Disc gear 10. O-ring(2)
11. Planetary gear(4) 12. Internal gear 13. Return spring(8) 14. Snap ring 15. Planetary pin(4) 16. Oil seal 17. Washer(16) 18. Washer 19. O-ring 20. O-ring
①892N-m (91.0kgf-m) (658lb-ft) ②1373N-m (140.0kgf-m) (1,013lb-ft)With lubrication oil (Engine oil or gear oil)
22-8
21. Steel plate(2) 22. Brake friction disc(2) 23. Brake retainer 24. Axle washer(lock plate) 25. Axle nut 26. Taper roller bearing(inner) 27. Taper roller bearing(outer) 28. Needle bearing(8) 29. Brake piston
85Z Ⅳ -2
Axle Assembly
Axle Assembly
POWER 22
(S/N 85C3-5601〜)
Construction Front axle assembly The only difference between the front and rear axle is the differential housing (1) and axle housing (2).
17
28
14
12
11 4
2
27
1
25
15 3 26 16 9 PT3/8
8 5
18 24
7 10 13
23 22 21 21 20 29 19
1. Differential assembly 2. Axle housing assembly 3. Wheel hub 4. Spider 5. Cover 6. Axle shaft 7. Air breather nipple 8. Sun gear 9. Disc gear 10. O-ring
6
11. Planetary gear 12. Internal gear 13. Return spring 14. Snap ring 15. Planetary pin 16. Floating seal 17. Washer 18. Washer 19. O-ring 20. O-ring
22-9
21. Steel plate 22. Friction plate 23. Brake retainer 24. Axle washer 25. Axle nut 26. Taper roller bearing 27. Taper roller bearing 28. Needle bearing 29. Brake piston
85Z Ⅳ -2
Axle Assembly
POWER 22
1 16 2 26
31
3
30 27
7 10 20
19
6(LH) 25
17 28 1128
29 14
13
12
17 24
15
21 22
5
9
21 22
4 8 18
1. Differential assembly 2. Axle housing 3. Wheel hub 4. Spider 5. Cover 6. Axle shaft 7. Air breather nipple 8. Sun gear 9. Disc gear 10. O-ring
11. Planetary gear 12. Internal gear 13. Return spring 14. Snap ring 15. Pin 16. Floating seal 17. Washer 18. Washer 19. O-ring 20. O-ring
22-10
21. Steel plate 22. Friction plate 23. Brake retainer 24. Axle washer 25. Axle nut 26. Taper roller bearing 27. Taper roller bearing 28. Needle bearing 29. Brake piston 30. Ring 31. O-ring
23
85Z Ⅳ -2
Rear Axle Support
POWER 22
Rear Axle Support
Grease pipe connection port (PT1/8)
8 Rear side of axle support
Grease pipe connection port (PT1/8) 7 (Rear side)
6
Front
Axle housing
7
9
7 3
5
Front side of axle support
2
1 5 4
12
4
13
5
11 85K22004
8 #8 Details
10 9 #9 Details
1. Rear axle support (front)
6. Wear ring
11.
Snap ring
2. Rear axle support (rear)
7. Breather
12.
O-ring
3. Thrust plate
8. Bushing
13.
O-ring
4. Packing
9. Bushing
5. Packing
10. Ring
22-11
85Z Ⅳ -2
Rear Axle Support
POWER 22
Grease piping
1
12
7 ②
7 ①
Rear axle 4 2
4
14
13 9 Grease piping
11
3 6 8
13
5
10
12
5 6
Front
８５Ｋ２２００５
1. Rear axle support (front)
6. Wear ring
11.
Snap ring
2. Rear axle support (rear)
7. Breather
12.
O-ring
3. Thrust plate
8. Bushing
13.
O-ring
4. Packing
9. Bushing
14.
Dowel pin
5. Packing
10. Ring
①441N-m (45.0kgf-m) (326lb-ft) ②686N-m (70.0kgf-m) (506lb-ft)
With lubrication oil (Engine oil or gear oil)
22-12
85Z Ⅳ -2
Differential Gear
POWER 22
Differential Gear
(Torque proportioning type differential) The figure below shows the front differential gear. The only difference between the front and rear differential gears are the shapes and dimensions of the carrier (2) and flange (5).
①
5
11
13
③ 14 10 15
4
2
16
②
1
⑤ 6
8
① 883N-m (90.0kgf-m) (651lb-ft) With liquid gasket Three bond 1215 ② 235N-m (24.0kgf-m) (174lb-ft) With liquid adhesive Three bond 1327 ③ 314N-m (32.0kgf-m) (232lb-ft) With liquid adhesive Three bond 1327 ④ 331N-m (33.7kgf-m) (244lb-ft) With liquid adhesive Three bond 1327 ⑤ 53N-m (5.35kgf-m) (39lb-ft) With liquid adhesive Three bond 1327
7
3
12
1. 2. 3. 4. 5. 6.
④
Adjusting nut Carrier Ring gear Drive pinion Flange Thrust washer (side gear) 7. Thrust washer (pinion gear) 8. Differential pinion
22-13
9
9. Side gear 10. Shim 11. Cage 12. Spider(cross shaft) 13. Oil seal(double lip) 14. Taper roller bearing 15. Collar 16. Pilot bearing
Differential Gear
85Z Ⅳ -2
The differential gear used for the machine is the torque proportioning type. Compared with the conventional differential, the torque proportioning differential (T.P.D.) can reduce tire slippage on sandy or muddy
POWER 22
ground.
・ Difference in gear shapes Conventional differential: Standard bevel gear T.P.D.: Special bevel gear The gear width is 35 to 50% longer than the conventional differential.
Conventional differential
T.P.D
・ Contact between pinion and side gear
R2
Conventional differential
R1
T.P.D
Conventional 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 distance between the contact point and the shaft center of the side gear also varies in the range of R1〜R2.
Shaft center of side gear
Movement The function of the T.P.D. is as follows: If the surface resistance values of the right and left wheels differ from each other, engagement position of the pinion gear with the side gears will be automatically shifted to transmit different torque to the right and left wheels. Different
torque in right and left wheels prevents the tires from slipping. The number of pinion gear teeth is an odd number, and the pinion gear operate as follows.
22-14
85Z Ⅳ -2
Differential Gear
POWER 22
TPD gear operation(cont'd) Rotational direction
Pinion
Pinion Side gear
L
R2
R
L
R2
R1
R
L
R1 〔A〕 The surface resistance values of the right and left wheels are identical to each other.
R1
R
R2 〔B〕 The surface resistance of the left wheel is low due to sandy ground or the like.
1)When the traction of the right and left wheels are identical to each other, the pinion and side gears will be engaged as shown in figure [A]. In this case, the torque arms of both side gears are identical to each other (R1 = R2). As a result, identical driving force will be applied to both the right and left wheels. 2) If the left wheel loses traction the engagement position between the pinion and side gears will be shifted as shown in figure [B] to quickly rotate(spin) the left wheel. As a result, the torque arms of the both side gears differ from each other (R1 > R2), and the driving force of the left wheel is small. As a result, tire slipping can be reduced. When the driving force of the left wheel is reduced(slipping occurs), the driving force of the right wheel will be increased to limit the reduction in the total amount of the driving force.
〔C〕 The surface resistance of the right wheel is low.
Assuming that the driving torque of the right wheel is TR, and that of the left wheel is TL, the relation between TR and TL can be expressed as follows: TR TL
=
R1 R2
The value obtained from the above formula is referred to as the bias ratio. The limit of the bias ratio is 1.82. In other words, until the difference in the surface resistance between the right and left tires is increased to 82%, the pinion gear will be properly engaged with the shifted side gears, and driving force will be properly applied to both the side gears to prevent the tires from slipping. 3) If the surface resistance of the right wheel is reduced, the engagement position between the pinion and side gears will be shifted as shown in figure [C] above. In this case, the right and left sides are reversed compared with the above description.
22-15
85Z Ⅳ -2
Differential Gear
POWER 22
Adjusting tooth contact : After adjusting the backlash to the standard value, 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 adjusting nut.
Tooth contact
A
Adjusting method
Correct
Loosen the bearing adjuster on the rear side of 2
ring gear, and tighten the adjuster of tooth side at B
the same quantity as loosening, so that the ring gear is far apart from the drive pinion. Check again the backlash and tooth contact.
2 C
Do the reverse adjusting as B.
Decrease the thickness of shim at the part of D
2
bearing cage being installed and makes drive pinion approach the ring gear. Check again the backlash and tooth contact. 1
E
2
Increase the thickness of shim reverse as D, and makes drive pinion apart from the ring gear. 1
22-16
85Z Ⅳ -2
Differential Gear
POWER 22
Three types of tooth contact shown below are acceptable as best tooth contact. Tooth contact position and length(rate) 10 1
Pattern A
5 TOP
4
HEEL 4〜5
Pitch line TOE
10
BOTTOM 10 2
Pattern B
4 TOP
4
Pitch line
HEEL 4〜5
10
TOE BOTTOM 10 3 Pattern C
4 TOP
3 HEEL
TOE Pitch line
4〜5
10
BOTTOM
Service parts : After adjusting the tooth contact and backlash in our factory, we will wrap the ring gear and drive pinion as a set. Therefore, replace the ring gear and drive pinion as a set.
Note : Single sale of the ring gear or the drive pinion is not possible.
22-17
85Z Ⅳ -2
Fuel Control
POWER 22
Fuel Control ３
１
２
４
８５ＺⅣ ＵＳ２３０１
1. Accelerator pedal 2. Control cable 3. Pedal stop bolt 4. Return spring
Adjusting accelerator pedal: Press the accelerator pedal at full stroke, and check that the stop bolt under the pedal comes in contact with the pedal just before the lever of the engine governor comes in contact with the full stroke stopper. If not, adjust the length of the stop bolt.
Caution regarding reinstallation of control cable: Carefully tighten the joints at both ends of the control cable to prevent distortion or damage.
22-18
85Z Ⅳ -2
Engine Oil Pressure
POWER 22
Engine Oil Pressure CAUTION
WARNING
Do not touch the fan or V-belt of the engine or high-temperature section if the engine is running. An accident resultng in injury may occur. Be sure to stop the engine before you open the side cover of the engine room. Keep all guards in place.
Unexpected movement of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items: ・ Park the machine on level ground. ・ Apply the parking brake. ・ Block the tires with chocks to prevent the tires from moving. ・ Determine the signals between the service men. ・ Prohibit any person from walking into dangerous areas. ・ Near articulation area of the machine ・ Under the machine ・ Around the engine ・ In front of or behind the machine
・ Measurement instrument ・ Pressure gauge : For 1MPa (10kgf/cm2) (142psi) with 2.5 〜 3m (8 〜 10 ft.) hose 1/4NPTF measurement port Note : For safety route the hose to an area where the measurement may be made by the operator. Stand away from the machine during operation.
Engine oil pressure gauge port location
・ Warm-up(Temperature of coolant : 50 〜80 ° C) Warm up the engine before starting pressure measurement.
・ Standard values MPa (kgf/cm2) (psi) Engine speed
Service standard
Idling
0.07 (0.7) (10) or more
High idling
0.3 (3.5) (50) or more
22-19
TORQUE CONVERTER AND TRANSMISSION GROUP
32 Torque Converter and Transmission Construction ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 32-2 Gear Arrangement ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 32-3 Torque Converter Operation ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 32-4 Clutch Pack ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 32-5 Clutch Plate ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 32-8 Gear Pump ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 32-10 Power Flow ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 32-11 Hydraulic System Diagram ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 32-14 Hydraulic Circuit Diagram ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 32-15
Control Valve Construction ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 32-16 System Diagram ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 32-17 Solenoid Valve Operation ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 32-18 Modulation Mechanism ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 32-21 Manual Operation of Clutch Solenoid Valve・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 32-26
Measuring Clutch Oil Pressure ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 32-27
32-1
85Z Ⅳ -2
Construction
TORQUE CONVERTER AND TRANSMISSION 32
Torque Converter and Transmission Model Type
90Z Ⅳ -2
Construction
Nissan E/G
Cummins E/G
85Z Ⅳ -2 CT250A01,A02,A03
CT250B01,B02,B03
CT270A01
CT270B01 CT270A02
10
1
11
2
9
3
8
5
14 15 18 17 16 19 20
4
21 23 22
24 7
25 6 26 27
34 28
36 35
29 30 12
31
13 33
32 37
８５ＺＡ３２０１
1. 2. 3. 4. 5. 6. 7.
Pump impeller Turbine impeller Stator Turbine Shaft Stator Shaft (Fixed) Front Cover Input plate (drive ring) (attached to flywheel) 8. P.T.O. drive gear A 9. P.T.O. drive gear B 10. Torque converter gear pump 11. P.T.O. shaft (For hyd. pump)
12. Idle gear 13. Idle shaft 14. Forward clutch gear 15. Forward clutch 16. 3rd speed clutch gear 17. 3rd speed clutch 18. Counter gear A 19. Counter shaft A 20. Counter gear B 21. 4th speed clutch 22. Counter shaft B 23. 4th speed clutch gear 24. 1st speed clutch gear 25. 1st speed clutch 32-2
26. Counter gear C 27. Counter shaft C 28. Counter shaft D 29. Reverse clutch gear 30. Reverse clutch 31. Counter gear D 32. 2nd speed clutch gear 33. 2nd speed clutch 34. Output shaft gear 35. Output shaft 36. Parking brake (Drum type) 37. Speed meter drive (S/N 85C3-5501 〜 5800)
85Z Ⅳ -2
Gear Arrangement
TORQUE CONVERTER AND TRANSMISSION 32
Gear Arrangement 9 8
4
12
14
16
18
20 23
24 26 27 34 29
31
32
８５ＺＡ３２０２
Number of teeth
No.
Gear name
4
Turbine shaft gear
30
8
PTO drive gear A
60
9
PTO drive gear B
53
12
Idle gear
35
14
Forward clutch gear
30
16
3rd speed clutch gear
82
18
Counter gear A
64
20
Counter gear B
47
23
4th speed clutch gear
99
24
1st speed clutch gear
83
26
Counter gear C
28
27
Counter shaft C gear
31
29
Reverse clutch gear
30
31
Counter gear D
66
32
2nd speed clutch gear
48
34
Output shaft gear
62
32-3
Torque Converter Operation
85Z Ⅳ -2
TORQUE CONVERTER AND TRANSMISSION 32
Torque Converter Operation The torque converter is between the engine and transmission, and consists of three impellers as shown in the figure. The three impellers are pump (P), turbine (T), and stator (S) impellers. The pump is attached 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 transmitted to the output shaft. If the engine speed/pump impeller speed stays the same but the turbine impeller speed is reduced due to the transmission load-output torque is increased. This is "torque multiplication". Heat is also generated.
Input
32-4
Output
85Z Ⅳ -2
Clutch Pack
TORQUE CONVERTER AND TRANSMISSION 32
Clutch Pack Forward and 3rd speed clutches (S/N 85C3-5501〜 5700) 1. Counter shaft 2. Forward clutch gear 3. 3rd speed clutch gear 4. Forward clutch 5. 3rd speed clutch 6. Forward clutch piston 7. 3rd speed clutch piston 8. Steel plate Lube 9. Friction plate oil 10. Return spring 11. Clutch drum (with counter gear) 12. Residual pressure preventive orifice 13. Seal rings 14. Needle bearings
4 9
6 11
12
7
5
3
8
2 1
13
14
10 ８５ＺＡ３２０３
Reverse and 2nd speed clutches 8
(S/N 85C3-5501〜 5700) 1. Counter shaft 2. Reverse clutch gear 3. 2nd speed clutch gear 4. Reverse clutch 5. 2nd clutch 6. Reverse clutch piston 7. 2nd speed clutch piston 8. Steel plate 9. Friction plate 10. Return spring 11. Clutch drum (also used as counter gear) 12. Residual pressure preventive orifice 13. Seal rings 14. Needle bearings
14
4
6
11
12
7
5 3
9
2 1
Lube oil
13
10
32-5
８５ＺＡ３２０４
85Z Ⅳ -2
Clutch Pack
TORQUE CONVERTER AND TRANSMISSION 32
Clutch Pack Forward and 3rd speed clutches (S/N 85C3-5701〜 ) 1. Counter shaft 2. Forward clutch gear 3. 3rd speed clutch gear 4. Forward clutch 5. 3rd speed clutch 6. Forward clutch piston 7. 3rd speed clutch piston 8. Steel plate 9. Friction plate 10. Return spring 11. Clutch drum (with counter gear) 12. Residual pressure preventive orifice 13. Seal rings 14. Needle bearings
４
１０ ６
１１
７ １０ １２
３
２ １３
５
１
１４ ９
８
８
９ ６５Ｊ３２００１
Reverse and 2nd speed clutches (S/N 85C3-5701〜 ) 1. Counter shaft 2. Reverse clutch gear 3. 2nd speed clutch gear 4. Reverse clutch 5. 2nd clutch 6. Reverse clutch piston 7. 2nd speed clutch piston 8. Steel plate 9. Friction plate 10. Return spring 11. Clutch drum (also used as counter gear) 12. Residual pressure preventive orifice 13. Seal rings 14. Needle bearings 15. Thrust bearing
１１ ２
１３
４
１０
６
１２ ７ ５ １０ １５ ３
１
１４
９
８
８
９ ６５Ｊ３２００２
32-6
85Z Ⅳ -2
Clutch Pack
TORQUE CONVERTER AND TRANSMISSION 32
8
1st speed clutch 6
7
5
10
4
3
2
1
12
1. Counter shaft 2. Counter gear A 3. Counter gear B 4. Clutch drum 5. Clutch piston 6. Steel plate 7. Friction plate 8. 1st speed clutch gear 9. Return spring 10. Residual pressure preventive orifice 11. Seal rings 12. Needle bearings
11
9
８５ＺＡ３２０５
4th speed clutch 2
3
9
1. Counter shaft 2. Counter gear 3. Clutch drum 4. Clutch piston 5. Steel plate 6. Friction plate 7. 4th speed clutch gear 8. Return spring 9. Residual pressure preventive orifice 10. Seal rings 11. Needle bearings
4
5
6
7 11
1 10
8 ８５ＺＡ３２０６
32-7
85Z Ⅳ -2
Clutch Plate
TORQUE CONVERTER AND TRANSMISSION 32
Clutch Plate (S/N 85C3-5501〜5700) Number of clutch plates Remarks: All the friction plates, steel plates and Name of clutch
Friction plate
Steel plate
Return spring
Forward clutch
7
8
20
Reverse clutch
7
8
20
1st speed clutch
9
8
20
2nd speed clutch
5
4
20
3rd speed clutch
5
4
20
4th speed clutch
5
4
20
Outer dia.
192 φ (7.55 in)
203 φ (7.99 in)
Inner dia.
124.5 φ (4.90 in)
133.5 φ (5.25 in)
When new
3.3 ± 0.1 (0.13 in)
2.6 ± 0.1 (0.10 in)
Wear limit
3.1 (0.12 in)
2.4 (0.09 in)
Thickness
Dimension(mm)
return springs are same for each clutch.
32-8
85Z Ⅳ -2
Clutch Plate
TORQUE CONVERTER AND TRANSMISSION 32
Clutch Plate (S/N 85C3-5701〜) Number of clutch plates Remarks: All the friction plates, steel plates and Name of clutch
Friction plate
Steel plate
Return spring
Forward clutch
7
6
20
Reverse clutch
7
6
20
1st speed clutch
9
8
20
2nd speed clutch
5
4
20
3rd speed clutch
5
4
20
4th speed clutch
5
4
20
Outer dia.
192 φ (7.55 in)
203 φ (7.99 in)
Inner dia.
124.5 φ (4.90 in)
133.5 φ (5.25 in)
When new
3.3 ± 0.1 (0.13 in)
2.6 ± 0.1 (0.10 in)
Wear limit
3.1 (0.12 in)
2.4 (0.09 in)
Mark
Name of clutch
Stroke (mm)
F
FORWARD
3.3 ± 0.5
R
REVERSE
3.3 ± 0.5
1
1st
3.5 ± 0.5
2
2nd
2.1 ± 0.5
3
3rd
2.1 ± 0.5
4
4th
2.1 ± 0.5
Thickness
Dimension(mm)
return springs are same for each clutch.
Clutch Piston Stroke
32-9
85Z Ⅳ -2
Gear Pump
TORQUE CONVERTER AND TRANSMISSION 32
Gear Pump 1. Driven gear 2. Needle bearing 3. Driven gear shaft 4. Oil seal 5. Drive gear 6. Pump body 7. Pump cover 8. Dowel pin 9. Gasket
1
2
3
4
5
Hydraulic pump side
T/M side
6
7
8
9
Gear pump specifications 3
Theoretical discharge
64.5 cc/rev (3.9 in /rev)
Maximum operation pressure
2MPa (20kgf/cm2) (284psi)
Maximum operation speed
2400min-1
Actual discharge
Approx. 120 l/min (31.7 GPM) Conditions: Pump speed 2,200min-1 Oil temp. 80 to 100 ° C (176 ° F) 〜212 ° Oil viscosity 40CST(SAE10W) Discharge pressure 1.4 to 1.6MPa (14 to 16kgf/cm2) (199〜 228psi)
32-10
Power Flow
85Z Ⅳ -2
TORQUE CONVERTER AND TRANSMISSION 32
Power Flow Forward 1st speed ・ The power from the torque converter is transmitted to the idle gear (12) and to the forward clutch gear (14) where the forward clutch (15) is connected. The forward clutch then transmits the power to the counter shaft A (19). ・ The counter shaft a (19) is spline-connected to the counter gear B (20), therefore the power is then transmitted to the 1st speed clutch gear (24). ・ The 1st speed clutch gear is connected to the 1st speed clutch (25) that transmits the power to the counter gear C (26) and then to the output shaft gear (34). After that, the power is finally transmitted to the output shaft (35).
12 15
The idle gear shown here is also connected to the reverse clutch gear.
19
20
24 25 26
14
34 35
Forward 2nd speed ・ The power from the torque converter is transmitted to the forward clutch (15). The forward clutch transmits the power to the counter gear A (18) and then to the counter gear D (31). ・ When the 2nd speed clutch (33) is engaged, the power will be transmitted to the 2nd speed clutch gear (32). ・ Since the 2nd speed clutch gear (32) is spline-connected to the counter shaft C (27), the power is transmitted to the counter gear C (26) and then to the output shaft gear (34). After that, the power is finally transmitted to the output shaft (35).
15 18
26
34 31 33
32-11
32 27
35
Power Flow
85Z Ⅳ -2
TORQUE CONVERTER AND TRANSMISSION 32
Forward 3rd speed ・ The power from the torque converter is transmitted to the forward clutch (15) and then to the 3rd speed clutch (17) that is connected to the 3rd speed clutch gear (16). The power is then transmitted to the 2nd speed clutch gear (32). ・ Since the 2nd speed clutch gear (32) is spline-connected to the counter shaft C (27), the power is transmitted to the counter gear C (26). ・ The counter gear C (26) transmits the power to the output shaft gear (34) and then to the output shaft (35).
16 15 17
32 27 26
34 35
Forward 4th speed ・ The power from the torque converter is transmitted to the forward clutch (15). The forward clutch (15) transmits the power to the counter gear A (18) and then to the counter shaft A (19). ・ The counter shaft A (19) is spline-connected to the counter gear B (20). ・ When the 4th speed clutch (21) is engaged, the power will be transmitted to the 4th speed clutch gear (23). ・ The 4th speed clutch gear (23) transmits the power to the counter shaft gear (27), counter gear C (26), and then to the output shaft gear (34). After that, the power is finally transmitted to the output shaft (35).
15 18
19
20 21
23
26 27
34 35
32-12
Power Flow
85Z Ⅳ -2
TORQUE CONVERTER AND TRANSMISSION 32
Reverse 1st speed 19
・ The power from the torque converter is transmitted to the idle gear (12) and then to the reverse clutch gear (29) where the reverse clutch (30) is connected. The reverse clutch then transmits the power to the counter gear D (31), the counter gear A (18), and then to the counter shaft A (19). ・ After that, the power is transmitted to the output shaft via the same route as forward 1st speed.
18 31 30 29-
12
Reverse 2nd, 3rd, and 4th speeds Refer to the transmission routes of the above reverse 1st speed and the forward 2nd, 3rd, and 4th speeds.
The torque converter and idle gear shown in this figure are actually identical to those shown in the forward speed diagrams. The idle gear is engaged with both the forward and reverse clutches.
32-13
10
25
19
23
1
21
24
32-14 13
5
18
Transmission oil pan
4
6
16
9
Control box
15
14
17
8
7
QUAD switch
Inching switch
Parking switch
85Z Ⅳ -2
2
20 22
3
Speed sensor
Shift lever
Hydraulic System Diagram TORQUE CONVERTER AND TRANSMISSION 32
Hydraulic System Diagram
85Z Ⅳ -2
Hydraulic Circuit Diagram
TORQUE CONVERTER AND TRANSMISSION 32
Thermo
Thermo
Hydraulic Circuit Diagram
S/W
25
0.5MPa 2 11 (4.7kgf/cm ) (67psi)
10 P
M16 × 1.5
T S
6
7
27
9
19
8 26
5
13 PF1/4 1.3 ± 0.2 to 1.5 ± 0.2MPa 13 ± 2 to 15 ± 2kgf/cm2 185 ± 28 to 213 ± 28psi
20 14 21 15
0.3MPa (3.5kgf/cm2) (50psi)
4
3
22 2
16
1
23 17 24 18
1. Transmission oil pan
10. Torque converter
20. Reverse clutch
2. Strainer
11. T/C inlet relief valve
21. 1st speed clutch
3. Torque converter gear pump
13. Forward clutch solenoid valve
22. 2nd speed clutch
4. Line filter with bypass valve
14. Reverse clutch solenoid valve
23. 3rd speed clutch
5. Control valve
15. 1st speed clutch solenoid valve
24. 4th speed clutch
6. Clutch pressure regulator valve
16. 2nd speed
25. Torque converter oil cooler
7. Trimmer plug mm
clutch
solenoid
valve
26. Residual pressure prevention
8. Orifice (1.3 -dia.)
17. 3rd speed clutch solenoid valve
9. Trimmer solenoid valve
18. 4th speed clutch solenoid valve 19. Forward clutch 32-15
orifice mm
27. Orifice (1.2 -dia.)
85Z Ⅳ -2
Construction
TORQUE CONVERTER AND TRANSMISSION 32
Control Valve Construction B
9 A
A
17
14 13
15
B
18
16
Section B-B ８５ＺＡ３２０８
9
6
Section A-A
7
８５ＺＡ３２０９
8
32-16
85Z Ⅳ -2
System Diagram
TORQUE CONVERTER AND TRANSMISSION 32
System Diagram From torque converter pump
To torque converter
6
9
7
8 Drain
17
13
14
16 18
15
To forward To 4th speed clutch clutch
To 2nd speed clutch
To 1st speed To reverse To 3rd speed
6. Clutch pressure regulator valve 7. Trimmer plug mm
8. Orifice (1.3 -dia.) 9. Trimmer solenoid valve 13. Forward clutch solenoid valve 14. Reverse clutch solenoid valve 15. 1st speed clutch solenoid valve 16. 2nd speed clutch solenoid valve 17. 3rd speed clutch solenoid valve 18. 4th speed clutch solenoid valve
32-17
85Z Ⅳ -2
Solenoid Valve Operation
TORQUE CONVERTER AND TRANSMISSION 32
Solenoid Valve Operation For forward/reverse and speed clutches ・ After power-off(clutch disengaged status) 5
4
3
2
1
Clutch pressure regulator
7
Transmission oil pan
1. Coil 2. Plunger 3. Push rod 4. Spring
Clutch piston chamber
5. Spool 6
6. Diode 7. Manual control pushbutton
When the power of the coil is turned off, the spool (5), push rod (3), and plunger (2) are returned fully to the right, and port A is closed. The line between port B and C is opened, and the clutch is disengaged.
In this case, pressing the manual control pushbutton (7) with the bolt (for emergency) opens the line between port A and B, and engages the clutch. Releasing the manual control pushbutton returns the spool fully to the right, and disengages the clutch.
・ After power-on (clutch engaged status) Clutch pressure regulator
Transmission oil pan
Clutch piston chamber
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 piston chamber. The clutch is engaged.
32-18
85Z Ⅳ -2
Solenoid Valve Operation
TORQUE CONVERTER AND TRANSMISSION 32
For trimmer ・ After power-off (high clutch pressure status) Trimmer plug chamber
7 To transmission oil pan via trimmer spring chamber
When the power of the coil is turned off, the spring returns the spool to the right.
The line between the trimmer plug chamber and the transmission oil pan is closed, therefore the clutch pressure is kept high. In this case if the manual control push button (7) is pushed by hand main clutch pressure should be reduced to approximatly 0 〜 2 0.1MPa (0〜1kgf/cm ) (0〜98psi).
・ After power-up (just after switching clutch) Trimmer plug chamber
To transmission oil pan via trimmer spring chamber
When the power is supplied to the coil, the oil in the trimmer plug chamber is discharged into the transmission oil pan. The clutch pressure, therefore, falls.
If debris were to stick the valve in this position pressure would remain low even if the power to the coil is turned off. 32-19
Solenoid Valve Operation
85Z Ⅳ -2
TORQUE CONVERTER AND TRANSMISSION 32
Torque converter and transmission oil flow route (refer to hydraulic system diagram) ・ From gear pump to torque converter The oil fed from the pump (3) flows through the line filter (4) into the control valve (5). In the clutch circuit, the oil flow rate is low, therefore, the clutch pressure regulator valve (6) opens the torque converter port so that the oil flows into the torque converter circuit. At the inlet of the torque converter, there is a inlet relief valve (11) in the case. If the oil pressure exceeds 0.5MPa (4.7kgf/cm2) (67psi), the relief valve will be opened to drain part of the oil into the transmission case.
・ Oil returned from torque converter The oil returned from the torque converter flows into the torque converter cooler (25) inside the radiator.
・ Oil returned from cooler The oil cooled by the cooler flows through the lubrication oil passages in the transmission housing to lubricate all the bearings and to cool the clutch plates. After that, the oil is drained into the oil pan.
Clutch oil flow route ・ To forward and reverse clutches When the oil flows into the control valve, the oil pressure is adjusted to the specified pressure 1.3 ± 2 0.2 to 1.5 ± 0.2MPa (13 ± 2 to 15 ± 2kgf/cm ) (185 ± 28 to 213 ± 28psi) by the clutch pressure regulator valve (6). After that, the oil flows to the forward and reverse clutch solenoid valves (13) (14). When the clutch is changed from "forward" to "reverse". The reverse clutch solenoid valve (14) is turned on, and the oil flows into the reverse clutch piston chamber. At the same time, the forward clutch solenoid valve is turned off, and the oil in the forward clutch piston chamber is drained. The oil then flows through the clutch solenoid valve into the transmission case. Oil is also drained from the forward clutch piston chamber through the residual pressure prevention orifice in the clutch hub.
・ To speed clutch The neutral position is available for forward/reverse. There is no neutral position for speed clutches. Therefore, after engine starting, the oil fed from the pump is regulated to the specified pressure by the clutch pressure regulator valve, and then directed to one of the speed clutch piston chambers. Note : The engine will not start if the shift lever is in the forward or reverse position. The shift lever must be in the neutral position to start the engine, therefore, the machine will not move the moment the engine is started. When the speed is changed, the oil flows in the same way as the forward/reverse clutch oil flow.
32-20
85Z Ⅳ -2
Modulation Mechanism
TORQUE CONVERTER AND TRANSMISSION 32
Modulation Mechanism The modulation mechanism controls the clutch oil pressure rising time as follows:
When changing direction or speed, the modulation mechanism works to reduce the time required for clutch engagement (time lag), to prevent the shock at clutch engagement, to improve the work efficiency and durability of the power system, and to ensure operator's comfort.
An electrical signal from the Shift Control Unit (SCU) controls the trimmer operation. For information on the SCU refer to section 62, "Electrical Group".
For trimmer "D" LED Solenoid valve
Electrical signals
Clutch control oil pressure curve
For forward clutch "F" LED For reverse clutch "R" LED
Main pressure Forward clutch pressure
Reverse clutch pressure
0.3〜0.4MPa (3.5〜4kgf/cm2) (50〜57psi)
Clutch oil pressure
Time Pressure increase Specified Initial Lowholding oil pressure pressure feeding holding
Initial oil feeding*
Low-pressure holding
Pressure increase
0〜0.05 sec.
0.2 sec.
Approx. 1 sec.
*Note : The initial oil feeding time depends on the capacity of the clutch piston chamber.
32-21
1.3 ± 0.2〜1.5 ± 0.2MPa 2 (13 ± 2〜15 ± 2kgf/cm ) (185 ± 28〜213 ± 28psi)
85Z Ⅳ -2
Modulation Mechanism
TORQUE CONVERTER AND TRANSMISSION 32
Pressure holding (Traveling at forward 1st speed) 9
From torque converter pump
To torque converter
6 7
The power of the trimmer solenoid valve (9), however, is off, and the clutch regulator valve (6) and trimmer plug (7) apply pressure to the modulator spring to keep the clutch pressure at the specified value 1.3 ± 0.2 〜 1.5 ± 0.2MPa (13 ± 2 〜 15 ± 2 2kgf/cm ) (185 ± 28〜213 ± 28psi).
For trimmer Solenoid valve
While the machine is traveling, the forward and 1st speed clutch solenoid valves are energized on, the clutch oil is flowing into each clutch piston chamber, and the clutch is kept engaged.
Electrical signals
To each clutch solenoid valve
For forward clutch For reverse clutch
Main pressure Forward clutch pressure Reverse clutch pressure Clutch oil pressure Time
Specified pressure holding
32-22
Modulation Mechanism
85Z Ⅳ -2
TORQUE CONVERTER AND TRANSMISSION 32
Changing the shift lever from "forward" to "reverse", turns off the power of the forward clutch solenoid valve. The oil in the forward clutch piston chamber is immediately drained to release the clutch. On the other hand, power to the reverse clutch solenoid valve is turned on, and the oil flows into the reverse clutch piston chamber. After changing the shift lever, power to the trimmer solenoid valve is kept off for a short time, therefore the high-pressure oil flows into the reverse clutch piston chamber to rapidly move the piston. As a result, initial oil supply is quick, and time lag can be prevented.
For trimmer Solenoid valve
・ Releasing forward clutch and feeding initial oil to reverse clutch
Electrical signals
Changing from forward 1st speed to reverse 1st speed
For forward clutch For reverse clutch
Main pressure Forward clutch pressure Reverse clutch pressure
Clutch oil pressure Time
Initial oil feeding
32-23
85Z Ⅳ -2
Modulation Mechanism
TORQUE CONVERTER AND TRANSMISSION 32
・ Low-pressure holding
From torque converter pump
To torque converter
9 6
Roll pin
7
For trimmer Solenoid valve
0.05 seconds after changing the shift lever, the power of the trimmer solenoid valve (9) is turned on. The oil in the trimmer plug chamber is drained, and the trimmer plug (7) is returned by spring tension fully to the right. The modulator spring is released to reduce the pressure applied to the regulator valve (6). The regulator valve may move fully to the right until it contacts the roll pin pressed into the control valve housing. In this position more oil from the T/C charge pump is drained. The main pressure and reverse clutch pressure, therefore, falls immediately. As a result, the shock at clutch engagement will be softened.
Electrical signals
To each clutch solenoid valve
For forward clutch For reverse clutch
Main pressure Forward clutch pressure Reverse clutch pressure
Cluth oil pressure Time
Low-pressure holding
32-24
85Z Ⅳ -2
Modulation Mechanism
TORQUE CONVERTER AND TRANSMISSION 32
・ Pressure increase (Clutch engagement starting)
From torque converter pump
To torque converter
6
7
9
8
Solenoid valve
To soften the shock, the clutch should slip during engagement. When the power of the trimmer solenoid valve is turned off again after about 0.2 seconds, the drain port of the trimmer plug chamber is closed, and the oil is fed into the trimmer plug chamber. Pressure is applied to the trimmer plug and the spring to raise the clutch oil pressure. The oil flow rate to the trimmer plug chamber is limited by the orifice (8), therefore the trimmer plug (7) slowly shifts to the left. The clutch pressure, therefore, slowly rises. As spring tension increases on the regulator valve (6) the regulator valve begins to block off the drain passage. This increases main and clutch pressure. As a result, the clutch engagement is smooth and causes no shock.
Electrical signals
To each clutch solenoid valve
For trimmer For forward clutch For reverse clutch
Main pressure Forward clutch pressure Reverse clutch pressure
Clutch oil pressure Time
Pressure increase
32-25
Manual Operation of Clutch Sol. Valve
85Z Ⅳ -2
TORQUE CONVERTER AND TRANSMISSION 32
Manual Operation of Clutch Solenoid Valve If the electric control system malfunctions, the solenoid valves will not operate. In this case, the valves may be manually operated to move the vehicle to a safe place. The manual operation bolts are installed over several solenoid valves; the forward, reverse, 1st speed, and 2nd speed clutch solenoid valves.
Control valve Transmission
WARNING Locknut
During engine running manual operation of a solenoid valve may cause unexpected movement of the vehicle. The movement may cause an accident resulting in injury or death. To prevent such an accident, be sure to stop the engine and remove the starter key before you manually operate the solenoid valves. In addition, hang a "DO NOT START!" tag in the cab.
Solenoid valve manual operation bolt
To manually operate the solenoid valve, remove the bolt, the locknut, and insert the bolt (M10×30mm (L)).
IMPORTANT
８５／９０ＺⅣ３２０１
The transmission will be damaged, if manual operation bolts for the forward and reverse solenoid valves or the 1st and 2nd speed solenoid valves are inserted at the same time. Therefore select forward or reverse and solenoid valve for bolt insertion, and also select 1st or 2nd speed solenoid valve for bolt insertion.
IMPORTANT After emergency moving of the vehicle to a safe place, be sure to remove the manual operation bolts, replace the locknuts, and reset the solenoid valves to the original positions.
32-26
85Z Ⅳ -2
Measuring Clutch Oil Pressure
TORQUE CONVERTER AND TRANSMISSION 32
Measuring Clutch Oil Pressure WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. To prevent such an accident during clutch oil pressure measurement, be sure to closely communicate with the person in the cab by giving signals to each other. Also use a gauge with a hose long enough to reach outside from the articulation area.
For USA spec. the quick coupler is installed on the gauge port.
85W0301
Main clutch pressure measurement port : PF 1/4 A central main pressure test port is provided (shown at right). Test ports on the control valve and transmission case allow direct testing of each individual clutch pack and converter pressures.
Torque converter inlet oil pressure measurement port : PT1/2
Reverse clutch oil pressure measurement port : PF1/4
2nd speed clutch oil pressure measurement port : PF1/4
3rd speed clutch oil pressure measurement port : PF1/4 Forward clutch oil pressure measurement port : PF1/4
4th speed clutch oil pressure measurement port : PF1/4
1st speed clutch oil pressure measurement port : PF1/4
８５ＺＡ３３０１
・ Pressure gauge 2MPa (20kgf/cm2) (284psi) with 2 〜 3m hose ・ Clutch oil pressure measurment value : 2 1.3 ± 0.2MPa (13 ± 2kgf/cm ) (185 ± 28psi) at engine idling speed (LI) 2 1.5 ± 0.2MPa (15 ± 2kgf/cm ) (213 ± 28psi) at engine maximum speed (HI) ・ Torque converter oil temperature : 50 to 80 ° C (120〜 180 ° F) 32-27
HYDRAULIC GROUP 42 Loading/Steering Hydraulic Line ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-2 Loading/Steering Hydraulic System Diagram ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-4 Layout of Hydraulic Units ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-6 Hydraulic Tank ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-7 Hydraulic Pump ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-11 Hydraulic Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-12 Loading System ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-15 Pilot Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-16 Pilot Valve Filter ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-20 Relief Valve Unit (for pilot valve) ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-21 Accumulator ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-26 Multiple Control Valve (KVML) ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-28 Slow Return Check Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-37 Adapter ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-38 Steering System ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-39 Steering Gear Box ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-41 Steering Valve (KVMT) ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-44 Standard Measurement Values for Performance Check ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-52 Cautions Regarding Replacement of Hydraulic Parts ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-53 Flushing Hydraulic Line ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-54 Measuring Steering Wheel/Lever Operating Force ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-58
42-1
85Z Ⅳ -2
Loading/Steering Hydraulic Line
HYDRAULIC 42
Loading/Steering Hydraulic Line (S/N 85C3-5501〜5700) 2 4
5
O-ring
6 O-ring
O-ring
O-ring
16
150 mesh
13 17 O-ring
3 O-ring
1
14
O-ring
O-ring
10
9 8
Hydraulic tank
12
11
85V42001
1. Hydraulic pump
8. Breather valve/Filter cap
14. Pilot relief valve unit
2.Multiple control valve
9. Cooler bypass valve
16. Slow return check valve
3. Steering valve
10. Oil cooler
17. Pilot valve filter
4. Boom cylinders
11. Return filter element
5. Bucket cylinder
12. Filter bypass valve
6. Steering cylinders
13. Pilot valve 42-2
Loading/Steering Hydraulic Line
85ZIV-2
Loading/Steering Hydraulic Line
HYDRAULIC 42
(S/N 85C3-5701〜) ２
４
1. Hydraulic pump 2. Multiple control valve 3. Steering valve 4. Boom cylinders 5. Bucket cylinder 6. Steering cylinders 7. Breather valve/Filler cap 8. Cooler bypass valve 9. Return filler element 10. Relief valve 11. Pilot valve 12. Pilot relief valve unit 13. Adapter (with orifice) 14. Filter 15. Accumulator 16. Oil cooler
５
６
１３
１１ １４ １５ １２
３ １６ １ ８
７
１０
９
８５Ａ４２２０６
42-3
85Z Ⅳ -2
Loading/Steering Hydraulic System
HYDRAULIC 42
Loading/Steering Hydraulic System Diagram (S/N 85C3-5501〜5700) 5
16 13
2
4
17
14
6
1 8
10
9
3 11
42-4
12
85Z Ⅳ -2
Loading/Steering Hydraulic System
HYDRAULIC 42
Loading/Steering Hydraulic System Diagram (S/N 85C3-5701〜) 5
Hoist lever
Bucket lever
13 11
2
4
14 15
12
16 6
1 7
8
3 9 ６５Ａ４２２１０
42-5
10
85Z Ⅳ -2
Layout of Hydraulic Units
HYDRAULIC 42
Layout of Hydraulic Units
4
1
7
6
2
8
5
3
4
8
85V42003
1.Multiple control valve 2.Steering valve 3.Pilot valve(for loading) 4.Pilot circuit relief valve
5.Hydraulic pump (3 section) 6.Boom cylinders 7.Bucket cylinder 8.Steering cylinders
42-6
85Z Ⅳ -2
Hydraulic tank
HYDRAULIC 42
Hydraulic tank To hydraulic pump
1
11
From multiple control valve and steering valve return line From pilot relief valve
8
9
From oil cooler
7 A-A From pilot valve (drain)
A 3
4
2
6
A ８５Ｖ４２００４
5
1. Oil tank 2. Oil level sight gauge 3. Tank cap (with air breather) 4. Inlet screen 5. Drain cock/Plug 6. Inspection hole cover 7. Return filter element 8. Spring 9. Filter bypass valve 11. Return filter cover 12. Gasket (Rubber seal type)
12 6
A
B-B Torque to 20N-m (2kgf-m) (14 lb-ft) torque all nuts evenly to prevent leaks
42-7
A : Center of hydraulic oil level gauge : 130 l (34 Gal)
85Z Ⅳ -2
Hydraulic tank
HYDRAULIC 42
Hydraulic tank cap (with air breather) 1
3
2
5
4
6
A
7
7 a b
Viewed from section A
c
1. Cover
5. Spring (for suction valve)
2. Filter element
6. Key (same as starter key)
3. Spring (for exhaust valve)
7. Attaching bolts (3 pcs) socket head
4. Valve assembly (a)Exhaust valve (b)Suction valve (c)Air bleeder valve
Functions When the pressure inside the hydraulic tank drops below the outside air pressure, the outside air flows through the filter element (2) and to the valve assembly (4). The suction valve (b) is then opened to let the air flow into the tank. When the air pressure inside the hydraulic tank rises 2 to a certain point 0.08MPa (0.8kgf/cm ) (11psi), the exhaust valve (a) is lifted (opened) so that the air can flow out of the tank through the filter element (2). One cycle (down and up) of the boom applies pressure to the inside of the tank. There is difference between the suction valve (b) opening pressure and the exhaust valve (a) opening pressure, therefore 0.08MPa (0.8kgf/cm2) (11psi) pressure is always applied to the inside of the hydraulic tank. The pressure applied to the inside of the hydraulic tank prevents the dust and dirt from being drawn into the tank and improves performance of the pump. The positive pressure pushes the oil to the pump reducing the posibility of pump cavitation.
To release the internal pressure from the hydraulic tank, press the cover (1). The air bleeder valve (c) will be lowered to release the internal pressure.
・ Unlocking cap key Turn the cap key 180°counterclockwise (arrow direction) to unlock the cap key.
・ Installing cap
42-8
The cap can be installed in disregard of the boom or bucket position
85Z Ⅳ -2
Hydraulic tank
HYDRAULIC 42
Specifications of hydraulic tank Type
Sealed pressure type
130 (34 Gal)
Tank capacity (at center of level gauge) (l)
25,500
2
Filtration area (cm ) Return filter
10
Filtration particle size ( μ ) Relief valve opening pressure MPa (kgf/cm2) (psi)
0.1 ± 0.02 (1.0 ± 0.2) (14 ± 2.8)
Suction side setting pressure MPa (kgf/cm2) (psi)
0.01 (0.01) (0.14)
2
Discharge side setting pressure MPa (kgf/cm ) (psi) Oil filling port (also used as air breather)
0.08 (0.8) (11)
Filtration area (cm )
235
Filtration particle size ( μ )
10
2
Pushing load before turning cap required for removing or installing cap (kg)
42-9
19〜22 (42〜48lb)
Hydraulic tank
85Z Ⅳ -2
HYDRAULIC 42
Hydraulic Oil Level Check Before checking the hydraulic oil level, observe the following items: ・ Check that the machine is on a level ground. ・ Check the hydraulic oil level before operation (when oil is not warm). ・ Lower the boom to the lowest limit, and tilt down the bucket onto the ground.
Bucket on ground
Check that the oil level is at the center of the oil level sight gauge. Hydraulic oil tank
Oil level sight gauge
130 l
Cold level
42-10
(34 Gal)
Oil amount : 130 l (34 Gal) Note : If the oil is at operating temperature (60℃ 〜 90℃ (140°F 〜 200°F)) the oil level may be at or near the top of the oil level sight gauge.
85Z Ⅳ -2
Hydraulic Pump
HYDRAULIC 42
Hydraulic Pump Triple pump
80V42002
Triple pump specifications KAWASAKI PART NUMBER
JSB PART NUMBER
44093-61180 2104870
DISPLACEMENT 3 in /REV (mL/REV)
JOHN S. BARNES MODEL NUMBER
F3-G302020W-4EJ30CJ11AJ-DJ7AJ-12861L
Measurement conditions: Oil temperature 50 ℃〜80 ℃ Hydraulic oil ISO VG46
42-11
FRONT PUMP
CENTER PUMP
REAR PUMP
5.89 (97)
2.18 (36)
1.41 (23)
MIN. RATED RATED SPEED PRESS SPEED AT RATED P.S.I. -1 (min ) PRESSURE (bar) -1 (min ) 2500
4000 (276)
1000
85Z Ⅳ -2
Hydraulic Cylinder
Hydraulic Cylinder
(S/N 85C3-5501〜5600)
Boom cylinder 14 12
16
15
22
21 13
3
8
11 10
6
7
1
9
23 ・ 20
17 5
25
4
Bucket cylinder
Steering cylinder 23 ・ 20
15 13 12 1 14 22 16
2
HYDRAULIC 42
3
8 7
6
4
11 23 9 ・ 17 5 ・ 10 20 24
42-12
1.Piston 2. Piston rod 3. Cylinder tube 4. Rod cover 5. Dust seal 6. Backup ring 7. U-packing 8. Buffer ring 9. Wear sleeve 10.Back up ring 11.O-ring 12.Slipper ring 13.Square ring 14.O-ring 15.Wear ring 16.Piston nut 17.Stop ring 19.Back up ring 20.Dust seal 21.Wear ring 22.Stop ring 23.Bushing 24.Set screw 25.Bolt 26.Washer
85Z Ⅳ -2
Hydraulic Cylinder
Hydraulic Cylinder
HYDRAULIC 42
(S/N 85C3-5601 〜)
Boom cylinder 12 21 16 15 ・ 13
23 ・ 20
６５Ａ４２０３５
11 ・ 2 8 7 10 6 9 17 24
1
14
17
18
3 4
: Tightening torque #16 ・・・・・ 4756N-m(485kgf-m)(3510Ib-ft) #18 ・・・・・ 843N-m(86kgf-m)(622Ib-ft) Ｎ‐ｍ
Bucket cylinder
６５Ａ４２０３６
６５Ａ４２０３８
: Tightening torque #16 ・・・・・ 5394〜5884N-m(550〜600kgf-m) (3979〜4341Ib-ft) #18 ・・・・・ 735 〜 883N-m(75 〜 90kgf-m)(543 〜 651Ib-ft) Ｎ‐ｍ
Steering cylinder 16 ・ 22
15 14 13
12 1
2
3
11 23 11 ・ 8 7 10 4 9 17 5 ・ 20
６５Ａ４２０３７
: Tightening torque #4 ・・・・・・ 1569〜1765N-m(160〜180kgf-m) (1160〜1300Ib-ft) #16 ・・・・・ 1079〜1275N-m(110〜130kgf-m) (796〜941Ib-ft) Ｎ‐ｍ
42-13
1. Piston 2. Piston rod 3. Cylinder tube 4. Rod cover 5. Dust seal 6. Backup ring 7. U-packing 8. Buffer ring 9. Wear sleeve 10. Back up ring 11. O-ring 12. Slipper ring 13. Square ring 14. O-ring 15. Wear ring 16. Piston nut 17. Stop ring 18. Bolt 19. Back up ring 20. Dust seal 21. Wear ring 22. Stop ring 23. Bushing 24. Scraper ring
85Z Ⅳ -2
Hydraulic Cylinder
HYDRAULIC 42
Steering cylinder
Bucket cylinder
Boom cylinder
Cylinder specifications Inner dia. × rod dia. × stroke Pin hole
φ 160 ×φ 80 × 814
Piston rod
φ 90 × 202
Cylinder
φ 90 × 148.5
(inner dia. × width)
Inner dia. × rod dia. × stroke Pin hole
φ 190 ×φ 100 × 538
Piston rod
φ 100 × 120
Cylinder
φ 100 × 120
(inner dia. × width)
Inner dia. × rod dia. × stroke Pin hole
φ 90 ×φ 50 × 440
Piston rod
φ 50 × 70
Cylinder
φ 50 × 70
(inner dia. × width)
42-14
Loading System
85Z Ⅳ -2
HYDRAULIC 42
Loading System Operation The pilot operation system uses the pilot valve pressure to control the plungers of the multiple control valve and move the boom cylinders and bucket cylinder. When the control lever is set, the pilot valve line is opened, and the oil pressure is generated depending on the set position of the control lever. The pilot pressure entering the oil pack to the multiple control valve moves the plunger against its return spring. The plunger press-in distance (displacement) depends on the pilot valve pressure. Oil from the loader pump is then directed through the valve to the cylinder. Return oil from the cylinders flows through the valve to the oil cooler, return filter and into the tank.
Control lever
Relief valve
Pilot valve
Oil packs
Multiple control valve
Oil packs
From steering valve
Cooler Filter
Filter Tank ８５Ｗ４２１０
42-15
85Z Ⅳ -2
Pilot Valve
HYDRAULIC 42
Pilot Valve Structure For bucket control
Neutral Roll back
1 Dump For bucket control
For boom control
8 2
3
T
To tank port
4 5 6
From pump port
7
P
８５Ｗ４２１１
To MCV oil packs
８５Ｗ４２１８
View from the rear
For boom control
Raise
Neutral
Down
1. Lever 2. Disc 3. Push rod 4. Spring seat 5. Spring for secondary pressure 6. Return spring 7. Spool 8. Detent magnet solenoid
Float
To tank port ８５Ｗ４２１９
42-16
85Z Ⅳ -2
Pilot Valve
HYDRAULIC 42
Function The pilot valve applies oil pressure in proportion to the operating angle of the lever, there-by carrying out remote control of the plunger in the multiple control valve.
1 2
8
Operation (Modulated position) When the lever (1) is in the neutral position, the spool (7) closes the pilot pump port and the tank port is opened. Therefore the oil pressure is not applied to the multiple control valve oil pack. The plunger of the multiple control valve is held in neutral by its centering springs. There is no oil flow to the cylinder. When the lever (1) is shifted from the neutral, the spool (7) is forced down by the spring (5). Then the tank port is closed and the pilot pump port is opened. As a result, the pressurized oil from the pilot pump flows into the multiple control valve oil pack. The plunger of the multiple control valve moves allowing oil from the main pump to flow to the cylinder. When the oil pressure in the multiple control valve oil pack reaches over the desired pressure, the spool (7) moves up. As a result, the tank port is opened and the pilot pump port is closed.
3 T
4 5 6
P 7
Pilot relief valve unit
Multiple control valve
Oil pack
＊ Spool diameter at tank side is greater
than spool diameter at pilot pump side. Accordingly the pilot oil pressure in the multiple control valve oil pack is reduced below the desired pressure. The spool (7) moves down again by the spring (5) and closes the tank port. The pilot pump port is opened. It raises the oil pressure in the multiple control valve oil pack again. This cycling action maintains a constant pressure to the multiple control valve. The pilot oil pressure to the multiple control valve is proportional to the lever (1) angle, and is balanced with the lever angle. This results in the multiple control valve plunger being moved the desired amount. Oil flow from the main pump to the cylinder is also proportional. Cylinder speed is easily controlled. 42-17
P
８５Ｗ４２１２
85Z Ⅳ -2
Pilot Valve
HYDRAULIC 42
1
To tank port
To tank port
5 From pump port
From pump port
7
7
Port 3
Port 4
８０Ｖ４２００３
８０Ｖ４２００４
Port 3
Port 4
When lever is shifted from neutral
When lever is in neutral
Operation (Full pressure position) When the lever (1) is moved fully forward or back the multiple control valve plunger should also be moved full stroke. This allows maximum oil flow to the cylinders for the fastest cylinder movement. In the boom down circuit the multiple control valve plunger must be fully stroked to reach the "FLOAT" position. To be sure the multiple control valve plunger is fully stroked a special spring (5) and spring seat (4) are used. This allows the spool (7) to be fully stroked and full pilot pressure will be directed into the oil pack fully stroking the multiple control valve plunger.
42-18
Pilot Valve
85Z Ⅳ -2
HYDRAULIC 42
Detent magnet solenoid The detent magnet works to hold the lever at it's position, when the lever is shifted to "Bucket Roll Back" or "Boom Raise" or "Boom Float" position. When the proximity switch for the bucket positioner or the boom kick-out (option) is turned on, the magnet coil is energized and magnetized so that the holding plate is held by magnetic force. When the lever is shifted, the steel ball is positioned at the detent notch and the lever is held at that position. As a result, pilot oil moves the multiple control valve plunger to the full stroke position, and the pressurized oil fed from the main pump flows to the cylinder. When the proximity switch is turned off, the magnet coil is de-energized and de-magnetized. The steel ball is pushed out of the detent notch by the return spring (6) so that the control lever is returned to the neutral position. When the control lever is set to the "Boom Float" position, the control lever will be held at the "Float" position. The "Boom Float" magnet is not switched and is energized and magnetized whenever the key switch is on. For "Boom Float" position, manually reset the control lever.
42-19
Magnet
Plate
Steel ball
Disc
８５Ｗ４２１３
85Z Ⅳ -2
Pilot Valve Filter
Pilot Valve Filter Construction
2
3
1
1.Nipple 2. Screen 3. Screen 4. O-ring
Function Pilot valve filter is installed in the pilot valve P port to keep dust, dirt and debris out of the pilot valve. In the event of a pilot pump failure remove the filter and clean or replace it. If the pilot valve will not operate normally, remove the filter and inspect it. If there is contamination in the filter, determine the cause and correct it.
42-20
4
HYDRAULIC 42
85Z Ⅳ -2
Pilot Relief Valve Unit
Pilot Relief Valve Unit
HYDRAULIC 42
(S/N 85C3-5501〜5700)
Construction The pilot relief valve unit consists of relief valve, reduction valve, and check valve.
Pilot valve 20
Bottom side of boom cylinder
21 22
11
12
10
13
PC
1. Relief valve 2. Pilot poppet 3. Relief poppet 4. Sleeve 5. Spring 6. Pilot spring 7. Adjusting screw 8. Lock nut 9. Cap
TS2 Check valve for P→PP
8 Orifice
9
TS
7 6
10.Reduction valve 11. Shuttle 12. Spring 13. Plug
1 P
T
20.Check valve 21. Spring 22. Plug 23.Check ball 24. Spring 25. Plug
TS
2
5 4
3 Pump port
Tank port TS2
Check valve for PC → PP PP
25
Relief valve setting pressure: 3.6 ± 0.3MPa 2 (37 ± 3kgf/cm ) (526 ± 43psi) Reduction valve setting pressure: 1.5 ± 0.3MPa 2 (15 ± 3.5kgf/cm ) (213 ± 50psi) PC :Port from bottom side of boom cylinder PP :Port to pilot valve TS :Test port for pilot pressure TS2:Test port for reduction pressure
Reduction valve press. test port
Pilot valve port PP(PF1/4)
８５Ｗ４２１４
24
23
TS2(PF1/4)
23
10 PC(PF1/4)
20
Bottom side of boom cylinder
TS(PF1/4)
Relief valve press. P(PF1/2) test port Pump port
42-21
1
T(PF1/2) Tank port
Pilot Relief Valve Unit
85Z Ⅳ -2
HYDRAULIC 42
Relief valve Function The relief valve is placed between the pump and the pilot valve. The pilot relief valve regulates the oil pressure in the pilot circuit to a safe operating range. The pressure is held constant whenever the engine is running. When the pilot circuit pressure reaches the operating pressure the relief valve opens and directs some of the oil back to the tank.
Pilot valve
P
Filter screen assembly (95ZⅣ〜 115ZⅣ )
Tank
3
2
6
7
７０ＺＡ４２３１
Operation ・ When oil pressure is lower than the set point Oil discharged from the pump passes through the orifice of the poppet (3) and reaches to the pilot poppet (2). The pilot poppet (2) is pushed to the left by the pilot spring (6) and closes the port.
From pump
・ When oil pressure exceeds the set point When the pumped oil pressure surpasses the set 2 spring pressure 3.6 ± 0.3MPa (37 ± 3kgf/cm ) (526 ± 43psi) of the pilot poppet (2), the pilot poppet (2) opens to allow oil to escape into the tank. In the result, the force pushes the relief poppet (3) to the left decreases and thereby the relief poppet (3) moves to the right, allowing high-pressure oil in the pump line into the tank line.
To tank
７０ＺⅣ４２０４
To tank
７０ＺⅣ４２０５
From pump
Adjust to the set pressure at 3.6MPa (37kgf/cm2) (512psi) using the adjusting screw (7). Normally the pilot relief valve is open during machine operation. The pilot pressure may be measured through test port TS.
42-22
Pilot Relief Valve Unit
85Z Ⅳ -2
HYDRAULIC 42
Reduction valve Function The pressure oil in the bottom end of the boom cylinder can be supplied to the pilot valve to operate the multiple control valve even if hydraulic oil is not available from the pilot pump (engine off or pump failure). The boom can be lowered or the bucket can be moved to the dump position, under the force of gravity. Raising the boom or rolling the bucket back is not possible if there is no main pump oil flow.
Pilot valve
23
Under normal conditions When the supply of pilot pressure from the pilot pump is normal, the check valve (23) closes the reduction valve port. On the other hand, the pressure in the bottom of the boom cylinder is applied to the left hand side of the shuttle (11) of the reducing valve. Shuttle (11) is moved to the right. When pressure in the chamber C rises above 1.5 ± 2 0.3MPa (15 ± 3.5kgf/cm ) (213 ± 50 psi), spring (12) is compressed, and the shuttle (11) is moved to the right, allowing the oil to escape to the tank. After that, the pressure in the chamber C decreases and the shuttle (11) moves to the left. As a result the tank port is closed. The shuttle (11) keeps the pressure in the chamber C with 1.5 ± 0.3MPa (15 ± 3.5kgf/cm2) (213 ± 50 psi) and blocks the cylinder bottom port and the tank port.
C
11
12
20
P
Tank ８５Ｗ４２１５
Pilot valve
When pilot pressure drops (below 1.5 0.3MPa (15 3.5kgf/cm2) (213 50 psi))
TS2
When the pilot pressure from the pump drops due to engine shut down or other causes, the check valve opens and the oil from the reduction valve flows out to the pilot valve. In this case, the pressure is kept at 1.5 ± 0.3MPa (15 ± 3.5kgf/cm2) (213 ± 50 psi). This operation can occur only while oil is trapped in the bottom end of the boom cylinder. When the boom is on the ground or supported this operation stops. The reduction pressure may be measured through test port TS2.
23
C P
11
12
20
Tank ８５Ｗ４２１６
42-23
85Z Ⅳ -2
Pilot Relief Valve Unit
Pilot Relief Valve Unit
HYDRAULIC 42
(S/N 85C3-5701〜)
Construction The relief valve unit consists of relief valve and check valve. Ｐ ｉ ｌ ｏ ｔ ｖａ ｌ ｖｅ
３
１
４ Ｐ Ｐｕｍｐ ｐｏｒ ｔ
Ｔ
Ｏｉ ｌ ｐｒｅｓｓｕｒｅ ｇａｕｇｅ ｐ ｌ ｕｇ（ＰＦ１／４）
２
Ｔａｎｋ ｐｏｒ ｔ
６５Ａ４２０１３ ６２Ａ４２０１４
1. Relief valve unit 2. Relief valve 3. Check valve 4. Plug
Oil press gauge port
・ After removing the plug on the relief valve unit upper side, install the pressure gauge then check hydraulic oil pressure. ・ Relief valve setting pressure. 65ZIV/65TM/70ZIV/80ZIV/85ZIV: 2 3.6±0.3MPa(37±3 kgf/cm )(526±43psi) 2 90ZIV: 3.7±0.3MPa(38±3 kgf/cm )(540±43psi) 2 95ZIV: 3.9±0.3MPa(40±3 kgf/cm )(569±43psi) 2 115ZIV:4.0±0.3MPa(41±3 kgf/cm )(583±43psi) Note 1) : Tightening torque #2, #3 ・・・・・ 45〜50N-m (4.59〜5.10kgf-m)(33〜37Ib-ft) 2)Relief valve unit hexagon bolt ・Width across flats mm(in.) 22.4mm(0.88).
Pilot valve
Ｇ１／４
Ｐｐ
Check valve
Accumulator
Ａ
Ｂ
Ｇ１／４
Ｇ１／４
Relief valve Ｇ１ press test port Ｇ１／４
Relief valve
Ｎ‐ｍ
Ｇ２
Ｔ２
Ｇ１／４
Ｇ１／４
Ｇ１／２ Ｐ
Tank port
Pump port
Hydraulic line
42-24
Ｇ１／２
85Z Ⅳ -2
Pilot Relief Valve Unit
HYDRAULIC 42
Relief valve Function The relief valve is placed between the pump and the pilot valve. The pilot relief valve regulates the oil pressure in the pilot circuit to a safe operating range. The pressure is held constant whenever the engine is running. When the pilot circuit pressure reaches the operating pressure the relief valve opens and directs some of the oil back to the tank.
Ｂ ｌ ｏｃｋ
Ｔ
５
Ｐ
Operation ・When oil pressure is lower than the set point Oil discharged from the pump passes through the orifice of the poppet (1) and reaches to the pilot poppet (2). The pilot poppet (2) is pushed to the left by the pilot spring (3) and closes the port. ・When oil pressure exceeds the set point When the pumped oil pressure surpasses the set 2 spring pressure 3.6 ± 0.3MPa (37 ± 3kgf/cm ) (526 ± 43psi) of the pilot poppet (2), the pilot poppet (2) opens to allow oil to escape into the tank. In the result, the force pushes the relief poppet (1) to the left decreases and thereby the relief poppet (1) moves to the right, allowing high-pressure oil in the pump line into the tank line.
１
４
２
６５ＴＭ４２０３２
1. Poppet 2. Pilot poppet 3. Pilot spring 4. Spring 5. Adjusting screw Note : Adjusting screw adjustable range : 5 turns
Adjust to the set pressure at 3.6MPa (37kgf/cm2) (526psi) using the adjusting screw (5).
Check valve Construction Width across flat mm(in.): 22.4mm (0.88) ②
Pilot valve port ② ① ６５Ａ４２０１８
Pump port ①
42-25
３
85Z Ⅳ -2
Accumulator
Accumulator
HYDRAULIC 42
(S/N 85C3-5701〜)
1. Accumulator installation position Installing around the multiple control valve. Accumulator
Socket adapter U-bolt
Note:Models 85/90Z Ⅳ -2 shown Detail A
６５Ａ４２０１９
2. Construction ６ ７ １
1. Shell 2. Bladder 3. Poppet 4. Holder 5. Oil port 6. Gas plug 7. O-ring 8. Caution plate 9. O-ring
８
３ ４ ２ ５ ９
Width across flat 27mm(1.08 in.)
PF1/2
６５Ａ４２０２０
42-26
85Z Ⅳ -2
Accumulator
HYDRAULIC 42
3. Specification 1) Type : Accumulator used nitrogen gas (Bladder type) 2 2) Normal operation pressure 1.5〜3.5MPa(15〜35kgf/cm ) (213〜497psi) 2 3)Maximum operation pressure 5.4MPa(55kgf/cm ) (782psi) 2 4)Gas charged pressure 2.45MPa(25kgf/cm )(355psi) 3 5)Gas capacity 300cm 6)Accumulator charging time 10sec 7)Discharge time 5sec
4. Operation
Gas plug
・ If there is no supply oil from the pump coming to the pilot hydraulic circuit, due to engine not running or some other cause, the accumulator keeps a small reserve of oil ready to engage the pilot controls if necessary.
Bladder Nitrogen gas
・ The bladder works pilot oil pressure against the Nitrogen gas charge inside the accumulator. ・ The pilot controls can be activated without the engine running and boom can be lowered, or bucket dumped within about a space of five minutes after engine has been shut off.
Seat surface Hydraulic oil from pilot circuit. Poppet
CAUTION Lower the boom and bucket to the ground immediately if engine stops by some reason. From pump
5. Maintenance ・ No maintenance necessary (Do not remove the gas plug on the accumulator in any case.) ・ Replace the accumulator assy with new one if necessary. Loosen the gas plug 3.5 turns and keep it 3 minutes to let gas exhausted. After removing the gas plug completely remove the accumulator from the machine. ・ Do not weld near the accumulator because the high pressure gas is in the accumulator.
WARNING Never weld on or near gas charged accumulator. Serious injury may result.
42-27
To pilot valve
６５ＴＭ４２０１１
85Z Ⅳ -2
Multiple Control Valve (KVML)
HYDRAULIC 42
Multiple Control Valve (KVML)
5 Make-up valve(MUV)
Boom cylinder
3 Boom plunger Pilot valve
Pilot valve
Pilot valve
Pilot valve Bucket 2 plunger
240kg/cm
2
240kg/cm2 4 Overload relief valve (OLRV)
4 Overload relief valve (OLRV) 210kg/cm2 1 Main relief valve
Inlet cover Tank 6 Load check valve
Pump
Bucket cylinder
Bucket cylinder
42-28
Model
KVML-270-2
Main relief valve setting presure
point
installation
Bucket Boom
point
installation
OLRV
Overload relief valve setting pressure
MUV
The bucket priority line is used for the multiple control valve, and consists of the following units: 1.Main relief valve relieves the pressure when the working pressure exceeds the relief setting pressure. 2. Bucket plunger Used for bucket operation, such as roll back, holding a tilt angle, and dumping. 3. Boom plunger Used for the boom operation, such as raising, holding height, lowering, and floating. 4. Overload relief valve (With make-up function, on the bucket side) Relieves the internal pressure from the cylinder if the pressure is extremely high. 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".
Bucket Boom
Rod side
20.6MPa (210kgf/cm2) (2986psi) 23.5MPa (240kgf/cm2) (3413psi) Installed
Bottom side
Installed
Rod side
Non-installed
Bottom side
Non-installed
Rod side
Installed
Bottom side
Installed
Rod side
Installed
Bottom side
Non-installed
Note : A third spool for an auxiliary function (Log clamps, Side dump bucket, etc) is available. If required, the inlet cover is removed and the third spool is installed. The inlet cover is reinstalled. Priority oil then goes to the third spool function.
Multiple Control Valve (KVML)
85Z Ⅳ -2
HYDRAULIC 42
Main relief valve Function The main relief valve is installed between the pump and the control plunger. When the cylinder comes to the stroke end, or if the pressure is above the set pressure, the oil fed from the pump will be discharged into the tank through this valve (main relief valve) to prevent the pump and pipes from damage.
Operation ・ When the oil pressure is at the set point or below The pressurized oil fed from the pump flows through the orifice of main poppet C and then into the chamber D. The pressures applied to the both sides of the main poppet are equalized and the main poppet C is moved to the left due to the area difference. The pressure area in the chamber D is larger than the area of the pump side of the sleeve E, therefore, the pump port is closed by sleeve E.
E
Adjusting screw
To tank
From pump
C
D
F
・ When the oil pressure exceeds the set point When the oil pressure exceeds the set spring force of the pilot poppet, the pilot poppet F is opened, and the oil flows along the sleeve and returns to the tank. To tank As a result, the pressure in the chamber D drops below the pump-side pressure, therefore the main poppet C is moved to the right, and the high-pressure From pump oil in the pump line is returned to the tank line. The set pressure 20.6MPa (210kgf/cm2) (2986psi) can be adjusted by turning the adjusting screw. Note : Clogging of the orifice in poppet C will cause low pressure. Another possible cause of low pressure is contamination in, or damage to, the seat of poppet C or F.
42-29
C
D
F
85Z Ⅳ -2
Multiple Control Valve (KVML)
HYDRAULIC 42
Bucket plunger ・ Bucket "tilt-up" position
B
A D
PA1 Pilot valve
C
Tank
Pump
When the pilot valve applies pressure to PA1, the plunger is shifted to the left, and the center bypass line is closed at plunger shoulder C. The pressurized oil from the pump, flows through check valve D and then port A. The oil finally reaches the bottom side of the cylinder to tilt up the bucket.
42-30
On the other hand, the oil in the rod side of the cylinder is returned to the tank through port B.
85Z Ⅳ -2
Multiple Control Valve (KVML)
HYDRAULIC 42
・ Bucket "dump" position
E A
B D
Pilot valve PB1
C
Tank
Pump
When the pilot valve applies pressure to PB1, the plunger is moved to the right, and the center bypass line is closed at plunger shoulder C. The pressurized oil fed from the pump, therefore, flows through check valve D and then port B. The oil finally reaches the rod side of the cylinder to dump the bucket. On the other hand, the oil in the bottom side of the cylinder is returned to the tank through port A.
42-31
Extremely quick dumping opens make-up valve E to feed the oil of the tank line to the rod side of the cylinder. Such a function prevents forming a vacuum in the rod side when the bucket is dumped too quickly due to the bucket weight and/or low pump flow.
85Z Ⅳ -2
Multiple Control Valve (KVML)
HYDRAULIC 42
Boom plunger ・ Boom "up" positon
B
A D
PA2
C
Tank
Pump
When the pilot valve applies pressure to PA2, the plunger is moved to the left, and the center bypass line is closed at plunger shoulder C. The pressurized oil fed from the pump, therefore, flows through check valve D and then port A. The oil finally reaches the bottom side of the cylinder to raise the boom. On the other hand, the oil in the rod side of the cylinder is returned to the tank through port B.
42-32
Pilot valve
85Z Ⅳ -2
Multiple Control Valve (KVML)
HYDRAULIC 42
・ Boom "down" position
E B
A D
PB2 Pilot valve C
Tank
Pump
When the pilot valve applies pressure to PB2, the plunger is moved to the right, and the center bypass line is closed at plunger shoulder C. The pressurized oil fed from the pump, therefore, flows through check valve D and then port B. The oil finally reaches the rod side of the cylinder to lower the boom. On the other hand, the oil in the bottom side of the cylinder is returned to the tank through port A.
42-33
Extremely quick boom lowering opens make-up valve E to feed the oil of the tank line to the rod side of the cylinder. Such a function prevents forming a vacuum in the rod side when the boom is lowered too quickly due to the boom weight and/or low pump flow.
85Z Ⅳ -2
Multiple Control Valve (KVML)
HYDRAULIC 42
・ Boom "float" position
B
Pilot valve
A
PB2
Tank
Pump
When the control lever is shifted beyond the down position to "FLOAT", a higher pilot pressure forces the plunger of the multiple loader control valve to move further to the right. As a result of this, all ports (ie, pump port, tank port, cylinder bottom end port, and cylinder rod end port) are connected together. Therefore, the cylinder piston can move freely up and down by external force, which is useful for leveling uneven ground.
42-34
Multiple Control Valve (KVML)
85Z Ⅳ -2
HYDRAULIC 42
Overload relief valve (with make-up function) (Installed on both the rod and bottom sides of the bucket line)
Function Each overload relief valve (with make-up function) is installed between the cylinder and the control plunger. When the plunger is in the neutral position, if external force on the cylinder becomes too high and the oil pressure will be greatly increased, the overload relief valve returns the oil to the tank to protect the cylinders and pipes from breakage.
Operation Operation as overload relief vavle ・ When the oil pressure is at the set point or below. The pressurized oil is fed to the chamber X via the orifice of poppet C. Poppet E is closed due to the normal oil pressure (below set pressure) and spring S tension, therefore, the oil line from cylinder to the tank is completely closed. The pressure area in the chamber X is bigger than the area of the cylinder port on sleeve K, therefore, sleeve K is moved to the left to seat the valve at the cylinder port.
Tank
Cylinder
S
・ When the oil pressure exceeds the set point
Tank
The pilot poppet E is opened by compressing spring S and the oil returns to the tank along sleeve K. As a result, the pressure in the chamber X is low compared with that of the cylinder side. Poppets C and D, therefore, are moved to the right and the high pressure oil from the cylinder is returned to the tank.
Cylinder
S
・ Operation as make-up valve When the cylinder pressure drops to a pressure lower than that of the tank port, sleeve K is moved to the right due to difference in the right and left pressures (pressure area=G-A). As a result, sleeve K is moved to the right ,and the oil fed from the tank goes to the cylinder to increase the pressure.
Tank
Cylinder
42-35
Multiple Control Valve (KVML)
85Z Ⅳ -2
HYDRAULIC 42
Make-up valve (Installed on the rod side of the hoist cylinder line)
Function Extremely quick boom lowering may generate low pressure due to low oil supply speed compared with boom lowering speed. The low pressure could form a vacuum that may cause cavitation. The purpose of the make-up valve is to prevent generation of such a vacuum. When the pressure in the rod side is lower than tank pressure, the make-up valve is opened to feed oil from the tank to the cylinder.
Tank line Valve
Cylinder line
Operation When the cylinder pressure is high enough, the cylinder pressure is applies to the valve (pressure area =B). The valve, therefore, is moved to the right and seated on the valve seat. When the cylinder pressure is lower than tank pressure, the tank pressure is applied to the valve (pressure area=B-A). The valve, therefore, is moved to the left (opened) to feed oil from the tank to the cylinder.
Cylinder pressure is greater than tank pressure Tank line
Cylinder line
Cylinder pressure is less than tank pressure
42-36
85Z Ⅳ -2
Slow Return Check Valve
Slow Return Check Valve
HYDRAULIC 42
(S/N 85C3-5501〜5700)
Construction 3
5
2
4
To multiple control valve
6
1
From pilot valve
1. Casing 2. Poppet 3. Spring seat
4. Spring 5. C-ring 6. Orifice (1.3mmφ)
Function The slow return check valve is installed in the boom lowering line between the pilot valve and multiple control valve. Just after lowering the boom, if the control lever is shifted to the holding position, the boom plunger of the multiple control valve is quickly returned to the holding position by the return spring. However, the boom still has lowering inertia that will cause a shock.
42-37
To prevent the shock, the slow return check valve controls the plunger return speed by slowly returning the pressurized pilot oil from the plunger. This is also called a "one-way orifice". Pilot oil flowing to the multiple control valve is not restricted. Oil returning to the pilot valve seats the poppet (2) and is restricted by the orifice (6). Since very cold oil is thicker it will flow through the orifice more slowly. The plunger will return to the neutral position more slowly. The boom takes longer to stop moving downward. Use the proper oil viscosity for the temperature. Allow the oil to warm up before operation.
85Z Ⅳ -2
Adapter (with orifice)
Adapter (with orifice)
HYDRAULIC 42
(S/N 85C3-5701〜)
Construction １ ２
Orifice
From pilot valve
To multiple control valve
６５Ａ４２０２２
1. Adapter 2. O-ring
Function The Adapter (with orifice) is installed in the boom lowering line between the pilot valve and multiple control valve. Just after lowering the boom, if the control lever is shifted to the holding position, the boom plunger of the multiple control valve is quickly returned to the holding position by the return spring. However, the boom still has lowering inertia that will cause a shock. To prevent the shock, the Adapter (with orifice) controls the plunger return speed by slowly returning the pressurized pilot oil from the plunger.
42-38
Steering System
85Z Ⅳ -2
HYDRAULIC 42
Steering System Operation The steering wheel is connected to the steering valve via the drop arm and the drag link. When the steering wheel is turned, pressure is applied to the steering plunger depending on the wheel turning amount and direction, and the hydraulic oil goes to the steering cylinders. When the steering valve plunger is in neutral, almost all the hydraulic oil from the steering pump (front pump) goes to the loading line.
Steering cylinder
Steering valve To loading line
Cooler
Pump
Filter
Tank
Feed back system (1)Neutral position
Steering valve
While the steering wheel is not turned, the plunger ④ is in the neutral position. ④
③ ⑤ ① ②
80ZⅣ 4216
42-39
Steering System
85Z Ⅳ -2
HYDRAULIC 42
(2) Right turn position
Steering valve
When the steering wheel is turned to the right, the plunger ④ is pulled out and the machine starts to steer to the right.
④
③ ⑤ ① ②
８０ＺⅣ ４２１７−１
(3) Return to neutral position 1. When the steering wheel stops turning, the drop arm ① , drag rod ② and link ③ stop moving. 2. But the machine continues to be steered to the right because the plunger remains pulled out. 3. The bracket ⑤ fixed on the front chassis pushes the link ③ back, accordingly the plunger is pushed back to the neutral position. 4. Hereby the machine stops steering.
(4) Left turn position
Drop arm
②
Drag rod
③
Link
④
Plunger
⑤
Bracket
④
③ ⑤ ①
When the steering wheel is turned to the left, the plunger ④ is pushed in and the machine starts to steer to the left. When the steering wheel stops turning, the drop arm ① , drag rod ② and link ③ stop moving but the machine continues to be steered to the left until the plunger ④ is pulled out to the neutral position by the bracket ⑤ fixed on the front chassis. Hereby the machine stops moving. ①
Steering valve
②
８０ＺⅣ ４２１７−２
42-40
Steering Gear Box
85Z Ⅳ -2
HYDRAULIC 42
Steering Gear Box Structure
６５ＴＭ４２０３６
1. 2. 3. 4. 5. 6. 7.
Gear box Bush Bush Sector shaft Worm shaft Ball nut Ball tube
8. Ball 9. Adjusting screw 10. Locknut 11. Shim 12. Drop arm 13. Nut 14. Oil seal
The worm shaft (5) is threaded so that balls (8) can slide along the thread. In addition, the worm shaft is equipped with a ball nut (6). When the worm shaft (5) rotates, the balls (8) in the ball thread will circulate while being guided by the ball tube (7). Under the worm shaft (5), there is a worm shaft bearing (19) preload adjustment shim (17) between the front cover (16) and the gear box (1). Adjust this shim (17) to adjust the steering operation force. On the side surface of the ball nut (6), there is a rack, and the rack teeth are engaged with the gear of the sector shaft (4). This gear is a taper gear, and the adjust screw (9) adjusts the backlash between the gear and the rack teeth. This means that increasing the backlash will increase the play of the steering wheel.
15. Oil port plug 16. Front cover 17. Shim 18. Air breather 19. Bearing 20. Bolt (Drain plug)
Turning the steering wheel clockwise will rotate the worm shaft (5) via the steering shaft and universal joint. In addition, turning the steering wheel clockwise will lift the ball nut (6). When the ball nut is lifted, the sector shaft (4) will be lifted, and the drop arm (12) will be moved forward (to the front of the machine).
42-41
Sector shaft inclination angle: 39 °in vertical direction
85Z Ⅳ -2
Steering Gear Box
Checking and Adjusting Play of Steering Wheel: ・ How to measure the play: While turning the steering wheel clockwise and counterclockwise, check the maximum wheel turning range where the drop arm (12) will not move. Measure this wheel turning range (play of steering wheel). Reference value: 20-70 mm(0.78〜2.75 in)
６５ＴＭ４２０３７
・ How to adjust the play if the measurement value is out of the reference value: Loosen the locknut (10), and turn the adjust screw (9) clockwise or counterclockwise to adjust the play. Turning the adjust screw (9) clockwise will reduce the play. Turning the adjust screw (9) counterclockwise will increase the play.
42-42
HYDRAULIC 42
Steering Gear Box
85Z Ⅳ -2
HYDRAULIC 42
Checking and Adjusting Gear Box Oil Level: Remove the oil port plug (15), and check that the gear oil is at the level specified in the right figure. If the oil is below the specified level: Supply the gear oil of class GL-5 to the specified level.
Gear Oil Replacement Procedure: 1) Remove the front cover (16) fixing bolt (20) to drain the gear oil. Gear oil: 0.4 l (0.1gal) 2) At the completion of oil draining, wind the seal tape to the front cover fixing bolt (20). : 25 N-m (2.5 kgf-m)(18 lb-ft) 3) Remove the oil port plug (15), and supply gear oil to the oil level specified in the right figure. Gear oil: Class GL-5, 0.4 l (0.1gal) 4) Reinsert the oil port plug (15).
６５ＴＭ４２０３８
42-43
85Z Ⅳ -2
Steering Valve (KVMT)
HYDRAULIC 42
Steering Valve (KVMT) 2
From pump
3
5
5
4
Top view
4
1 Tank port
Loading port
3
2
Side view-flow control spool/relief Cylinder port
Cylinder port
4 4
5
Side view-steering plunger 1
1. Steering plunger 2. Flow control plunger 3.Main relief valve 4.Overload relief valve with make-up function 5. Check valve
42-44
5
85Z Ⅳ -2
Steering Valve (KVMT)
1.Steering plunger The steering plunger is connected to the steering wheel via the link. Turning the steering wheel changes the oil flow direction. At the center of the plunger, there is a variable orifice having chamfers (throttle grooves). This orifice controls the oil flow rate. Also inside the steering plungers are check valves which apply a back pressure to oil returning from the cylinders.
2.Flow control plunger The flow control plunger sends oil to the steering line depending on the displacement of the steering plunger. The excess oil goes to the loading line.
3.Main relief valve The main relief valve controls the maximum operating pressure when turning the steering wheel.
4.Overload relief valves with make-up function These valves prevent excessive oil pressure caused by external force and a vacuum in the steering oil line. Model
KVMT200L
Main relief valve setting pressure
20.6MPa (210kgf/cm2) (2986psi)
Overload relief valve setting pressure
24.5MPa (250kgf/cm2) (3555psi)
42-45
HYDRAULIC 42
85Z Ⅳ -2
Steering Valve (KVMT)
HYDRAULIC 42
Operation ・ NEUTRAL position
To loading line
2
1
In the NEUTRAL position, steering plunger (1) closes all the ports to stop flow of the pressurized oil from the steering pump. The pressure in the pump line, therefore, will rise. When the pump line pressure increases to 0.3MPa 2 (3.5kgf/cm ) (50psi), flow control valve (2) is moved to the right due to the pressure difference between chambers A and B. Thus the flow control valve is opened, and all the oil from the steering pump is sent to the loading line.
42-46
85Z Ⅳ -2
Steering Valve (KVMT)
HYDRAULIC 42
・ Left turn position (steering plunger "in" position) Pump Loading line
2
1 Left-turn command
Tank Variable throttle section
When steering plunger (1) is pushed in to the left, the pressurized oil from the pump is sent to steering cylinders through the variable throttle section and the check valve. The pressurized oil moves the cylinder rods and the machine turns to the left. During low-speed turning, displacement of steering plunger (1) is small. However, since the oil flow rate to the steering cylinder is reduced at the variable throttle section at the center port, the pressure difference between the front and rear of the throttle section is increased. When the pressure difference 2 is increased to 0.3MPa (3.5kgf/cm ) (50psi), flow control plunger (2) is opened to discharge excess oil to the loading line. In this way, the flow control plunger prevents extreme increase in the pressure of the oil from the steering pump, and adjusts the oil flow rate to the cylinder. For high-speed turning, steering plunger (1) is 42-47
pushed all the way to the left, and the variable throttle is fully opened. Under such a condition, all the oil is used for steering to enable high-speed turning. At a low engine speed, the oil flow rate from the steering pump is low, therefore the pressure difference between the front and rear of the throttle section is small, and flow control plunger (2) is closed. At a high engine speed, oil flow rate to the variable throttle is increased, therefore the pressure difference between the front and rear of the throttle section is increased to activate the flow control plunger. As a result, the excess oil is sent to the loading line. Note : Right turn operation is the same except the plunger is pulled out. This directs oil to the opposite ends of the cylinders.
Steering Valve (KVMT)
85Z Ⅳ -2
HYDRAULIC 42
Variable throttle of steering plunger When the steering plunger is pushed in, the variable throttle is opened, and the pressurized oil from the pump is sent to the variable throttle and to chambers A and B. The pressure difference depends on the opening area of the variable throttle and the oil flow rate, and the maximum pressure for opening the flow control valve is set to 0.3MPa (3.5kgf/cm2) (50psi).
Operation of flow control plunger
Loading line
When the pump discharge is small, the pressure difference between chambers A and B is small (PA ≒ PB), and the flow control plunger is being pushed to the left by the spring. Therefore, all the oil from the pump is sent to the steering line.
When the pump discharge is increased and the pressure difference (PA-PB) is increased to 0.3MPa (3.5kgf/cm2) (50psi), the flow control plunger is moved to the right, and the excess oil is bypassed to the loading line. Features As described the above, the steering line is given priority in receiving pressurized oil from the pump. However, when the engine speed is increased and the oil flow rate exceeds the set point, the flow control plunger bypasses the excess oil to the loading line. This keeps the oil flow rate constant in the steering line
42-48
Pump
PA
Variable throttle section
PA
Spring
85Z Ⅳ -2
Steering Valve (KVMT)
HYDRAULIC 42
Main relief valve ・ When the oil pressure is at the set point or below. Loading line
Pump
Flow control plunger
A
Steering plunger
In the above figure, the steering plunger is opened, and chambers A and B are filled with oil. The flow control plunger is balanced at the position shown in the figure.
・ When the oil pressure exceeds the set point. Loading line
Pump
Flow control plunger
Relief valve
Steering plunger Cylinder
Tank
When the pressure in the cylinder line rises above the set point (oil pressure in chamber A and B rise also), the oil in chamber B opens the relief valve and flows to the tank line. As a result, the pressure in chamber A is higher than that of chamber B. The flow control plunger, therefore, is moved to the right, and all the oil 42-49
Cylinder
from the pump is sent to the loading line. Pressure is still being applied to the steering cylinders.
85Z Ⅳ -2
Steering Valve (KVMT)
HYDRAULIC 42
Overload relief valve (with make-up function) Construction The overload relief valves installed on both sides of the cylinder are in the line between the cylinder and the control valve
When the steering plunger is in the neutral position, the cylinder line is closed.
A
B
Overload relief function Make-up function
Tank
Operation ・ Operation of overload relief valve:
・ Operation of make-up valve:
Under the above condition, if a shock (external force) is applied to the cylinders (bottom-side cylinder in the above figure), the pressure in the oil circuit is increased abnormally. In this case, the overload relief valve discharges oil from port A to prevent the cylinder and pipes from breakage.
42-50
On the other side (rod side in the above figure), a vacuum (negative pressure) may be formed depending on the discharged oil amount. To prevent a vacuum, the make-up valve opens to feed oil from the tank line.
Steering Valve (KVMT)
85Z Ⅳ -2
HYDRAULIC 42
Operation as overload relief valve ・ When the oil pressure is at the set point or below: The pressurized oil is sent to chamber X via the orifice of poppet C. Poppet E is closed due to the normal oil pressure (set pressure or below) and spring S tension, therefore, the oil line from cylinder to the tank is completely closed. Under this condition, since the pressure area in Cylinder chamber X is bigger than the area in the cylinder-side, sleeve K and poppet D are moved to the left to seat C the valve at the cylinder port.
X K Tank
E
D
・ When the oil pressure exceeds the set point: The pilot poppet E compresses spring S and is opened, and the oil is returned to the tank through along sleeve K. As a result, the oil pressure in chamber X is lower than the pressure of the cylinder side. Poppet C, therefore, is moved to the right and presses the pilot poppet E to the right to open the oil path. Since chamber X, is connected with the tank line, Cylinder poppet D is moved to the right to open another oil path, and the high pressure oil from the cylinder is returned to the tank through the opened oil path.
S
K Tank
C
X
E
G
K
D
・ Operation as make-up valve: When the cylinder pressure drops below tank pressure, sleeve K is moved to the right due to A difference in the right and left pressures (pressure area=G-A). As a result, the valve is opened, and the oil is fed from the tank to the cylinder to increase the pressure. Cylinder
42-51
Tank
S
85Z Ⅳ -2
Standard Measurement Values
HYDRAULIC 42
Standard Measurement Values for Performance Check 2
1.Relief valve setting pressure MPa (kgf/cm ) (psi) Measurement conditions: Oil temperature 50 ℃〜80 ℃ Hydraulic oil ISO VG46 or equivalent oil For measurement of the relief valve setting pressure, refer to "Measurement for Performance Check".
20.6 ± 1 (210 ± 10) (2986 ± 142) Loading line 23.5 ±01. 5 Overload relief pressure (240 ±15 0) (Engine at idling speed) (3413 ±17412) 20.6 ± 1 Main pressure (210 ± 10) (Engine at maximum speed) (2986 ± 142) Steering line 24.5 ±01. 5 Overload relief pressure (250 ±15 0) (Engine at idling speed) (3557 ±17412) 3.6 ± 0.3 Main pressure (37 ± 3) (Engine at idling speed) (526 ± 43) Pilot line 1.5 ± 0.3 Reducing pressure (Engine stop) (15 ± 3.5 S/N 85C3-5501〜5700 (213 ± 50) Main pressure (Engine at maximum speed)
IMPORTANT After measuring the relief valve setting pressure in the steering line, be sure to reset the drop arm stopper to the original position by referring to Section 03, "Measurement for Performance Check".
2.Steering valve Plunger displacement (mm) Plunger
(A)
(B)
9
9
3.Stroke of hydraulic cylinder(mm) Boom cylinder
814±2
Bucket cylinder
538±2
Steering cylinder
440±2
4.Natural drift of hydraulic cylinder
(B)
(A)
(mm/min) Boom cylinder Bucket cylinder
3 or less
36.5
Neutral
4 or less
For measurement of the hydraulic cylinder natural drift, refer to Section 03 of a separate section, "Measurement for Performance Check".
42-52
Cautions Regarding Replacement
85Z Ⅳ -2
Cautions Regarding Replacement of Hydraulic Parts After oil or parts replacement, abnormal movement or seizure may occur during break-in. Causes of these problems are mostly incomplete air bleeding or improper lubrication after replacement. To prevent these problems, observe the following cautions. (Refer to Section 44 for additional cautions.)
Cautions regarding oil pump replacement 1. Before installing a new oil pump, lubricate the inside of the pump using new oil. After that, operate the pump to check that the pump turns smoothly by hand. 2. If oil in the pump, cylinder, or oil tank is completely drained for oil replacement or repair, follow the procedure below before restarting the pump or cylinder piston.
①At the completion of pipe reconnection, close the cap of the hydraulic tank, and remove the plug of the pump suction pipe. Pour hydraulic oil through the plug port until oil overflows from the port. ②Operate the engine at idling speed for 5 minutes. Do not operate the cylinder pistons. ③After 5 minutes, while continuing operation of the engine at idling speed, operate cylinder pistons 5 times or more for each. To operate pistons, observe the following items: ・ Be sure to operate each piston to almost its stroke end while taking care not to operate the relief valve. ・ To lower the boom, or to dump the load from the bucket, slowly operate the piston. ④Perform general operation, and check the pump or cylinder for abnormal noise and heat. ⑤Observe the oil in the oil level gauge, and check that the oil is not foaming. 3. After being reasonably certain that hydraulics are operating ok, check main and overload relief valve pressures. Reset these if needed.
42-53
HYDRAULIC 42
Flushing Hydraulic Lines
85Z Ⅳ -2
HYDRAULIC 42
Flushing Hydraulic Lines Purpose of flushing 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 flows into the return filter or hydraulic tank. However, there are some debris that remain in the valves, cylinders, or pipes. Therefore, even if the damaged cylinder or valve is replaced, the debris sticking in other valves, cylinders, or pipes breaks loose and then is fed into the cylinders, where the debris damages the inside of the cylinders, or sticks to the valve plungers or relief valves, and causes another malfunction. To prevent such problems, be sure to remove all the debris from the line.
Debris To tank
Flushing hydraulic line 〔Example〕Flushing when the inside of a cylinder is broken
1.Disassembling and checking cylinders Assuming that two cylinders form pairs, if one of the cylinders is damaged or if debris is detected in one of cylinders, be sure to disassemble and check the other cylinder. If right and left cylinders form pairs, the oil sent from one cylinder joins the oil sent from the other cylinder. Therefore, if one of the cylinders is damaged, the debris will be sent into the other cylinder. This is why the other cylinder should be also disassembled and checked when one of cylinders is damaged or if debris is detected in one of cylinders.
It is not necessary to disassemble and check cylinders of other circuits if no internal leakage is detected. ・ For instance, if inside of the bucket cylinder is damaged, operating the cylinder feeds the oil together with the debris and iron particles from the cylinder to the oil tank via the control valve.
42-54
〔Debris fed to the other cylinder on the opposite side〕
Damaged cylinder
Debris
Flushing Hydraulic Lines
85Z Ⅳ -2
HYDRAULIC 42
・ There is little possibility that the debris of the bucket cylinder are sent to the boom cylinders via the control valve. Assuming that the boom is lowered quickly while dumping the load of the bucket, the debris from the bottom side of the bucket cylinder may be sent to the drain port of the control valve, and then sent to the rod side of the boom cylinder via the make-up valve. Such possibility, however, is very small. However, for precaution's sake, it is recommended that the natural drift of the other cylinders should be measured. If the obtained measurement value is larger than the standard value, disassemble and check the cylinders. For a detailed discription of natural drift measurement, refer to "Measurement for Performance Check". For a detailed description of disassembly and reassembly, refer to "Hydraulic Group Disassmbly and Reassembly".
2.Cleaning inside of oil tank Check the relief valve of the return filter, and replace the filter element. If the inside of a cylinder is damaged, a large number of debris or iron particles will be sent into the return filter together with the oil. The filter element, therefore, will be clogged, and debris may be stuck into the bypass valve. Be sure to disassemble and check the filter and bypass valve, and replace the element with a new one.
６５ＴＭ４２０１８
Clogged filter
Foreign material sticking in filter bypass valve
Clear debris and iron particles from the bottom of the oil tank. If the inside of a cylinder is damaged, a large amount of debris and iron particles are sent into the oil tank and deposited on the bottom of the tank. Wash the tank using light oil, etc. to clear debris and iron particles from the tank.
８５Ｗ４３０１
Pieces
42-55
Flushing Hydraulic Lines
85Z Ⅳ -2
3.Flushing pipes Flushing pipes connected to the damaged cylinder ・ Generally, the cylinder debris will not be stuck in pipes. Most of broken pieces are caught by the multiple control valve or return filter, and some of them are sent into the hydraulic tank. However, for precaution's sake, flush all the pipes connected to the broken cylinder. ・ If there are long and thick low-pressure hoses, as the figures, disconnect the cylinder hoses from the cylinder, and then connect the low-pressure hoses to the connectors of the cylinder hoses. Insert the other ends of low-pressure hoses into a drum. Flush the pipes with oil for 10 seconds by operating engine at full speed. The pipes and hoses will be cleared of debris, and the control valve will be also cleared of debris if there are any residual pieces. Use the hydraulic oil in the hydraulic tank for this oil flushing method. Therefore, be sure to clean the inside of the hydraulic tank before flushing the pipes. ・ If there are no long and thick hoses, disconnect the cylinder hoses and pipes, and feed light oil or cleaning solvent into the pipes and hoses. Cover the both ends and shake the hoses and pipes. After that, discharge light oil or cleaning solvent from the pipes and hoses. The broken pieces will be discharged together with the oil or solvent.
4.Disassembling and checking valves Remove all the plungers and relief valves, and then check their sliding surfaces for scratches. Also check the grooves on the bodies for residual broken pieces. For a detailed description of valve disassembly and reassembly, refer to "Hydraulic Group Disassembly and Reassembly".
42-56
HYDRAULIC 42
[Flushing pipes]
To multiple control valve
Low-pressure hoses Drum
IMPORTANT Oil level must be kept full in hydraulic tank, or pump damage may result.
Pieces
Flushing Hydraulic Lines
85Z Ⅳ -2
HYDRAULIC 42
5.Others Flushing oil cooler and its pipes 〔When the inside of boom, or bucket or steering cylinder is damaged〕 If the inside of the cylinder is damaged the debris will be sent into the oil cooler line. Comparatively large pieces will be caught by the plunger of the valve, and small pieces will be sent into the oil cooler. Very small pieces will pass through the oil cooler and reach the tank. Therefore, if the inside of the cylinder is damaged, be sure to flush the steering valve, multiple control valve, oil cooler, cooler bypass valve, hydraulic tank, and all the pipes.
Oil cooler
Hydraulic tank
Cooler bypass valve
From steering cylinder From pump
Steering valve
From multiple control valve
・ Clean the pilot valve filter. Note : I f the pilot pump has failed causing contamination in the pilot circuit ・Remove and disassemble the pilot relief valve. ・Remove and clean or replace the pilot valve filter. Note : If the filter is damaged or not installed, the pilot valve and each oil pack on the multiple control valve must be disassembled and cleaned.
42-57
85Z Ⅳ -2
Measuring Steering Wheel/Lever
Measuring Steering Wheel/Lever Operating Force WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. To prevent such an accident, observe the following items before starting test: ・Park the machine on solid and level ground. ・Apply the parking brake. ・Block the tires with chocks to prevent the wheels from moving. ・Determine the signals between the service persons. ・Prohibit any person to walk into the dangerous area. Under raised components or in articulation area Under the machine Front or rear of the machine
Measuring steering wheel operating force 1.Measurement instrument Pull scale or spring balance 2.Measurement procedure Stop the engine, and attach the push-pull scale to the steering wheel. Gradually turn the steering wheel. 3. Standard measurement value Operating force at strat of turning (for both clockwise and counter clockwise) : 15 ± 5N (1.5 ± 0.5kgf) (3.3 ± 1lb)
Measuring pilot valve lever operating force 1.Measuring instrument Push-pull scale or spring balance 2.Measurement procedure Operate the engine at the idling speed, and pull the center of the lever knob using the pull scale. 3. Standard measurement value (Unit:N) Raising boom
Lowering boom
Boom lever 32 ± 14 36 ± 16 operating force (3.3 ± 1.4kgf) (6.6 ± 3.1lb) (3.7 ± 1.6kgf) (6.6 ± 3.5lb) Dumping load from bucket
Tilting up bucket
Bucket lever 32 ± 14 36 ± 16 operating force (3.3 ± 1.4kgf) (6.6 ± 3.1lb) (3.7 ± 1.6kgf) (6.6 ± 3.5lb)
Measurement conditions Hydraulic oil temperature… 50 ℃ to 80 ℃ Lever angle… Just before full stroke
42-58
HYDRAULIC 42
BRAKE GROUP 52 Brake and Air Circuit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-2 Layout of Brake and Air Units ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-4 Air Governor ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-5 Air Tank (with attachments) ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-6 Brake Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-11 Air Pressure Switch (for inching) ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-16 Double Check Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-17 Air Master ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-18 Auto-adjuster Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-21 Service Brake ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-24 Parking Brake ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-26 Solenoid Valve (for parking brake) ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-28 Air Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-30 Brake Oil Tank ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-31 Checking Braking Performance ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-32 Checking Brake Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-33 Checking Air Master ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-35 Checking Wear of Service Brake Friction Plate ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-37 Adjusting Parking Brake Clearance ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-38 Brake Line Air Bleeding ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-39
52-1
85Z Ⅳ -2
Brake and Air Circuit
Brake 52
Brake and Air Circuit 6
Rear axle
7
8
17
5 16
4 (R.H)
4 (L.H)
Front axle
9
19 13
14 12 10
18
18
11
15
2 3 15
E/G
1
８５Ｖ５２００１
1. Air compressor
8. Auto-adjuster valves
15. Drain valves
2. Air tank (3 chambers)
9. Solenoid valve
16. Pressure switch
3. Air governor
(for parking brake)
(for clutch cut-off)
4. Brake valves
10. Air cylinder
5. Double check valves
11. Automatic drain valve
6. Brake oil tank (w/level sw)
12. Air pressure sensor (for gauge)
18.Check valves
7. Air masters (w/stroke sw)
13. Safety valve
19.Wet-type brake
17. Pressure switch
14. Air pressure switch (for alarm)
52-2
(for stop lamp)
Brake and Air Circuit
85Z Ⅳ -2
Outline of brake system This machine uses an air-hydraulic pressure booster brake system with the front and rear independent brake system to ensure further operator safety. The service brake is the wet disk type, and the parking brake is the internal expansion type. There is an auto-adjuster valve between the air master and the brake piston. The auto-adjuster valve controls the brake piston return distance to ensure equal brake pedal strokes even if the friction plates are worn. The oil used for the wet-type brake is mineral. Do not mix the vegetable brake oil or DOT 3 type brake fluid, as used for the conventional dry brakes, into this mineral oil.
52-3
Brake 52
85Z Ⅳ -2
Layout of Brake and Air Units
Brake 52
Layout of Brake and Air Units 4
9
5
Top view
5
3
7
6
8
4
2
11
5
1
11
9
12
Left side view
13
10
1. Air tank (3 chambers) 2.Air governor 3.Brake valve 4.Air masters 5.Auto-adjuster valve 6.Air cylinder (for park brake) 7.Solenoid valve (for parking brake)
8.Brake oil tank 9.Air pressure switch (for alarm) 10.Air pressure switch (for clutch cut-off) 11.Air pressure sensor (for gauge) 12.Safety valve 13.Air pressure switch (for brake light)
52-4
８５ＺⅣ ＵＳ５２０１
85Z Ⅳ -2
Air Governor
Brake 52
Air Governor Construction 8
7
6
5
4
3
2
1.Cover 2.Locknut 3.Body 4.Adjusting screw 5.Spring guide 6.Exhaust stem 7.Piston 8.Exhaust valve
1
Specifications Compressor off-load pressure
Compressor on-load pressure
637 ±390 kPa 2 (6.5 ±0.4 0 kgf/cm ) 5.7 (92 ± 0 psi) 530 ±390 kPa 2 (5.4 ±0.4 0 kgf/cm ) 5.7 (77 ± 0 psi)
Operation ・ Compressor off-load When the air tank pressure rises, the piston moves to the right, and the exhaust valve also moves to the right and stops at the exhaust stem. When the air 2 pressure exceeds 637kPa (6.5kgf/cm ) (92psi), the piston further moves to the right, and is separated from the exhaust valve. The air flows through the clearance between the exhaust valve and the piston, and then flows to the unloader valve of the compressor. The air presses down the unloader valve to turn off the compressor.
Air tank
・ Compressor on-load When the air tank pressure drops, the spring returns the piston to the left until the piston comes in contact with the exhaust valve. When the air pressure drops 2 below 530kPa (5.4kgf/cm ) (77psi), the exhaust valve is separated from the exhaust stem. The air pressing the unloader valve flows through the clearance between the valve and the stem to the center of the exhaust stem. The air is then discharged from the unloader valve chamber to the outside. Since the unloader valve is returned to the initial position by the spring, and the compressor compresses the air again.
52-5
Air tank
85Z Ⅳ -2
Air Tank
Brake 52
Air Tank Air tank mount
1 6 6 5
4
7
7 8
2
3
8 ８５ＺⅣＵＳ５２０２
1. Air tank (3 chamber type) 2.Automatic drain valve 3.Safety valve 4.Air pressure switch (for alarm) 5.Air pressure sensor (for gauge) 6.Check valves 7.Manual drain valves 8.Manual drain ring
52-6
85Z Ⅳ -2
Air Tank
Brake 52
Air tank Construction The air tank consists of one primary chamber (wet chamber) and two secondary chambers (dry chambers). The air from the air compressor is fed into the primary chamber first. The primary chamber then feeds air into the secondary chambers.
Secondary chamber (Dry chamber)
To brake valve
dary econ ber s o m T cha
Primary chamber
Ａ
Ａ
Ａ
The secondary chambers supply air to the right and left brake valves. The primary chamber has safety valve, air pressure sensor, automatic drain valve, and air pressure switch. The secondary chambers have manual drain valves.
To s e chamcondar Secondary chamber y (Dry chamber) ber Ａ
Ａ Ｄ
To brake valve
Ａ
Ｃ Ａ
From air compressor To air governor Safety valve port
Air pressure switch and air pressure sensor port
(Wet chamber)
Ｂ
Ｃ
Drain valve port
Ｂ
Automatic drain valve port
Capacity of air tank
Dimensions installation
Capacity (l) Primary chamber Secondary chamber
Drain valve port
6
of
８５ＺⅣＵＳ５２０３
screws
used
Mark
Q'ty
Dimension (inch)
A
7 points
PT1/2
right
14.5
B
2
PT3/4
left
14.5
C
2
PT1/4
D
1
PT1/8
52-7
for
unit
Air Tank
85Z Ⅳ -2
Units installed on air tank Automatic drain valve Operation ①
Brake 52
Adapter
Filter
If the air pressure inside the air tank is zero, the exhaust valve is closed. Air tank
Valve guide Inlet and exhaust valves
②When air is fed into the air tank, the air pressure will rise. Even slight air pressure can open the inlet valve to feed air, oil, and water into the chamber A. Until the pressure inside the tank rises to its maximum (governor-off point), the inlet valve will remain open.
Chamber A Wire stem
Air tank
Chamber A
③When the tank pressure is equal to the chamber A pressure, the spring of the valve guide closes the inlet valve. The exhaust valve still remains closed.
Air tank
Chamber A
④When the air pressure inside the tank drops (brake pedal applied and released) and the difference between the tank pressure and chamber A pressure is 2 approximately 29kPa (0.3kgf/cm ) (4.3psi), the exhaust valve will be opened to discharge air, oil, and water.
Air tank
Chamber A
52-8
85Z Ⅳ -2
Air Tank
Brake 52
Safety valve When the pressure inside the air tank rises to 2 8.5kg/cm , the ball of the safety valve will be pushed up, compressing the spring, and the compressed air will be discharged from the air tank to the outside. To adjust the pressure of the safety valve, loosen the locknut and turn the adjustment nut. Note : Tightening the adjustment nut raises the pressure. Setting value 834 ± 39kPa (8.5 ± 0.4kgf/cm2) (121 ± 5.7psi)
1 2
3 Exhaust
4 1. Adjusting nut 2. Locknut 3. Spring 4. Ball
Tank pressure
Pressure switch (for low air pressure alarm) When the air pressure is above the specified value, the air compresses the spring to open the contact. When the air pressure is below the specified value, the spring closes the contact. When the contact is closed, the electric current flows through the body to ground. Air pressure kPa (kgf/cm2) (psi)
Switch operates:
466 ± 29 (4.75 ± 0.3) (68 ± 4.3)
Pilot lamp, buzzer
Terminal
Spring
Contact
Diaphragm Normal status (Open contact)
52-9
Low-air pressure status (Closed contact)
85Z Ⅳ -2
Air Tank
Brake 52
Pressure sensor (for E/G oil and air pressure) The pressure sensor converts the detected lubrication oil pressure or air pressure into the corresponding electric signal, and then transmits the signal to the meter. Adjustment or correction of the pressure sensor is not possible.
Contactor
〔Principle of operation〕
Spring
Air pressure is applied to the bottom of the diaphragm. As the air pressure exceeds the spring pressure, the cup will be raised. The movement of the cup will be transmitted to the crankshaft, therefore the contactor at the end of the crankshaft will slide along the resistance wire according to the cup movement. The contactor position on the resistance wire depends on the balanced point between the spring pressure and air pressure. Therefore, the resistance value shows accurate air pressure even as the pressure fluctuates. The pointer of the meter indicates the pressure value according to the transmitted resistance value.
Cup
Diaphragm Pressure
Pressure kPa (kgf/cm2) (psi) Resistance ( Ω ) between terminal and body
Check valve If a problem occurs in the line between the air compressor and the primary tank, the check valve will prevent the reverse air flow from the secondary chambers and will keep the brake air pressure in the secondary chamber. Check valve
To secondary tank
From primary tank
Valve opening pressure difference : 29kPa (0.3kgf/cm2) (4.3psi) more
Resistance wire
Crankshaft
or
52-10
490 (5) (71)
785 (8) (114)
31.9
17.2
85Z Ⅳ -2
Brake Valve
Brake 52
Brake Valve Construction
1
2 16
3
17
5 4 8 9 6
10
7
Primary section
※ To air master
From air tank
11
12
From air tank
Secondary section
To air master
14
13
A
15
The valve inlet and outlet ports are shown by displacement drawing.
※・ ・ ・ ・ ・ ・ ・There are four slits in this section of the relay piston. The slits serve as exhaust ports when the brake pedal is released. 1.Brake pedal 2.Roller 3.Plunger 4.Rubber spring 5.Upper piston 6.Upper piston return spring 7.Upper valve 8.Stem 9.Stem springs
10.Upper valve spring 11.Relay piston 12.Relay piston spring 13. Lower valve 14. Lower valve spring 15.Exhaust valve 16.Brake pedal angle setting screw 17. Locknut 52-11
85Z Ⅳ -2
Brake Valve
Brake 52
Performance curve (psi) 100
16.1±2(psi)
588
6
85
85
490
5
71
71
392
4
57
57
294
3
43
43
196
2
28
28
98
1
14
14
100
0
6
8 7 ± 1.5
10
12
14
16
18
Brake pedal angle (deg.)
Pedal angle - discharge pressure curve
Discharge pressure
Discharge pressure
2
KPa (kgf/cm ) 686 7
KPa (kgf/cm2)
(psi)
686
7
100
473±20N (48.2±2 kgf) (106±4 lbf) (psi) 100
588
6
85
85
490
5
71
71
392
4
57
57
294
3
43
43
196
2
28
28
98
1
14
14 0
98 196 294 (20) (10) (30) (44) (22) (66) 6N-0+20 (7 -0+2 kgf)(15-0+4 lbf)
392 (40) (88)
490 N (50) (kgf) (110) (lbf)
Pedal force (kg, 150mm (5.9 in) away from fulcrum)
Pedal force - discharge pressure curve
52-12
Brake Valve
85Z Ⅳ -2
Brake 52
Operation Primary section : Activates the front brake line. Secondary section : Activates the rear brake line. Rubber spring
Braking function In normal operation Stepping on the brake pedal applies pressure to the upper piston of the primary section via the rubber spring. The piston opens the upper valve to feed air to the front brake air master. When the primary section operates, part of the air flows through the path to the top of the relay piston in From the secondary section. The air presses down the air tank relay piston to open the lower valve. The air then Relay flows through the lower valve to the rear brake air piston master.
Upper piston Upper valve To air Primary master section
Path Secondary section
To air master
From air tank
Lower valve
Balancing function If the brake pedal angle is kept constant, the air under the upper piston of the primary section applies pressure to the upper piston to raise the piston. As the upper piston rises, the rubber spring is compressed, and the upper valve is closed. When the upper valve comes in contact with the body's suction valve, air supply will be completely stopped. The air Piston exhaust pressure in the primary section is now stable. valve seat On the other hand, when the air pressure applied to the top of the relay piston is equal to that of the Body's suction valve seat bottom of the relay piston, the relay piston will be raised again, and the lower valve will be closed. When the lower valve comes in contact with the body's suction valve, the air supply will be completely Body suction valve seat stopped. The pressure in the secondary section is now equal to that of the primary section, therefore the secondary section is now stable. Relay piston exhaust valve seat
52-13
Rubber spring
Path
Brake Valve
85Z Ⅳ -2
Brake 52
When problem occurs in secondary line The relay piston separates the secondary section from the primary section. Therefore, the primary section will operate as usual even if a problem occurs in the secondary line. The air in the primary section will apply pressure to the relay piston of the secondary section to open the lower valve. However, there is no air in the secondary section, therefore, the rear brake line will not operate.
Path Primary section
Secondary section
When problem occurs in primary line When problem occurs in the primary line, stepping on the brake pedal applies pressure to the upper piston that opens the upper valve. However, there is no air in the primary line, therefore the relay piston will not operate. Further pedal pressure causes the bottom of the upper piston to press down the relay piston from the top. When the relay piston is pressed, the relay piston exhaust valve seat applies pressure to the lower valve to open it. The air flows through the open lower valve to the rear brake air master.
Rubber spring
Upper piston Primary section
Exhaust valve seat
Secondary section Relay piston
Lower valve
52-14
Brake Valve
85Z Ⅳ -2
Brake 52
Releasing air pressure When the brake pedal is released, both the upper piston return spring and the compressed air in the Stem spring primary line raise the upper piston of the primary section. The upper piston exhaust valve seat is separated from the upper valve so that the air in the primary line is fed Upper piston return spring through the exhaust path and then discharged from the exhaust valve. Exhaust When the air pressure in the primary line drops, the valve seat compressed air in the secondary section and the stem Exhaust port spring will raise the relay piston. The relay piston exhaust valve seat is separated from the lower valve so that the air in the secondary line is Exhaust valve seat fed through the exhaust path and then discharged from the exhaust valve. Thus the air is released from the rear brake line.
Stem
Upper piston Upper valve Primary section
Path Secondary section
Exhaust path Exhaust path
52-15
Exhaust valve
Air Pressure Switch (for inching)
85Z Ⅳ -2
Brake 52
Air Pressure Switch (for inching) Construction Ｕｐ （ｍｏｕｎ ｔ ｉ ｎｇ ｄ ｉ ｒ ｅｃ ｔ ｉ ｏｎ）
Air pressure switch
Stop lamp switch
６５ＴＭ５２００６
Mounting section
When the transmission cut-off selector switch (rocker type) is on, pressing down the left brake pedal turns on the air pressure switch and releases the forward or reverse clutch. Adjustment of the operating pressure is not possible.
Specifications(Air press.switch) Air pressure kPa(kgf/cm2)(psi)
ON
226±20(2.3±0.2)(33±2.8)
OFF
127 (1.3) (18)
Capacity of contact
Min. 18V Max. 32V Min. 10mA Max. 2.3A
Specifications(Stop lamp switch)
52-16
Operation pressure kPa(kgf/cm2)(psi)
29(0.3)(4.3)
Capacity
DC24V 25W
Max. allowable 2pressure MPa(kgf/cm )(psi)
2(20)(284)
85Z Ⅳ -2
Double Check Valve
Brake 52
Double Check Valve Construction To air master
From clutch/brake valve
(A)
1
(B)
3 4
The double check valves are installed between the brake valve and the air master. When the right or left brake valve is depressed, or if one of the brake valve malfunctions, the double check valve prevents reverse flow of air to ensure proper operation of the air master.
Operation When the clutch/brake pedal (left side) is depressed, air flows through port (A) and applies pressure to the shuttle (3). When the shuttle moves to the right, the air flows to the air master and port (B) is blocked. (see the figure above). When the brake pedal (right side) is depressed, air flows through port (B) and applies pressure to the shuttle (3). When the shuttle moves to the left, the air flows to the air master and port (A) is blocked.
52-17
1.Body 2.Cap 3.Shuttle 4.Plug
2
From brake valve
85Z Ⅳ -2
Air Master
Brake 52
Air Master The air master, which converts air pressure into the hydraulic pressure and then boosts it, is consists of the following two sections:
Air cylinder section
Hydraulic cylinder section
The air cylinder section includes air piston (2), push rod (5), return spring (3), etc.
The hydraulic cylinder section includes the hydraulic piston (7), check valve (8), etc. The pin (14) connects the hydraulic piston (7) to the push rod (5) in the air cylinder section.
Hydraulic cylinder section
Air cylinder section
4
1
11
3
Reservoir tank
2
7
9
8
Wet brake piston
Brake valve
10
14
6
5 12 13
1. Air cylinder
6. Hydraulic cylinder
11. Air breather
2. Air piston
7. Hydraulic piston
12. Stroke switch rod
3. Return spring
8. Check valve
13. Overstroke switch
4. Seal
9. Seal
14. Pin
5. Push rod
10. Seal
52-18
85Z Ⅳ -2
Air Master
Brake 52
Performance curve 2
Brake oil pressure
MPa (kgf/cm) (psi) 5.9
60
853
4.9
50
711
3.9
40
569
2.9
30
427
2.0
20
284
1.0
10
142 0 49 0.5 7
196 2 28
392 4 57
588 6 85
785 8 114
981 10 142
kPa (kgf/cm2) (psi)
Air pressure
Operation ・ When the brake is released
5
22 14 23
When the brake pedal is released, air is discharged from the air cylinder to the outside via the brake valve. By discharging the air, the push rod (5) and hydraulic piston (7) are moved to the left because of the return spring (3). The valve plate (21) comes in contact with the support ring (22). As a result, the check valve (8) is moved to the right (specified distance: A) so that the line between the pressure chamber and the brake oil tank is opened. This allows oil to flow back to the tank or make up oil may flow into pressure chamber if required.
8
21
24
7
Return oil Pressure chamber
A
25
26 7 23
26
21
25
Piston assembly Disassembly is not possible because the push plate (26) is pressed in the piston (7)
52-19
Air Master
85Z Ⅳ -2
Brake 52
・ When the brake pedal is pressed down When the brake pedal is pressed down, air is fed into the air cylinder depending on the pedal angle. The air applies pressure to the air piston (2) and the push rod (5). When the push rod and the hydraulic piston (7) move their positions to the right, the valve plate (21) will be separated from the support ring (22). As a result, the valve spring (24) moves the check valve (8) to the left to cut off the oil path between the pressure chamber and the brake oil tank. The oil in the pressure chamber, therefore, pressurize the oil in the wet brake piston chamber.
・ When the overstroke switch is actuated If oil is leaking from the pipe or brake piston seals, the pressure inside the hydraulic cylinder will not rise even though the air pressure rises. The air piston, therefore, moves to the stroke end (fully right). There the air piston presses the stroke switch rod (12) that actuates the overstroke switch (13). When the overstroke switch is actuated, the buzzer sounds, and the pilot warning lamp lights. The stroke switch rod is not the automatic reset type. Therefore, manual reset is needed to reset the electric alarm circuit. Push the stroke switch rod fully in and restart the machine.
52-20
5
22
21
7
8 24
Pressure chamber
Auto-adjuster Valve
85Z Ⅳ -2
Brake 52
Auto-adjuster Valve Construction 5
1
2
6
Brake piston port
Air master port
4
3 85V52002
1.Cylinder 2.Piston 3.Check valve 4.Spring 5.Air bleeder 6.Plug The auto-adjuster valve is installed between the air master and the brake piston, and ensures constant return distance of the brake piston. In addition, the auto-adjuster valve also ensures constant stroke of the brake pedal even if the brake disc is worn.
52-21
Check valve specifications Dia. of pressure receiving section
Valve opening pressure
9mm 1.4MPa (14.5kgf/cm2) (206psi)
Auto-adjuster Valve
85Z Ⅳ -2
Brake 52
Operation 1)In brake released condition 2
Wet brake piston port
Air master port
When the brake pedal is released, the return spring returns the brake piston of the disc brake section. The returning brake piston applies hydraulic pressure to the piston (2). The piston (2), therefore, is returned to the left end as shown in the figure. When the piston (2) reaches the end of it stroke (as shown)no more oil can return to the air master.The brake piston return travel is also limited.The brake piston cannot fully return to its limit. In this condition, the brake piston port chamber has residual pressure of approximately 2.1kg/cm2 even if the friction plate is worn to its limit. The return of the piston (2), allows a small clearance between the brake disc plates. On the other hand, the check valve (3) is closed in the above illustrated condition. (Check valve opening pressure : 1.4MPa 2 (14.5kgf/cm ) (206psi))
52-22
3
Auto-adjuster Valve
85Z Ⅳ -2
Brake 52
2)In brake applied condition 2
Wet brake piston port
Air master port
4
3 85V52003
When the brake pedal is depressed, oil is fed from the air master to move the piston (2) to the right. The oil, therefore, is fed into the brake piston. Normally the piston (2) does not move fully to the right because pressure on both sides of the pistion equalizes. If the front end of the check valve (3) comes in contact with the cylinder side wall, the brake piston internal pressure is still low (oil shortage). The piston will further move to the right to press in the end of the check valve. As a result, the check valve is opened, and the brake piston internal pressure is raised. This occurs when friction plate wear has increased. It also occurs if there is brake piston seal leakage or during brake bleeding. When the brake piston internal pressure is equal to the pressure of the air master port, the valve spring (4) returns the piston (2), and the check valve (3) is closed.
52-23
85Z Ⅳ -2
Service Brake
Brake 52
Service Brake 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 large braking power even on a muddy or sandy ground.
Construction 9
8
10 11
Brake oil inlet
6 5
12
3
7 13
4
1
2
1. Internal gear hub
8.O-ring (for brake piston)
2. Brake piston
9.O-ring (for brake piston)
3. Piston return spring/pin
10. O-ring (for gear hub)
4. Steel pressure plate
11. O-ring (for gear hub)
5. Friction plate (2)
12. Air bleeder nipple
6. Disc gear
13. Steel separator plate
502kg 234kg Length for brake disc wear limit: 43.3mm
Installation length:49mm
7. Brake retainer (backing plate)
Free length: 54mm Brake piston spring force (Total force shown for 8 springs)
52-24
Service Brake
85Z Ⅳ -2
Brake 52
Friction plate 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 (A) of two friction plates with each other to ensure smooth flow of gear cooling oil. 7 ± 0.1 5.0 ± 0.15 1.2
0.65mm
φ 375
(A)
Steel plate
Internal gear
A brake disc includes two steel plates, and the shapes of two steel plates differ from each other. Carefully install the steel plates. The steel plate shown in the upper figure should be installed on the piston side as the pressure plate. For this steel plate, adjustment of circumferential direction is not needed. The steel separator plate has section (A) where several teeth are missing. This steel plate should be installed on the brake retainer side (outer side of the machine). The section (A) of this plate is used for measurement of friction plate wear. Therefore, for this steel plate, the circumferential direction should be carefully installed so that the center of the teeth missing section is aligned with the spring pin as shown.
Detailed drawing of groove
Top
Spring pin
Steel pressure plate (item 4)
Top
Spring pin
(A) Steel pressure plate (item 13)
52-25
85Z Ⅳ -2
Parking Brake
Brake 52
Parking Brake The parking brake is a propeller shaft braking drum type, and is connected to the transmission output shaft. Turning on (pulling out) the parking switch turns off the power of the solenoid valve (condition shown in the figure). Air is discharged from the air cylinder to the outside, and the spring in the air cylinder pulls the parking brake lever to apply the brake.
Air Air discharge to outside Solenoid valve
Parking switch
Air cylinder Piston Spring
Brake system alarm
Bracket
Item
Pilot lamp ON
Sounding buzzer
Air master stroke sensor ON
○
○
Lever
Link Pin Link ON
Air pressure too low (air pressure range: below 466 ± 29kPa (4.75 ± 0.3kgf/cm2) (68 ± 4.3psi)
○
OFF
○
Pin Parking brake Parking brake "OFF" → "ON"
Operation of parking brake Parking switch
ON
OFF
Solenoid valve
Power-off
Power-on
Air cylinder
Air discharge
Air feeding
Parking brake
Braking
Released
Note :1. If the operator continues to operate the machine with the air pressure below 436kPa 2 (4.45kgf/cm ) (63psi) the spring overcomes the air pressure. This will cause rapid parking brake wear. 2. Refer to Section 54 for the Air cylinder linkage adjustment procedure.
52-26
85Z Ⅳ -2
Parking Brake
Brake 52
Construction 6
5
C-C 5 5
Drum rotational direction for running reverse
B
6
3 C
C
4
A 1
2 B
A
B-B
A-A 3
4
When the parking switch is turned on (pulled out), air is discharged from the air cylinder, and the air cylinder rod pulls up the lever (6). Since the lever (6) is connected to the cam shaft (5), the cam shaft rotates when the lever is pulled up. The rotation of the cam shaft causes the shoes on both sides of the cam to expand. As a result, the rotating brake drum is stopped. For adjustment, refer to "Adjusting parking brake clearance". The parking brake is designed to hold a machine that is stopped. If used to stop a moving machine it will cause rapid brake shoe wear and require frequent adjusment.
52-27
1.Brake drum 2.Brake shoe 3.Brake lining 4.Adjusting screw 5.Cam shaft 6. Lever
85Z Ⅳ -2
Solenoid Valve (for parking brake)
Brake 52
Solenoid Valve (for parking brake) Air cylinder (Parking brake)
Manual operation knob
ChamberA
2
85W5202
1
Exhaust
Air tank
De-energized
Chamber A
Air cylinder (Parking brake)
3
1
85W5203
Air tank
Energized
Installation position
Normal operation
Installed on the upper frame of the center pin of the rear chassis (beside the fuel tank) (Refer to "Layout of Brake and Air Units" #7.)
52-28
When the parking switch is turned on, the power of the solenoid valve is turned off, and the air in the chamber A is discharged from PE port then the spool (1) is returned to the neutral position (to the right). Air is discharged from the air cylinder, and the parking brake is applied. When the parking brake switch is turned off the coil assembly (2) is energized. The pilot air is supplied to the chamber A and this shifts the piston (3) and the plunger (1) to the left . This allows air pressure to flow from the air tank to the air cylinder releasing the parking brake. The exhaust port is blocked.
Solenoid Valve (for parking brake)
85Z Ⅳ -2
Brake 52
WARNING Sudden accidental movement of the machine could result in serious injury or death. Before manually operating the parking brake solenoid: ・Lower the boom and attachment to the ground. ・Place chocks on both sides of the tires. ・Be sure the machine is in neutral and engine is stopped.
Manual operation When the solenoid valve has a problem due to coil damage, or wiring problems, the parking brake can be released by the following manual operation. In this case, turn the manual operation knob on the side surface of the solenoid valve 90° clockwise as shown in the figure. Air pressure is then directed into the chamber A . The spool (1) in the valve moves to the left, and air will be fed into the air cylinder to release the brake. Note that releasing the parking brake will not be possible if the air pressure is not normal.
Manual operation knob
Normal position of manual operation knob 85W5204
WARNING If the knob is left at the ON position, the parking brake will not work. Under such a condition, an accident resulting in injury or death may occur. After manual releasing of the parking brake, be sure to return the manual operation knob to the initial (OFF) position.
Parking brake manual releasing position 85W5205
Outside source of a pressure
Air discharge to outside
〔 Note〕 To release the parking brake with low air pressure (below the specified pressure range) due to engine problem, follow the procedure below: Using another air source: Supply air to the air cylinder from the another air source, and then remove the pin. Without another air source: Apply a cable to the link, and then pull it down using a bar to release the spring of the air cylinder. After that, remove the pin.
Solenoid valve Air cylinder
Link Lever
Pin (Remove) Link ON OFF
Cable Bar
52-29
85Z Ⅳ -2
Air Cylinder
Brake 52
Air Cylinder 11
5
8 10
4
6
2
1
12
7
3
9
Stroke 65 Air
1.Cylinder 2.Piston rod 3.Rod cover 4.Piston
5.U-nut 6.Spring 7.Wear ring (bushing) 8.U-packing
9.Dust seal 10.O-ring 11.O-ring 12.Breather port filter
Operation
161kg
The compressed air applies pressure to the internal spring to release the parking brake. To prevent pressure build up on the spring side a breather port with a pressed metal filter (12) is provided.
WARNING
106kg
0kg
Careless disassembling work may cause serious injury or death. The spring applies high force to the rod cover, therefore carefully disassemble the air cylinder using a press.
Note : Refer to the free length (340mm) to check the spring for damage.
137
Stroke: 65 Installation length: 203mm Free length: 340mm
Spring length (S/N 5501〜5727)
Installation length Free length
(S/N 5728〜)
52-30
85Z Ⅳ -2
Brake Oil Tank
Brake 52
Brake Oil Tank 4
3
1
5 MAX
Switch off Approx. 6.8mm
MIN
Alarm oil level 54 ± 3
2
Tank capacity: 2,400cc, maximum 1,200cc, minimum
1.Tank 2.Float 3.Cap 4.Baffle (for pouring) 5.Rubber mounting pads
Operation of level switch When the brake oil level is 56mm below the maximum position, the switch will open and the alarm will be activated. Above the "MIN" level the switch is closed and the alarm is turned off. The switch is non-replaceable. If defective the tank assembly must be replaced. ・Reed switch is closed during normal operation. ・Reed switch is open when the tank level is low or empty.
52-31
85Z Ⅳ -2
Checking Braking Performance
Brake 52
Checking Braking Performance WARNING
IMPORTANT
Unexpected movement of the machine may cause serious injury or death. When checking the braking performance while operating the engine, observe the following items to prevent an accident: ・ Park the machine on level ground. ・ Check the area around the machine for safety. ・ Prohibit any person from walking into the dangerous area.
・ Checking service brake performance
Do not move the machine without releasing the parking brake. The brake lining may be burnt. After checking the parking brake performance, be sure to connect the solenoid valve electric line connector to the initial position again.
・ Checking parking brake performance
1. Fully depress the brake pedal. To use the clutch/brake pedal, be sure to turn off the transmission cut-off switch. 2. Set the shift lever to the 2nd reverse position, and then slowly increase the engine speed to its maximum. 3. Then check that the machine will not move under the above conditions.
1. Turn on the parking brake switch 2. Disconnect the electric line connector from the parking brake solenoid valve. 3. Turn the parking brake switch to "OFF" position. 4. Set the shift lever to the 3rd reverse position, and then slowly increase the engine speed to its maximum. 5. Then check that the machine will not move under the above conditions.
・ Possible causes when the machine moves under the above conditions.
・ Possible causes when the machine moves under the above conditions.
Possible cause
Solution
Possible cause
Solution
Brake air pressure too low
Check and adjustment Check and adjustment Check and repair
Clearance between brake drum and lining too large Improperly adjusted air cylinder linkage
Adjusting clearance Check and adjustment Check and repair
Brake oil pressure too low Worn brake disc
Damaged/broken air cylinder spring
Checking Air Line Setting Pressure For check and adjustment procedure, refer to Section 03 "Measuring Air Line Setting Pressure".
52-32
85Z Ⅳ -2
Checking Brake Valve
Brake 52
Checking Brake Valve WARNING Unexpected movement of machine may cause serious injury or death. To prevent such an accident, observe the following items before checking the brake valve: ・ Park the machine on level ground. ・ Lower the bucket onto the ground. ・ Apply the parking brake. ・ Block the tires with chocks or the like to prevent the wheels from moving. ・ If the air pressure drops during the valve check work, the engine should be started to raise the air pressure. Determine the signals between the persons related to this work for engine starting to prevent an accident.
・ Checking of brake pedal free play Free play angle D=7 ° ±1.5 ° Free play dimension A=23.5±5mm(0.92±0.20 in.) Dimension B=159 ±6(6.25±0.24 in.) Dimension C=135.5 ±10(5.33 ±0.39 in.)
IMPORTANT
D
Brake pedal
Brake valve mounting surface
If there is no free play, the brake valve may be unexpectedly activated. In addition, dragging or seizure of the brake may occur. Carefully check and adjust the free play of the brake pedal. Brake valve
・ Adjustment of free play To adjust the play of the brake pedal, loosen the locknut and then turn the set screw. Turning the set screw clockwise increases the free play. Turning the set screw counterclockwise reduces the free play. After adjustment, be sure to tighten the locknut. Also be sure the pivot pin is free and not sticking from corrosion.
Set screw Locknut
52-33
Checking Brake Valve
85Z Ⅳ -2
Brake 52
Checking brake valve Checking of brake valve without removing it from machine : ・ Measurement instrument Pressure gauge : Approx. 981kPa 2 (10kgf/cm )(142psi)
Brake pedal
・ Measuring port Discharge all brake air pressure. Remove one of plugs (B position appropriate for measurement), and install the pressure gauge to the port. (If direct installation of the gauge is not possible, use an elbow.)
Brake valve mounting surface Brake valve
・ Pressure gauge outlet port : PT3/8
Checking of brake valve removed from machine : ・ Measurement instrument Pressure gauge : Approx. 981kPa 2 (10kgf/cm )(142psi)
7 99
16.1 ± 2 ° 686
6 85
598
5 71
490
4 57
392
3 43
294
2 28
196
1 14
98 0
6
Air pressure rising point
8 10 12 14 7 ± 1.5 ° Brake pedal angle (deg.)
16
Pedal angle-discharge pressure curve
・ Air inlet port and measuring port Air inlet port : Section A (for upper and lower) Measuring port : Section B (for upper and lower) Any port is possible.
B
A
・ Standard measurement value Same as above B
B Viewed from bottom of brake valve
52-34
0 18
Discharge pressure (KPa)
・ Standard measurement value While gradually pressing down the brake pedal, check that the air pressure starts to rise at the pedal height (dimension A) of 135.5 ±10mm. (5.33±0.39in.) If the air pressure rising point is out of the above range, adjust the free play of the pedal. For adjustment of the free play, refer to "Adjustment of free play".
Discharge pressure (kgf/cm2)(psi)
B
６５ＴＭ５２０１２
85Z Ⅳ -2
Checking Air Master
Brake 52
Checking Air Master WARNING Unexpected movement of machine may cause serious injury or death. When checking the braking performance while operating the engine, observe the following items to prevent an accident: ・ Park the machine on a level ground. ・ Apply the parking brake. ・ Block the tires with chocks to prevent the wheels from moving. ・ Determine the signals between the persons related to this work for engine starting to prevent an accident.
Checking of air master without removing it from machine
Possible cause
Solution
Air piston or hydraulic piston stuck
Check and repair
Hydraulic piston oil seal broken
Check and repair Check and repair
Air piston seal broken *
5
1 2 6
Brake piston port
Air master port
4
3
Auto-adjuster valve
49 196
392
588
785
981
5.9
2
60 855 50 711
4.9
40 570
3.9
30 425
2.9
20 285
2.0 1.0
10 143 0
0
0 0.5 7
2 28
4 57
6 85
8 114
Brake oil pressure (MPa)
Air pressure (KPa) Brake oil pressure (kgf/cm )(psi)
Note : There is one air master for the front brake circuit and one for the rear. This test should be performed first for one circuit then repeated for the other circuit. ・ Gauge for air pressure 2 Pressure gauge : Approx. 981kPa (10kgf/cm )(142psi) (For pressure gauge measuring port and outlet port, refer to "Checking brake valve".) ・ Gauge for oil pressure 2 Pressure gauge : Approx. 9.8MPa (100kgf/cm ) (1,422psi) ・ Pressure measuring port Remove air bleeder (5) of the auto-adjuster valve, and then install the pressure gauge to the bleeder position. Size of air bleeder port : M10 ×1.0 ・ Measuring procedure Gradually (and quickly later) press down the brake pedal to check that the oil pressure smoothly rises in proportion to the air pressure. Gradually (and quickly later) release the brake pedal to check that the oil pressure smoothly drops to zero in proportion to the air pressure. In addition, visually check the brake for air and oil leakage. ・ Measured value Refer to the standard performance curve shown in the right figure. ・ When the measured value is not correct compare to the standard performance curve, check the following points. (When the air pressure is normal).
10 142
Air pessure (kgf/cm2) (psi)
Standard performance curve ６０ＴＭ５２０１３
Note air will leak out the breather on the air * master while the brake is applied.
52-35
85Z Ⅳ -2
Checking Air Master
Brake 52
Checking of air master removed from machine: ・ Gauge for air pressure 2 Pressure gauge : Approx. 981kPa(10kgf/cm )(142psi) Measuring port: Install a T-joint to the air inlet port of the air master air cylinder, and then install the pressure gauge to the T-joint. Measuring port size : PT3/8 ・ Gauge for oil pressure 2 Pressure gauge : Approx. 9.8MPa (100kgf/cm ) (1,422psi) Measuring port: Install the pressure gauge to the brake oil outlet port of the air master. Measuring port size : PF1/2 O-ring ・ Brake oil 1)Before installing the brake oil pressure gauge, fill the cylinder with brake oil through the brake oil outlet port. 2) Install the hose and the brake oil tank to the brake oil inlet port (PT 1/2), and then allow brake oil to flow in through the tank port. Brake oil・ ・ ・ ・ ・ ・ ・ ・Class CD, SAE 5W engine oil or Mobil Delvac 1
Air cylinder section
Hydraulic cylinder section
413
11 Reservoir tank 7 9 8
2
Air gauge Air
Fill with brake oil
T-joint Air inlet port
IMPORTANT Do not use vegetable oil or DOT 3 brake fluid for the brake. The seals between the air master and the brake piston may be deteriorated or damaged. Be sure to use mineral oil (Mobil Delvac 1) for the brake.
Oil gauge
10 14
6
Brake oil outlet port
5 12 13
・ Measuring procedure While gradually (and quickly later) feeding air, check that the oil pressure smoothly rises in proportion to the air pressure. While gradually (and quickly later) discharging air, check that the oil pressure smoothly drops to zero in proportion to the air pressure. In addition, visually check the brake for air and oil leakage. ・ Measured value Refer to the standard performance curve on the previous page. ・ When the measured value is not correct compare to the standard performance curve, check the following point. (When the air pressure is normal). Possible cause
Solution
Air piston or hydraulic piston stuck
Check and repair
Hydraulic piston oil seal broken
Check and repair
Air piston seal broken
Check and repair
※To repair the air master, refer to page Section 54 and the following pages of another section, "Disassembly and Reassembly".
52-36
85Z Ⅳ -2
Checking Wear of Service Brake
Brake 52
Checking Wear of Service Brake Friction Plate WARNING
IMPORTANT
Unexpected movement of machine may cause serious injury or death. To prevent such an accident, observe the following items before checking the brake valve: ・ Park the machine on level ground. ・ Apply the parking brake. ・ Stop the engine. ・ Determine the signals between the persons related to this work for engine starting to prevent an accident. ・ Prohibit any person from walking into the dangerous area.
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 should be disassembled.
A
200 mm (8") Slide calipers
Turn the planetary gear so that the oil supply plug is positioned at the top. Check that the teeth of steel plates are as shown in the right figure (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 and the air pressure is in the green zone. The wear limit for dimension A is 25.1mm. Note that dimension A is 29mm when the plate is new and unused.
IMPORTANT To replace the friction and steel plates only, loosen the air breather nipple, and release the internal pressure from the line between the brake piston chamber and auto-adjuster valve. In addition, check that the return spring resets the brake piston to the initial (fully retracted) position. After that, install new plates. If you do not follow the above procedure, the friction plates may be seized in a short operation time.
52-37
Oil inlet port
Inner steel plate teeth
Outer steel plate teeth
Hint : To aid quick measurement on the front axle-raise the front of the machine so the front tires clear the ground by about 25mm (1 inch). This allows easy rotation of the wheel to align the gear teeth.
Adjusting Parking Brake Clearance
85Z Ⅳ -2
Brake 52
Adjusting Parking Brake Clearance WARNING
Drum rotational direction for forward traveling
Unexpected movement of the machine may cause serious injury or death. The adjusting parking brake clearance requires the parking brake to be released. So, to prevent accidental movement, observe the following items: ・ Park the machine on level ground. ・ Block the tires with chocks to prevent the wheels from moving. ・ Place the bucket to the ground. ・ Stop the engine, and then remove the starter key. Place "DO NOT OPERATE!" tag on the steering wheel. ・ Prohibit any person from walking into the dangerous area.
Brake lining
Brake shoe
Brake drum A
B
B
If the machine moved during parking brake performance check, judge that the clearance between the brake drum and the lining is too large.
A
Brake shoe expansion direction A-A Adjusting screw
B-B
Adjusting clearance 1. To rotate the brake drum during adjustment, lift the front and rear wheels on one side (or both sides) using safety blocks or the like. 2. Turn the inspection hole of the brake drum approximately 8°clockwise from the vertical position as shown in the right figure. After that, turn the adjustment screw to adjust the clearance. Turn the adjustment screw clockwise (upward) to expand the brake shoes until the linings come in contact with the brake drum. After that, turn the adjustment screw 8 notches counterclockwise (down). The clearance will be adjusted to 0.23mm. Adjustment range・ ・ ・ ・ ・0.1 to 0.25mm 3. After the adjustment, check the performance of the parking brake by referring to "Checking braking performance".
Checking brake lining for abrasion loss 12 rivets are inserted to fix the lining to the brake shoe. If the distance from the lining to the rivet head "B" is 0.8mm or less at one of the 12 rivet areas, replace the shoe assembly.
Top
Inspection hole
Approx. 8 °
2nd propeller shaft ８５ＺⅣＵＳ５２０４
For replacement of shoe assembly refer to Section 54, "Disassembly and Reassembly". Rivet
Brake shoe
A Brake lining
Lining thickness A : 6.15mm Wear limit B : 0.8mm Shoe
Rivet
B
Abrasion limit
Lining
52-38
Position of adjustment screw
85Z Ⅳ -2
Brake Line Air Bleeding
Brake 52
Brake Line Air Bleeding WARNING To bleed the brake line of air, the engine should be started to keep the air pressure at the specified range. Unexpected movement of the machine during engine operation may cause serious injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground. ・ Apply the parking brake. ・ Block the tires with chocks to prevent the wheels from moving. ・ Determine the signals between the persons related to this work for engine starting to prevent an accident. ・ If the boom is raised during the service work, be sure to use a safety support. ・ Apply the articulation stopper.
1. Feed brake oil (class CD, SAE 5W or Mobil Delvac 1 engine oil) into the brake oil tank.
IMPORTANT Do not use vegetable oil or DOT 3 brake fluid for the brake. The seals between the air master and the brake piston may be deteriorated or damaged. Be sure to use mineral oil or Mobil Delvac 1 for the brake.
2. Connect the vinyl tube to the air bleeder nipple of the auto-adjuster valve. Outer dia. of nipple 6mm (1/4 in.)
Ａ ｉ ｒｂ ｌ ｅｅｄｅ ｒｎ ｉ ｐｐ ｌ ｅ
3. Each time when pressing down the brake pedal, slightly loosen the nut of the bleeder nipple to slightly discharge brake oil. 4. Repeat the above procedure until no air is in the brake oil. At the completion of air bleeding, close the air bleeder nipple. Repeat this procedure at the other auto-adjuster valve. Note During air bleeding, enough oil should be in the brake oil tank. Be sure to check the oil level of the brake oil tank frequently, and add oil into the tank.
52-39
９０Ｖ５２００２
Brake Line Air Bleeding
85Z Ⅳ -2
Brake 52
5. Connect the vinyl tube to the air bleeder nipple of the axle housing, and place an oil can to catch the oil. Vinyl tube length : 1.2 to 1.3m (4 to 4.5 ft.) Outer dia. of nipple : 7mm (1/4 ″)
Follow the above steps 3 and 4 again. Completely bleed the brake line of air for each wheel by following the above procedure. At the completion of air bleeding, follow the procedure below: 1) Tighten the nut of the air bleeder nipple by applying the specified torque. kg-m Air bleeder nipple of auto-adjuster valve : 10N-m (1.0kgf-m) (7lb-ft) Air bleeder nipple of axle housing : 10N-m (1.0kgf-m) (7lb-ft) ｋｇｍ
52-40
Vinyl tube Air bleeder nipple
ELECTRICAL GROUP 62 How to Use Electrical Wiring Diagram ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-3 Cable Color Codes ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-4 Electrical Wiring Diagram ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-5 Layout of Electrical Equipment ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-13 Electrical Connection Diagram ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-17 Layout of Electrical Equipment Inside Cab Control Box ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-20 Fusible Link ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-21 Engine Start Circuit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-23 Transmission Control and Monitor Circuit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-29 Instrument Panel ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-49 Electric Detent Circuit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-52 Cautions Regarding Electric Circuit Check ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-54 Flow Chart for Troubleshooting of Electrical Transmission Control System ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-56 Judgment of Transmission Controller Abnormal Operation ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-57 On/Off Statuses of Transmission Controller LED Indicators ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-58 Function of Diagnostic System for Monitor Controller ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-62 Checking Shift Lever Input Circuit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-69 Checking Inching Input Circuit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-71 Checking PUS (QUAD) Switch Input Circuit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-73 Checking Speed Sensor Input Circuit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-74
62-1
Checking Clutch Solenoid Valve Output Circuit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-75 Checking Trimmer Plug Solenoid Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-77 Checking Neutral Relay Circuit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-79 Checking Parking Brake Circuit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-81 Checking Engine Stopper Circuit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-82 Checking Gauge Circuit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-84
62-2
85Z Ⅳ -2
How to Use Electrical Wiring Diagram
Electrical 62
How to Use Electrical Wiring Diagram The address method is used for electrical wiring diagrams. For this method, a symbol is attached to each connector and connector terminal in order to easily locate the other terminal where the other end of the cable is connected. Example 1 : Symbol under (or above) connector, such as E9: Shows the address of the connector.
Example 3 : Checking the other connector terminal where F303 LW(Item ③ ) is connected:
① F303 Shows that the terminal is connected to the 3rd terminal of the F3 connector. Check the description in the 3rd terminal of the F3 connector (F303), it shows that the F303 terminal is connected to F618. This means that the 3rd terminal of the F3 connector is connected to the 18th terminal of the F6 connector.
Example 2 : Symbol at the multi-terminal connector, such as 1 and 14: Shows the terminal number and the numbering direction. Example:
② LW １４１３１２１１１０ ９ ８
７ ６ ５ ４ ３ ２ １
２８２７２６２５２４２３２２
２１２０１９１８１７１６１５
Shows the color of the wire"LW" represents that the insulation color is blue, and "W" represents white stripe is on the blue insulation.
２９ ４３ ７０６９６８６７
Horn relay
６０５９５８５７
R relay
N relay
E/G stop relay
Controller unusual relay
② ①
③
65V62001
62-3
85Z Ⅳ -2
Cable Color Codes
Electrical 62
Cable Color Codes Cable color code Color of stripe Color of insulation
Yellow
Green Sky blue Brown
Blue
White
Red
Black
Orange
YL
YW
YR
YB
YO
GL
GW
GR
GB
GO
SbW
SbR
Y
(Yellow)
Y
YG
G
(Green)
GY
G
Sb
(Sky blue)
SbY
Br
(Brown)
BrY
BrG
Br
BrL
BrW
BrR
BrB
L
(Blue)
LY
LG
LBr
L
LW
LR
W
(White)
WL
W
R
(Red)
RY
RG
RL
B
(Black)
BY
BG
O
(Orange)
OY
OG
Lg (Light green)
LgY
LgG
P
(Pink)
Gy
(Grey)
V
(Violet)
YSb
YBr
Sb
Pink
SbO
SbLg
SbP
LB
LO
LLg
LP
WR
WB
WO
RW
R
RB
RO
RLg
BL
BW
BR
B
BO
BLg
OL
OW
OR
OB
O
LgL
LgW
LgR
LgB
PG
PL
PW
GyG
GyL
GyW
WG
GyY
Light green
RBr
LgSb
LgBr
PB GyR
GyB
Grey
Violet
YGy
YV
WV RGy BP
Lg P Gy V
Insulation color Stripe color
62-4
Electrical Wiring Diagram (1 / 2) (85ZⅣ)
Electrical Wiring Diagram(1/2)(85ZⅣ )
85ZⅣ‑2
Electrical 62
(S/N 85C3-5501〜5600)
62-5
Electrical Wiring Diagram (2 / 2) (85ZⅣ)
Electrical Wiring Diagram(2/2)(85ZⅣ )
85ZⅣ‑2
Electrical 62
(S/N 85C3-5501〜5600)
62-6
ELECTRICAL WIRING DIAGRAM (1 / 2) (85ZIV)
85ZⅣ‑2
ELECTRICAL WIRING DIAGRAM (1/2)(85ZIV)
Electrical 62
(S/N 85C3-5601〜5700)
DECLUTCH HAZARD S/W
1 3 4 6
2
1 3
2
REAR WORKING LAMP
T/M CUT OFF S/W
5
7
4
5
6
7
4
5
6
8
1
2
3
8
1
2
3
EP
RO RO BP B503 G109 E802
LgY A603
B
Gy GyW GyR LgW D607 D610 D609 F402
RBr RBr BP B502 G119 E802
LLg LgR D504 C402
WB WP C608 G126
4
1
4
A0
1
4
TT
WT
+
ES
B
AP
CE
(+)
C
4
5
WTM TTM APM
+
FM
GND
-
YBr G125
B
Lg O O C609 B901 B902
1
A2
DD
RB WG G129 G813
LgL GyL GyG D608 D605 D604 1
A1
AC
YB YSb YV G105 G115 G820
A
2
3
4
P
W
LB LY D612
LG
LO
LW
SbW B302
GyB D601
GR D602
LP D611
Lg C609 6
1
10
A3
N 1
1
A4
TM
TM
GND
H
TC
PH
L
R
RY RBr B506
B
WL
RO RGy A805
Lg C609
1
1
8
A5
A6
2
1 3
7
4
5
6
7
4
5
6
8
1
2
3
8
1
2
3
R RGy C613 A601 G117 RLg RLg D102 C102
B
LgY A206
WB WB G806 G812
HM
CAB WORKING LAMP
1 3 4 6
2 INSTRUMENT PANEL
GND
COLD STARTER
4
RLg RLg D105 C108
L G F601 F602
1
A7
R W F603 F604
4
1
A8
B
A9
B
B1
SHIFT LEVER HORN S/W GW
GL
PARKING S/W
G
B
L
GR
GB
G Y B
R2
C
A INPUT
B OUTPUT
G F
R
1
2
3
A
P
I
AM
G
+
A
B
AP
AC
EP
TT
WT
BZ
NL
(BLUE)
W MR A/M GNDTXD
GR GR
LW BY D506 D502
RY RW RB A612 G108 G129 F501 RO RBr P A107 A103 E702 B002 B004
LY LG LO D509 D508 D507 1
3
B5
GR
WR
WR
BG
WB
WB
G
W
WBr C906
W C904 D401 W G601
E
AP
B
GyR Y LgL Gy G802 G818 G103 G814
SS
AC
EP
TT
WT
EA
BL
S
F
GyL GyG WL V YL G113 G124 G107 G114 E101
R
1
2
3
4
D
NR
RR
X
LR LBr LY LG LO LW LP SbP LB LgW G704 G703 G708 G707 G706 G705 G701 F104 F204 F404
LR LBr LY LG LO LW GO LLg GyW BY,Y L B403 B402 B409 B408 B407 B406 B306 A202 G123 G101
W
WR WR G C901 C903 C902 4
1
B3
BW
11
E102 B304 B401 B405 C401 G824
D5
1
LP GyW GyR LgL Gy A608 A307 A306 A303 A308
COM
FUSE BOX R5
FUSE BOX R5
R5
R5
R5
RL RG LR LW YR YW
B9
O O A409 A408
1
2
3
4
5
6
7
8
W
R
Y B E201 E301 E401 G102
L
G
Br
O WR
1
CAB RBr RBr B502 G119
6
1
B0
13
14
15
16
17 18
19 20
21 22
23
W
R
B
L
G Br
O WR RL RG LR LW YR Y W
O
WR
RG
YR
YW
B
L
RL
LR
LW
RG
LR
LW
YR
YW
WR
R5
YW
YR
LW
G
Br
R
Y
B
L
G
Br
O
R5
R5
LR
RG
RL
W
R
Br
R
L Lg G101
A410 A506 A701 WR G WR E601 G809 F102 G801 F201
R
R
WBr B706
C110 E501 E803 E901 E902 7
PB PL OR OL RLg G816 G822 G821 D108 A801
G
WBr C109
WB A006
1 C502 E703 F202 C6
C1
G301 G302 G401 G402 G501 G502
R
C7
W B802
Y
24
OL OR O C103 G821 C107
G301 WR G WR G302 B702 B701 B703 G401 G402 G501 3 1 G502
RLg A906
25
26
27
28
29
1
30
R5 R5
R5
YW
R
R
W B802
G301 G302 G401 G402 G501 G502
RLg A802
5
C9
C8
Y
R
D2
D1
G301 G302 G401 G402 G501 G502
D3
D4
SHIFT S/W NEUTRAL RELAY
HORN RELAY BUZZER DECLUTCH
BRAKE LAMP
BZ
B
Br C612
Br C612
Br
Br
1 (BLUE)
E1
R P C611 B501
G BP C607 A105 A101
B
1
2
Lg C609 G C607
RG G127
1 C4
Br C612 1
R C611
2
FLASHER UNIT (HAZARD)
R
G122 BrW
1
G
FLASHER UNIT (WINKER)
PILOT VALVE G112 BrB
GR
LgR BY A201 D502
BrB E2
BrW E3
E4
E5
1 E6
RL G807
GW GL G128 B602 2
SbP D615 G Lg C602 D612
G G C607 C607
3
1
B
LB D614 RL R Lg G137 C611 C609 3
3
1
R B601
W R B103 B104
RY RY G118 B506
G L B101 B102 1
2
F2
F5
F4
G7
5
G3
G4
G5
F6
A403 YB
1
1
1
4
A402 D513 D516 E202 B303 YSb V GyL BrB LgG
R
A417 D515 D503 E302 YBr GyG GyW BrW
R
C701 C801 C802 D201 D301 D302
R R
C701 C801 C802 D201 D301 D302
R R
G8
G6
1 D501 D519 C612 C610 LgL Br L
36
35
31
2
WY G803 1
F1
E9
E8
C5
6 B001 A106 B505 D514 RO RW WL B003 F703 A102 F502 A805 GL RBr RY RGy B504 F702 A420 E904 C501 A005 GO RB GW RG WP
GL GO G120 G130 1
2
1
E7
1
6
D622 D621 D612 D616 LR LBr LB LP C701 C801 C802 D201 D301 D302
B801 W
D620 D619 D618 D617 LY LG LO LW
F203 RL 40
B
LgW D613 LgW Lg A305 D612
1
G1
10
CONTROLLER UNUSUAL RELAY
BACK LAMP RELAY
S/W
YL
INCHING S/W
BY
1
11 12
W
D603 LgBr
RO RO B503 G109 2
10
RL
R R B601 A806
O G WBr RLg C607 C605 A905 D106
9
24
4
3
1
A606 WB
F701 D521 C601 WY GyR WR
A605 WB
C603 WR
D520 Y
C106 PB
D502 Y
C105 PL 22
F106 RL
D518 A419 Gy WG C104 D107 A401 OR YV 21 19
62-7
F7
MC E A512 F101 F401 G702
1 D6
B8
R5
LB
GyL GyG LgBr GR GyB A302 A301 E602 A501 A616
11
1 B7
D512
B
R
D502
BY D502
GW
RY
B4
B602
GO D505
GB
RB
1
R
G
GL
LR LBr BY D511 D510 D502
3
GL
L
LgG SbW G111 A507
BG
WRx2 WBx2
BR B ACC
STARTER SWITCH
R
3
R1
W3 W5
E903
Y
STARTER S/W
BW
B
C614 F503
B
COMBINATION S/W
B601
R
T/M CONTROLLER UNIT
GY
DDI DDOOPT
RXD SPI SPO
ELECTRICAL WIRING DIAGRAM (2 / 2) (85ZIV)
85ZⅣ‑2
ELECTRICAL WIRING DIAGRAM (2/2)(85ZIV) J501 R102 R404 R604
FRONT HEAD LAMP(OUTSIDE) H101
40
24 36
35
GW RG WP J505 R401 N601 R601 GL RBr RY RGy K507 J504 J503 R103 R701 RO RW WL J508 J507 N701 R301 10 6
H2 J503
4
1
YSb V GyL BrB LgG K301 K505 K201 J511 J602 YB L301
Y L902
22 PL L703
Y L901
PB L702
21
19
OR YV L701 J801
WB L802
Gy WG L102 N503
R N102
R N102
R N102
RL N501
R N102
R N102
R N102
WR M001
WY GyR WR M901 J901 N504
WB L801
LgL Br L K504 J502 J601 K101
6
5
4
1
3
GW RBr RY G128 G119 G118 B K501
F
2
R
-
2
1
-
1
2
C
PARKING SOLENOID
SPEED METER SPEED SENSOR
M3
1
2 1
2
M4
3
RB J501 (OPT)
-
+
1
2
K1 AIR DRYER
4
-
J503 T/C OIL TEMP.S/W
2
RW
J507
RY
J503
G113
D
-
H901
WR G809
1
2
M9
W RL RGy G137 G117
G115 AIR MASTER
B
2 (WHITE)
J2
B
B
BrB J511
BrB
N1
E/G WATER TEMP.S/W
FUEL LEVEL
GW J505
J4
Y
1
L6
C GyB GyW P101 G123
AIR MASTER
NO
B K501
GL GO K507 K506
2
B
K901 K601 K802 BrR LgL V K703 K702 GO GL
B
3
J510 B
G114 G103 N602 V LgL BrR
2
(COLD STARTER)
G137
R502 B N302 N002 N003
BACK LAMP R503
RL
G137
R504 B
R6
ALTERNATOR 1
2
G
B
REAR COMBINATION LAMP
R R7
2 GyB WL M801 N502
G120 G130 GL GO B
2
TURN SIGNAL LAMP (OPT)
B
P102 G107 P1
BATTERY +
GyB WL J702 N701 1
1 L4
COMBINATION LAMP
BACK LAMP R501
N5
1
L501 B
G124 GyG
B
RL
2
K5
K8
K9
WL N402 N506
B B N508 N508
B
DIODE UNIT
E/G WATER TEMP. S/W
L502 L503 R Y
1
BrR K503
WG N503
RL WL G807 P102
1 1
K701 B
WG N503
WG WR G813 G801
L5 2
RL N501
2
L503 L501 L502 B R Y
1
1 ETHER INJECTION VALVE
NC
1 1
K7
B
REAR
3 WL N502
W G601
J7
1
BRAKE OIL TANK
2
1
STARTER
2
V K505
4 2
N901 N004 RL WL N902 N001 N401 WG WR N402 N004 WL B
N301 WV N506 N504 N004 WR WL
B
1
2 FAN MOTORS TO AIRCON CONDENSER (OPT)
1
1
N4
S
(WHITE)
2
B
B
2 K6
B
BATTERY RELAY
N8 YBr G125
TURN SIGNAL LAMP (OPT)
B
1
R
2 B N508
R G301 G302 G401 G402 G501 G502
J3
B AIR CLEANER
R3
N9 1
FUSE BOX
1
AIR HORN
1
R4
BOX
B
LgL K504
2
2
VOLTAGE RELAY N0
FUSE
B
2
MAGNET S/W
WV N403
70A
N2
(OPT)
N3
B
G129 RB
BrB
30A
1
K503
W
Br
G126
B
W
Br J502
WP
KICKOUT
Br
M8
GyB P101
L3 G105
RB G129
R
FUSIBLE LINK
70A
E/G WATER TEMP. S/W
1
YB
R
FUSIBLE LINK
B
70A
Br J502
2
1 R206 R205 R204 RB B R202 R203 R201 RL RGy
1
BrR
BUCKET POSITIONER
2
R1 YSb
B
(OPT)
R101 J9
M0
K3
L
LICENSE LAMP
RB B
G802
BW
J1
BrW J512
R205
M7
T/C OIL TEMP.SENSOR
Br
GyR
LOW PRESS. S/W
2
H902
R
J8
1
LP LB G701 G702
+
BACK BUZZER (OPT)
G820
R206
G814 Gy
M6
K2 GyL
W
WY G803
L1
FRONT HEAD LAMP(OUTSIDE)
YV
AIR PRESS. SENSOR
R102
1
LB LW G705 G702
+
R203 R204
2
RY
A/C REFRIGERANT COMPRESSOR (OPT)
B
H8
R103
L9 1
2
L201 B
M5
Br G102
AUTO SHIFT SPEED SENSOR
2
LgG LO LB G706 G702
Y Y G824 G818
L202 L203 R Y
J504
FRONT HEAD LAMP(INSIDE)
RGy
W
3
L2
1
REAR LAMP R202
B
H702 H703
R
LG LB G707 G702
+
L8 1
2
1
RBr
-
WB WB G812 G806
B
2
LAMP (OPT)
J501
2
J6
G
L203 L201 L202 B R Y 1
R103
GR
H701 COMBINATION RB
LgG L G111 G101
B
RGy
W
G
R
REAR LAMP R201
B
NC
FUEL VALVE
L
P
NO
L7
PL G822
(BLUE)
H602 J505
PB PL
3 B
M2
LY LB G708 G702
+
H601
B
4
1
LBr LB G703 G702
+
J505
HORN(H)
GW
-
MOTOR (OPT) R
BrW BrB G122 G112
+
WASHER
M1
LR LB G704 G702
+
RO RW G109 G108
H502 GW
-
BATTERY
PB OR G816 G821
F
YG
B
E/G OIL PRESS. S/W
OR
1
2 T/M SOLENOID VALVE
B
H501
1 Br RB G102 G129
GR
RW RO H101 H302 H901 BrB BrW J202 J102
(OPT) B
RBr H702
2
H502 H602 J401
G
RY
Br J103 J203 GW
YG
H4
J5
2 RB
R101 B
H102 H201 H801 H902
1
B
J501
G6
B
H303
RB
G5
R104 RL
H302
RB J501 (OPT)
HORN(L)
G4
G129 RB
J508
G3
1
RO
H301 H303 H401 H701 H703
WL
COMBINATION LAMP (OPT)
1
1 G8
J501
1
1
G1
H301 RB
W N201
G7
G109 RO
RY
LR LBr LB LP M102 M202 M101 M702 〜701
YBr GyG GyW BrW L602 L401 J701 J512
GO RB K506
FRONT HEAD LAMP(INSIDE) R
LY LG LO LW M302 M402 M502 M602
31
RL
1
J503
G127 RG
J507
RY
G127 RG
RW
H102
R
(S/N 85C3-5601〜5700)
R104 R501 R503
G119 RBr
W
Electrical 62
2
N7
N6
2
62-8
ELECTRICAL WIRING DIAGRAM (1 / 2) (85ZIV)
ELECTRICAL WIRING DIAGRAM (1/2)(85ZIV)
85ZⅣ‑2
Electrical 62
(S/N 85C3-5701〜5800)
62-9
ELECTRICAL WIRING DIAGRAM (2 / 2) (85ZIV)
ELECTRICAL WIRING DIAGRAM (2/2)(85ZIV)
85ZⅣ‑2
Electrical 62
(S/N 85C3-5701〜5800)
62-10
ELECTRICAL WIRING DIAGRAM (1 / 2) (85ZIV)
ELECTRICAL WIRING DIAGRAM (1/2)(85ZIV)
85ZⅣ‑2
Electrical 62
(S/N 85C3-5801〜)
62-11
ELECTRICAL WIRING DIAGRAM (2 / 2) (85ZIV)
ELECTRICAL WIRING DIAGRAM (2/2)(85ZIV)
85ZⅣ‑2
Electrical 62
(S/N 85C3-5801〜)
62-12
Layout of Electrical Equipment
85Z Ⅳ -2
Layout of Electrical Equipment The connector numbers in the following figure correspond to those of electrical wiring diagrams.
Front chassis
62-13
Electrical 62
Layout of Electrical Equipment
85Z Ⅳ -2
Floor board and cab
62-14
Electrical 62
Layout of Electrical Equipment
85Z Ⅳ -2
Rear chassis(1/2)
62-15
Electrical 62
Layout of Electrical Equipment
85Z Ⅳ -2
Rear chassis(2/2)
62-16
Electrical 62
Electrical Connection Diagram 85Z Ⅳ
85ZⅣ‑2
Electrical Connection Diagram 85ZⅣ
(S/N 85C3-5501〜5600) B
STARTER SWITCH
W F10 LR
L
1
30A F6 (Lg)
BATTERY WR
F15
WL
5A
2
BR' LO
RELAY, BATTERY
5A
5A
F12
G1.25 F14
LG
5A
3
G1.25 70A
LW COLD STARTER SW
F7 15A
WB
THERMO SW
4
ETHER KIT
RB
(BY) 12
(SbP)
NR
RR
RL 1.25
40A
F6
(Lg)
LAMP, CHARGE
WL
(Gy)
MONITOR CONTROLLER
(GyG)
ALTERNATOR 70A
B
(GyL)
GAUGE, AIR PRESS HOUR METER
(YV)
3
LO
A
LW
(GO) P (YL)
3 1 5 2 WIPER RELAY 4
WASHER MOTOR PB
F18
SPEEDOMETER FOR OPERATION PANEL LAMP
(RB)
OL
6
M
PARKING SWITCH SHIFT SWITCH
S SENSOR (Y) FOR SPEED
(WB)
E
(WB)
SWITCH COMBINATION T
F1
R 1.25
+
(BY)
(RY)
H
20A
HIGH BEAM PL
F3
1.25
L
RY
R WIPER
RIGHT HEAD LIGHT(H)
F23 Br
BrW
BUCKET POSITIONER
10A
B WASHER MOTOR M
PL
RLg
RLg
RLg
RLg
S 1 S2 WASH WIPER SW.
REAR LEFT WORKING LIGHT
10A
REAR RIGHT WORKING LIGHT
RIGHT HEAD LIGHT(L)
RW
1.25
(Y)
BrB
RY
F21
KICK OUT
LEFT HEAD LIGHT(H)
WORKING LIGHT PL
10A LEFT HEAD LIGHT(L) F2
RR
AM
B
BL
AP
AP
EP
EP
WT
WT
GyW
V
REAR LEFT WORKING LIGHT
TANK RESERVOIR
REAR RIGHT WORKING LIGHT R
F4
GyR
F20 10A
AIR DRYER(OPT) BR'
WORKING LIGHT O
E
RL LAMP, BACK
AIR PRESSURE
15A
RR
RADIO LAMP, BACK
Gy E/G OIL PRESSURE
BACK BUZZER(OPT)
GyG
TT
FLOAT
WORKING LIGHT PL
SWITCH WORKING LIGHT RGy
10A
AIR MASTER
WORKING LIGHT
(RGy)
R
E/G WATER TEMP
SWITCH, STOP RG
R E
GAUGE, FUEL
S 2 S3 B WASH S int S 1
5A
NR
(GyR)
VOLTAGE RELAY
(WG)
(YBr)
LG
2
SS
(GyW)
NR
T/M GAUGE, OIL TEMP
3 A
X (LB)
(YSb)
F WIPER
WIPER SW.
M
LAMP, LEFT TAIL
LgW
X
L
E/G GAUGE, WATER TEMP
LAMP, RIGHT TAIL
C
MAGNETIC SWITCH
(YB)
WIPER MOTOR M
OR
10A
LY
1
D
B
N F
R (BY)
WP STARTER
B
LBr
R
SIFT LEVER
C O N T R O L L E R
R LY
12V
LR
F
F
F19
FOR OPT LAMP F6 (OPT) FOR OPT LAMP (OPT) RIGHT FRONT MACHINE WIDTH LAMP LEFT FRONT MACHINE WIDTH NUMBER LAMP(OPT)
(BY)
10A
LBr
BR R1 B AC R2 C
BR' (Lg)
L
15A
B BRACCR1 R2 C
12V
W5
E
BR'
PARKING SOLENOID F5
PRHEAT OFF ON START
Electrical 62
GyL
TT
F12
(WBr)
RIGHT BRAKE LAMP
T/M OIL TEMP
CONVERTER (24) 4 2 1
5
3 6
LEFT BRAKE LAMP (LgL) F13
WR
5A
FUEL VALVE
(LP)
AUTO
P X FLASHER UNIT L (FOR WINKER)
LgL
AC
AIR CLEANER
AC
A
P
A/M SWITCH A/M
(GR)
N
N
WL EA
(GyB) B
BR'
L
ALTERNATOR TERMINAL N
W LLg
I
(BY)
BZ BUZZER
T/M CUT OFF
(RO)
RIGHT WINKER PL G
RIGHT FRONT WINKER
RO
F10
ROOM LAMP
RIGHT REAR WINKER
RBr
(RBr) LEFT WINKER PL
FLASHER UNIT (HAZARD) G BP X L P
(LgR)
E
SWITCH COMBINATION F R RO
BR'
E
LEFT FRONT WINKER
RBr
CAB
LEFT REAR WINKER
LgBr (GL)
SWITCH, HORN
(LgY) GW (LgW)
G
X BR'
CONTROLLER SELF-DIAGNOSIS ON
(GO)
CONTROLLER
15
5A
30
20A
14
5A
29
20A
(Lg)
F6
(SbW)
RELAY, HORN
HORN E
(BY)
OFF ON
24
3A
22
5A
11
15A
10
15A
9
15A
8
15A
23
10A
7
15A
10A
27
5A
5A
21
10A
5
10A
20
10A
4
15A
19
10A
3
10A
18
5A
2
10A
17
5A
1
20A
16
5A
(Rear)
SPARE
6
SPARE
SPARE
5A
12
20A
PARKING SWITCH
LgG E
SPARE
5A
5A
PARKING SOL
SPARE
26 25
13
L
SPARE
SPARE
28
SPARE
OFF
F5
８５Ｖ６２００５
(Front) 62-17
Electrical Connection Diagram 85Z Ⅳ
85ZⅣ‑2
Electrical Connection Diagram 85ZⅣ
Electrical 62
(S/N 85C3-5601〜5800)
STARTER SWITCH B
BR
ACC
○
○
○
○
○
○
C BR'
ON START
E
B
BR'
E
BR' FOR OPT LAMP (OPT)
W
10A
(BY)
○ F
F R
LBr
LB
LR
12V
12V
1
C O N T R O L L E R
WL
BATTERY LG
2
5A
(WBr)
G1.25
LO
BATTERY RELAY
5A
F12 (WBr)
G1.25
3
TO CAB
70A
LW COLD START SWITCH
F7 15A
WB
THERMO SWITCH
4
1 2 3 A
P
S LP
NUMBER LAMP (OPT)
D SS
HOUR METER
TACHO METER
LO
FOR INSTRUMENT PANEL LAMP
(RB)
NR
5A
BW5
(GO)
PARKING SWITCH
RR
VOLTAGE RELAY
(WG)
(LB)
R1.25
+
(RY) 1.25 RY
H
20A
L
(BY)
HIGH BEAM PL
RW
F3
RIGHT HEAD LIGHT (H)
SENSOR FOR SPEED
Br
F23 RLg
BrW
(GyW)
15
70A
MONITOR CONTROLLER
10A
BOOM KICKOUT
F21 RLg
REAR WOKING LAMP PL
FLOAT
F21
REAR WOKING LAMP
AIR DRYER (OPT)
10A
BrB
LEFT HEAD LIGHT (H)
RLg REAR WORKING LAMP
(RGy)
WORKING LAMP SWITCH RGy
RLg
B
1.25 WR
(Gy)
(GyG)
15
AM
GyW
F4
AIR MASTER
B
BL
AP
AP
EP
EP
WT
WT
TT
TT
(GyL) FUEL VALVE
WORKING LAMP
O
GyR
BR'
AC
E
AC
A
(GR)
N
BACK BUZZER (OPT)
GyG P X L
E/G WATER TEMP GyL
T/M OIL TEMP
LgL
AIR CLEANER
A/M SWITCH
ALTERNATOR TERMINAL N
I
LLg
(LgR)
BZ
13
5A
28
20A
12
5A
27
5A
COMBINATION SWITCH RO F R RBr
X L P
(RO)
RIGHT FRONT WINKER
F10
LEFT WINKER PL RBr
BR'
G HORN RELAY BR'
HORN SWITCH
HORN E
SPARE
X
CONTROLLER SELF-DIAGNOSIS 26
5A
15A
25
5A
24
10A
SPARE
9
SPARE
15A
F6
7
15A
22
3A
6
5A
21
10A
5
10A
20
10A
4
15A
19
10A
3
10A
18
5A
2
10A
17
5A
1
20A
16
5A
(Rear)
(BY)
OFF ON
L
PARKING SOL LgG
PARKING SWITCH E
SPARE
10A
(SbW)
SPARE
23
SPARE
15A
(Lg)
OFF F5
8
ON
(GO)
CONTROLLER
6
ROOM LAMP
G
CAB
LEFT REAR WINKER
(LgY) (LgW)
3
E
LEFT FRONT WINKER
GW
LgBr
5
RIGHT REAR WINKER (RBr)
(GL)
4
RIGHT WINKER PL
RO
BP
(BY)
2 1
T/M CUT OFF
BUZZER
(WBr)
LEFT BRAKE LAMP
FLASHER UNIT (FOR WINKER)
FLASHER UNIT (FOR HAZARD) G
WL
F12 RIGHT BRAKE LAMP
W
20A
20A
CONVERTER (24 → 12)
RG
E/G OIL PRESSURE
N
(GyB)
CENTRALIZED WARNING LAMP
29
RADIO BACK LAMP
AIR PRESSURE
Gy
A/M
EA
5A
BACK LAMP
RR
L
(LP)
AUTO
14
E
RL
TANK RESERVOIR
P (LgL)
30
R
15A
V
WR
5A
10
WORKING LAMP
10A
STOP SWITCH
R E
15A
WIPER SWITCH
RIGHT HEAD LIGHT (L)
1.25 RY
R
10A
BR'
WL
(GyR)
11
WASH
REAR WORKING LAMP
BUCKET POSITIONER
10A
X
RR
ALTERNATOR
SPARE
B
(WB) WASHER MOTOR PL M
BR' (Lg)
CHARGE LAMP
5A
(WB)
REAR WOKING LAMP
F6
15
R WIPER
S1 S2
T
F1
SHIFT SWITCH
NR
LgW
X
WIPER MOTOR M
6
COMBINATION SWITCH
F2
(SbP)
OL
E
LW
NR
B
F18
LEFT HEAD LIGHT (L) F6 (Lg)
3
2 WIPER RELAY 4
6
5A
Y
RL1.25
F13
M
5
PB
GAUGE, AIR PRESS
(YV)
LG
Y
1
WASHER MOTOR
LY
(YL)
F WIPER
S2 S3 WASH B Sint S1
GAUGE, FUEL
23A
B C
MAGNETIC SWITCH
T/M OIL TEMP GAUGE
(YBr)
LAMP, TAIL 1
ETHER KIT
WP
(YSb)
SHIFT LEVER
(BY)
M
WIPER SWITCH
LAMP, TAIL
STARTER
SPARE
F14
WR
5A
E/G WATER TEMP GAUGE
MACHINE WIDTH
RB
(BY)
OR
10A (YB)
MACHINE WIDTH
B
LBr
R
LY
30A 1.25 WR F15
E F19
(Lg)
F6
FOR OPT LAMP (OPT)
R N F
R1 BR B AC R2 C
BR' WIPER MOTOR
L
LR
W5
E
PARKING SOLENOID F5
F10
○
15A
OFF
(Front)
62-18
Electrical Connection Diagram 85Z Ⅳ
85ZⅣ‑2
Electrical Connection Diagram 85ZⅣ
(Rear)
Electrical 62
(S/N 85C3-5801〜)
(Front) 62-19
85Z Ⅳ -2
Layout of Electrical Equipment
Electrical 62
Layout of Electrical Equipment Inside Cab Control Box
3
4
1
2
5
6
６５Ｖ６２００６
1. Transmission controller 2. Fuse box 3. Fuse box 4. Buzzer 5. Horn relay 6. Relay
62-20
85Z Ⅳ -2
Fusible Link/Fuse
Fusible Link/Fuse For the purpose of protection, the electrical circuit has fusible link and fuses.
CAUTION Possible burn hazard. Before replacing a fuse, be sure to turn off the starter switch.
IMPORTANT Replace a fuse with the same capacity. If a fuse blows immediately after replacement, the electric system is defective. Localize the defective part, and then repair it.
Fuse inside the control box
Ａ Ａ
BUZZER MONITOR
Ａ Ａ ５
Ａ ５ Ａ ５ Ａ ５
BATTERY RELAY
Ａ
２０
NEUTRAL RELAY
５
２０
FUEL VALVE
５
２０ Ａ Ａ Ａ
(Front)
Ａ ５
Ａ
RADIO
Ａ ５ １
Ａ
SPARE
Ａ ５ １
Ａ ３
SPARE
AIRCON(OPTION)
Ａ ５ １
4WAY FLASHER HORN ROOM LAMP
SPARE
AIRCON(OPTION)
１５
１０
SPARE
SPARE
AIRCON(OPTION)
１５
１０
SPARE
SPARE
Ａ
１０
R. WORK LIGHT(CAB)
COLD STARER
Ａ
１０
SPARE
Ａ ５
１０
F. WORK LIGHT
Ａ
Ａ
PARKING BRAKE CONTROLLER
SPARE
Ａ
Ａ ５
BACK LAMP STOP LAMP TURN SIGNAL
F. WIPER
Ａ ０ １
Ａ ５
BOOM KICKOUT BUCKET POSITIONER
R. WIPER
Ａ ０ １
Ａ ５
R. WORK LIGHT
Ａ ０ ２
SPARE
１０
LIGHTING HEAD LIGHT
１５
SPARE
(Rear) 62-21
Electrical 62
85Z Ⅳ -2
Fusible Link/Fuse
Electrical 62
Fusible link(fuse)
BATTERY W5
WR
BR R1 B AC R2 C
F15
WL
5A
RELAY, BATTERY
5A
5A
F12
G 1.25 F14 G1.25 70A
The fusible link is located in the box as shown in the following 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 fused 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.
F7 15A
WB
WP STARTER
B
Fusible link
C
MAGNETIC SWITCH RL 1.25
Cover
Fuse element
40A
NR (Lg)
VOLTAGE RELAY
(WG)
F6
LAMP, CHARGE
WL
MONITOR CONTROLLER
ALTERNATOR 70A
F13
B
E
WR
5A
Box for Fusible link
R
FUEL VALVE
Fusible link B
８５ＺⅣ ＵＳ６２０６
BR'
E
８５Ｖ６２００６
Problems caused by fused fusible link Problem (symptom) Fuse damaged 30A
70A (BR line)
During engine operation
During engine stop
・ Horn will not operate. ・ Flasher unit (Hazard-option) will not operate.
・ All the electrical circuit will not function. ・ (Engine can not be started.)
・ Horn will operate. ・ Flasher unit (Hazard-option) will operate. ・ All the others will not operate but engine can be stopped.
・ The same conditions as "During engine operation" but engine can be started and stopped.
70A ・ The machine can be operated but the (Alternator batheries can not be changed and the line) batteries will be discharged soon.
・ The same conditions as "During engine operation".
62-22
85Z Ⅳ -2
Engine Start Circuit
Electrical 62
Engine Start Circuit (S/N 85C3-5501〜5800)
12V
12V
30A
(W5)
Battery F15
(WR ニ) (WL)
5A (WV)
(WR)
Circuit protecter
Shift lever
F
Battery relay
70A
N R
F14
forward/reverse position
Controller
IN
5A
+24V
Cold starter sw (WB)
1
Ether kit
F7 15A
+24V
Thermo sw
(WP) (BrR)
3 Neutral relay
LED (Indication: N)
2
Starter
4
B
C
(R5) (BW 5) Magnetic sw
(WG)
Voltage relay
＊When shift lever is F/R position / LED ON When shift lever is N position / LED OFF
８０Ｖ６２００７
Neutral starting device To prevent the machine from unexpected movement at engine start up, the engine will not start if the shift lever is not in the neutral position (N).
Shift lever forward/reverse 「F」「R」position
Shift lever neutral (N) position When the shift lever is set to the neutral (N) postion, no power will be supplied to the coil of the neutral relay, and the main contact is turned on (switch closed). When the starter switch is turned to the START position, the electric current will flow from the starter switch terminal C to the magnetic switch via the neutral relay. Therefore, current will flow through the starter motor, and the engine will start. The "N" LED will be off.
62-23
When the shift lever is set to the forward or reverse (F or R) position, the neutral relay coil is connected to the ground line of the controller and is energized. Therefore, the neutral relay will be opened. The current from the starter switch will not be transmitted through the magnetic switch, therefore the engine will not start. The "N" LED of the output circuit is on.
85Z Ⅳ -2
Engine Start Circuit
Electrical 62
Engine Start Circuit (S/N 85C3-5801〜)
12V
12V
30A
(W5)
Battery F15
(WR ニ) (WL)
5A (WV)
(WR)
Circuit protecter
Shift lever
F
Battery relay
70A
N R
F14
forward/reverse position
Controller
IN
5A
+24V
Cold starter sw (WB)
1
3
Ether kit
F7 15A
+24V
Thermo sw
(WP) (BrR)
Neutral relay LED (Indication: N)
2
Starter
4 B
C
(R5) (BW 5) Magnetic sw
(WG)
Voltage relay
＊When shift lever is F/R position / LED OFF When shift lever is N position / LED ON
８０Ａ６２２０２
Neutral starting device To prevent the machine from unexpected movement at engine start up, the engine will not start if the shift lever is not in the neutral position (N).
Shift lever forward/reverse 「F」「R」position
Shift lever neutral (N) position When the shift lever is set to the neutral (N) postion, the neutral relay coil is connected to the ground line of the controller and is energized. Therefore, the neutral relay will be closed. When the starter switch is turned to the START position, the electric current will flow from the starter switch terminal C to the magnetic switch via the neutral relay. Therefore, current will flow through the starter motor, and the engine will start. The "N" LED will be on.
62-24
When the shift lever is set to the forward or reverse (F or R) position, no power will be supplied to the coil of the neutral relay, and the main contact is turned off (switch opened). The current from the starter switch will not be transmitted through the magnetic switch, therefore the engine will not start. The "N" LED of the output circuit is off.
85Z Ⅳ -2
Engine Start Circuit
Electrical 62
Starter switch Off
30 °Run 35 ° Start
Connection table BR ACC R1
○ ○ ○
Start
○ ○ ○
R2
C
○ ○ To neutral relay
Run
To battery relay
○
From battery
Off
To heater relay
B
６５Ｖ６２０１４
Function Off: Enables insertion and removal of the starter key. All the electrical circuits (except the horn and hazard flasher 〔opt 〕) will be turned off. Setting the starter switch to this position automatically activates the engine stopper that stops the engine. Run : Supplies power to the charge, lamp, and monitor circuits. Start : Starts the engine.
62-25
85Z Ⅳ -2
Engine Start Circuit
Electrical 62
Battery relay Function When power supply or charging condition (switch is in any position except OFF), the battery relay (switch) is turned on. When the starter switch is set to the off position, the alternator stops generating power, and the battery relay is automatically turned off so that the electrical circuits will not function.
Terminals for coil energizing current
Moving contact Main contacts
BR
If the battery relay was not used, a large amount of current would be directly sent through the starter switch when it is turned on. However , use of the battery relay reduces the amount of current because this relay needs only a small amount of current to energize it.
Coil for energizing
Terminals for main current
Operation When current flows from the starter switch terminal BR, 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.
Fusible link
(W5)
Battery (WL)
5A (WR)
Rated voltage
DC24V
(G)
Rated current
Continuous 100A
F14
Voltage drop
0.2V or less(at 100A)
(G)
Pull in voltage
20V or less
Release voltage
6V or less
5A
Battery relay
Battery relay
８０Ｖ６２００８
Diode unit The diode unit is incorporated in the milky white connector near the battery relay. The diode unit absorbs the surge voltage generated when turning off the battery relay coil. Therefore, if the diode unit is defective, the engine will not shut off.
506 N504 N N004
(WR ニ)
F15
WV:To battery relay WR:To starter switch terminal BR (VIA F15), fuel solenoid WL:To alternator Diode storage section ８０Ｖ６２００９
62-26
85Z Ⅳ -2
Engine Start Circuit
Electrical 62
(S/N 85C3-5501〜5700) Neutral relay (The structures of the back-up relay and controller unusual relay are identical to each other)
4 2
1
3 5
3
1
5
2
4
Internal connection diagram
Rating
24V・10A
Between 1 and 2
Between 3 or 4
Starting
Operating voltage Reset voltage
Position of shift lever
16V or less
F or R
Energized
OFF
Impossible
1.2V or more
N
Not energized
ON
Possible
(S/N 85C3-5701〜5800) Neutral relay (The structures of the controller unusual relay are identical to each other)
Body blue
2
4
1
3
Internal connection dia.
62-27
Position of shift lever
Between 1 and 2
Between 3 or 4
Starting
F or R
Energized
OFF
Impossible
N
Not energized
ON
Possible
85Z Ⅳ -2
Engine Start Circuit
Electrical 62
(S/N 85C3-5801〜) Neutral relay (The structures of the back-up relay are identical to each other)
Body black
3 4
Position of shift lever
Between 1 and 2
Between 3 or 4
Starting
F or R
Not energized
OFF
Impossible
N
Energized
ON
Possible
1 2
Internal connection dia. ６５Ａ６２２０４
62-28
85Z Ⅳ -2
Transmission Control and Monitor Circuit
Electrical 62
Transmission Control and Monitor Circuit (S/N 85C3-5501 〜5600) Controller There are various IC's inside the controller. The IC's have programs for various functions described later.
LED inspection windows IN(input circuit)
IMPORTANT
Input LED
Symbol
Signal
Shift lever position F
F
Clutch solenoid valve F
Shift lever position R
R
Clutch solenoid valve R
1
Shift lever position 1
1
Clutch solenoid valve 1
2
Shift lever position 2
2
Clutch solenoid valve 2
3
Shift lever position 3
3
Clutch solenoid valve 3
A
Shift lever position A
4
Clutch solenoid valve 4
M
Auto/manual switching signal :manual
D
Trimmer solenoid valve
S
PUS(QUAD) switch:ON
N
Shift lever position :ON in F or R
P
Parking switch:Running position
RR
Back-up relay:ON in R
I
Inching switch:Inching sw ON
X
Controller :Normal
AM
Air master stroke sw:Pushed
BZ
Buzzer
AC
Air cleaner sensor:Clogged
SS
Speed sensor input signal
AP
Air pressure(alarm) sw ON ES
Emergency steering :Output (Optional)
F R
Output LED
EP TT Circuit protector
WT
A
BL EA
CN3(White)
Signal
Symbol
If the controller malfunctions, be sure to replace the controller assembly. Do not replace or repair any parts.
OUT(output circuit)
CN1
CN4(Blue)
CN2
ES
Engine oil pressure sw :below 0.5kg-cm2 Transmission oil temperature sw :above 120 ℃ Water temperature sw :above 101 ℃ Brake oil level sw:Normal Alternator neutral voltage :Power generation Steering oil pressure switch :(optional)opt. Connector CN3(Input)
1 2 3 4 5 6 7 8 9 1011
1 21 31 41 51 6
1 71 81 920 2 1
No. Color
1
Signal Auto/manual switching R/G signal
1
R/L
B / Y Input ground
2
L/W Steering oil pressure switch
2 1 2 1 31 41 51 6
1 7 1 81 92 02 1
1
2 3 4 5 6
For color code chart refer to page 158.
Connector CN1 (Input) Signal
No. Color
Signal Emergency steering :Output (Optional)
7 8 9 10 1 1
※The couplers shown are for controller side (the couplers of A).
No. Color
Connector CN4
No. Color
Connector CN2(Output) Signal
No. Color
Signal
No. Color
Signal
1
G / R Shift lever
F
11
R
+24V IN
1
G / R Clutch solenoid valve F
11
R / B +24V OUT
2
G / B Shift lever
R
12
B
Ground
2
G / B Clutch solenoid valve R
12
Lg
AUTO (lamp)
3
G/W Shift lever
1
13 W / B Air pressure (alarm) switch
3
G/W Clutch solenoid valve 1
13
Y/L
Brake (lamp)
4
G/L
Shift lever
2
14
L / R Speed sensor
4
G/L Clutch solenoid valve 2
14 W / B Air pressure (lamp)
5
G / Y Shift lever
3
15 Y / G Air cleaner sensor
5
G / Y Clutch solenoid valve 3
15
6
G
Shift lever
A
16 W / G Engine oil pressure sw
6
G
Clutch solenoid valve 4
16 W / G Engine oil pressure (lamp)
7
Y/B
Parking switch
Transmission oil 17 W/L temperature sw
7
L
Trimmer solenoid valve
Transmission oil 17 W/L temperature (lamp)
8
Y/W Inching switch
18
W
Water temperature sw
8
Gy
Neutral relay
18
W
Water temperature (lamp)
9
Y / R Air master switch
19
O
Alternator neutral voltage
9
B/W Back-up relay
19
Br
Buzzer
10
B / R Input unit common ground
20 W / R Brake oil level sw
20
Y
Neutral lamp
21
R / Y Centralized alarm lamp
1 0 G / O Controller failure alarm relay
21 R/W PUS (QUAD) switch
62-29
Y/G Air clearner (lamp)
85Z Ⅳ -2
Transmission Control and Monitor Circuit
Electrical 62
Transmission Control and Monitor Circuit (S/N 85C3-5601〜5800)
Controller LED inspection windows IN(input circuit) Signal
Symbol
Input LED
Output LED
OUT(output circuit) Signal
Symbol
F
Shift lever position F
F
Clutch solenoid valve F
R
Shift lever position R
R
Clutch solenoid valve R
1
Shift lever position 1
1
Clutch solenoid valve 1
2
Shift lever position 2
2
Clutch solenoid valve 2
3
Shift lever position 3
3
Clutch solenoid valve 3
A
Shift lever position A
4
Clutch solenoid valve 4
P
Parking switch : Running position
D
Trimmer solenoid valve
S
PUS (QUAD) switch : ON
I
Inching switch : Inching sw ON
N
Shift lever position : ON in F or R
M
Auto/manual switching signal : manual
RR
Back-up relay : ON in R
X
Controller : Warning relay
Inspection window
Circuit protector
DD CN1
CN2
DD switch
*
* OPT
1
2
3
4
1
2
3
MR Diag sw (Malfunction Recall)
DD
D/D Solenoid valve
5
6
7
8
4
5
6
MC Reset sw (Malfunction Clear)
BZ
Buzzer
※
AM Air master stroke sw : Pushed
XX
Controller : Normal
※※
BL
Brake oil level sw : Normal
SS
Speed sensor input signal
AP
Air pressure (alarm) sw ON
EG
AC
Air cleaner sensor : Clogged
CN3(Blue) 1 2 3 4 5 6 7 8 9 10 11
12 13 141516
17 1819 2021
CN4(Blue) 17 1819 2021
12 13 141516
1 2 3 4 5 6 7 8 9 1011
Engine oil pressure sw : below 0.5kg ・ EP cm2 (7psi) Transmission oil temperature sw : above TT 120 ℃ (248 ° F) Water temperature sw : above 101 ℃ WT (215 °F) Steering circuit press.(Emergency SP steering) OPT
※ 65ZIV, 70ZIV, 80ZIV・ON : Abnormal ※ 85ZIV, 90ZIV ・・・・・・・ ON : Normal ※※ 65ZIV・・・・・ ON : Abnormal ※※ 70ZIV, 80ZIV, 85ZIV, 90ZIV ・ ON : Normal
Connector CN1 (Input) No.
Symbol
No. 1
F
2 3
Signal Shift lever F
11
+
R
Shift lever R
12
1
Shift lever 1
13
4
2
Shift lever 2
14
5
3
Shift lever 3
15
6
A
Shift lever A
16
7
P
Parking switch
17
8
I
Inching switch
9
AM
10
G
Inspection window (7segment display)
*DD=Dynamic Damping(Ride control system) **This output LED light up but on 65Z Ⅳ -2 & 70Z Ⅳ -2 the signal is not used.
Alternator neutral voltage : Power generation
EA
Symbol
** **
Connector CN2 (Output) No.
Symbol
Signal +24V IN
1
F
Clutch solenoid valve F
11
E
Ground
2
R
Clutch solenoid valve R
12
A
AUTO (lamp)
AP
Air pressure (alarm) switch
3
1
Clutch solenoid valve 1
13
B
Brake (lamp)
SS
Speed sensor
4
2
Clutch solenoid valve 2
14
AP
Air pressure (lamp)
AC
Air cleaner sensor
5
3
Clutch solenoid valve 3
15
AC
Air cleaner (lamp)
EP
Engine oil pressure sw
6
4
Clutch solenoid valve 4
EP
Engine oil pressure (lamp)
Transmission oil temperature sw
7
D
** Dump solenoid valve **
16
TT
17
TT
Transmission oil temperature (lamp)
18
WT
Water temperature sw
8
N
Neutral relay
18
WT
Water temperature (lamp)
Air master switch
19
EA
Alternator neutral voltage
9
RR
Back-up relay
19
BZ
Buzzer
Input unit common ground
20
BL
Brake oil level sw
10
X
Controller failure alarm relay
20
NL
Neutral lamp
21
S
PUS (QUAD) switch
21
W
Centralized alarm lamp
62-30
Signal
No.
Signal
Symbol
Solenoid return
85Z Ⅳ -2
Transmission Control and Monitor Circuit
Connector CN3(Input) No.
Signal
Connector CN4 No.
1
Diag sw
1
2
Auto/manual switching signal
2
signal
* OPT D/D Relay * OPT D/D Switch
3
3
(Spare) Solenoid valve
4
4
Steering circuit pressure Steering circuit pressure warning lamp
5
Reset sw
5
6
1 ・2 ・5 COM ground
6
7 8
Note : Connect No.2 and No.6 terminals of connector CN3 using a jumper wire to cancel the automatic shift function.
62-31
Electrical 62
85Z Ⅳ -2
Transmission Control and Monitor Circuit
Electrical 62
Transmission Control and Monitor Circuit (S/N 85C3-5801〜)
Controller LED inspection windows IN(input circuit) Signal
Symbol
Input LED
Output LED
OUT(output circuit) Signal
Symbol
F
Shift lever position F
F
Clutch solenoid valve F
R
Shift lever position R
R
Clutch solenoid valve R
1
Shift lever position 1
1
Clutch solenoid valve 1
2
Shift lever position 2
2
Clutch solenoid valve 2
3
Shift lever position 3
3
Clutch solenoid valve 3
A
Shift lever position A
4
Clutch solenoid valve 4
P
Parking switch : Running position
D
Trimmer solenoid valve
S
PUS (QUAD) switch : ON
I
Inching switch : Inching sw ON
N
Shift lever position : ON in Neutral
M
Auto/manual switching signal : manual
RR
Back-up relay : ON in R
X
Controller : Warning relay
Inspection window
Circuit protector
DD CN1
CN2
DD switch
*
* OPT
1
2
3
4
1
2
3
MR Diag sw (Malfunction Recall)
DD
D/D Solenoid valve
5
6
7
8
4
5
6
MC Reset sw (Malfunction Clear)
BZ
Buzzer
※
AM Air master stroke sw : Pushed
XX
Controller : Normal
※※
BL
Brake oil level sw : Normal
SS
Speed sensor input signal
AP
Air pressure (alarm) sw ON
EG
AC
Air cleaner sensor : Clogged
CN3(Blue) 1 2 3 4 5 6 7 8 9 10 11
12 13 141516
17 1819 2021
CN4(Blue) 17 1819 2021
12 13 141516
1 2 3 4 5 6 7 8 9 1011
Engine oil pressure sw : below 0.5kg ・ EP cm2 (7psi) Transmission oil temperature sw : above TT 120 ℃ (248 ° F) Water temperature sw : above 101 ℃ WT (215 °F) Steering circuit press.(Emergency SP steering) OPT
※ 65ZIV, 70ZIV, 80ZIV・ON : Abnormal ※ 85ZIV, 90ZIV ・・・・・・・ ON : Normal ※※ 65ZIV・・・・・ ON : Abnormal ※※ 70ZIV, 80ZIV, 85ZIV, 90ZIV ・ ON : Normal
Connector CN1 (Input) No.
Symbol
No. 1
F
2 3
Signal Shift lever F
11
+
R
Shift lever R
12
1
Shift lever 1
13
4
2
Shift lever 2
14
5
3
Shift lever 3
15
6
A
Shift lever A
16
7
P
Parking switch
17
8
I
Inching switch
9
AM
10
G
Inspection window (7segment display)
*DD=Dynamic Damping(Ride control system) **This output LED light up but on 65Z Ⅳ -2 & 70Z Ⅳ -2 the signal is not used.
Alternator neutral voltage : Power generation
EA
Symbol
** **
Connector CN2 (Output) No.
Symbol
Signal +24V IN
1
F
Clutch solenoid valve F
11
E
Ground
2
R
Clutch solenoid valve R
12
A
AUTO (lamp)
AP
Air pressure (alarm) switch
3
1
Clutch solenoid valve 1
13
B
Brake (lamp)
SS
Speed sensor
4
2
Clutch solenoid valve 2
14
AP
Air pressure (lamp)
AC
Air cleaner sensor
5
3
Clutch solenoid valve 3
15
AC
Air cleaner (lamp)
EP
Engine oil pressure sw
6
4
Clutch solenoid valve 4
EP
Engine oil pressure (lamp)
Transmission oil temperature sw
7
D
** Dump solenoid valve **
16
TT
17
TT
Transmission oil temperature (lamp)
18
WT
Water temperature sw
8
N
Neutral relay
18
WT
Water temperature (lamp)
Air master switch
19
EA
Alternator neutral voltage
9
RR
Back-up relay
19
BZ
Buzzer
Input unit common ground
20
BL
Brake oil level sw
10
X
Controller failure alarm relay
20
NL
Neutral lamp
21
S
PUS (QUAD) switch
21
W
Centralized alarm lamp
62-32
Signal
No.
Signal
Symbol
Solenoid return
85Z Ⅳ -2
Transmission Control and Monitor Circuit
Connector CN3(Input) No.
Signal
Connector CN4 No.
1
Diag sw
1
2
Auto/manual switching signal
2
signal
* OPT D/D Relay * OPT D/D Switch
3
3
(Spare) Solenoid valve
4
4
Steering circuit pressure Steering circuit pressure warning lamp
5
Reset sw
5
6
1 ・2 ・5 COM ground
6
7 8
Note : Connect No.2 and No.6 terminals of connector CN3 using a jumper wire to cancel the automatic shift function.
62-33
Electrical 62
85Z Ⅳ -2
Transmission Control and Monitor Circuit
Electrical 62
Controller connection diagram PARKING SOLENOID (BY)
10A LR L
F
R LY
1
F6 (Lg) 5A
LG
Transmission clutch control solenoid valve
LO
Speed indicator lamp
LW
2
3
4
LR LBr
N
R
F
(BY)
SIFT LEVER
C O N T R O L L E R
LBr
F R
(BY) 1 2
3 A
LY
1
LG
2
LO
3
LW
A
(GO) P (YL)
PARKING SWITCH SHIFT SWITCH
S
(Y)
SENSOR FOR SPEED
(BY)
D
Neutral relay
NR
Controller failure relay
Back-up relay
NR LgW
X
L
RR
(Y)
SS
(SbP)
X (LB)
GyW
RR
AM
B
BL
AIR MASTER
(GyW)
(GyR)
(Gy)
(GyG)
(GyL)
(LgL)
(LP) AUTO
AP
AP
EP
EP
V
BRAKE TANK RESERVOIR
GyR AIR PRESSURE Gy E/G OIL PRESSURE GyG
WT
WT
E/G WATER TEMP GyL
TT
TT
AC
AC
T/M OIL TEMP LgL AIR CLEANER
A
A/M SWITCH A/M
(GR)
N
N
WL EA
(GyB)
ALTERNATOR TERMINAL N
W
(LgR) LLg
I
(BY)
BZ BUZZER
T/M CUT OFF LgBr
(LgY)
(LgW)
X
CONTROLLER SELF-DIAGNOSIS ON
(GO)
CONTROLLER
(BY)
OFF
(Lg)
F6
(SbW)
ON
OFF
F5
L
PARKING SOL
PARKING SWITCH LgG E
62-34
８５Ｖ６２００７
85Z Ⅳ -2
Transmission Control and Monitor Circuit
Forward/reverse(F/R)shifting change
and
Electrical 62
speed
Each clutch has one solenoid valve for transmission control. When electric current flows through the solenoid valve, the clutch oil is fed into the clutch piston chamber. When the piston operates, the clutch is engaged. When the current stops flowing through the solenoid valve, the oil is drained from the clutch piston chamber, and the clutch is disengaged.
From T/C pump
Clutch press regulator valve
To solenoid valve +24V IN Circuit protector
R
Clutch piston +24V
OUT
+24V LED(indecation: F) +Vcc LED (indecation: F)
N F
Drain
F Shift lever
(For input detection) A
3 2
Clutch control solenoid valves
Clutch control solenoid valve
energized → clutch engage de- energized → clutch disengage
R
1 1
Shift switch
Speed indicator lamp
LED(indecation: S) 2
Speed sensor
LED(indecation: SS)
3
Surge suppression diode (incorporated in solenoid valve)
LED(indecation: M) 4
Auto/manual switching (Switch on: Manual)
Setting shift lever to A : Switch on Auto indicator lamp
Shift lever :
Input detection
The shift lever has two direction and four speed positions; forward and reverse (F and R) and "1", "2", and "3" speed positions are respectively used for 1st, 2nd, and 3rd fixed speeds. The "A" speed position is used for the variable speed where the 2nd through 4th speed clutches are automatically changed in both the forward and reverse operation. Operator controlled shifting from 2 → 1 → 2 in either "2" or "A" is done by momentarily depressing the QUAD (PUS) switch on the boom lever.
62-35
When the shift lever is set to the F (forward) position, electric current of input detection signal is sent from the transmission controller to the grounding circuit inside the transmission controller via shift lever contact F. The transmission controller, 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. In this status, the forward (F) indicator lamp will light, and the reverse (R) incdicator lamp will not light. For the speed change, the transmission controller judges the set speed position of the shift lever in the same way as described above.
Transmission Control and Monitor Circuit
85Z Ⅳ -2
Operation of solenoid valve When the input signal is transmitted, the output circuit of the corresponding solenoid valve is connected to the grounding circuit inside the controller. As a result, power is supplied to the solenoid valve and the clutch is engaged. At the same time, the speed indicator lamp in the cab lights. In addition, the LED indicator of the corresponding output circuit lights on the controller. Note that when the parking brake or inching brake is applied, the forward or reverse (F or R) clutch solenoid valve is turned off and the transmisssion is set to neutral.
Electrical 62
Operation error preventive function (Simulー taneous input of two or more commands) If both the forward and reverse commands are input at the same time due to a problem, the forward and reverse clutches will not function. In addition, if two or more speed commands are input at the same time, no speed clutches will function.
Shift up Shift down
Automatic shift When the shift lever is set to A, the AUTO indicator lamp in the cab will light and one of the 2nd through 4th speed solenoid valves will be automatically energized according to the machine speed. In addition, the speed indicator lamp will light. The input signal for automatic shift is controlled by the pulse generated by the speed sensor. While the speed sensor is transmitting the pulse, the "SS" LED indicator flashes according to the pulse.
Speed 4
3
2
18 15
10
9
0
9 10.5
15.5 18.5
Forward (Approx. speed)
Speed : km/h
Reverse
Automatic shift map
Switching from automatic to manual (S/N 85C3-5501〜5600) The machine has automatic shift cancellation function for troubleshooting. Connect both terminals of the controller connector CN3 (white connector ) to each other using a jumper wire. The "M" input LED indicator of the controller will light and the mode will be switched from automatic to manual. Position "A" of the shift lever, therefore, is fixed to the 4th speed.
Input LED indicator
Output LED indicator
・ M
Circuit protector
CN3(White)
CN1
CN2
CN4(Blue)
Jumper wire
Connect both terminals of connector CN3 to each other using a jumper wire to cancel the automatic shift function.
62-36
Transmission Control and Monitor Circuit
85Z Ⅳ -2
Electrical 62
Switching from automatic to manual (S/N 85C3-5601〜) The machine has automatic shift cancellation function for troubleshooting. Connect No.2 and No.6 terminals of the controller connector CN3 using a jumper wire to cancel the automatic shift function. The "M" input LED indicator of the controller will light and the mode will be switched from automatic to manual. Position "A" of the shift lever, therefore, is fixed to the 4th speed.
・
Input LED
M
Output LED Inspection window
Circuit protector
CN1
CN2
1
2
3
4
1
2
3
5
6
7
8
4
5
6
CN3(Blue)
CN4(Blue) ６５Ａ６２２０５
Connect No.2 and No.6 terminals of connector CN3 using a jumper wire to cancel the automatic shift function.
62-37
85Z Ⅳ -2
Transmission Control and Monitor Circuit
Electrical 62
ＱＵＡＤ ｓｗｉ ｔ ｃｈ
Operation of QUAD switch The QUAD switch is attached to the boom control lever. In any operation mode, pressing the QUAD switch during 2nd speed operation shifts the 2nd speed to 1st speed. After that, if the QUAD switch is pressed again, the speed is changed from the 1st to the 2nd, or to moving 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 "S" LED indicator of the controller will momentarily light (blink).
Shift lever
Shift lever neutral (N) position
Ｓｈ ｉ ｆ ｔｌ ｅｖｅｒ
Grounding for speed change side(B)
７０Ｖ６２００３
The shift lever has no neutral (N) contact. Therefore, if neither the forward nor the reverse (F and R) signal is input, the controller will judge that the shift lever is at the neutral
2nd speed(GL) 3rd speed(GY)
1st speed(GW) Unused Auto(G) F(GR)
Grounding for F/R side(BY) ９５Ｖ６２０１２
R(GB)
Clutch solenoid valve (Common to F. R. 1. 2. 3. 4 and trimmer) Solenoid valve(with built-in diode)
7〜10N-m (0.7〜1.0kgf-m) (5.1〜7.2lb-ft)
Positive side
Negative side
29〜34N-m (3〜3.5kgf-m) (22〜25lb-ft)
62-38
Rated voltage
DC24V
Coil resistance value
Approx. 26 Ω
Transmission Control and Monitor Circuit
85Z Ⅳ -2
Electrical 62
PUS(QUAD)switch
Allowable value
The PUS (QUAD) switch is of the momentary type. It is spring loaded to the "OFF" position.
Max Voltage
DC24V
Current
10mA
Speed sensor The detector of the speed sensor is adjacent to the transmission output gear. The pulse voltage is transmitted to the transmission controller. 25 ± 0.25
20〜29N-m (2〜3kgf-m) (14〜21lb-ft)
Output gear
Clearance adjustment 0.7〜1.3mm
IMPORTANT At the completion of sensor replacement, be sure to check the clearance between the gear and the sensor.
62-39
Output
1V or more
Internal resistance ＊
1.6k Ω (20 ℃ )
Transmission Control and Monitor Circuit
85Z Ⅳ -2
Electrical 62
Modulation at clutch switching When the forward/reverse direction or speed is changed, time lag may be caused due to clutch engagement and a shock may be applied to the machine. To shorten the time lag and prevent the shock, the clutch engagement time is controlled by activating the trimmer solenoid valve. When the shift lever signal is changed, the trimmer plug solenoid valve is energized. This causes the clutch oil regulator valve to control the clutch engagement time.
Torque converter Trimmer plug Clutch oil pressure regulator valve
Trimmer plug solenoid valve
P From gear pump (T/C pump) Clutch solenoid valve
To other clutch solenoid valves
Clutch modulation chart
Clutch piston chamber
+24V
Clutch switching
Controller
Clutch changed completely
IN +24V Circuit protector OUT
ON
Clutch solenoid valve OFF
t0
t1
+24V F
Shift lever
OFF
Trimmer plug solenoid valve
N
1.3〜1.6MPa (13〜16kgf/cm2) (185〜228psi) (Engine middle speed)
4 (A)
3 2
1
Clutch switching signal
R
ON
LED(indication: D)
Trimmer plug solenoid valve ８５Ｖ６２００８
Approx. 0.4MPa 2 (4kgf/cm ) (57psi) Approx. 1.2sec t 0 : 0 to 0.05sec (slight difference between clutches) t 1 : 0.20sec (common to all the clutches)
Refer to the transmission section 32 for additional information on clutch modulation.
62-40
Transmission Control and Monitor Circuit
85Z Ⅳ -2
Electrical 62
Inching Pressing down the left brake pedal applies air pressure to the inching switch, and the contacts of the inching switch are closed. In this status, the power of the forward/reverse clutch solenoid valve is turned off. The transmission is set in neutral. At the same time, the "I" LED indicator of the controller will light. To cancel this inching function, turn off the clutch cut-off switch on the operator panel, and the function of the left brake is switched to brake only. The left brake pedal may be used as a brake only pedal just like the right brake pedal. In addition, the T/M CUT OFF monitor lamp of the operator panel will go out.
Inching switch
６５ＴＭ６２０２６
Controller
24V IN
Clutch cut-off switch
OUT +24V
+24V
LED +Vcc
Monitor lamp
F (Indication : Ｉ) R
Solenoid valve Inching switch (Air pressure)
Setting Air pressure : 177±20kPa (1.8±0.2kgf/cm2) or less (26±2.8psi)
Between both terminals : OFF
Air pressure : 216±20kPa (2.2±0.2kgf/cm2) or more (31±2.8psi)
〃
６５Ｖ６２００８
62-41
: ON
85Z Ⅳ -2
Transmission Control and Monitor Circuit
Electrical 62
(S/N 85C3-5501〜5700) Back-up alarm When the shift lever is set to the reverse (R) position, the coil of the back-up (or reverse) relay will be energized, and the main contact will be closed. The back-up lamp, therefore, will light, and the buzzer (optional) will sound.
+24V +24V
LED
IN Circuit protector +Vcc
R
N
F
Shift lever
4 (A)
Back-up lamp Back-up relay
+24V
(Indication: R)
LED (indication: RR)
3
5
1
2
Back buzzer (opt)
(For input detection) 3 2
1
+24V
Back-up relay Note: This relay is identical to the relays for neutral and controller unusual relay. They may be interchanged for testing purposes. 4 2 1
5 1
3 5
4
Rating
24V・10A
Shift lever position
Operation voltage
16V or less
R
Reset voltage
1.2V or more
3
F or N
62-42
2
Between 1and 2
Between 3 and 5
Lamp and buzzer
Electric power supply
ON
ON
No electric power supply
OFF
OFF
85Z Ⅳ -2
Transmission Control and Monitor Circuit
Electrical 62
(S/N 85C3-5701〜) Back-up alarm When the shift lever is set to the reverse (R) position, the coil of the back-up (or reverse) relay will be energized, and the main contact will be closed. The back-up lamp, therefore, will light, and the buzzer (optional) will sound. +24V +24V
LED
IN Circuit protector +Vcc
R
N
F
Back-up relay
(Indication: R)
Shift lever
4 (A)
Back-up lamp +24V
LED (indication: RR)
Back buzzer (opt)
(For input detection) 3 2
1
+24V
６５Ａ６２２０６
Back-up relay Note: This relay is identical to the neutral relay. It may be interchanged for testing purposes.
3
1
4
2
Body black Internal connection dia. ６５Ａ６２２０７
62-43
85Z Ⅳ -2
Transmission Control and Monitor Circuit
Electrical 62
Parking brake The parking brake solenoid valve activates the parking brake.
In parking mode :
In running mode:
When the power of the solenoid valve is turned off, no compressed air will be fed to the air cylinder. The spring inside the cylinder applies force to make the brake apply. (drum type). In this condition, the input "P" LED indicator is off. If the transmission shift lever is set to the forward or reverse (F or R) position, the buzzer will sound and the clutch will not be engaged. 5A
When the power of the solenoid vavle is turned on, compressed air will be fed into the air cylinder. The compressed air will depress the spring to release the brake. In addition, the "P" LED indicator will light.
+24V
F6 P Parking switch
Monitor lamp
Surge suppression +24V
Parking
Parking brake Air cylinder
Running
Parking solenoid C.P Atmosphere
+Vcc LED Indicator 「P」
F 10A F5
Compressed air inlet (from air tank)
R +24V
85V62010
Operation of parking brake Parking switch
Monitor lamp
Buzzer
Parking brake solenoid valve
LED indicator of controller
Parking ＊
"Parking" position (pulled up)
P
Sounds when shift lever is set to F or R
No electric power supply
Input "P" LED indicator : Off
Running
"Running" position (pushed in)
Off
No buzzer
Electric power supply
Input "P" LED indicator : On
＊ When the parking switch is set to "parking", the forward or reverse clutch is disengaged and set to neutral.
62-44
85Z Ⅳ -2
Transmission Control and Monitor Circuit
Emergency movement If the controller fails, or if the electric system malfunctions, the emergency movement function can be used as follows.
① Manual releasing of parking brake Set the solenoid valve manual operation knob to the ON position. Setting the knob to the ON position connects the air tank to the air cylinder, and the parking brake is released. The air pressure shifts the spool of the solenoid valve. Therefore, before you set the knob to the ON position, if possible, start the engine, and keep the air pressure built up. In addition, apply the foot brake.
Electrical 62
WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. To prevent such an accident, observe the following caution when manually releasing the parking brake : ・Before releasing the parking brake, start the engine, and raise the brake air pressure to the specified value. After that, stop the engine. ・After stopping the engine, apply the foot brake, and the machine will not move even if the parking brake is manually released.
WARNING
O
Manual operation knob
Normal position
O
85W5205
Unexpected movement of the machine may cause an accident resulting in injury or death. To prevent such an accident, observe the following caution when manually engaging the transmission clutch : ・Stop the engine. ・The person in the cab should not start the engine until the other person in charge of forced clutch engagement gives the engine start signal.
Position for manual releasing of parking brake
85W5204
② Forced connection of transmission clutch To move forward, press the forward ① and 1st speed ③ solenoid valves all the way. To move reverse, press the reverse ② and 1st speed ③ solenoid valves all the way. In this condition, the pump port is open and connected to the clutch piston chamber. Therefore, when starting the engine, the clutch is immediately engaged to start the machine. Be careful!
IMPORTANT The transmission will be damaged, if the forward and reverse solenoid valves and the 1st speed solenoid valve are inserted at the same time.Therefore select forward or reverse and the 1st speed solenoid valve.
② For reverse
③ For 1st speed
IMPORTANT
① For forward
After emergency moving of the machine to a safe place, be sure to reset the solenoid valves to the original positions. 85ZA3210
62-45
Transmission Control and Monitor Circuit
85Z Ⅳ -2
Electrical 62
Monitor During operation, if a problem of a unit is detected, the monitor lamp will light to inform problem occurrence. For some problems, the buzzer will also sound, and the centralized alarm lamp will also flash. No.
Item to be monitored
1
Controller failure
2
Air pressure
3
Monitor lamp
When turning the starter key to "ON" position, all the monitor lamps turn on for 3 seconds, it shows that those lamps are normal (not burnt out).
Operation condition
Buzzer
Lamp test
Defective controller CPU
○
○
466±29kPa (4.75±0.3kgf/cm2) or less (67±4psi) or less
○
○
Oil level below lower limit for 3 seconds
○
Remarks
○
Brake
Alarm self holding
Abnormal air master stroke
○
0.05±0.01MPa or below (0.5±1kgf/cm2) or below during engine operation (7±14psi) or below
○
○
4
Engine oil pressure
5
Engine water temperature
101±2 ° C or more
-
○
6
Torque-converter (Transmission) oil temperature
120±5 ° C or more
-
○
7
Clogged air cleaner
Filter resistance : 635±58mmAq or more
-
○
8
Charging condition
Defective charge system
-
-
9
Centralized alarm
For items 1 through 7 above
-
○
62-46
Flashing type
85Z Ⅳ -2
Transmission Control and Monitor Circuit
Electrical 62
(S/N 85C3-5501〜5700) Controller failure alarm During normal operation of the CPU, the controller failure alarm relay is energized, and the output "X" LED indicator is on. If a CPU failure is detected, the relay will be de-energized, and the output "X" LED indicator lamp will go out.
In addition, the controller failure monitor lamp of the instrument panel will light to inform occurrence of a controller failure. The centralized failure lamp and alarm buzzer will also come on. +24V
+24V
F6 5A
IN OUT
c.p
LED (Indication: X)
3
4
1
2
Monitor lamp During normal CPU operation :On
Controller failure relay
Controller failure relay Note: This relay is identical to the relays for neutral and back-up relay. They may be interchanged for testing purposes. 4 2 1
3 5 1
3
2
5
4
Testing condition
24V・10A
CPU
On:Operation voltage
16V or less
Normal
OFF:Reset voltage (Returning)
1.2V or more
Defective
62-47
Between "1"and "2" Electric power supply No electric power supply
Between "3" and "4"
Monitor lamp
OFF
OFF
ON
ON
85Z Ⅳ -2
Transmission Control and Monitor Circuit
Electrical 62
(S/N 85C3-5701〜) Controller failure alarm During normal operation of the CPU, the controller failure alarm relay is energized, and the output "X" LED indicator is on. If a CPU failure is detected, the relay will be de-energized, and the output "X" LED indicator lamp will go out.
In addition, the controller failure monitor lamp of the instrument panel will light to inform occurrence of a controller failure. The centralized failure lamp and alarm buzzer will also come on. +24V
+24V
F6 5A
IN c.p
OUT
LED (Indication: X)
3
4
1
2
Monitor lamp During normal CPU operation :On
Controller failure relay
Controller failure relay
3
1
4
2
Internal connection dia.
Body blue
CPU ６５Ａ６２２０８
Normal Defective
62-48
Between "1"and "2" Electric power supply No electric power supply
Between "3" and "4"
Monitor lamp
OFF
OFF
ON
ON
85Z Ⅳ -2
Instrument Panel
Electrical 62
Instrument Panel 20
19
15
16
17 1
14
2
13
1/10h
9
AUTO
10
N
C
4
F
5
FUEL
6
11
2
24
12
22
1
5 H
C
10
0 AIR PRESS
T/C OIL TEMP kgf/cm2
18
1.Controller failure alarm 2.Low air pressure alarm 3.Brake alarm (low level ; stroke sensor) 4.Low engine oil pressure alarm 5.Engine water temperature alarm 6.Torque converter (T/M) oil temperature alarm 7.Air cleaner clogging alarm 8.Low alternator charging lamp 9.Centralized alarm 10.Parking brake lamp 11. Transmission cut-off lamp 12.Work lamp
13. Transmission neutral 14.Automatic shift 15.Winker (left) 16.Headlight high-beam 17.Winker (right) 18. Transmission shift position 19.Hour meter 20. Tachometer 21.Engine water temperature gauge 22. Torque converter oil temperature gauge 23. Fuel gauge 24.Air pressure gauge
62-49
3 4
E
H WATER TEMP
3
x100r/min
23
21
7 8
85Z Ⅳ -2
Instrument Panel
Electrical 62
Rear surface of instrument panel
Hour meter
Fuel gauge
Air pressure
Engine water temperature
Tachometer
Transmission oil temperature
Layout of connector pins (instrument panel side)
Pin No.
1
CN3(28P)
CN1(8P)
CN2(20P)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 22 23 24 25 26 27 28
Signal
Lamp No.
Pin No.
-
CN4(2P)
29 30 31 32 33 34 41 42 43 44 35 36 37 38 39 40 49 50
Signal
46 47 48 53 54 55 56
58 57
Lamp No.
Pin No.
-
41
-
42
-
L16
Signal
L9
21
2
Air cleaner clogging alarm
L7
22
3
T/C (T/M) oil temperature alarm
L6
23
-
-
43
Tachometer ( + )
-
4
Engine water temperature alarm
L5
24
-
-
44
Tachometer (-)
-
5
Engine oil temperature alarm
L4
25
-
-
45
6
Brake alarm
L3
26
-
-
46
Transmission cut-off lamp
L17
7
Air pressure alarm
L2
27
-
-
47
8
Controller failure alarm
L1
28
GND(-)
-
48
Work lamp
L18
9
+24V Power supply
-
29
+24V Power supply
-
49
Centralized alarm lamp
L14
10
Emergency steering (optional)
L22
30
-
-
50
GND(-)
-
11
Dynamic damper (optional)
L23
31
-
-
51
12
-
L25
32
-
-
52
13
-
L24
33
-
-
53
High-beam lamp
L12
14
-
L26
34
Neutral
L21
54
Winker (left) lamp
L13
15
-
L27
35
+24V Power supply
-
55
Winker (right) lamp
L11
16
Engine water temperature
-
36
1st speed indication
-
56
-
-
17
T/C (T/M) oil temperature gauge
-
37
2nd speed indication
-
57
Hour meter (-)
-
18
Air pressure gauge
-
38
3rd speed indication
-
58
Hour meter ( + )
-
19
Instrument panel illumination
L10
39
4th speed indication
-
20
Charge lamp
L8
40
Parking brake lamp
L15
Fuel gauge
62-50
AUTO lamp
Lamp No.
L20
-
-
-
85Z Ⅳ -2
Instrument Panel
Gauge circuit
Electrical 62
Note : If a gauge is removed from the panel, the resistance between the terminals will differ from the standard value shown in the table.
Sensors respectively detect the temperature, pressure, and fuel level, and then convert them into electric signals. The signals are transmitted to the corresponding gauges that indicate the transmitted values.
Sensor
Resistance between gauge terminals ( Ω ) Between S and E
110
Between S and V
110
Between E and V
150
S
Grounding
Power supply 24V
E
V
15V
Viewed from rear of instrument panel
Gauge
Engine water temperature
67 ° C 〔152 °F〕 102 ° C F〕 〔215 °
T/C .T/M oil temperature
50 ° C F〕 120 ° 〔122 ° F〕 C〔248 °
Air pressure
490kPa (5kgf/cm2) 〔71psi〕
Red
Red
White
Temperature sensor (For engine water temperature and converter oil temperature)
torque
E
F
785kPa 2 (8kgf/cm ) 〔114psi〕
Indication
White
Fuel level
White
Red
White
Pressure sensor (For air puressure)
Terminal
Temperature detection part
Temperature of detection part ( ° C)
60 80 100 120 〔140 °F〕〔176 °F〕〔212 °F〕〔248 °F〕
Resistance ( Ω ) between terminal and body
56.3
29.5
16.5
10
Fuel level sensor Fuel level
E
F
Resistance ( Ω ) between two terminals
80
10
62-51
Pressure (kPa)
490 (5kgf/cm2) 〔71psi〕
785 (8kgf/cm2) 〔114psi〕
Resistance ( Ω ) between terminal and body
31.9
17.2
85Z Ⅳ -2
Electric Detent Circuit
Electrical 62
Electric Detent Circuit Bucket positioner After dumping, if the control lever is set to the "roll-back" position, the control lever will be held at that position until the bucket is tilted to the set angle. This is because the detent magnet in the pilot valve is energized so that the holding plate connected to the spool is held by magnetic force. When the bucket is positioned at the set angle, the rod will retract from the proximity switch. The proximity switch, therefore, is turned off, and the coil of the pilot valve is de-energized and demagnetized. The control lever is automatically returned to the neutral position by the spring. As a result, the bucket is set to the selected digging angle automatically.
Detent magnet
Multiple control valve Bucket positioner
Adjusting rod
5±2
Boom kick-out unit (optional) While the boom is being raised, the control lever is held at the "raise" position. When the boom is raised to the set height, the boom kick-out unit automatically returns the control lever to the "neutral" position. The detent functions and the units are the same way as those of the bucket positioner.
Bucket cylinder Proximity switch
Connector
Kick-out unit Adjusting plate
Connector 5±2
Float When the control lever is set to the "float" position, the control lever will be held at the "float" position. For the "float" position, manually reset the control lever. The float magnet is energized whenever the starter switch is "ON".
Switch main circuit
Boom 70V62005
+24V
Proximity switch LED
Proximity switch
R ① Detent coil inside pilot valve
W ② B ③
Sensor section
+24V Operation indicator lamp(LED)
②
φ 27
③
Object to be detected
①
5±2mm
Adjusting clearance Adjust the clearance between the sensor and the adjusting rod or adjusting plate to 5±2mm (1/8 ″〜 1/4 ″).
In this condition, the operation indicator
lamp (LED) is on, and the circuit between switches (2)-(3) in on. 62-52
85Z Ⅳ -2
Electric Detent Circuit
Electrical 62
Pilot valve For bucket control
Neutral
1 Dump
Roll back
For bucket control
For boom control
8 2
T 3 To tankport
4 5
P
6 From pumpport
7
To MCV oil packs
View from the rear ７０Ｖ６２０１４
７０Ｖ６２０１５
For boom control
Raise
Neutral
Down
Float
To tank port ８５Ｗ４２１９
62-53
1. Lever 2. Disc 3. Push rod 4. Spring seat 5. Spring for secondary pressure 6. Return spring 7. Spool 8. Detent magnet solenoid
Cautions Regarding Elec. Circuit Check
85Z Ⅳ -2
Electrical 62
Cautions Regarding Electric Circuit Check Before checking the electric units, observe the following cautions: Before disconnecting or reinstalling the connector, be sure to turn the power off (turn the starter switch to OFF).
To disconnect a connector, firmly grab the connector, and press and hold the stopper claw. While holding down the claw, pull out the connector in the straight direction. Do not pull the electric cable or wires. They may be damaged. Do not twist the connector or the female terminal cover may be damaged to cause poor contact.
Removing square connector
When reconnecting, insert it until the stopper claw clicks. If the connector is not completely connected, it may cause poor contact.
Note : In corrosive environments (such as salt air, phosphate plants, or fertilizers) the square type connectors will require special coatings to prevent or minimize electrical problems. Use only an approved sealant like Dow Corning 738 or Loctite "Ultra Blue". Other silcone sealants may contain acetic acid which may corrode the wiring. (Hint:If the silicon has a vinegar type odor it has acetic acid and should not be used.)
Removing waterproof round connector
Inserting square connector
62-54
Inserting waterproof round connector
Cautions Regarding Elec.Circuit Check
85Z Ⅳ -2
Electrical 62
When checking the conductivity or the voltage, follow the procedure below:
・ Square connector Insert the probes for the tester to the wire side of the connector. Do not insert the probes into the open side of the connector. The damaged connector may cause poor contact.
・ Waterproof round connector For the waterproof round connector, do not attach the probes of the tester to the wire side because the
How to attach the probes of the circuit tester to the square connector.
wire side is waterproofed. Attach the probes to the open connector side. Do not force the probes into the female side.
The damaged connector may
cause poor contact.
How to attach the probes of the circuit tester to the waterproof round connector.
62-55
85Z Ⅳ -2
Flow Chart for Troubleshooting
Electrical 62
Flow Chart for Troubleshooting of Electrical Transmission Control System For a problem regarding transmission control, check the electric control system first, and then check the mechanical system.
To check the electric control system, determine the cause of the problem while referring to the flow chart below, and then solve the problem.
■ Standard troubleshooting flowchart Cause of problem Is the "controller failure" monitor lamp on ?
On
・ The transmission controller failure. If the circuit protector in the controller is Off, the power supply or output circuit is shortcircuited. Check for damaged solenoid coils or their wiring.
Off
Check the other monitor lamps.
Normal
Abnormal
＊ Check that the monitor lamps are properly turned on and off according to operation of the respective unit, such as shift lever and parking switch.
Check the on/off statuses of the transmission controller LED indicators.
Normal
Check operation of the output circuit and output units.
No problem
Check mechanical operation of the output units.
・ The input circuit or one of the input units is defective.
Abnormal
・ The input circuit or one of the input units is defective. ・ The transmission controller is defective. (The defective controller judgment standard is described on the next page)
＊ Refer to the table, "On/Off Statuses of Transmission Controller LED Indicator"
Problem detected (disconnection, etc,)
・ The output circuit or one of the output units is defective.
＊ Measure the resistance of the output circuit and output units (solenoid valve, etc.) while operating the input units.
Problem detected
・ An output unit is defective.
＊ Disassemble the output units No problem
(solenoid valve, etc.), and check them for sticking.
Check the driveline and the transmission for mechanical problems.
62-56
85Z Ⅳ -2
Judgment of Abnormal T/M Controller
Electrical 62
Judgment of Transmission Controller Abnormal Operation To judge whether the transmission controller operates properly, follow the procedure below:
1.When the "controller failure" monitor lamp lights :
Under that condition, check the position of the circuit protector switch (bottom side of controller) (on or off). (After turning the starter switch to the OFF position, turn on the circuit protector switch.)
Circuit protector
Judgment for controller
Cause
OFF
Normal
Power supply or output circuit shortcircuited
ON
Abnormal
Defective transmission controller (IC self-diagnosis)
2.When the output units (solenoid valve, etc.) do not operate properly :
Solution Check the power supply and output circuits Replace the transmission controller assembly
Remove connector CN2 from the output side. Operate the shift lever, parking switch, etc., and check the on/off statuses of the transmission controller LED indicator.
ON/OFF status of LED Judgment for controller
Input side
Output side
No LED
No LED
Normal LED
Normal LED
Normal LED
No LED
Cause
Solution
Defective input unit or circuit
Check the input units and the circuit
Defective output unit
Check the output units and the circuit Replace the transmission controller assembly
Normal Abnormal
Defective transmission controller
Checking transmission controller If the input units or circuit are not defective, there is a strong possibility that the transmission controller is defective. To check the transmission controller, directly input the input signal, and then check the on/off statuses of the transmission controller LED indicator. If a LED indicator is not on, judge that the transmission controller is defective. Replace it. 1.Set-up Remove all the controller connectors, and then supply power to connector CN1 (terminal 11: +24V/Terminal CN2 CN1 12:Grounding). 2.Directly inputting input signal Shortcircuit (connect) the terminals of connector CN1 1 2 3 4 5 6 7 8 9 10 1 1 using the probes of the tester or a jumper wire. Terminals to be connected
Inlet LED
Output LED
F
1-10
F&P
F&N
R
2-10
R&P
R&RR
1
3-10
1
1
2
4-10
2
2
3
5-10
3
3 4
Comparable Shift lever position
Input signal
6-10
4
Parking
A
7-10
P
Inching
8-10
I
62-57
1 11 221 313 4 14 5156 617 17 8189290210 11
12
+24V Jumper wire
Simulating "R" position of shift lever
85Z Ⅳ -2
On/Off Statuses of T/M Controller LED
Electrical 62
On/Off Statuses of Transmission Controller LED Indicator (S/N 85C3-5501〜5800) The transmission controller LED indicator should be on as shown below if the transmission controller is operating normally and inputs are correct.
Input side LED window Output side LED window
Shift lever position ・A
M
Automatic shift cancel
S
Shift switch (QUAD Sw)
P
Parking switch
I
Inching switch
1
2
3
A
1
2
3
A
◎ ◎ ◎ ◎
◎
switch switching
PUS (QUAD)
Inching
Speed change
◎ ◎
LED on: During switch operation only
◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎
◎ ◎
LED on: In running status
◎ ◎
◎ ◎ ◎ ◎ ◎
◎
Clutch solenoid valve ・1 Clutch solenoid valve ・2
3
Clutch solenoid valve ・3
◎ ◎ ◎
Neutral relay
◎ ◎
◎ ◎
◎
2
◎ ◎ ◎ ◎
◎ ◎ ◎ ◎ ◎
◎
◎ ◎ ◎
◎ ◎
◎
◎
◎ ◎
◎ ◎
◎
◎ ◎ ◎
◎
◎ ◎ ◎ ◎ ◎
◎ ◎
◎ ◎
◎ ◎
◎ ◎
◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎
◎ ◎
◎ ◎ ◎ ◎ ◎
◎ ◎ ◎ ◎
RR
◎ ◎
◎ ◎
1
N
◎
◎ ◎ ◎ ◎ ◎
Clutch solenoid valve ・R
Trimmer plug solenoid valve
◎ ◎ ◎ ◎ ◎
◎
Clutch solenoid valve ・F
Clutch solenoid valve ・4
◎ ◎
F
4
F R F1 F2 F F2 F2 R2 R2 ↓ ↓ R1 F1 4 4 F2 R2 2
◎ ◎ ◎ ◎ ◎
R
D
cancel
R
Automatic shift
R
Remarks
・
Shift lever position ・3
・
3 A
R
・
Shift lever position ・2
R
・
2
F
・
Shift lever position ・1
F
・
Shift lever position ・R
1
F
・
R
F
・
Shift lever position ・F
Backward
・
F
Forward
・
◎-◎- ◎ Related LED on
Normal running ("A" shows automatic shift position)
・
◎ LED on
Shift lever Machine condition position
In running status
◎
◎
◎ ◎
X
Controller failure alarm relay ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎
BZ
Buzzer
SS
Speed sensor input signal
◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎
62-58
LED on: During switching
◎ ◎
LED on: In normal condition
LED flashes depending on machine speed
85Z Ⅳ -2
On/Off Statuses of T/M Controller LED
Output side LED window
Input side LED window
Circuit protector on when controller failure alarm is on
Emergency
Circuit protector OFF
Usual parking Neutral
◎-◎-◎ Related LED on
Other than neutral
◎ LED on
Shift lever Machine condition position
In parking status(during engine operation)
F
Shift lever position ・F
◎
◎
R
Shift lever position ・R
◎
◎
1
Shift lever position ・1
◎ ◎
◎
2
Shift lever position ・2
◎ ◎
◎
3
Shift lever position ・3
◎ ◎
◎
A
Shift lever position ・A
◎ ◎
◎
M
Automatic shift cancel
S
Shift switch (QUAD Sw)
P
Parking switch
I
Inching switch
F
Clutch solenoid valve ・F
R
Clutch solenoid valve ・R
◎
1
Clutch solenoid valve ・1
◎ ◎
2
Clutch solenoid valve ・2
◎ ◎
3
Clutch solenoid valve ・3
◎ ◎
4
Clutch solenoid valve ・4
D
Trimmer plug solenoid valve
N
Neutral relay
RR
Back-up relay
X
Controller failure alarm relay
BZ
Buzzer
SS
Speed sensor input signal
◎
◎ (◎) ◎ ◎ ◎
◎
◎
( ◎ ) : LED ON only shift lever "reverse"
62-59
Electrical 62
85Z Ⅳ -2
On/Off Statuses of T/M Controller LED
Electrical 62
On/Off Statuses of Transmission Controller LED Indicator (S/N 85C3-5801〜) The transmission controller LED indicator should be on as shown below if the transmission controller is operating normally and inputs are correct.
Input side LED window Output side LED window
Shift lever position ・A
M
Automatic shift cancel
S
Shift switch (QUAD Sw)
P
Parking switch
I
Inching switch
1
2
3
A
1
2
3
A
◎ ◎ ◎ ◎
◎
switch switching
PUS (QUAD)
Inching
Speed change
◎ ◎
LED on: During switch operation only
◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎
◎ ◎
LED on: In running status
◎ ◎
◎ ◎ ◎ ◎ ◎
◎
Clutch solenoid valve ・1 Clutch solenoid valve ・2
3
Clutch solenoid valve ・3
◎ ◎ ◎
Neutral relay
◎ ◎
◎ ◎
◎
2
◎ ◎ ◎ ◎
◎ ◎ ◎ ◎ ◎
◎
◎ ◎ ◎
◎ ◎
◎
◎
◎ ◎
◎ ◎
◎
◎ ◎ ◎
◎
◎ ◎ ◎ ◎ ◎
◎ ◎
◎ ◎
◎ ◎
◎ ◎ ◎ ◎ ◎
◎ ◎ ◎ ◎
RR
◎ ◎
◎ ◎
1
N
◎
◎ ◎ ◎ ◎ ◎
Clutch solenoid valve ・R
Trimmer plug solenoid valve
◎ ◎ ◎ ◎ ◎
◎
Clutch solenoid valve ・F
Clutch solenoid valve ・4
◎ ◎
F
4
F R F1 F2 F F2 F2 R2 R2 ↓ ↓ R1 F1 4 4 F2 R2 2
◎ ◎ ◎ ◎ ◎
R
D
cancel
R
Automatic shift
R
Remarks
・
Shift lever position ・3
・
3 A
R
・
Shift lever position ・2
R
・
2
F
・
Shift lever position ・1
F
・
Shift lever position ・R
1
F
・
R
F
・
Shift lever position ・F
Backward
・
F
Forward
・
◎-◎- ◎ Related LED on
Normal running ("A" shows automatic shift position)
・
◎ LED on
Shift lever Machine condition position
In running status
◎
◎ ◎
◎
◎ ◎
X
Controller failure alarm relay ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎
BZ
Buzzer
SS
Speed sensor input signal
◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎
62-60
LED on: During switching
◎ ◎
LED on: In normal condition
LED flashes depending on machine speed
85Z Ⅳ -2
On/Off Statuses of T/M Controller LED
Output side LED window
Input side LED window
Circuit protector on when controller failure alarm is on
Emergency
Circuit protector OFF
Usual parking Neutral
◎-◎-◎ Related LED on
Other than neutral
◎ LED on
Shift lever Machine condition position
In parking status(during engine operation)
F
Shift lever position ・F
◎
◎
R
Shift lever position ・R
◎
◎
1
Shift lever position ・1
◎ ◎
◎
2
Shift lever position ・2
◎ ◎
◎
3
Shift lever position ・3
◎ ◎
◎
A
Shift lever position ・A
◎ ◎
◎
M
Automatic shift cancel
S
Shift switch (QUAD Sw)
P
Parking switch
I
Inching switch
F
Clutch solenoid valve ・F
R
Clutch solenoid valve ・R
◎
1
Clutch solenoid valve ・1
◎ ◎
2
Clutch solenoid valve ・2
◎ ◎
3
Clutch solenoid valve ・3
◎ ◎
4
Clutch solenoid valve ・4
D
Trimmer plug solenoid valve
N
Neutral relay
RR
Back-up relay
X
Controller failure alarm relay
BZ
Buzzer
SS
Speed sensor input signal
◎
◎ (◎) ◎ ◎ ◎
◎
◎
( ◎ ) : LED ON only shift lever "reverse" position
62-61
Electrical 62
85Z Ⅳ -2
Function of Diagnostic System
Electrical 62
Function of Diagnostic System for Monitor Controller (S/N 85C3-5601〜) Starter SW ON
Current condition
(engine OFF)
Abnormal
Normal
Diagnostic SW
Warning lamp ON
2 seconds ON: Release switch to the "off" position when the screen goes blank. (Timing is critical.)
Failure history indication Warning lamp flashes on and off every 3 seconds.
Reset SW
3 seconds ON: Release switch to the "off" position when the screen goes blank. (Timing is critical.)
Failure history memorized is deleted completely.. (Buzzer sounds 2 seconds)
62-62
If more than one failure code is memorized, the newer failure code will flash first. In case no failure code is memorized, all warning lamps come on for 1.5 seconds.
85Z Ⅳ -2
Function of Diagnostic System
Electrical 62
Function of Diagnostic Memory Data Warning monitor control １
２ ３ ４
km/h
000000 1/10h
AUTO N 4 3 2 1
５ ６ ７ ８ ９
1. 2. 3. 4. 5.
Automatic shift Centralized alarm Controller failure alarm Low air pressure alarm Brake alarm
6. Low engine oil pressure alarm 7. Engine water temperature alarm 8. Torque converter (T/M)oil temperature alarm 9. Air cleaner clogging alarm
(1) If there was some abnormality found more than 2 seconds for T/M oil temp., E/G water temp., and Air cleaner during engine running, abnormal condition is memorized in the controller memory.
(4) If there was some abnormality found more than 2 seconds for air press., abnormal condition is memorized in the controller memory.
(2) If there was some abnormality found more than 2 seconds for E/G oil press., during engine running, abnormal condition is memorized in the controller memory. (3) If there was some abnormality found more than 2 seconds for brake oil level during engine running, abnormal condition is memorized in the controller memory.
62-63
(5) If there was some abnormality found for air master stroke end during engine running, immediately abnormal condition is memorized in the controller memory.
85Z Ⅳ -2
Function of Diagnostic System
Electrical 62
Failure Code The failure code is indicated in the failure code inspection window of the controller. code
Failure
Malfunction
12
Transmission Output Circuit Malfunction
Machine System Input Malfunction
Transmission Input Circuit
11
23
Detection Condition
Shift lever F and R contacts ON at
In case the failure continues for more than 3
the same time
seconds
Shift lever any of more than two 1・ 2・ 3・A contacts on the same time
The same as the above
Shift lever all 1・2・3・A contacts
In case all 1・2・3・A signal OFF continues for
OFF
more than 3 seconds In case the switch is ON for more than 10
Mode A A A
25
QUAD switch malfunction
26
Inching switch malfunction
31
Air cleaner element clogging
32
Transmission oil temperature high
The same as the above
B
33
Engine water temperature high
The same as the above
B
34
Engine oil pressure low
35
Air pressure low
In case the failure continues for more than 2 seconds
B
36
Air master stroke end
In case the stroke sensor is pushed out immediately
B
37
Brake oil level low
In case the failure continues for more than 2 seconds
B
51
1st solenoid valve malfunction
Output circuit is open or disconnected
A
52
2nd solenoid valve malfunction
The same as the above
A
53
3rd solenoid valve malfunction
The same as the above
A
54
4th solenoid valve malfunction
The same as the above
A
55
F solenoid valve malfunction
The same as the above
A
56
R solenoid valve malfunction
The same as the above
A
72
Machine speed sensor malfunction
Input circuit is disconnected
A
81
F・1 solenoid valve malfunction
Output circuit is open or disconnected
A
82
F・2 solenoid valve malfunction
The same as the above
A
seconds In case the switch is ON for more than 3 minutes In case the failure continues for more than 2 seconds
In case the failure continues for more than 2 seconds during engine running
62-64
A A B
B
85Z Ⅳ -2
Function of Diagnostic System
Transmission Output Circuit Malfunction
code
Failure
Electrical 62
Detection Condition
Mode
83
F・3 solenoid valve malfunction
The same as the above
A
84
F・4 solenoid valve malfunction
The same as the above
A
85
R・1 solenoid valve malfunction
The same as the above
A
86
R・2 solenoid valve malfunction
The same as the above
A
87
R・3 solenoid valve malfunction
The same as the above
A
88
R・4 solenoid valve malfunction
The same as the above
A
FF
No failure record memorized
Note : Mode A : Transmission control input/output circuit malfunction. 1) If there was some abnormality during engine running, abnormal condition is memorized in the controller memory. 2) If more than one failure code is in memory the newest failure code will be displayed first (1 time only).
62-65
Mode B : Malfunction at chassis side. 1) If there was some abnormality, abnormal condition is memorized in the controller memory during engine running only. 2) If the failure code memorized is more than one the newer failure code flashes on and off first in order.
Function of Diagnostic System
85Z Ⅳ -2
Electrical 62
Diagnostic (Controller) 1. Failure code indication for current failure: If more than one failure code is stored in memory the current one is displayed first. To review older failure codes switch ON the diagnostic switch. 2. Shift lever failure detection codes (codes 11, 12, 23): Codes 11 and 12 indicate a short circuit in either the shift lever or the wiring. Code 23 indicates an open circuit in the shift lever or a broken wire. The machine may operate normality in all but one speed. 3. QUAD switch malfunction code (code 25): Normally the switch is not pushed for more than 10 seconds. If the switch stays ON (contacts closed) for more than 10 seconds the controller considers it to be a short circuit in the switch or its wiring. If, for some reason, the operator does hold the switch down for more than 10 seconds the code 25 will be stored in the controller but the machine will operate normally. 4. Inching (declutch) switch malfunction code (code 26): When using the inching (also called declutch or clutch-cutout) switch it is normal for it to be ON (contacts closed) while the left brake pedal is depressed. However, if the switch remains ON for more than 3 minutes the controller considers that there is a short in the switch or its wiring. Should the operator keep the pedal depressed more than 3 minutes the malfunction code will be stored in the controller but the machine will continue to operate normally. 5. Solenoid open circuit codes (codes 51 〜 56, 81 〜 88): If the transmission solenoid coil is internally open, has high resistance (more than 35 Ω ), or a broken wire between the controller and the solenoid coil, the machine will not move in the gear that has the open circuit (malfunction codes 51-56). The symptom may be the same as 2 above. Read the malfunction code to determine which malfunction has actually occurred. 6. Machine speed sensor malfunction (code 72) indicates the machine speed sensor is internally open or the wiring between the sensor and the controller is disconnected or broken.
62-66
7. No malfunction code recorded (code FF): If the diagnostic switch is installed and pressed and there are no malfunction codes stored in memory the display will be shown "FF". If the machine will not move and "FF" is displayed check the input LED's to be sure there are no open circuit (except code 23 which is for speed circuits 〔 1,2,3,A 〕only) from the shift lever will not be stored in memory.
85Z Ⅳ -2
Function of Diagnostic System
Electrical 62
Failure History Indication and Deletion 1. Failure history indication When the starter switch is ON (but no engine started), place the diagnostic switch to ON position. About 2 seconds later, the autoshift indicator lamp AUTO and all warning lamps on the instrument panel light up and the indication of "FF" on the diagnosis display window comes to disappear. After that in a moment place the diagnostic switch to OFF position. The failure code is displayed on the diagnosis display window of the controller. If fail to do this, no failure code is displayed on the diagnosis display window of the controller.
・Failure history indication
2. Failure history deletion When the starter switch is ON (but no engine started), place the reset switch to ON position. About 3 seconds later, the autoshift indicator lamp AUTO and all warning lamps on the instrument panel light up and the indication of "FF" on the diagnosis display window comes to disappear. After that in a moment place the reset switch to OFF position. The indication of "PP" is displayed on the diagnosis display window of the controller and at the same time the buzzer sounds. Then the failure history deletion is completed. If fail to do this, no failure history deletion is completed.
2sec
Diag.sw 1.5 1.0 sec sec
3sec
Warning lamp All warning lamp
Each warning lamp
AUTO All warning lamps (Except centralized warning lamp)
Controller (7seg)
1.0 sec
1.0 sec
T/M control Input/output circuit malfunction
Malfunction at chassis side
・Failure history deletion Reset sw
3sec 2sec
Failure history deletion completely
Buzzer
All warning lamps (Except centralized warning lamp) All warning lamp
Warning lamp
Controller (7seg) 1.5sec
62-67
2sec
3sec
85Z Ⅳ -2
Function of Diagnostic System
Electrical 62
Electrical Wiring Connection When performing the diagnostic procedure, connect the diagnostic switch coupler to the controller as shown below. 1. Necessary parts 1)Diagnostic switch assembly (A) Part Number : 35020-20510 ・Diagnostic sw ・Reset sw ・Harness assembly 2)Harness assembly (B) Part Number : 33191-52950 2. Connection procedure
Diag.SW
Reset SW OFF
ON OFF
(A)
Controller
8P
21P
ON
21P
6P
G
R
Y
B
Connect
B Y
R
Y
(B)
R B
62-68
85Z Ⅳ -2
Checking Shift Lever Input Circuit
Electrical 62
Checking Shift Lever Input Circuit 〔Transmission controller LED indicator〕 Check that the LED indicator corresponding to the shift lever position is on. LED
Judgment Normal
Corresponding LED indicator is on Corresponding LED indicator is off Wrong LED indicator is on
Shift lever assembly
disconnection
Abnormal
Shortcircuit
Connector B4
If the judgment is abnormal, follow the check procedure below:
A
<Step 1> Shift lever conductivity test Set the starter switch to the OFF position, and then disconnect connector B4 so that the shift lever assembly is disconnected. Perform conductivity test using a tester (circuit tester).
Disconnection check: Shift lever position
F R 1 2 3 A
Terminals to be checked Between terminals F and F/R common grounding Between terminals R and F/R common grounding Between terminals 1 and speed change common grounding (B) Between terminals 2 and speed change common grounding (B) Between terminals 3 and speed change common grounding (B) Between terminals A and speed change common grounding (B)
Check result
Judgment
F R 1 2 3 A
Between terminals R and F/R common grounding Between terminals F and F/R common grounding Between terminals 1 and speed change terminal other than 1 Between terminals 2 and speed change terminal other than 2 Between terminals 3 and speed change terminal other than 3 Between terminals A and speed change terminal other than A
1st speed (GW)
2nd speed (GL) 3rd speed (GY) Speed common grounding (B)
F(GR) Unused
Conductive (Resistance
R(GB)
Normal
F/R common grounding(BY)
0Ω)
Shortcircuit check: Terminals to be checked
Details of connector (viewed from A)
A speed (G)
If the line is not conductive, judge that the switch or wire is damaged or defective.
Shift lever position
85V62012
Check result
Judgment
Non-conductive (Resistance
Normal
∞Ω )
If a section is conductive, judge that the switch is sticking. In this case two or more signals would be sent at the same time (eg forward and reverse ; 1st and 3rd)
<Solution> If disconnection or shortcircuit is detected, replace the shift lever assembly. The shift lever has no serviceable parts and must be replaced. If the conductivity check reveals that the shift lever is not defective, go to step 2. 62-69
85Z Ⅳ -2
Checking Shift Lever Input Circuit
Electrical 62
<Step 2> Checking conductivity of shift lever input circuit cable Connect connector B4 to the shift lever, and disconnect connector CN1 from the transmission controller. Check the conductivity of the cable connector terminals.
Shift lever position
Terminals to be checked
F
LR-BY
R
LBr-BY
1
LY-BY
2
LG-BY
3
LO-BY
A
LW-BY
Check result Judgment
Shift lever circuit
Conductive
Transmission controller
Normal
Output side LED
Input side LED
If a line is not conductive, judge that the cable is defective. Also check that only the above terminals are conductive. Other wise there could be a short circuit in the wiring.
Circuit protector
CN1 CN3 (White)
CN2 CN4 (Blue)
８０Ｖ６２０１６
<Solution> If a cable is defective, repair or replace it.
62-70
85Z Ⅳ -2
Checking Inching Input Circuit
Electrical 62
Checking Inching (declutch) Input Circuit 〔Transmission controller LED indicator〕
ON
OFF
Transmission cut-off monitor lamp
Input LED " I " Brake pedal
Judgment
Remarks
Pressed down Released
◎
-
-
-
◎
◎
-
-
Normal Abnormal
Transmission cut-off switch
Checking conditions 1) Engine "OFF" key "ON" 2 2) Air pressure above 490kPa (5kgf/cm )〔71psi〕 Turn the transmission cut-off switch on the instrument panel "ON". Note that the transmission cut-off monitor lamp will light if the lamp circuit is not defective. Press down the left brake pedal, and check the on/off status of the transmission controller "I" LED indicator.
Disconnect
Inching impossible
Defective sw or shortcircuit
Machine stays in the inching (declutch) mode
Normal
Inching function cancel
◎ On - Off
<Step 1> Checking inching switch Ｃｏｎｎｅｃ ｔ ｏｒ Ｃ４
Check that the brake air pressure is 216±20kPa (2.2 ±0.2kgf/cm2) (33±3psi) or more. After that, press down the left brake pedal, and check the resistance of the inching switch at the connector C4. If the connector resistance dose not change from ∞Ω to 0 Ω, the piston of the switch is sticking, or the cable is disconnected. Repair or replace the defective unit.
６５Ｖ６２００８
Setting Air pressure : 177±20kPa (1.8±0.2kgf/cm2) (26 ± 3psi) or less
Between both terminals : OFF
Air pressure : 216±20kPa (2.2±0.2kgf/cm2) (31 ± 3psi) or more
Between both terminals : ON
62-71
85Z Ⅳ -2
Checking Inching Input Circuit
Electrical 62
<Step 2> Checking
transmission cut-off switch assembly Disconnect the A2 connector of the transmission cut-off switch assembly from the instrument panel. Perform conductivity test using a tester.
ON
OFF
Transmission cut-off switch
Conductivity test
Between terminals 5 and 6 (Transmission controller input) Between terminals 2 and 3 (Lamp circuit)
Switch position ON
OFF
0Ω
∞Ω
∞Ω
∞Ω
Judgment (Test switch here)
Normal
0Ω 0Ω(other than∞Ω )
Abnormal
Terminals to be checked
Disconnect
Cable-side connector
Shortcircuit
<Step 3> Checking cable
６５Ｖ６２００４
If the inching pressure switch and transmission cut-off switch are not defective, judge that the cable or connector is defective. <Solution> Repair or replace the defective unit. Inching input circuit +24V 15A
ON
"Transmission cut-off" monitor lamp Transmission controller CN1
OFF A6 2
Transmission cut-off switch
Inching switch
A2
B LgY
3 6
LLg
5
LgR
G B
C4
LgR BY
８０Ｖ６２０１７
62-72
Checking QUAD Switch Input Circuit
85Z Ⅳ -2
Electrical 62
Checking QUAD Switch Input Circuit 〔 While traveling at the 2nd speed, turn on the QUAD switch, and the speed will be shifted to the 1st. (For both manual and automatic modes) 〕 Turn the switch ON again and the transmission should be shifted back to 2nd speed.
Problem:The QUAD switch does not shift the speed. 〔Checking transmission controller input LED indicator〕 Check that the transmission controller "S" LED indicator lights when the QUAD switch is turned on. LED ON OFF
E1
Judgment Normal Abnormal
Disconnect
If the "S" indicator does not light: Checking QUAD switch : Disconnect the switch E1 connectors. Check that the terminal line is conductive (0Ω) when the switch is depressed.
Transmission controller CN1
<Solution> If the switch is defective (non-conductive), replace it. If the switch is not defective, judge that the cable or connector between the transmission controller and switch is defective. Repair or replace the defective unit.
80V62018
62-73
Checking Speed Sensor Input Circuit
85Z Ⅳ -2
Electrical 62
Checking Speed Sensor Input Circuit Problem:The automatic shift function is not working. The automatic shift function needs a speed signal. 〔Transmission controller input LED indicator〕 Checking conditions 1) Select an open site away from people, other equipment and buildings. 2) Watch the input LED "SS" while the machine is moving at 1〜5km/H. Check the speed sensor by checking the transmission controller "SS" LED indicator. LED「SS」
Normal
Does not light (flash)
Abnormal
Gear
0.7〜1.3mm Sensor
M18 x pitch 1.5mm
Gasket
Judgment
Flashes according to the speed
Transmission output gear
Torque 20〜29N-m (2〜3kgf-m) (14〜21lb-ft)
<Step 1> Checking sensor Note :No need for the clearance adjustment.
Checking sensor for disconnection : Disconnect the sensor connector, and then measure the resistance between the terminals. Resistance
Judgment
Approx. 1.6kΩ (20 ° C)
Normal
∞Ω (Disconnection) 0 Ω (short)
Abnormal F4
<Solution> If the sensor is defective, replace it. If the sensor is not defective, the cable or connector between the sensor and the transmission controller is defective. Repair or replace the defective unit. Transmission controller CN1
８５Ｖ６２０１３
62-74
Checking Solenoid Valve Output Circuit
85Z Ⅳ -2
Electrical 62
Checking Clutch Solenoid Valve Output Circuit Problem:A clutch will not engage. Set the shift lever to the problem position. If the corresponding transmission controller input/output LED indicator is properly turned on and off, judge that the coil of the corresponding solenoid valve is disconnected, or the valve is sticking, or the cable of the output circuit is disconnected or poorly connected.
Problem;The machine can run at only one shift lever position. The machine runs at a certain shift lever position, though it does not run or runs too slow at any other position. In this case, judge that the cable (negative) of the solenoid valve is short circuited, or the valve is sticking.
Problem:The circuit protector is turned off. The cable (power supply side) between the transmission controller and the solenoid valve is shortcircuited or the solenoid valve coil is internally defective.
<Step 1> Checking solenoid valve Measuring coil resistance Disconnect the connector from the solenoid valve, and then measure the coil resistance using a tester. Note that a diode is incorporated in the coil. Coil resistance
Judgment
Approx. 26Ω
Normal
Disconnect ∞Ω short 0 Ω
Abnormal
Manual operation knob
To check the coil and the diode : Use an analog (needle type) volt-0hm meter (V0m) with an Rx1 Ω setting. Adjust the meter's zero setting. Measure the resistance through the coil in both directions by reversing the test probes. The meter readig will be different for each measurement. If the diode is good. If the diode is defective the meter will read the same in both directions. If the diode is defective replace the solenoid valve assembly. A defective diode can cause a controller failure over time.
Checking valve for sticking Push the manual operation knob to the ON position by hand, and then check that the spool operates smoothly. If it does not operate smoothly, judge that the valve is sticking. <Solution> If the coil is disconnected or the valve is sticking, replace the defective unit as an assembly.
62-75
85Z Ⅳ -2
Checking Solenoid Valve Output Circuit
WARNING
Electrical 62
Layout of solenoid valves Control valve
Unexpected movement of the machine may cause an accident resulting in injury or death. Be sure to observe the following items before starting work. ・ Position the machine on a level ground, and lower the bucket onto the groung. ・ Block the tires with chocks to prevent them from moving.
D
3 R F 4
2
1
F: R: 1 : 2 : 3 : 4 : D:
For forward clutch For reverse clutch For 1st speed clutch For 2nd speed clutch For 3rd speed clutch For 4th speed clutch For trimmer plug
<Step 2> Checking output circuit and cable Disconnect the connector from the problem solenoid valve, and then set the starter switch to the ON position (engine OFF ; shift lever set to problem speed ; parking brake OFF). Measure the voltage of the connector terminal on the cable side using a tester. Example : Measure the voltage between terminals LY and L to check the connector of the 1st speed solenoid valve. Note : Power is supplied to a solenoid valve only when the shift lever is set to the corresponding position. (When the output LED on) To check the 4th speed connector, be sure to cancel the automatic shift function.
Colors of output circuit cables
(-) (+) F LR R LBr 1 LY 2 LG L 3 LO 4 LW D LP
IMPORTANT When measuring voltage, do not shortcircuit two terminals of a connector. This is because the electronic parts inside the controller may be damaged.
Checking positive cable Terminals to be checked
Voltage
Judgment
Between terminals L and body grounding (For 1st speed solenoid)
Approx. 24V
Normal
Approx. 0V
Abnormal
８５Ｖ６２０１４
Checking negative cable Terminals tobe checked
Voltage
Judgment
Between terminals LY and body grounding (For 1st speed solenoid)
Approx. 1V
Normal
Approx. 24V
Abnormal
<Solution> If the voltage is abnormal, judge that the cable is disconnected. In this case, check the next connector (G7 shown in the figure), and find the defective unit. Repair or replace the defective unit.
62-76
85Z Ⅳ -2
Checking Trimmer Plug Solenoid Valve
Electrical 62
Checking Trimmer Plug Solenoid Valve Problems and causes of trimmer plug solenoid valve malfunction and abnormal clutch oil pressure Clutch solenoid valve
Clutch oil pressure (MPa)
Cause
Just after clutch switching
Several seconds after switching
Disconnected 1.3〜1.5 cable or sticking valve at (13〜15kgf/cm2) non-energized (185〜213psi) position Sticking valve at energized position
Approx. 0.4 (4kgf/cm2) (57psi)
←
←
Clutch switching
Problem A shock will be applied to the machine when the speed is changed.
Clutch switching complete ON
OFF
ON
Trimmer plug solenoid valve
OFF Sticking in non-excited status
No power Frequent slip
t0
t1 1.3〜1.6MPa 2 (13〜16kgf/cm ) (185〜228psi) (Engine middle speed)
Note : The same problems occur when the clutch pressure regulator valve is sticking. Therefore, if the solenoid valve is not defective, check the regulator valve. Low pressure condition can also be caused by debris (like o-ring pieces or gasket pieces) sticking in the solenoid valve.
Normal Pressure
Approx. 0.4MPa 2 (4kgf/cm ) (57psi) Approx. 1.2sec
<Step 1> Checking solenoid valve Measuring coil resistance Disconnect the connector from the solenoid valve, and then measure the coil resistance using a tester. Note that a diode is incorporated in the coil. Coil resistance
Judgment
Approx. 26Ω
Normal
Disconnect ∞Ω
Abnormal
Trimmer plug chamber
To transmission oil pan via trimmer spring chamber
Checking valve for sticking Push the manual operation knob to the ON position by hand, and then check that the spool operates smoothly. If it does not operate smoothly, judge that the valve is sticking. Disassemble, clean, inspect and reassemble and retest the solenoid valve. <Solution> If the coil is disconnected or the valve is sticking, replace the defective unit as an assembly.
62-77
Sticking at excited status
85Z Ⅳ -2
Checking Trimmer Plug Solenoid Valve
<Step 2> Checking output circuit and cable
Electrical 62
Layout of solenoid valves
Disconnect the M7 connector from the trimmer plug, and set the starter switch to the ON position. Measure the voltage of the connector terminal on the cable side using a tester. Note that the voltage reading occurs for 1-2 seconds just after shifting the shift lever.
Control valve
D
3 R F 4
2
1
F: R: 1 : 2 : 3 : 4 : D:
For forward clutch For reverse clutch For 1st speed clutch For 2nd speed clutch For 3rd speed clutch For 4th speed clutch For trimmer plug
IMPORTANT When measuring voltage, do not shortcircuit two terminals of a connector. This is because the electronic parts inside the controller may be damaged.
Checking positive cable Terminals to be checked
Voltage
Judgment
Between terminals L and body grounding (For D trimmer solenoid)
Approx. 24V
Normal
Approx. 0V
Abnormal
Colors of output circuit cables
(-) (+) F LR R LBr 1 LY 2 LG L 3 LO 4 LW D LP
Checking negative cable Terminals to be checked
Voltage
Judgment
Between terminals LP and body grounding (For D trimmer solenoid)
Approx. 1V
Normal
Approx. 24V
Abnormal
<Solution> If the voltage is abnormal, judge that the cable is disconnected or broken. In this case, check the next connector (G7 shown in the figure), and find the defective unit. Repair or replace the defective unit.
62-78
８５Ｋ６２０１５
85Z Ⅳ -2
Checking Neutral Relay Circuit
Electrical 62
Checking Neutral Relay Circuit (S/N 85C3-5501〜5800) Problem:Engine does not start with the shift lever in neutral position.
Problem:The engine will start at the shift lever forward or reverse position.
Though the transmission controller "N" LED indicator is off, the engine will not start, judge that the neutral relay contact is not closed.
If the engine starts though the transmission controller "N" LED indicator is on, judge that the neutral relay contact is sticking, or the relay coil is defective.
<Step 1> Checking cable of output circuit ①Disconnect connector F1 from the neutral relay, and then set the starter switch to the ON position. Set the shift lever to the forward or reverse (F or R) position, and then measure the voltage of the connector terminal on the cable side. (Normal=24V)
In "F" or "R" Neutral relay
①
②
24V
③
24V
0〜1V
②Checking positive cable Terminals to be checked
Voltage
Judgment
Between terminals L and body ground
Approx. 24V
Normal
Approx. 0V
Abnormal G : From fuse F14(starter switch terminal C)
③Checking negative cable Terminals to be checked
Voltage
Judgment
Between terminals Sbp and body ground
Approx. 1V
Normal
Approx. 24V
Abnormal
Transmission controller CN2
<Solution> If the voltage is abnormal, judge that the cable is disconnected or short circuited. replace the cable.
Repair or
<Step 2> Checking neutral relay
８０Ｖ６２０２２
The neutral relay is the same type as the back-up lamp relay and controller failure relay. Therefore, to check the neutral relay, replace the neutral relay with one of these relays, and attempt to start engine. If the engine now starts, the relay is defective. <Solution> If the relay is defective, replace it.
62-79
85Z Ⅳ -2
Checking Neutral Relay Circuit
Electrical 62
12V
12V
30A
(W5)
Battery F15
(WR ニ) (WL)
5A (WV)
(WR)
IN
Circuit protecter
Shift lever
F
Battery relay
70A
N R
forward/reverse position
Controller
F14
5A
+24V
Cold starter sw (WB)
Ether kit
F7 15A
1
+24V
Thermo sw
(WP) (BrR)
3 Neutral relay
LED (Indication: N)
2
Starter
4
B
C
(R5) (BW 5) Magnetic sw
(WG)
Voltage relay
＊When shift lever is F/R position / LED ON When shift lever is N position / LED OFF
８０Ｖ６２００７
Note :The above shows 85C3-5501〜5800.
for
the
machines
S/N
62-80
85Z Ⅳ -2
Checking Parking Brake Circuit
Electrical 62
Checking Parking Brake Circuit Problem:The parking brake cannot be applied or cannot be released. The parking switch is interlocked to the parking lamp of the instrument panel. It turns on and off the parking lamp. If the lamp turns on when the switch is pulled up and goes off when it is pushed in the switch is working properly. If the lamp does not work the switch, lamp or wiring is defective. If the lamp works with the switch, check the parking brake solenoid or its wiring.
Parking switch
Transmission controller CN1
WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. To prevent such an accident, observe the following items before checking the parking brake circuit: ・ Park the machine on level ground. ・ Block the tires with chocks to prevent wheels from moving.
<Step 1> Checking cable of output circuit Disconnect the connector from the solenoid valve, and then measure the voltage of the connector terminal on the cable side using a tester. Note that the key should be "ON", engine off and the parking switch should be at the OFF position.
Checking positive cable Terminals to be checked
Voltage
Between terminals L and body grounding (Parking brake solenoid)
Approx. 24V
Normal
Approx. 0V
Abnormal
Parking solenoid
Judgment
(24V)
Checking negative cable Terminals to be checked
Voltage
Judgment
Between terminals LgG and body grounding (Park brake solenoid)
Approx. 1V
Normal
Approx. 24V
Abnormal
(290 Ω )
<Solution> If a cable is disconnected or a wire broken, measure the voltage of the next G1 connector in the same way. Find the defective cable, and then repair or replace the cable. <Step 2> Checking solenoid valve
Measuring coil resistance Disconnect the connector from the solenoid valve, and then measure the resistance of the coil using a tester. Coil resistance
Judgment
Approx. 290Ω
Normal
Disconnect ∞Ω or short circuited 0 Ω
Abnormal
(0〜1V)
62-81
〔STEP 2〕
〔STEP 1〕
Coil resistance
Parking brake switch OFF ８５Ｖ６２０１６
Checking solenoid valve for sticking Feed compressed air into the air tank. Turn the manual operation knob of the solenoid valve 90 ° to set the knob to the ON position. Check that the parking brake can be manually applied or released. If it cannnot be applied or released, the solenoid valve is sticking. <Solution> If the coil is defective or the valve is sticking, replace the valve assembly.
85Z Ⅳ -2
Checking Engine Stop Circuit
Electrical 62
Checking Engine Stop Circuit Fuse inside the control box
Ａ ５
Ａ ０ １
Ａ ５ Ａ Ａ Ａ
Ａ Ａ Ａ ５ Ａ Ａ Ａ ５ １
SPARE 4WAY FLASHER HORN ROOM LAMP
Ａ ５ Ａ ５
SPARE
Ａ ５
RADIO
Ａ Ａ Ａ
N4
Ａ ５
２０
506 N504 N N004
Ａ
２０
AIRCON(OPTION)
FUEL VALVE NEUTRAL RELAY BATTERY RELAY
５
２０
AIRCON(OPTION)
５
AIRCON(OPTION)
Ａ ５
Open
Ａ
Ａ
SPARE
Ａ ５ １
Ａ
SPARE
Ａ ５ １
Ａ ３
SPARE
Shortcircuit
Abnormal Both are non-conductive
Ａ ０ １
Conductive Both are conductive
Ａ ５
1-3
SPARE
SPARE
１５
Normal
Reverse the positive and negative sides Reverse the positive and negative sides
R. WORK LIGHT(CAB) Judgment
COLD STARTER
１５
Conductive
SPARE
１０
2-3
BUZZER MONITOR
F. WORK LIGHT
１５
Non-conductive
PARKING BRAKE CONTROLLER
SPARE
１０
3-1
BACK LAMP STOP LAMP TURN SIGNAL
１０
Non-conductive
BOOM KICKOUT BUCKET POSITIONER
R. WIPER
１０
3-2
R. WORK LIGHT
１０
Negative side Positive side of of tester tester
Conductivity
SPARE
F. WIPER
If the inside of the diode is shortcircuited, the voltage generated by the alternator is continuously applied to the fuel solenoid valve. In this case, the engine will not stop even if the starter switch is set to the OFF position. Disconnect connector N4 where the diode unit is located. Check the conductivity of the terminals on the diode side. Terminals to be checked
LIGHTING HEAD LIGHT
１０
<Step 1> Checking diode unit
SPARE
Ａ ０ ２
Turn the starter switch to the OFF position. If the engine is not stopped, the cause may be one of the following electrical causes. ・ Defective diode unit ・ Defective starter switch ・ Others: Defective cable or connector Note : To stop the engine remove fuse for the fuel valve.
WV:To battery relay WR:To starter switch terminal BR (VIA F15), fuel solenoid WL:To alternator Diode storage section ８０Ｖ６２０２４
Note : If the circuit tester is the digital (number indication)type, reverse the tester probe attachement sides compared with the above figure.
<Solution> If the diode unit is defective, replace the diode unit.
62-82
85Z Ⅳ -2
Checking Engine Stop Circuit
Electrical 62
<Step 2> Checking starter switch Disconnect the connector from the starter switch. While turning the switch on and off, check the resistance between the terminals. Starter position OFF Run
Terminals to be checked
Resistance
Judgment
W-WR
∞Ω
Normal
W-WR
0Ω
Normal
W-WR
∞Ω
Abnormal
<Solution> If the switch is defective, replace it as an assembly.
62-83
Rear surface of starter switch
85Z Ⅳ -2
Checking Gauge Circuit
Electrical 62
Checking Gauge Circuit The sensors respectively detect temperature, pressure, and fuel level, and then convert them into electric signals. The electric signals are then fed to the respective gauges and indicated on the gauges. If a gauge indicates wrong values, either the sensor, gauge or wiring will be defective. Determine the defective unit as following procedure.
Instrument panel CN2(20p)
Ground Air pressure Fuel level
Torque converter temperature Engine water temperature
<Step 1> Checking sensor signal Disconnect connector CN2 from the instrument panel, or disconnect the connector from the corresponding sensor. Measure the resistance between the sensor signal terminal and the ground terminal. If the measurement value (temperature, pressure, or fuel level) is acceptable compared with the standard value shown below, the sensor is not defective. If the measurement value is abnormal, check the wire in addition to the sensor because the cable may be defective (Corroded, broken, or high resistance).
AIR PRESS. SENSOR
Air pressure sensor Pressure kPa (kgf/cm2) (psi) Resistance between terminal and body ( Ω )
490 (5) (71)
785 (8) (114)
31.9
17.2
Torque converter oil temperature and engine water temperature
Temperature of detection area ( ° C)
60
80
100
120
Resistance between terminal and body ( 56.3 Ω)
29.5
16.2
10 ８５Ｖ６２０１７
Fuel level sensor Fuel level
E
F
Resistance between two terminals ( Ω )
80
10
62-84
85Z Ⅳ -2
Checking Gauge Circuit
Electrical 62
<Step 2> Checking gauge
Sensor
Remove the instrument panel, and then disconnect the connector from the panel. Measure the resistance between the screw terminals on the rear surface of the panel. Judge whether the resistance value is acceptable. Note : If a gauge is removed from the panel, the resistance between the terminals will differ from the standard value shown in the table.
S
Ground
Power supply 24V
E
V
15V
Viewed from rear surface of instrument panel Resistance between gauge terminals ( Ω )
Between S and E
110
Between S and V
110
Between E and V
150
S E Fuel sensor
Air pressure sensor
V Engine water temperature
Transmission oil temperature
Note : If a gauge is removed from the panel, the resistance between the terminals are as follows. S
E
V
Viewed from rear surface of gauge Resistance between gauge terminals ( Ω )
62-85
Between S and E
160
Between S and V
150
Between E and V
310
85Z Ⅳ -2 General Information, Functions & Structure AAA-S85C3V00-979 AAA-S85C3V00-012
① 1997.9
K
② 2001.2
KAWASAKI HEAVY INDUSTRIES, LTD. Rolling Stock, Construction Machinery & Crushing Plant Company Construction Machinery Division Tokyo Head Office
W.T.C. Bldg., 2-4-1 Hamamatsu-cho Minato-ku, Tokyo 105-6116
Kobe Head Office
Kobe Crystal Tower, 1-1-3 Higashi Kawasaki-cho Chuo-ku, Kobe, Hyogo 650-0044
Banshu Works
2680 Oka Inami-cho Kako-gun, Hyogo 675-1113
All rights reserved. No copy allowed without written consent.