DOWNLOAD PDF : Kawasaki Wheel Loader 95ZIV-3 Operation Maintenance Shop Parts Manual

AAA-M97C3E01-006 (93115-00092)

OPERATION & MAINTENANCE MANUAL WHEEL LOADER

95Z -3 WITH CUMMINS N14-C ENGINE

SERIAL NUMBERS 97C3-1001 and up. 97C3-9001 and up.

NOTICE READ AND UNDERSTAND THIS MANUAL BEFORE OPERATING AND SAVE THIS MANUAL ON THE MACHINE

FOREWORD Congratulations on your purchase of the Kawasaki Wheel Loader 95ZIV-3. This manual contains safety, operation, transportation, maintenance and troubleshooting information. Read and understand the information in this manual carefully before operating or performing any maintenance of the machine. Failure to do so could result in personal injury or equipment failure. The safety of yourself and others depends upon your care and judgement in the operation and maintenance of this machine. Keep the manual with this machine at all times. Kawasaki pursues a policy of continuing improvement in design and performance of this machine. The right is therefore reserved to vary specifications without prior notice or obligation. This machine gives you, our customer, the maximum in performance and durability, state of the art technology and safety. Should you have any question regarding this machine or manual, please contact the Kawasaki loader dealer in your area during regular business hours. A satisfied customer is our goal. This manual is compiled for persons who understand English. If an operator or maintenance person does not understand English, please translate what said in this manual into his mother language.

MACHINE SPECIFICATION Specification

Serial numbers

Remarks

Standard specification

97C3 -1001 and up

Europe specification

97C3 -9001 and up

With CUMMINS N14 -C Engine

Copyright © 2000 Kawasaki Heavy Industries, Ltd. All rights reserved.

SAFETY NOTICE Whenever you see the symbols shown below in this manual or on the machine, read and understand their messages.

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.

Always follow safe operating and maintenance practices. Kawasaki cannot anticipate every possible circumstance, use, or misuse of the machine that might involve a potential hazard. The warnings in this Operation & Maintenance Manual and on the machine are therefore not all inclusive. If an operation or maintenance procedure is not performed as specifically recommended by Kawasaki, you must satisfy yourself that it is safe for you and others. You should also ensure that the machine will not be damaged by the operation or maintenance procedure you choose. Kawasaki makes every effort to supply machines which conform to every regulation applicable in your country / state. However, if your machine is not supplied through the authorized Kawasaki loader dealer, it may not be equipped as the regulations require. Kawasaki cannot be responsible for anything on that kind of machine. Also, some local agencies or certain jobsites may require special equipment that has not been provided. Contact your nearest Kawasaki loader dealer for further information or assistance. No liability can be accepted for any inaccuracies or omissions in this publication, although every possible effort has been made to ensure it as complete and accurate as possible.

CONTENTS SAFETY・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・1 Safe Operation・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・1 Safe Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・11 Safety Signs・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・16 Safety Devices・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・24 COMPONENT NAME / LOCATION・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・27 OPERATOR'S AREA・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・28 Pedals and Levers・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・28 Switches・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・34 Indicators・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・39 Seat・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・46 Electrical Protection・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・48 Air Conditioner (option)・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・50 Vibration Damper (option)・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・53 Grease Gun Holder・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・53 OPERATION・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・54 Check Before Operation・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・54 Starting the Engine・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・62 Check after Starting the Engine・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・65 Operating the Machine・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・69 Parking・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・72 Stopping the Engine・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・73 Operating Techniques・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・74 SPECIAL PROCEDURES・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・80 Adjustments・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・80 Roading / Special Applications・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・83 Booster Batteries / Jumper Cables・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・84 Towing・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・86 Transportation・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・87 Long Term Storage・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・89

MAINTENANCE・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・91 Serial Number Location・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・91 Inspection and Maintenance Table・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・93 When Required Inspection and Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・95 Daily Inspection and Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・101 Every 50 Hours or 1 Week Inspection and Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・102 Every 250 Hours or 1 Month Inspection and Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・107 Every 500 Hours or 3 Months Inspection and Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・120 Every 1000 Hours or 6 Months Inspection and Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・122 Every 2000 Hours or 1 Year Inspection and Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・129 Recommended Lubricants and Capacity・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・140 Coolant Specification・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・141 TROUBLESHOOTING・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・142 SPECIFICATIONS・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・147 PERIODICAL REPLACEMENT PARTS LIST・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・149

SAFETY

SAFETY Safe Operation Operator Safety

Read and understand the Operation & Maintenance Manual.

Be aware of the location and meaning of safety signs (decals) on the machine. Report or replace any that are missing or unreadable. Be alert and ready to operate the machine safely: ・Do not operate if excessively tired. ・Do not operate if taking medication that causes drowsiness. ・Do not operate if under the influence of alcohol or drugs.

Wear safe clothing: ・Close fitting clothing -- loose or baggy clothing can catch on equipment or controls. ・Protective clothing as required by the job or conditions for example: -Hard hat -Gloves -Steel-toe shoes ・Do not wear jewelry that may catch on the equipment, controls or may short and cause burns if in contact with electrical components.

Mounting and Dismounting Safety

Face the machine when mounting or dismounting. Maintain three points of contact when climbing (two hands and one foot, or two feet and one hand). When mounting or dismounting, never carry tools or other objects in your hands. Climb and step only where steps and handrails are provided.

1

SAFETY

Use only the handrails provided to climb -- not use the steering wheel, shift lever, mirror brackets, or control lever. Use extra caution mounting and dismounting when slippery conditions exist (oil, ice, snow, mud, or wet conditions). Never jump from the machine regardless of that machine is moving or stopped. Report or replace any damaged or missing steps, handrails, or anti-skid material. Do not allow unauthorized personnel on the machine.

Before Starting Safety

Know the location of safety items and procedures: ・Fire extinguishers ・Fire blankets ・First aid kits ・Emergency phone numbers Walk around the machine to be sure no one is working or laying under the machine. Inspect the machine for safety hazards and, if found, have them corrected: ・Broken lights, mirrors, windows, etc. ・Fuel leaks, oil leaks, or debris build-up ・Improper tire inflation or tire damage ・Missing or unreadable safety signs (decals) Be sure the Roll Over Protective Structure (ROPS) is: ・in place. ・properly attached (no bolts loose or missing). ・not damaged. ・not modified.

2

SAFETY

Perform the normal daily maintenance.

Be sure the following safety devices work or are positioned properly. ・Parking Brake -- Applied ・Control Lever Lock -- Locked Ｌｏｃｋ Ｕｎ ｌ ｏｃｋ

・Transmission Shift Lever -- Neutral

Ｎ

・Articulation Stopper -- Locked in the "STORED" position. ・Back-up Alarm -- Operational

Securely lock the cab door either fully open or closed. Secure any loose items inside the cab (lunch boxes, tools, vacuum bottles, etc.). After using the ashtray, close the ashtray cap to avoid fire.

3

SAFETY

Do not leave a lighter in the cab. The lighter may cause explosion by high temperature in the cab. Do not bring inflammable or explosive materials such as : -spray can -chemical cylinder Do not attach a suction cup on the window to avoid firing. In case of fire during operation : ・Turn off the starter switch and stop the engine. ・Extinguish fire with a fire extinguisher (Depend on the situation). ・With hand rails and steps, get off the machine and stay away from it. Depending on the situation, the way of evacuation will be changed. If necessary, periodic fire drill is needed at the work area. Adjust the seat, seat belt and steering column, mirrors, etc. Properly fasten the seat belt.

Do not start or operate the machine if a "DO NOT START" or a "DO NOT OPERATE" tag is on the key switch, steering wheel or controls. Do not operate the engine where there are or can be combustible vapors. These vapors can be drawn through the air intake system and cause engine overspeeding, which can result in a fire, and explosion.

4

DANGER ＤＯ ＮＯＴ ＳＴＡＲＴ ＭＥＮ ＷＯＲＫＩＮＧ ＯＮ ＭＡＣＨＩＮＥＲＹ Ｓ ＩＧＮＥＤ ＢＹ ＤＡＴＥ

SAFETY

Do not start to work in an enclosed area if adequate ventilation is not provided. Fumes could build up during operation that could cause drowsiness, injury, or death.

Blow the horn for a few seconds just before starting the engine to alert bystanders. Start the machine only from in the operator's seat. ・Do not reach through the window to start. ・Do not stand on the ground and start. ・Never attempt to start by shorting across the starter motor terminals since this can bypass the neutral start safety device. If jumper cables are required to start the engine, follow the correct procedure in "Booster Batteries/Jumper Cables" page 84.

Operational Safety SITE SAFETY:

Consider the safety of the job site before operating the machine: ・Be aware of and avoid cliffs, ditches, trenches, overhead or underground wires, underground pipes, other equipment, and workers in the area. ・If required, be aware of hand signals that may be used by ground guides. Avoid working under or near overhanging material that could fall on the machine. Keep bystanders out of the work area. Keep the work site as clean and flat as possible. Do not operate the machine at work area close to fire or dry grass is.

5

SAFETY

Operate the machine slowly over rough ground and on a grade. Do not operate on any grade that may be unstable (loose material, soft material, snow, or ice). The range of temperature the machine is to be operated is between -35 ℃ ～ 45 ℃ . When working on a grade: ・Turn "OFF" the transmission cut-off selector switch. ・Keep the attachment low. ・Keep the attachment facing up the grade as often as possible. ・Drive directly up or down the grade -- never across the grade. ・Stop when changing direction on a grade to maintain stability. ・Never coast down a grade. ・Select the same low gear to go down the grade as was selected to climb the grade. This provides some engine braking. Before crossing a bridge, make sure that the capacity of the bridge is greater than the weight of the machine and any load it may be carrying. Check for enough clearance before entering a building, doorway, tunnel, under wires or other structures. Do not expose the machine to flames.

SAFETY DURING NORMAL OPERATIONS:

Vision to the rear on any machine is limited. Always use special caution when backing up. Know the machine limits and do not exceed them. Using the machine for purposes other than specified in the Operation & Maintenance Manual may create hazards that are not mentioned in this manual. Do not use the machine as a crane where the safety of the operator or other workers are involved.

6

SAFETY

Properly counterweight and ballast the machine depending upon the bucket size and material or attachment application. Do not exceed the recommendations and limits. Maintain stability by carrying the load as low as possible throughout each cycle. ・The normal carry position is about 40 cm (16 in.) above the ground.

approx. 40cm (16in)

When roading the machine: ・Travel in forward only. ・Travel only as fast as conditions and safety allow. ・Know and follow all local laws that may require rotating beacon, slow moving vehicle (SMV) signs, width signs or flags, lead or chase vehicles, four-way flashers, or clearance lights, etc.. ・If roading long distances (over 3 km (2 miles)), periodically stop to allow tires, transmission, engine to cool down. Excessive tire heat caused by roading can cause blow-outs and loss of control.

Stop the machine motion immediately if any failure occurs that causes reduced control (e.g.; engine, pump, or brake system failures). Lower the bucket or attachment to stop the machine only when an emergency, like loss of braking occurs. Be sure there are no bystanders under the raised bucket or attachment.

7

SAFETY

Never position or move the load over the cab of a truck or other vehicle.

Never use the "Float" position to lower the boom since it will fall rapidly.

Drive into a load at a medium speed. Do not run into the material at high speed. Always be alert for abnormal noises, odors, vibrations, heat, etc.

SPECIAL OPERATING CONDITIONS:

Avoid entering water deeper than the bottom of the wheel rim. If entering water is unavoidable: ・Use caution that there are no hidden hazards -- (drop-offs, holes, rocks, logs, etc.). ・Check for normal braking after leaving the water. ・Check differential gear oil for contamination. Reduce speed and avoid rapid steering movement when traction is poor -- mud, snow, ice, etc.. Use tire chains if necessary. When darkness, fog, snow, dust, smoke, etc. reduce visibility, use the following precautions: ・Use adequate lighting. ・Use flashers or beacons (if equipped). ・Reduce speed. ・Periodically stop and inspect the job site. ・Take more frequent breaks to reduce fatigue.

8

SAFETY

If towing or pulling something is required: ・Keep helpers or bystanders away from between the machine and the towed vehicle or object. ・Use a cable of adequate capacity and in good condition. ・Use a cable that has appropriate pull hooks. ・Use only the hitch provided on the rear of the machine. ・Be sure the hitch pin is fully in its bore before applying tension. ・If brakes and steering are working on the towed vehicle, keep an operator in the operator's seat and have him control the vehicle. ・If brakes are not working on the towed vehicle, attach another vehicle of adequate size to the rear to act as a braking vehicle. ・Use the machine as a tow vehicle only for short distance.

Parking Safety

Stop the machine on a level ground with the service brakes -not the parking brake. Lower the attachment to the ground and apply the parking brake. If parking on a level ground is not possible, follow these precautions: ・Lower the attachment to the ground and apply some down pressure. ・Block the tires. ・Apply the parking brake.

To prevent unauthorized use: ・Remove the key. ・Close and lock all cab doors and windows (if equipped with a cab). ・Install vandal covers (if equipped).

9

SAFETY

Inspect the machine and report any needed repairs. If parking near a road, be sure and erect safety barriers and lights as required.

10

SAFETY

Safe Maintenance Safety Preparations Before Maintenance

Do not rush. Walk, do not run. Avoid shortcuts that may cause accidents. Perform maintenance and repairs only if trained. Follow the Operation & Maintenance Manual or Shop Manual. Air conditioner servicing and repair should be performed by trained specialists since injury and/or environmental pollution can result from improper servicing. Allow only properly trained tire mechanics with the proper tools to service tires and rims. Wear safe clothing to perform maintenance: ・Close fitting clothing -- loose or baggy clothing can catch on equipment or controls. ・Protective clothing as required by the job or conditions -- for example: -Hard hat -Gloves -Steel-toe shoes -Eye / face protection -Approved respirator ・Do not wear jewelry that may catch on equipment, controls, or may short and cause burns if in contact with electrical components.

Before performing any maintenance: ・Park on a level ground. ・Block the tires securely. ・Apply the parking brake. ・Lower the boom and attachment to the ground. ・Stop the engine (unless specified in the Operation & Maintenance Manual or Shop Manual).

11

SAFETY

Use a piece of cardboard or wood to find fluid leaks under pressure but do not use your bare hand. Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes and cause serious injury, blindness or death. Never make repairs on pressurized components. Release all trapped air and hydraulic pressure by: ・Stopping the engine after lowering the attachment to the ground. ・Moving the loading control levers back and forth. ・Turning the steering wheel right and left several times. ・Turning the hydraulic oil tank cap 1/3 turn counterclockwise. Attach a "DO NOT START" or "DO NOT OPERATE" tag on the key switch or the steering wheel. DANGER

When working beneath the machine, use sturdy and stable supports to hold it up. Do not depend on hydraulic cylinders or attachment.

ＤＯ ＮＯＴ ＳＴＡＲＴ ＭＥＮ ＷＯＲＫＩＮＧ ＯＮ ＭＡＣＨＩＮＥＲＹ Ｓ ＩＧＮＥＤ ＢＹ ＤＡＴＥ

If working under the raised boom or attachment, be sure to properly block or support boom. Do not stand on tires. Use safe and sturdy working platforms.

Explosion / Fire / Burn Prevention

Before removing any coolant hoses or plugs, relieve any trapped pressure in the cooling system. Cooling system additives and cleaners may contain alkali that can cause caustic burns or blindness. Avoid contact with skin or eyes. Pour all fuel and oil into appropriate containers. Leave the containers at well ventilated place where unauthorized persons are prohibited.

12

SAFETY

Hot oils or coolant and components can cause burns. Allow components to cool to a safe temperature before servicing. Keep flame and sparks away from flammable and explosive materials such as: -Fuel -Oil -Antifreeze -Batteries -Wood chips -Straw, leaves, pine straw -Oily rags -Grease -Ether starting fluid Never smoke while fueling a machine. Stop the engine before fueling. ・Fill oil at well ventilated place. ・Do not leave the machine when filling oil. ・Fasten the oil filler cap tightly.

Remove flammable materials from hot engine component areas (i.e.; muffler, manifold, etc.). Clean up all spills of coolant, fuel, oil, etc. to prevent fire and slipping hazards. Never use flammable solvents like gasoline or diesel fuel for cleaning parts. If overheated tire is suspected, never stand in front of the tire. Stay away until the tire and rim cool down.

13

SAFETY

Tire and rim assemblies if improperly serviced can explode with deadly force. When inflating tires; ・Make sure wheel parts are correctly installed. ・Use a self attaching (locking) air chuck. ・Use a remotely located valve to turn air pressure on and off. ・Stand behind the tread not beside the rim. ・Do not inflate tires more than the recommended pressure. ・Use a safety cage for a repaired tire.

Do not operate the engine where there are or can be combustible vapors. These vapors can be drawn through the air intake system and cause engine overspeeding, which can result in a fire, and explosion. To prevent ignition, use the luminaire when checking oil, cooling water, fuel and battery electrolyte level. Move ignitable things to a safe place when grinding welding or gas cutting. Charge a battery at well ventilated place and keep fire away from it during charging.

Other Maintenance Safety Concerns

Periodically check the ROPS bolts (if equipped) to be sure they are in place and tight. Never weld, drill or in any way modify the ROPS without approval from the manufacturer. Stop the engine before opening the engine side panel. Contact with belts, pulleys, or other moving parts will cause injuries.

During servicing, inspect the wiring harnesses, connections and wires and replace any that may be chafed, or tighten any that may be loose.

14

SAFETY

Keep the area clear of bystanders and wear eye protection when striking pins, teeth, or cutting edges during removal or installation. Metal pieces can fly off and cause injury. Use a brass drift or a dead blow hammer as required by the job. Keep the area clear of bystanders and wear proper eye protection and protective clothing when grinding or welding. Do not enter the articulation area when engine is running. When transporting the machine on a truck or lifting the machine, lock the articulation stopper in the "LOCKED" position. Used oil may cause skin disease if allowed to remain on the skin for extended periods. Wash skin completely to remove used oils. Drain and discard of used oil and coolant properly to prevent environmental pollution. When oil or fuel leaks from the high pressure rubber hose, it may cause an accident or fire by a wrong actuation. If something is wrong with the rubber hose, immediate repair is needed : ・Correct them and fasten the rubber hose when a clamp, guard and cushion are loosen. Do not keep them loosen, or the rubber hose is damaged by vibrating or scratching other parts. ・Fasten the rubber hose with designated torgue when the connection is loosen. ・Exchange the hose base when it is damaged or deformed. ・Exchange the hose cover when it is damaged, cut or expanded. ・Exchange the moving contact of the rubber hose when it is twisted or bent.

15

Ａｒ ｔ ｉ ｃｕ ｌ ａ ｔ ｉ ｏｎ Ｓｔ ｏｐｐｅ ｒ “ＬＯＣＫＥＤ”

SAFETY

Safety Signs All safety signs which are on the machine are shown here. Read them and understand them thoroughly. They contain information which is important for the safe operation and the safe maintenance. Follow the directions on the safety signs carefully. It is very important that all safety signs be on the machine in the locations shown. If any sign is missing, damaged, or worn, get a replacement from your Kawasaki loader dealer and install it in the correct position. NOTE: The sample safety signs in this section have part numbers to help you and your dealer obtain the correct replacement.

DANGER

No room in this area when turning. Crushing will cause serious injury or death. Stay out of this area when machine could move or turn. 44787-20810

16

SAFETY

WARNING

Improper operation or maintenance can cause serious injury or death. Read,understand,and follow Operation & Maintenance Manual before operating or servicing machine. Follow all safety signs in Operation & Maintenance Manual or on machine. For replacement Operation & Maintenance Manual or safety signs,contact Kawasaki loader dealer. 44787-20760

WARNING

Sudden or accidental movement of boom may cause injury or death. Before walking or working under raised boom: ・Securely block or brace boom. ・Remove key and tag "Do Not Operate." ・Relieve all trapped oil pressure before opening any piping. 44787-20740

17

SAFETY

WARNING Check transmission oil level properly to avoid serious injury or death. ・Park on level ground. ・Lower bucket to ground. ・Place transmission in neutral. ・Set parking brake. ・Tag "Do Not Operate." 44787-20750

WARNING

Machine will not turn with articulation stopper in locked position. Unlock articulation stopper before operating machine. 44787-21060

18

SAFETY

WARNING

Serious injury or death may result if engine starts in gear. ・Do not start engine by shorting across starter terminals. ・Do not start engine while standing on ground. Make sure to start engine only from operator's seat with transmission in neutral and parking brake applied. 44787-20840

WARNING Serious injury or death may result if Roll Over Protective Structure (ROPS) is missing or damaged. Always keep ROPS in place. Do not operate this machine if ROPS has been removed, damaged, or altered. 44787-20790

19

SAFETY

WARNING

Batteries produce explosive gases which can cause burns or blindness. Keep flames and sparks away. Vent area before servicing. 44787-20800

WARNING

Batteries contain lead, and acid which causes burns. Avoid contact with skin or clothing. If lead, or acid contacts skin or clothing, immediately wash with water. 44787-20770

20

SAFETY

CAUTION

Contact with moving belts or pullies will cause injuries. Stop engine before working in this area. 44787-20860

CAUTION

Contact with fan will cause injury. Keep all guards in place. Keep hands away from fan area. 44787-20850

21

SAFETY

CAUTION

Pressurized system: spray of hot fluid could cause burns. Allow system to cool and vent pressure slowly before servicing. 44787-20820

22

SAFETY

CAUTION

Compressed spring may accidently be released and cause injury. Read Shop Manual before repairing this part. 44787-20830

CAUTION

Nitrogen accumulator contains compressed gas and fluid which can cause injuries. Release all brake circuit oil pressure before removing any oil lines or piping. Do not attempt to service or repair accumulator unless properly trained and equipped. 44787-20880

23

SAFETY

Safety Devices Loading Control Lever Lock DANGER Accidental movement of boom or machine will result in death or serious injury. When parking or leaving machine, or when performing maintenance on it, always lower attachment to ground and lock loading control levers. This device locks the loading control levers to prevent accidental lowering of the attachment or boom. ・ To lock, set the loading control levers to "NEUTRAL" and pull-up the lock lever to forward. ・ To unlock, push down the lock lever to backward.

Ｌｏｃｋ Ｕｎ ｌ ｏｃｋ

Articulation Stopper WARNING With articulation stopper in LOCKED position, machine will not steer; which, while operating, could cause an accident, injury or death. Do not lock Articulation Stopper during normal operation. Articulation stopper locks the front and rear chassis to prevent them from sudden articulation during inspection or transportation. To lock: 1. Align the front and rear chassis straight ahead. 2. Using a 14mm wrench remove the bolt that fixes the articulation stopper to the storage bracket under the hydraulic oil tank. 3. Remove the clip pin and pin from the end of the Articulation Stopper. 4. Turn the link and fix the end to the bracket on the front chassis (as shown).

24

"LOCKED" position

SAFETY

5. Insert the pin and clip pin. (This is the LOCKED position.) To unlock: 1. Remove the clip pin and pin from the end of the articulation stopper on the front chassis bracket. 2. Turn the link to the rear chassis bracket. 3. Insert the pin and clip pin. (This is the STORED position.) 4. Tighten the bolt to fix the articulation stopper on the bracket.

Neutral Start System

The transmission has a neutral start system which allows the engine to start only when the transmission shift lever is in NEUTRAL position.

Emergency Brake

When the service brake does not work, emergency brake can be applied manually. ・ Pull the emergency brake switch to engage the emergency brake and disengage the transmission.

25

“ＳＴＯＲＥＤ”ｐｏｓ ｉ ｔ ｉ ｏｎ

SAFETY

Emergency Steering (Option except Europe specification) WARNING Operation without normal steering could cause loss of control and injury or death. If emergency steering lamp lights up, steer machine IMMEDIATELY to safe location and stop it. Emergency steering works automatically when the steering hydraulic pressure goes down or the engine stops while the machine is operating. When the steering hydraulic pressure goes down while the engine is running, the steering hydraulic warning lamp lights up. Refer to "Steering Hydraulic Warning Lamp" page 45. If the emergency steering works: 1. Keep the starter switch in the "ON" position even when the engine unexpectedly stops. 2. Immediately operate the steering wheel to bring the machine to a road shoulder or safe location. 3. Stop the machine. If necessary, use the emergency brake or lower the attachment to stop the machine. 4. Place wheel chocks in front of and behind the tires to prevent the machine from moving. 5. Contact your local Kawasaki loader dealer for necessary testing and repair.

ROPS (Roll Over Protective Structure) (Option except Europe specification) WARNING Operating with damaged or improperly mounted ROPS could cause serious injury or death. Be sure to observe the following. ・ Whenever seated,fasten the seat belt. (If equipped) ・ Do not modify ROPS, such as drilling or welding. ・ Do not use ROPS deformed. ・ If any damage or loose bolts are found, do not operate until

repaired.

・ Never repair or modify ROPS without manufacturer's

approval and instructions.

26

COMPONENT NAME/LOCATION

COMPONENT NAME / LOCATION １８ １３

４ ３

１

６

８

５

２

１１

１５

１４

1. Bucket (Attachment) 2. Boom 3. "Z" Lever 4. Boom Cylinders 5. Bucket Cylinders 6. Engine 7. Torque Converter & Transmission Ass'y 8. Radiator, Torque Converter Cooler (Lower tank), & Hydraulic Oil Cooler 9. Fuel Tank (Right hand side)

９，１０ ７ １６

１２

１７

10. Hydraulic Oil Tank (Left hand side) 11. Front Axle / Differential Ass'y 12. Rear Axle / Differential Ass'y 13. Air Cleaner (Right hand side) 14. Parking Brake 15. 2nd Propeller Shaft 16. 3rd Propeller Shaft 17. Batteries (one each side--two 12VDC=24VDC system) 18. ROPS (Option except Europe specification)

NOTE: When a component or an item location is given as "Left hand side" or "Right hand side", it is according to the operator's left side or right side when sitting in the seat.

27

OPERATOR'S AREA

OPERATOR'S AREA Pedals and Levers 11

2

1

3

4

6 （ｏｐｔｉｏｎ） 7

5 9

10 9 8

1. Transmission Shift Lever 2. Horn Button 3. High-Low Beam Lever / Turn Signal Lever (option) 4. Boom Control Lever 5. Bucket Control Lever 6. Auxiliary Attachment Control Lever (option) 7. Wrist Rest 8. Accelerator Pedal 9. Brake Pedals 10. Steering Column Tilt Handle 11. Steering Wheel

1. Transmission Shift Lever

Transmission Shift Lever is used to control machine speed and direction. ・ Push the lever forward to move the machine forward. ・ When the lever is in NEUTRAL, the machine should not move on level ground. ・ Pull the lever backward to move the machine backward. ・ The four forward and four reverse speed shifting modes are selected by rotating the shift lever.

28

OPERATOR'S AREA

1・ ・ ・ ・ ・ ・ ・1st speed (fixed) 2・ ・ ・ ・ ・ ・ ・2nd speed (fixed) 3・ ・ ・ ・ ・ ・ ・3rd speed (fixed) A ・ ・ ・ ・ ・ ・2nd, 3rd and 4th speed is automatically selected for the machine running condition.

2. Horn Button

Horn Button is used to blow the horn. ・ Press the button in the center of the steering wheel to blow the horn.

3. High-Low Beam Lever / Turn Signal Lever (option) This lever is used to change the head lights beam high and low, and to flash the head lights. This lever also turns on the turn signals. ・ Lift the lever to turn the front lights on momentarily (Flash position). ・ The head lights are in the high beam position when the lever is pushed down (lowest position). ・ The light switch can be operated regardless of the lever position. ・ Push the lever forward to turn on the left turn signal. ・ Pull the lever backward to turn on the right turn signal. ・ Return the lever to the center position when the turn is completed. The lever does not return automatically when the steering wheel is returned to center.

29

Flash position

High beam position

OPERATOR'S AREA

4. Boom Control Lever

Boom control lever is used to control the boom movement. (a) Float

・ Move the lever to full forward detent position. The boom will lower and move freely following the ground surface.

(b) Lower

・ Move the lever forward. The boom will lower. When held in this position, down pressure will be applied to the attachment.

(c) Hold

・ Return the lever to the center position. The boom will stop and remain in that position.

(d) Raise

・ Move the lever rearward. The boom is raised. ・ An automatic boom height positioner (option) is provided which will automatically release the detent and return the lever to the "Hold" position when a preset boom height is reached. ・ For adjustment procedure refer to "Boom Kickout Adjustment" page 81.

（ｃ（ ）ｄ） （ｂ） （ａ）

5. Bucket Control Lever

Bucket control lever is used to control the bucket or attachment movement. (a) Dump

・ Move the lever forward. The bucket or attachment will dump.

(b) Hold

・ Return the lever to the center position. The bucket or attachment will stop and remain in that position.

(c) Roll Back ・ Move the lever rearward half way. The (Dual Motion) bucket or attachment will roll back slowly. ・ When the boom control lever is in the "Raise" detent position, both bucket or attachment and boom will move slowly.

30

（ｃ） （ｄ） （ｂ） （ａ）

OPERATOR'S AREA

(d) Roll Back

・ Move the lever rearward. The bucket or attachment will roll back. ・ An automatic bucket or attachment leveler is provided which will automatically release the detent and return the lever to the "Hold" position when the bucket or attachment reaches to the preset angle. ・ For adjustment procedure refer to "Bucket Positioner Adjustment" page 80.

6. Auxiliary Attachment Control Lever (option)

Auxiliary attachment control lever is used to control the auxiliary attachment such as log clamps, multi-purpose buckets, etc.. (a) Normally this position will close the attachment. (b) This center position will cause the attachment to stop and remain in that position. (c) Normally this position will open the attachment. NOTE: If equipped with attachments other than the standard bucket, consult the attachment supplier for specific instructions.

IMPORTANT Kawasaki will not accept any liability for any attachments and spare parts not approved by Kawasaki.

7. Wrist Rest

Wrist rest is used to put on the wrist or arm while operating the bucket/boom control levers. To adjust the position (High/Low or Front/Rear loosen the screws.

31

（ｂ） （ｃ） （ａ）

OPERATOR'S AREA

8. Accelerator Pedal

Accelerator pedal is used to control the engine speed. ・ Depress the pedal to increase the engine speed. ・ Release the pedal to decrease the engine speed.

WARNING Control pedals which stick could cause loss of control and injury or death. ・ Be sure control pedals move freely before operating. ・ Do not allow dirt, mud, or debris to build up under or

around pedals.

9. Brake Pedals WARNING Continuous use of brake could cause rapid or abnormal brake disc wear and / or brake circuit malfunctions which could cause loss of control and injury or death. ・ Do not use brake pedals as foot rest. ・ Do not ride brakes. ・ Use brake pedals only when applying brakes.

Brake pedals are used to reduce the machine ground speed, stop the machine, or to hold the machine. Left and right Brake Pedals・ ・ ・ ・ ・ ・ ・ ・ ・ ・May be used either of two ways: 1. As a brake only pedal by turning the transmission cut-off selector switch (See page 36) to the "OFF" position. Use this position when working on slopes or ramps. 2. Disengage the transmission while applying the brakes. This is normally used when loading trucks. It allows higher engine speed to provide faster hydraulic operations. To use this feature, turn the transmission cut-off selector switch to the "ON" position. When the switch is "ON", a green indicator lamp on the dash will also be turned on.

32

OPERATOR'S AREA

CAUTION Transmission cut-off feature momentarily places transmission in neutral, which may allow machine to roll when on a grade. Be sure to turn off transmission cut-off selector switch when operating on a grade.

10. Steering Column Tilt Handle WARNING Unexpected movement of steering column could cause loss of control and result in death or serious injury. ・ Stop machine before adjusting angle of steering column. ・ Be sure to pull up fully the tilt handle before operating

machine.

Steering column tilt handle is used to tilt the steering column forward or backward for operator's comfort. 1. Pull up the tilt handle and move the steering wheel to the desired position. 2. Push down the tilt handle fully to lock the steering wheel in position.

33

Release Lock

OPERATOR'S AREA

Switches

６ ７

20

10

0 100min-130

C

H

C

H

F E

１

１０８ ９

１１

１２ ３

２

1. Starter Switch 2. Parking Brake Switch 3. Light Switch 4. Front Working Light Switch ( ＊ ) 5. Rear Working Light Switch 6. Transmission Cut-Off Selector Switch

４ ５

0000001/10h

AUTO N 4 3 2 1

7. Cold Start (ether infection) Switch 8. Front Wiper Switch ( ＊ ) 9. Rear Wiper Switch ( ＊ ) 10. Cigarette Lighter ( ＊ ) 11. Power Up Switch ( ＊ ) 12. Cab Electrical Mirror Switch (option) ( ＊ : Option except Europe specification)

1. Starter Switch "OFF"

"ON"

・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・Key can be either inserted or pulled out. Engine is stopped and most electrical circuits are turned off. ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・Current flows to all circuits.

"START"・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・When the transmission shift lever is in NEUTRAL, starter motor turns, starting the engine. When released the key will automatically return to the "ON" position.

34

ＯＦＦ ＯＮ ＳＴＡＲＴ

OPERATOR'S AREA

2. Parking Brake Switch WARNING Accidental movement of machine could result in death or serious injury. Be sure to pull parking brake switch when parking or leaving machine, and during maintenance or transportation. Parking brake switch is used for parking the machine. When the switch is pulled, the parking brake is applied and the transmission is disengaged. When the switch is pushed, the parking brake is released. Should the directional shift lever be moved into the forward or reverse position while the parking brake is applied and the engine is running, a warning buzzer will sound.

3. Light Switch

This is a three position switch. "OFF"

: Width (clearance) lamps (option), tail lamps, front head lights, and gauge lamps turn off.

" ● "

: Width (clearance) lamps (option), tail lamps, and gauge lamps turn on.

" ●● " : Width (clearance) lamps (option), tail lamps, front head lights, and gauge lamps turn on.

4. Front Working Light Switch (Option except Europe specification) Front working light switch is used for turning on and off the front working lights. Turn off the front working lights when roading to prevent blinding the driver in front of you.

35

OPERATOR'S AREA

5. Rear Working Light Switch

Rear working light switch is used for turning on and off the rear working lights. Turn off the rear working lights when roading to prevent blinding the driver behind you.

6. Transmission Cut-Off Selector Switch

Transmission cut-off selector switch is used to change the function of the brake pedals. Normally this switch should be "ON". "OFF"・ ・ ・When the brake pedals is depressed, only the service brakes are engaged keeping the transmission directional clutch engaged. (brake only) "ON"・ ・ ・ ・ ・When the brake pedals is depressed, the service brakes are engaged and the transmission directional clutch is disengaged (brake and declutch). Refer to "Brake Pedals" page 32 for the function of the left brake pedal.

CAUTION Transmission cut-off feature momentarily places transmission in neutral which may allow machine to roll when on a grade. Do not turn transmission cut-off selector switch to "ON" when operating on a grade.

7. Cold Start (ether injection) Switch

Cold Start Switch is used for easy engine starting in cold weather. Ether is injected into the engine after turning this switch to "ON" and "OFF". Refer to "Cold Start" page 63 for proper use.

36

OPERATOR'S AREA

8. Front Wiper Switch (Option except Europe specification) Front wiper switch is used to wipe the front windshield and spray solvent. "OFF"

:

"INT"

: Intermittent

"LOW"

: Low speed INT

"HIGH" : High speed

LOW

OFF

HIGH

"PUSH" : Spraying solvent on the windshield PUSH

9. Rear Wiper Switch (Option except Europe specification) Rear wiper switch is used to wipe the rear windshield. "OFF"

:

"ON"

: Low speed

"PUSH" : Spraying solvent on the windshield

OFF

ON

PUSH

10. Cigarette Lighter (Option except Europe specification) Cigarette lighter is used to light a cigarette or cigar. ・ Push the lighter in and wait for a few seconds. The lighter will spring back to be ready for lighting a cigarette or cigar. ・ The cigarette lighter power-outlet socket can be used as a power source with max. 24 volts 10 amperes in case of emergency.

37

OPERATOR'S AREA

11. Power Up Switch (Option except Europe specification) Power up switch is used to quickly shift down the transmission from 2nd gear to 1st gear without moving the transmission shift lever. ・ When operating the machine in 2nd speed with the shift lever in 2 or A position, the transmission will shift down to 1st gear by pressing power up switch. ・ Pressing power up switch again, moving the transmission shift lever to the neutral position, or operating the parking brake switch releases the 1st gear setting to return the transmission to 2nd gear.

12. Cab Electrical Mirror Switch (option)

This switch is to adjust the cab mirror direction electrically. Before pushing the see-saw switch, decide which cab mirror should be adjusted. ・ Push the see-saw switch R to adjust the right mirror, on the other hand push the see-saw switch L to adjust the left mirror.

toggle switch

L

R see-saw switch

・ Move the toggle switch up / down / right / left to adjust the disignated mirror direction.

38

OPERATOR'S AREA

Indicators

２２

２１ ５ １８ ２０９ ６１９７

２４ １０

１ ４

AUTO

N

２

P

4 3 2 1

x100min-1

２６

２５

Ｆ Ｅ

２３ ８

1. Tachometer 2. Engine Coolant Temperature Gauge 3. Torque Converter Oil Temperature Gauge 4. Fuel Gauge 5. Parking Brake Indicator Lamp 6. Auto Brake Indicator Lamp 7. Transmission Cut Off Selection Lamp 8. Working Light Indicator Lamp 9. Central Warning Lamp 10. Transmission Control Warning Lamp 11. Brake Pressure Warning Lamp 12. Engine Oil Pressure Warning Lamp 13. Engine Coolant Temperature Warning Lamp

３

１２ １３ １４ １５ １６ １７

14. Torque Converter Oil Temperature Warning Lamp 15. Air Cleaner Warning Lamp 16. Charge Lamp 17. Transmission Oil Filter Warning Lamp 18. Turn Signal Indicator Lamp (Left) (option) 19. Turn Signal Indicator Lamp (Right) (option) 20. High Beam Indicator Lamp 21. Auto Shift Indicator Lamp 22. Neutral Indicator Lamp 23. Transmission Status Monitor 24. Hour Meter 25. Steering Hydraulic Warning Lamp (option) 26. Coolant Level Warning Lamp

When the starter switch is turned to "ON", all warning lamps (9) ～ (17), (25) and (26) light up for three seconds. This is the lamp (bulb) test period (lamp (16) lights up until engine starts).

IMPORTANT Operating machine while any of red lamps are ON may cause injury or damage to machine. Stop machine and correct problems if any red lamps come on.

39

１１

OPERATOR'S AREA

1.Tachometer

Indicates the engine revolutions per minute.

x100min-1

2.Engine Coolant Temperature Gauge

Indicates engine coolant temperature. It is normal when the indicator stays in the green zone (70～ 95° C (158～ 203 F)). °

H

C WATER TEMP

・ If the indicator enters the red zone while operating, slow the engine down to mid-range speed and wait until the indicator reaches the green zone. ・ If the gauge stays in the red zone, stop the engine and allow it to cool naturally. After cooling, check the cooling system. Refer to "Troubleshooting" page 141.

3.Torque Converter Oil Temperature Gauge

Indicates the temperature of oil circulating through the torque converter and the transmission. It is normal if the C (122 ～ 203 ° F)) indicator is in the green zone (50 ～ 95° while operating.

H

C T/C OIL TEMP

・ If the indicator enters the red zone while operating, slow the engine down to mid-range speed, shift to neutral, and wait until the indicator reaches the green zone. ・ If the indicator does not come back into the green zone quickly, stop the engine and find the cause. Refer to "Troubleshooting" page 145.

4.Fuel Gauge

Indicates the fuel amount in the fuel tank. F

・ Be sure to refuel at the end of each work day to avoid condensation in the tank. E FUEL

40

OPERATOR'S AREA

5.Parking Brake Indicator Lamp (red)

Lights up when the parking brake is applied. If the transmission shift lever is moved into "F" or "R" position while this lamp is on, an alarm sounds and the machine stays in neutral.

6.Auto Brake Indicator Lamp (red)

Lights up when the auto brake works. Reger to "Auto Brake" page 71 for the detail.

7.Transmission Cut-Off Selection Lamp (green)

Lights up when the transmission cut-off selector switch is "ON".

・ When lit, the service brakes are engaged and the transmission directional clutch is disengaged by depressing the brake pedals. ・ When not lit, only the brakes are engaged as the left brake pedal is depressed.

8.Working Light Indicator Lamp (green) Lights up when working lights are on.

9.Central Warning Lamp (red)

Lights up when any of the warning lamps come on.

41

P

OPERATOR'S AREA

10. Transmission Control Warning Lamp (red) Lights up when transmission controls malfunction.

・ If it lights up while operating, stop the engine and contact your nearest Kawasaki loader dealer for necessary repair.

11. Brake Pressure Warning Lamp (red) WARNING Loss of braking force could result in death or serious injury. Stop machine IMMEDIATELY and correct problem if brake pressure warning lamp lights up during operation. Brake Pressure Warning Lamp lights up and the warning buzzer sounds when the brake oil pressure is lower than 3.9MPa(40kgf/cm2 ) or the pressure difference between the front and rear brake circuit is larger than 1.5MPa(15kgf/cm2 ). ・ If it lights up while operating, IMMEDIATELY stop the machine and find the cause. Refer to "Troubleshooting" page 144.

12. Engine Oil Pressure Warning Lamp (red) Lights up when engine oil pressure is low. warning buzzer sounds.

Also the

・ If it lights up while operating, IMMEDIATELY stop the engine and find the cause. Refer to "Troubleshooting" page 141.

13. Engine Coolant Temperature Warning Lamp (red) Lights up when coolant temperature overheats. (Over C (215° F)) 102° ・ If it lights up while operating, slow the engine speed down to mid-range, shift to neutral, and wait until the lamp goes out. Check the coolant temperature gauge before resuming operation. ・ If the light does not go out quickly or lights up again after resuming the operation, stop the engine and find the cause. Refer to "Troubleshooting" page 141.

42

OPERATOR'S AREA

CAUTION Hot coolant spray may cause burns. Never open radiator cap when engine is hot. Stop engine and allow radiator and coolant to cool completely before opening cap slowly to relieve pressure.

14. Torque Converter Oil Temperature Warning Lamp (red) Lights up when transmission oil overheats. (Over 120±5° C F)) (248±9° ・ If it lights up while operating, slow the engine speed down to mid-range, shift to neutral, and wait until the lamp goes out. Check the torque converter oil temperature gauge before resuming the operation. ・ If the light does not go out quickly or lights up again after resuming the operation, stop the engine and find the cause. Refer to "Troubleshooting" page 145.

15. Air Cleaner Warning Lamp (red) Lights up when air filter is clogged.

・ If it lights up while operating, stop the engine and clean or replace the air cleaner outer element. Refer to "Clean or Replace Air Cleaner Element" page 97.

16. Charge Lamp (red)

Lights up when alternator charge level is low.

・ If it lights up, check the charging circuit. Refer to "Troubleshooting" page 142.

17. Transmission Oil Filter Warning Lamp (red) Lights up when the transmission oil filter cloggs.

・ When lit, replace the transmission oil filter cartridge. Refer to "Replace Transmission Oil Filter" page 120.

43

OPERATOR'S AREA

18.Turn Signal Indicator Lamp (Left) (green)(option) Flashes when the turn signal switch lever is moved forward.

19. Turn Signal Indicator Lamp (Right) (green) (option) Flashes when the turn signal switch lever is moved rearward.

20. High beam Indicator Lamp (blue)

Lights up when headlights are switched to high beam.

21. Auto Shift Indicator Lamp

Lights up when the transmission control lever is in the A position.

22. Neutral Indicator Lamp

AUTO

N

Lights up when transmission is in neutral.

23. Transmission Status Monitor

・ 1st Gear

Lights up when the shift lever is in 1 position and transmission is in 1st gear. Machine stays in this gear until manually shifted.

・ 2nd Gear Lights up when the shift lever is in 2 or A position and transmission is in 2nd gear. ・ 3rd Gear Lights up when the shift lever is in 3 or A position and transmission is in 3rd gear.

・ 4th Gear

Lights up when the shift lever is in A position and transmission is in 4th gear.

44

4 3 2 1

OPERATOR'S AREA

24. Hour Meter

Hour meter indicates the accumulated total hours of engine operation. Use to determine the timing of periodic inspection and maintenance service.

25. Steering Hydraulic Warning Lamp (red)

Lights up when the steering hydraulic pressure downs below specified when the engine is running.

26. Coolant Level Warning Lamp

Lights up when engine coolant level is lower than specified.

45

0 0 0 0 0 0

1/10h

OPERATOR'S AREA

Seat Seat Adjustment

Adjust the seat for comfort and so that the pedals may be pushed fully down when the operator's back is fully back.

WARNING Unexpected movement of seat could result in death or serious injury. Stop machine before adjusting seat position.

Reclining

Rotate control handle (1) forward and hold, select backrest angle, release control handle.

Forward / Backward

Lift lever (2) up and hold, slide seat to desired position, release handle.

Suspension

Rotate handwheel (3) until your body weight is selected on indicator for maximum suspension performance. If the seat suspension is set below your body weight, excessive bouncing will occur. This will result in premature seat suspension wear and/or failure.

Seat Height

Lift front handle (4) or rear handle (5) up and hold to release lock for spring loaded seat. Adjust to desired position by adding or removing your body weight to front or rear of seat cushion. Release handles to lock.

Armrests

・Rotate control knob (6) to select desired angle. Pivot up and parallel with backrest when not in use.

Seat Belt (Option except Europe specification) WARNING Improper use or maintenance of seat belt could result in death or serious injury. ・ Inspect seat belt and mounting hardware before operating

machine and replace any defective components. ・ Always fasten seat belt when operating machine. ・ Properly adjust seat belt at beginning of each shift or when operator changes.

46

６ １ ３ ２

４ ５

OPERATOR'S AREA

1. Fasten Seat Belt along your body without kinking or twisting it. 2. Adjust the length of the seat belt on both buckle (2) and belt end (3) so that both come to the midpoint of your body front. 3. Hold buckle (2) and insert belt end (3) into buckle (2). Be sure it locks securely. 4. For releasing the seat belt, press the "press button" in the buckle (2) and remove the belt end (3) from the buckle(2). (Excluding Europe specification) NOTE: Be sure tether (1) is securely attached to the seat and floor. When the seat is properly adjusted and no one is in the seat the tether should be snug or taut.

３ ２

47

１

OPERATOR'S AREA

Electrical Protection Fuse Boxes

Fuse box is located in the side console and contains thirty fuses.

IMPORTANT When replacing fuse, be sure to turn the starter switch to "OFF" position.

IMPORTANT Using wrong capacity fuse or bypassing fuse may cause electrical system damage. Never replace fuses with higher amperage rating.

2 PERSONS CAB F . WIPER (LH) (OPTION)

LIGHTING HEAD LIGHT

2 PERSONS CAB F . WIPER (RH) (OPTION)

R . WORK LIGHT

R . WIPER

BOOM KICKOUT BUCKET POSITIONER

F . WIPER

BACK LAMP STOP LAMP TURN SIGNAL

CIGARETTE LIGHTER

PARKING BRAKE CONTROLLER

F . WORK LIGHT

BUZZER MONITOR

RADIO

COLD STARTER

SPARE

SPARE

SPARE

SPARE (Standard spec.) R.WINDOW HEATING (Europe spec.)

SPARE

4 WAY FLASHER HORN

SPARE

SPARE

AIRCON (OPTION)

SPARE

AIRCON (OPTION)

FUEL VALVE

AIRCON (OPTION)

NEUTRAL RELAY

SPARE

BATTERY RELAY

48

OPERATOR'S AREA

Fusible Link

Fusible link protects the main hot wire from short circuits. 1. If the fusible link is blown, the horn will not sound.

CAUTION Contact with moving parts or engine components may result in injury or burns. Use extra caution when stopping engine by manually operate engine stop lever. 2. To check the cause and replace the fusible link, call your nearest Kawasaki loader dealer.

49

OPERATOR'S AREA

Air Conditioner (Options) Ventilation name and location DEF

DEF

DEF

FACE

FACE

FOOT FACE

Switches ４

５

３

A/C

OFF

HI

LO

２

１

1. Air Flow Control Switch

Air flow control switch is used to control air flow supplied by blower for heating or cooling in four stages. It is also used as a main air conditioner switch. ・ Press the switch "LO", " flow.

", "

" or "HI" to control air

・ Select "OFF" to stop the fan and also air conditioner system.

2. Temperature Control Switch

Temperature control switch is used to control the air temperature in the cab. Press switch for higher temperature and press for lower temperature. ・ More green lights when the lower air temperature. ・ More red lights when the higher air temperature.

50

switch

OFF

LO

HI

OPERATOR'S AREA

3. Air Intake Control Switch

Air intake control switch is used to select intake air, either outside air or recirculated air. ) switch to allow filtered fresh air from outside ・ Press ( the machine and pressurize the cab. ) switch to recirculate and filter air inside the ・ Press ( cab. The cab is heated or cooled more effectively with this mode.

4. Air Conditioner On-Off Switch

Air conditioner on-off switch is used to turn on and off the air conditioner for cooling and dehumidifying function. ・ With the switch pressed, the air conditioner turns on. ・ Pressing the switch again will turn the air conditioner off.

5. Ventilation Mode Selecting Switches

These switches are mode for selecting the ventilation mode. Five selection mode are prepared such as FACE, FACE / FOOT, FOOT, FOOT / DEF, DEF. When pushing one of the ventilation selecting switches, a green indicator lamp lights and the ventilation location is shown on the switch.

Operation Cooling

・ For maximum cooling, open the vents FACE and close other vents. ・ If the air in the cab is very hot, ventilate the cab by opening the door and window before cooling.

C (9 ° F) ・ In summer, the ideal air temperature is about 5 ° lower than the outside temperature.

Dehumidifying

・ The air conditioner dries air regardless of the air temperature controlled by the temperature control switch. In very humid weather, dehumidifying can make more comfortable environment for the operator. ・ If the windows fog up in humid weather, push the ventilation selecting switch DEF or FOOT / DEF, then run the air conditioner for a short time.

51

Ａ／Ｃ

OPERATOR'S AREA

Heating

・ Heating is not very effective until the engine has been fully warmed up. ・ For maximum heating, push the ventilation selecting switch FOOT.

CAUTION In dry environment cigarette smoke may irritate eyes. Ventilate or use "

" position to take fresh air periodically.

NOTE: ・ When heating or cooling the cab for a long period, occasionally take fresh air in by setting air intake control switch in the position. ・ In seasons when the air conditioner is not used, run it for a few minutes two or three times a month in order to maintain an oil film on the compressor parts. At this time, also check that the refrigerant is not leaking. Refer to "Check Air Conditioner Refrigerant" page 127.

52

OPERATOR'S AREA

Vibration Damper (option) Roading a wheel loader over rough terrain will cause fore and aft pitching motion to the machine. The pitching motion is reduced when the vibration damper is installed.

Operation and Function

1. Before start the travelling machine, turn the vibration damper switch (1) ON. The vibration damper pilot lamp (2) comes to ON.

1 2. Move the machine forward. The vibration damper functions automatically when the machine travelling speed reaches more than 7 km/h.

AUTO N 4 3 2 1

x100min-1

2 NOTE:

When the bucket is fully tilted the vibration damper does not work. Dump the bucket a bit when travelling.

Grease Gun Holder Grease Gun Holder is provided in the left battery box. It is used for keeping the grease gun on the machine when not in use.

53

0000001/10h Ｆ Ｅ

OPERATION

OPERATION Check before Operation Before performing the following checks, make sure the parking brake is engaged, the attachment is on the ground, the engine is shut off, and the machine is on a level surface. Follow all the safety cautions mentioned in the safety section of this manual when checking the machine.

A. Walk-Around Inspection

For your own safety and maximum service life of the machine, make a thorough walk-around inspection before mounting the machine to start the engine. Report or correct any problems found during the Walk-Around inspection.

Items to Check and What to Look for: Items to Check

What to Look for

□Bucket / Attachment

Damage, missing bolts, leaks, and excessive wear

□Bucket Control Linkage

Damage, missing bolts, excessive wear, and looseness

□Lights

Broken bulbs, wires or lenses

□Radiator Fins

Trash and dirt build-up (between Fan and Radiator)

□Cooling System

Leaks and trash build-up

□Batteries

Loose terminals

□Steps and Handrails

Damage and cleanliness

□Differentials (front and rear)

Leaks

□Hydraulic System

Leaks

□Final Drive (front and rear)

Leaks

□Covers and Guards

Damage or missing

□Transmission

Leaks

□Instrument Panel

Broken gauges or indicator lights

□Brake Lines

Damage and leaks

□Engine Compartment

Leaks, debris build-up and flammable materials left

□Battery

Loose items, leaks and debris build-up

Date :

Model-S/N :

Hours :

You may wish to copy this page and use it as a daily check list.

54

Inspector :

OPERATION

B. Check Engine Oil Level CAUTION Hot engine oil and components may cause burns. Avoid contact with hot oil or engine components. 1. Check the oil level with the dipstick. 2. Keep the oil level between the "H" (high) mark and "L" (low) mark on the dipstick. 3. If needed, add the required amount of the same brand and viscosity oil as originally used through the refill port. Refer to "Recommended Lubricants" page 139 for the suitable viscosity of the oil according to the ambient temperature. 4. If the oil is particularly dirty or contains water (milky appearance), replace the oil. Refer to "Replace Engine Oil and Oil Filter Cartridge" page 108 for the procedure. NOTE: Wait about five minutes after stopping the engine to measure the oil level. The precise oil level cannot be measured immediately after stopping engine due to residual oil in the upper parts of the engine.

IMPORTANT Improper oil level may damage engine. Do not operate engine with oil level below "L" (low) mark or above "H" (high) mark. Add or drain oil to keep proper oil level.

C. Check Hydraulic Oil Level CAUTION Pressurized hydraulic tank is used for this machine. Pressure may throw tank cap and hot oil out of tank causing injury or burns. Vent all pressure by slowly turning cap 1/3 turn counterclockwise.

55

ＭＡＸ ＭＩＮ

OPERATION

1. Lower the attachment to the ground. 2. Stop the engine. 3. Check the oil level gauge on the side of the hydraulic oil tank. 4. The oil level is OK if the oil reaches the middle of the level gauge. 5. If needed, add the required amount of the oil. Refer to "Recommended Lubricants" page 139 for the suitable viscosity of the oil according to the ambient temperature.

D. Check Engine Coolant Level CAUTION Pressurized radiator tank is used for this machine. Spray of hot coolant could cause burns. Stop engine and allow radiator and coolant to cool completely, then open cap slowly to relieve pressure.

CAUTION Cooling system conditioner contains alkali that could caustic burns or blindness. Avoid contact with skin and eyes to prevent injury. 1. Stop the engine and allow the radiator and coolant to cool completely. 2. Push the button (1) on the cap (2) of the radiator tank and slowly open the cap (2).

１

3. Check the coolant level. ＰＵＳＨ

4. Coolant level is normal if coolant is to the lower part of neck pipe. 5. If needed, add the required amount of the coolant. Refer to "Coolant Specification" page 140 for the correct mixture.

56

２

OPERATION

6. Change the coolant if it is particularly dirty. Refer to "Replace Coolant" page 132.

Ｒａｄ ｉ ａ ｔ ｏｒ ｇｕａｒ ｄ

7. If the coolant contains oil, diagnose the problem and correct it.

Ｃａｐ

Ｎｅｃｋ ｐ ｉ ｐｅ Ｗａ ｔ ｅ ｒ ｓｕｒ ｆ ａｃｅ

E. Drain Water and Sediment from Fuel Filter

・ Open the drain cock on the bottom of the fuel filter to allow water and sediment to drain into a suitable container. ・ Dispose of properly.

CAUTION Escaping fuel is flammable and harmful to skin. ・ Do not smoke while draining moisture and sediment from

filter.

・ Do not drain with engine running. ・ Do not allow diesel fuel to remain on skin for an extended

period of time.

F. Check Wiring Harnesses CAUTION Short circuit of wiring harnesses may cause fire. ・ Keep the connection of wiring harnesses clean and tight. ・ Repair the damaged wiring harness or exchange it for new

one.

Be sure the wiring harnesses are not damaged and the connection is kept clean and tight.

G. Articulation Stopper

・ Make sure the articulation stopper is secured in the "STORED" position as shown.

57

OPERATION

H. Check Tire Air Pressure

Tire performance and its life depend greatly on the tire air pressure. ・ Low air pressure causes excessive deflection, heat, and accelerated wear. ・ High air pressure cause reduced traction, slippage, and possible blow outs. It is important to keep the tire pressure at the recommended level. Special applications, such as long load and carry operations, may require different pressures. Consult the tire manufacturer.

WARNING Overheated tire may explode causing serious injury or death. If overheated tire is suspected, do not approach tire to distance of less than 15m. Stay away until tire and rim cool down. 1. Before starting work and while the tires are still cool, measure the tire air pressure with the tire pressure gauge.

WARNING Explosive separation of tire and rim parts could result in death or serious injury. When inflating tires;

・ Make sure wheel parts are correctly installed. ・ Use self-attaching air chuck with remote shutoff valve. ・ Stand behind tread of tire and keep all persons away from

side of tire.

・ Do not inflate tire more than recommended pressure. ・ Use safety cage if available.

2. Adjust air pressure according to the recommended pressures below. When inflating a tire, stand behind the tread and use a self-attaching chuck with a remotely located valve to turn air pressure on and off.

58

Low Pressure

OK

High Pressure

OPERATION

Recommended Tire Air Pressure Radial tire

29.5 R25 ☆

Air Pressure Note Front Rear 471～490kPa 373～392kPa (4.8～5.0kgf/cm2) (3.8～4.0kgf/cm2) Standard

26.5 R25 ☆

471～490kPa (4.8～5.0kgf/cm2)

373～392kPa (3.8～4.0kgf/cm2)

Pattern

Air Pressure

Note

392～412kPa (4.0 ～ 4.2kgf/cm2)

Optional

324～343kPa (3.3 ～ 3.5kgf/cm2)

Optional

Size

Optional

Bias ply tire Size 26.5-25-24PR 29.5-25-22PR

L3 L4 L5 L3 L4 L5

Same pressure for all four tires.

I . Check Tire for Damage WARNING Improper servicing or changing tires and rims could cause explosion resulting in serious injury or death. Do not service or change tires and rims unless properly trained and equipped. Contact your nearest Kawasaki loader dealer or tire manufacturer's local dealer for tire servicing or changing.

WARNING Overheated tire could explode causing serious injury or death. If overheated tire is suspected, do not approach tire to distance of less than 15m. Stay away until tire and rim cool down. If the following defects are found in tires, for safety reasons the tires should be replaced with new tires. For the replacement contact Kawasaki loader dealer or a tire manufacturers local dealer.

Tread Side walls

Breakers Carcass

・ Bead wire is broken or bent, or the tire is greatly deformed. ・ Wear is excessive and the carcass ply (including breaker) is exposed for more than 1/4 of the circumference. 59

Beads / Bead wire

OPERATION

・ Damage to the carcass exceeds 1/3 of the tire width. ・ Tire layers are separated. ・ Radial cracks reach the carcass. ・ Deformation or damage which makes the tire unsuitable for use.

J. Check Horn Operation

1. Push the horn button in the center of the steering wheel. 2. The horn should sound loudly.

K. ROPS (Roll Over Protective Structure) (Option except Europe specification) WARNING Operating with damaged or improperly mounted ROPS could result in death or serious injury. If any damage or loose bolts are found, do not operate until repaired. Never repair or modify ROPS without manufacturer's approval and instructions. ・ Check the condition of the ROPS and its mounting bolts.

L. Adjust and Check Rear View Mirrors

・ Adjust and check the condition of the rear view mirrors. ・ If there is any dirt on or damage to the rear view mirrors, clean or fix them.

M. Check Parking Brake

・ Make sure the parking brake switch is pulled up.

N. Check Monitor Panel Operation

1. Turn the starter switch to the "ON" position. 2. Eleven warning lamps (red) should come on for about three seconds. Refer to "Indicators" page 39. 3. Rotate and move the transmission shift lever to each position, pull the high-low beam lever, and operate the rear working light switch and transmission cut-off selector switch.

60

OPERATION

4. The transmission status monitor lamps (green) and the indicator lamps (green or blue) should come on respectively. 5. If any lamps do not light up, replace the bulbs. Refer to "Indicators" page 39 ～ 45.

O. Check Control Levers

・ Make sure the boom and tilt control levers are in the "HOLD" position.

P. Check Transmission Shift Lever

・ Make sure the transmission shift lever is in the neutral position.

61

OPERATION

Starting the Engine WARNING If engine starts in gear due to bypassing neutral start device from ground could result in death or serious injury. ・ Do not start engine by shorting across starter terminals. ・ Do not start engine while standing on ground.

Make sure to start engine only from operator's seat with transmission in neutral and parking brake applied.

Normal Start (Ambient temperature above 0 ° C (32 ° F)) 1. Do not depress the accelerator pedal. 2. The turn the starter switch key to "START" position to start the engine. To protect starter and battery, do not keep the starter switch in the "START" position for more than 20 seconds.

ＯＦＦ ＯＮ

ＳＴＡＲＴ

3. If the engine fails to start, wait about two minutes before trying to restart. This allows the starter motor to cool which prevents starter motor damage. 4. After the engine starts, release the key and it will return to the "ON" position. 5. If the transmission shift lever is not in the "NEUTRAL" position, the engine will not crank. NOTE・ Do not turn the starter switch key to the "START" position while the engine is running. ・ The engine oil pressure warning lamp should go out in less than ten seconds after the engine starts. If it remains on, stop the engine immediately and see "Troubleshooting" page 141.

IMPORTANT Low engine oil pressure may cause severe engine damage. Be sure engine oil pressure warning lamp goes out quickly.

62

ＯＦＦ ＯＮ

ＳＴＡＲＴ

OPERATION

Cold Start(Ambient temperature below 0 ° C (32 ° F)) 1. Do not depress the accelerator pedal. 2. The turn the starter switch key to the "ON" position and press the cold start switch for two seconds. (Here the ether is filled into a metering valve and measured.) 3.

Turn the starter switch key to the "START" position to start the engine and release the cold start switch. To protect starter and battery, do not keep the starter switch in the "START" position for more than 20 seconds.

4. If the engine fails to start, wait about two minutes before trying to restart. This allows the starter motor to cool which prevents starter motor damage. 5. After the engine starts, release the key and it will return to the "ON" position. 6. If the transmission shift lever is not in the "NEUTRAL" position, the engine will not crank. 7. In case the engine does not start on the first attempt, repeat the above procedures after intervals of about one to two minutes.

WARNING Ether is very flammable and could cause serious injury or death. ・ Avoid heat, electric sparks and flames near ether cylinder. ・ Do not store ether cylinders at temperature above 40° C (100° F). ・ Store ether cylinders out of children's reach. ・ When winter season is over (outside temperature is above 5° C (40° F)), remove ether cylinder from machine and store it

safely according to above instructions.

IMPORTANT Ether may cause serious engine damage. Never attempt to inject ether into warm engine. Use ether only as specified in this manual.

63

OPERATION

NOTE・ Do not turn the starter switch key to the "START" position while the engine is running. ・ The engine oil pressure warning lamp should go out in less than ten seconds after the engine starts. If it remains on, stop the engine immediately and see "Troubleshooting" page 141.

IMPORTANT Low engine oil pressure may cause engine damage. Be sure engine oil pressure warning lamp goes out quickly.

64

OPERATION

Check after Starting the Engine ・ Keep the engine running at low to medium speed and warm it up for about five minutes. ・ Do not subject the engine to sudden acceleration until the end of the warm-up period.

A. Check Warning Lamps 1. Check the warning lamps on the instrument panel. 2. If any red lamp (except for "PARKING") is on, do not operate the machine. 3. Refer to "Indicators" page 39 for the meaning of each lamp and the correction.

10

20

0

30 100r/min

0000001/10h

AUTO N 4 3 2 1

C H C H

B. Check Fuel Level

1. Check the fuel level with the fuel level indicator on the instrument panel. F

2. Add fuel to fill the tank if the indicator shows below "F". Refer to "Recommended Lubricants" page 139 for the proper fuel.

C. Check Transmission Oil Level DANGER There is no room in articulation area when machine is turning. Crushing will result in serious injury or death. When checking oil level: ・ Lower attachment to ground. ・ Put transmission shift lever in neutral. ・ Apply parking brake. ・ Place "DO NOT OPERATE" tag on steering wheel. ・ Make sure nobody is on machine.

65

E FUEL

F E

OPERATION

1. Park the machine on a level ground, apply the parking brake, and lower the attachment to the ground. 2. Check the oil level with engine at low idle. 3. At low oil temperature, use the side of dipstick marked "COLD". Normal oil level is within shaded area as shown. 4. At high oil temperature, use the side of dipstick marked "HOT". Normal oil level is within shaded area as shown. 5. If the oil level is lower than the specified, add recommended oil while the engine is at idle. Do not overfill. Refer to "Recommended Lubricants" page 139.

In hot

In cold

Specified oil level

WARNING With articulation stopper in "LOCKED" position, machine will not steer which, while operating, could cause an accident result in death or serious injury. Return articulation stopper to "STORED" position after checking transmission oil level.

IMPORTANT Never mix CD engine oil and auto transmission fluid. Either may be used in transmission but they must not be mixed. Determine what type of oil is in transmission and use only that type.

D. Check Service Brake Operation

1. Firmly depress the right hand brake pedal. 2. Release the parking brake. 3. Select the transmission shift lever 2nd and REVERSE. 4. Slowly accelerate the engine to full speed. 5. The machine should not move.

66

OPERATION

IMPORTANT If machine moves when firmly depressing right hand brake with transmission in 2nd and REVERS, there is some problem with service brake. Do not operate until problem has been corrected.

E. Check Parking Brake Operation 1. If the service brakes work normally, test the parking brake. 2. Move the machine to a safe open place on a slope. 3. Stop the machine with the service brake. 4. Pull up the parking brake switch. 5. Release the service brakes. 6. The machine should not move.

IMPORTANT If machine moves when parking brake switch is pulled, there is some problem with parking brake. Do not operate until problem has been corrected.

F. Check Steering Wheel Operation 1. Be sure the area is clear of bystanders. 2. Release the brakes. 3. Steer fully right and then left. 4. Steering should be smooth in both directions.

G. Check Back-up Alarm Operation 1. Apply the service brakes.

2. Release the parking brake.

67

OPERATION

3. Move the shift lever to "REVERSE". 4. The back-up alarm should sound and be heard in the operator's seat.

IMPORTANT If back-up alarm does not sound when parking brake is released and shift lever is in REVERSE position, there is some problem with back-up alarm. Do not operate until problem has been corrected.

H. Check Exhaust Gas

1. Check the color of the exhaust gas. Normal exhaust gas color is clear or light gray when engine is warm. White, black, or blue smoke during steady warm operation of the engine indicates a malfunction. (It is normal for some black smoke to occur during rapid acceleration.) 2. If abnormal exhaust gas color occurs, have the machine checked immediately. Refer to "Troubleshooting" page 142.

I . General Inspection

With the parking brake applied, transmission shift lever in NEUTRAL, loading levers in NEUTRAL, and the attachment on the ground, walk around the machine and look for any problems, leaks, or signs of failure.

WARNING Accidental movement of machine could result in death or serious injury. When inspecting machine while engine is running;

・ Make sure nobody is on machine. ・ Lower attachment to ground. ・ Turn parking brake switch to "ON". ・ Do not enter or access hazardous areas of machine:

-Articulation area -Under machine -Engine compartment, etc.

68

OPERATION

Operating the Machine WARNING Stopping engine while machine is moving will cause loss of steering control which could cause serious injury or death. Do not stop engine while machine is moving.

WARNING Moving machine in congested areas could result in death or serious injury. Be sure area is clear of personnel and obstructions.

IMPORTANT Operating machine on a grade may cause lack of lubrication resulting in severe engine or components damage. Do not operate machine on a grade over 30 ° . 30°Max.

Starting the Machine

1. Raise the bucket to the carry position approximately 40cm above the ground. 2. Depress the brake pedal. 3. Push the parking brake switch to release the parking brake. 4. Turn the transmission shift lever to the desired travel speed mode and then shift to the desired direction. 5. Release the brake pedal then depress the accelerator pedal to drive the machine.

WARNING When parking brake is released, machine could roll on a grade unexpectedly causing injury or death. When starting machine on a grade, firmly depress brake pedal before releasing parking brake.

69

approx. 40 cm

OPERATION

Starting the Machine on a Grade

1. Turn "OFF" the clutch cut-off selector switch. 2. Depress the left brake pedal (declutch brake pedal). 3. Depress the accelerator pedal while releasing the left brake pedal to start the machine off slowly.

Speed and Direction Change

1. Select the proper gear shifting mode by rotating the transmission shift lever. Refer to the following tables on page 70 for the gear selection mode. This machine is equipped with the automatic shifting system which selects the proper gear automatically using a micro computer to eliminate tiresome manual shifting.

2. For a direction change, decelerate the machine then move the transmission shift lever to forward or reverse.

IMPORTANT Changing direction with transmission in 3rd or 4th gear may cause serious transmission damage. Slow down machine and shift transmission to 1st or 2nd gear when changing direction.

3. When the transmission is in the 2nd gear, it can be quickly shifted down to the 1st gear by pressing the power up switch (Option except Europe specification). 4. Pressing the power up switch again, moving the transmission shift lever to the neutral position, or operating the parking brake switch releases the 1st gear setting to return the transmission to the 2nd gear. Refer to "Power Up Switch" page 38.

70

OPERATION

Lever

Selected Gear 1 □ 2 □ 3 □ A □

Operating Condition

1st

1.Excavating or scooping in a narrow space 2.Running downhill on a steep slope

2nd

1.Scooping or loading loose material 2.Running downhill on a slope

3rd

Carrying or roading

2nd, 3rd or 4th (automatically

Scooping, loading, carrying or roading

IMPORTANT Using too high gear for job may cause torque converter overheating. Use proper gear for each job.

Auto Brake

Auto Brake feature protects the transmission from excessive speed. It applies the service brakes and turns on the warning buzzer. Monitor lamp also turns on. Auto Brake works under the following conditions: 1. If the machine runs above the following speeds; 1 ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 15km/h 2 ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 22km/h 3 or A ・ ・ ・ 36km/h 2. When the direction is changed while running over 11km/h.

CAUTION When auto brake applies, machine may slow down suddenly. Be prepared. Wear seat belt.

71

10

20

0

30 100r/min

AUTO N 4 3 2 1

0000001/10h C H C H

F E

OPERATION

Parking WARNING Unexpected movement of machine could result in death or serious injury. Park machine in safe place on firm level ground. If machine has to be parked on a grade, place wheel chocks under wheels and dig attachment into ground.

IMPORTANT Applying parking brake while moving may cause rapid brake lining wear and loss of parking braking force. Except for emergency do not apply parking brake while machine is moving. 1. Release the accelerator pedal. 2. Apply the service brake to stop the machine. 3. Shift the transmission shift lever to "NEUTRAL". 4. Pull up the parking brake switch to apply the parking brake. 5. Lower the attachment to the ground and apply a small amount of down pressure.

72

OPERATION

Stopping the Engine WARNING Stopping engine while machine is moving will cause loss of steering control and braking force which may cause serious injury or death. Do not stop engine while machine is moving.

IMPORTANT Failure to allow engine to cool down before stopping may cause premature turbocharger failure. Run engine at low idle speed for about five minutes before stopping engine. 1. Let the engine idle for about five minutes before stopping. 2. Turn the starter switch to the "OFF" position to stop the engine. 3. After stopping the engine, remove the key and store it in a safe place.

WARNING Unauthorized operation could cause accidents resulting in death or serious injury. Prevent unauthorized operation. When leaving machine for extended period of time, remove the starter key, lock cab doors or lock vandal cover over dashboard and right hand console (if equipped).

73

ＯＦＦ ＯＮ ＳＴＡＲＴ

OPERATION

Operating Techniques IMPORTANT Operating machine on a grade may cause lack of lubrication resulting in severe damage on engine or other components. Do not operate machine on a grade over 30 ° . 30°Max.

Loading IMPORTANT Machine damage may result from improper loading procedures. ・ Do not dig or scoop with machine frame articulated. ・ Do not drive machine into material at high speed.

NOTE・ When loading rocks or hardpacked material, the use of bucket teeth is recommended. ・ For loose stockpile material replaceable bolt-on cutting edges should be used.

1. Move the machine forward to the material. 2. Steer the machine in a straight ahead position when entering the material.

3. Lower the bucket parallel to the ground.

4. Drive the bucket straight into the material. Use approximately 1/2 - full engine speed.

74

OPERATION

5. Move the boom control lever to the "Raise" detent position and run the machine forward slowly in 1st or 2nd speed. Reduce wheel slippage by slightly reducing engine speed.

6. Move the bucket control lever to the "Roll Back" and the "Hold" position several times to get more material in the bucket.

7. When the bucket is filled, move the bucket control lever to the "Roll Back" position. 8. Release the bucket control lever to the "Hold" position and the boom will rise. 9. Reverse the machine. 10. On later passes, aim the center of the bucket at the protruding portion of the material.

Excavating

1. Move the machine forward to the material. 2. Steer the machine in a straight ahead position when entering the material.

75

OPERATION

3. Lower the bucket parallel to the ground or dump it slightly forward.

4. Run the machine slowly in 1st or 2nd speed. Increase engine speed as the bucket digs deeper. 5. When the bucket is filled, move the bucket control lever to the "Roll Back" position.

6. Move the boom control lever to the "Raise" position to clear the ground.

Dozing IMPORTANT Dozing or pushing with dumped bucket or attachment may cause severe damage to linkages. Keep bucket or attachment bottom parallel to ground.

Ground Levelling

1. Keep the loaded bucket slightly above the ground. 2. While running the machine backward, dump the bucket little by little to evenly spread material on the ground.

76

OPERATION

3. Dump the bucket, allow the cutting edge to contact the ground, and run the machine backward.

4. To get smoother surface, put some material in the bucket, place the bucket parallel to the ground, run the machine backward with the boom control lever in the "Float" position.

IMPORTANT Pushing material with dumped bucket may cause severe damage to linkages. Be sure to run machine backward when leveling ground.

Carrying

1. Fully roll back the loaded bucket before carrying to prevent spillage. 2. Keep the bucket approximately 40cm above the ground when carrying.

IMPORTANT

approx. 40cm

When carrying material over 450m at high speed, tire overheating may occur. Follow tire manufacturer's instructions for tire inflation on this type of application.

Dumping into Truck or Hopper WARNING When boom is raised, machine stability is reduced and could cause machine to tip over causing serious injury or death. Do not make quick turns or abrupt braking when boom is raised. Keep boom low for best stability especially on slopes.

77

OPERATION

WARNING Machine contact with overhead wires or other objects could result in death or serious injury. Be sure there are no overhead wires or obstructions before raising boom to full height. Refer to "Loading" or "Excavating" page 74, 75 for the loading procedure. 1. Move the boom control lever to the "Raise" position to raise the loaded bucket while approaching the truck or the hopper.

2. Use the transmission cut-off selector switch in the "ON" position if working on a level site. When the left brake pedal (declutch pedal) is depressed, the transmission is placed automatically in neutral and the boom rises faster. 3. Return the boom control lever to the "Hold" position when the bucket reaches the enough height to clear the truck or hopper sideboards. If the boom is equipped with the kickout device (option), the boom will automatically stop and the boom control lever will return to the "Hold" position when the bucket reaches the preset height. Holding the boom control lever in the "Raise" position will continue to raise the boom if required. Refer to "Boom Kickout Adjustment" page 86 for adjustment of the preset height . 4. Position the machine in the center of the truck body or hopper to dump the load. 5. Push the bucket control lever forward to the "Dump" position to empty the bucket.

78

OPERATION

6. Roll back the bucket to clear the truck or hopper sideboards and lower the boom while reversing the machine.

CAUTION Fast boom lowering motion may cause machine rear wheels to jump up, reducing stability and control. Do not lower boom using detented "Float" position especially when bucket is full.

Typical Truck Loading Methods I Cycle Operation This method is recommended where the working area is limited.

V or L Cycle Operation This is the most efficient operation for the shortest cycle time.

T Cycle Operation This method is effecive for the sites where trucks continuously come and go.

79

(L-cycle)

( V-cycle)

SPECIAL PROCEDURES

SPECIAL PROCEDURES Adjustments Bucket / Attachment Positioner Adjustment WARNING Accidental movement of machine could result in death or serious injury. Apply parking brake and use wheel chocks to prevent sudden movement of machine.

WARNING Standing on tire, boom or linkage could cause accidents resulting in death or serious injury. Use safe sturdy platform to reach bucket positioner adjustment. 1. Park the machine on a level ground and apply the parking brake. 2. Lower the attachment to the ground, adjust it to the desired angle, set the bucket control lever to the hold position, and stop the engine. 3. Loosen the bolts (1) with a 19mm wrench. 4. Move the bracket (2) forward to increase, or rearward to decrease the attachment preset angle. 5. Tighten the bolts (1). 6. To test the adjustment; start the engine, raise the boom approximately half way, dump the attachment, and move the bucket control lever to the "Roll Back" detent position to rollback the attachment. When the preset angle is reached, the bucket control lever should return to the "Hold" position. Lower the attachment to the ground and confirm the proper angle has been set.

80

２

１

SPECIAL PROCEDURES

NOTE: Clearance between the switch (4) and rod (3) should be about 5mm. The switch may be adjusted in or out to set this clearance.

４

３ 5 ± 2mm

Boom Kickout Adjustment (Option except Europe specification) DANGER Sudden or accidental movement of boom will result in death or serious injury. Before walking or working under raised boom: ・ Securely block or brace boom. ・ Remove key and tag "Do Not Operate" on the steering wheel.

WARNING Standing on tire can cause accidents resulting in death or serious injury. Use safe sturdy platform to reach boom kickout adjustment. 1. Park the machine on a level ground and apply the parking brake. 2. Raise the boom to the desired height and stop the engine. 3. Lock the bucket and boom control levers in the "Hold" position using the loading control lever lock. 4. Block the boom and linkage from falling down using a proper support.

81

SPECIAL PROCEDURES

5. Loosen the two bolts (1). Align the plate (2) with the switch (3).

１

6. Move the plate (2) clockwise to decrease, or counterclockwise to increase the boom lift kickout height. 7. Tighten the bolts (1).

３

8. Remove the support from the boom and linkage. 9. To test the adjustment; start the engine, slowly lower the boom to the ground, and move the boom control lever to the "Raise" detent position to raise the boom. When the preset height is reached, the boom control lever should return to the "Hold" position. NOTE: Clearance between the switch (3) and plate (2) should be about 5mm. The switch may be adjusted in or out to set this clearance.

３

２ 5 ± 2mm

82

２

SPECIAL PROCEDURES

Roading / Special Applications WARNING Overheated tire could explode causing serious injury or death. If overheated tire is suspected during operation or servicing, do not approach tire to distance of less than 15m. Stay away until tire and rim cool down. When the machine travels at high speed or for a long distance, the tires or other components may become extremely hot causing an explosion or early wear. If the machine must be driven for a long distance, take the following precautions: ・ Follow the regulations related to this machine, and drive carefully. ・ The most suitable tire pressure, travel speed, or tire type differ according to the condition of the travel surface. Contact your nearest Kawasaki loader dealer or a tire dealer for information. ・ "Ton km/h" limitations must be observed. Consult a tire dealer for the speed limit of the tires involved. ・ After traveling for 30 minutes, stop the machine with engine running to allow the tires and components to cool. Check the tires and other parts for damage. ・ Do not put calcium chloride or dry ballast in the tires when traveling. ・ Whenever possible use a lead and/or follow vehicle and all available warning devices even if not required by regulations.

83

SPECIAL PROCEDURES

Booster Batteries / Jumper Cables WARNING Improper procedure to start engine using jumper cables could cause battery case explosion. ・ Do this work by two persons. While one person sits on the

operator's seat, the other person connects jumper cables.

・ Wear eye or face protection when working on or around

batteries. ・ The booster batteries should be of similar size and capacity as the batteries being boosted. ・ Do not allow the two machines to touch. This prevents possible sparks between or in the machines being used. ・ Keep flames and sparks away from batteries. ・ Keep jumper cable ends from touching each other or machine to avoid sparks. ・ Make last connection to grounded part of frame away from battery compartment.

WARNING If the battery is being used with insufficient battey electrolyte level, the deterioration on the parts in the case could be in the advanced stage. It could cause to shooten the battery life or to emit sparks from the deterioration parts in the case, as a result the battery case could explode. Keep the battery electrolyte level in the proper level.

WARNING Batteries contain lead, and acid which may cause burns. Avoid contact with skin or clothing and wear hand, eye, and face protection when working on or around batteries.

If lead, or acid contacts skin or clothing, immediately wash with water. NOTE: This machine uses a 24VDC negative ground electrical system. 1. Before connecting jumper cables: ・ The booster cables must be of the heavy duty type and in good condition.

84

SPECIAL PROCEDURES

・ Be sure the problem is inadequate battery charge and not some other electrical problems. ・ Stop the engine of the boost machine or turn off the booster supply if using an auxiliary power source.

2. Raise and lock the battery box covers. 3. Be sure vent caps are tight and level. Place damp cloth over vent caps on both batteries. 4. Move back the protective rubber covers (red) from the positive post (+) of the battery. 5. Connect one end of the red jumper cable to the positive post (+) of the discharged battery. 6. Connect the other end of the red jumper cable to the 24 volt side of the booster battery set or power source. 7. Connect one end of the black jumper cable to the ground side of the booster battery set or power source. 8. The final connection should be the remaining end of the black jumper cable to the engine block or frame away from the battery compartment on the machine being jump started. 9. Start the booster machine's engine or turn the auxiliary power source on. 10. Allow a few minutes to provide partial charge to the discharged batteries. 11. Start the machine being boosted as described on "Starting the Engine" page 61 . 12. As soon as the engine starts, disconnect the jumper cables in the reverse order (Step 8, Step 7, Step 6, Step 5). 13. Remove the damp cloth and replace the protective covers over the battery terminals and close the battery box covers. 14. Test the starting / charging system to determine the cause of the problem and correct it.

85

－

＋

＋

－

＋

－

＋

－

Booster Batteries Batteries being boosted Engine block of machine being jump started

SPECIAL PROCEDURES

Towing WARNING Improper towing could result in death or serious injury. Follow safety warnings found under "Safe Operation -Special Operating Conditions" page 8. This machine is equipped with a hitch on the rear end for towing a troubled machine. 1. Inspect the cable for damage. Never use a damaged cable. 2. Pull the handle to open the radiator grill. 3. Connect the cable to the drawbar. Make sure the drawbar and split pin are in the original position. 4. Close the radiator grill. 5. Connect the other end of the cable to the troubled machine. 6. If the service brake on the towed machine does not work; do not allow an operator on the towed machine, and attach another vehicle of adequate size to the rear to act as a braking vehicle. 7. Keep personnel away from between the towing machine and the towed machine. 8. Tow the machine slowly with gradual and smooth movement. 9. Use flashing lights or other warning signals when towing. If your machine must be towed, contact your nearest Kawasaki loader dealer for the necessary information or assistance.

86

SPECIAL PROCEDURES

Transportation When transporting the machine, observe the various road rules, road transportation vehicle laws and vehicle limit ordinances, etc. It is a good idea to obtain a special platform for loading and unloading the machine. 1. Park the trailer on a flat firm roadbed. Keep a fairly long distance between the road shoulder and the machine. 2. Properly apply the brakes of the trailer and place wheel chocks in front of and behind the tires to ensure that the trailer does not move. 3. Fix the ramp in line with the centers of the trailer and the machine.

4. Determine the position of the ramp, then slowly load the machine onto the specified part of the trailer. NOTE: Have someone in clear view and in a safe position provide directions while loading. 5. Lower the bucket and lock each control lever using the loading control lever lock (page 24). 6.

Apply the parking brake and set the articulation stopper in the "LOCKED" position (page 24).

7. Tape over the exhaust stack outlet to prevent turbo "Wind-milling" damage. 8. Place blocks in front of and behind the tires to prevent the machine from moving.

87

SPECIAL PROCEDURES

9. Fasten the machine to the trailer with chains or cables at 4 fixing points (red painted for Europe specification machine) provided on the machine. Additional cables or chains may be used but do not damage brake lines or cylinder rods.

IMPORTANT Brake pipe runs on axle housing. Do not fasten axle housing. 10. Determine the route for transporting the machine by taking into account the width, height and weight of the machine and truck. 11. In the case that it is necessary to lift the machine, sling the machine at 4 fixing points (red painted for Europe specification machine) provided on the machine as shown. ・ ・ ・34ton : Europe specification Weight・ 30ton : Standard specification ＧＲＡＶ Ｉ ＴＹ ＣＥＮＴＥＲ

88

SPECIAL PROCEDURES

Long Term Storage Before Storage

1. Wash and clean all parts of the machine. 2. Lubricate every greasing point described in "Greasing" section page 102 and 107. 3. Replace engine oil, transmission oil, differential and planetary oil and hydraulic system oil. For the engine and transmission, add 10% anticorrosive oil to new oil. 4. Add 10% anticorrosive oil to the fuel tank. 5. Idle the engine for about 15 minutes so that fuel and lubricant circulate throughout the engine, transmission and torque converter. 6. Store the machine indoors and keep it dry. Never leave it outdoors. If forced to leave it outdoors, choose a flat place, place the machine on wooden blocks and securely cover it with a canvas or plastic cover, etc. The range of temperature the machine is to be stored is between -35 ℃～45 ℃ . 7. Disconnect the cables from the batteries or if freezing temperatures are expected, remove the batteries from the machine and store separately in a heated area. 8. If freezing temperatures are expected, check and adjust the antifreeze/water mixture. Refer to "Coolant Specification" page 140 for the mixing ratio. 9. Securely cover the inlet and outlet ports of the air cleaner and muffler.

During Storage

Once a month remove the covers, run the engine, and move the machine a short distance to form a new oil film on the lubricated parts.

89

SPECIAL PROCEDURES

1. Check the following points. Refer to "Check before Operation" page 55 and "Check after Starting the Engine" page 65. ・ Coolant level ・ Engine oil level ・ Hydraulic oil level ・ Transmission oil level ・ Brake function ・ Steering function

2. Operate the machine as follows. ・ Run just the engine for about five minutes at low idle. ・ Move all cylinders of the hydraulic system full stroke 2 to 3 times. ・ Run the machine about 10m in every gear and direction. ・ Move the steering full stroke each way about 2 ～ 3 times.

After Storage

1. Loosen the drain cock or plug of the fuel tank and the hydraulic oil tank to drain any water into a suitable container. Dispose of properly. 2. Remove the covers and start the engine. 3. Replace engine and transmission oil with new specified oil after warming up both engine and transmission. Refer to "Replace Engine Oil" page 108 and "Replace Transmission Oil" page 122. 4. Start the engine and check for any abnormalities. 5. Warm up the machine until all gauges reach the normal range.

90

Serial Number Location

MAINTENANCE Before performing maintenance or repairs, read, understand and follow "Safe Maintenance" section page 11. The maintenance or repair of the machine must be performed by well-Trained or experienced personnel only.

Serial Number Location When contacting Kawasaki loader dealer or the dealers of other products for servicing or repair, refer to the serial number found in the following locations. See next page for general location. For quick reference, record each serial number in the blanks below. If a component, like engine or transmission, is changed, record the new serial number here. 1. Machine Serial Number

Europe specification ＨＥＡＶＹ ＩＮＤＵＳＴＲＩＥＳ， ＬＴＤ． ＳＥＲＩＡＬ ＮＵＭＢＥＲ

ＭＯＤＥＬ ＴＯＴＡＬ ＷＥＩＧＨＴ

ＦＡＢＲＩＣＡＴ ＩＯＮ ＤＡＴＥ

ＲＡＴＥＤＰＯＷＥＲ

ｋｇ

ｋＷ ＲＥＡＲ ＡＸＬＥ

ＰＥＲＭＩＳＳＩＢＬＥ ＬＯＡＤ：ＦＲＯＮＴ ＡＸＬＥ

Ｎ

Ｎ ＴＵＧ－ＨＯＯＫ ＶＥＲＴ． ＳＴＲＡＩＮ

ＴＵＧ－ＨＯＯＫ ＭＡＸ． ＰＵＬＬ

Ｎ

Ｎ

ＴＨＩＳ ＰＬＡＴＥ ＭＡＹ ＢＥ ＮＥＩ ＴＨＥＲＫＡＷＡＳＡＫ Ｉ ＨＥＡＶＹ ＩＮＤＵＳＴＲＩＥＳ， ＬＴＤ． ＡＬＴＥＲＥＤ ＮＯＲ ＲＥＭＯＶＥＤ． ４－１ ＨＡＭＡＭＡＴＵ ＣＨＯ ２ＣＨＯＭＥ ＭＩＮＡＴＯ ＫＵ ＴＯＫＹＯ ＪＡＰＡＮ ＭＡＤＥ ＩＮ ＪＡＰＡＮ Ｐ／Ｎ ４１６６８－２０３８０

Standard specification

SERIAL No.

KAWASAKI HEAVY INDUSTRIES, LTD. MADE IN JAPAN

2. Engine Serial Number

Ｄａ ｔ ａｐ ｌ ａ ｔ ｅ

91

Serial Number Location

3. Transmission / Torque Converter Serial Number

TRANSMISSION

Model

ＭＯＤＥＬ ＰＴ３１５Ｂ０１ ＳＥＲＩＡＬ ＮＯ

Serial Number

KAWASAKI

Design Number 4. ROPS Cab Serial Number (Option except Europe specification) SERIAL NO. Model Number Serial Number

Engine S/N

ROPS S/N (option)

Machine S/N (Right hand) Transmission S/N

92

Inspection and Maintenance Table

Inspection and Maintenance Table Section

Items for check

Daily

Check oil level Check coolant level Check air filter (warning lamp) Check exhaust gas color Drain water from fuel filter Check fuel level Drain water from fuel tank Check and adjust belts (fan,alternater,water pump) Replace oil Replace oil filter cartridge Clean crankcase breather Check air intake system Engine Replace DCA coolant filter cartridge Replace fuel filter cartridge Clean fuel tank Check compression pressure Check injection pressure Check injection timing Check valve lash clearance Check vibration damper Replace coolant Replace ether cylinder Clean air cleaner element Clean radiator fins Replace air cleaner element Check oil level Transmission Replace oil filter cartridge & Torque Replace oil Converter Clean or Replace breather Check tire air pressure Check tire for damage Axle system Grease axle support Check oil level (diff. and planet.) Grease propeller shaft

○ ○ ○ ○ ○ ○

Operating hours When Page 50 250 500 1000 2000 Required 55 56 65 68 57 65 ○ 105 ○

113～115

○

108 108 112 115 111 110 125 127 127 127 136 135 132 100 97 98 97 65 120 122 123 58 59 105 116 107, 108

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

After six cleanings or once a year ○ ○ ○ ○ ○ ○ ○ ○ ○

93

○

Inspection and Maintenance Table

Section Axle system Steering system Brake system

Loading system

Operating hours

Items for check

Daily

Check tightness of wheel nuts Replace gear oil (diff. and planet.) Check steering wheel operation Grease steering cylinder pins Check service brake operation Check parking brake operation Adjust parking brake lining Overhaul auto adjuster valve Check service brake disk wear Check brake accumulator Check hydraulic oil level Grease pins Replace return filter Clean filter for pilot pump control line Replace hydraulic oil Replace filter in the oil tank cap

50

250 ○

○ ○ ○ ○

○

When Page Required 500 1000 2000 117 ○ 130, 131 67 104 66 67 ○ 126 ○ 136 ○ 136 ○ 135 55

○

102～104

○ ○ ○ ○

Replace filter for pilot pump control line

Chassis

○

Replace bucket teeth (option) Replace cutting edge (option) Check rear view mirrors

○

Check ROPS and mounting bolts (option)

○

○ ○

Grease center pins

○ ○

Check vibration damper accumulator (option)

Check seat belt

○

Check windshield washer fluid (option)

○

Check monitor panel operation Check horn operation Check back-up alarm operation Electrical system Check wiring harnesses Check battery electrolyte level Check fuses Check compressor belt Clean filter Air Check refrigerant Conditioner Replace filter elements (option) Clean condenser Replace receiver dryer Others Walk-around inspection

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ (3000) ○ 94

124 128 129 137 138 95 96 60 60 108 138 96 99 60 60 67 57 106 98 117 118 127 136 99 137 54

WHEN REQUIRED MAINTENANCE

When Required Inspection and Maintenance WARNING Improper inspection or maintenance could result in death or serious injury. Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 11 before performing any inspection or maintenance procedures.

A. Replace Bucket Teeth (option)

When the bucket teeth are worn, replace them as follows. 1. Park the machine on a level ground and apply the parking brake. 2. Raise the bucket to a convenient height and put blocks under the bucket to prevent it from coming down.

1

3. Stop the engine. 4. Remove the bolts and nuts (1), then remove the bucket teeth (2). 5. Install the new teeth on the bucket with new bolts.

CAUTION Teeth and bucket edges are hardened steel which may chip when struck by steel hammer causing injury. ・ Always wear eye protection. ・ Use deadblow hammer or brass drift between hammer and

tooth.

・ Keep bystanders away from work area.

6. To prevent any clearance between the tooth and the edge of the bucket, tighten the nut partially, then hit the top of the tooth. 7. Tighten the nuts to 1314N・m(134kgf・m). 8. Retighten them after operating the machine for a few hours. NOTE:

For non-Kawasaki buckets or teeth, consult the manufacturer for the proper procedures.

95

2

Block

WHEN REQUIRED MAINTENANCE

B. Replace Cutting Edge (option)

1. Park the machine on a level ground and apply the parking brake. 2. Raise the bucket to a convenient height and put blocks under the bucket to prevent it from coming down. 3. Stop the engine. 4. Remove the cutting edge. Clean all contact surfaces (bottom of bucket, top of cutting edge). 5. If other side of the cutting edge is not worn, turn it around and install it so that the new side faces the front. If both sides are worn, install a new cutting edge. 6. Install all bolts and tighten them to 1314N・m(134kgf・m). 7. Retighten them after a few hours operation.

C. Check and/or Replace Seat Belt (Option except Europe specification) 1. Inspect the condition of the seat belt and all mounting hardware frequently. 2. Replace the seat belt or any part of the mounting hardware if it is damaged. 3. Replace the seat belt every three years regardless of its condition or apperance.

96

WHEN REQUIRED MAINTENANCE

D. Clean or Replace Air Cleaner Element

When the warning monitor lamp lights up, clean or replace the air cleaner element.

IMPORTANT

１

２

Improper procedure of cleaning air cleaner may cause severe engine damage. ・ Do not clean or replace cleaner while engine is running. ・ Clean only outer element. Never clean inner element. ・ Clean or replace element only when indicator lamp comes

on.

1. Park the machine on a level ground, apply the parking brake, lower the attachment to the ground, and stop the engine. 2. Remove the cover (2) by loosening wing nut (1). 3. Remove the outer element. 4. If the element is clogged by dirt or dust, spray dry compressed air (196kPa[2kgf/cm2]) along the inside of the element up and down to blow off dust.

5. Insert a lamp inside of the element for checking a damaged element. 6. If bright light spots are seen through the element, there are cracks or pinholes in the element. Replace it with a new element. 7. Inspect the rubber seal (3). If there is any damage to the seal, replace the element. 8. Confirm that the wing nut is tight and the inner element is properly seated, then reinstall the outer element, cover (2) and wing nut (1). 9. Even after cleaning, if the engine exhaust gas is not clean enough (excessive black smoke), replace the element.

97

３

WHEN REQUIRED MAINTENANCE

10. After six cleanings or once a year replace the outer element together with the inner element.

E. Clean Radiator Fins

1. Park the machine on a level ground, apply the parking brake, lower the attachment to the ground, and stop the engine. 2. Pull the knob and open the radiator grill. 3. Blow off mud, dirt, or clogging debris from the radiator fins with compressed air. Use a pressure washer or steam cleaner to remove harder debris. Compressed air, water, or steam should be directed from rear toward the engine.

IMPORTANT High pressure air, water, or steam may damage radiator fins. ・ Be sure pressure is below 196kPa(2kgf/cm2). ・ Move nozzle from side to side; not up and down.

If pressure exceeds 196kPa(2kgf/cm2), keep nozzle at least 50cm away from surface of radiator core. 4. Reverse the direction to flush all debris from the radiator fins. 5. Close the radiator grill.

F. Check or Replace Fuses

1. Park the machine on a level ground, apply the parking brake, and lower the attachment to the ground. 2. Stop the engine and turn the starter switch key to the "OFF" position. 3. Open the covers of the main fuse box and cab fuse box. 4. Check the fuses. If any blown fuses are found, replace them with new ones. Refer to "Fuse Box" page 48. 5. Determine the cause of the blown fuses.

98

WHEN REQUIRED MAINTENANCE

IMPORTANT Using wrong capacity fuse or bypassing fuse may cause electrical system damage. Never replace fuses with higher amperage rating.

G. Check Windshield Washer Fluid (option)

1. Park the machine on a level ground, apply the parking brake, and lower the attachment to the ground. 2. Check the fluid level. 3. Replace the fluid if it is dirty. 4. If the level is low, add fluid to proper level. 5. Use windshield washer solvent for both better cleaning and to prevent freezing. Adjust the mixture according to the manufacturer's instructions.

H. Clean Air Conditioner Condenser (option)

If mud, insects, or other debris are stuck to the air conditioner condenser, air flow through the condenser will be reduced causing decreased cooling ability. 1. Park the machine on a level ground, apply the parking brake, lower the attachment to the ground, and stop the engine. 2. Inspect the condenser and replace it if any damage is found. 3. Clean its fins using compressed air, a pressure washer, steam cleaner, or a soft brush. Be sure the air pressure is below 196kPa(2kgf/cm2). If a pressure washer or steam cleaner is used, keep the nozzle about 50cm away from the fins to prevent fin damage. 4. If water is used for the cleaning, cover the electrical parts of the engine and the electric condenser fan with plastic sheets. Remove the plastic sheets after cleaning.

99

WHEN REQUIRED MAINTENANCE

I . Replace Ether Cylinder WARNING Ether is very flammable and could cause serious injury or death if exploded. Do not store new or used ether cylinder in operators area or at temperatures above 40° C (105° F). Store new or used ether cylinder in cool place and out of children's reach. Never dispose of cylinder by burning, crusing, or puncturing. 1. Remove the cover. 2. Loosen the clamp. 3. Remove (turn counterclockwise) the cylinder. 4. Install (turn clockwise) a new ether cylinder. 5. Tighten the clamp.

100

DAILY MAINTENANCE

Daily Inspection and Maintenance WARNING Improper inspection or maintenance could result in death or serious injury. Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 11 before performing any inspection or maintenance procedures. See "Check before Operation" page 54 and "Check after Starting the Engine" page 65.

101

EVERY 50Hrs MAINTENANCE

Every 50 Hours or 1 Week Inspection and Maintenance WARNING Improper inspection or maintenance could result in death or serious injury. Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 11 before performing any inspection or maintenance procedures. Every 50 hours or 1 week, whichever comes first, perform the following inspection and maintenance in addition to the "Daily Inspection and Maintenance".

A. Greasing

1. Park the machine on a level ground, apply the parking brake, lower the attachment to the ground, and stop the engine. 2. Lubricate fittings on the following components. Wipe and clean all fittings before greasing. Lubricate until fresh grease is seen at each joint. Immediately replace or report any broken or defective grease fittings. Refer to "Recommended Lubricants" page 139 for the correct grease.

・ Bucket-Boom (two places)

・ Bucket-Rod (two places)

102

EVERY 50Hrs MAINTENANCE

・ Lever-Rod (two places)

・ Lever-Boom (two places)

・ Bucket Cylinder-Lever (two places)

・ Bucket Cylinder-Front Chassis (two places)

・ Boom Cylinder-Boom (two places)

103

EVERY 50Hrs MAINTENANCE

・ Boom Cylinder-Front Chassis (two places)

・ Boom-Front Chassis (two places)

・ Steering Cylinder (four places)

L.H. and R.H.

・ Axle support (two places)

104

EVERY 50Hrs MAINTENANCE

B. Drain Water and Sediment from Fuel Tank CAUTION Escaping fuel is flammable and harmful to skin. ・ Do not smoke while draining moisture and sediment from

fuel tank.

・ Do not drain fuel with engine running. ・ Do not allow fuel to remain on skin for extended period of

time. Wash thoroughly with soap and water.

1. Park the machine on a level ground, apply the parking brake, lower the attachment to the ground, and stop the engine. 2. Prepare a suitable container. 3. Open the drain cock on the bottom of the fuel tank. 4. Drain water and sediment along with fuel. 5. Close the drain cock. 6. Dispose of the drained fuel and water properly. 7. Add fuel. NOTE: To reduce water and sediment build up in the tank, refuel the machine at the end of each shift.

105

EVERY 50Hrs MAINTENANCE

C. Check Battery Electrolyte Level WARNING Batteries produce explosive gases which could cause burns or blindness. ・ Ventilate area to remove explosive gases. ・ Wear eye or face protection when working on or around

batteries.

・ Keep flames and sparks away from batteries.

WARNING If the battery is being used with insufficient battey electrolyte level, the deterioration on the parts in the case could be in the advanced stage. It could cause to shooten the battery life or to emit sparks from the deterioration parts in the case, as a result the battery case could explode. Keep the battery electrolyte level in the proper level.

WARNING Batteries contain lead, and acid which may cause burns. Avoid contact with skin or clothing and wear hand, eye, and face protection when working on or around batteries.

If lead, or acid contacts skin or clothing, immediately wash with water. 1. Park the machine on a level ground, apply the parking brake, lower the attachment to the ground, and stop the engine. 2. Clean the battery surface with a clean cloth or soft brush.

3. Check the battery electrolyte level in each cell. Electrolyte should cover the cell plates. 4. If the level is low, add distilled water until it reaches the bottom of the filler neck. NOTE: If a maintenance free battery is used, step 3 and 4 of this inspection and maintenance is not required.

106

Low

OK

High

EVERY 250Hrs MAINTENANCE

Every 250 Hours or 1 Month Inspection and Maintenance WARNING Improper inspection or maintenance could result in death or serious injury. Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 11 before performing any inspection or maintenance procedures. Every 250 hours or 1 month, whichever comes first, perform the following inspection and maintenance in addition to the "Daily" and "50 hours" inspections and maintenance.

A. Greasing

1. Park the machine on a level ground, apply the parking brake, lower the attachment to the ground, and stop the engine. 2. Lubricate fittings on the following components. Refer to "Recommended Lubricants" page 139 for the correct grease. Use lithium base grease for universal joints.

・ 2nd Propeller Shaft (five places)

107

EVERY 250Hrs MAINTENANCE

・ 3rd Propeller Shaft (two places)

・ Center Pin (two places)

(lower)

(upper)

B. Replace Engine Oil and Oil Filter Cartridges CAUTION Hot oil and engine components may cause burns. Avoid contact with hot oil or engine components. 1. If the machine is cold operate the engine to bring the C (105° F). When engine coolant temperature about 40° the needle of the coolant temperature gauge reaches the C middle of the white zone, the temperature is about 40° F). (105° 2. Park the machine on a level ground, apply the parking brake, lower the attachment to the ground, and stop the engine. 3. Remove the drain plug from the drain port. 4. Drain oil, about 43 liters, into a suitable container.

108

EVERY 250Hrs MAINTENANCE

5. Remove the oil filter and properly dispose of them. Make sure the O-ring is removed with the filter. 6. Clean the oil filter head gasket surface. 7. Fill the new filter with clean engine oil. Refer to "Recommended Lubricants" page 139 for the oil specifications. 8. Apply a light film of engine oil to the gasket surface of the new filter cartridge. 9. Install and tighten the filter until the gasket contacts filter head surface. Then tighten it by hand an additional three-fourths to one turn. Refer to the instructions supplied with the filter. 10. Clean and install the oil drain plug, and tighten to 80N ・ m(8.2kgf-m) torque. 11. Fill the engine with clean oil to the proper level. Refer to "Recommended Lubricants" page 139 for the oil specifications. Total system capacity including the filter is 43 liters. 12. Idle the engine to inspect for leaks at the filter and the drain plug. 13. Stop the engine. Wait approximately five minutes to let the oil drain back to the oil pan. 14. Check the oil level again. 15. Add the specified oil if necessary to bring the oil level to the "H"(High) mark on the dipstick. 16. Properly dispose of or recycle the waste oil.

CAUTION Used engine oil may cause skin disease. Do not allow used engine oil to remain on skin for prolonged periods of time. Clean skin thoroughly with soap and water.

109

EVERY 250Hrs MAINTENANCE

C. Replace Fuel Filters CAUTION Escaping fuel is flammable and harmful to skin. ・ Do not smoke while draining moisture and sediment from

fuel filter.

・ Do not drain with engine running. ・ Do not allow fuel to remain on skin for extended period of

time. Wash thoroughly with soap and water.

1. Park the machine on a level ground, apply the parking brake, lower the attachment to the ground, and stop the engine. 2. Place a small drain pan (about 1 liter) under the fuel filter. 3. Remove and properly dispose of the fuel filter. 4. Clean the filter head gasket surface. 5. Apply a light film of clean engine oil to the gasket surface of the new filter. 6. Fill the filter with clean fuel. 7. Install the filter on the filter head. Turn it until the gasket contacts the filter head surface. 8. Tighten the filter an additional one-half to three-fourths turn after the gasket contacts the filter head surface. Follow the instructions supplied with the filter.

110

EVERY 250Hrs MAINTENANCE

D. Replace DCA4 Coolant Filter Cartridge CAUTION Pressurized radiator tank is used for this machine. Spray of hot coolant can cause burns. Stop engine and allow radiator and coolant to cool completely, then open cap slowly to relieve pressure.

CAUTION Hot coolant and engine components can cause burns. Avoid contact with coolant or engine components. NOTE: The filter to be used here is WF2073 that is smaller than the filter initially installed when the machine is shipped from the factory. 1. Park the machine on a level ground, apply the parking brake, lower the attachment to the ground, and stop the engine. 2. Press the button on the radiator tank cap to release any remaining pressure, and remove the cap slowly.

ＰＵＳＨ

3. Turn the coolant shut-off valve (2).

２

4. Remove and properly dispose of the coolant filter (1).

１

5. Clean the filter head gasket surface. 6. Apply a light film of clean engine oil to the gasket surface of a new DCA4 coolant filter cartridge (WF2073).

111

EVERY 250Hrs MAINTENANCE

7. Install the filter firmly by hand. Follow the instructions supplied with the filter.

8. Open the coolant shut-off valve and install the radiator cap. 9. Run the engine and check for coolant leaks. 10. Idle the engine for about five minutes to purge all the air from the coolant. 11. After air has been purged from the system, stop the engine and check the coolant level again. 12. If needed, add required amount of the coolant. Refer to "Coolant Specification" page 140 for the correct mixture.

E. Clean Crankcase Breather There are three breather elements on the top of the cylinder head cover. Clean all three. 1. Park the machine on a level surface, apply the parking brake, lower the attachment to the ground, and stop the engine.

2. Loosen the wing nut (6) and remove cover (1) and element (2).

６ １

3. Clean the element (2). 4. Inspect the element (2) and rubber gasket (4). Replace it if necessary. 5. Install a cleaned or new breather element. Tighten the wing nut (6).

２ ３ ４ ５

112

EVERY 250Hrs MAINTENANCE

F. Check and Adjust Fan Belt CAUTION Contact with moving belts or pulleys may cause injuries. Stop engine before opening engine side panel.

Inspection

1. Park the machine on a level ground, apply the parking brake, lower the attachment to the ground, and stop the engine. Remove the key and tag "Do Not Operate". 2. Open the engine side panel. 3. Visually inspect the fan belt for looseness and damage. 4. If the belt is too stretched to permit adjustment or shows cuts or cracks, replace it and adjust the tension correctly. If multiple belts are used as a set, replace all of them. 5. Apply pressure, approximately 98N(10kgf), to the center of the belt between the pulleys. Correctly adjusted belts will deflect one belt thickness per 30cm of pulley center distance.

Adjustment

1. Loosen the three capscrews (1) which secure the fan hub shaft to the bracket. 2. Loosen the lock nut (3).

２

3. Turn the adjusting screw (2) to adjust the belt tension correctly. 4. Tighten the lock nut (3). 5. Tighten the three capscrews to 108N・m(11kgf・m). 6. Loosen the adjusting screw 1/2 turn to prevent breakage.

113

１

３

EVERY 250Hrs MAINTENANCE

G. Check and Adjust Alternator Drive Belt CAUTION Contact with moving belts or pulleys may cause injuries. Stop engine before opening engine side panel.

Inspection

1. Park the machine on a level ground, apply the parking brake, lower the attachment to the ground, and stop the engine. Remove the key and tag "Do Not Operate". 2. Open the engine side panel. 3. Visually inspect the alternator drive belt for looseness and damage. 4. If the belt is too stretched to permit adjustment or shows cuts or cracks, replace it and adjust the tension correctly. 5. Apply pressure, approximately 98N(10kgf), to the center of the belt between the pulleys. Correctly adjust belt will deflect one belt thickness per 30cm of pulley center distance.

Adjustment

1. Loosen the bolts (1), (2) and (3) which secure the alternator to the bracket.

１

2. Shift the alternator outward to increase the belt tension.

２

3. Tighten the bolts.

３

H.Check and Adjust Water Pump Belt CAUTION Contact with moving belts or pulleys may cause injuries. Stop engine before opening engine side panel.

Inspection

1. Park the machine on a level ground, apply the parking brake, lower the attachment to the ground, and stop the engine. Remove the key and tag "Do Not Operate".

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EVERY 250Hrs MAINTENANCE

2. Open the engine side panel. 3. Visually inspect the water pump drive belt for looseness and damage. 4. If the belt is too stretched to permit adjustment or shows cuts or cracks, replace it and adjust the tension correctly. 5. Apply pressure, approximately 98N(10kgf), to the center of the belt between the pulleys. Correctly adjusted belt will deflects one belt thickness per 30cm of pulley center distance.

Adjustment

1. Loosen the lock nut (1) which secures the idler pulley to the water pump. 2. Turn the adjusting screw (2) to adjust the belt tension. 3. Secure the idler pulley in position by tightening the lock nut (1) to 69N・m(7kgf・m).

4. Loosen the adjusting screw (2) 1/2 turn to prevent breakage.

I . Check Air Intake System CAUTION Hot engine components may cause burns. Avoid contact with hot engine components. 1. Park the machine on a level ground, apply the parking brake, lower the attachment to the ground, and stop the engine. 2. Check the engine intake hose, intake pipes, pipe clamps and hose bands for damage and tightness.

3. If damaged or loose, replace or retighten or contact your nearest Kawasaki loader dealer.

115

２ １

EVERY 250Hrs MAINTENANCE

IMPORTANT Severe engine damage may result from running with unfiltered air. Do not operate engine if any leaks or defects are found on air intake system.

J. Check Differential Gear Oil

1. Park the machine on a level ground, apply the parking brake, lower the attachment to the ground, and stop the engine. 2. Remove the oil level plug from the front axle housing, using a 12mm hex (Allen) wrench. 3. If the oil level is lower than the plug, add the specified oil through the level plug hole. Refer to "Recommended Lubricants" page 139. 4. If there is any sign of water in the oil, drain and replace the oil. Oil containing water looks milky.

Ｆｒ ｏｎ ｔ Ａｘ ｌ ｅ

5. Retighten the level plug. 6. Check the rear axle oil level following the same steps.

K. Check Planetary Gear Oil

1. Check the oil level on all four wheels. 2. Move the machine on a level ground so that "TOP" mark (1) on the planetary gear housing comes top.

１ ＴＯＰ

3. Turn "ON" the parking brake switch, lower the attachment to the ground, and stop the engine. 4. Remove the oil level plug (2) on the housing, using a 12mm hex (Allen) wrench.

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２

EVERY 250Hrs MAINTENANCE

5. If the oil level is lower than the plug, add the specified oil through the level plug hole. Refer to "Recommended Lubricants" page 139. 6. Magnetic plugs are used for the planetary gear housing. Wipe off the small amount of fine metallic powder that normally sticks to the plugs. If abnormal debris is found, determine the cause and correct it. 7. If there is any sign of water in the oil, drain and replace the oil. Oil containing water looks milky. 8. Retighten the plug.

L. Check Tightness of Wheel Nuts

1. Park the machine on a level ground, apply the parking brake, lower the attachment to the ground, and stop the engine. 2. Check the wheel bolts are tightened to 892N・m (91kgf ・ m). ＴＯＰ

3. Retighten if necessary.

M. Check and Adjust Air Conditioner Belt (option) CAUTION Contact with moving belts or pulleys may cause injuries. Stop engine before opening engine side panel. 1. Park the machine on a level ground, apply the parking brake, lower the attachment to the ground, and stop the engine. Remove the key and tag "Do Not Start". 2. Open the engine side panel. 3. Visually inspect the compressor belt on both top and bottom sides for looseness and damage. 4. If the belt is too stretched to permit adjustment or shows cuts or cracks, replace it and adjust the tension correctly.

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EVERY 250Hrs MAINTENANCE

5. Measure the belt tension using a belt tension gauge so that it is applied 637 ± 98N (65 ± 10kgf). 6. If the belt is too loose or tight, adjust the tension by loosening the lock nuts (1) and turning the adjusting nut (2) under the compressor bracket.

１

7. Tighten the lock nuts (1).

１ ２

N. Clean Air Conditioner Filter Element (option) Outer filter cleaning

1. Park the machine on a level ground, apply the parking brake, lower the attachment to the ground. 2. Turn the air conditioner "OFF" and stop the engine. 3. The cover for the outer filter is located at the right rear side of the cab. Turn the rings counterclockwise and then remove the cover.

4. Remove the outer filter from the cab.

5. Remove dust with compressed air. below 196kPa(2kgf/cm2).

Use air pressure

6. To remove more stubborn debris, wash the filter with clean water. Leave them for five to seven days for dry in the shade.

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EVERY 250Hrs MAINTENANCE

7. After approximately 20 cleanings, replace the filter with new one. Refer to "Replace Air Conditioner Filter Elements" page 136. 8. When installing the outer filter into the cab, be sure to align the air flow arrow on the outer filter to point toward the cab. 9. Install the cover to the cab and turn the rings clockwise to fix the cover.

Inner filter cleaning

1. The inner filters (2pcs) are located at the right behind the operator's seat. Open the unit cover and remove the cover (1) using screw driver. Loosen the screw (2) by fingers to remove the cover (3). Remove the filters and clean them.

１ ２

２ 2. Remove dust with compressed air. below 196kPa(2kgf/cm2).

Use air pressure

3. To remove more stubborn debris, wash the filter with clean water. Leave them for five to seven days for dry. 4. After approximately 20 cleanings, replace the filters with new ones. Refer to "Replace Air Conditioner Filter Elements" page 136. 5. Install the filter elements, install the filter cover (3) and cover (1). NOTE: It is recommended to have a second set of filters to use while another set is being dried.

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３

EVERY 500Hrs MAINTENANCE

Every 500 Hours or 3 Months Inspection and Maintenance WARNING Improper inspection or maintenance could result in death or serious injury. Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 11 before performing any inspection or maintenance procedures. Every 500 hours or 3 months, whichever comes first, perform the following inspection and maintenance in addition to the "Daily", "50 hours", and "250 hours" inspection and maintenance.

A. Replace Transmission Oil Filter CAUTION Hot oil and components may cause burns. Avoid contact with hot oil or components. 1. If the machine is cold, operate the machine to bring the C (85 to torque converter oil temperature about 30 to 40° F). 105° 2. Park the machine on a level ground, turn "ON" the parking brake switch, lower the attachment to the ground, and stop the engine. 3. Place a suitable container (about 4 liters) under the transmission oil filter. 4. Turn the filter counterclockwise to remove. dispose of the oil and filter.

Properly

5. Clean the filter head gasket surface. 6. Apply a light film of clean engine oil to the gasket surface of the new filter. 7. Install the filter on the filter head. Turn it clockwise to tighten. Follow the instructions on the filter. 8. Idle the engine about ten minutes and inspect for leaks around the filter.

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EVERY 500Hrs MAINTENANCE

DANGER Accidental movement of machine will result in death or serious injury. When inspecting or servicing machine in articulation area:

・ Lower attachment to ground. ・ Put transmission shift lever in neutral. ・ Apply parking brake. ・ Set articulation stopper in "LOCKED" position. ・ Make sure nobody is on machine. ・ Place "DO NOT OPERATE" tag on steering wheel.

9. Check transmission oil level. Refer to "Check Transmission Oil Level" page 64. Add the specified oil as necessary to bring the oil level to the "H" (high) mark on the dipstick. Refer to "Recommended Lubricants" page 139 for the specified oil.

CAUTION Used oil may cause skin disease. Do not allow used oil to remain on skin for prolonged periods of time. Clean skin thoroughly with soap and water.

121

EVERY 1000Hrs MAINTENANCE

Every 1000 Hours or 6 Months Inspection and Maintenance WARNING Improper inspection or maintenance could result in death or serious injury. Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 11 before performing any inspection or maintenance procedures. Every 1000 hours or 6 months, whichever comes first, perform the following inspection and maintenance in addition to the "Daily", "50 hours", "250 hours", and "500 hours" inspection and maintenance.

A. Replace Transmission Oil WARNING Accidental movement of machine could result in death or serious injury. When inspecting or servicing machine in articulation area:

・ Lower attachment to ground. ・ Put transmission shift lever in neutral. ・ Apply parking brake. ・ Make sure nobody is on machine. ・ Place "DO NOT START" or "DO NOT OPERATE" tag on

steering wheel.

CAUTION Transmission oil may be hot and may cause burns. Avoid contact with transmission oil. 1. If the machine is cold operate the machine for a few minutes to bring the transmission oil temperature about C (85 to 105° F). 30 to 40° 2. Park the machine on a level ground, turn "ON" the parking brake switch, lower the attachment to the ground, and stop the engine.

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EVERY 1000Hrs MAINTENANCE

3. Remove the drain plug (1) with a 12mm wrench. 4. Drain oil into a suitable container (about 55 liters). Properly dispose of or recycle the waste oil. 5. Loosen the four bolts (2) with a 17mm wrench. 6. Remove the flange (3) together with the pipe and suction strainer. 7. Remove the suction strainer from the flange, brush off any debris and clean with solvent. It is normal for a few fine particles to be on the strainer. Large pieces or a large quantity of particles indicates a problem. Contact a Kawasaki loader dealer. 8. Reinstall the drain plug and the strainer with a new gasket. 9. Tighten the four bolts (2) to 44N・m(4.5kgf・m). 10. Fill with the specified oil. Refer to "Recommended Lubricants" page 139. 11. Idle the engine and check for leaks. 12. Check the oil level with the dipstick. Add the specified oil if necessary to maintain the proper oil level. Refer to "Check Transmission Oil Level" page 65 and "Recommended Lubricants" page 139.

B. Clean or Replace Transmission Breather

1. Park the machine on a level ground, apply the parking brake, lower the attachment to the ground, and stop the engine. 2. Remove the breather from the transmission case. 3. Clean the breather in the cleaning oil tub, then spray dry compressed air from the bottom of the breather. Even after cleaning, if the breather is not clean enough, replace the breather. 4. Install the breather onto the transmission case.

123

１

３

２

EVERY 1000Hrs MAINTENANCE

C. Replace Hydraulic Oil Return Filter CAUTION Pressurized hydraulic tank is used for this machine. Pressurized hot oil may cause injury or burns. Vent all pressure by slowly turning cap 1/3 turn counterclockwise. 1. Park the machine on a level ground, apply the parking brake, lower the attachment to the ground, and stop the engine. 2. Open the access cover on the left deck. 3. Press down the filler cap to relieve the tank pressure.

4. Clean around the top of the filter cover (1).

２

5. Remove two bolts (2) with a 19mm wrench and open the filter cover (1). The two bolts (3) may be used as "Jacking screws" to push up the cover. Install them into the two threaded holes in the cover. Screw them in equally to force the cover up evenly.

１

6. Remove the O-ring (3), spring (4), and bypass valve (5) from the filter housing.

２ １

7. Remove and porperly dispose of the filter (6) and waste oil.

３

8. Clean the inside of the filter housing.

４

9. Replace the gaskets and seals.

５

10. Apply a light film of clean hydraulic oil on the filter cover O-ring surface. 11. Install the filter element (6), bypass valve (5), spring (4), new O-ring (3), and filter cover (1). 12. Close the access cover.

124

６

EVERY 1000Hrs MAINTENANCE

D. Clean Fuel Tank CAUTION Escaping fuel is flammable and harmful to skin. ・ Do not smoke while draining moisture and sediment from

tank.

・ Do not drain with engine running. ・ Do not allow fuel to remain on skin for an extended period

of time. Wash thoroughly with soap and water.

NOTE: It is easiest to clean the fuel tank when the fuel is almost empty. 1. Park the machine on a level ground, apply the parking brake, lower the attachment to the ground, and stop the engine. 2. Open the drain cock (1) on the bottom of the fuel tank. 3. Drain the remaining fuel into a suitable container. 4. Remove the nuts with a 17mm wrench to remove the inspection cover (2).

２

5. Clean inside of the tank. 6. Install the inspection cover with a new gasket. Tighten the nuts. Do not overtighten. 7. Close the drain cock. 8. Fill the fuel tank. 9. Check for any leaks at the cover and plug.

125

１

EVERY 1000Hrs MAINTENANCE

E. Adjust Parking Brake Lining WARNING When parking brake is released for adjusting brake lining, machine could move unexpectedly causing serious injury or death. Make sure to lower attachment to ground, and put chocks under wheels. 1. Park the machine in a safe place on firm level ground and steer it fully to one side for easier access.

１

2. Lower the attachment to the ground and turn "OFF" the parking brake switch.

3. Align the inspection hole (1) with the adjuster wheel by turning the hole 8° counterclockwise from the bottom. Do not enter the articulation area or under the machine. 4. Place wheel chocks in front of and behind the tires to prevent the machine from moving.

１

5. Place a "DO NOT OPERATE" tag on the steering wheel. 6. Remove a cap of the inspection hole (1) on the brake drum. 7. Turn the adjuster wheel fully upward to close the clearance between the brake drum and the brake lining (shoe). The adjuster wheel can be reached through the inspection hole. 8. Return the adjuster wheel eight clicks downward. (Now the clearance is 0.23mm) 9. Check parking brake operation as described on page 67. NOTE: If the brake drum has been excessively hot (ie. burnt paint) or the parking brake will not adjust, contact your Kawasaki loader dealer.

126

8°

Adjuster wheel

１ Special Tool (Accessory)

EVERY 1000Hrs MAINTENANCE

F. Check Air Conditioner Refrigerant (Option) 1. Apply the parking brake and lower the attachment to the ground. 2. Remove the cover. 3. Press the "HI" flow control switch to set maximum air flow. 4. Set the temperature control switch fully to the cool position and fully open the cab doors. 5. Slightly accelerate the engine to about the middle speed range (compressor speed 1500-1800min-1.) 6. Compare the flow of bubbles in the sight glass with the drawings in the following table.

CAUTION Overfilled refrigerant may cause dangerous high pressure and poor cooling action; and low refrigerant level may cause compressor damage. Always maintain refrigerant in normal level. Amount of refrigerant

Appearance of the sight glass

Normal

Almost clear. Any bubbles disappear if the engine speed is increased to 1,500min-1.

High

No bubble is seen.

Low

A flow of bubbles is visible.

G. Check and Adjust Engine

Contact your nearest Kawasaki loader dealer or local Cummins engine dealer for checking and adjusting the following items: ・ Engine Compression Pressure ・ Injection Pressure ・ Injection Timing

127

Solutions

Contact your local Kawasaki loader dealer for inspection and recharging refrigerant.

EVERY 1000Hrs MAINTENANCE

H. Clean Filter for Pilot Pump Control Line CAUTION Hot oil and components may cause burns. Avoid contact with hot oil or components. 1. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine. 2. Place a suitable container (about 2 L) under the oil filter. 3. Remove the filter case (5) with 24mm wrench. 4. Remove the element (3) and inspect and clean it by a toothbrush. Remove the spring (4) and inspect and clean it with solvent and compressed air. 5. Install the element (3) , new O-ring (1), new backup ring (2) and spring (4) to the filter case (5). 6. Install and tighten the filter case (5) to 25～34N・m (2.5～ 3.5kgf・m) on the filter head. 7. Check for oil leakage from the filter after installing the filter case (5).

１ ２ ３ ４

Parts to be replaced Symbol

Part Name

Part Number

Q'ty

1

O-ring

47131-73540

1

2

Backup ring

47194-70800

1

CAUTION Used oil may cause skin disease. Do not allow used oil to remain on skin for prolonged periods of time. Clean skin thoroughly with soap and water.

128

５

EVERY 2000Hrs MAINTENANCE

Every 2000 Hours or 1 Year Inspection and Maintenance WARNING Improper inspection or maintenance could result in death or serious injury. Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 11 before performing any inspection or maintenance procedures. Every 2000 hours or 1 year, whichever comes first, perform the following inspection and maintenance in addition to the "Daily", "50 hours", "250 hours", "500 hours", and "1000 hours" inspections and maintenance.

A. Replace Hydraulic Oil CAUTION Pressurized hydraulic tank is used for this machine. Pressurized hot oil may cause injury or burns. Relieve all pressure by slowly turning cap 1/3 turn counterclockwise. 1. Park the machine on a level ground, apply the parking brake, lower the attachment to the ground, and stop the engine. 2. Move the bucket and boom control levers back and forth to relieve the pressure. 3. Insert the key into the side of the filler cap and turn the key counterclockwise. (Europe specification) 4. Press down the filler cap to relieve the tank pressure. 5. Remove the inlet cap.

CAUTION Hydraulic oil may be hot and may cause burns. Avoid contact with hydraulic oil. 6. Prepare a suitable container to catch the draining oil (about 150 liters).

129

EVERY 2000Hrs MAINTENANCE

7. Remove the drain plug (1) with a 12mm Hex (Allen) wrench to drain oil.

２

8. Dispose of the waste oil properly. 9. Remove the nuts with a 17mm wrench to remove the inspection cover (2).

１

CAUTION Compressed air may cause injury. ・ Wear protective clothing and eye protection. ・ Air pressure must be below 196kPa(2kgf/cm2).

10. Clean inside of the tank and magnet plug. 11. Install the new gasket, and inspection cover (2), and tighten the nuts. Do not overtighten. 12. Install and tighten the drain plug. 13. Add the specified hydraulic oil through the oil inlet hole. Refer to "Recommended Lubricants" page 139. 14. Close the oil inlet cap. 15. Start the engine and allow the engine to idle for about five minutes. 16. Operate the bucket, boom, and steering cylinders for about five minutes, then lower the attachment to the ground. 17. Inspect for leaks. 18. Make sure hydraulic oil is to the center of the oil level gauge. Add hydraulic oil if necessary.

B. Replace Differential Gear Oil CAUTION Differential gear oil may be hot and may cause burns. Avoid contact with differential gear oil. 1. If the machine is cold operate the machine for a few minutes to bring the differential gear oil temperature C (105° F). about 40°

130

EVERY 2000Hrs MAINTENANCE

2. Park the machine on a level ground, apply the parking brake, lower the attachment to the ground, and stop the engine.

WARNING If the boom is raised to ease access securely block or brace the boom to prevent accidental lowering. 3. Remove the level plug (1) and drain plug (2) from the front axle housing, with a 12mm Hex (Allen) wrench. Some fine metallic powder will normally stick to the magnet plugs. Simply wipe it off.

１

4. Drain the oil (about 55 liters) into a suitable container.

２

5. Dispose of the waste oil properly.

CAUTION Used oil may cause skin disease. Do not allow used oil to remain on skin for prolonged periods of time. Clean skin thoroughly with soap and water. Note: While the oil is drained measure brake wear as described in item H. 6. Install the drain plug. 7. Refill the recommended oil through the level plug hole (1) until the oil comes out from the hole. Refer to "Recommended Lubricants" page 139. 8. Install and tighten the level plug. 9. Replace the rear differential oil following the same steps. Required oil volume for the rear differential is about 60 liters.

C. Replace Planetary Gear Oil CAUTION Planetary gear oil may be hot and may cause burns. Avoid contact with planetary gear oil.

131

EVERY 2000Hrs MAINTENANCE

1. Replace the planetary gear oil on all four wheels. 2. Move the machine on a level ground so that "TOP" mark (1) on the planetary gear housing comes to the top.

１ ＴＯＰ

3. Turn "ON" the parking brake switch, lower the attachment to the ground, and stop the engine.

WARNING If the boom is raised to ease access securely block or brace the boom to prevent accidental lowering.

２

4. Remove the level plug (2) and drain plug (3) from the planetary gear housing, using a 12mm hex (Allen) wrench. Some fine metallic powder will normally stick to the magnet plugs. Simply wipe it off. 5. Drain the oil (about 20 liters) into a suitable container. 6. Dispose of the waste oil properly.

CAUTION Used oil may cause skin disease. Do not allow used oil to remain on skin for prolonged periods of time. Clean skin thoroughly with soap and water. 7. Install and tighten the drain plug. 8. Refill the recommended oil through the level plug hole (2) until the oil comes out from the hole. Refer to "Recommended Lubricants" page 139. 9. Install and tighten the level plug. 10. Repeat these steps for all four planetaries.

D. Replace Coolant

・ Since the Anti-Freeze "Long Life Coolant" (LLC) is originally used for the machine shipped from the factory, it is not necessary to replace the coolant for the first two years.

132

３

EVERY 2000Hrs MAINTENANCE

・ If the cooling system conditioner (from a local supplier) is used at the time of last replacement, follow its instructions or contact your nearest Kawasaki loader dealer for the replacement interval.

CAUTION Pressurized radiator tank is used for this machine. Spray of hot coolant may cause burns. Stop engine and allow radiator and coolant to cool completely, then open cap slowly to relieve pressure. 1. Park the machine on a level ground, apply the parking brake, lower the attachment to the ground, and stop the engine. 2. Inspect all coolant hoses. Replace any that are cracked, swollen, or brittle. 3. Press the button (1) to release any remaining pressrue.

１

4. Remove the cap (2) slowly.

ＰＵＳＨ

２ 5. Open the drain cocks (3) and (4) and drain coolant (about 100 liters) into a suitable container. Do not remove the coolant filter.

３

6. Follow local regulations to properly dispose of or recycle the coolant.

４

133

EVERY 2000Hrs MAINTENANCE

CAUTION Cooling system conditioner contains alkali that may cause caustic burns or blindness. Avoid contact with skin and eyes to prevent injury. 7. Close the drain cocks and fill the cooling system with clean water and cooling system cleaner. Follow the manufacturer's instructions. Do not install the radiator cap. 8. Operate the engine for one hour with the coolant C (180° F). temperature above 80° 9. Stop the engine and open the drain cocks to drain the cooling system. 10. Close the drain cocks and fill the cooling system with clean water. Do not install the radiator cap or the new coolant filter. 11. Operate the engine for five minutes with the coolant C (180° F). temperature above 80° 12. Stop the engine and open the drain cocks to drain the cooling system. 13. If the water being drained is still dirty, the system must be flushed again until the water is clean (step 7～13). 14. Close the drain cocks and fill the system with the premixed coolant. Refer to "Coolant Specification" page 140 for the mixing instruction. 15. Add two pieces of DCA65L and one piece of DCA60L coolant additive at the same time. 16. Replace the DCA4 coolant filter (WF2073). Refer to "Replace DCA4 Coolant Filter" page 111 for the procedure. 17. Idle the engine for five minutes to purge air mixed into the coolant. (Leave the radiator cap off.) 18. Add coolant as neccessary.

134

EVERY 2000Hrs MAINTENANCE

19. Reinstall the radiator cap. For additional cold weather servicing information, refer to "Coolant Specification" page 140 for details.

E. Check Vibration Damper

1. Park the machine on a level ground, apply the parking brake, lower the attachment to the ground, and stop the engine. 2. Check the damper on the fan end of the engine crankshaft. 3. If dents, cracks, or any deformations are found, contact your nearest Kawasaki loader dealer or Cummins Engine dealer for replacement.

F. Check Brake Accumulator

Test the brake accumulator for proper precharge of nitrogen gas.

WARNING Pressurized nitrogen gas in brake accumulator could explode causing serious injury or death. Never service brake accumulator unless trained properly. 1. Park the machine on a level ground, apply the parking brake, and lower the attachment to the ground. 2. Run the engine at low idle for five minutes to fill the brake accumulator with oil. 3. Stop the engine. 4. Turn the key switch to the "ON" position. 5. Count the number of times you can depress the right hand brake pedal before the brake warning light comes on. 6. If the number counted is less than five, there is some problem with the accumulator. Contact your nearest Kawasaki loader dealer.

135

EVERY 2000Hrs MAINTENANCE

G. Overhaul Auto-adjuster Valve Contact your Kawasaki loader dealer.

H. Check Service Brake Disk Wear

Contact your Kawasaki loader dealer or local Cummins engine dealer.

I . Check and Adjust Valve Lash Clearance

Contact your Kawasaki loader dealer or local Cummins engine dealer.

J.Replace Air Conditioner Filter Elements(option) Outer filter replacement

1. Park the machine on a level ground, apply the parking brake and lower the attachment to the ground. 2. Turn the air conditioner "OFF" and stop the engine. 3. The cover for the outer filter is located at the right rear side of the cab. Turn the rings counterclockwise and then remove the cover.

4. Remove the outer filter from the cab, and replace it with new one. When installing the outer filter into the cab, be sure to align the air flow arrow on the outer filter to point toward the cab.

5. Install the cover to the cab and turn the rings clockwise to fix the cover.

136

EVERY 2000Hrs MAINTENANCE

Inner filter replacement

1. The inner filters (2pcs) are located at the right behind the operator's seat. Open the unit cover and remove the cover (1) using screw driver. Loosen the screw (2) by fingers to remove the cover (3). Remove the filters and replace them with new ones.

１ ２

２

３

K. Replace Air Conditioner Receiver Dryer (option) (Every 3 years or 6000 hours) ・ Contact your Kawasaki loader dealer.

L. Replace Filter in the Oil Tank Cap CAUTION Pressurized hydraulic tank is used for this machine. Pressurized hot oil may cause injury or burns. Vent all pressure by pressing cap before opening. 1. Park the machine on a level ground, apply the parking brake, lower the attachment to the ground, and stop the engine.

１

2. Move the bucket and boom control levers back and forth to relieve the pressure.

５ ４

3. Insert the key into the side of the filter cap (1) and turn the key counterclockwise. 4. Press down the filter cap (1) to relieve the tank pressure. 5. Remove the filter cap.

３

6. Remove spiral snap ring (2), valve assy (3), spring (4), filter element (5).

２

7. Replace element (5). 8. Install the element, spring, valve assy, and spiral snap ring.

137

EVERY 2000Hrs MAINTENANCE

M. Replace Filter for Pilot Pump Control Line CAUTION Hot oil and components may cause burns. Avoid contact with hot oil or components. 1. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine. 2. Place a suitable container (about 2 L) under the oil filter. 3. Remove the filter case (5) with 24mm wrench. 4. Remove the element (3) and the spring (4). Inspect and clean the spring (4) with solvent and compressed air. 5. Install new element (3) , new O-ring (1), new backup ring (2) and spring (4) to the filter case (5). 6. Install and tighten the filter case (5) to 25～34N・m (2.5～ 3.5kgf・m) on the filter head.

１ ２

7. Check for oil leakage from the filter after installing the filter case (5).

３

Parts to be replaced

４

Symbol

Part Name

Part Number

Q'ty

1

O-ring

47131-73540

1

2

Backup ring

47194-70800

1

3

Filter element

30981-70570

1

CAUTION Used oil may cause skin disease. Do not allow used oil to remain on skin for prolonged periods of time. Clean skin thoroughly with soap and water.

138

５

EVERY 2000Hrs MAINTENANCE

N. Check Vibration Damper Accumulator (option) WARNING Pressurized nitrogen gas in brake accumulator could explode causing serious injury or death. Never service brake accumulator unless trained properly. Contact your nearest Kawasaki loader dealer.

139

Recommended Lubricants

Recommended Lubricants Ambient Temperature Kind of Oil

Refill capacity

Engine

Engine oil (CE or CF4)

43 liter

Transmission

Engine oil ATF

55 liter

Hydraulic tank

Hydraulic oil

Differential & Planetary

Gear oil (GL-5) Engine oil (CD)

Front : 95 liter Rear :100 liter

Fuel tank

Diesel fuel

405 liter

＊1

150 liter

‐４° １４° ３２° ５０° ６８° ８６°１０４°Ｆ ‐２０°‐１０° ０°Ｃ １０° ２０° ３０° ４０°

SAE 10W-30 SAE15W-40 SAE10W ATF ISO VG46 ISOVG32 Gear oil SAE90 Engine oil SAE40 or SAE50 ASTM D975 No.2 ASTM D975 No. 1

Change Interval (Hours) 250 1,000 2,000 2,000 daily

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

Use oil that meets engine oil classification API CE or CF4.

Transmission

Use engine oil classification API CD or A.T.F. (Auto Transmission Fluid). Never mix engine oil and A.T.F.

Hydraulic System

Use industrial-type hydraulic oils which are certified by suppliers having anti-wear, anti-foam, anti-rust and anti-oxidation additive properties for heavy duty use. Use of the wrong viscosity of oil can cause improper operation of hydraulic functions or premature pump failure.

Differential & Planetary

Use class GL-5 gear oil or class API CD engine oil.

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.

Diesel Fuel

Requirements for diesel fuel Grade No.1-D Grade No.2-D 38 52

Specifications Flash Point

℃.

min.

Water and Sediment

% vol.

max.

Distillation Temperature ℃ 90% vol. Kinematic Viscosity mm2/s at 40 ℃ Ash % mass

recovered max. min. max.

max.

Sulfer % mass Cetane Number

max. min.

Carbon residue on 10% distillation residue % mass

140

max.

0.05

0.05

288 1.3 2.4 0.01

338 1.9 4.1 0.01

0.50

0.50

40

40

0.15

0.35

Coolant Specification

Coolant Specification The machine is originally filled with Long Life Coolant which need not be replaced for the first two years or 3000 hours. If Long Life Coolant (permanent type) is not used for the replacement, it should be replaced every six months.

Recommended Mixture of Antifreeze Expected Minimum Ambient Temperature

-35 ° C (-31 ° F)

C -30 ° (-22 ° F)

C -25 ° (-13 ° F)

C -20 ° (-4 ° F)

C -15 ° (5 ° F)

Pure Water

(liter)

47.0

52.0

57.0

62.0

67.0

Antifreeze

(liter)

53.0

48.0

43.0

38.0

33.0

53

48

43

38

33

Mixture Ratio (%)

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

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

141

TROUBLESHOOTING

TROUBLESHOOTING This troubleshooting section is not intended to cover every condition, however many of the common possibilities are listed. Following are example of problems and their solutions. Contact your local Kawasaki loader dealer for the items marked with Ｋａｗａｓａｋｉ or your local Ｃ ＵＭＭ Ｉ Ｎ Ｓ authorized CUMMINS ENGINE dealer for the items marked with to repair.

ENGINE PROBLEM

Engine oil pressure warning lamp lights up, and buzzer sounds

POSSIBLE CAUSES Low engine oil level Wrong grade oil for weather conditions Clogging oil filter element Defective alarm switch Oil leakage from pipe or joint Clogging suction strainer Excessive engine wear Defective oil pump

SOLUTIONS Add oil Change oil Change filter and oil

Ｋａｗａｓａｋ ｉ

ｏｒ

Add coolant Adjust or replace belt Clean Flush or professionally clean

Fuel filter element clogging Engine does not start Starter motor speed too low when the starter motor Defective engine shut off solenoid is turning Fuel pump failure (Also see Incorrect fuel injection timing ELECTRICAL Compression pressure too low TROUBLESHOOTING) Defective injectors

Replace fuel filter Booster Battery may be used

Air in fuel lines Fuel filter element clogging Unstable (rough) idling Fuel pump failure Incorrect fuel injection timing

Tightenfuel connections andfilter Replace fuel filter

Insufficient power

Air cleaner element clogging Fuel filter element clogging Throttle linkage adjustment wrong Engine oil level too high Incorrect valve clearance Piston ring wear Defective injectors Fuel pump failure

142

Ｋａｗａｓａｋ ｉ

Ｋａｗａｓａｋ ｉ

ｏｒ

ｏｒ

ｏｒ

ｏｒ

56 113 98 132

ＣＵＭＭＩＮＳ

110 84

ＣＵＭＭＩＮＳ

110 110

ＣＵＭＭＩＮＳ

Clean or replace element Replace fuel filter Check and adjust linkage Check dipstick and correct level Ｋａｗａｓａｋ ｉ

55 108 108

ＣＵＭＭＩＮＳ

Low engine coolant level Loose/slipping/broken fan belt Clogging radiator fins Coolant temp. warning Scale or mineral build up inside radiator lamp lights up Defective alarm switch (gauge is in green) Low water pump flow Thermostat stuck or missing

Ｋａｗａｓａｋ ｉ

PAGE

ＣＵＭＭＩＮＳ

97 110 55

TROUBLESHOOTING

PROBLEM

POSSIBLE CAUSES

SOLUTIONS

PAGE

Use correct type of oil Correct oil level

139 55

Unusual combustion noise or mechanical noise

Wrong type of oil Engine oil level too low or too high Defective injectors Incorrect valve clearance Main bearing / con-rod bearing wear Crankshaft uneven wear Connecting rod bent Timing gear wear Water pump bearing wear Failed turbo or muffler

White exhaust smoke (After engine has reached operating temp.)

Fuel being diluted with water Wrong grade fuel Incorrect fuel injection timing Compression pressure too low Turbo seal leakage

Replace with specified fuel and replace fuel filter

Clean or replace element

Black exhaust smoke

Air cleaner element clogging Turbo damage Incorrect fuel injection timing Fuel injection pump failure Defective injectors

Ｋａｗａｓａｋ ｉ

Ｋａｗａｓａｋ ｉ

Ｋａｗａｓａｋ ｉ

ｏｒ

ｏｒ

ｏｒ

ＣＵＭＭＩＮＳ

110

ＣＵＭＭＩＮＳ

97

ＣＵＭＭＩＮＳ

ELECTRICAL PROBLEM

POSSIBLE CAUSES

SOLUTIONS

PAGE

Broken or slipping alternator belt Defective battery Alternator failure Defective wiring Defective wiring to ground (short)

Adjust or replace belt Replace battery

113

Starter motor does not turn when starter switch key is turned to "START"

Transmission not in NEUTRAL Insufficient battery charge Starter switch failure Defective wiring Starter motor failure

Shift to NEUTRAL Battery charge or booster

Starter motor turns engine slowly

Hydraulic control levers not in NEUTRAL Insufficient battery charging Engine oil viscosity too high (thick) Poor connection at batteries or ground Defective wiring Starter motor failure

Move levers to NEUTRAL Battery charge or booster Replace oil Clean and tighten all terminals

Charge lamp lights up

143

Ｋａｗａｓａｋ ｉ

ｏｒ

ＣＵＭＭＩＮＳ

28 84

Ｋａｗａｓａｋ ｉ Ｋａｗａｓａｋ ｉ

ｏｒ

ＣＵＭＭＩＮＳ

Ｋａｗａｓａｋ ｉ Ｋａｗａｓａｋ ｉ

ｏｒ

ＣＵＭＭＩＮＳ

30 84 108

TROUBLESHOOTING

STEERING PROBLEM

Hard steering

Will not steer

Steering Drift

POSSIBLE CAUSES

SOLUTIONS

Tires are underinflated Severe conditions (over loaded, deep mud, etc.) Oil pressure too low Steering valve failure Steering cylinder failure

Check/adjust tire pressure Change operation

Articulation stopper in locked position

Move articulation stopper to "STORED" position Reduce load

Excessive load on steering Steering valve failure Orbitroll failure Pump failure Relief valve failure Steering cylinder failure

PAGE 58

Ｋａｗａｓａｋ ｉ

24

Ｋａｗａｓａｋ ｉ

Warm oil / Replace oil with proper viscosity for temperature

139

POSSIBLE CAUSES

SOLUTIONS

PAGE

Excessively cold oil Wrong grade oil Oil pressure too low Damaged cylinder piston or piston packing Pump flow too low Pilot pressure too low Engine RPM too low

Warm oil Replace with proper grade oil

139

Excessively cold oil / Wrong oil type

Warm oil / Replace oil with proper viscosity for temperature

Excessively cold oil / wrong grade oil

HYDRAULIC PROBLEM

Boom raises too slowly

Boom natural drift excessively

Bucket / Attachment floating or drifting

Leakage from control valve plunger Damaged cylinder piston or piston packing Leakage in pilot relief valve Over load relief pressure too low Control valve failure Natural drift of cylinder / packing

144

Ｋａｗａｓａｋ ｉ

Ｋａｗａｓａｋ ｉ

Ｋａｗａｓａｋ ｉ

139

TROUBLESHOOTING

BRAKE PROBLEM

POSSIBLE CAUSES

SOLUTIONS

PAGE

Adjust or replace lining

126

Parking brake does not work properly

Worn brake lining Insufficient oil pressure (will not release) Failure of switch or solenoid valve Poor wiring or ground to switch or solenoid valve

Remove or clean

Brake dragging

Dirt, debris under base of brake pedal Warped brake discs Air in brake oil circuit Auto-adjuster valve failureValve failure

Air in brake oil circuit Braking power too low Auto-adjuster valve failure Brake piston seal leakage Brake pressure drops rapidly

Cracked or leaking brake line Brake valve failure Parking brake cylinder leakage Defective brake accumulator

Ｋａｗａｓａｋ ｉ

Ｋａｗａｓａｋ ｉ

Ｋａｗａｓａｋ ｉ

Ｋａｗａｓａｋ ｉ

TORQUE CONVERTER & TRANSMISSION PROBLEM

POSSIBLE CAUSES Excessively cold oil / Wrong oil type

Engine is running but machine does not move

Parking brake is applied Transmission oil level too low Transmission suction strainer clogging Clutch oil pressure too low Transmission clutch failure Transmission controller failure Defective electrical circuit

145

SOLUTIONS

PAGE

Warm oil / Replace oil with proper viscosity for temperature Release parking brake Add oil / Repair leak Clean strainer

139

Ｋａｗａｓａｋ ｉ

65 122

TROUBLESHOOTING

PROBLEM

POSSIBLE CAUSES

SOLUTIONS

Service or parking brake dragging Low oil level in transmission Suction strainer in transmission clogging Clutch oil pressure too low Torque converter oil pressure too low Transmission clutch failure

Inspect and correct Refill oil / Repair leak Clean or replace strainer

Oil leakage from transmission

Air breather clogged Seal damage (between engine and torque converter housing)

Clean and refill with oil

Torque converter overheat

Oil level too low Dozing, continuous pushing application Operating in too high a speed range Long downhill driving Radiator clogged: coolant temp also high Defective alarm switch (gauge is in green) Torque converter / Transmission failure Oil pressure too low

Add oil / Repair leak Reduce load Use lower gear Change application Clean radiator fins

Low power

PAGE 65 122

Ｋａｗａｓａｋ ｉ

123

Ｋａｗａｓａｋ ｉ

65 70 98

Ｋａｗａｓａｋ ｉ

AIR CONDITIONER (option) PROBLEM

POSSIBLE CAUSES

Hot water continues to flow through heater core A/C not set for maximum cooling Low cooling when A/C Condensor fins plugged "ON" A/C filters plugged A/C compressor belts slipping/broken A/C refrigerant charge low

Low heater out put

Engine not warmed up No hot water flow to heater core Air conditioner running Heater vents not adjusted properly Defective heater motor or switch

146

SOLUTIONS

PAGE

Shut off valve in heater hose line at block Adjust controls/vents Clean Clean or replace Adjust/Replace

50 99 118 117

Ｋａｗａｓａｋ ｉ

Warm up engine Open shut off valve on block Turn A/C off Adjust controls/vents Ｋａｗａｓａｋ ｉ

50

SPECIFICATIONS

SPECIFICATIONS (For Europe Specification)

Specifications shown are for a machine equipped with standard features. Some options or special attachment will change the specifications shown. Specifications subject to change without notice.

Bucket General Purpose Bucket with cutting edge

General Purpose Bucket with teeth

Bucket capacity (m3)

5.0

4.8

4.3

Dumping height (mm)

3,220

3,105

3,320

Dumping reach (mm)

1,350

1,420

1,295

Rock Bucket no teeth

Kind of bucket

V-edged Rock Bucket no teeth

Rock Bucket with teeth

V-edged Rock Bucket with teeth

Kind of bucket

Bucket capacity (m2)

4.3

4.5

4.5

Dumping height (mm)

3,100

3,165

2,970

Dumping reach (mm)

1,425

1,450

1,550

Operating Load

7,800kg

Operating Weight

29,660kg (with ROPS canopy, cabin and General purpose bucket with teeth)

Engine Model Type

CUMMINS N14 Diesel 4 cycle, Water Cooled, Turbo charged, after cooled and direct injection 14,010cm3 235kW / 2,100min-1

Displacement Net Flywheel Horsepower Tire (standard)

29.5 R25 ☆

Max. Running Speed (forward/reverse)

1st : 7.7 / 8.1km/h 2nd : 14.5 / 15.3km/h 3rd : 22.7 / 23.5km/h 4th : 35.0 / - km/h

147

SPECIFICATIONS

Sound Level 75dB (A) Continuous A-Weighted sound pressure level at workstation. Measurement is obtained in accordance with ISO 6394. Airborne sound power level 111dB (A) Measurement is obtained in accordance with 86 / 662 / EEC. Hand-arm vibration Less than 2.5m/s2 The weighted root mean square acceleration value to which the hands/arms are subjected. Measurements are obtained in accordance with ISO 5349. Whole-body vibration Less than 0.5m/s2 The weighted root mean square acceleration value to which the body is subjected. Measurements are obtained in accordance with ISO 2631.

148

PERIODICAL REPLACEMENT PARTS LIST

PERIODICAL REPLACEMENT PARTS LIST Section

Part Name Oil filter

Part Number

Q'ty

Remarks

YE3318853

1

Every 250 hrs

DCA4 Coolant filter YEWF2073

1

Every 250 hrs

DCA4 Liquid

YEDCA60L YEDCA65L

1 2

Every 2000 hrs

Fuel filter

YE3315847

2

Every 250 hrs

Ether cylinder

YE259370

1

When required

Fan belt

YE3040385

2

When required

Water pump belt

YE217638

1

When required

Alternator belt

YE3040303

2

When required

Air cleaner element

30981-70440-7 30981-70430-7

1 1

After six cleanings or once a year

Transmission & Oil filter Torque Converter

30981-70340-7

1

Every 500 hrs

Hydraulic tank

Return filter

30981-20060

1

Every 1000 hrs

O-ring

47131-73540

1

Every 1000 hrs

Pilot pump control Backup ring line filter

47194-70800

1

Every 1000 hrs

Filter element

30981-70570

1

Every 2000 hrs

Filter element

40330-60270 40330-70370

1 5

Every 2000 hrs

Compressor belt

78023-11280

1

When required

Engine

Air Conditioner (option)

149

95ZIV-3 OPERATION & MAINTENANCE MANUAL AAA-M97C3E01-996 AAA-M97C3E01-99Z AAA-M97C3E01-006

① 1999.6.30 ③ 1999.12.1 ⑤ 2000.9.10

K

② 1999.7.30 ④ 2000.6.25 ⑥ 2001.3.15

KAWASAKI HEAVY INDUSTRIES, LTD. CONSTRUCTION MACHINERY DIV. 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.

AAA-S97C3E00-00Z (93215-00101)

WHEEL LOADER SHOP MANUAL

95ZIV-3

Powered by CUMMINS N14-C Engine. SERIAL NUMBERS 97C3-9001 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 95ZIV-3 Shop Manual AAA-S97C3E01-00Z (93215-00112). ② For Disassembly and reassembly and Service standard, refer to the 95ZIV-3 Shop Manual AAA-S97C3E14-00Z (93215-00121). 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 opinions 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 (20kgf 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 AND TRANSMISSION GROUP ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 32-1 HYDRAULIC GROUP ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-1 BRAKE GROUP ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-1 ELECTRICAL GROUP ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-1 OPERATOR STATION GROUP ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 72-1

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 Hose Band Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 00-8 Flanged Hexagon Bolt Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 00-9 Liquid Gasket and Screw Lock Agent ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 00-10 Cautions Regarding Welding Repair Service ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 00-11

00-1

Layout of Main Components

95ZIV-3

OUTLINE 00

Layout of Main Components ７

３

１１

９ ４

１１

６

１３

５

３

２

８

１７

１４

１５

１

１２

１０

１６

９５Ｖ００００１

1. Engine assembly (Cummins N14-C) 2. Transmission / Torque converter assy 3. Hydraulic pump 4. Multiple (loader) control valve 5. Steering valve 6. Pilot valve (for loading) 7. Transmission control valve 8. Air cleaner 9. Muffler

10. Radiator 11. Front axle assembly 12. Rear axle assembly 13. 2nd propeller shaft 14. 3rd propeller shaft 15. Hydraulic oil cooler (air-to-oil type) 16. T / C oil cooler (lower tank of radiator) 17. Parking brake

00-2

Recommended Lubricants

95ZIV-3

OUTLINE 00

Recommended Lubricants Ambient Temperature

Engine

Kind of Oil

Refill capacity

Engine oil (CE)

43 liter

Engine oil

Transmission

ATF

‐４° １４° ３２° ５０° ６８° ８６°１０４°Ｆ ‐２０°‐１０° ０°Ｃ １０° ２０° ３０° ４０°

SAE 10W-30 SAE15W-40 SAE10W

55 liter ＊

150 liter

ATF Dexron VG46

Hydraulic system

Hydraulic oil

Differential & Planetary

Gear oil (GL-5)

Front : 95 liter

Gear oil SAE90

Engine oil (CD)

Rear :100 liter

Engine oil SAE40 or SAE50

Fuel tank

Diesel fuel

405 liter

ISOVG32

ASTM D975 No.2 ASTM D975 No. 1

Change Interval (Hours) 250 1,000 2,000 2,000 daily

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

Engine Use oil that meets engine oil classification "CE" (MIL-L-2104C). Transmission

Use engine oil classification API CD or A.T.F. (Automatic Transmission Fluid) Dexron Ⅱ . Never mix engine oil and A.T.F. Dexron Ⅱ .

Hydraulic System Use industrial-type hydraulic oils which are certified by suppliers having anti-wear, anti-foam, anti-rust and anti-oxidation additive properties for heavy duty use. Use of the wrong viscosity of oil can cause improper operation of hydraulic functions or premature pump failure. Differential & Planetary

Use class GL-5 gear oil or class API CD engine oil.

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

Lubrication Chart

95ZIV-3

OUTLINE 00

Lubrication Chart

ＤＩＦＦ＆ ＧＥＡＲ ＢＯＸ

ＨＹＤ． ＯＩＬ ＴＡＮＫ

ＤＩＦＦ

ＴＲＡＮＳＭＩＳＳＩＯＮ

ＤＩＦＦ＆ ＧＥＡＲ ＢＯＸ ＤＩＦＦ

ＣＥＮＴＥＲ ＰＩＮ

Ｌ ＩＮＫ ＳＹＳＴＥＭ

ＢＵＣＫＥＴ

ＳＴＥＥＲＩＮＧ ＡＸＬＥ ＣＹＬ． ＳＵＰＰＯＲＴ ２ｎｄ ＰＲＯＰＥＬＬＥＲ ＳＨＡＦＴ

３ｒ ｄ ＰＲＯＰＥＬＬＥＲ ＳＨＡＦＴ ９５Ｃ００００１

○・ ・ ・ ・ ・ ・ ・ ・Grease point

・ ・ ・ ・ ・ ・ ・ ・Multipurpose grease G・

・ ・ ・ ・ ・ ・Hydraulic oil HO・

△・ ・ ・ ・ ・ ・ ・ ・Check and add if necessary

GO・ ・ ・ ・ ・ ・ ・Gear oil

TO・ ・ ・ ・ ・ ・ ・Engine oil

EO・ ・ ・ ・ ・ ・ ・Engine oil

□・ ・ ・ ・ ・ ・ ・ ・Oil replacement

00-4

Weight of Main Components

95ZIV-3

OUTLINE 00

Weight of Main Components

Part name

Approx. Weight (kg)

Bucket

2,850

GSC bucket

Boom

2,100

Standard

" Z " -Lever

285/pc

Link (Bucket to Lever)

60/pc

Engine room assembly

400

Hydraulic tank

250

Excluding oil

Fuel tank

230

Excluding fuel

Item Unit name

Chassis

Power line

Deck

Right

55

Left

80 350

Floor board

340

Rops

570

Front chassis

2,520

Bare chassis

Rear chassis

2,200

Bare chassis

Counterweight

2,100

Engine

1,400

Radiator

380

Transmission

1,000

Second propeller shaft

100

Third propeller shaft

23

Air cleaner

25

Exhaust silencer (Muffler)

30

Including air conditioner unit and seat

Excluding oil Excluding water and oil Excluding oil

Excluding precleaner

Front axle assembly

2,010

Excluding tires and oil

Rear axle assembly

2,220

Excluding tires and oil (Including axle support)

350

Front

360

Rear

Multiple control valve

100

Pilot valve

7

Steering valve

48

Hydraulic

Other

Including hand rail

Cab

Differential

system

Remarks

40

Double pump

30

Single pump

Boom cylinder

285/pc

Excluding oil

Bucket cylinder

150/pc

Excluding oil

Steering cylinder

40/pc

Excluding oil

Tire(No Hydro Inflation)

690/pc

With rim (26.5-25-24PR)

Battery

60/pc

Gear pump

00-5

Hexagon Bolt Tightening Torque

95ZIV-3

OUTLINE 00

Hexagon Bolt Tightening Torque 少 Bolt type: 6 1 0 0 1 - 1 2 0 3 0 ① Thread type: Metric thread=0 少 ① ②③ ④ ⑤ 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

Hexagon Bolt Tightening Torque

95ZIV-3

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

Hose Band Tightening Torque

95ZIV-3

OUTLINE 00

Hose Band Tightening Torque Low pressure hose (heat resisting hose)

Hose band

Tightening torque

Tightening torque

(N-m)

(kgf-cm)

1.6

16

4

40

Tightening torque (N-m)

Tightening torque (kgf-cm)

1.6

16

4

40

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

00-8

Pipe

Flanged Hexagon Bolt Tightening Torque

95ZIV-3

OUTLINE 00

Flanged Hexagon Bolt Tightening Torque 1. Bolt Type 2. Bolt strength

Metric thread 4〜8T

3. Thread pitch

Coarse pitch thread(C)

(N-m) Bolt size Type

Metric thread

Bolt strength

Nominal dimension

Pitch

4.8 (4T)

8.8 (8T)

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

(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

-

23.5

M20

2.5

-

45.0

M24

3

−

78.0

00-9

Liquid Gasket and Screw Lock Agent

95ZIV-3

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 or 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

(High strength) Loctite 262

ＡＢ０２

Three Bond

(Medium strength) Three Bond 1327

ＡＢ０３

Three Bond

(Low strength) 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 operation.

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 R Primer T cleans threads and speeds curing time.

Antiseize Agent Code

Manufacturer

ＡＣ０１

Loctite

Product name Loctite 767 (Paste or spray)

00-10

Cautions Regarding Welding Repair Service

95ZIV-3

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)

00-11

Caution Regarding Welding Repair Service

95ZIV-3

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, or Harness

Remove and if necessary wrap Chassis

00-12

CHASSIS GROUP 12 Front Chassis ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 12-2 Rear Chassis ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 12-4 Center Pin ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 12-5 Clearance Adjustment for Pin Section ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 12-6 Center Pin ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 12-8

12-1

Front Chassis

95ZIV-3

CHASSIS 12

Front Chassis Loading system

2

8

3

9

4

5

10

1

7

6 ９７ＺＡ１２０１

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

4440 41〜43 °

A 50 °

Hinge pin height at 270 bucket on ground

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

Typical bucket roll-back stopper adjustment (Contact attachment supplier for details on non-standard attachments)

12-2

Front Chassis

95ZIV-3

CHASSIS 12

Linkage 1. Bucket - Boom

2. Boom - Lever

3. Boom - Boom cylinder

φ１１０ φ

4. Front chassis- Boom

φ１００

5. Bucket - Rod

6. Lever - Rod

φ

φ１１０

φ

8. Bucket cylinder Front chassis

7. Lever - Bucket cylinder

9. Boom cylinder Front chassis

φ１００

φ

φ

10. Front chassis Steering cylinder

11. Steering cylinder Rear chassis

97ZA1202

φ

φ

2

7

3

8

4

10

5

1

6

9

12-3

11

97ZA1203

Rear Chassis

95ZIV-3

CHASSIS 12

Rear Chassis Fuel tank B

２

７ １０

A-A

３ ２ ４

１

９ １０

６ ８

８ ５

９７Ｊ１２００１

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 9. Pipe (for vacuum prevention) 10. Fuel return pipe

B Detail

12-4

97ZA1205

Center Pin

95ZIV-3

Center Pin １ ４

Upper

９，１０

Upper 1. Center pin 2. Bushing 3. Bearing cover ３ 4. Washer ５ 5. Shim 6. Bearing assy Ｆｒｏｎ ｔ 7. Dust seal ｃｈａｓｓ ｉ ｓ 8. Bolt ６ 9. Bolt ７ 10. Washer ２ １０ ８

Lower

６

１

７ ２

３

Ｆｒｏｎ ｔ ｃｈａｓｓ ｉ ｓ

９５Ｃ１２００１

５

４

Lower 1. Center pin 2. Bearing retainer 3. Bearing assy 4. Dust seal 5. Bushing 6. Bolt 7. Plate

Ｒｅａｒ ｃｈａｓｓ ｉ ｓ

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.

Center pin

Dust seal position 97ZA1208

12-5

CHASSIS 12

Clearance Adjustment for Pin Section

95ZIV-3

CHASSIS 12

Clearance Adjustment for Pin Section WARNING

CAUTION

Unexpected movement of the machine could 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 could 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.

5

4

3 2

7

6

1

97ZA1203

Adjustment portion

1

2

3

4

5

6

7

Liner hole dia. (mm)

110

81

111

91

111

Adjustment unnecessary

61

Adjustment For #5 portion, only in case the clearance at the machine center side is more than 4.5mm, shim adjustment is necessary. ※

※

More than 4.5mm

Adjust the clearance ( ※ ) to 1.2mm or less between the bosses using liners. For the steering cylinder, be sure to adjust the clearance on the rear chassis side first and then on the front chassis side while checking that the cylinder is not inclined. (Refer to the next page for the adjustment of portion 1)

(L.H)

Boom #3 Detail

97ZA1301

12-6

Clearance Adjustment for Pin Section

95ZIV-3

CHASSIS 12

Bucket Hinge Pin Section

Boom ※

Bucket

※

Bushing

Hinge pin(#1)

Bolt Dust seal

Shim

Seal ring assy

Shim

97ZA1302

How to assemble 1. Insert the bushings into the boom boss and attach the seal ring assy to the bushing. (When installing the dust seal to the seal ring assy, be sure to check the direction of the dust seal.) 2. Align the pin holes in the bucket and the boom then insert the pin. 3. Place the shim between the bucket boss and the seal ring assy so that the clearance between the boom boss and the seal ring ( ※ marked) is less than 1mm. Tighten the bolt for the seal ring assy.

N-m (kg-m)

Shim

Shim thickness ・・・・・・・・・・ 1.0, 0.5mm (2 kinds of shim)

417N-m (42.5kgf-m)

12-7

Center Pin

95ZIV-3

CHASSIS 12

Center Pin 9

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.

Front chassis

N-m (kgf-m) #8・ ・ ・ ・461N-m (47.0 kgf-m) #9・ ・ ・ ・421N-m (43.0 kgf-m)

９５Ｃ１２００２

8

Installing bearing cover Install the bearing cover so that the grease nipple mounting hole is positioned at the specified angle as shown in the right figure.

Rear chassis

Front chassis

Front

Bearing cover

Grease nipple direction

15 °

９５Ｃ１２００３

Installing bearing outer ring(#3)

6

Install the bearing outer ring so that the split is perpendicular to the front-rear line of the machine.

3

Front chassis

９５Ｃ１２００４

Rear chassis

Front

Rear 3

Grease nipple installation direction

Split of outer bearing 26°

12-8

90ZA13-004-4

POWER GROUP 22 Outline of Power Line ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 22-2 Engine Mount ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 22-3 Radiator Mount ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 22-4 Propeller Shaft ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 22-5 Front Axle Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 22-7 Rear Axle Support ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 22-9 Differential Gear ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 22-11 Fuel Control ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 22-16

22-1

Outline of Power Line

95ZIV-3

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

1

10

3

13 11

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

4

8

5

7

12

9. Air cleaner 10. Muffler 11. Hydraulic oil cooler 12. Transmission oil cooler(bottom tank of radiator) 13. Precleaner(option)

22-2

Engine Mount

95ZIV-3

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.

９５Ｃ２２００１

Ｅ／Ｇ Ｂｒ ａｃｋｅ ｔ １ １ ２

９５Ｃ２２００２

Engine installation section

Ｅ／Ｇ ｆ ｌ ｙｗｈｅｅ ｌ ｈｏｕｓ ｉ ｎｇ

９７Ｊ２２０２５

Transmission installation section

３

Engine-to-transmission connection section ９５Ｃ２２００３

1. Rubber cushion 2. Ring gear 3. O-ring

22-3

Radiator Mount

95ZIV-3

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. ２

４

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.

１

３

Coolant IN

Hyd. oil IN

Hyd. oil OUT

T/C oil OUT

T/C oil IN Coolant OUT ９５Ｃ２２００４

Ｒａｄ ｉ ａ ｔ ｏ ｒ

５

Ｒａｄ ｉ ａ ｔ ｏ ｒ

９７Ｊ２２００５

６ Ｒｅａｒ ｃｈａｓｓ ｉ ｓ

1. Radiator assembly (three piece type) 2. Fan guard 3. Stay(Bracket) 4. Coolant inlet hose 5. Coolant outlet hose 6. Rubber cushion

Ｂ−Ｂ

Ｃ−Ｃ ９５Ｃ２２００５

９７５Ｃ２２００６

Ｓｈｒｏｕｄ

６

Ｈ−Ｈ ９５Ｃ２２００８

Capacity in radiator: l Cooling water 70 l Hydraulic oil 7.0 l Torque converter oil 3.9 l Dry weight 380kg 22-4

Ｄ−Ｄ ９５Ｃ２２００７

Propeller Shaft

95ZIV-3

POWER 22

Propeller Shaft Function 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 ３

２

Front axle

Rear axle ９７ＺＡ２２１０

４

1. 2nd propeller shaft 2. 3rd propeller shaft(fixed type) 3. Center bearing 4. Slip joint

22-5

Propeller Shaft

95ZIV-3

POWER 22

Construction ・ 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

AA

Transmission side

Front Axle Assembly

95ZIV-3

POWER 22

Front Axle Assembly Construction 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.

１

２ １０１６ ２７１３ １１１２ ２６ ３

２５

４ １４

１５

９ ８ ３１ ５ １７ ２４ ２３ ３０ ２９

７

２２

３３ ６

６

２１ ２０１９ ２８ １８ ３３

９７Ｊ２２０１０

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. Planetary gear (4) 11. Internal gear 12. Internal gear hub

13. Snap ring 14. Planetary pin (4) 15. Floating seal 16. Washer (8) 17. Washer 18. Brake piston 19. Brake friction disc (2) 20. Steel plate (2) 21. Brake retainer 22. Spring pin 23. Axle washer (lock plate) 24. Axle nut

Note: For details on service brake components refer to Section 52.

22-7

25. Taper roller bearing (inner) 26. Taper roller bearing (outer) 27. Needle bearing (8) 28. O-ring 29. O-ring 30. O-ring 31. Snap ring 32. Oil level plug 33. Drain plug

Front Axle Assembly

95ZIV-3

POWER 22

２５ Ｒ． Ｈ

３

２

Front Differential ３３

７

２６

２１

３０

２２

３２

６

３３ １３

１２

１１

１７ ９

２９２８

１４

２０

２４ ２３

１９ １８

２０

５

１５ １９

４

３２ ８

３１ Ｌ． Ｈ

９５Ｃ２２００９

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. Planetary gear (4) 11. Internal gear 12. Internal gear hub

13. Snap ring 14. Planetary pin (4) 15. Floating seal 16. Washer (8) 17. Washer 18. Brake piston 19. Brake friction disc (2) 20. Steel plate(2) 21. Brake retainer 22. Spring pin 23. Axle washer (lock plate) 24. Axle nut

22-8

25. Taper roller bearing (inner) 26. Taper roller bearing (outer) 27. Needle bearing (8) 28. O-ring 29. O-ring 30. O-ring 31. Snap ring 32. Oil level plug 33. Drain plug

Rear Axle Support

95ZIV-3

POWER 22

Rear Axle Support Construction

Grease pipe connection port (PT1/8)

Grease pipe connection port (PT1/8) Rear side of axle support

Pin (Axle housing)

9

9 Front 5 Front side of axle support

4

9

View A-A

6 1 10

7

14

2

3

11

7 8

11

13

12

10 #11 Details

#10 Details

97K22003

1. Shaft

6. Plate

11. Bushing

2. Rear axle support (front)

7. Packing

12. Snap ring

3. Rear axle support (rear)

8. Packing

13. Snap ring

4. Wear ring

9. Breather

14. O-ring

5. Plate

10. Bushing

22-9

Rear Axle Support

95ZIV-3

POWER 22

Rear axle

7

Grease piping

14 9 9

4 5 4

2

Grease piping

15 11

10

5

3 Front

14 7 12 11

8

1 13

９７Ｋ２２００５

1. Shaft

7. Packing

13. Snap ring

2. Rear axle support (front)

8. Packing

14. O-ring

3. Rear axle support (rear)

9. Breather

15. Dowel pin

4. Wear ring

10. Bushing

5. Plate

11. Bushing

6. Plate

12. Snap ring

22-10

Differential Gear

95ZIV-3

POWER 22

Differential Gear Construction (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 (9) and flange (1). １ ２ ３

４ ５

６ ７ ８ ９

１０ １１

１２ １３

１４

１５

１７

１６ １８

1. Flange 2. Oil seal(double lip) 3. Seal retainer 4. Bearing retainer 5. Shim 6. Taperroller bearing 7. Collar 8. Drive pinion 9. Carrier

10. Pilot bearing 11. Bolt 12. Snap ring 13. Taper roller bearing 14. Adjusting nut 15. Side gear 16. Thrust washer (pinion gear) 17. Differential pinion 18. Ring gear 22-11

９７ＺＡ２２１１

Differential Gear

95ZIV-3

POWER 22

Function 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 ground.

This prevents some of the reduction in rim-pull and tire wear caused by tire slippage.

・ 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.

22-12

Differential Gear

95ZIV-3

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.

22-13

Differential Gear

95ZIV-3

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

Tooth contact

A

contact, adjust the thickness of the shim between the pinion and cage, and turn the adjusting nut.

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

22-14

Differential Gear

95ZIV-3

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

TOE Pitch line

3 HEEL 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.

22-15

Note: Individual sale of the ring gear or the drive pinion is not possible.

Fuel Control

95ZIV-3

POWER 22

Fuel Control ３

１

２

２０°

Ｂ

９７Ｊ２２００２

Ball joint

Spring

1. Accelerator pedal 2. Control cable 3. Pedal stop bolt

B Detail

９５Ｃ２２００９

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. Prevent distortion

Caution regarding reinstallation of control cable:

＊Bolt

Carefully tighten the joints at both ends of the control cable to prevent distortion or damage.

Nut

Full (Stroke Idle 30mm)

Accel. pedal

Ball joint Idle ９５Ｃ２２０１０

22-16

TORQUE CONVERTER AND TRANSMISSION GROUP

32 Torque Converter and Transmission ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 32-2 Torque Converter ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 32-3 Transmission ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 32-4 Clutch Pack ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 32-6 Gear Pump ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 32-7 Power Flow Path in the Transmission ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 32-8 Hydraulic System Diagram ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 32-11 Hydraulic Circuit Diagram ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 32-12 Torque Converter/Transmission Oil Flow ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 32-13 Modulator Valve Unit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 32-14 Clutch Solenoid Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 32-16 Modulation Mechanism ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 32-18 Measuring Clutch Oil Pressure ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 32-21

32-1

Construction

95ZIV-3

TORQUE CONVERTER AND TRANSMISSION 32

Torque Converter and Transmission (Model : Kawasaki PT315B01)

Construction ７

６

３ １ ９

４ ２

１１

２７

１０

２６ ２８

They are located on the transmission left side, view from the parking brake.

１９ ２０

８ ５

２１

１３ ２３

１２

２５

１４ １５ １６ １７ ２４ １８ ２２

９７ＺＡ３２−０１

1. Pump impeller 2. Turbine impeller 3. Stator 4. Turbine shaft 5. Stator shaft (Fixed) 6. Drive cover 7. Driven gear 8. P.T.O. drive gear 9. P.T.O. gear 10. Torque converter gear pump

11. Torque converter output gear 12. Clutch input gear 13. Transmission input shaft 14. High range clutch 15. Reverse clutch 16. Low range clutch 17. 3rd speed clutch 18. 2nd speed clutch 19. 1st speed clutch 20. Clutch output gear 32-2

21. Output gear 22. Output shaft 23. Parking brake (Drum type) 24. Output flange (3rd propeller shaft side) 25. Output flange (2nd propeller shaft side) 26. Modulator valve unit 27. Clutch solenoid valve mount 28. 1st speed clutch solenoid

Torque Converter

95ZIV-3

TORQUE CONVERTER AND TRANSMISSION 32

Torque Converter Operation of Torque Converter 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

Output

９７ＺＡ３２−０２

Torque ratio(t)

４

３

２

１

０． ５

１． ０

Speed ratio(e)

９７ＺＡ３２−０３

32-3

Transmission

95ZIV-3

TORQUE CONVERTER AND TRANSMISSION 32

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

Clutch

L

Speed range

F 1

○

F 2

○

F 3

○

H

R

1

2

○ ○ ○ ○

F 4

3

○ (Either 1st or 2nd or 3rd)

N

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

R 1

○

R 2

○

R 3

○

○ ○ ○

Ring gear

Planetary gear carrier Sun gear

Planetary gear

９７ＺＡ３２−０４

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

32-4

Position of shift lever

Function

1

Held in 1st speed range for both forward and reverse.

2

Held in 2nd speed range for both forward and reverse.

3

Held in 3rd speed range for both forward and reverse.

A

Automatic speed change according to shift map (computer) for 2nd through 4th speeds forward and 2nd through 3rd speeds reverse.

Transmission

95ZIV-3

TORQUE CONVERTER AND TRANSMISSION 32

Gear Train and Number of Teeth Ｔ／Ｃ

Ｌ

Ｒ

３

２

L : Low range clutch

Ｅ／Ｇ

H : High range clutch R : Reverse clutch

１

Ｈ

1 : 1st speed clutch 2 : 2nd speed clutch 3 : 3rd speed clutch

2nd propeller shaft

3rd propeller shaft

９７ＺＡ３２−０５

Clutch specifications Name of clutch

Friction plate

Piston stroke (mm)

Number of plate

Low range clutch

3.5 ± 0.5

6

Reverse clutch

3.5 ± 0.5

6

High range clutch

2.5 ± 0.5

3

1st speed clutch

4.5 ± 0.5

7

2nd speed clutch

2.0 ± 0.5

3

3rd speed clutch

2.5 ± 0.5

Outer dia. (mm)

Inner dia. (mm)

360φ 279φ

236φ 159φ

360φ 279φ 3

Steel plate

Thickness(mm) New/Wear limit 4 ± 0.13/3.5 (Sintered)

4 ± 0.1/3.4 (Sintered)

4 ± 0.13/3.8 (Paper)

32-5

Number of plate

Outer dia. (mm)

Inner dia. (mm)

Thickness(mm) New/Wear limit

426φ 298φ

3.5 ± 0.1/3.3

6

5 5

12 12

2 252φ 173φ

3.2 ± 0.1/3.0

6

12 12

2 426φ 298φ 3

Number of return spring

3.5 ± 0.1/3.3 12

Clutch Pack

95ZIV-3

TORQUE CONVERTER AND TRANSMISSION 32

Clutch Pack

９

Inlets for Inlets for 2nd and 3rd reverse and speed １５ １７ １１ １２ １０ low range clutch oil clutch oil ２２ ２ １ １６

８

２４

５ ６

２３

２５

２６

２７

Inlet of 1st speed clutch oil

２８

Inlet of high range clutch oil

Inlet of lubricating and cooling oil

１

７ ４ ２

３

１４ １３ １９

１８

２０

３２

２９

３０

３１

９７ＺＡ３２−０６

1. Clutch input shaft 2. High speed range clutch drum 3. Spider 4. High speed range clutch piston 5. Friction plate 6. Steel plate 7. Piston return spring 8. Reverse planetary gear carrier 9. Reverse planetary gear 10. Reverse clutch piston 11. Friction plate

12. Steel plate 13. Anchor pin 14. Piston return spring 15. Reverse ring gear 16. Low speed range clutch piston 17. Low speed range planetary gear 18. Low speed range ring gear 19. Low speed range sun gear 20. Anchor pin 21. 3rd speed clutch piston

32-6

22. 2nd speed clutch piston 23. 3rd speed planetary gear 24. 3rd speed ring gear 25. 2nd speed ring gear 26. 2nd speed planetary gear 27. 1st speed clutch piston 28. Piston return spring 29. 1st speed clutch drum 30. 1st speed clutch gear 31. Drop gear 32. Clutch output shaft

Gear Pump

95ZIV-3

TORQUE CONVERTER AND TRANSMISSION 32

Gear Pump １０

１

２ ４ ６

７

３

Hydraulic pump side ８

９

５

１１，１２

９７ＺＡ３２−０７

Theoretical discharge

73.6 cc/rev

Maximum operation pressure

3.4MPa (35kgf/cm )

Maximum operation speed

2600min-1

Actual discharge

2

Approx. 40 l/min Conditions: Pump speed 830min-1 Oil temp. 80 to 100 ° C (176〜212 ° F) Oil viscosity 10CST(SAE10W) 2 Discharge pressure 3.4MPa (35kgf/cm )

32-7

1. Pump body 2. Pump cover 3. Drive gear 4. Driven gear 5. Needle bearing 6. Needle bearing 7. Bearing retainer 8. Bearing retainer 9. Snap ring 10. Dowel pin 11. Bolt 12. Washer

Power Flow Path in the Transmission

95ZIV-3

TORQUE CONVERTER AND TRANSMISSION 32

Power Flow Path in the Transmission Forward 1st speed Inlet of low １８ １７ ２４ range clutch oil Low range １６ clutch

２３ ３２ ３０ 1st speed clutch

Input power

Inlet of 1st speed clutch oil

３１

１

Output power

１９

２０ ９７ＺＡ３２−０８

When first speed forward is selected by the operator or the computer, oil is sent from the modulator valve to the low range clutch and the 1st speed clutch. When the clutch plates are pressed by the low range clutch piston, low range ring gear (18) is locked to the housing by the anchor pins (20). The torque converter rotates the low range sun gear (19) via the clutch input shaft (1). This causes low range planetary gears (17) to rotate around sun gear (19) while rotating on their own axis. This forces the carrier to rotate. Since the low range planetary carrier and 3rd speed planetary carrier are one piece, the 3rd speed planetary gears (23) also rotate around sun gear.

When the 1st speed clutch is engaged, drop gear (31), 1st speed clutch gear (30), 3rd speed ring gear (24) and clutch output shaft (32) form one unit. As a result, the rotation of the 3rd speed planetary gear (23) around sun gear is output as the rotation of the drop gear (31). 3rd speed planetary gear (23) (does not rotate on its own axis)

3rd speed ring gear (24) and clutch output shaft (32) form one unit

Low range ring gear (18) Sun gear (19) Low range planetary gear (17)

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

32-8

Power Flow Path in the Transmission

Forward 2nd speed

95ZIV-3

Low range clutch oil

TORQUE CONVERTER AND TRANSMISSION 32

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

Input power

Output power ９７ＺＡ３２−０９

Forward 3rd speed

3rd speed clutch oil

Low range clutch oil Low range clutch

3rd speed clutch

Input power

Output power ９７ＺＡ３２−１０

Forward 4th speed High range clutch

2nd speed clutch oil 2nd speed clutch

Input power

High range clutch oil

Output power ９７ＺＡ３２−１１

32-9

Power Flow Path in the Transmission

Reverse 1st speed Reverse clutch

95ZIV-3

TORQUE CONVERTER AND TRANSMISSION 32

Reverse clutch oil 1st speed clutch

Input power 1st speed clutch oil

Output power ９７ＺＡ３２−１２

Reverse 2nd speed Reverse clutch

Reverse clutch oil

2nd speed clutch oil 2nd speed clutch

Input power

Output power ９７ＺＡ３２−１３

Reverse 3rd speed Reverse clutch

Reverse clutch oil 3rd speed clutch

3rd speed clutch oil

Input power

Output power ９７ＺＡ３２−１４

32-10

Hydraulic System Diagram

95ZIV-3

TORQUE CONVERTER AND TRANSMISSION 32

Hydraulic System Diagram Shift lever

Control box １２ １０ ９

１５

１１ ６ ５

１７ １８

２１ １９ ２０

４ ８

１３

７

１６

３

２２

２６

２３ ２４ ２７ ２５

２

１

９７ＺＡ３２−２７

32-11

Hydraulic Circuit Diagram

95ZIV-3

TORQUE CONVERTER AND TRANSMISSION 32

Hydraulic Circuit Diagram Neutral position Modulator valve unit

１２

９ φ３． ０

ＧＡ φ４． ５

Ｈ

１６

φ０． ９

６Ｋ

４Ｋ

１０

ＧＰ

１３

２２

５

１１

Ｐ

Ｔ Ｓ

１７

Ｒ

ＧＢ

８

３０Ｋ

２３ １４

９Ｋ

７

ＧＴ

６

１８

Ｌ

４

２４ １５

１９

１ｓ ｔ ２５

３

２ｎｄ

２０ ２

２６

３ｒ ｄ

１

２１

２７

９７ＺＡ３２−１５

1. Transmission oil pan

11. Check valve (2)

19. 1st speed clutch solenoid valve

2. Strainer

12. Pressure difference sensor

20. 2nd speed

3. Torque converter gear pump

13. Torque converter

valve

4. Line filter with bypass valve

14. T/C outlet relief valve

21. 3rd speed clutch solenoid valve

5. Clutch pressure regulator valve

15. Oil cooler

22. High speed range clutch

6. Modulator valve (1)

16. High speed range clutch

23. Reverse clutch

7. Relief valve

solenoid valve

clutch

24. Low speed range clutch

8. T/C inlet relief valve

17. Reverse clutch solenoid valve

25. 1st speed clutch

9. Modulator valve (2)

18. Low speed range clutch

26. 2nd speed clutch

10. Check valve (1)

solenoid valve

32-12

solenoid

27. 3rd speed clutch

Torque Converter/Transmission Oil Flow

95ZIV-3

TORQUE CONVERTER AND TRANSMISSION 32

Torque Converter/Transmission Oil Flow Oil flow in the torque converter line ・ From the torque converter charge pump to the torque converter Oil from the torque converter gear pump (3) passes through the line filter (4) and enters the modulator valve unit. Since only a small amount of oil flows to the clutch circuit, most of the oil flows to clutch pressure regulator valve (5), forces it open, and passes into the torque converter circuit. If the torque 2 converter's inlet pressure exceeds 9kg/cm , it forces open the torque converter inlet relief valve (8), allowing the oil to escape to the oil pan.

・ From the torque converter to cooling circuit Return oil from the torque converter flows through the outlet relief valve (14) (set pressure=0.3MPa (3kgf/c 2 m ) in the torque converter housing and to the torque converter cooler (15).

・ rom the cooler to the lubrication circuit

Oil flow to the clutch Oil, regulated to a specified pressure by the modulator valve 1 (6) and clutch pressure regulator valve (5), flows to each clutch solenoid valve. Assuming that the transmission is shifted from 1st speed forward to 1st speed reverse, the reverse clutch solenoid is energized, and the clutch oil thus flows into the reverse clutch piston chamber. As the low range clutch solenoid is de-energized, the oil in the low range clutch piston chamber flows through the low range clutch solenoid valve and drains into the transmission case.

32-13

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

Modulator Valve Unit

95ZIV-3

TORQUE CONVERTER AND TRANSMISSION 32

Modulator Valve Unit Construction

Red

１２ Black

White

Ｄ

E-E section

Ｄ

×

Ｅ

ＧＡ

ＧＰ Ｅ

φ0.9 orifice

φ3.0 orifice

９７ＺＡ３２−１６ ９７ＺＡ３２−１８

６ ９

９ ＧＴ ６

ＧＢ ７

Ｆ

Ｃ

Ｃ

F-F section

９７ＺＡ３２−１７

５

View X ９７ＺＡ３２−１９

φ4.5 orifice Line red ９７ＺＡ３２−２０

Line black

Connector for modulator valve (1) and (2)

5. Clutch pressure regulator valve 6. Modulator valve (1) 2 7. Relief valve (2.9MPa) (30kgf/cm ) 2 8. T/C inlet relief valve (0.9MPa) (9kgf/cm ) 9. Modulator valve (2) (Solenoid valve) 2 10. Check valve 1 (0.6MPa) (6kgf/cm ) 2 11. Check valve 2 (0.4MPa) (4kgf/cm ) 12. Pressure difference sensor

１１ C-C section

８

32-14

D-D section

１０

９７ＺＡ３２−２１

９７ＺＡ３２−２２

Modulator Valve Unit

95ZIV-3

TORQUE CONVERTER AND TRANSMISSION 32

Interior schematic (not exact representation) １２

１１

To clutch solenoid valve

φ0.9

１０ φ4.5

９

0.4MPa2 0.6MPa (6kgf/cm2) (4kgf/cm )

φ3.0

５ ６

To torque converter

0.9MPa (9kgf/cm2) 2.9MPa (30kgf/cm2)

Drain

８

From pump

７

Drain

９５Ｃ３２００１

5. Clutch pressure regulator valve 6. Modulator valve (1) 2 7. Relief valve (2.9MPa) (30kgf/cm ) 2 8. T/C inlet relief valve (0.9MPa) (9kgf/cm ) 9. Modulator valve (2) (Solenoid valve) 2 10. Check valve 1 (0.6MPa) (6kgf/cm ) 2 11. Check valve 2 (0.4MPa) (4kgf/cm ) 12. Pressure difference sensor

１２ ９ φ３． ０

ＧＡ φ４． ５

φ０． ９

４Ｋ

To transmission clutch

６Ｋ

１０

ＧＰ ５

１１

To torque converter ＧＢ

８ ３０Ｋ ９Ｋ

７

ＧＴ

６

Hydraulic circuit GA〜GT: gauge port: PT 1/8"

32-15

From pump

Clutch Solenoid Valve

95ZIV-3

TORQUE CONVERTER AND TRANSMISSION 32

Clutch Solenoid Valve ７

６

９

２

Ｒ

５

３ ４

Ｌ

２ Ｈ

３

１

８

８

９７ＺＡ３２−２４

SIDE VIEW 1. High range clutch solenoid valve 2. Reverse clutch solenoid valve 3. Low range clutch solenoid valve 4. 2nd speed clutch solenoid valve 5. 3rd speed clutch solenoid valve 6. Reverse clutch pressure measuring port (PF1/4) 7. Low range clutch pressure measuring port (PF1/4) 8. 2nd speed clutch pressure measuring port (PF1/4) 9. 3rd speed clutch pressure measuring port (PF1/4) NOTE: The 1st speed clutch solenoid valve is installed as a separate unit on the transmission housing.

32-16

Clutch Solenoid Valve

95ZIV-3

TORQUE CONVERTER AND TRANSMISSION 32

Construction and Operation When not energized (Clutch disengaged) From modulator valve

３ ４

To T/M oil pan

２

１ From clutch piston chamber

９７ＺＡ３２−２５

When the coil is not energized, main spool (1) is moved back to the right end by spring (2). Thus, oil from the modulator valve to the clutch piston chamber is disconnected. Oil from the clutch piston chamber is open to the transmission oil pan.

When energized (Clutch engaged) From modulator valve

To T/M oil pan

１

２

To clutch piston chamber

３

９７ＺＡ３２−２６

When the coil is energized, the main spool (1) moves to the left end, and this causes the modulator valve and the clutch piston chamber to be connected, allowing the clutch oil to flow to the clutch piston chamber.

32-17

Modulation Mechanism

95ZIV-3

TORQUE CONVERTER AND TRANSMISSION 32

Modulation Mechanism 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.

The modulation mechanism controls the clutch oil pressure rising time as follows: An electrical signal from the Shift Control Unit (SCU) controls the modulation operation. For information on the SCU refer to section 62, "Electrical Group".

Function of modulator valve 1 (Refer to the illustration at right)

Pressure difference sensor

The modulator valve 1 is a solenoid-operated proportional pressure reducing valve. Downward magnetic force (F) acts on the top of the spool in proportion to the amount of current applied to the coil. The bottom of the spool is acted upon by the upward hydraulic force (f). When this upward force (f) and magnetic force (F) are in balance, the spool is stationary, which generates the specified pressure at port P. The hydraulic force adjusted by modulator valve 1 acts on the right end of the clutch pressure regulator valve, and so the hydraulic force from the pump to the clutch is also controlled by modulator valve 1. In other words, when the control pressure from the modulator valve 1 is low, oil from the pump easily moves the clutch pressure regulator valve to the right end and relieves the oil to the torque converter or, above 0.9MPa (9kgf/cm2) to the drain port, reducing clutch oil pressure.

To clutch solenoid valve

φ4.5

φ0.9

6kgf/cm2

Modulator valve 2

4kgf/cm2

φ3.0

Clutch pressure regulator valve

Modulator valve 1

Port P

Ｆ ｆ To torque converter 0.9MPa (9kgf/cm2)

From pump

Drain

2.9MPa (30kgf/cm2)

Drain

９５Ｃ３２００２

Function of modulator valve 2 As mentioned above, the clutch oil pressure is controlled depending on the size of current applied to the coil of modulator valve 1. Even at a minimum value of current, however, the clutch oil pressure is too high for smooth clutch engagement due to the resistance of flow across the clutch pressure regulator valve. The modulator valve 2 is used to reduce the clutch oil pressure to appropriate pressure for clutch engagement.

32-18

When the modulator valve 2 is energized, the spool moves to the left and the oil in the clutch circuit is drained through the φ0.9 orifice. The oil from the 2 pump forces open the 0.6MPa (6kgf/cm ) check valve and flows to the clutch. The pressure drop due to the check valve allows a lower minimum clutch oil pressure maintained. This lower pressure allows some clutch slippage for smooth clutch engagement.

Modulation Mechanism

95ZIV-3

TORQUE CONVERTER AND TRANSMISSION 32

Function of pressure difference sensor The shock and the time lag when engaging the clutch vary by the clutch oil pressure rising time after the completion of the oil charging into the clutch piston chamber. In the case that the clutch oil pressure rising time is early, it causes a large shock. If it is late, it causes a large time lag. As the modulator valve 2 is ON during the oil is charging into the clutch piston chamber, oil flows to the clutch piston chamber through the check valve 0.4 MPa (4kgf/cm2) and the φ4.5 orifice.

Oil stops flowing through the check valve and the φ4.5 orifice at the completion of the oil charging into the clutch piston chamber. As a result, there is no oil pressure difference between the both sides of the φ4.5 orifice. The pressure difference sensor detects the changing of the pressure difference and transfers the signal to the controller. The controller decides the completion of the oil charging into the clutch piston chamber and transfers the signal to the modulator valve 1 to increase the clutch pressure.

Just after the engine starting, the clutch oil pressure is unstable and the pulse pressure arises. To prevent the pulse pressure, the current applied to the modulator valve 1 is kept at a minimum value in 3 seconds after the starter switch is ON. (This program does not work over 3 seconds after the starter switch is ON.)

Clutch oil pressure

Clutch oil pressure control at the time of engine starting

０

32-19

Starter Engine SW start ON Specified pressure 3 sec

Time

Modulation Mechanism

95ZIV-3

TORQUE CONVERTER AND TRANSMISSION 32

・ Initial oil charging (t1) into the clutch piston Modulation chart (Neutral → 1st forward)

chamber When the shift lever is shifted from the neutral to the 1st speed forward, the low range clutch solenoid valve is energized and oil under pressure flows into the clutch piston chamber. The 1st speed clutch solenoid valve remains energized. After a given time, the control current to the modulator valve 1 is reduced. At the same time, the modulator valve 2 is energized and the main clutch oil pressure is sharply reduced, concluding the initial oil charging into the chamber. The time taken for this initial charging, which depends on the capacity of the clutch piston chamber, is controlled by a microcomputer.

ＯＮ Low range clutch ＯＦＦ solenoid valve ＯＮ

1st speed clutch solenoid valve

Oil filling completed Modulator valve 1

Current (mA)

abt 400mA

abt 170mA

０

・ Low pressure holding (t2) To reduce clutch engagement shock, it is necessary to engage the clutch while allowing some slippage of it. To do this, the current to modulator valve 1 is held low for a given time. During this time, the clutch piston moves while compressing the piston return spring. This low pressure holding time depends on the speed of the engine: longer with lower engine speed, shorter with higher speed. Modulator 2 is kept energized allowing some oil to escape to drain. This time is also controlled by the microcomputer. ・ Pressure rise (t3) When the clutch piston comes into contact with the clutch plate and the clutch plates start to transmit power, the control current to modulator valve 1 is gradually raised. This causes the clutch oil pressure to also gradually rise, and the clutch completes engagement while some slippage occurs. This rise time is also controlled by the microcomputer.

ＯＮ

Modulator valve 2

Main pressure

ＯＦＦ

ＯＦＦ

Pressure (MPa)

Ｐ２

Ｐ１

Ｐ３

０ Low range clutch Pressure pressure (MPa) ０

ｔ１ ｔ２ ９５Ｃ３２００３

・ Restoration of clutch pressure (t4) At the completion of clutch engagement, the circuit opened by modulator 2, which maintained the lower pressure by draining part of the clutch oil since the initial charging, is closed. When the power to modulator valve 2 is turned off, the clutch oil pressure is restored to the specified pressure.

When shifted

ｔ４ Shift completed

ｔ1

Initial charging time

Changes with combination of clutches

0〜0.12 sec

ｔ2

Low pressure holding time

Changes with engine speed

Less than 0.5 sec

ｔ3

Pressure rise time

Changes with combination of clutches

0.3〜0.7 sec

ｔ4

Restoration time

Changes with combination of clutches

0.5〜1.3 sec

Ｐ1

0.2〜0.5MPa (2〜5kgf/cm2)

Ｐ2

2.3〜2.8MPa (23〜28kgf/cm2)

Ｐ3

1st speed abt 2.5MPa (25kgf/cm2) 2 Except 1st speed abt 2.9MPa (30kgf/cm )

・E/G high idle

32-20

ｔ３

Measuring Clutch Oil Pressure

95ZIV-3

TORQUE CONVERTER AND TRANSMISSION 32

Measuring Clutch Oil Pressure WARNING Unexpected movement of the machine could 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.

3rd clutch oil pressure (PF 1/4) 1st clutch oil pressure (PF 3/8)

2

・ Pressure gauge 4.9MPa (50kgf/cm ) with 2〜3m hose ・ Clutch oil pressure measurement value: 2 1st speed 2.5MPa (25kgf/cm ) 2 Except 1st speed 2.9MPa (30kgf/cm ) ・ Torque converter oil temperature: 50 to 80 ℃ (120〜180 ° F)

Main clutch oil pressure (PF 3/8) ９７Ｋ０３００２

For USA spec. the quick coupler is installed on the main clutch oil pressure gauge port.

Reverse clutch oil pressure (PF 1/4) Low range clutch oil pressure (PF 1/4) ９７Ｋ０３００３

32-21

2nd clutch oil pressure (PF 1/4)

HYDRAULIC GROUP 42 Loading/Steering Hydraulic Line ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-2 Loading/Steering Hydraulic System Diagram ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-3 Flushing Hydraulic Lines ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-4 Layout of Hydraulic Units ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-8 Hydraulic Tank ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-9 Hydraulic Oil Level Check ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-12 Hydraulic Pump ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-13 Hydraulic Cylinde r・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-15 Loading System ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-17 Pilot Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-18 Pilot Control Line Filter ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-22 Pilot Relief Valve Unit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-23 Multiple Control Valve (KML) ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-25 Adapter (with orifice) ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-34 Steering System ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-35 Steering Valve (Pilot) ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-36 Main Steering Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-42 Emergency Steering ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-52 Stop Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-54 Accumulator ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 42-55

42-1

Loading/Steering Hydraulic Line

95ZIV-3

HYDRAULIC 42

Loading/Steering Hydraulic Line ４

1. Hydraulic pump (double) 2. Multiple control valve 3. Steering valve

２

4. Boom cylinders ５

５

１１

5. Bucket cylinder 7. Steering cylinders

１５

8. Check valve 9. Return filter element 10. Relief valve 11. Steering valve (pilot) 12. Stop valve

１２

１２

13. Pilot valve (for loading) 14. Pilot relief valve unit 15. Adapter (with orifice) 17. Breather valve 18. Unloader valve 19. Line filter (pilot hydraulic line)

７

20. Oil cooler

１３

３

１８ １４

Ｔｏ ａｃｃｕｍｕ ｌ ａ ｔ ｏ ｒ

Ｔｏ ｓｏ ｌ ｅｎｏ ｉ ｄ ｖａ ｌ ｖｅ

１ １７ １

１９

Ｔｏ ｂ ｒ ａｋｅ ｖａ ｌ ｖｅ

８

９５Ｃ４２００１

１０

９

２０

42-2

Loading/Steering Hydraulic System Diagram

95ZIV-3

HYDRAULIC 42

Loading/Steering Hydraulic System Diagram

Hoist lever

Bucket lever

5 15

13 13

4

2

14

18

7

To brake line

19

3 1 17

8

20

11

12

10 9 ６５Ａ４２０１１

42-3

Flushing Hydraulic Lines

95ZIV-3

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 cause 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 〔Debris fed to the other cylinder on the opposite side〕

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 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.

42-4

Damaged cylinder

Debris

Flushing Hydraulic Lines

95ZIV-3

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.

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

42-5

Flushing Hydraulic Lines

95ZIV-3

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.

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 results.

Pieces

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".

42-6

Flushing Hydraulic Lines

95ZIV-3

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

掻

From pump

挿

Steering valve

From multiple control valve

・ Clean the pilot valve filter. Note : If 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.

42-7

掻

Layout of Hydraulic Units

95ZIV-3

HYDRAULIC 42

Layout of Hydraulic Units

8

1

7

3

5

2

9

6

4

９７Ｖ４２００３

1.Multiple control valve 2.Steering valve (main) 3.Steering valve (pilot) 4.Pilot valve (for loading) 5.Pilot relief valve

6.Hydraulic pump 7.Boom cylinders 8.Bucket cylinders 9.Steering cylinders

42-8

Hydraulic Tank

95ZIV-3

HYDRAULIC 42

Hydraulic Tank

8

9

Return filter 3

(40 US Gal.)

150 l

7

4

1

2

6

5 ９７ＺＡ４２１３

6. Inspection hole cover 7. Return filter element 8. Spring 9. Bypass valve

1. Oil tank 2. Oil level sight gauge 3. Tank cap (with air breather&filter) 4. Inlet screen 5. Drain cock / Plug

42-9

Hydraulic Tank

95ZIV-3

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 0.1MPa (0.8kgf/cm ) , 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 0.1MPa (0.8kgf/cm2) 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

42-10

The cap can be installed in any boom or bucket position

Hydraulic Tank

95ZIV-3

HYDRAULIC 42

Specifications of hydraulic tank Type

Sealed pressure type

150

Tank capacity (at center of level gauge) ( l )

25,500 × 1

2

Filtration area (cm ) Return filter

10

Filtration particle size ( μ )

0.1 (1.0 ± 0.2)

Relief valve opening pressure MPa (kgf/cm2) 2

0.01

Suction side setting pressure (kgf/cm ) 2

Discharge side setting pressure MPa (kgf/cm ) 2

Oil filling port (also used as air breather)

0.1 (0.8)

Filtration area (cm ) (Breather element)

235

Filtration particle size ( μ ) (Breather element)

10

Pushing load before turning cap required for removing or installing cap (kg)

19〜22

42-11

Hydraulic Oil Level Check

95ZIV-3

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 tank

Oil level sight gauge Cold level 150 l

Oil amount : 150 l 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.

９５Ｃ４２００２

42-12

95ZIV-3

HYDRAULIC 42

Hydraulic Pump Double Pump

1. Oil seal 2. Oil seal 3. Pressure plate 4. Driven gear 5. Drive gear 6. Coupling

４ ３

５ ６

３

１

２

９７Ｊ４２００４

４

Single Pump

３

４ ５ ３

１２

５

Measurement conditions : Oil temperature 50 ℃〜80 ℃ Hydraulic oil ISO VG46

３ Double pump

Applicable circuit

Front

Rear

Main circuit

Pilot-brake circuit

３ Single pump Steering, main & switch circuit

Theoretical discharge cm3/rev

91

36

113

Maximum operation pressure MPa (kgf/cm2)

20.6 (210)

18.1 (185)

20.6 (210)

Maximum speed min-1

2,500

2,500

2,500

42-13

Hydraulic Pump

95ZIV-3

HYDRAULIC 42

Features ・ Maintains stable performance under pressure as high 2 as 20.6MPa (210kgf/cm ). ・ Large shaft diameter, and heavy-duty bearing (bushing) of special design ensure long service life. ・ Pressure-balancing, floating wear plates maintain an appropriate clearance on the gear sides for higher efficiency. ・ Rigid housing of high-grade cast iron helps maintain high efficiency, even during high-temperature operation. ・ The front and rear pumps are independent of each other in construction, and either pump can be replaced individually.

Action of Floating Wear Plate ・ As the gears rotate, oil under pressure is carried along the inner circumference of the casing to the discharge port. Part of this oil passes by the groove shown at the right, and into the rear side of the wear plate, where the oil pushes the wear plate to the gear side. Thus the clearance between the gear side and the wear plate is kept at a minimum according to the discharge pressure. Higher pressure reduces the clearance while lower pressure allows clearance.

Gear side Rear side Discharge port side

Inlet port side

９７ＺＡ４２１９

・ The pressure on the gear side of the wear plate is higher on the discharge port side than on the inlet port side, and the pressure on the rear side of the wear plate needs to be correspondingly stronger on the discharge port side than on the inlet port side.

O-ring

High press. side Low press. side

Backup ring

９７ＺＡ４２２０

42-14

Hydraulic Cylinder

95ZIV-3

HYDRAULIC 42

Hydraulic Cylinder Boom cylinder 12 14 15 ・ 13 16

23 ・ 20

22

21

1

7 11, 10

8

2

6 9

17 5

18

3

９７Ｋ４２０２０−１

Bucket cylinder 23 ・ 20

4 22 16 14

15

12 13 21 1

3

2

7 11 10

8

6

9

17 5

23 ・ 20

24

９７Ｊ４２０１７

Steering cylinder 23 ・ 20

17 16

22 15

14 13 12

1

2

3

8

7

6 4 9 11, 10

5

23 ・ 20

24

９５Ｃ４２００３

42-15

1.Piston 2. Piston rod 3. Cylinder tube 4. Rod cover 5. Dust seal 6. Backup ring 7. U-packing 8. Buffer ring 9. Bushing 10.Backup ring 11.O-ring 12.Slipper ring 13.Square ring 14.O-ring 15.Wear ring 16.Piston nut 17.Stop ring 18.Bolt 20.Dust seal 21.Wear ring 22.Stop ring 23.Bushing 24.Set screw 25.Bolt 26.Washer

Hydraulic Cylinder

95ZIV-3

HYDRAULIC 42

Cylinder specifications

Steering cylinder

Bucket cylinder

Boom cylinder

mm (in.) Inner dia. × rod dia. × stroke Pin hole

Piston rod

φ 100 × 226 (3.93 × 8.90)

Cylinder

φ 100 × 228.5 (3.93 × 9.00)

(inner dia. × width)

Inner dia. × rod dia. × stroke Pin hole

φ 90 × 100 (3.54 × 3.93)

Cylinder

φ 90 × 100 (3.54 × 3.93)

Inner dia. × rod dia. × stroke Pin hole

φ 90 ×φ 50 × 600 (3.54 × 1.96 × 23.62)

Piston rod

φ 60 × 70 (2.36 × 2.75)

Cylinder

φ 60 × 70 (2.36 × 2.75)

(inner dia. × width)

φ 160 ×φ 80 × 605 (6.30 × 3.15 × 23.82)

Piston rod

(inner dia. × width)

φ 190 ×φ 100 × 953 (7.48 × 3.93 × 37.52)

42-16

Loading System

95ZIV-3

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

Filter

Cooler Filter Tank ７０Ｎ４２０１０

42-17

Pilot Valve

95ZIV-3

HYDRAULIC 42

Pilot Valve Structure For bucket control

Neutral

1 Dump

Roll back

For bucket control

For boom control

8 2

3

T To tank port

4 5 6

From pump

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

42-18

Pilot Valve

95ZIV-3

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. 42-19

P

８５Ｗ４２１２

95ZIV-3

HYDRAULIC 42

槽

Pilot Valve

To tank port

To tank port

槽

5

槽 From pump port

槽 From pump port

7

7 ８０Ｖ４２００４

８０Ｖ４２００３

Port 3

Port 4

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 (11) and spring seat (12) 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.

42-20

Pilot Valve

95ZIV-3

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.

42-21

Magnet

Plate

Steel ball

Disc

８５Ｗ４２１３

Pilot Control Line Filter

95ZIV-3

Pilot Control Line Filter Construction

1. Head 2. Case 3. Filter element 4. Spring 5. Backup ring 6. O-ring

1

6 5

3 2

4

９７ＺＡ４２１８

Function The filter is installed in the pilot control line to keep dust, dirt and debris out of the line.

42-22

HYDRAULIC 42

Pilot Relief Valve Unit

95ZIV-3

HYDRAULIC 42

Pilot Relief Valve Unit Construction The relief valve unit consists of relief valve and check valve. Pilot valve

３

１

４

Oil pressure gauge plug(PF1/4)

２ P Pump port

T Tank port

６５Ａ４２０１３ ６２Ａ４２０１４

1. Relief valve unit 2. Relief valve 3. Check valve 4. Plug

Oil press test 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 3.9±0.3MPa(40±3 2 kgf/cm ).

Pilot valve

Ｇ１／４

Note 1) : Tightening torque #2, #3 ・・・・・ 45〜50N-m (4.59〜5.10kgf-m) 2)Relief valve unit hexagon bolt ・Width across flats mm 22.4mm.

Ｐｐ

Check valve

Ｇ１／４

Ｇ１／４

Relief valve Ｇ１ press test port Ｇ１／４

Relief valve

Ｇ２

Ｔ２

Ｇ１／４

Ｇ１／４

Ｇ１／２ Ｐ

Ｇ１／２

Tank port

Pump port

Hydraulic line

42-23

Accumulator

Ａ

Ｂ

９７Ｃ４２００４

Pilot Relief Valve Unit

95ZIV-3

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 3.9±0.3MPa(40±3kgf/cm ) 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

６５Ａ４２０１７

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 3.9MPa(40kgf/cm2) using the adjusting screw (5).

Check valve Construction Width across flat mm:22.4mm ②

Pilot valve port ② ① ９５Ｃ４２００５

Pump port ①

42-24

３

Multiple Control Valve (KML)

95ZIV-3

HYDRAULIC 42

Multiple Control Valve (KML) 3 2

A

A Bucket cylinder rod side 6

B

B

C Tank port

Pump port

Bucket cylinder bottom side

4

4

C

Tank port

Section B-B

1

Boom cylinder rod side

From To pump tank

5

Section C-C

42-25

Boom cylinder bottom side

Section A-A

20.6MPa (210kgf/cm2)

Overload relief valve setting pressure

23.5MPa (240kgf/cm2)

installation point

Main relief valve setting pressure

Bucket

installation point

KML35A / 2T003

OLRV

Model

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 the 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".

6

Bucket

Boom

Boom

Rod side

Installed

Bottom side

Installed

Rod side

Non-installed

Bottom side

Non-installed

Rod side

Installed

Bottom side

Installed

Rod side

Installed

Bottom side

Non-installed

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

Multiple Control Valve (KML)

95ZIV-3

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 pump and pipe damage.

Operation ・ When the oil pressure is at the set point or below

Relief poppet

Pressure from the pump port passes through the orifice in the center of the plunger and acts on the relief poppet. The force of the spring to the left of the poppet is stronger, so the relief poppet and plunger remain closed preventing any oil from escaping to tank.

Plunger Tank port

Pump port

Orifice

・ When the oil pressure exceeds the set point When the oil pressure on the relief poppet from the pump port becomes greater than the force of the spring, the relief poppet opens. As a result, the oil pressure in the chamber at the left of the plunger drops sharply, and the plunger moves to the left, opening the passage to the tank line. Consequently, the oil from the pump port escapes to the tank line. This prevents the pump oil pressure from becoming too high and damaging the hydraulic components.

Adjusting screw

Note : Clogging of the orifice in plunger will cause low pressure. Another possible cause of low pressure is contamination in, or damage to, the seat of relief poppet or plunger.

・ Adjusting the pressure setting Tighten (turn clockwise) the adjusting screw to raise the set pressure, or loosen it (turn counterclockwise) to lower set pressure.

42-26

Multiple Control Valve (KML)

95ZIV-3

HYDRAULIC 42

Bucket plunger ・ Bucket "tilt-up" position

B

Load check valve

A

From pilot valve

To pilot valve

From pump

When the pilot oil pressure applies to the right side oil pack of the multiple control valve, the plunger is shifted to the left, and the center bypass line is closed at plunger shoulder. The pressurized oil from the pump flows through the load check valve and then port A. The oil finally reaches the bottom side of the cylinder to tilt up the bucket.

42-27

On the other hand, the oil in the rod side of the cylinder is returned to the tank through port B.

Multiple Control Valve (KML)

95ZIV-3

HYDRAULIC 42

・ Bucket "dump" position

B

A

To pilot valve

From pilot valve

From pump

When the pilot oil pressure applies to the left side oil pack of the multiple control valve, the plunger is moved to the right, and the center bypass line is closed at plunger shoulder. The pressurized oil fed from the pump, therefore, flows through the load check valve 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.

42-28

Extremely quick dumping opens make-up valve 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.

Multiple Control Valve (KML)

95ZIV-3

HYDRAULIC 42

Boom plunger ・ Boom "up" positon

B

A

To pilot valve

From pump

When the pilot oil pressure applies to the right side oil pack of the multiple control valve, the plunger is moved to the left, and the center bypass line is closed at plunger shoulder. The pressurized oil fed from the pump, therefore, flows through the load check valve 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.

42-29

From pilot valve

Multiple Control Valve (KML)

95ZIV-3

HYDRAULIC 42

・ Boom "down" position

A

B

To pilot valve

From pilot valve

From pump

When the pilot oil pressure applies to the left side oil pack of the multiple control valve, the plunger is moved to the right, and the center bypass line is closed at plunger shoulder. The pressurized oil fed from the pump, therefore, flows through the load check valve 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.

42-30

Extremely quick boom lowering opens make-up valve 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.

Multiple Control Valve (KML)

95ZIV-3

HYDRAULIC 42

・ Boom "float" position

To pilot valve

From pilot valve

From pump

When the control lever is shifted beyond the down position to "FLOAT", a higher pilot pressure forces the plunger of the multiple 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.

42-31

Multiple Control Valve (KML)

95ZIV-3

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 ・ As overload relief valve If, due to external force, pressure above the set pressure occurs in the cylinder port, the pilot poppet overcomes the force of the spring A and is opened. As a result, oil flows through orifice A and the pressure in the chamber to the left of the relief plunger drops sharply. The relief plunger moves to the left compressing spring B. This allows the high pressure in the cylinder port to escape to the tank port. Setting pressure : Cylinder rod circuit 23.5MPa (240kgf/cm2) 2 Cylinder bottom circuit 23.5MPa (240kgf/cm )

Adjusting screw

Pilot poppet

Relief plunger (moves left)

Orifice A

Spring A

Spring B

Cylinder port

Tank port

Tighten (turn clockwise) the adjusting screw to raise the set pressure, or loosen (counter-clockwise) it to lower it.

90Z Ⅳ 4201

・ As makeup valve When the overload relief valve on one side of the cylinder port is actuated, the plunger in the control valve is in neutral. The port opposite to the one in which high pressure was produced has a greatly reduced pressure. When the pressure is reduced below the tank pressure, the makeup valve is opened. When the pressure at the cylinder port becomes less than tank pressure, the plunger seat compresses the spring C and moves to the right. Oil is pushed in through the tank port and sent to the cylinder port. This prevents cavitation (negative pressure) in the cylinder. The makeup valve also functions when the bucket is dumped and engine speed is low. Oil flow from the hydraulic pumps is not enough to fill the cylinders with oil during rapid dumping. This reduces the pressure in the cylinder circuit and the makeup valve operates as described above. : The makeup valve function is non-adjustable. 42-32

Relief plunger

Plunger seat (moves right)

Spring C

Tank port

Cylinder port

90Z Ⅳ 4202

Multiple Control Valve (KML)

95ZIV-3

HYDRAULIC 42

Make-up valve (Installed on the rod side of the hoist cylinder line) When engine speed is low and the boom is being lowered, if pump output is less than what is needed to fill the lift cylinder, reduced pressure will occur in the rod end of the cylinder. When the cylinder pressure becomes less than tank pressure, the makeup valve is opened. The higher pressure of the tank port moves the poppet to the let, and oil from the tank flows in to prevent negative pressure (also called cavitation or vacuum). The makeup valve is non adjustable.

Shown open

Cylinder port

Poppet Tank port 90Z Ⅳ 4203

42-33

Adapter (with orifice)

95ZIV-3

HYDRAULIC 42

Adapter (with orifice) Construction １ ２

Orifice

From pilot valve

To multiple control valve

６５Ａ４２０２２

1. Adapter 2. O-ring

Location

Multiple control valve

Adapter

Ｃ

C Detail ９７Ｊ４２０１４

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. 42-34

９７Ｊ４２０１５

Steering System

95ZIV-3

HYDRAULIC 42

Steering System Operation The pilot operating method of the steering system consists of activating the steering valve, which is the main valve, with a small amount of oil flowing from the steering valve (pilot) in order to carry out steering. This is known as the full-hydraulic method. When the steering wheel is turned, an amount of oil proportional to the turning speed is sent from the steering valve (pilot) and supplied to the oil pack (pilot pressure) of the main steering valve. The main steering valve has a flow control function, and supplies to the steering cylinder circuit a large amount of hydraulic oil proportional to the pilot flow rate supplied. In short, with this method, the steering valve is designed to supply oil to the steering cylinder circuit by multiplying the small flow of pilot oil ; therefore, it is also known as the flow amplifier method.

From pilot pump

Steering valve (pilot)

Steering cylinder

Stop valve

RH

LH

Stop valve

Main steering valve To loading line

Pump

42-35

Steering Valve (Pilot)

95ZIV-3

HYDRAULIC 42

Steering Valve (Pilot) Construction ・ Valve Part Spool (1) and sleeve (2) as a set form a rotary-type directonal change-over valve. The spool (1) in this valve is linked to the steering wheel by means of a spline. When the steering wheel is not being turned, the spool (1) and the sleeve (2) are held in the neutral position by the centering spring (6); the oil groove of the spool does not match the oil hole of the sleeve, so the flow route of oil is totally closed. When the steering wheel is turned, the oil groove of the spool matches the oil hole of the sleeve, opening the oil passage, permitting oil to flow.

8

6 7 Valve part

1 2 5

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

4 3

Rotor part

1

2

Oil groove

Oil hole

3 4

90Z Ⅳ 4204

1. Spool 2. Sleeve 3. Stator 4.Rotor

42-36

5.Drive shaft 6.Centering spring 7.Cross pin 8.Check valve

Steering Valve (Pilot)

95ZIV-3

HYDRAULIC 42

Operation The spool (1) and the sleeve (2) of the valve part each have a slit into which the centering spring (6) consisting of plate springs is set. When the steering wheel is not being turned, the spool (1) and the sleeve (2) are kept in the neutral position by means of the center spring (6).

8

6 7 1 2 5

4 3

6 1

2

Oil hole

Oil groove

90Z Ⅳ 4205

1. Spool 2. Sleeve 3. Stator 4.Rotor

42-37

5.Drive shaft 6.Centering spring 7.Cross pin 8.Check valve

Steering Valve (Pilot)

95ZIV-3

HYDRAULIC 42

・ Turn (when the steering wheel is being turned) When in the neutral position, the valve part is totally closed and oil remains sealed inside the rotor, and the rotor cannot move. The sleeve (2) is directly linked to the rotor by means of a cross pin (7) and drive shaft (5); it is also fixed.

As a result, all four ports (pump, tank and oil pack on right and left side of steering valve) are opened, allowing the oil to flow and rotating the rotor. 6 1

When the steering wheel begins to be turned, rotary force is applied to the spool (1), which then pushes and compresses the centering spring (6) set in the slit ; the oil groove of the spool matches the oil hole of the sleeve, and opens the hydraulic circuit.

2

Oil hole Oil groove

90Z Ⅳ 4206

8

6 7 1 2 5

B

A

4 3

1. Spool 2. Sleeve 3. Stator 4.Rotor

5. Drive shaft 6. Centering spring 7. Cross pin 8. Check valve 90Z Ⅳ 4207

42-38

Steering Valve (Pilot)

95ZIV-3

HYDRAULIC 42

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

B

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

A

90Z Ⅳ 4208

42-39

Steering Valve (Pilot)

95ZIV-3

HYDRAULIC 42

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

When there is plenty of oil flowing from the pump, the force required to turn the steering wheel need only overcome the sliding resistance of the sleeve or rotor, so the steering wheel turns very smoothly. When the amount of oil from the pump is small, the displacement angle of the spool and sleeve reaches a maximum point ; even if the hydraulic circuit is wide open, the flow of oil from the pump to the rotor is small, so the rotor turns slowly. For this reason, the spool rotates faster than the rotor, and the displacement angle reaches a maximum point, and the spool turns the rotor by means of the cross pin and drive shaft. At that time, the rotor works as a hydraulic pump, and the steering wheel is harder to turn.

42-40

High steering speed

1 3 Large displacement angle

2

90Z Ⅳ 4209

1. Spool 2. Sleeve 3. Centering spring

Steering Valve (Pilot)

95ZIV-3

HYDRAULIC 42

Operating principle of the rotor Inside the rotor there is a stator with 7 internal gears that is fixed to the housing and a 6-tooth rotor that is engaged with the stator. Half of the chamber formed by the stator and the rotor is connected to the high-pressure side and the other half to the low-pressure side. When high-pressure oil flows into the chamber, the rotor is forced to turn in the direction that will expand the area of the chamber (by means of pressure difference). Out of this turning movement, rotation alone is taken out by the drive shaft to turn the sleeve by means of the cross pin.

Drive shaft (0 rotation)

Rotor center Locus of rotor center

With this rotation, and at the same time due to the relationship of the position between the sleeve port and the housing port, the position of oil flowing into the rotor part is gradually delayed in sequence. The rotor makes a 1/6 turn per rotation of the rotor, pushing out oil equivalent to 7 chambers. When the rotor rotates once, oil equivalvent to 42 chambers (7 chambers x 6 turns) is pushed out. For the motor, it has 6 times larger torque or a 1/6 reduction effect.

Drive shaft (1/4 rotation)

Drive shaft (1/7 rotation)

Rotor (rotation) Startor (fixed)

90Z Ⅳ 4210

: Flow of high-pressure oil : Flow of low-pressure oil

42-41

Main Steering Valve

95ZIV-3

HYDRAULIC 42

Main Steering Valve To loading line From steering pump

2

3

A

A

B B

Pilot operating port

Pilot operating port

1

Tank port

To loading line

3

Section A-A

Cylinder port

Cylinder port

4

4

Section B-B

90Z Ⅳ 4211

1. Steering plunger 2. Flow control plunger 3.Main relief valve 4. Over load relief valve with make-up valve

42-42

Main Steering Valve

95ZIV-3

Function 1.Steering plunger The movement of the steering plunger is controlled by the oil pressure supplied from the steering valve (pilot) to the main steering valve oil pack. 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. Main relief valve setting pressure

20.6MPa (210kgf/cm2)

Overload relief valve setting pressure

24.5MPa (250kgf/cm2)

42-43

HYDRAULIC 42

Main Steering Valve

95ZIV-3

HYDRAULIC 42

Operation ・ NEUTRAL position When wheels are straight (steering plunger in "Neutral"), all the oil from the steering pump is supplied to the loading line.

To loading line

2

1

95V42006

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 ), 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. 42-44

Main Steering Valve

95ZIV-3

HYDRAULIC 42

・ Left turn position

(steering plunger "in" position) Pump Loading line

2

1

To steering valve (pilot)

From steering valve (pilot)

Tank Variable throttle section

90Z Ⅳ 4219

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 ) , 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 pushed all the way to the left, and the variable throttle is fully opened. Under such a condition, all 42-45

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.

Main Steering Valve

95ZIV-3

HYDRAULIC 42

Variable throttle of steering plunger The variable throttle of the steering plunger is constructed as shown in the drawing; the open area of the throttle changes depending on the distance the plunger is shifted. Any fine change in the difference in pressure (Pa-Pb) before and after the variable throttle is sent to the flow control valve as signal pressure in order to regulate the flow rate.

Pa Pb

Variable throttle

90Z Ⅳ 4225

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.

Pump

Spring

PA PB A

B

Variable throttle section

When the pump discharge is increased and the pressure difference (PA-PB) is increased to 0.3MPa (3.5kgf/cm2), 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.

90Z Ⅳ 4216

PA PB

90Z Ⅳ 4217

42-46

Main Steering Valve

95ZIV-3

HYDRAULIC 42

Main relief valve ・ When the oil pressure is at the set point or

below. Loading line Pump

Flow control plunger

A B

90Z Ⅳ 4220

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

A

B

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

Cylinder

90Z Ⅳ 4221

plunger, therefore, is moved to the right, and all the oil from the pump is sent to the loading line.

42-47

Main Steering Valve

95ZIV-3

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 90Z Ⅳ 4222

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.

42-48

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.

Main Steering Valve

95ZIV-3

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, Cylinder 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, C 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.

・ 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

42-49

S

K Tank

X

E

G

K

D

Tank

S

Main Steering Valve

95ZIV-3

HYDRAULIC 42

Pilot circuit and its operation Note: The stop valves are not shown for simplicity. To tank

From pilot pump Steering valve (pilot)

To cylinder

From cylinder

A

B

Oil pack Oil pack

Pilot groove Pilot circuit 90Z Ⅳ 4212

・ Oil flow The hydraulic oil from the steering valve (pilot) first enters the oil pack of the steering valve, then passes through the pilot groove and flows to the oil pack on the opposite side, returning to the tank through the steering valve (pilot).

42-50

As the amount of oil throttled down when the oil entering the oil pack passes through the pilot groove (flow amplifier notch), the pressure of the oil inside the oil pack increases, pushing in the steering plunger. The variable throttle opens, regulating the amount of oil flowing to the cylinder circuit, depending on the distance the plunger is pushed in.

Main Steering Valve

95ZIV-3

HYDRAULIC 42

・ Operation of the pilot groove (flow amplifier notch) If no oil is sent from the steering valve (pilot), the plunger is held in the neutral position by the return spring and the pilot groove is closed. When pilot oil is sent from the steering valve (pilot), the pressure of the oil inside the oil pack rises, pushing the plunger and opening the pilot groove, making the oil flow out.

Return spring

Pilot groove Oil pack Pilot circuit ９５Ｃ４２００２

When pilot flow is low, when the plunger is pushed in a little, opening the pilot groove a little, the pilot oil easily flows out, and the plunger will not be pushed in any further. (The hydraulic force applied at the end of the plunger is in balance with the force of the return Pilot pressure spring.)

Hydraulic force

Return spring force

Pilot groove

90Z Ⅳ 4214

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

Hydraulic force Return spring force

90Z Ⅳ 4215

42-51

Emergency Steering

95ZIV-3

Emergency Steering Function The emergency steering works automatically when the steering hydraulic pressure goes down or the engine stops while the machine is operating. When the steering hydraulic pressure goes down while the engine is running, the steering hydraulic warning lamp lights up.

Operation condition All the following conditions need to be satisfied to allow the emergency steering to operate. 1) The starter switch is ON position. 2)Hydraulic pressure in the steering hydraulic circuit 2 lowers below 0.4MPa (4kgf/cm ). 3)Hydraulic pressure in the orbitrol hydraulic circuit 2 rises above 0.4MPa (4kgf/cm ).

Oil flow In normal operation : Oil flows from #(5) → Gear pump → #(13) → #(15) → #(14) → #(9) → #(12) → #(4) → steering valve → Steering cylinder to steer the machine. When the emergency steering system works : Oil flows from #(5) → #(19) or #(23) → Motor pump → #(21) → #(16) → #(8) → #(11) → #(4) → steering valve → Steering cylinder to steer the machine.

42-52

HYDRAULIC 42

Emergency Steering

95ZIV-3

HYDRAULIC 42

Hydraulic Line Diagram

Motor pump

Motor pump

Gear pump

From oil tank Port P Steering valve

4. Block 5. Oil pipe 8. Check valve 9. Check valve 11. Nipple fitting 12. Nipple fitting 13. High pressure hose

14. Connector 15. Elbow fitting 16. Nipple fitting 17. Connector 19. Heat resisting low pressure hose 21. High pressure hose 23. Heat resisting low pressure hose

42-53

Stop Valve

95ZIV-3

HYDRAULIC 42

Stop Valve Construction

From steering valve (pilot)

To main steering valve

1

3

2

4

1. Steering stopper (adjustable) 2. Plunger 3.Check valve 4.Oil seal

90Z Ⅳ 4223

Operation A stop valve is provided to reduce the impact caused to the swing stopper when the machine is making a full turn while the hydraulic pressure of the steering cylinder is still working. Shortly before the full turn, the pilot circuit is closed, returning the steering plunger to the neutral position. After a full turn, when the steering wheel is being turned in the opposite direction, the plunger (2) of the stop valve remains pushed in, closing the circuit ; the pilot oil opens the check valve (3) and flows out.

B

A

90Z Ⅳ 4224

42-54

Accumulator

95ZIV-3

HYDRAULIC 42

Accumulator Function The oil pressure accumulated in the accumulator can be supplied to the pilot valve to operate the multiple control valve even if hydraulic oil is not supplied from the pilot pump because of the engine stop or the pilot pump failure. The boom can be lowerd or the bucket can be moved to the dump position, under the force of gravity. Raising the boom or rolling bucket back is not possible if there is no main pump oil flow.

Pilot valve

Accumulator

Oil supply circuit Unloader valv3

Relief valve Parking brake Reducing valve

９５Ｃ４２００６

Hydraulic oil tank

Hydraulic Line

42-55

BRAKE GROUP 52 Brake Circuit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-2 Layout of Brake Units ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-4 Unloader Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-6 Brake Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-8 Auto-Adjuster Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-12 Service Brake ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-14 Checking Wear of Service Brake Friction Plate ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-16 Purging Air from Park Brake / Auto Brake circuits ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-17 Brake Line Air Bleeding ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-19 Parking Brake ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-21 Adjusting Parking Brake Clearance ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-23 Parking Brake (for front) ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-24 Solenoid Valve (for front parking brake) ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-25 Solenoid Valve (for rear parking brake) ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-26 Solenoid Valve (for auto brake) ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-28 Oil Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-29 Accumulator ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-30 Reducing Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-31 Low Pressure Switch ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 52-32

52-1

Brake Circuit

95ZIV-3

BRAKE 52

Brake Circuit 1. Oil pump 2. Unloader valve 3. Brake valve (Left) 4. Brake valve (Right) 5. Auto-adjuster valve 6. Solenoid valve (for auto-brake) 7. Solenoid valve (for parking brake) 8. Reducing valve 9. Accumulator 10. Check valve 11. Pressure switch 12. Pressure switch (for brake lamp) 13. Pressure switch (for inching) 14. Check valve 15. Line filter

52-2

95ZIV-3

BRAKE 52

Outline of brake system This machine uses an all-hydraulic wet multi disc service brake and a internal expansion type parking brake.

・ Oil from the pump is regulated to 6.9〜11.8MPa (70〜 2 120kgf/cm ) by the unloader valve (2) and enters the accumulators (9).

・ The parking brake is applied when the power of the solenoid valve (7) is turned off. ・ This machine is also equipped with an automatic braking system. The service brakes are automatically applied if the machine speed exceeds a specific value, and if shifting between forward and reverse is done with high machine speed.

・ When the brake pedal is depressed, the oil from the accumulator (9) flows through the auto-adjuster valve (5), and operates the service brake pistons in proportion to the movement of the brake pedal.

52-3

Layout of Brake Units

95ZIV-3

BRAKE 52

Layout of Brake Units

８

８

７

４

３

６

２

５

１

９５Ｃ５２００２

1. Accumulator (2 pcs) 2. Parking cylinder 3. Solenoid valve (for auto-brake) 4. Solenoid valve (for parking brake)

5. Unloader valve 6. Shuttle valve 7. Reducing valve 8. Auto-adjuster valve

52-4

Layout of Brake Units

95ZIV-3

BRAKE 52

ACCUMULATOR

VALVE UNIT

９５Ｃ５２０００３

UNLOADER VALVE

PILOT RELIEF VALVE

UNLOADER VALVE ９５Ｃ５２００４

52-5

Unloader Valve

95ZIV-3

BRAKE 52

Unloader Valve Accumulator port

Ｂ−Ｂ

６

Tank port

２４

Ａ−Ａ

７

２２

２１

Port to pilot relief valve

１０

２３

２０ １９

８

１８

１

９

Pilot port (Accumulator feed back port)

１７

３

１６

５

１５ ４ １１

１２

２

１４

Pump port

９５Ｃ５２００５

１３

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

Body Spring Spool O-ring Plug Orifice Orifice O-ring Plug

10. Plug (For gauge port) 11. Plunger governor 12. Spring 13. O-ring 14. Plug 15. Pilot poppet 16. Spring seat 17. Spring 18. Spring

19. O-ring 20. Plug 21. Adjusting screw 22. Lock nut 23. Packing 24. Cap nut

Ｏｕ ｔ ｓ ｉ ｄｅ ｖ ｉ ｅｗ Accumulator port Port to pilot relief valve

Ｈｙｄｒ ａｕ ｌ ｉ ｃｌ ｉ ｎｅ

Gauge port

Port to tank

Pump port

Port to pilot relief valve Pilot port

Tank port Pump port Accumulator port

Accumulator feed back port

６５Ａ５２００６

９０Ｃ５２００６

52-6

Unloader Valve

95ZIV-3

The unloader valve is to regulate the amount of the oil and pressure that flows from pump to the accumulator. There are the pump port, the port to the pilot relief valve, the accumulator port, the accumulator feed back port and the tank port on the body (1). The unloader valve has the spool (3) that closes and opens the port between the pump port and the port to the pilot relief valve, the orifice (6) that controls oil flow to the accumulator port and the pressure governor mechanism that controls hydraulic pressure at the accumulator port side.

Function The port between the pump port and the port to the pilot relief valve (pilot relief valve port) is closed because the spool (3) is pushed by the spring (2) to the original position when no unloader valve is working. When oil is supplied to the unloader valve from the pump port it flows to the accumulator port through the orifice (6) and the pressure at the accumulator port rises accordingly. If the oil amount from the pump port is large, spool (3) moves to the port to the pilot relief valve and some oil leaks to the port to the pilot relief valve. The oil pressure at the accumulator port is transfered to the pressure governor through the orifice (7). When the oil pressure at the accumulator port exceeds the set point the pilot poppet (15) is opend. And the pressure at the accumulator port stops rising. (Cut out pressure) At this moment the plunger governor (11) is pushed up by the accumulator pressure connected to the pilot port, then the pilot poppet (15) is kept to release. When the accumulator pressure is getting low and the pilot poppet (15) is pushed by the spring to the original position the pilot poppet (15) closes the port and the pressure to the accumulator starts to rise.

OFF

11.8 ± 0.5MPa (120 ± 5kgf/cm2)

ON

6.9 ± 1.0MPa (70 ± 10kgf/cm )

Setting pressure 2

52-7

BRAKE 52

Brake Valve

95ZIV-3

BRAKE 52

Brake Valve Brake Valve (Main Valve) (This is located in the left side of the operator's room)

Ａ−Ａ ３６

３５

４０ ４１ ３８ ３７ ２９

３９

４４ Ａ

３４

３２

４３

３３ ２５

４２

２６

２８ Ａ

３０ ３１ ２４ １４ １５ １７ １６

５１ ２３

Tank port

Pilot port

２７ １９ ２２ ２１

１８

２０

４

１３ ５ １

３

Ｂｒ ａｋｅ ｐｏｒ ｔ

４７ ４６

２

Accumulator port

１０ ６

1. Body 2. Spool 3. Spring 4. Spring seat 5. E-ring 6. Spring seat 7. Stop ring 8. Plunger 9. Spring 10. O-ring

７

９ ４５

11. Cover 12. Bolt 13. Spool 14. Input spool 15. Spring seat 16. Sleeve 17. Case 18. Spring 19. Spring 20. Case

１１ ６５Ａ５２００３ １２

８

21. Stop ring 22. Spring 23. Cover 24. Oil seal 25. Stopper 26. C-ring 27. O-ring 28. Mounting plate 29. Bushing 30. Bolt

52-8

31. Washer 32. Seat 34. Pedal 35. Roller 36. Pedal cover 37. Pedal pin 38. L pin 39. Pedal collar 40. Washer

41. Pin 42. Screw 43. Nut 44. Pedal cover 45. Orifice 46. Plug 47. O-ring 51. Orifice

Brake Valve

95ZIV-3

BRAKE 52

Construction The brake valve is the combined pedal tandem type. The brake system is "completely independent system for front and rear wheels". The spools (2) (13) are placed in the center of the body (1) in series. Each spool has the plunger (8) in it. The springs (18) (19), that convert the depressed force to the pedal to the regulated hydraulic oil pressure, are placed between the input spool (14) and the spool (13).

Function -Refer to the drawing1.No brake applied

3.When releasing brake

1) Brake valve is not depressed / no oil supplied to pilot port. When the brake valve is not depressed and or no oil supplied to pilot port, the spools (2) (13) are pushed up to the original position by the spring (9). Accordingly the brake port is opened to the tank port as a result the hydraulic pressure in the brake cylinder is relieved. The spool closes the accumulator port and the brake port. High oil pressure in the accumulator is being kept.

1) Not depressing brake pedal. When the brake valve is released (brake pedal is not depressed) the input spool (14) returns to the original position by the spring (22). The springs (18) (19) return to the original position, and the spools (2) (13) return to the original position by the hydraulic pressure that pushes the plunger (8) and the spring (9) force. In this case a port between the brake port and the accumulator port is closed by the spool (2) (13) and port between the brake port and tank port is opened.

2.Brake applied 1) When the brake pedal is depressed the input spool (14) is pushed via the roller (35). The input spool pushes the spring (18) (19) then moves the spool (2) (13) to the bottom side. Because of the spool moving the brake port and tank port are closed. When the spool moves more the port between brake port and accumulator port is open. The high pressure oil from the accumulator flows into the brake cylinder and the brake starts to work. The high pressure oil at the brake port side flows through the orifice in the spool and pushes the plunger (8) in the spool, can be the force to the spool moved back to the orginal position. (Hydraulic pressure reaction) The hydraulic pressure reaction and the load added to the spring (9), balancing the load to the spring (18) (19), control the brake oil pressure at the brake port side. The spring (18) (19) move and the load added to then give an operator the brake feeling by the brake pedal stroke and the depressed force. 2) When oil supplied to pilot port. When the oil is supplied to the pilot port, the oil goes through the spool input oil path, and pushes the sleeve (16), and the springs (18) (19) then moves the spools (2) (13) to the bottom side. 52-9

13 To tank port

９５Ｃ５２００７

2) When no oil supplied to pilot port. When releasing the hydraulic pressure from the pilot port, the springs (18) (19) return to the original position and the spools are pushed back to the original position by the hydraulic pressure that pushes the plunger (8) and the spring (9) force.

Brake Valve

95ZIV-3

BRAKE 52

Brake Valve (Pilot Valve) (This is located in the right side of the operator's room)

Ａ−Ａ

３３

３２ ３７

３５ ３８

３４ ２６

３６

４１ ２９

Ａ

３１

３０ ２２

４０

２３ ２７ ２８

Ａ

２１

３９ ２５

２０ １２ １４

１０ １１

Ｔａｎｋ ｐｏｒ ｔ

１３ １６

２４ １５

１９

１８

１

Accumulator port

３ １７

８ ２

９

６ ７ ４

Brake port

５ Pressure switch port

1. Body 2. Orifice 3. Spool 4. Spring seat 5. Stop ring 6. Spring 7. O-ring 8. Cover 9. Bolt 10. Input spool

11. Spring seat 12. Case 13. Spring 14. Retainer 15. Bolt 16. Spring 17. Case 18. Stop ring 19. Spring 20. Cover

21. Oil seal 22. Stopper 23. C-ring 24. O-ring 25. Mounting plate 26. Bushing 27. Bolt 28. Washer 29. Seat 30. Dust cover

52-10

31. Pedal 32. Roller 33. Pedal collar 34. Pedal pin 35. L pin 36. Pedal collar 37. Washer 38. Pin 39. Screw 40. Nut 41. Pedal cover

６５Ａ５２００４

Brake Valve

95ZIV-3

BRAKE 52

Construction The brake valve is the combined pedal tandem type. The spool (3) is placed in the center of the body (1) in series. This spool has the plunger (8) in it. The springs (13) (16) that convert the depressed force to the pedal to the regulated hydraulic oil pressure, are placed between the input spool (10) and the spool (3).

Function -Refer to the drawing1.No brake applied

3.When releasing brake

1) Brake valve is not depressed / no oil supplied to pilot port. When the brake valve is not depressed and or no oil supplied to pilot port, the spool (3) is pushed up to the original position by the spring (6). Accordingly the brake port is opened to the tank port as a result the hydraulic pressure in the brake cylinder is relieved. The spool closes the accumulator port and the brake port. High oil pressure in the accumulator is being kept.

1) Not depressing brake pedal. When the brake valve is released (brake pedal is not depressed) the input spool (10) returns to the original position by the spring (19). The springs (13) (16) return to the original position, and the spools (2) (13) return to the original position by the hydraulic pressure that pushes the plunger and the spring (6) force. In this case a port between the brake port and the accumulator port is closed by the spool (3) and port between the brake port and tank port is opened.

2.Brake applied 1) When the brake pedal is depressed the input spool (10) is pushed via the roller (35). The input spool pushes the spring (13) (16) then moves the spool (3) to bottom side. Because of the spool moving the brake port and tank port are closed. When the spool moves more the port between brake port and accumulator port is open. The high pressure oil from the accumulator flows into the brake cylinder through the brake valve (main valve) and the brake starts to work. The high pressure oil at the brake port side flows through the orifice in the body and pushes the spool (3), can be the force to the spool moved back to the orginal position. (Hydraulic pressure reaction) The hydraulic pressure reaction and the load added to the spring (6), balancing the load to the spring (13) (16), control the brake oil pressure at the brake port side. The springs (13) (16) move and the load added to then give an operator the brake feeling by the brake pedal stroke and the depressed force.

52-11

Auto-adjuster Valve

95ZIV-3

BRAKE 52

Auto-adjuster Valve Construction 5

6

Brake piston port

Brake valve port

1

2

4

3

９５Ｃ５２００８

7

1. Cylinder 2. Piston 3. Check valve 4. Spring 5. Air bleeder 6. Plug 7. Return spring The auto-adjuster valve (sometimes called a "slack adjuster") is installed between the brake valve 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.

Check valve specifications

52-12

Dia. of pressure receiving section

9mm

Valve opening pressure

2 1.4MPa(14.5kgf/cm )

Auto-adjuster Valve

95ZIV-3

BRAKE 52

Operation 1)In brake released condition 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. In this condition, the brake piston port chamber has residual pressure of approximately 0.9kgf/cm2(12.8psi) 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 )

2

Brake valve port

Brake piston port

3

１１５Ｅ５２００５

2

2)In brake applied condition When the brake pedal is depressed, oil is fed from the brake valve to move the piston (2) to the right. The oil, therefore, is fed into the brake piston. 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 brake valve port, the valve spring (7) returns the piston (2), and the check valve (3) is closed.

52-13

Brake valve port

Brake piston port

4

3

7

９５Ｃ５２００９

Service Brake

95ZIV-3

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 good braking power and protects the brakes from mud or sand.

Construction ９

７

８

Brake oil inlet port

４ ５ ６

１３

２

３

１１

１０

１

１２

1. Internal gear hub

8. O-ring (brake piston-inner)

2. Brake piston

9. Brake retainer

3. Piston return spring

10. O-ring (gear hub)

4. Disc gear

11. O-ring (gear hub)

5. Friction plate

12. Air bleeder nipple

6. Steel separator plate

13. Steel pressure plate

7. O-ring (brake piston-outer)

52-14

９７ＺＡ５２１１

Service Brake

95ZIV-3

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 ± 0.1mm-New 5.0 ± 0.15mm-Worn

1.2mm

0.65mm φ 400mm

(A)

Detailed drawing of groove

Steel plate 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, install by aligning with splines and spring pin. 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 (refer to "Checking Wear of Service Brake Friction Plate"). Therefore, for this steel plate, the direction should be carefully installed so that the center of the teeth missing section is aligned with the spring pin as shown.

52-15

Spring pins Friction plate

(A) Cooling holes Steel plate

Spring pins Internal gear

Friction plate wear measurement point

Checking Wear of Service Brake

95ZIV-3

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 must be disassembled.

Ａ 200mm (8 ″) Slide caliper

Air bleeder nipple

９７ＺＡ５２１９

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. The wear limit for dimension A is 25.1mm. Note that dimension A is 29mm when the plate is new and unused.

IMPORTANT

Oil inlet port

Inner steel plate teeth

Outer steel plate teeth

Hint : To aid quick measurement on the front

To replace the friction and steel plates only, loosen the air bleeder 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.

axle-raise the front of the machine so the front tires clear the ground by about 25mm. This allows easy rotation of the wheel to align the gear teeth.

52-16

Puring AirAir from Park Brake / Auto BrakeBrake Circuits Purging from Park Brake / Auto Circuits

95ZIV-3

BRAKE 52

Purging Air from Park Brake / Auto Brake Circuits Bleeding park brake circuit

Park brake solenoid valve

DANGER While performing this work, do the following steps to keep from causing serious injury or death.

Manual release

8 TAG THE MACHINE OUT OF SERVICE!

6 3

9

・ Park on level ground, apply park brake, and block the tires with heavy wheel chocks. ・ Do not work alone, and agree upon signals used before starting this work. ・ If boom is raised during this service work, it is important to use a safety support that is strong enough to hold the weight of the boom and front of machine. ・ Apply articulation stopper.

2 Ｔ Ａ Ｐ

Ｂ Ｔ

5

4

Ｓｏ ｌ ｅｎｏ ｉ ｄ

Push and turn handle clockwise to disengage park brake.

1. Start machine, and run until you are certain that the unloader valve has reached the "cut off" pressure. 2. Shut off engine. DO NOT RUN ENGINE! 3.Manually apply and release park brake solenoid 3 times, with a time lapse of 5 seconds between each application. This will purge any trapped air from valve, and keep if from getting into auto brake feed, and eventually into the brake valves. 4. Continue with bleeding of air from brakes at auto brake circuit. [Refer to next page.]

WARNING Purpose of this procedure is to remove all air from before the brake valves, where it can cause brake modulation troubles. If air is left at park brake valve, it can create problems with brake application due to air in brake valves.

52-17

7 1 ９５Ｃ５２０１０

Puring AirAir from Park Brake / Auto BrakeBrake Circuits Purging from Park Brake / Auto Circuits

95ZIV-3

BRAKE 52

Bleeding auto brake circuit

WARNING

DANGER While performing this work, do the following steps to keep from causing serious injury or death.

This must be done after bleeding the air from the park brake circuit, and before bleeding the rest of the brake circuit at hub bleeder valves.

TAG THE MACHINE OUT OF SERVICE! Purpose of this procedure is to remove all air from before the brake valves, where it can cause brake modulation troubles.

・ Park on level ground, apply park brake, and block the tires with heavy wheel chocks. ・ Do not work alone, and agree upon signals used before starting this work. ・ If boom is raised during this service work, it is important to use a safety support that is strong enough to hold the weight of the boom and front of machine. ・ Apply articulation stopper.

If air is left at auto brake valve, it can create problems with brake application due to air in brake valves.

1. Start machine, and run until you are certain that the unloader valve has reached the "cut off" pressure. 2. Shut off engine. DO NOT RUN ENGINE! 3.Manually apply and release auto brake solenoid 15 times, with a time lapse of 5 seconds between each application. Refer to illustration below to saee how to do this. 4. Continue with bleeding of air from brakes at the wheels. Auto brake solenoid valve

8

6

Insert stem and force solenoid valve spool to move inward to apply circuit.

3 2

Ｔ

Ａ

Ｐ

Ｂ

Ｔ

Solenoid

7 5

52-18

4

1

９５Ｃ５２０１１

Brake Line Air Bleeding

95ZIV-3

BRAKE 52

Brake Line Air Bleeding WARNING To bleed the brake line of air, the engine should be started to keep the oil 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.

Front axle

Air bleeding positions and its order A. Auto-adjuster valve B. Axle housing Rear axle

１１５Ｅ５２０１２

1. Bleed air in order of the above (alphabetical order) at each air bleeder of the above equipments. 2. Connect the vinyl tube to the air bleeder nipple of the brake valve, and place an oil can to catch the oil. Vinyl tube length : 1.2 to 1.3m Outer dia. of nipple : 7mm

3. Slightly loosen the nut of the air bleeder nipple. Repeat pressing down of the brake pedal until hydraulic oil comes out from the air bleeder nipple. After that tighten the nut to close the air bleeder nipple. 4. Connect the vinyl tube to the air bleeder nipple of the auto-adjuster valve. Outer dia. of nipple 6mm

B

A Air bleeder nipple

5. To bleed each wheel, press the brake pedal, slightly loosen the nut of the bleeder nipple to discharge hydraulic oil. Repeat at all 4 wheels. 6. Repeat the above procedure until no air is in the brake hydraulic oil. At the completion of air bleeding, close the air bleeder nipple.

52-19

９５Ｃ５２０１２

Brake Line Air Bleeding

95ZIV-3

BRAKE 52

7. Connect the vinyl tube to the air bleeder nipple of the axle housing, and then follow the above steps 5 and 6 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. Air bleeder nipple of auto-adjuster valve : 10N-m (1.0kgf-m) Air bleeder nipple of axle housing : 10N-m (1.0kgf-m)

Vinyl tube Air bleeder nipple

8. Some air may still be trapped in the auto adjuster. To remove it, please do the following. a. Shut off engine, remove keys from key switch. b. Do NOT apply brakes! Loosen valve "B" to one turn. c. Loosen bleeder valve "A" to purge any air from auto adjuster.

B

A Air bleeder nipple

When finished purging trapped air, tighten "A" and "B" and check for leaks. Note: Procedure 8 removes oil via residual brake pressure that is pent up behind the brake piston, due to piston return springs.

DANGER While performing this work, do the following steps to keep from causing serious injury or death. TAG THE MACHINE OUT OF SERVICE! ・ Park on level ground, apply park brake, and block the tires with heavy wheel chocks. ・ Do not work alone, and agree upon signals used before starting this work. ・ If boom is raised during this service work, it is important to use a safety support that is strong enough to hold the weight of the boom and front of machine. ・ Apply articulation stopper.

52-20

９５Ｃ５２０１２

Parking Brake

95ZIV-3

BRAKE 52

Parking Brake Oil

The parking brake is a propeller shaft braking drum type, and is connected to the transmission output shaft.

To hydraulic tank Solenoid valve

Turning on (pulling out) the parking switch turns off the power of the solenoid valve (shown in the figure). Oil is returned from the oil cylinder to the tank, and the spring in the oil cylinder pulls the parking brake lever to apply the brake.

Parking switch Oil cylinder Piston Spring Bracket Lever

Operation of parking brake

Link Pin

Parking switch

ON

OFF

Solenoid valve

Power-off

Power-on

ON

Oil discharge Oil feeding

OFF

Oil cylinder Parking brake

Braking

Link

Released

Pin Parking brake Parking brake "OFF" → "ON" ９５Ｃ５２０１３

Brake drum construction

1.Brake drum 2.Brake shoe 3.Brake lining 4.Adjusting screw 5.Cam shaft 6.Lever

6

5

C-C 5 5

Drum rotational direction for traveling in reverse

B

6

3 C

C

4

A 1

2 B

A

B-B

A-A 4

Adjusting screw rotation for brake shoe expansion

52-21

3

Parking Brake

95ZIV-3

BRAKE 52

Construction 6

5

C-C 5 5

Drum rotational direction for traveling in reverse

B

6

3 C

C

4

A 1

2 B

A

B-B

A-A 4

Adjusting screw rotation for brake shoe expansion

When the parking switch is turned on (pulled out), oil is returned to the tank from the oil cylinder, and the oil 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. ＊ ＊ 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 adjustment.

52-22

3

1.Brake drum 2.Brake shoe 3.Brake lining 4.Adjusting screw 5.Cam shaft 6. Lever

Adjusting Parking Brake Clearance

95ZIV-3

BRAKE 52

Adjusting Parking Brake Clearance WARNING

Drum rotational direction for forward traveling

Unexpected movement of the machine could cause serious injury or death. 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

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 jacks, cribbing, etc.. 2. Turn the inspection hole of the brake drum approximately 8°counter-clockwise from the vertical position as shown in the right figure. After that, turn the adjustment screw to adjust the clearance by using the special tool. 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.

Top

Inspection hole 2nd propeller shaft

９０ＺⅣ

For replacement of shoe assembly refer to Section 54, "Disassembly and Reassembly". Rivet

Brake shoe

A

Rivet

Brake lining

Abrasion limit

Lining

Approx. 8 °

９５Ｃ５２０１４

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.

B

Position of adjustment screw

Special tool

Checking brake lining for abrasion loss

Shoe

Brake shoe expansion direction A-A Adjusting screw

Lining thickness A : 6.15mm Wear limit B : 0.8mm

52-23

Parking Brake (for front)

95ZIV-3

BRAKE 52

Parking Brake (for front) Front diff. gear

Brake disc

Disc brake

９５ＺⅣ ＵＳ５２０１

Solenoid valve

Accumulator

Front axle ９５Ｖ５２００５

52-24

Solenoid Valve (for front parking brake)

95ZIV-3

BRAKE 52

Solenoid Valve (for front parking brake)

Ａ

９５Ｖ５２００２

９６Ｖ５２００３

52-25

Solenoid Valve (for rear parking brake)

95ZIV-3

BRAKE 52

Solenoid Valve (for rear parking brake)

８

６

３ ２

９

Ｔ

Ａ

Ｐ

Ｂ

Ｔ

The figure shows neutral position.

Solenoid

７ ５

４

１ ９５Ｃ５２０１６

1. Body

5. Square ring

2. Plug

6. O-ring

3. Spool

7. Spring

4. Spring retainer

8. Solenoid valve

A B

P T

9. Knob(for manual operation)

Installation position Installed on the hydraulic tank (left side of the chassis). (Refer to "Layout of Brake Units")

Normal operation When the parking switch is turned on, the power of the solenoid valve is turned off, and the spool (3) is returned to the neutral position. The oil in the cylinder is returned to the tank, and the parking brake is applied.

52-26

Solenoid Valve (for rear parking brake)

95ZIV-3

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, push the manual operation knob and turn it 90 ° clockwise. The spool in the valve will be locked, and oil will be fed into the oil cylinder to release the brake. Note that releasing the parking brake will not be possible if the oil pressure is not normal.

8

6 3 2

Ｐ

Ｂ

Ｔ

Solenoid

Push and turn clockwise

WARNING

Ａ

Ｔ

5

4

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 could occur. After manual releasing of the parking brake, be sure to return the manual operation knob to the initial (OFF) position.

1

7

９５Ｃ５２０１７

〔 Note〕 To release the parking brake with low oil pressure (below the specified pressure range) due to engine problem, follow the procedure below: Using another oil source: Supply oil to the oil cylinder from the another oil source, and then remove the pin. Without another oil source: Apply a cable to the link, and then pull it down using a bar to release the spring of the oil cylinder. After that, remove the pin.

Oil To hydraulic tank Solenoid valve Parking switch Oil cylinder Piston Spring Bracket Lever

Link Pin Link ON OFF Pin Parking brake Parking brake "OFF" → "ON" ９５Ｃ５２０１３

52-27

Solenoid Valve (for auto brake)

95ZIV-3

BRAKE 52

Solenoid Valve (for auto brake)

8

6

3 2

Ｔ

Ａ

Ｐ

Ｂ

Ｔ

Solenoid

The figure shows neutral position.

7 5

4

1 ９５Ｃ５２０１８

Installation position Installed on the hydraulic tank (the left side of the rear chassis) (beside the parking brake solenoid valve) (Refer to "Layout of Brake Units")

Operation Auto-braking will occur under the following conditions: 1. When shifting between forward and reverse is done with the shift lever in " A " position and the machine speed is over 12 km/H. 2. When the specified speed limit for each speed range is reached.

Speed limit for Auto brake

(Refer to the Electrical Group Section 62 for the details of Auto brake operation.)

52-28

Speed range

Speed limit

1st

Approx. 15km/H

2nd

Approx. 22km/H

3rd

Approx. 36km/H

4th

Approx. 36km/H

Oil Cylinder

95ZIV-3

BRAKE 52

Oil Cylinder

１２ ２

３

１

６

４

８

１１

５

１０

７ １３

９

１４

1. Cylinder tube 2. Piston rod 3. Rod cover 4. Piston 5. U-nut

９７ＺＡ５２１４

11. O-ring 12. Filter 13. Head cover 14. Tie rod

6. Spring 7. Bushing 8. U-packing 9. Dust seal 10. O-ring

Operation

225kg

The compressed oil applies pressure to the internal spring to release the parking brake. g rin p S

WARNING

e rc fo

202kg

149kg

Careless disassembling work could 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 (324.4mm) to check the spring for damage.

18.6 25 Stroke 60 118

136 161

221 (installation length) 339 (free length)

Spring length

52-29

９５Ｃ５２０１９

Accumulator

95ZIV-3

BRAKE 52

Accumulator

stroke 344

９５Ａ５２２０７

Slider seal Back up ring O-ring

T-ring

(SN 97C3-9001〜9050)

(SN 97C3-9051〜)

2. Cylinder

6. Piston

10. Core

3. Top cover

7. O-ring

11. Seal washer

4. Oil port

8. Back-up ring

12. Cap

5. Nut

9. Seal

13. Spring pin

The accumulator holds hydraulic oil under pressure. It is installed in the service brake circuit. The cylinder contains N2 (Nitrogen) gas at 2.94MPa 2 (30kgf/cm )(capacity 2.8 l).

52-30

Reducing Valve

95ZIV-3

BRAKE 52

Reducing Valve The reducing valve is installed in order to adjust the degree of effectiveness of the automatic brake. If the set pressure of the reducing valve is too high, there will be a jolt when the automatic brake is applied, but if the pressure is set too low, the brake will not work well.

Operation

To tank port

To solenoid valve (B) (for auto-brake) From accumulator (A)

１１５Ｅ５２００９ 2

If pressure at port B is below the set pressure of 2.3MPa(23kgf/cm ), oil flows from A to B, as shown in the diagram.

Lock nut Adjusting screw

Solenoid valve port (B)

Spool

From accumulator (A) To tank port 2

When pressure at port (B) exceeds 2.3MPa(23kgf/cm ), the spool is moved to the right, then opening the passage to the tank line. Consequently, the oil from the accumulator port escapes to the tank line. To adjust the set pressure, loosen the lock nut, and tighten or loosen the adjusting screw as required.

52-31

１１５Ｅ５２０１０

Low Pressure Switch

95ZIV-3

BRAKE 52

Low Pressure Switch Structure Low pressure indicator switch signals abnormally low pressure in the accumulator. When the accumulator circuit pressure drops below the 2 specified pressure [3.9±0.5MPa(40±3kgf/cm ) (570± 40psi)], the pressure switch contact comes to ON and turns the alarm buzzer ON. ・ Low pressure indicator actuating pressure = 3.9±0.5MPa 2 (40±3kgf/cm )

Construction Tube

Cap

No 1

2

3

4

5 6

7

8

9

10

６５Ａ５２００８

17 16 15 14 13 12 11

Pressure switch

Contact point : Normal open

52-32

1

Case

2

Packing

3

Seal film

4

Disc

5

Inner lid

6

Guide pin

7

Spring

8

Connector

9

Base

10

Cover

11

Connector

12

Contact

13

Contact

14

Guide

15

Stopper

16

Guide hed

17

Teflon film

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 ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-9 Electrical Connection Diagram ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-13 Layout of Electrical Equipment Inside Cab Control Box ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-15 Layout of Electrical Equipment Around Battery Relay ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-16 Fusible Link/Fuse ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-17 Engine Start Circuit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-19 Alternator/Charge Circuit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-25 Engine Stop Circuit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-26 Transmission Control Circuit and Monitor Circuit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-27 Monitor Circuit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-46 Instrument Panel ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-51 Electric Detent Circuit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-55 Emergency Steering Circuit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-57 Cautions Regarding Electric Circuit Check ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-58 Flow Chart for Troubleshooting of Electrical Transmission Control System ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-60 Judgment of Transmission Controller Abnormal Operation ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-61

62-1

On/Off Statuses of Transmission Controller LED Indicators ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-62 Function of Diagnostic system for Electrical Transmission Controller ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-66 Function of Diagnostic system for Monitor Controller ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-71 Warning Lamps Checked by Diagnostic Circuit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-72 Electrical Wiring Connection ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-75 Checking Shift Lever Input Circuit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-76 Checking Inching Input Circuit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-78 Checking QUAD Switch Input Circuit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-80 Checking Machine Speed Sensor Input Circuit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-81 Checking Clutch Solenoid Valve Output Circuit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-82 Checking Modulator Valve (1), (2) Input Circuit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-84 Checking Neutral Relay Circuit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-86 Checking Parking Brake Circuit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-88 Checking Auto Brake Circuit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-89 Checking Fuel Valve Circuit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-90 Checking Gauge Circuit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-92 Checking Fuel Level Gauge Circuit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 62-94

62-2

How to Use Electrical Wiring Diagram

95ZIV-3

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

Cable Color Codes

95ZIV-3

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)(95ZIV)

95ZIV-3

ELECTRICAL 62

Electrical Wiring Diagram(1/2)(95ZIV) (97C3-9001〜9050)

62-5

Electrical Wiring Diagram(2/2)(95ZIV)

95ZIV-3

ELECTRICAL 62

Electrical Wiring Diagram(2/2)(95ZIV) (97C3-9001〜9050)

62-6

Electrical Wiring Diagram(1/2)(95ZIV)

95ZIV-3

ELECTRICAL 62

Electrical Wiring Diagram(1/2)(95ZIV) (S/N 97C3-9051〜)

62-7

Electrical Wiring Diagram(2/2)(95ZIV)

95ZIV-3

ELECTRICAL 62

Electrical Wiring Diagram(2/2)(95ZIV) (S/N 97C3-9051〜)

62-8

Layout of Electrical Equipment

95ZIV-3

ELECTRICAL 62

Layout of Electrical Equipment The connector numbers in the following figure correspond to those of electrical wiring diagrams.

ＯＰＴ ＩＯＮ

ＫＩＣＫＯＵＴ ＳＥＮＳＯＲ（ＯＰＴ ＩＯＮ）

ＢＵＣＫＥＴ ＰＯＳＩＴＩＯＮＥＲ

ＨＥＡＤ ＬＡＭＰ

ＨＯＲＮ

ＯＰＴ ＩＯＮ

ＡＩＲ ＨＯＲＮ（ＯＰＴ ＩＯＮ）

ＥＬＥＣＴＲＩＣＡＬ ＷＩＲＩＮＧ−ＲＥＡＲ ＣＨＡＳＳＩＳ （１／２）

Front chassis

９７Ｊ６２００３

62-9

ＳＰＡＲＥ

62-10 ＩＮＣＨＩＮＧ ＳＷＩ ＴＣＨ

ＥＬＥＣＴＲＩＣＡＬ ＷＩＲＩＮＧ−ＲＥＡＲ ＣＨＡＳＳＩＳ（１／２）

ＯＰＴ ＩＯＮ

ＦＵＳＥ ＢＯＸ

ＳＨＩＦＴ ＬＥＶＥＲ

ＰＡＲＫＩＮＧ ＳＷＩ ＴＣＨ

Ｐ ＩＬＯＴ ＶＡＬＶＥ

ＰＵＳ（ＱＵＡＤ） ＳＷＩ ＴＣＨ

Ｔ／Ｍ ＣＵＴ ＯＦＦ ＳＷＩ ＴＣＨ

ＣＯＬＤ ＳＴＡＲＴＥＲ

４−ＷＡＹ ＦＬＡＳＨＥＲ

ＳＴＡＲＴＥＲ ＳＷＩ ＴＣＨ

ＳＴＯＰ ＬＡＭＰ Ｓ／Ｗ

ＯＰＥＲＡＴ ＩＯＮ ＳＴＡＮＤ

ＷＯＲＫＩＮＧ ＬＡＭＰ（ＲＥＡＲ）

ＷＯＲＫＩＮＧ ＬＡＭＰ（ＣＡＢ）（ＯＰＴ ＩＯＮ）

ＣＯＭＢＩＮＡＴ ＩＯＮ ＳＷＩ ＴＣＨ

ＨＯＲＮ ＲＥＬＡＹ

ＥＬＥＣＴＲＩＣＡＬ ＷＩＲＩＮＧ−ＲＥＡＲ ＣＨＡＳＳＩＳ（１／２）

ＴＯ ＡＩＲＣＯＮ ＵＮＩＴ （ＯＰＴ ＩＯＮ）

ＥＬＥＣＴＲＩＣＡＬ ＵＮＩＴ

（ＯＰＴ ＩＯＮ）

ＯＰＴ ＩＯＮ

４−ＷＡＹ ＦＬＡＳＨＥＲ

ＴＵＲＮ ＳＩＧＮＡＬ ＦＬＡＳＨＥＲ ＲＥＬＡＹ

Layout of Electrical Equipment 95ZIV-3 ELECTRICAL 62

Floor board and cab

９７Ｊ６２００４

62-11

ＥＬＥＣＴＲＩＣＡＬ ＷＩＲＩＮＧ− ＦＲＯＮＴ ＣＨＡＳＳＩＳ（１／２）

ＰＲＥＳＳＵＲＥ ＳＷＩ ＴＣＨ （ＦＯＲ ＡＩＲーＣＯＮ）

ＳＴＡＲＴＥＲ ＭＯＴＯＲ

ＰＡＲＫＩＮＧ ＳＯＬＥＮＯＩＤ

ＷＡＳＨＥＲ ＭＯＴＯＲ

ＦＵＳＩＢＬＥ ＬＩＮＫ

ＡＵＴＯ ＢＲＡＫＥ ＳＯＬＥＮＯＩＤ

Ｅ／Ｇ ＴＡＣＨＯーＳＥＮＳＯＲ

ＥＬＥＣＴＲＩＣＡＬ ＷＩＲＩＮＧ− ＦＬＯＯＲ ＢＯＡＲＤ（１／２）

ＡＩＲ ＣＬＥＡＮＥＲ

ＣＯＮＤＥＮＳＥＲ

ＶＯＬＴＡＧＥ ＲＥＬＡＹ

ＧＥＮＥＲＡＴＯＲ

Ｅ／Ｇ ＷＡＴＥＲ ＴＨＥＲＭＯ ＳＥＮＳＯＲ

ＴＨＥＲＭＯ ＳＷＩ ＴＣＨ （ＦＯＲ ＣＯＬＤ ＳＴＡＲＴＥＲ）

ＭＡＧＮＥＴ ＳＷＩ ＴＣＨ

ＢＡＴＴＥＲＹ ＲＥＬＡＹ

Ｅ／Ｇ ＷＡＴＥＲ ＴＨＥＲＭＯ ＳＷＩ ＴＣＨ

Layout of Electrical Equipment 95ZIV-3 ELECTRICAL 62

Rear chassis(1/2)

９７Ｊ６２００５

62-12 Ｔ／Ｍ ＳＯＬＥＮＯＩＤ ＶＡＬＶＥ

Ｔ／Ｍ ＯＩＬ ＴＨＥＲＭＯ ＳＷＩ ＴＣＨ

ＳＰＥＥＤ ＳＥＮＳＯＲ （ＦＯＲ ＡＵＴＯ−ＳＨＩＦＴ）

Ｔ／Ｃ ＯＩＬ ＴＨＥＲＭＯ ＳＥＮＳＯＲ

Ｔ／Ｃ ＯＩＬ ＴＨＥＲＭＯ ＳＷＩ ＴＣＨ

Ｅ／Ｇ ＯＩＬ ＰＲＥＳＳＵＲＥ ＳＷＩ ＴＣＨ

ＦＵＥＬ ＶＡＬＶＥ

Ｅ／Ｇ ＴＡＣＨＯ− ＳＥＮＳＯＲ

ＥＴＨＥＲ ＳＯＬＥＮＯＩＤ

ＢＡＣＫ ＬＡＭＰ

ＬＩＣＥＮＳＥ ＬＡＭＰ

ＢＡＣＫ ＢＵＺＺＥＲ

ＷＯＲＫＩＮＧ ＬＡＭＰ

95ZIV-3

ＩＮＤＩＣＡＴＯＲ （ＦＯＲ ＬＩＮＥ Ｆ Ｉ ＬＴＥＲ）

ＥＬＥＣＴＲＩＣＡＬ ＷＩＲＩＮＧ−ＦＬＯＯＲ ＢＯＡＲＤ（１／２）

Ｃ

ＦＵＥＬ ＳＥＮＤＩＮＧ ＵＮＩＴ

ＡＩＲＣＯＮ ＣＯＭＰＲＥＳＳＯＲ

ＢＡＴＴＥＲＹ

ＷＡＴＥＲ ＬＥＶＥＬ ＳＥＮＳＯＲ

ＲＥＡＲ ＣＯＭＢＩＮＡＴ ＩＯＮ ＬＡＭＰ

Layout of Electrical Equipment ELECTRICAL 62

Rear chassis(2/2)

９７Ｊ６２００７

Electrical Connection Diagram(95ZIV)

95ZIV-3

ELECTRICAL 62

Electrical Connection Diagram(95ZIV) (97C3-9001〜9050)

62-13

Electrical Connection Diagram(95ZIV)

95ZIV-3

ELECTRICAL 62

Electrical Connection Diagram(95ZIV) (S/N 97C3-9051〜)

62-14

Layout of Electrical Equipment

95ZIV-3

ELECTRICAL 62

Layout of Electrical Equipment Inside Cab Control Box

４

５

１

３

２

９７Ｊ６２００８

1. Transmission controller 2.Monitor controller 3. Fuse box 4. Fuse box 5. Circuit protector

62-15

Layout of Electrical Equipment

95ZIV-3

ELECTRICAL 62

Layout of Electrical Equipment Around Battery Relay

５

３

４

２

５ＢＷ

Starter

ＲＬ ＷＢ

５Ｒ １００Ｂ

１ １００Ｂ

５Ｗ

５Ｒ

ＷＬ

ＷＢ Ｂ Ｂ

２０Ｂ ２０Ｂ

５Ｗ

To alternator terminal (B)

６

５Ｒ ５Ｗ

To rear chassis harness

ＷＬ

To rear chassis harness

Ｂ

To rear chassis To battery (+) harness

９７ＺＡ６２０６

1. Battery relay 2. Voltage relay 3.Magnet switch 4. Fusible link (30A, Spare 70A) 5. Fusible link (70A, 70A) 6. Diode unit

62-16

Fusible Link/Fuse

95ZIV-3

ELECTRICAL 62

Fusible Link/Fuse For the purpose of protection, the electrical circuit has fusible link and fuses.

１５Ａ １０Ａ ５Ａ １５Ａ １５Ａ １５Ａ １５Ａ １５Ａ ５Ａ ５Ａ ５Ａ ５Ａ

BUZZER INSTRUMENT PANEL

RADIO

COLD STARER

SPARE

１０Ａ

１０Ａ

F. WORK LIGHT

１０Ａ

１０Ａ

PARKING BRAKE CONTROLLER

１０Ａ

BACK LAMP STOP LAMP TURN SIGNAL

１０Ａ

２０Ａ

F. WIPER

BOOM KICKOUT BUCKET POSITIONER

１０Ａ

・ 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.

R. WIPER

R. WORK LIGHT

５Ａ

IMPORTANT

FR WIPER

LIGHTING HEAD LIGHT

５Ａ

Possible burn hazard. Before replacing a fuse, be sure to turn off the starter switch.

FL WIPER

５Ａ

CAUTION

Fuse inside the control box

SPARE

SPARE

CIGARETTE LIGHTER

３Ａ

SPARE

SPARE

５Ａ

4WAY FLASHER HORN

SPARE

５Ａ

SPARE

AIRCON

５Ａ

SPARE

AIRCON

２０Ａ

FUEL VALVE

AIRCON

２０Ａ

NEUTRAL RELAY

SPARE

２０Ａ

BATTERY RELAY

62-17

Fusible Link/Fuse

95ZIV-3

ELECTRICAL 62

Fusible link 12V

12V

30A W5 BATTERY

1.25

B

AC C

R2

WL

5A (WBr)

BR

WR

F15

WR R1

5A

F12

RELAY, BATTERY

70A

(WBr)

G 1.25

5A

G 1.25 F14

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.

(A)

COLD STARTER SW

F7 WB

15A

THERMO SW

ETHER KIT

WP

Fusible link

STARTER

Cover

B C

Fuse element

MAGNETIC SWITCH BW 5 VOLTAGBE RELAY RL 1.25 NR

(Lg)

(WG) WL

F6

MONITOR CONTROLLER

LAMP, CHARGE ALTERNATOR R

20 70A

Box for fusible link

B E

(B)

Fusible link

1.25

WR

85Z Ⅳ US6206

F13

WR

5A

FUEL VALVE

９０Ｖ６２００７

Problems caused by fused fusible link Fuse damaged

Fusible link

Problem (symptom) During engine operation

During engine stop

30 A

・Engine will be stopped. ・All the power for all electrical circuit will be OFF.

・All the electrical circuit will not function. ・Engine can not be started.

70 A (A)

・Engine can be stopped. ・The same conditions as ・Horn will operate. "During engine operation" ・All the others will not operate but engine can be started and the machine can not be and stopped. operated.

70 A (B)

・The machine can be operated but the batteries can not be ・The same conditions as charged and the batteries will "During engine operation". be discharged soon.

62-18

Engine Start Circuit

95ZIV-3

ELECTRICAL 62

Engine Start Circuit (S/N 97C3-9001〜9050)

Starter switch B

C

BR

OFF

Fusible link

ON START

Battery (24V)

T/M controller

R

N

Forward/reverse position

F15

F

Shift lever

5A Battery relay Diode unit Starter motor

From alternator F14 +24V

LED (Indication:NR)

Magnet sw

5A 3 4 1

2

Neutral relay Voltage relay +24V Alternator * When shift lever is in N position/LED OFF When shift lever is in F/R position/LED ON

９５Ｖ６２００８

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 neutral relay, magnet switch and voltage relay. Therefore, current will flow through the starter motor, and the engine will start. The "N" LED will be off.

62-19

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.

Engine Start Circuit

95ZIV-3

ELECTRICAL 62

Engine Start Circuit (S/N 97C3-9051〜)

Starter switch B

C

BR

OFF

Fusible link

ON START

Battery (24V)

T/M controller

R

N

Forward/reverse position

F15

F

Shift lever

5A Battery relay Diode unit Starter motor

From alternator F14 +24V

LED (Indication:NR)

Magnet sw

5A 3 4 1

2

Neutral relay Voltage relay +24V Alternator ＊ When shift lever is in N position/LED ON When shift lever is in F/R position/LED OFF

９５Ｖ６２００８

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 magnet switch via the neutral relay. Therefore, current will flow through the starter motor, and the engine will start. The "N" LED will be on.

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 magnet switch, therefore the engine will not start. The "N" LED of the output circuit is off.

62-20

Engine Start Circuit

95ZIV-3

ELECTRICAL 62

Starter switch OFF 30 ° RUN 35 ° START

97K62040 ８５ＺⅣ ＵＳ６２０８

Connection table B

○

Run

○ ○

Start

○ ○ ○ To magnet switch

９７Ｋ６２００７

C

Off

From battery

BG

BR

To battery relay

BW

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. Run : Supplies power to the charge, lamp, and monitor circuits. Start : Starts the engine.

62-21

Engine Start Circuit

95ZIV-3

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. 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.

Terminals for coil energizing current

Moving contact Main contacts

BR

Coil for energizing

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.

starter switch BR

B

Battery relay Rated voltage

Battery Relay Main circuit

DC24V

Rated current

Continuous 100A

Voltage drop

0.2V or less(at 100A)

Pull in voltage

20V or less

Release voltage

6V or less

(BR)

From charging circuit

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. Ｎ６

WV: To battery relay WR: To starter switch teminal BR (VIA F15), N301 fuel solenoid N701 N702 WL: To alternator

Diode storage section ９７Ｋ６２００９

62-22

(B) (E)

Terminals for main current

Engine Start Circuit

95ZIV-3

ELECTRICAL 62

Neutral relay (The structures of the back relay and the controller unusual relay is identical to each other) (S/N 97C3-9001 〜 9050) ４ ２

３

１

５

３

１

５

２

４

Rating

24V・10A

Position of shift lever

Between 1 or 2

Between 3 or 4

Starting

Operating voltage Reset voltage

16V or less

F or R

Energized

OFF

Impossible

1.2V or more

N

Not energized

ON

Possible

Neutral relay (The structures of the back-up relay are identical to each other) (S/N 97C3-9051〜)

Body black

3

1

4

2

Internal connection dia. ６５Ａ６２２０４

62-23

Position of shift lever

Between 1 and 2

Between 3 or 4

Starting

F or R

Not energized

OFF

Impossible

N

Energized

ON

Possible

Engine Start Circuit

95ZIV-3

ELECTRICAL 62

Magnet switch Ｒａｔ ｉ ｎｇ ２４Ｖ×２００Ａ

９７ＺＡ６２１１

Voltage relay Voltage relay

９７ＺＡ６２１２

62-24

Contact point closed

6 V

Contact point open

9 V

Alternator/Charge Circuit

95ZIV-3

ELECTRICAL 62

Alternator/Charge Circuit The alternator/charge circuit generates and supplies electric power to all the electric units of the vehicle. The circuit consists of the alternator, regulator, and battery, etc.

Mechanical energy supply Engine

Alternator

The alternator utilizes the engine rotational power to generate electric current (3-phase alternating current), and then rectifies the current (full-wave rectification) into direct current using 6 diodes. The direct current is then supplied to the battery, light circuit, etc. The current generated by the alternator causes voltage fluctuation depending on the engine speed or load. To prevent voltage fluctuation, the regulator in this circuit regulates the current and ensures constant voltage supply to the load circuit and the battery.

Electrical energy

Rotor coil excitation current

Generated voltage IC regulator

Regulated voltage For rotor coil initial excitation

For activation of battery relay

For activation of battery relay

For rotor coil initial excitation

Ａｃ ｔ ｉ ｖａｔ ｉ ｏｎ ｏ ｆ ｌ ｏａｄ ｃ ｉ ｒｃｕ ｉ ｔ

<Load>

Ｃｈａｒｇｉｎｇ ｂａｔ ｔ ｅ ｒ ｙ

<Starter switch>

<Battery>

Alternator Construction

Ｓ ｔ ａ ｒ ｔ ｅ ｒ

Ｒｅｃ ｔ ｉ ｆ ｉ ｅ ｒｂ ｒ ｉ ｄｇｅ

Ｖｏ ｌ ｔ ａｇｅ ａｄ ｊ ｕｓ ｔｍｅ ｔ

Ｂａｔ ｔ ｅ ｒ ｙ

Ｆ ｉ ｅ ｌ ｄ

Ｄ ｉ ｏｄｅ ｔ ｒ ｉ ｏ

Ｒｅｇｕ ｌ ａ ｔ ｏ ｒ ９７ＺＡ６２１５

62-25

Engine Stop Circuit

95ZIV-3

ELECTRICAL 62

Engine Stop Circuit When the starter switch is turned to ON, the fuel valve solenoid is activated to open the fuel valve to start the engine.

Fuel valve Rating voltage

DC24V

Coil resistance

Approx. 30 Ω

When the starter switch is turned to OFF, the fuel valve is closed to stop the engine. If the fuel valve fails, or if the electric system malfunctions, the emergency starting function can be used as follows. Screw the manual operation screw of the fuel valve to open the fuel circuit. And then the engine can be started.

(-) Short (+) Long

Solenoid Fuel

Valve plate

Manual operation screw (Screw-in:Engine run position)

FUEL VALVE

62-26

９７ＺＡ６２１８

Transmission Control and Monitor Circuit

95ZIV-3

ELECTRICAL 62

Transmission Control Circuit and Monitor Circuit Controller

LED inspection windows

There are various IC's inside the controller. The IC's have programs for various functions described later.

IN (input signal) Signal

symbol

IMPORTANT If the controller malfunctions, be sure to replace the controller assembly. Do not replace or repair any parts.

LED

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

Auto shift cancellation

S

Shift switch ON

P

Parking switch OFF 〔Running position〕

I

Inching switch ON

SI1 Spare SI2 Spare OUT (output signal) Signal

symbol

X

Controller failure

RR Back relay ON

D5

D6

DC Modulator valve 2 ON

D9

L

Low clutch solenoid valve ON

H

High clutch solenoid valve ON

R

Reverse clutch sol. valve ON

BZ

Buzzer

N

Neutral relay ON

９５Ｗ６２００１

Note: 1. The couplers are shown for controller side. 2. The following symbol are the same as the ones used for the wiring diagram.

BRK Auto brake sol. valve ON

Connector D5(input) No.

Symbol

1

I

Inching switch (+)

Signal

2

A

Auto shift

No.

4

5V

Spare 1 +

2nd clutch sol. valve ON

3

3rd clutch sol. valve ON

Connector D6(output) Signal

Signal

Connect D9 (output)

No.

No.

Symbol

1

4R

4 (right) lamp

1

3

3rd clutch sol. valve

Signal

Power for diff. press. sensor

2

3R

3 (right) lamp

2

2

2nd clutch sol. valve

3

2R

2 (right) lamp

3

1

1st clutch sol. valve

+24V

4

1R

1 (right) lamp

4

PC+ Modulator valve 1 (+)

1

Shift lever 1 (+)

5

R

Shift lever R (+)

5

4L

4 (left) lamp

5

BZ

Buzzer

6

EG

Engine rev. sensor (+)

6

3L

3 (left) lamp

6

R

Reverse clutch sol. valve

7

2L

2 (left) lamp

7

H

High clutch sol. valve

7

Engine rev. machine COM speed (−)

8

1L

1 (left) lamp

8

L

Low clutch sol. valve

8

SP

9

SG

Spare

9

DC

Modulator valve 2

9

GND GND

Machine speed sensor (+)

20

1st clutch sol. valve ON

2

Symbol

Symbol

18 SSG Diff. press. sensor signal 19

3

1

10 RXD Spare

10 BRK Auto brake solenoid valve

10

A

Shift lever A (+)

11 TXD Spare

11

PC-

Modulator valve 1 (-)

11

3

Shift lever 3 (+)

12

12

G2

Solenoid valve (-)

12

2

Shift lever 2 (+)

13

A

Auto lamp

13

P

Parking switch (+)

14

AB

Auto brake lamp

14

S

Shift switch (+)

15

N

Neutral lamp

15

F

Shift lever F (+)

16

X

Controller relay

16

M

Auto shift cancellation (+)

17

RR

Back relay

17

D

For switch input (−)

18

NR

Neutral relay

Spare

62-27

Transmission Control and Monitor Circuit

95ZIV-3

ELECTRICAL 62

T/M Controller connection diagram ＢＲ

Ｅ ７Ａ

Ｆ５

Circuit protecter Parking solenoid

ＣＰ

１０Ａ Ｆ６ （Ｌｇ） ５Ａ

ＬＲ

T/M clutch solenoid valve

（Ｙ） １ （Ｇ） ２ Ｗ ３ （Ｌ）

Modulator valve 2

ＤＣ

（Ｂｒ）

ＳＰＰＣ

ＢＹ

ＢＹ

ＳｂＹ

１２ ３Ａ

ＧＹ

ＬＹ ＧＹＧ

ＬＧ ＬＯ

ＧＹＬ

ＬＷ

Machine speed sensor

Ｙ

ＬｇＬ ＳｂＯ

Ｙ

E/G rev. sensor

Ｗ

Ｓｂ

Ｗ

（Ｐ）

Modulator valve 1

Ｒ Ｎ Ｆ

Buzzer ＬｇＢｒ

（Ｌｇ）

Neutral relay

ＮＲ

Controller relay

Ｘ

Back relay

ＲＲ

（ＳｂＰ）

ＬｇＢｒ

Ｎ １ ２

Monitor lamp on instrument panel

３ ４ ＡＢ

Ｇｏ

Oil level sensor （ＬＢ）

ＹＲ

（Ｖ）

ＹＢ

（Ｂｒ）

（Ｌｐ） （ＧＲ）

ＹＬ

ＢｒＹ ＳｂＬｇ

（ＬＹ）

ＹＢｒ

ＲＸＤ

ＹＧ

ＴＸＤ

ＢＬ

Parking switch

ＳｂＹ

Brake oil press. (main) Ｂ

Brake oil press. (diff)

Ｂ

Brake oil level

ＧＹ

E/G oil press.

ＧＹＧ

E/G water temp.

ＧＹＬ

T/M oil temp.

ＬｇＬ

Air cleaner

ＳｂＯ

ＳｂＲ

T/M oil filter Radiator water level Alternator terminal N Fuel revel sensor

（Ｌｗ） （Ｏ）

ＡＵＴＯ

ＧＹＢ

Sift lever

（Ｓ） Ｒ

T/M CONTROLLER

（ＧＹ） Ｈ

Centralized alarm lamp

ＬＢｒ

MONITOR CONTROLLER

（Ｒ） Ｌ

ＢＲ

ＹＲ

Ｆ

ＹＢ

３／４ １／２ １／４

ＹＬ ＹＢｒ ＹＧ

Ｅ

３／４ １／２ １／４ １／８ ＥＭＰＴＹ

ＳＧ

（ＬＧ） （ＬＯ）

Shift switch

（Ｌｗ）

Ｄ

（ＧＹ）

Ｒ （ＢＹ）

Ｄ Ｒ ＯＮ

Ｆ６

（Ｓｂｗ）

（Ｌｇ）

（ＬｇＧ）

Parking sol

ＯＦＦ ＯＮ ＯＦＦ

（ＧＯ）

Auto brake solenoid

ＷＯ

Parking switch

（ＢＹ）

Inching switch （ＬｇＲ）

（ＬＬｇ）

T/M cut off Ｆ６

T/M cut off switch

Controller failure Centralized alarm lamp

（Ｌｇｗ）

（ＧＹＢ）

Ｘ

Monitor controller Ｅ

62-28

９７Ｊ６２００８

Transmission Control Circuit and Monitor Circuit

Forward/reverse(F/R)shifting change

and

95ZIV-3

ELECTRICAL 62

speed From T/C pump

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.

Clutch press regulator valve

To solenoid valve Clutch piston

Drain

Clutch control solenoid valve

energized → clutch engage de - energized → clutch disengage

Clutch solenoid valve

LED(indication: F)

L

Shift lever

Shift switch

LED (indication: F)

H

(For input detection)

R

Surge suppression diode (incorporated in solenoid valve)

LED(indication: S) 1

2

Speed indicator lamp Speed sensor

Engine rev. sensor

7 segment LED(indication: Character)

LED (indication:2)

7 segment LED(indication: Character)

LED(indication: M)

Auto/manual switching (Switch on:Manual)

3

Common ground

Auto indicator lamp

Setting shift lever to A:Switch on ９７ＺＡ６２２１

*Input detection

Shift lever : 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. (For rev. 2nd to 3rd.) Operator controlled shifting from 2 → 1 → 2 in either "2" or "A" is done by momentarily depressing the QUAD switch on the boom lever.

62-29

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) indicator 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

95ZIV-3

ELECTRICAL 62

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.

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, the lowest speed clutch 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 segment LED indicates in characters according to the pulse.

Speed 4 3 2

13.5 11.5 Reverse

0

10 12

Speed km/h

17 20 Forward (Approx. speed)

7 segment LED indication Machine speed LED

Indication 0

Machine speed (km/H) 0

16

32

E/G rev. LED

E/G rev. (rpm) 0

1

1

17

160

2

2

18

320

3

3

19

480

4

4

20

640

5

5

21

800

6

6

22

960

7

7

23

1120

8

8

24

1280

9

9

25

1440

A

10

26

1600

b

11

27

1760

C

12

28

1920

d

13

29

2080

E

14

30

2240

F

15

31

2400

T/M controller

Displayed font Machine speed

E/G rev.

９７ＺＡ６２２２

62-30

Transmission Control Circuit and Monitor Circuit

95ZIV-3

ELECTRICAL 62

Switching from automatic to manual The machine has automatic shift cancellation function for troubleshooting. Turn the controller dip switch No.6, 7 and 8 to ON position. 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.

IMPORTANT The automatic gear shifting cancellation capability is only for use for diagnosing a problem, and after diagnosis, the automatic gear shifting capability must be restored.

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).

ＱＵＡＤ ｓｗｉ ｔ ｃｈ

７０Ｖ６２００３

Shift lever *Shift lever position

Ｓｈ ｉ ｆ ｔｌ ｅｖｅ ｒ

Grounding for speed change side(B)

2nd speed(GL) 3rd speed(GY)

F(GR)

(N)

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 (N) position.

1st speed(GW) Auto(G)

neutral

Unused

Grounding for F/R side(BY)

R(GB) ９５Ｖ６２０１２

62-31

Transmission Control and Monitor Circuit

95ZIV-3

ELECTRICAL 62

Clutch solenoid valve (Common to L. H. R. 1. 2. 3 ) 10〜14.7N-m (1〜1.5kgf-m) Solenoid valve(with built-in diode)

Negative− side

Rated voltage

DC24V

Coil resistance value

Approx. 24 Ω

Positive side ＋

49〜59N-m (5〜6kgf-m)

９５Ｃ６２００４

QUAD switch

Allowable value

The QUAD switch is of the momentary type. It is spring loaded to the "OFF" position.

Max Voltage

DC24V

Current

10mA

９７ＺＡ６２２６

Sensor for machine speed and E/G revolution The detectors are adjacent to the transmission output gear (machine speed) and to the torqueconverter PTO drive gear (E/G rev.) .

25 ± 0.25

The pulse voltage is transmitted to the transmission controller. The pulse of machine speed sensor is used for auto-shift, auto-brake and the pulse of E/G rev. sensor is used for clutch pressure modulation.

20〜29N-m (2〜3kgf-m)

Output gear

Clearance adjustment 0.7〜1.3mm

９５Ｃ６２００５

IMPORTANT At the completion of sensor replacement, be sure to check the clearance between the gear and the sensor (Refer to Section 63).

62-32

Output

1V or more

Internal resistance ＊

1.6k Ω (20 ℃ )

＊ Internal resistance changes greatly with temperature. At lower temperature resistance is lower. At operating temperature the resistance increases. If resistance is 0 Ω or ∞Ω the speed sensor is defective.

Transmission Control Circuit and Monitor Circuit

95ZIV-3

ELECTRICAL 62

Diff. press. sensor

Modulator valve (2)

Ｅ／Ｇ ｒｅｖ．ｓｅｎｓｏｒ

To T/M clutch

Ｍａｃｈ ｉ ｎｅ ｓｐｅｅｄ ｓｅｎｓｏｒ

To T/C

９５Ｖ６２０１３

Modulation at clutch switching The rise time of clutch oil pressure is controlled by modulator valve (1) and modulator valve (2) to shorten the time lag and reduce shock that occurs when shifting between forward and reverse, and between gears.

Modulator valve (1) From pump

Modulator valve unit

Modulator valve (1) Modulator valve (2) Diff. press. sensor

T/M controller F

Shift lever

4 3 2

Clutch oil differential press. sensor

1

Clutch selection input signal

N

R

+24V

Output current control

Modulator valve (1)

No output LED is provided

On during modulation +24V

Modulator valve (2) Output LED (indication:DC)

E/G rev. sensor Machine speed sensor

62-33

９７ＺＡ６２２７

Transmission Control and Monitor Circuit

95ZIV-3

Modulator valve (1) [MV1]

ELECTRICAL 62

Operation of modulator valve (1), (2)

Clutch oil pressure during clutch application is controlled according to the current passing through the coil of MV1 . The pressure rises and falls along with the current.

Clutch selection

ＯＮ Low clutch sol. valve

Operation (1) Initial charging (t1) The current flow through the coil of MV1 immediately after clutch selection is maintained as high as it was before clutch selection (400 mA). This allows a lot of oil to flow rapidly into the empty clutch piston chamber, reducing the time lag. (2) Charging (t2) On completion of the initial charging, the current through the coil of MV1 is sharply reduced (170 mA). This reduced current is maintained until the end of the charging to prevent a sudden pressure rise and shift shock. (3) Completion of the charging The differential pressure sensor of the modulator valve unit sends electrical signal to the transmission controller. When the charging is completed, due to no pressure difference between the orifices in the line, the transmission controller determines it by the signal sent from the sensor. Then the transmission controller sends signal to rise the current through the MV1 coil gradually. (4) Pressure rise (t3) The clutch oil pressure rises gradually in proportion to the current rise. Note:・If the MV1 coil is damaged or disconnected, the clutch oil pressure rises 2 only 0.2 〜 0.5MPa (2 to 5kgf/cm ) and the pressure value is not enough to engage the clutch. ・Transmission controller prevides the protection program so as to rise the control current again at the time of 0.5 seconds after decreasing the MV1 control current when the differential pressure sensor is damaged.

1st clutch sol. valve

ＯＦＦ ＯＮ Completion of charging

Modulator valve (1) Current flow (mA)

Approx. 400mA

Approx. 170mA

０ ＯＮ Modulator valve (2)

ＯＦＦ

Pressure Main pressure (kg/cm2)

Ｐ２

Ｐ１

０

Low clutch pressure

62-34

Pressure 2 (kg/cm )

０

ｔ１ ｔ２

ｔ３

ｔ４

Ｐ３

Transmission Control and Monitor Circuit

95ZIV-3

Modulator valve (2) [MV2] This valve assists MV1 in controlling (lowering) the clutch oil pressure. Unlike MV1, it performs an ON and OFF operation. (1) Controlling the clutch oil pressure Modulator valve (2) is energized simultaneously when the current in MV1 changes from high to low current flow. It is de-energized some time after the current in MV1 returns to a higher level and the clutch oil pressure reaches the specified value. Note: Modulator valve (2) If MV2 is damaged or disconnected, the machine will have severe shift shock during clutch engagement. In this case, the lowest clutch pressure will be only about 0.7 〜 1.0MPa (7 〜 2 10kgf/cm ) during charging. The highest clutch oil pressure reaches the specified value.

62-35

ELECTRICAL 62

Transmission Control Circuit and Monitor Circuit

95ZIV-3

ELECTRICAL 62

Transmission cut - off (Inching) The operator may select, by means of a switch, the transmission cut ー off function. In the "ON" position the brake pedal (left or right), when depressed, will place the transmission in neutral and apply the service brakes. In the "OFF" position the brake pedal operates the service brakes only. When the brake pedal (left or right) is depressed with the selector switch "ON", a pressure switch (inching) is actuated (LED ON). The input LED indicates: "I" on the controller lights up. The transmission controller turns off the power to the forward / reverse clutches (L. H. R.), causing the transmission to be placed in neutral. The dush board monitor lamp "N" lights up.

Ｐｒ ｅｓｓｕ ｒ ｅ ｓｗｉ ｔ ｃｈ （Ｉ ｎｃｈ ｉ ｎｇ）

Ｂｒ ａｋｅ ｖａ ｌ ｖｅ （Ｒ ｉ ｇｈ ｔ） Ｐｒｅｓｓｕｒ ｅ ｓｗｉ ｔ ｃｈ （Ｂｒ ａｋｅ ｌ ａｍｐ）

Ｂｒ ａｋｅ ｖａ ｌ ｖｅ （Ｌｅ ｆ ｔ） ６５Ａ６２００１

Clutch cut-off switch (Located on operator's LH console) Transmission controller Forward/reverse clutch solenoid valves

Ｆ６

(Indication:Ｉ)

Transmission cut-off

ＢＹ

６５Ａ６２００２

Inching pressure switch

Operation pressure 2

1.13±0.15MPa(11.5±1.5kgf/cm )

1. Case 2. Seal 3. Packing 4. Disc 5. Inner lid 6. Guide pin 7. Spring 8. Contact 9. Contact 10. Connector 11. Connector 12. Base ６５Ａ６２００３ 13. Cover (Connector) 14. Guide 15. Stopper 16. Connector 17. Housing

Contact Normal open

Return pressure 2

0.90±0.1MPa(9.2±1.0kgf/cm ) 62-36

Transmission Control and Monitor Circuit

95ZIV-3

ELECTRICAL 62

Back-up alarm When the shift lever is placed in the R position, the back-up lamp relay coil is energized. It's main contacts are turned ON, lighting the lamps and sounding the buzzer.

F4 15A

T/M controller

Back-up lamp Back-up relay (indication: R)

Back-up buzzer (opt)

Shift lever F6 5A

LED (indication: RR)

ON with lever in R OFF with lever in other than R ９５Ｖ６２０１７

Back-up relay (S/N 97C3-9001〜9050)

4 2 1

5

3

1 2

5

4

Rating

24V・10A

Shift lever position

Operation voltage

16V or less

R

Reset voltage

1.2V or more

3

F or N

62-37

Between 1and 2

Between 3 and 5

Lamp and buzzer

Electric power supply

ON

ON

No electric power supply

OFF

OFF

Transmission Control and Monitor Circuit

95ZIV-3

ELECTRICAL 62

Back-up relay (S/N 97C3-9051〜) 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

62-38

Transmission Control and Monitor Circuit

95ZIV-3

ELECTRICAL 62

Parking brake The parking brake solenoid valve activates the parking brake.

In parking mode (shown below) :

In running mode :

When the power of the solenoid valve is turned off, no pressurized oil will be fed to the oil 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

For front parking brake: When the power of the solenoid valve is turned on, pressurized oil will be discharged from parking disc brake (dry type brake) and returned to the oil tank to release the brake. For rear parking brake: When the power of the solenoid valve is turned on, pressurized oil will be fed into the oil cylinder. The pressurized oil will depress the spring to release the brake. In addition, the "P" LED indicator will light.

+24V

F6 P Parking switch

Monitor lamp

Parking brake solenoid valve

Parking Parking brake Oil cylinder

Running

L +Vcc LED indication「P」 C.P

H

P

R

F5 10A

+24V ９５Ｃ６２００６

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

Not energized

Input "P" LED indicator : Off

Running

"Running" position (pushed in)

Off

No buzzer

Energized

Input "P" LED indicator : On

＊ When the parking switch is set to "parking", the forward or reverse clutch is disengaged and set to neutral.

62-39

Transmission Control and Monitor Circuit

95ZIV-3

ELECTRICAL 62

Parking brake solenoid valve

Solenoid valve (with diode) （＋）

（−）

Ｍａｎｕａ ｌ ｏｐｅ ｒ ａ ｔ ｉ ｏｎ ｋｎｏｂ （Ｐｕｓｈ ａｎｄ ｔ ｕ ｒ ｎｃ ｌ ｏｃｋｗｉ ｓｅ）

Rating

DC24V

Coil resistance

Approx. 25 Ω

ＡＢ

ＰＴ

Auto brake solenoid valve Parking brake solenoid valve

９５Ｗ６２０３５

９７Ｊ６２０１３

62-40

Transmission Control and Monitor Circuit

95ZIV-3

ELECTRICAL 62

Auto-brake Auto-brake applies the service brakes at a reduced 2 pressure 2.3MPa (23kgf/cm ) to prevent a sudden stop. This pressure provides smooth brake application. If the transmission is shifted between forward and reverse (or reverse to forward) when machine speed is above 12 km/hr. The auto-brake functions to protect the transmission. Auto-braking also occurs when machine speed reaches or exceeds a set limit. Auto-braking is actuated by a solenoid valve that engages the service brake. When the auto brake solenoid valve is energized by the signal from the controller, hydraulic oil flows from the pump to the check valve through the unloader valve and the brake valve (left side) pilot port. Then it operates the piston in the brake valve. High oil pressure from the unloader valve and the accumulator flows to the service brake through the brake valve and the auto adjuster valve, and operates the service brake pistons in proportion to the movement of the brake pedal. At this moment, LED BRK lights and the monitor lamp in the instrument panel goes on also the buzzer sounds. During auto-braking the transmission's forward/reverse clutches (L. H. R.) are disengaged and the transmission is placed in neutral until the set machine speed is reached. Input side

To service brake

To service brake

Check valve

Brake valve

Brake valve

T/M controller

From unloader valve (From pump) Auto brake solenoid valve From pilot supply at accumulator at reducing valve ９５Ｃ６２００７

Output side

Shift lever

Shift lever position signal (LEDs)

Auto brake solenoid valve +24V LED (indication:BRK)

Auto brake monitor lamp, buzzer Machine speed sensor signal (LEDs)

Machine speed sensor

+24V

L

Forward/reverse clutch solenoid valve

H R

９７ＺＡ６２３５

62-41

Transmission Control Circuit and Monitor Circuit

95ZIV-3

ELECTRICAL 62

Auto brake solenoid valve Parking brake solenoid valve

９５Ｃ６２００８

Rear axle

Auto-adjuster valve

Front axle

Brake valve

Brake valve Accumulator

From unloader valve Accumulator Auto brakke solenoid valve

９５Ｃ６２００９

62-42

Transmission Control and Monitor Circuit

95ZIV-3

・ When shifting between forward and reverse occurs above 12km/hr.

ELECTRICAL 62

Operation chart (Example:Shifting from forward to reverse) Machine Machine speed speed Shifting between 10km/H 2km/H forward and reverse

When shifting between forward and reverse is attempted with the shift lever in the "A" position and machine speed is over 12km/h, the auto-braking solenoid valve is energized. The service brakes are applied until the machine speed is reduced to 10km/hr. Immediately upon auto-braking, the forward or reverse clutch's solenoid valve is de-energized and the transmission is placed in neutral. Also the auto-brake indicator light on the solenoid and on the monitor panel are turned on. An alarm buzzer in the cab is also turned on. The service brake continues to be applied until 2km/hr is reached. (draining time from service brake piston chamber is required.) When shifting between forward and reverse is done with the shift lever in other than the "A" position, auto-braking does not occur.

Machine speed

F solenoid valve

OFF T/M in neutral

ON

OFF

R solenoid valve

ON Brake solenoid OFF valve Monitor lamp and buzzer

・ When machine speed is excessive

OFF

Service brake operating

Operation chart (Example:Machine speed excessive in forward direction)

When the machine speed reaches or exceeds the set value, the service brake is applied as in the above case. When the machine speed drops below the specified value, the service brake is released. During service brake application, the transmission is placed in neutral.

T/M in neutral

Machine speed F solenoid valve

Speed range

ON

ON

ON

Set value

OFF

1st

About 15km/hr

9.4 mph

2nd

About 22km/hr

13.8 mph

3rd

About 36km/hr

22.5 mph

4th

About 36km/hr

22.5 mph

Speed clutch solenoid valve

Brake solenoid valve

Auto brake solenoid valve

Monitor lamp and buzzer

ON

OFF

Service brake operating

（＋）

Solenoid valve (with diode) Rating

DC24V

Coil resistance

Approx. 25 Ω

ＡＢ

ＰＴ

９７ＺＡ６２３３

62-43

Transmission Control and Monitor Circuit

95ZIV-3

ELECTRICAL 62

Warning for transmission controller failure Should the transmission controller stop working due to any of the following causes, a dash mounted monitor lamp lights up to give warning. T/M controller failure monitor lamp (1) If a warning is given as a result of

self-diagnosis controller

of

the

transmission

Replacement of the transmission controller If the monitor lamp lights up under the conditions mentioned in (1) above, it is an indication that the

The transmission controller has a self-diagnosis function incorporated in it, and if the computer program becomes abnormal due to abuse or defect, a dangerous condition may occur, the monitor lamp lights up and all the outputs from the controller are turned OFF. In this case, the LEDs on the output circuit side of the controller will not be lit. Some input LEDs may still be operating (ON). (2) If the circuit protector (CP) is turned OFF If the circuit protector is automatically turned OFF due to a short circuit, etc, in the output circuit, the monitor lamp lights up and all the outputs from the controller are turned OFF. In this case, the none of the LEDs on the controller will be lit.

62-44

transmission controller's program has malfunctioned and the transmission controller assembly must be replaced. If the monitor lamp lights up under the conditions mentioned in (2) above, the cause is NOT the transmission controller. Once the cause is removed, the controller may be reset and continue to be used. To reset simply turn the circuit protector switch to "ON".

Transmission Control and Monitor Circuit

95ZIV-3

Emergency movement If the controller fails, or if the electric system malfunctions, the emergency movement function can be used as follows. (1) Parking brake manual release Start the engine to accumulate the pressure in the accumulator. Push and turn clockwise the manual operation knob of the parking brake solenoid valve. Remove the pin connecting the parking brake cylinder and the brake lever.

Ｐａｒｋ ｉ ｎｇ ｂ ｒ ａｋｅ ｃｙ ｌ ｉ ｎｄｅ ｒ

Ｒｅｍｏｖｅ ｔ ｈ ｉ ｓｐ ｉ ｎ

Ｂｒ ａｋｅ ｄｒｕｍ

９７ＺＡ６２３６

62-45

ELECTRICAL 62

WARNING Sudden accidental movement of the machine could result in serious injury or death. Before manually releasing the parking 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 start the engine to accumulate the pressure in the accumulator. After that, stop the engine.

Monitor Circuit

95ZIV-3

ELECTRICAL 62

Monitor Circuit Monitor During operation, if a problem of a unit is detected, the monitor lamp will light to inform the operator. For some problems, the buzzer will also sound, and the centralized alarm lamp will also flash.

62-46

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).

Monitor Circuit

95ZIV-3

Monitor controller There are various IC's inside the controller. The IC's have programs for various functions described later.

IMPORTANT If the controller malfunctions, be sure to replace the controller assembly. Do not replace or repair any parts.

Connector Connector pin layout F9

F0

＊ The couplers shown are for controller side.

Connector (F9) (Input) No. Symbol

Signal

９５Ｗ６２００６

Connector (F0) (Output) No. Symbol

Signal

1

EA

Alternator voltage

1

2

ES

Steering oil press. sw. (opt)

2

W

Centralized alarm sw.

3

1/8

Fuel level (1/8)

3

1/8

Fuel level lamp (1/8)

4

1/2

Fuel level (1/2)

4

1/2

Fuel level lamp (1/2)

5

EL

Engine oil level

5

F

Fuel level lamp (F)

6

TF

T/M oil filter sw.

6

7

WT

E/G water temp. sw.

7

TF

T/M oil filter alarm lamp

8

EP

E/G oil press. sw.

8

WT

Water temp. alarm lamp

9

BD

Brake press. diff. sw.

9

EP

E/G oil press. alarm lamp

10

P

Parking sw.

10

B

Brake oil press. alarm lamp

11

-

-

-

11

12

+

+24V

12

13

+

+24V

13

BZ

Buzzer

14

-

14

E

Fuel level lamp (E)

15

-

15

1/4

Fuel level lamp (1/4)

16

3/4

Fuel level lamp (3/4)

17

ES

Emergency steering lamp (option)

16

E

Fuel level (E)

17

1/4

Fuel level (1/4)

18

3/4

Fuel level (3/4)

19

WL

E/G water level sw.

18

WL

E/G water level alarm lamp

20

AC

Air cleaner sensor

19

AC

Air cleaner alarm lamp

21

TT

T/M oil temp. sw.

20

TT

T/M oil temp. alarm lamp

22

-

21

-

22

-

23

BM

Brake oil press. (Main) sw.

24

R

Delete

25

-

GND (-)

26

-

GND (-)

62-47

ELECTRICAL 62

Monitor Circuit

95ZIV-3

ELECTRICAL 62

ＢＲ

Ｅ ７Ａ

Ｆ５

Parking solenoid

ＣＰ １０Ａ Ｆ６

（Ｌｇ）

５Ａ

ＧＹＢ

Ｇｏ

C O N T R O L L E R

Centralized alarm lamp

ＳｂＹ

ＧＹ

Monitoro lamp at instrument panel

ＧＹＧ

ＧＹＬ

Parking switch

ＳｂＹ

Brake oil press. (main) Ｂ

Brake oil press. (diff)

Ｂ

Brake oil level ＧＹ

E/G oil press. ＧＹＧ

E/G water temp. ＧＹＬ

M O N I T O R

T/M oil temp. ＬｇＬ

ＳｂＯ

Ｓｂ

Buzzer ＬｇＢｒ

ＬｇＬ ＳｂＯ

Air cleaner ＳｂＲ

T/M oil filter Radiator water level

Alternator terminal N

Fuel level sensor ＹＲ

ＹＲ Ｆ

ＹＢ

Fuel level indiation lamp

ＹＬ

ＹＢｒ

ＹＢ

３／４

３／４

１／２

ＹＬ

１／２

１／４ ＹＢｒ

１／４

１／８

ＹＧ

ＹＧ Ｅ

ＥＭＰＴＹ

Ｄ

Ｒ

９７Ｊ６２０１７

62-48

Monitor Circuit

Air cleaner sensor

95ZIV-3

clogging

ELECTRICAL 62

Air filter clogging alarm sensor

alarm

Set value

９５Ｖ６２０２７

T/M oil filter clogging alarm switch

635±58mmAg or less

Continuity established across terminal and body.

Set value

0.3MPa 2 (3.15±0.28kgf/cm ) or more

Continuity established across terminals and body.

９５Ｖ６２０２８

62-49

Monitor Circuit

95ZIV-3

Ｃｏｏ ｌ ａｎ ｔｔ ｅｍｐ．ｓｅｎｓｏｒ

Ｃｏ ｌ ｄｓ ｔ ａｒ ｔ ｅ ｒｔ ｅｍｐ． ｓｗ ｉ ｔ ｃｈ

ELECTRICAL 62

Ｃｏｏ ｌ ａｎ ｔｔ ｅｍｐ．ａ ｌ ａｒｍ ｓｗ ｉ ｔ ｃｈ．

Ｅ／Ｇ ｃｏｏ ｌ ａｎ ｔ ｌ ｅｖｅ ｌａ ｌ ａｒｍ ｓｗ ｉ ｔ ｃｈ

Ｅ／Ｇ ｏ ｉ ｌ ｐｒｅｓｓｕｒｅ ａ ｌ ａｒｍ ｓｗｉ ｔ ｃｈ Ｔ／Ｍ ｏ ｉ ｌｔ ｅｍｐ． ａ ｌ ａｒｍ ｓｗ ｉ ｔ ｃｈ

Ｔ／Ｍ ｏ ｉ ｌｔ ｅｍｐ ｓｅｎｓｏｒ

Ｔ／Ｍ ｏ ｉ ｌｔ ｅｍｐ．ｓｗ ｉ ｔ ｃｈ

９７Ｋ６２０２２

Engine water temperature alarm switch Set value

101±2 ° C (214±3.6 ° F) or more

Continuity established across Set 120 C ±5 ° valueterminals (248±C9and F) NO. or more ° Continuity across Set 50established C ±2 ° and body. value terminal (122± 4° F) or more Continuity established across Set Less than specified terminal and body. value value No continuity established across terminal and body. 0.1MPa Set 2 (0.84±0.14kgf/cm ) value or less

T/M oil temperature alarm switch T/M oil switch

temperature

Engine coolant alarm switch

Engine oil alarm switch

level

pressure

Continuity established across terminals C and NO.

62-50

Instrument Panel

95ZIV-3

ELECTRICAL 62

Instrument Panel

10

20

0 100r/min30

⑥②

⑤

⑨

①

1. Tachometer 2. Engine Coolant Temperature Gauge 3. Torque Converter Oil Temperature Gauge 4. Fuel Level Gauge 5. Parking Brake Indicator Lamp 6. Auto Brake Indicator Lamp 7. Transmission Cut Off Selection Lamp 8. Rear Working Light Indicator Lamp 9. Central Warning Lamp 10. Transmission Control Warning Lamp 11. Brake Pressure Warning Lamp 12. Engine Oil Pressure Warning Lamp 13. Engine Coolant Temperature Warning Lamp 14. Torque Converter Oil Temperature Warning Lamp 15. Air Cleaner Warning Lamp

⑩ ⑪

0000001/10h

AUTO N 4 3 2 1

⑧

④

C

H

F

⑫ ⑬ ⑭ ⑮

E C

⑦

H

③

９７Ｊ６２０１９

16. Charge Lamp 17. Transmission Oil Filter Warning Lamp 18. Turn Signal Indicator Lamp (Left) (option) 19. Turn Signal Indicator Lamp (Right) (option) 20. High Beam Indicator Lamp 21. Auto Shift Indicator Lamp 22. Neutral Indicator Lamp 23. Transmission Status Monitor 24. Hour Meter 25. Steering Hydraulic Warning Lamp (option) 26. Coolant Level Warning Lamp 27. Working Light Switch (Front) 28. Working Light Switch (Rear) 29. Transmission Cut Off Selection Switch 30. Cold Starter Switch 31. Four-way Flasher Switch (option)

62-51