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95ZV

93215-00226

SHOP MANUAL General Information Function & Structure

Printed in Japan (K) ( ヨーロッパ・輸出一般用 )

93215-00226

September 2014

SHOP MANUAL WHEEL LOADER

95ZV General Information Standard Measurement Values for Performance Check Function & Structure Check & Adjustment Powered by CUMMINS QSX15 ENGINE Serial No. 97C4-0101 and up 97C4-9001 and up

93215-00226 September 2014

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

MACHINE SPECIFICATION Market

Serial numbers

Asia and Africa

97C4-0101 and up

Europe

97C4-9001 and up

Remarks Powered by CUMMINS QSX15 Engine

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

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

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

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

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

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

CONTENTS 00 General Information ......................................................................................................................................... 00-1 How to Use Manual ........................................................................................................................................... 00-2 Safety precautions ...................................................................................................................................... 00-2 Symbols ...................................................................................................................................................... 00-3 Outline ............................................................................................................................................................... 00-4 Layout of main components ........................................................................................................................ 00-4 Recommended lubricants ........................................................................................................................... 00-8 Coolant ..................................................................................................................................................... 00-10 Lubrication chart ........................................................................................................................................00-11 Weight of main components ..................................................................................................................... 00-12 Bolt tightening torque ................................................................................................................................ 00-13 Hose band tightening torque ..................................................................................................................... 00-17 Liquid gasket and screw lock agent .......................................................................................................... 00-18 Cautions regarding welding repair service ................................................................................................ 00-20 03 Measurement for Performance Check ............................................................................................................. 03-1 Cautions on Safety ............................................................................................................................................ 03-2 Standard Measurement Values for Performance Check ................................................................................... 03-3 12 Function & Structure Chassis Group ................................................................................................................ 12-1 Front Chassis .................................................................................................................................................... 12-2 Loading linkage ........................................................................................................................................... 12-2 Loading linkage pin ..................................................................................................................................... 12-4 Rear Chassis .................................................................................................................................................... 12-5 Fuel tank (S/N 0101~0262, 9001~9064) ..................................................................................................... 12-5 Fuel tank (S/N 0263~, 9065~) ..................................................................................................................... 12-6 Floor board mount ....................................................................................................................................... 12-7 Center Pin ......................................................................................................................................................... 12-8 Upper center pin ......................................................................................................................................... 12-8 Lower center pin ......................................................................................................................................... 12-8 Dust seal ..................................................................................................................................................... 12-9 13 Check & Adjustment Chassis Group ................................................................................................................ 13-1 Linkage Pin ....................................................................................................................................................... 13-2 Liner ............................................................................................................................................................ 13-2

Center Pin ......................................................................................................................................................... 13-5 Adjusting shim ............................................................................................................................................. 13-5 Grease nipple installation direction ............................................................................................................. 13-5 Installing bearing outer ring ......................................................................................................................... 13-6 22 Function & Structure Power Group .................................................................................................................. 22-1 Power Line ........................................................................................................................................................ 22-2 Engine / Transmission ....................................................................................................................................... 22-3 Engine / transmission mount ....................................................................................................................... 22-3 Radiator ............................................................................................................................................................. 22-4 Radiator mount ............................................................................................................................................ 22-5 Propeller Shaft .................................................................................................................................................. 22-6 Second propeller shaft assembly ................................................................................................................ 22-7 Third propeller shaft assembly .................................................................................................................... 22-8 Axle Assembly ................................................................................................................................................... 22-9 Axle Support .................................................................................................................................................... 22-12 Differential Gear .............................................................................................................................................. 22-18 Function of T.P.D ....................................................................................................................................... 22-22 Operation of T.P.D ..................................................................................................................................... 22-23 23 Check & Adjustment Power Group ................................................................................................................... 23-1 Engine ............................................................................................................................................................... 23-2 Measuring engine speed ............................................................................................................................. 23-2 Measuring engine oil pressure .................................................................................................................... 23-2 Propeller Shaft .................................................................................................................................................. 23-3 Propeller shaft phase .................................................................................................................................. 23-3 Second propeller shaft alignment ................................................................................................................ 23-3 Propeller shaft tightening torque ................................................................................................................. 23-4 Axle ................................................................................................................................................................... 23-5 Axle nut tightening procedure ..................................................................................................................... 23-5 Differential gear adjustment procedure ....................................................................................................... 23-7 32 Function & Structure Torque Converter and Transmission Group ................................................................... 32-1 Torque Converter .............................................................................................................................................. 32-2 Torque converter structure .......................................................................................................................... 32-2 Power flow path ........................................................................................................................................... 32-2 Torque multiplication ................................................................................................................................... 32-2

Torque Converter Gear Pump ........................................................................................................................... 32-3 Gear pump specifications ........................................................................................................................... 32-3 Gear pump specifications ........................................................................................................................... 32-4 Clutch combination ..................................................................................................................................... 32-5 Planetary gear ............................................................................................................................................. 32-5 Shift lever position ....................................................................................................................................... 32-5 QUAD switch operation ............................................................................................................................... 32-5 Gear train and number of teeth ................................................................................................................... 32-6 Clutch Pack ....................................................................................................................................................... 32-9 Power Flow Path in the Transmission ............................................................................................................. 32-10 Hydraulic System Diagram ............................................................................................................................. 32-15 Hydraulic Circuit Diagram ............................................................................................................................... 32-16 Oil Flow ........................................................................................................................................................... 32-17 Oil flow in the torque converter line ........................................................................................................... 32-17 Oil flow to the clutch .................................................................................................................................. 32-17 T/C and T/M Oil Circulation ............................................................................................................................. 32-18 Modulator Valve Unit ....................................................................................................................................... 32-19 Interior schematic (example) ..................................................................................................................... 32-21 Modulation Mechanism ................................................................................................................................... 32-22 Modulator valve function ........................................................................................................................... 32-22 Modulator valve operation ......................................................................................................................... 32-24 Clutch Solenoid Valve ..................................................................................................................................... 32-25 For high/reverse and speed clutches ........................................................................................................ 32-27 33 Check & Adjustment Torque Converter and Transmission Group ................................................................... 33-1 Clutch Oil Pressure and Time Lag .................................................................................................................... 33-2 Measuring clutch oil pressure ..................................................................................................................... 33-2 Measuring clutch time lag ........................................................................................................................... 33-4 42 Function & Structure Hydraulic Group ............................................................................................................. 42-1 Flushing Hydraulic Circuit ................................................................................................................................. 42-2 Purpose of flushing ..................................................................................................................................... 42-2 Cautions on Hydraulic Parts Replacement ....................................................................................................... 42-3

Hydraulic Circuit Symbols ................................................................................................................................. 42-4 Hydraulic lines ............................................................................................................................................. 42-4 Pumps & motors .......................................................................................................................................... 42-4 Cylinders ..................................................................................................................................................... 42-4 Operation methods ...................................................................................................................................... 42-5 Pressure control valve ................................................................................................................................. 42-5 Flow control valve ....................................................................................................................................... 42-5 Directional control valve .............................................................................................................................. 42-6 Check valve ................................................................................................................................................. 42-6 Miscellaneous hydraulic symbols ................................................................................................................ 42-7 Hydraulic System Operation ............................................................................................................................. 42-8 Hydraulic system operation outline ............................................................................................................. 42-8 Layout of Hydraulic Units ................................................................................................................................ 42-10 Hydraulic Tank ................................................................................................................................................. 42-11 Hydraulic tank specifications ..................................................................................................................... 42-11 Hydraulic oil level check ............................................................................................................................ 42-11 Hydraulic tank (S/N 0101~0450, 9001~) ................................................................................................... 42-12 Hydraulic tank (S/N 0451~) ....................................................................................................................... 42-15 Hydraulic Pump ............................................................................................................................................... 42-17 Loading and pilot and brake pump ............................................................................................................ 42-19 Pump specifications .................................................................................................................................. 42-19 Steering pump (S/N 0101~0258, 9001~9065) .......................................................................................... 42-20 Pump specifications .................................................................................................................................. 42-20 Steering pump (S/N 0259~0398, 9066~) .................................................................................................. 42-21 Pump specifications .................................................................................................................................. 42-21 Steering pump (S/N 0399~0465) .............................................................................................................. 42-23 Pump specifications .................................................................................................................................. 42-23 Steering pump (S/N 0466~) ...................................................................................................................... 42-25 Pump specifications .................................................................................................................................. 42-25 Hydraulic pump principle ........................................................................................................................... 42-26 Hydraulic pump wear plate ........................................................................................................................ 42-27 Hydraulic pump bushing lubrication .......................................................................................................... 42-27

Hydraulic Cylinder ........................................................................................................................................... 42-28 Boom cylinder ........................................................................................................................................... 42-28 Bucket cylinder .......................................................................................................................................... 42-29 Steering cylinder ....................................................................................................................................... 42-30 Hydraulic cylinder specifications ............................................................................................................... 42-31 Loading System .............................................................................................................................................. 42-32 Reducing Valve (for Pilot Pressure) ................................................................................................................ 42-33 Pilot Valve (S/N 0101~0290, 9001~9080) ....................................................................................................... 42-34 Pilot valve (S/N 0291~0408, 9081~) ............................................................................................................... 42-39 Pilot valve (S/N 0409~0410) ........................................................................................................................... 42-44 Pilot valve (S/N 0411~) ................................................................................................................................... 42-49 Multiple Control Valve (KML35A/2T003B) ....................................................................................................... 42-54 Multiple control valve specifications .......................................................................................................... 42-55 Multiple control valve main relief valve ..................................................................................................... 42-56 Multiple control valve overload relief valve ............................................................................................... 42-58 Multiple control valve make-up valve ........................................................................................................ 42-60 Multiple control valve bucket spool ........................................................................................................... 42-61 Multiple control valve boom spool ............................................................................................................. 42-63 Adapter (Orifice) .............................................................................................................................................. 42-66 Vibration Damper (OPT) ................................................................................................................................. 42-67 Vibration damper hydraulic circuit ............................................................................................................. 42-67 Vibration damper operation ....................................................................................................................... 42-68 Vibration damper hydraulic line ................................................................................................................. 42-77 Steering System .............................................................................................................................................. 42-78 Orbitrol® .......................................................................................................................................................... 42-79 Orbitrol® specification ............................................................................................................................... 42-79 Orbitrol® structure ..................................................................................................................................... 42-80 Orbitrol® operation .................................................................................................................................... 42-81 Orbitrol® feed-back mechanism operation ................................................................................................ 42-83 Steering speed and flow rate control ........................................................................................................ 42-84 Hydraulic pump oil amount and steering force .......................................................................................... 42-84 Orbit rotor operation principle ................................................................................................................... 42-85

Steering Valve (KVS32-A4.0) .......................................................................................................................... 42-86 Steering valve operation ........................................................................................................................... 42-89 Steering plunger variable throttle .............................................................................................................. 42-91 Steering valve flow control plunger ........................................................................................................... 42-92 Steering valve main relief valve ................................................................................................................ 42-93 Steering valve overload relief valve .......................................................................................................... 42-95 Steering pilot circuit and its operation ....................................................................................................... 42-97 Stop Valve ....................................................................................................................................................... 42-99 Stop valve function .................................................................................................................................. 42-101 Stop valve operation ............................................................................................................................... 42-102 Reducing Valve (for Orbitrol®) ....................................................................................................................... 42-103 Steering Line Filter ........................................................................................................................................ 42-104 Fan Motor System ......................................................................................................................................... 42-106 Fan Motor Line (S/N 0101~0230) .................................................................................................................. 42-108 Fan motor (GM30C) (S/N 0101~0230) ................................................................................................... 42-110 Valve assembly (for fan motor) ................................................................................................................42-111 Relief valve (two-step relief) .................................................................................................................... 42-112 Relief valve (two-step relief) operation .................................................................................................... 42-113 Solenoid valve (for fan speed control) ..................................................................................................... 42-115 Fan Motor Line (S/N 0231~) .......................................................................................................................... 42-116 Fan motor (GM30C) (S/N 0231~0313) ................................................................................................... 42-119 Fan motor (GM30W) (S/N 0314~0398) ................................................................................................... 42-120 Fan motor (FM30) (S/N 0399~0466) ....................................................................................................... 42-122 Fan motor (S/N 0467~) ........................................................................................................................... 42-124 Thermo sensing valve ............................................................................................................................. 42-127 Fan motor relief valve assembly ............................................................................................................. 42-129 Fan motor relief valve .............................................................................................................................. 42-130 Fan motor check valve (make-up valve) ................................................................................................. 42-130 Fan Motor Line (S/N 9001~9010) .................................................................................................................. 42-131 Fan motor (GM30C) (S/N 9001~9010) ................................................................................................... 42-133 Valve assembly (for fan motor) ............................................................................................................... 42-134 Relief valve (two-step relief) .................................................................................................................... 42-135 Relief valve (two-step relief) operation .................................................................................................... 42-136 Solenoid valve (for fan speed control) ..................................................................................................... 42-138

Fan Motor Line (S/N 9011~) .......................................................................................................................... 42-139 Fan motor (GM30C) (S/N 9011~9065) ................................................................................................... 42-142 Fan motor (GM30W) (S/N 9066~) .......................................................................................................... 42-143 Thermo sensing valve ............................................................................................................................. 42-145 Fan motor relief valve assembly ............................................................................................................. 42-147 Fan motor relief valve ............................................................................................................................. 42-148 Fan motor check valve (make-up valve) ................................................................................................. 42-148 Emergency Steering (for Europe) ................................................................................................................. 42-149 Emergency steering operation condition ................................................................................................. 42-149 Emergency steering line oil flow ............................................................................................................. 42-149 Emergency steering motor and pump ..................................................................................................... 42-151 43 Check & Adjustment Hydraulic Group .............................................................................................................. 43-1 Loading/Steering Circuit Relief Valve ................................................................................................................ 43-2 Loading circuit relief valve setting pressures .............................................................................................. 43-2 Steering circuit relief valve setting pressures .............................................................................................. 43-7 Hydraulic Cylinder ........................................................................................................................................... 43-12 Cylinder natural drift .................................................................................................................................. 43-12 Stop Valve ....................................................................................................................................................... 43-14 Stop valve adjustment procedure ............................................................................................................. 43-14 Fan Revolution (S/N 0101~) ........................................................................................................................... 43-15 Fan maximum revolution measurement (S/N 0101~0230) ....................................................................... 43-15 Fan maximum revolution measurement (S/N 0231~) ............................................................................... 43-17 Fan Revolution (S/N 9001~) ........................................................................................................................... 43-19 Fan maximum revolution measurement (S/N 9001~9010) ....................................................................... 43-19 Fan maximum revolution measurement (S/N 9011~) ............................................................................... 43-21 52 Function & Structure Brake Group ................................................................................................................... 52-1 Brake System Outline ....................................................................................................................................... 52-2 Service brake .............................................................................................................................................. 52-2 Parking brake .............................................................................................................................................. 52-2 Auto brake .................................................................................................................................................. 52-2 Adjustment of axle internal pressure ........................................................................................................... 52-2 Brake Units Layout ............................................................................................................................................ 52-3 Unloader Valve .................................................................................................................................................. 52-4 Unloader valve operation ............................................................................................................................ 52-6 Valve Unit .......................................................................................................................................................... 52-7

Reducing Valve ................................................................................................................................................. 52-8 Brake Accumulator Line .................................................................................................................................... 52-9 Brake circuit check valve ........................................................................................................................... 52-12 Brake Valve ..................................................................................................................................................... 52-13 Brake main valve (left pedal) ..................................................................................................................... 52-13 Brake pilot valve (right pedal) .................................................................................................................... 52-15 Brake valve performance chart ................................................................................................................. 52-17 Brake valve outline .................................................................................................................................... 52-20 Stop Lamp Pressure Switch ............................................................................................................................ 52-22 Pressure switch (for stop lamp) ................................................................................................................. 52-22 Pressure switch (for declutch) ................................................................................................................... 52-23 Service Brake .................................................................................................................................................. 52-24 Service brake operation ............................................................................................................................ 52-24 Service brake friction plate ........................................................................................................................ 52-25 Service brake steel plate ........................................................................................................................... 52-25 Service brake piston .................................................................................................................................. 52-26 Service brake pedal stroke adjusting mechanism (S/N 0101~0311, 9001~9095) .................................... 52-28 Brake circuit air bleeding procedure .......................................................................................................... 52-30 Parking Brake .................................................................................................................................................. 52-32 Parking brake operation chart ................................................................................................................... 52-32 Parking Brake (Rear) ...................................................................................................................................... 52-33 Parking brake solenoid valve (rear) .......................................................................................................... 52-34 Parking brake manual release procedure (rear) ....................................................................................... 52-35 Parking brake spring chamber .................................................................................................................. 52-37 Parking Brake (Front) (for Europe only) .......................................................................................................... 52-38 Parking brake solenoid valve (front) .......................................................................................................... 52-39 Front parking brake auto adjuster mechanism .......................................................................................... 52-40 Parking brake line air bleeding procedure (front parking) ......................................................................... 52-41 Parking brake manual release procedure (front) ....................................................................................... 52-42 Auto Brake ...................................................................................................................................................... 52-43 Auto brake circuit ...................................................................................................................................... 52-43 Auto brake operation set value ................................................................................................................. 52-43 Shuttle valve .............................................................................................................................................. 52-45

53 Check & Adjustment Brake Group ................................................................................................................... 53-1 Brake Circuit Oil Pressure ................................................................................................................................. 53-2 Unloader valve setting pressure ................................................................................................................. 53-2 Accumulator circuit pressure ....................................................................................................................... 53-4 Brake valve oil pressure .............................................................................................................................. 53-6 Service Brake .................................................................................................................................................... 53-8 Service brake performance check .............................................................................................................. 53-8 Service brake friction plate wear measurement .......................................................................................... 53-9 Parking Brake ................................................................................................................................................. 53-12 Parking brake performance check ............................................................................................................ 53-12 Parking brake clearance adjustment ......................................................................................................... 53-14 62 Function & Structure Electrical Group .............................................................................................................. 62-1 How to Use Electrical Wiring Diagram .............................................................................................................. 62-2 Utilisation des schémas des câblages électriques (FRANÇAIS) ...................................................................... 62-3 Verwendung des elektrischen Schaltplans (DEUTSCH) ................................................................................... 62-4 Modalità di utilizzo dello schema dei collegamenti elettrici (ITALIANO) ............................................................ 62-5 Cómo utilizar un Diagrama de Alambrado Eléctrico (ESPAÑOL) ..................................................................... 62-6 Como Utilizar o Diagrama de Ligações Eléctricas (PORTUGUÊS) .................................................................. 62-7 Electrical Cable Color Codes ............................................................................................................................ 62-8 Electrical Circuit Symbols ................................................................................................................................. 62-9 Sensor Mount .................................................................................................................................................. 62-10 Fuse .................................................................................................................................................................62-11 Fuse box ................................................................................................................................................... 62-12 Fusible link ................................................................................................................................................ 62-13

Engine Start Circuit ......................................................................................................................................... 62-15 Engine start circuit diagram (S/N 0101~0358, 9001~) .............................................................................. 62-15 Neutral starter ........................................................................................................................................... 62-15 Engine start circuit diagram (S/N 0359~) .................................................................................................. 62-16 Neutral starter ........................................................................................................................................... 62-18 Starter switch ............................................................................................................................................. 62-19 Battery relay .............................................................................................................................................. 62-20 Alternator I terminal wire ........................................................................................................................... 62-20 Diode unit .................................................................................................................................................. 62-21 Neutral relay .............................................................................................................................................. 62-21 Magnet switch ........................................................................................................................................... 62-22 Voltage relay ............................................................................................................................................. 62-23 Power Generating/Charging Circuit ................................................................................................................ 62-24 Alternator ................................................................................................................................................... 62-24 ECM (Engine Controller) ................................................................................................................................. 62-25 Function of ECM ....................................................................................................................................... 62-25 Connection diagram .................................................................................................................................. 62-25 Monitor lamp test ....................................................................................................................................... 62-26 Failure diagnosis ....................................................................................................................................... 62-27 Quantum fault code information ................................................................................................................ 62-32 Accelerator pedal ...................................................................................................................................... 62-39 Accelerator pedal ...................................................................................................................................... 62-41 Transmission Control Circuit and Monitor Circuit (S/N 0101~0358, 9001~) ................................................... 62-43 Controller ................................................................................................................................................... 62-43 Controller connection diagram .................................................................................................................. 62-45 Controller function ..................................................................................................................................... 62-46 Emergency steering function (for Europe spec only) ................................................................................ 62-65 Transmission Control Circuit and Monitor Circuit (S/N 0359~) ........................................................................ 62-66 Machine control unit (MCU) ...................................................................................................................... 62-66 Machine control unit (MCU) connection diagram (S/N 0359~0476) ......................................................... 62-68 Machine control unit (MCU) connection diagram (S/N 0477~) ................................................................. 62-69 Monitoring System (S/N 0101~0358, 9001~) .................................................................................................. 62-71 Monitor controller ...................................................................................................................................... 62-71 Monitor controller connection diagram ...................................................................................................... 62-72 Monitor controller function ......................................................................................................................... 62-73

Instrument Panel and Switch .......................................................................................................................... 62-76 Instrument panel ....................................................................................................................................... 62-76 Instrument panel rear surface ................................................................................................................... 62-78 Gauge circuit ............................................................................................................................................. 62-80 Tachometer circuit ..................................................................................................................................... 62-82 Fuel gauge circuit ...................................................................................................................................... 62-83 Electrical Detent Circuit ................................................................................................................................... 62-85 Bucket leveler ........................................................................................................................................... 62-85 Boom kick-out (option) .............................................................................................................................. 62-86 Detent solenoid ......................................................................................................................................... 62-87 Diode ............................................................................................................................................................... 62-88 Diode check method ................................................................................................................................. 62-89 Caution for diode check method ............................................................................................................... 62-89 Surge voltage and surge suppression diodes ........................................................................................... 62-91 Diagnostic System (S/N 0101~0358, 9001~) .................................................................................................. 62-92 Diagnostic system flow ............................................................................................................................. 62-92 Monitor controller ...................................................................................................................................... 62-96 Diagnostic failure history indication and deletion ...................................................................................... 62-99 Diagnostic switch .................................................................................................................................... 62-101 MODM (S/N 97C4-0359~) ............................................................................................................................ 62-102 MODM function ....................................................................................................................................... 62-102 Monitor Changeover ............................................................................................................................... 62-102 MODM: Input/output monitor - Input/output signal correspondence table .............................................. 62-109 63 Check & Adjustment Electrical Group .............................................................................................................. 63-1 Cautions Regarding Electric Circuit Check ....................................................................................................... 63-2 Disconnecting or reinstalling connector ...................................................................................................... 63-2 How to attach the probes of the circuit tester .............................................................................................. 63-4 Electrical Transmission Control System Troubleshooting Flowchart (S/N 0101~0358, 9001~) ........................ 63-5 Standard troubleshooting flowchart ............................................................................................................. 63-5 Transmission Controller Abnormal Operation Judgment (S/N 0101~0358, 9001~) .......................................... 63-6 Transmission controller check .................................................................................................................... 63-6 Transmission controller LED indicator ........................................................................................................ 63-8

Electrical Circuit Check (S/N 0101~0358, 9001~) ........................................................................................... 63-10 Shift lever input electrical circuit check ..................................................................................................... 63-10 Inching (declutch) input electrical circuit check ......................................................................................... 63-12 QUAD switch input electrical circuit check ................................................................................................ 63-14 Machine speed sensor input electrical circuit check ................................................................................. 63-15 Clutch solenoid valve output electrical circuit check ................................................................................. 63-16 Modulator valve output electrical circuit check .......................................................................................... 63-18 Check output circuit wiring ........................................................................................................................ 63-19 Neutral relay electrical circuit check .......................................................................................................... 63-20 Parking brake electrical circuit check ........................................................................................................ 63-21 Auto brake electrical circuit check ............................................................................................................. 63-24 Gauge circuit electrical circuit check ......................................................................................................... 63-26 Fuel level gauge electrical circuit check .................................................................................................... 63-28 Shift Lever ....................................................................................................................................................... 63-30 Operation force measurement .................................................................................................................. 63-30 72 Function & Structure Operator Station Group .................................................................................................. 72-1 Cabin ................................................................................................................................................................. 72-2 Glass ........................................................................................................................................................... 72-3 Wiper mount ................................................................................................................................................ 72-6 Wiper motor ................................................................................................................................................. 72-7 Operator Seat .................................................................................................................................................... 72-9 Steering and Transmission Shift Lever ............................................................................................................ 72-10 Tilt case ..................................................................................................................................................... 72-11 Column shaft ............................................................................................................................................. 72-12 Shift lever .................................................................................................................................................. 72-12 Air Conditioner ................................................................................................................................................ 72-13 Air conditioner components ....................................................................................................................... 72-13 Air conditioner structure ............................................................................................................................ 72-14 Cooling mechanism ................................................................................................................................... 72-19 Cooling circuit ............................................................................................................................................ 72-21 Electrical circuit ......................................................................................................................................... 72-22 Air conditioner functions of components ................................................................................................... 72-23 Charge of refrigerant ................................................................................................................................. 72-50 Air conditioner troubleshooting .................................................................................................................. 72-65

73 Check & Adjustment Operator Station Group .................................................................................................. 73-1 Air Conditioner .................................................................................................................................................. 73-2 Adjustment of lubricating oil quantity when components of air conditioner are replaced ............................ 73-2 Adjustment of air gap (between hub and rotor) in compressor magnetic clutch ......................................... 73-5 Parts to be replaced periodically ................................................................................................................. 73-6 92 Cross-Section Drawing & Diagrams ................................................................................................................. 92-1 Axle Assembly .................................................................................................................................................. 92-2 Torque Converter and Transmission ................................................................................................................. 92-3 Loading/Steering Hydraulic Line (S/N 0101~0230) ........................................................................................... 92-4 Loading/Steering Hydraulic Line (S/N 0231~) ................................................................................................... 92-5 Loading/Steering Hydraulic Circuit (S/N 9001~9010) ....................................................................................... 92-6 Loading/Steering Hydraulic Circuit (S/N 9011~) ................................................................................................ 92-7 Brake Circuit ..................................................................................................................................................... 92-8 Electrical Wiring Diagram (1/2) (S/N 0101~0358) ............................................................................................. 92-9 Electrical Wiring Diagram (2/2) (S/N 0101~0358) ........................................................................................... 92-10 Electrical Wiring Diagram (1/3) (S/N 0359~0476) ............................................................................................92-11 Electrical Wiring Diagram (2/3) (S/N 0359~0476) ........................................................................................... 92-12 Electrical Wiring Diagram (3/3) (S/N 0359~0476) ........................................................................................... 92-13 Electrical Wiring Diagram (1/3) (S/N 0477~0560) ........................................................................................... 92-14 Electrical Wiring Diagram (2/3) (S/N 0477~0560) ........................................................................................... 92-15 Electrical Wiring Diagram (3/3) (S/N 0477~0560) ........................................................................................... 92-16 Electrical Wiring Diagram (1/3) (S/N 0561~) ................................................................................................... 92-17 Electrical Wiring Diagram (2/3) (S/N 0561~) ................................................................................................... 92-18 Electrical Wiring Diagram (3/3) (S/N 0561~) ................................................................................................... 92-19 Electrical Wiring Diagram (1/2) (S/N 9001~9080) ........................................................................................... 92-20 Electrical Wiring Diagram (2/2) (S/N 9001~9080) ........................................................................................... 92-21 Electrical Wiring Diagram (1/2) (S/N 9081~) ................................................................................................... 92-22 Electrical Wiring Diagram (2/2) (S/N 9081~) ................................................................................................... 92-23 Electrical wiring diagram abbreviation chart (S/N 0101~0358, 9001~) ........................................................... 92-24 Electrical wiring diagram abbreviation chart (S/N 0359~0476) ....................................................................... 92-25 Electrical wiring diagram abbreviation chart (S/N 0477~) ............................................................................... 92-26 Electrical Wiring Diagram (CAB) ..................................................................................................................... 92-27 Electrical Connection Diagram (S/N 0101~0358) ........................................................................................... 92-29 Electrical Connection Diagram (S/N 0359~0476) ........................................................................................... 92-30 Electrical Connection Diagram (1/2) (S/N 0477~0560) ................................................................................... 92-31

Electrical Connection Diagram (2/2) (S/N 0477~0560) ................................................................................... 92-32 Electrical Connection Diagram (1/2) (S/N 0561~) ........................................................................................... 92-33 Electrical Connection Diagram (2/2) (S/N 0561~) ........................................................................................... 92-34 Electrical Connection Diagram (S/N 9001~) ................................................................................................... 92-35 Electrical Circuit Diagram (Cabin Air Conditioner) .......................................................................................... 92-36 Electrical Wiring Diagram (Cabin Air Conditioner) .......................................................................................... 92-37 Equipment Operation Table (Cabin Air Conditioner) ....................................................................................... 92-38 Electrical Equipment Layout ............................................................................................................................ 92-39

95ZV EX 00-1 00 General Information

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

95ZV EX 00-2 00 General Information How to Use Manual

How to Use Manual Safety precautions The most important point in providing repair service is safety. To ensure safety, observe the general cautions described below.

- Contact tire manufacturer's local dealer for tire servicing and changing. - Always store the tools in good condition, and use them properly.

- This manual is intended for properly trained and equipped service technicians.

- Keep the work area clean. Clean up spills immediately.

- Any work on the machine must be performed by the trained personnel only.

- Avoid the use of flammable solvents and cleaners.

- 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 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 (20 kg (40 lbs) or more), be sure to use a crane or other lifting tool. - Just after stopping operation, be careful not to directly touch a hot component. You may get burned.

- 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. - Any technician that operates a refrigerant recovery and recycling machine must first be certified through and EPA approved testing program.

95ZV EX 00-3 00 General Information How to Use Manual

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

Item

Description

Reference

Shows the condition or procedure that will be useful or efficient in doing service work.

Weight

Shows the weight of a part or unit. The weight should be considered in selecting wire rope or cable for slinging work or determining the working posture.

Tightening Shows the tightening torque of a section that should torque be carefully tightened during assembly work.

Coating

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

Oil or water supply

Shows the oil or water supply port and the refill amount.

Drainage

Shows the oil or water drain port and the drain amount.

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

Abbreviation To save space, abbreviations are used in sentences. To understand the contents of this manual, refer to the following abbreviation list. Additional abbreviations are listed on page 92-25. B ............Battery E/G ........... Engine R ............Rear or Reverse T/C ........... Torque converter RH ............Right hand side T/M ........... Transmission LH ............Left hand side SOL ........... Solenoid valve H ............High SW ........... Switch L ............Low F ........... Front or Forward QUAD......... Quick up and down shift GND ............Ground OPT ............Option A/M ........... Auto/Manual Assy ............Assembly

1st ............1st speed 2nd ............2nd speed 3rd ............3rd speed 4th ............4th speed DD ............Dynamic damper M/C ............Machine min-1 ............RPM

95ZV EX 00-4 00 General Information Outline

Outline Layout of main components

9 4

95ZV00001

1. Engine assembly (Cummins QSX-15) 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. Precleaner 10. Muffler 11. Radiator

12. Front axle assembly 13. Rear axle assembly 14. 2nd propeller shaft 15. 3rd propeller shaft 16. Hydraulic oil cooler (air-to-oil type) 17. T/C oil cooler (lower tank of radiator) 18. Air charge cooler 19. Fuel cooler 20. Front parking brake 21. Parking brake 22. Fan motor

95ZV EX 00-5 00 General Information Outline

Inspection and Maintenance Table △ : First time replacement or cleaning only Section

Item for check

Operating hours 10

Check Engine Oil Level

○

Check Engine Coolant Level

○

Check Warning Lamps

○

Check Exhaust Gas

○

Drain Water and Sediment from Fuel Filter

○

Check Fuel Level

○

Check Drive Belt

○

Check Crankcase Breather Tube

○

Check Air Intake System

○

Check Cooling Fan

○

Drain Water and Sediment from Fuel Tank

250

500

1000 1500 2000

When Required

○

Replace Engine Oil and Oil Filter Cartridge

Engine

○

Add DCA4 Coolant Additive

○

Inspect Automatic Belt Tension

○

Replace Fuel Filter Cartridge

○

Replace DCA4 Coolant Filter Cartridge (One year or 1,500 hours whichever comes first.)

○

Clean Fuel Tank

○

Check and Adjust Valve Lash Clearance

○

Check Vibration Damper

○

Check Engine Compression Pressure

○

Check Injection Pressure

○

Check and Adjust Injection Timing

○

Clean Crankcase Breather Tube

○

Replace Ether Cylinder

○

Clean or Replace Air Cleaner Element

○

Clean Radiator / Air Cooler / Hydraulic Oil Cooler Fins

○

Clean or Replace Air Cleaner Element

After six cleanings or once a year ○

Replace Coolant Check Transmission Oil Level

Transmission Replace Transmission Oil Filter Cartridge & Torque Converter Replace Transmission Oil Clean or Replace Transmission Breather

Every 2 years or 3000 hours ○ ○ △

○ ○ ○

95ZV EX 00-6 00 General Information Outline △ : First time replacement or cleaning only Section

Item for check Check Tire for Damage, Air and Tread Depth

Axle system

Operating hours 10

250

Check Tire Air Pressure

○

Greasing (Axle support)

○

Check Differential Gear Oil

○

Check Planetary Gear Oil

○

Greasing (Pillow Block Bearing Unit)

○

Check Tightness of Wheel Bolts

○ ○

Greasing (2nd Propeller Shaft)

○

Greasing (3rd Propeller Shaft)

○

Replace Differential Gear Oil

○

Replace Planetary Gear Oil

○

Check Steering Wheel Operation

○

Greasing (Steering Cylinder) Clean Filter for Orbitrol

Brake system

○

△

Check Service Brake Operation

○

Check Parking Brake Operation

○

Adjust Parking Brake Lining

○

Inspect the Front Parking Brake Pads and Rotor

○

Check Service Brake Disk Wear

○

Check Brake Accumulators

○

Clean Filter for Brake Line Check Hydraulic Oil Level Greasing Replace Hydraulic Oil Return Filter Loading system

1000 1500 2000

○

Greasing (Differential Seals)

Steering system

500

Replace Hydraulic Oil, Clean Filter Replace Filter in the Hydraulic Tank Cap (S/N 0101~0450, 9001~) Replace Filter in the Hydraulic Tank Breather Valve (S/N 0451~)

When Required

△

○

○ ○ △

○ ○ ○ ○

Replace Bucket Teeth (option)

○

Replace Cutting Edge (option)

○

95ZV EX 00-7 00 General Information Outline △ : First time replacement or cleaning only Section

Chassis

Electrical system

Item for check

Operating hours 10

Adjust and Check Rear View Mirrors

○

ROPS (Roll Over Protective Structure) Cab (option for other than Europe)

○

Greasing (Center Pin)

250

500

1000 1500 2000

○

Check Vibration Damper Accumulator (option)

○

Check and/or Replace Seat Belt (option for other than Europe)

○

Check Windshield Washer Fluid

○

Check Monitor Panel Operation

○

Check Horn Operation

○

Check Back-up Alarm Operation

○

Check Wiring Harnesses

○

Check Battery Electrolyte Level

○

Check or Replace Fuses Check Drive Belt

○ ○

Clean Air Conditioner and Heater Filter Element Air Conditioner

○

Check Air Conditioner Refrigerant

○

Replace Air Conditioner Filter Elements

○

Clean Air Conditioner Condenser

○

Replace Air Conditioner Receiver Dryer Others

When Required

Walk-Around Inspection

Every 3 years or 6000 hours ○ ○

95ZV EX 00-8 00 General Information Outline

Recommended lubricants

Engine

Ambient Temperature

Refill capacity (Approximate)

Kind of Oil

47 liter (12.4 gal)

Engine oil (CH4 or CG4)

14 -10

32 0

55 liter (14.5 gal)

Hydraulic tank

150 liter (39.6 gal)

Hydraulic oil

Differential & Planetary

Front: 100 liter (26.4 gal) Rear: 100 liter (26.4 gal)

Engine oil (CD)

Fuel tank

425 liter (112.3 gal)

Diesel fuel

50 10

68 20

86 30

104 40

SAE10W SAE10W-30

Change Interval (Hours) 250

SAE15W-40 SAE10W

Engine oil (CD) or ATF

Transmission

1

-22ºF -4 -30ºC -20

ATF ISO VG32 ISO VG46

Engine oil SAE40 or SAE50

ASTM D975 No.1 ASTM D975 No.2

1,000 2,000

2,000

daily

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

Use oil that meets engine oil classification API CH4 or CG4.

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. *2. In a case that fire-resistant fluid is to be used in the hydraulic circuit, some hydraulic equipment must be replaced. Contact your Kawasaki dealer for service. Be sure to use ISO VG32 when the temperature is below -15ºC. When replacing the hydraulic oil ISO VG46 with ISO VG32, the brakes must be bled to fully circulate the new oil, or brake problems could occur. Contact your Kawasaki dealer for service.

Differential & Planetary

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

Lubricating Grease

Use multipurpose-type EP/MOLY grease for most applications. NLGI NO.2 grease is suitable for most temperatures. NLGI NO.1 or NO.0 grease for extremely low temperature. Use lithium base grease for universal joints and a propeller shaft spline.

95ZV EX 00-9 00 General Information Outline

Diesel Fuel

Requirements for diesel fuel

Specifications Flash Point

ºC.

min.

Water and Sediment % vol.

max

Distillation Temperature

90% vol.

ºC

recovered

Kinematic Viscosity mm /s at 40ºC Ash % mass

max.

Cetane Number

min.

Carbon residue on 10% distillation residue % mass

Grade No.2-D

0.05

288

338

min.

1.3

1.9

max.

2.4

4.1

max.

Sulfer % mass

Grade No.1-D

max.

0.01

0.50

0.15

0.35

95ZV EX 00-10 00 General Information Outline

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

Recommended mixture of antifreeze Expected Minimum Ambient Temperature

-35ºC -30ºC -25ºC (-31ºF) (-22ºF) (-13ºF)

-20ºC (-4ºF)

-15ºC (5ºF)

Pure Water

(liter) (gal)

45.0 (11.9)

50.0 (13.4)

55.0 (14.4)

59.5 (15.8)

64.0 (16.9)

Antifreeze

(liter) (gal)

51.0 (13.5)

46.0 (12.0)

41.0 (11.0)

36.5 (9.6)

32.0 (8.5)

Mixture Ratio (%)

- Keep the antifreeze mixture ratio between 33% and 53% in all seasons, presuming the minimum ambient temperature 5ºC lower than a minimum ambient temperature in the working area. If the mixture ratio is less than 33%, it reduces antirust and anti-corrosion to the engine. Please note the antifreeze with a few mixture ratio may cause to corrode the engine. It may work as a corrosion accelerator. - 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 ºC) if the engine overheats in a high ambient temperature. - When adding coolant, do not add water only. Add the antifreeze with the same mixture ratio as filled first. - Do not use hard water or water with high levels of calcium and magnesium ions as the coolant water.

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

95ZV EX 00-11 00 General Information Outline

Lubrication chart DIFF & GEAR BOX

GO PILLOW UNIT

HYD. OIL TANK

DIFF

TRANSMISSION

DIFF & GEAR BOX

DIFF

EVERY 2000Hr

EVERY 1000Hr

G ENGINE OIL PAN

AXLE SUPPORT

LINK SYSTEM TO

EVERY 50Hr

EVERY 250Hr

EVERY DAY

STEERING CYL. CENTER PIN

BUCKET

2ND PROPELLER SHAFT

3RD PROPELLER SHAFT 95ZVE00001

Grease point

G Multipurpose grease

HO Hydraulic oil

Check and add if necessary

GO Gear oil

TO Engine oil

Oil replacement

EO Engine oil

95ZV EX 00-12 00 General Information Outline

Weight of main components Part name

Approx. weight (kg)

Approx. weight (lb)

Bucket

2,850

6,280

GSC bucket Standard

Item Unit name

Boom

2,150

4,740

“Z” -Lever

290/pc

640/pc

Link (Bucket to Lever)

60/pc

130/pc

180

400

Screen board Engine room

Chassis

Roof

150

Radiator guard

200

440

Side cover

35/pc

Hydraulic tank

280

620

Excluding oil

Fuel tank

240

530

Excluding fuel Including ope. board, instrument panel and control box

Floor board

250

550

Cab (ROPS)

620

1,370

Deck

Power line

Left side

180

With handrail

Right side

130

With handrail

Front chassis

2,410

5,310

Rear chassis

2,520

5,560

Counter weight

1,920

4,230

Engine

1,700

3,750

Excluding oil

Radiator assembly

650

1,430

Excluding water and oil

Transmission

1,310

2,890

Excluding oil

Second propeller shaft

100

220

Third propeller shaft

Front axle assembly

1,970

4,340

Excluding tires and oil

Rear axle assembly

2,130

4,700

Excluding tires and oil (Including axle support)

Front

350

770

Rear

360

790

Multiple control valve

100

220

Differential

Hydraulic system

Other

Remarks

Pilot valve

Steering valve

110

Gear pump

Double pump

Single pump

Fan motor

Boom cylinder

360/pc

790/pc

Excluding oil

Bucket cylinder

180/pc

400/pc

Excluding oil

Steering cylinder

40/pc

Excluding oil

Tire

790/pc

1,740

With rim (29.5-25-22PR(L-3)); No Hydro Inflation

Battery

60/pc

130/pc

95ZV EX 00-13 00 General Information Outline

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

Metric thread

Nominal dia.

Pitch

8.8 (8T)

10.9 (11T)

(F) 1.25

132

(F) 1.25

142

206

(F) 1.5

152

221

216

314

(F) 1.5

226

330

299

436

(F) 1.5

324

476

417

608

(F) 1.5

451

662

559

814

(F) 1.5

598

878

721

1,030

(F) 2.0

770

1,128

1,030

1,520

(F) 2.0

1,128

1,618

1,422

2,109

M10

M12

M14

M16

M18

M20

M22

M24

M27 M30

Unified thread

Bolt strength

Nominal dimension

27 30

M33

5/16

(F) 2.0

1,569

2,256

1,912

2,844

(F) 2.0

2,059

3,040

18 UNC

3/8

16 UNC

7/16

14 UNC

103

1/2

13 UNC

103

147

9/16

12 UNC

147

216

5/8

11 UNC

201

294

3/4

10 UNC

358

525

7/8

9 UNC

554

809

8 UNC

868

1,275

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

95ZV EX 00-14 00 General Information Outline

(kgf-m) Bolt size Type

Metric thread

Nominal dia.

Pitch

8.8 (8T)

10.9 (11T)

2.7

3.9

5.4

7.8

(F) 1.25

5.6

8.2

9.2

13.5

(F) 1.25

9.8

14.5

21.0

(F) 1.5

15.5

22.5

22.0

32.0

(F) 1.5

23.0

33.7

30.5

44.5

(F) 1.5

33.0

48.5

42.5

62.0

(F) 1.5

46.0

67.5

57.0

83.0

(F) 1.5

61.0

89.5

73.5

105.0

M10

M12

M14

M16

M18

M20

M22

M24

M27 M30

Unified thread

Bolt strength

Nominal dimension

27 30

M33

5/16

(F) 2.0

78.5

115.0

105.0

155.0

(F) 2.0

115.0

165.0

145.0

215.0

(F) 2.0

160.0

230.0

195.0

290.0

(F) 2.0

210.0

310.0

18 UNC

2.5

3.6

3/8

16 UNC

4.5

6.6

7/16

14 UNC

7.2

10.5

1/2

13 UNC

10.5

15.0

9/16

12 UNC

15.0

22.0

5/8

11 UNC

20.5

30.0

3/4

10 UNC

36.5

53.5

7/8

9 UNC

56.5

82.5

8 UNC

88.5

130.0

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

95ZV EX 00-15 00 General Information Outline

(lb-ft.) Bolt size Type

Metric thread

Nominal dia.

Pitch

8.8 (8T)

10.9 (11T)

19.5

(F) 1.25

105

150

(F) 1.5

110

160

230

(F) 1.5

165

245

220

320

(F) 1.5

235

350

305

450

(F) 1.5

330

490

410

600

(F) 1.5

440

650

530

760

M10

M12

M14

M16

M18

M20

M22

M24

M27 M30

Unified thread

Bolt strength

Nominal dimension

27 30

M33

5/16

(F) 2.0

565

830

760

1,120

(F) 2.0

830

1,190

1,050

1,550

(F) 2.0

1,160

1,660

1,410

2,100

(F) 2.0

1,520

2,240

18 UNC

18.0

3/8

16 UNC

7/16

14 UNC

1/2

13 UNC

105

9/16

12 UNC

110

160

5/8

11 UNC

150

215

3/4

10 UNC

265

385

7/8

9 UNC

410

595

8 UNC

640

940

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

95ZV EX 00-16 00 General Information Outline

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

Metric thread

Bolt strength

Nominal dimension

Pitch

0.8

1.25

M10

1.5

M12

1.75

8.8 (8T)

M16

231

M20

2.5

441

M24

765 (kgf-m)

Bolt size Type

Metric thread

Bolt strength

Nominal dimension

Pitch

0.8

0.7

1.2

8.8 (8T)

1.25

2.9

M10

1.5

5.4

M12

1.75

9.6

M16

23.5

M20

2.5

45.0

M24

78.0 (lb-ft)

Bolt size Type

Metric thread

Bolt strength

Nominal dimension

Pitch

8.8 (8T)

0.8

5.0

8.6

1.25

20.9

M10

1.5

38.9

M12

1.75

69.1

M16

169.2

M20

2.5

324.0

M24

561.6

95ZV EX 00-17 00 General Information Outline

Hose band tightening torque Low pressure hose (heat resisting hose)

Hose band

Tightening torque (N-m)

Tightening torque (kgf-cm)

Tightening torque (lb-ft)

69002-02200

1.6

1.2

2.9

Hose band

Tightening torque (N-m)

Tightening torque (kgf-cm)

Tightening torque (lb-ft)

69002-02200

1.6

1.2

2.9

Inner dia. (mm) Outer dia. (mm) 6.3

16.5

7.9

18.5

9.5

20.5

12.7

24.5

15.9

29.9

19.0

30.0

25.4

38.0

69002-04400

31.8

45.8

69002-05200

38.1

52.1

69002-05700

50.8

67.8

69002-07100

60.5

76.0

69002-08200

75.5

93.0

69002-09500

Low pressure hose Inner dia. (mm) Outer dia. (mm) 6

16.5

18.5

20.5

22.0

24.5

26.0

29.0

30.5

32.0

34.0

39.5

41.5

46.0

48.0

54.0

70.5

73.0

69002-02700 69002-03100

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

To connect the hose to the pipe, tighten the hose band at the following position:

Hose

Pipe

Hose band Center of pipe protrusion

10~20 mm

70ZV00003

95ZV EX 00-18 00 General Information Outline

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: Code Liquid Gasket

Screw Lock Agent

Manufacturer

Product name

AA01

Loctite

Plastic Gasket 568

AA02

Loctite®

Hydraulic sealant

AA03

Three Bond

Three Bond 1215

AB01

Loctite®

Loctite® 262

AB02

Three Bond

Three Bond 1327

AB03

Three Bond

Three Bond 1374

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

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

Cautions regarding reassembly To reassemble a screw Completely remove the hardened lock agent from the screw and the threaded hole before reassembling the screw. Note A piece of hardened lock agent may be peeled off and remain in the component. The remaining piece may cause malfunction during fastener installation.

To bond a plane or to fit a shaft Remove the hardened lock agent using a wire brush or the like, and polish the surface using sand paper. Use of a Loctite primer like Locquic ® Primer T cleans threads and speeds curing time. Antiseize Agent Code

Manufacturer

AC01

Loctite®

Product name Loctite® 767 (Paste or spray)

95ZV EX 00-19 00 General Information Outline

Screw lock agent application procedure

How to wind a seal tape

Through-hole Apply screw lock agent one or two lines on the male threads. Seal tape Screw lock agent Leave 1~2 screw

65ZV00004a

65ZV00002

Blind hole Apply screw lock agent all-round on the female threads at 1/3 of the female thread length from the bottom.

As the screw is tightened by turning clockwise, seal tape must be wound up clockwise direction as shown above. If not, the tape will be loosened or removed while tightening the screw, resulting in oil leakage. To avoid a piece of seal tape left in the circuit, leave 1 or 2 screws from the end of the thread and start threading it clockwise. Slightly stretch the tape when cutting it out, and press to fit the tape onto the screw thread.

H About 1/3H

65ZV00003

95ZV EX 00-20 00 General Information Outline

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

Cautions 1. Turn the starter switch OFF. 2. Remove the battery terminals both positive and negative sides from the battery. 3. Disconnect the connectors for SCU (transmission controller), ECM (engine controller), air conditioner and tachometer converter as per Cummins Engine Co. 4. Ground the welder near the section to be welded.

5. To ground the welder, check that the electric current will not flow through the cylinders. Cylinder head covers for some models have a low conductive metal that will cause spark if the welding current flows through it. The spark may damage the cylinder rod or other parts. 6. Calibrate throttle pedal to ECM. (a) Turn the starter switch to "ON". (b) Fully depress and release the throttle pedal three times. (c) Turn the starter switch to "OFF".

Example 1

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

35C00002

Example 2

Do not ground this section. Electric current may flow through the cylinders.

Section to be welded

Ground this section. (correct grounding)

35C00006

95ZV EX 00-21 00 General Information Outline 7. The weld spattered on the hydraulic cylinders and on the plated sections of pins will damage the cylinders and pins. There are other parts that may be damaged by the spatter; hydraulic units, harnesses, hydraulic hoses, and nylon tubes. Be sure to mask these units and parts before welding.

Hydraulic cylinder

Section to be welded

Hydraulic hose Nylon tube Harness Chassis

Remove and if necessary wrap

35C00005

Plated section (Mask this section.)

(c) Hydraulic hoses, nylon tubes, or harnesses are easily damaged by the heat during welding. To protect them from the heat, remove them from the section to be welded to make enough clearance.

Pin section with pin temporarily inserted Pin

Plated section (Mask this section.)

35C00003

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

1m or more

Scrap material, etc.

Section to be welded

1m or more 35C00004

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

95ZV EX 00-22 00 General Information

MEMO

95ZV EX 03-1 03 Measurement for Performance Check

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

95ZV EX 03-2 03 Measurement for Performance Check Cautions on Safety

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

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

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

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

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

95ZV EX 03-3 03 Measurement for Performance Check Standard Measurement Values for Performance Check

Standard Measurement Values for Performance Check For Asia and Africa (S/N 0101~) STD: Standard fuel consumption Saving: Low fuel consumption

Measurement conditions Temperature of torque converter oil: 50 ~ 80°C (120 ~ 180°F) Temperature of hydraulic oil: 50 ~ 80°C (120 ~ 180°F) Temperature of engine coolant: 50 ~ 80°C (120 ~ 180°F) Item Measurement item

System

Engine

Standard measurement values for performance check

Engine speed (min-1) (rpm)

775 ± 50

Maximum no-load speed, High Idle (HI)

2,350 ± 50

Maximum speed in torque converter stall mode

2,160 ± 100

2,070 ± 100

Maximum speed in multiple control valve relief mode

2,160 ± 100

1,990 ± 100

Maximum speed in torque converter stall plus multiple control valve relief mode

1,630 +150 - 100

1,550 +150 - 100

Transmission

Engine speed High idle

Clutch time lag (sec)

Saving

Minimum no-load speed, Low Idle (LI)

Low idle Clutch pressure MPa (kgf/cm2) (psi)

STD

NeutralForward 1st speed (engine speed: 1,500 min-1 (rpm))

Remarks

1st speed

2.2~2.5 (22~25) (313~356)

Except 1st speed

2.3~2.5 (23~26) (327~370)

1st speed

2.5~2.8 (26~29) (370~412)

Except 1st speed

2.6~2.9 (27~30) (384~427) 0.3 ± 0.1

Before wheels move

95ZV EX 03-4 03 Measurement for Performance Check Standard Measurement Values for Performance Check

Item

Standard measurement values for performance check

Measurement item

System

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

Hydraulic line

Full steering time (sec)

Relief valve setting pressure MPa (kgf/cm2) (psi)

STD

Saving

Boom cylinder

3 (1/8) or less

Bucket cylinder

4 (5/32) or less

Engine speed

Idling (LI)

23 ± 3.0

1,500 min-1 (rpm)

10.5 ± 1.0

Maximum (HI)

6.7± 0.5

Idling (LI)

5.0 ± 0.5 -1

1,500 min (rpm)

2.4 ± 0.3

Maximum (HI)

2.4 ± 0.5

Loading line main relief pressure (HI)

20.6 ± 0.5 (210 ± 5) (2,986 ± 71)

Loading line overload relief pressure (LI)

23.5 ± 0.5 (240 ± 5) (3,413 ± 71)

Steering line main relief pressure (HI)

20.6 ± 0.5 (210 ± 5) (2,986 ± 71) +10 24.5 +1.0 0 (250 0 ) (3,555 +1420 )

Steering line overload relief pressure (LI)

S/N 0101~0230 Fan motor line relief pressure (HI) (Reference values) S/N 0231~ Pilot line reducing pressure (LI) S/N 0101~0230 Fan maximum revolution min-1 (rpm) S/N 0231~

Remarks

Run engine at lowest possible speed while setting

Low press.: 8.5 (86.7) (1,233) High press.: 16.1 (164.2) (2,335) Low press.: 6.2 (63) (895) High press.: 16.2 (165) (2,345) 3.5 (36) (512)

Engine water temp. < 94ºC (200ºF)

1,050

Low press. 8.5 MPa

Engine water temp. > 94ºC (200ºF)

1,500

High press. 16.1 MPa

Engine water temp. < 80ºC (176ºF)

955

Low press. 6.2 MPa

Engine water temp. > 93ºC (200ºF)

1,500

High press. 16.2 MPa

95ZV EX 03-5 03 Measurement for Performance Check Standard Measurement Values for Performance Check

Item

Standard measurement values for performance check

Measurement item

System

Shift lever position 2nd speed reverse Performance of service brake Engine speed

Maximum (HI)

STD

Saving

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

Shift lever position 3rd speed reverse Performance of parking brake

 Engine speed

Brake

Unloader valve setting pressure (LI) Brake line setting pressure MPa (kgf/cm2) (psi)

Maximum (HI)

Off (Cut-out)

11.8 ± 0.5 (120 ± 5) (1,706 ± 71)

On (Cut-in)

6.9 ± 1.0 (70 ± 10) (995 ± 142)

Low-pressure alarm switch setting pressure (For brake accumulator circuit)

3.9 ± 0.5 (40 ± 5) (569 ± 71)

Brake line reducing pressure

12.3 (125) (1,778)

Auto brake reducing pressure

3.5 (36) (512)

The time from the low-pressure alarm is turned off till the unloading valve cuts off pressure

Accumulator charge time (sec)

Engine speed (LI)

Number of brake pedal applications

Run engine 1 minute high idle, then stop the engine. (Turn key switch “ON” with engine off.) Step on the brake pedal and release, and check the number of times until the low-pressure alarm is turned on.

Declutch engagement Engine: Maximum speed/ Inching pedal: Quick release (cm) (in) (Distance the loader rolls back before moving forward.)

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

Remarks

Before brake check, be sure to disconnect the cable connector of parking brake solenoid valve.

at least 11 times

Repeat stepping on the brake pedal as follows: On: 5 seconds Off: 5 seconds

15 (6) or less

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

95ZV EX 03-6 03 Measurement for Performance Check Standard Measurement Values for Performance Check For Europe (S/N 9001~) Measurement conditions Temperature of torque converter oil: 50 ~ 80°C (120 ~ 180°F) Temperature of hydraulic oil: 50 ~ 80°C (120 ~ 180°F) Temperature of engine coolant: 50 ~ 80°C (120 ~ 180°F) Item Measurement item

System

Engine

Standard measurement values for performance check

Engine speed (min-1) (rpm)

775 ± 50

Maximum no-load speed, High Idle (HI)

2,250 ± 50

Maximum speed in torque converter stall mode

2,160 ± 100

2,080 ± 100

Maximum speed in multiple control valve relief mode

2,170 ± 100

2,000 ± 100

Maximum speed in torque converter stall plus multiple control valve relief mode

1,650 +150 - 100

1,560 +150 - 100

Transmission

Engine speed High idle

Clutch time lag (sec)

Saving

Minimum no-load speed, Low Idle (LI)

Low idle Clutch pressure MPa (kgf/cm2) (psi)

STD

NeutralForward 1st speed (engine speed: 1,500 min-1 (rpm))

Remarks

1st speed

2.2~2.5 (22~25) (313~356)

Except 1st speed

2.3~2.5 (23~26) (327~370)

1st speed

2.5~2.8 (26~29) (370~412)

Except 1st speed

2.6~2.9 (27~30) (384~427) 0.3 ± 0.1

Before wheels move

95ZV EX 03-7 03 Measurement for Performance Check Standard Measurement Values for Performance Check

Item

Standard measurement values for performance check

Measurement item

System

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

Hydraulic line

Full steering time (sec)

Relief valve setting pressure MPa (kgf/cm2) (psi)

STD

Saving

Boom cylinder

3 (1/8) or less

Bucket cylinder

4 (5/32) or less

Engine speed

Idling (LI)

23 ± 3.0

1,500 min-1 (rpm)

10.5 ± 1.0

Maximum (HI)

6.7± 0.5

Idling (LI)

5.0 ± 0.5 -1

1,500 min (rpm)

2.4 ± 0.3

Maximum (HI)

2.4 ± 0.5

Loading line main relief pressure (HI)

20.6 ± 0.5 (210 ± 5) (2,986 ± 71)

Loading line overload relief pressure (LI)

23.5 ± 0.5 (240 ± 5) (3,413 ± 71)

Steering line main relief pressure (HI)

20.6 ± 0.5 (210 ± 5) (2,986 ± 71) +10 24.5 +1.0 0 (250 0 ) (3,555 +1420 )

Steering line overload relief pressure (LI)

S/N 9001~9010

Low press.: 8.2 (84) (1,190) High press.: 15.1 (154) (2,190)

S/N 9011~

Low press.: 6.2 (63) (895) High press.: 16.5 (168) (2,390)

Fan motor line relief pressure (HI) (Reference values)

Pilot line reducing pressure (LI) S/N 9001~9010 Fan maximum revolution min-1 (rpm) S/N 9011~

Remarks

Run engine at lowest possible speed while setting

3.5 (36) (512)

Engine water temp. < 94ºC (200ºF)

955

Low press. 8.2 MPa

Engine water temp. > 94ºC (200ºF)

1,365

High press. 15.1 MPa

Engine water temp. < 80ºC (176ºF)

955

Low press. 6.2 MPa

Engine water temp. > 93ºC (200ºF)

1,365

High press. 15.1 MPa

95ZV EX 03-8 03 Measurement for Performance Check Standard Measurement Values for Performance Check

Item

Standard measurement values for performance check

Measurement item

System

Shift lever position 2nd speed reverse Performance of service brake Engine speed

Maximum (HI)

STD

Saving

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

Shift lever position 3rd speed reverse Performance of parking brake

 Engine speed

Brake

Unloader valve setting pressure (LI) Brake line setting pressure MPa (kgf/cm2) (psi)

Maximum (HI)

Off (Cut-out)

11.8 ± 0.5 (120 ± 5) (1,706 ± 71)

On (Cut-in)

6.9 ± 1.0 (70 ± 10) (995 ± 142)

Low-pressure alarm switch setting pressure (For brake accumulator circuit)

3.9 ± 0.5 (40 ± 5) (569 ± 71)

Brake line reducing pressure

12.3 (125) (1,778)

Auto brake reducing pressure

3.5 (36) (512)

The time from the low-pressure alarm is turned off till the unloading valve cuts off pressure

Accumulator charge time (sec)

Engine speed (LI)

Number of brake pedal applications

Declutch engagement Engine: Maximum speed/ Inching pedal: Quick release (cm) (in) (Distance the loader rolls back before moving forward.)

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

Remarks

Before brake check, be sure to disconnect the cable connector of parking brake solenoid valve.

at least 11 times

Repeat stepping on the brake pedal as follows: On: 5 seconds Off: 5 seconds

15 (6) or less

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

95ZV EX 12-1 12 Function & Structure Chassis Group

12 Function & Structure Chassis Group Front Chassis ........................................................................12-2 Rear Chassis.........................................................................12-5 Center Pin .............................................................................12-8

95ZV EX 12-2 12 Function & Structure Chassis Group Front Chassis

Front Chassis Loading linkage

6 95ZV12001

1. Bucket 2. Link 3. Lever 4. Boom 5. Bucket cylinder 6. Boom cylinder 7. Dump stopper surface 8. Roll-back stopper surface 9. Lever stopper surface 10. Bucket stop plate (Design differs by manufacturer of the attachment)

95ZV EX 12-3 12 Function & Structure Chassis Group Front Chassis

4,440 mm (14.57 ft)

Even contact both sides

50 º

42.5 º 270

Hinge pin height at bucket on ground

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

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 K95ZV12002

95ZV EX 12-4 12 Function & Structure Chassis Group Front Chassis

Loading linkage pin mm (in) 1. Bucket - Boom

2. Boom - Lever

3. Boom - Boom cylinder

4. Front chassis - Boom

5. Bucket - Rod

6. Lever - Rod

7. Lever - Bucket cylinder

8. Bucket cylinder Front chassis

9. Boom cylinder Front chassis

10. Front chassis Steering cylinder

11. Steering cylinder Rear chassis

5 10

K95ZV12003

95ZV EX 12-5 12 Function & Structure Chassis Group Rear Chassis

Rear Chassis Fuel tank (S/N 0101~0262, 9001~9064) B (S/N 0257~) (S/N 9064)

A-Detail

3 9

1. Fuel tank 2. Fuel level sensor 3. Fuel tank filler assembly 4. Filter 5. Drain plug 6. Inspection hole cover 7. Gasket (Rubber seal type) 8. Suction pipe 9. Pipe (for vacuum prevention) 10. Fuel return pipe B-Detail

K95ZVE12001

95ZV EX 12-6 12 Function & Structure Chassis Group Rear Chassis

Fuel tank (S/N 0263~, 9065~) B

A-Detail

3 9

11 8 1. Fuel tank 2. Fuel level sensor 3. Fuel tank filler assembly 4. Filter 5. Drain plug 6. Inspection hole cover 7. Gasket (Rubber seal type) 8. Suction pipe 9. Pipe (for vacuum prevention) 10. Fuel return pipe 11. Magnet plug (S/N 0477~)

B-Detail

K95ZV12004

95ZV EX 12-7 12 Function & Structure Chassis Group Rear Chassis

Floor board mount

Viscous mount

Floor board

2 2

90ZVE12008

1. Floor board 2. Viscous mount

5 6 7

The floor board is installed on the rear chassis by the rubber cushion. The instrument panel, control box, operator’s seat and the air conditioner unit are on the floor board.

8 9

95ZV12008

Inspection hole (S/N 0154~) (S/N 9004~) K115ZVE12002

Note The access hole for floor servicing is provided on S/N 9004~ (Europe) and S/N 0154~ (other area).

1. Stud bolt 2. Stud 3. Cushion rubber 4. Case 5. Seal plate 6. Damping rubber 7. Damping plate 8. Silicone oil 9. Plain washer 10. Hexagon head bolt 11. Plug The floor board is supported by a viscous mount in four positions so that vibrations, impacts and sounds generated in the chassis are not transmitted to the inside of cabin.

95ZV EX 12-8 12 Function & Structure Chassis Group Center Pin

Center Pin Upper center pin

Lower center pin 1

9, 10 3 Front chassis

Front chassis

6 2 Rear chassis

7 Rear chassis

8, 10 Upper

Lower

95ZV12009

Upper

Lower

1. Center pin 2. Cover 3. Bearing cover 4. Sleeve 5. Shim 6. Bearing assembly 7. Dust seal 8. Bolt 9. Bolt 10. Washer

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

95ZV12010

95ZV EX 12-9 12 Function & Structure Chassis Group Center Pin

Dust seal

Center pin

Dust seal position

97ZA1208

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

95ZV EX 12-10 12 Function & Structure Chassis Group

MEMO

95ZV EX 13-1 13 Check & Adjustment Chassis Group

13 Check & Adjustment Chassis Group Linkage Pin ...........................................................................13-2 Center Pin .............................................................................13-5

95ZV EX 13-2 13 Check & Adjustment Chassis Group Linkage Pin

Linkage Pin WARNING

CAUTION

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

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

Liner

95ZV12004

Adjustment portion

Liner hole dia. mm (in)

110 (4.33)

81 (3.19)

111 (4.37)

91 (3.58)

111 (4.37)

Adjustment unnecessary

51 (2.01)

95ZV EX 13-3 13 Check & Adjustment Chassis Group Linkage Pin

Adjustment

(3.54 in)

#1 K95ZV13001

95ZV12005

Adjust the clearance (*) to 1.0 mm (0.04 in) or less for #1 (split type), to 1.2 mm (0.05 in) or less for #2 ~ #7 between the bosses using liners. For the steering cylinder, be sure to adjust the clearance on the rear chassis side first and then on the front chassis side while checking that the cylinder is not inclined.

95ZV EX 13-4 13 Check & Adjustment Chassis Group Linkage Pin

Bucket hinge pin section Boom Bushing A

Bucket

Bushing B

Hinge pin

Bolt

Dust seal

Seal retainer assy

Shim

Adjust the clearance ( pin (#1).

Shim (as required)

90V2E13002

) to 1.0 mm or less for the hinge

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

R122 .

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 1 mm.

Tighten the bolt for the seal retainer assy. : 441 N-m (45 kgf-m) (326 lb-ft) Shim

Shim thickness 90V2E13001

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

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

95ZV EX 13-5 13 Check & Adjustment Chassis Group Center Pin

Center Pin Adjusting shim

Grease nipple installation direction 1 4 9, 10 3 Front chassis

Grease nipple Front

5 6 7 Rear chassis 2 Upper

8, 10 95ZV12009

The clearance between the front chassis and bearing cover (3) is 0.75±0.5 mm (0.03±0.02 in) before shim adjustment. Add shims (5) so that the clearance is 0.1±0.05 mm (0.004±0.002 in). After that, tighten the bolt (9). : (8): 422 N-m (43.0 kgf-m) (311 lb-ft) (with lubrication oil) : (9): 441 N-m (45.0 kgf-m) (326 lb-ft)

[Upper]

[Lower] 95ZV13002

Install the both grease nipples (for the upper center pin and the lower center pin) as illustrated.

95ZV EX 13-6 13 Check & Adjustment Chassis Group Center Pin

Installing bearing outer ring

Front

Rear

Center line

Split of outer bearing

95ZV13003

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

95ZV EX 22-1 22 Function & Structure Power Group

22 Function & Structure Power Group Power Line ............................................................................22-2 Engine / Transmission...........................................................22-3 Radiator.................................................................................22-4 Propeller Shaft.......................................................................22-6 Axle Assembly.......................................................................22-9 Axle Support........................................................................22-12 Differential Gear ..................................................................22-18

95ZV EX 22-2 22 Function & Structure Power Group Power Line

Power Line

2 11

95ZV22001

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. Front parking brake 9. Parking brake 10. Air cleaner 11. Precleaner 12. Muffler 13. Hydraulic oil cooler (at right side) 14. Torque converter oil cooler (bottom tank of radiator) 15. Air charge cooler 16. Fuel cooler

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 back side of the engine, there is a radiator. The radiator incorporates engine coolant, torque converter oil cooler, air charge cooler, fuel cooler and an external air type hydraulic oil cooler. On the second propeller shaft side of the transmission, a parking brake is installed.

95ZV EX 22-3 22 Function & Structure Power Group Engine / Transmission

Engine / Transmission Engine / transmission mount

Transmission side

Bracket Bracket

Engine side

Flywheel

3 2 A-Detail

B-Detail

C-Detail 95ZV22002

1. Bushing 2. Sleeve 3. Block 4. Washer 5. Ring gear

Bolts are used to connect the engine flywheel housing to the torque converter housing, and a spline ring coupling (5) is used to transmit the engine power to the torque converter. Therefore no thrust load is placed on the engine flywheel or crankshaft. Rubber cushions are used to mount the engine and the transmission on the chassis.

95ZV EX 22-4 22 Function & Structure Power Group Radiator

Radiator Hydraulic oil cooler IN

Charge air cooler OUT

Coolant IN

Charge air cooler IN

1 B

D D A

A C 2 5

7 6

Hydraulic oil cooler OUT

Bypass coolant IN T/C oil cooler OUT

Fuel cooler IN Fuel cooler OUT

T/C oil cooler IN

Coolant OUT

(S/N ~0262) (S/N ~9064) (S/N 0263~) (S/N 9065~)

Fuel cooler OUT

Fuel cooler IN

6 K95ZV22001J

1. Radiator assembly 2. Radiator duct 3. Stay (Bracket) 4. Charge air cooler

5. Hydraulic oil cooler 6. T/C oil cooler 7. Fuel cooler

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

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. The fuel cooler and air charge cooler are required to meet engine emission regulations.

95ZV EX 22-5 22 Function & Structure Power Group Radiator

Fuel line (S/N 0101~0262) (S/N 9001~9064)

(S/N 0263~) (S/N 9065~)

Radiator assy

To fuel tank To fuel tank

From engine

From engine K95ZV22002J

Radiator mount

A-Detail

B-Detail

C-Detail

D-Detail K95ZVE22012

1. Strip seal Capacity in radiator: 61.4 L (16.2 gal) Cooling water 8.2 L (2.2 gal) Hydraulic oil Torque converter oil 3.9 L (1 gal) 2.1 L (0.6 gal) Fuel Dry weight

650 kg (1,430 lbs)

95ZV EX 22-6 22 Function & Structure Power Group Propeller Shaft

Propeller Shaft 1

K95ZV22001

1. 2nd propeller shaft 2. 3rd propeller shaft (fixed type) 3. Pillow block 4. Slip joint

The engine power is transmitted to the torque converter and the transmission, and is then transmitted to the second and the third propeller shafts to the front and the rear axle. For the second propeller shaft, the universal joint and slip joint type spline shaft are used for smooth power transmission at any steering angle or change in propeller shaft length. The third propeller shaft is the fixed type with universal joints.

95ZV EX 22-7 22 Function & Structure Power Group Propeller Shaft

Second propeller shaft assembly Front differential – Transmission

4 2

Every 2000 hours greasing

Front differential

3 4

Transmission

Every 2000 hours greasing K95ZVE22001

1. Journal spider assembly 2. Journal spider assembly 3. Propeller shaft assembly 4. Pillow block 5. Spline yoke 6. Sleeve yoke assembly

Note When the bolts are removed always replace them with new bolts. Never reuse the drive line bolts.

95ZV EX 22-8 22 Function & Structure Power Group Propeller Shaft

Third propeller shaft assembly Transmission – Rear differential

Every 2000 hours greasing

K95ZVE22002

1. Journal spider assembly 2. Propeller shaft

95ZV EX 22-9 22 Function & Structure Power Group Axle Assembly

Axle Assembly Front axle group 51

1 42

41 43 30 24

50 7 (S/N 9004~) (S/N 0188~) 7 (S/N 9001~9003) (S/N 0101~0187)

45 25

35 12 32

(S/N 0101~0311) (S/N 9001~ 11 9095)

(S/N 0101~0207) (S/N 0208~) 2 (S/N 9001~9004) (S/N 9005~)

49 48

20 19

23 46

(S/N 9001~9095) (S/N 9096~)

20 12

(S/N 9096~) (S/N 0312~)

21 34 5

16 (SN 9001~9095) (S/N 0101 26 10 ~0311) 26

(S/N 0101~0311)

16 (SN 9001~9095)

16 (S/N 9096~) (S/N 0312~) 40

52 36

4 53

19. Separation disc 20. Friction disc 21. Brake backing plate 22. Plate 23. Axle nut 24. Taper roller bearing (inner) 25. Taper roller bearing (outer) 26. Needle cage 27. Axle lock plate 28. Separation disc 29. Snap ring 30. Floating seal 31. D-ring 32. D-ring 33. O-ring 34. O-ring 35. Magnet plug 36. O-ring

35 8 29

37. Socket bolt 38. Spring 39. U-nut 40. Bolt 41. O-ring 42. Spacer 43. Ring 44. O-ring 45. Plug 46. Spring 47. Sleeve 48. Bushing 49. Socket bolt 50. Bolt 51. Bolt 52. Bolt 53. Socket bolt 54. Flange bolt

(FM) K95ZVE22003

95ZV EX 22-10 22 Function & Structure Power Group Axle Assembly Rear axle group (S/N 0101~0290) 1 (S/N 9001~9080)

R.H

(S/N 0188~) 7 (S/N 9004~)

7 (S/N 9001~9003) (S/N 0101~0187) 50 6 44

41 30

(S/N 0291~) 3 1 (S/N 9081~)

39 38

(S/N 0101~0311) (S/N 9001 ~9095) 25

(S/N 9001~9095) (S/N 9096~)

32 31 33

48 20

54 27

(S/N 0101~0311) (S/N 0312~)

(S/N 0312~) 12 (S/N 9096~)

16 (S/N 9096~) (S/N 0311~)

26 10

21 34

16 (S/N 0101~0310) (S/N 9001~9095)

5 9

14 22 40

52 36

L.H

4 35 53

29 (FM) K95ZVE22004

95ZV EX 22-11 22 Function & Structure Power Group Axle Assembly 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 11. Internal gear 12. Internal gear hub 13. Snap ring 14. Planetary pin 15. Spring pin 16. Wear ring 17. Wear ring 18. Piston

37. Socket bolt 38. Spring 39. U-nut 40. Bolt 41. O-ring 42. 43. Ring 44. O-ring 45. Plug 46. Spring 47. Sleeve 48. Bushing 49. Socket bolt 50. Bolt 51. 52. Bolt 53. Socket bolt 54. Flange bolt

95ZV EX 22-12 22 Function & Structure Power Group Axle Support

Axle Support Axle support assy (S/N 0101~0141, 9001~9003)

Grease pipe connection port Grease pipe connection port

(PT1/8)

Pin (Axle housing)

(PT1/8)

Rear side of axle support

Front

Front side of axle support

17 4

15 1 16

View A-A

10 #10 Details

#11 Details

K95ZVE22005

1. Shaft 2. Rear axle support (front) 3. Rear axle support (rear) 4. Wear ring 5. Plate 6. Plate 7. Lip seal 8. Lip seal 9. Breather

10. Bushing 11. Bushing 12. Snap ring 13. Snap ring 14. O-ring 15. Bolt 16. Bolt 17. Bolt

95ZV EX 22-13 22 Function & Structure Power Group Axle Support

Axle support group (S/N 0101~0141, 9001~9003)

7 14 9

2 11

10 17

7 FRONT

16 12

8 13 6

1 4 5 15 4

K95ZV22006

1. Shaft 2. Rear axle support (front) 3. Rear axle support (rear) 4. Wear ring 5. Plate 6. Plate 7. Lip seal 8. Lip seal 9. Breather

10. Bushing 11. Bushing 12. Snap ring 13. Snap ring 14. O-ring 15. Bolt 16. Bolt 17. Dowel pin

95ZV EX 22-14 22 Function & Structure Power Group Axle Support

Axle support assy (S/N 0142~0290, 9004~9080)

Grease pipe connection port Grease pipe connection port

(PT1/8) A

(PT1/8) Rear side of axle support

Pin Axle housing

Front

5 16 4

Front side of axle support

17 A

View A-A

13 15 12 10 #10 Details

#11 Details

K95ZV22007

1. Shaft 2. Rear axle support (front) 3. Rear axle support (rear) 4. Wear ring 5. Plate 6. Plate 7. Lip seal 8. Lip seal 9. Breather

10. Bushing 11. Bushing 12. Ring 13. Snap ring 14. O-ring 15. Plate 16. Bolt 17. Bolt 18. Bolt

95ZV EX 22-15 22 Function & Structure Power Group Axle Support

Axle support group (S/N 0142~0290, 9004~9080) 12 7 14 9

2 10 16

7 12 FRONT

8 13 6 1

4 5 17

18 K95ZVE22006

1. Shaft 2. Rear axle support (front) 3. Rear axle support (rear) 4. Wear ring 5. Plate 6. Plate 7. Lip seal 8. Lip seal 9. Breather 10. Bushing

11. Bushing 12. Ring 13. Snap ring 14. O-ring 15. Plate 16. Bolt 17. Bolt 18. Bolt 19. Dowel pin

95ZV EX 22-16 22 Function & Structure Power Group Axle Support

Axle support assy (S/N 0291~, 9081~)

Grease pipe connection port Grease pipe connection port

(PT1/8)

Pin Axle housing

Rear side of axle support

Front

5 16 4

Front side of axle support

9 14 View A-A

1 15

8 7

10 12 #11 Details

#10 Details

K95ZVE22007

1. Shaft 2. Rear axle support (front) 3. Rear axle support (rear) 4. Wear ring 5. Plate 6. Plate 7. Lip seal 8. Lip seal

9. Breather 10. Bushing 11. Bushing 12. Ring 13. Snap ring 14. Bolt 15. Bolt 16. Bolt

95ZV EX 22-17 22 Function & Structure Power Group Axle Support

Axle support group (S/N 0291~, 9081~) 15 1

6 4

9 14

5 10

7 FRONT

12 3

8 13

K95ZV22010

1. Shaft 2. Rear axle support (front) 3. Rear axle support (rear) 4. Wear ring 5. Plate 6. Plate 7. Lip seal 8. Lip seal

9. Breather 10. Bushing 11. Bushing 12. Ring 13. Snap ring 14. Bolt 15. Bolt 16. Dowel pin

95ZV EX 22-18 22 Function & Structure Power Group Differential Gear

Differential Gear Front differential gear 1

Grease nipple

2, 19

3 4 5

Fill with grease when assembling.

6 7

A Details (S/N 0101~0336) (S/N 9001~9095)

10 Fill with grease when assembling.

12 Grease nipple

19 A Details (S/N 0337~) (S/N 9096~)

18 K95ZVE22008

1. Flange 2. Oil seal (single lip) 3. Seal retainer 4. Bearing retainer 5. Shim 6. Taper roller bearing 7. Collar 8. Drive pinion 9. Carrier 10. Pilot bearing

11. Nut 12. Snap ring 13. Taper roller bearing 14. Adjusting nut 15. Side gear 16. Thrust washer (pinion gear) 17. Differential pinion 18. Ring gear 19. Oil seal (Double lips)

95ZV EX 22-19 22 Function & Structure Power Group Differential Gear

Rear differential gear (S/N 0101~0141, 9001~9003)

Fill with grease when assembling.

Grease nipple

2 23

4 5

3 A Details

8 9 10 21 25

12 13 15

14 17 16

19 20

K95ZVE22009

1. Nut 2. Flange yoke 3. Oil seal (single lip) 4. Seal retainer 5. Flange 6. Shim 7. Taper roller bearing 8. Spacer 9. Spiral gear set 10. Carrier assembly 11. Taper roller bearing 12. Adjusting nut 13. Plate

14. Bushing 15. Side gear 16. Differential pinion 17. Pin 18. Wear ring 19. Spider 20. Housing 21. Roller bearing 22. O-ring 23. O-ring 24. O-ring 25. Snap ring

95ZV EX 22-20 22 Function & Structure Power Group Differential Gear

Rear differential gear (S/N 0142~0290, 9004~9080)

Fill with grease when assembling.

Grease nipple

23 3

4 5

3 A Details

8 9 10 21 25

12 13 15

14 17 16

19 20

K95ZVE22010

14. Bushing 15. Side gear 16. Differential pinion 17. Pin 18. Wear ring 19. Spider 20. Housing 21. Roller bearing 22. O-ring 23. O-ring 24. O-ring 25. Snap ring

95ZV EX 22-21 22 Function & Structure Power Group Differential Gear

Rear differential gear (S/N 0291~, 9081~) 1 2

Fill with grease when assembling.

Grease nipple

3, 26

5 6

7 8

3 A Details (S/N 9081~9095)

9 10

21 25

Grease nipple

Fill with grease when assembling.

12 26 A Details (S/N 9096~)

13 15

14 17 16

19 20

K95ZVE22011

1. Nut 2. Flange yoke 3. Oil seal (single lip) 4. Trunnion 5. Flange 6. Shim 7. Taper roller bearing 8. Spacer 9. Spiral gear set 10. Carrier assembly 11. Taper roller bearing 12. Adjusting nut 13. Plate

14. Wear ring 15. Side gear 16. Differential pinion 17. Pin 18. Wear ring 19. Spider 20. Housing 21. Roller bearing 22. O-ring 23. O-ring 24. O-ring 25. Snap ring 26. Oil seal (double lips)

95ZV EX 22-22 22 Function & Structure Power Group Differential Gear

Function of T.P.D

Contact between pinion and side gear

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.

T.P.D.

Conventional differential

Difference in gear shapes

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

Shaft center of side gear 95ZV22018

Conventional differential

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.

T.P.D.

95ZV22014

Conventional differential Standard bevel gear T.P.D. Special bevel gear The gear width is 35 to 50% longer than the conventional differential.

95ZV EX 22-23 22 Function & Structure Power Group Differential Gear

Operation of T.P.D Rotational direction

Pinion

Pinion Side gear

R1 [A] The surface resistance values of the right and left wheels are identical to each other.

[B] The surface resistance of the left wheel is low due to sandy ground or the like.

[C] The surface resistance of the right wheel is low.

95ZV22015

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. 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. 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: R TR ------ = ------1 TL R2 The value obtained from the above formula is referred to as the bias ratio. The limit of the bias ratio is 1.37. In other words, until the difference in the surface resistance between the right and left tires is increased to 37%, 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.

95ZV EX 22-24 22 Function & Structure Power Group

MEMO

95ZV EX 23-1 23 Check & Adjustment Power Group

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

95ZV EX 23-2 23 Check & Adjustment Power Group Engine

Engine Measuring engine oil pressure WARNING

Measurement instrument

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

- Pressure gauge

Measurement instrument install position 1. Location (A) 2. Measuring port: M14 X 1.5 3. Oil pressure gauge: 1.0 MPa (10 kgf/cm2) (150 psi) (A)

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

Measuring engine speed Measurement instrument - Tachometer

Standard measurement value For Asia and Africa (S/N 0101~)

For Europe (S/N 9001~)

Low idle (min-1)

775±50

High idle (min-1)

2,350±50

2,250±50

Low idle: 0.1 MPa (1.1 kgf/cm2) High idle: 0.25~0.27 MPa (2.5~2.8 kgf/cm2) [Engine coolant temperature 50 ºC (120 ºF)]

97ZV23004

QSX-15 Engine

95ZV EX 23-3 23 Check & Adjustment Power Group Propeller Shaft

Propeller Shaft Propeller shaft phase

Third propeller shaft

Second propeller shaft

Front differential

Transmission

Rear differential

95ZV22007

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

Second propeller shaft alignment

Top view Differential side

(C)

(B)

(A)

Transmission side

Side view 95ZV22008

- As misalignment may produce an abnormal noise, be sure to align points (A), (B), and (C) of the yokes when reassembling the propeller shaft.

95ZV EX 23-4 23 Check & Adjustment Power Group Propeller Shaft

Propeller shaft tightening torque

2nd propeller shaft

Pillow block (Center bearing)

3rd propeller shaft

T/M

Front diff.

Washer Bolt

Rear diff.

3 6

8 (S/N 0413~) 2nd propeller shaft

3rd propeller shaft

K95V23001

IMPORTANT Never reuse universal joint or driveline bolts or locks. Always use new bolts and secure with loctite® 262 and primer. : 1. 142 N-m (14.5 kgf-m) (105 lb-ft) 2. 142 N-m (14.5 kgf-m) (105 lb-ft) 3. 142 N-m (14.5 kgf-m) (105 lb-ft) 4. 441 N-m (45.0 kgf-m) (326 lb-ft) 5. 162 N-m (16.5 kgf-m) (119 lb-ft)

6. 162 N-m (16.5 kgf-m) (119 lb-ft) 7. 162 N-m (16.5 kgf-m) (119 lb-ft) 8. 417 N-m (42.5 kgf-m) (308 lb-ft) #1, 2, 3: Screw lock agent (Three Bond 1327) #4, 8: Screw lock agent (Loctite® 262)

95ZV EX 23-5 23 Check & Adjustment Power Group Axle

Axle Axle nut tightening procedure 10

PT3/8 Brake oil inlet

1 11

4 13 5

3 14

1. Tighten axle nut (7) with 2,746 N-m (280 kgf-m) (2,026 lb-ft) tightening torque to install taper roller bearing (8)(9). 2. Loosen the axle nut. 3. Tighten the axle nut again with 2,746 N-m (280 kgfm) (2,026 lb-ft) tightening torque. 4. Turn wheel hub (10) 2~3 turns back and forth, and measure the preload applied to section ( part). Preload of section ( part) 324~363 N (33~37 kgf) (73~81 lbs)  This is "breakaway" force. The force required to start the wheel turning. Note Use jig to install the floating seal to the axle assembly.

K95ZVE23001

: 1. 89.7 N-m (9.15 kgf-m) (66 lb-ft) 2. 417 N-m (42.5 kgf-m) (307 lb-ft) 3. 33.3 N-m (3.40 kgf-m) (25 lb-ft) 4. 53.0 N-m (5.40 kgf-m) (39 lb-ft) 5. 86.3 N-m (8.80 kgf-m) (64 lb-ft) 6. 50.0 N-m (5.10 kgf-m) (37 lb-ft) Bolt (1)(2)(4)(11): Screw lock agent (Three Bond 1327)

95ZV EX 23-6 23 Check & Adjustment Power Group Axle

Planetary gear oil drain and refill 1. Move the machine on level ground so that the “TOP” mark on planetary gear housing (12) comes to the top. 2. Turn ON the parking switch, lower the attachment onto the ground, and stop the engine. 3. Remove level plug (13) and drain plug (14) using a 12 mm hex (Allen) wrench. 4. Drain the oil into a suitable container. 5. Install and tighten drain plug (14). 6. Refill the recommended oil through level plug hole (13) until the oil comes out from the hole. 7. Install and tighten level plug (13).

95ZV EX 23-7 23 Check & Adjustment Power Group Axle

Differential gear adjustment procedure 1

B 9 Grease nipple

A 7

Apply grease.

9 9, 10 2 3

9 9(single lip) (S/N 9001~9095) 10(S/N (S/N0101~0336) 9096~) (double lips) (S/N (S/N9001~9095) 0337~) 10 (double lip) (S/N 0337~, 9096~)

A-details

Differential installation bolt 4

Bleeder

5 Grease nipple View B (FM) K95ZVE23002

: 1. 883 N-m (90.0 kgf-m) (651 lb-ft) 2. 314 N-m (32.0 kgf-m) (232 lb-ft) 3. 873 N-m (89.0 kgf-m) (644 lb-ft) 4. 216 N-m (22.0 kgf-m) (159 lb-ft) Diff. installation bolt (F) 314 N-m (32.0 kgf-m) (232 lb-ft) Diff. installation bolt (R) 608 N-m (62.0 kgf-m) (449 lb-ft)

#2, 3, 4, 5: Screw lock agent (Three Bond 1327) #1: Liquid gasket (Three Bond 1215 or a locally procured Room Temperature Vulcanizer (RTV) that does not contain Acetic Acid) Diff. installation bolt: Screw lock agent (Three Bond 1327)

95ZV EX 23-8 23 Check & Adjustment Power Group Axle

[Front differential]

[Rear differential]

TOP

Breather

Grease nipple

3mm (0.118 in)

5mm (0.197 in)

Oil lip seal Double lips

Single lip (Flange yoke)

Oil lip seal Double lips

Grease

Single lip (Flange yoke)

Grease

K95ZV23004

Preload adjustment Measure the preload at the bolt hole of cage (7). Standard preload 36~45 N (3.7~4.6 kgf) (8~10 lbs) If the preload is out of the above range, replace spacer (6) to adjust the preload to the specified range. Preload is the force required to start the cage movingbreakaway force.

Note There are 20 types of spacers from 22.10 mm (0.870 in) to 22.48 mm (0.885 in) in increments of 0.02 mm (0.0007 in). Thicker spacers reduce preload; thinner spacers increase preload.

95ZV EX 23-9 23 Check & Adjustment Power Group Axle

Bearing installation Install bearing (8) so that part faces to the drive pinion. Pinion gear Snap ring

Bearing (8)

K85ZV23003

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

Oil seal installation Before installing the oil seals (9)(10), be sure to apply grease to the lip, and liquid gasket on the outside of the seal.

Apply grease when assembling.

K85ZV23004

After reassembling the differential assembly, apply grease to the grease nipple until the grease comes out of the breather nipple.

95ZV EX 23-10 23 Check & Adjustment Power Group Axle

Adjusting tooth contact Tooth contact

Possible cause

Adjusting method

Correct

Ring gear is too close to the drive pinion

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

Ring gear is too far from the drive pinion

Do the reverse adjusting as B.

Drive pinion is too close to the ring gear.

Increase the thickness of shim at the part of bearing cage being installed, and make drive pinion apart from the ring gear. Check again the backlash and tooth contact.

Drive pinion is too far from the ring gear.

Decrease the thickness of shim reverse as D, and make drive pinion approach the ring gear. Check again the backlash and tooth contact.

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

95ZV EX 23-11 23 Check & Adjustment Power Group Axle Three types of tooth contact shown below are acceptable as best tooth contact. Tooth contact position and length (rate) 10

Pattern A

5 TOP

HEEL 4~5

Pitch line TOE

BOTTOM 10

Pattern B

Pitch line

4 TOP

HEEL 4~5

TOE BOTTOM 10 3

Pattern C

TOP TOE

HEEL 4~5

Pitch line BOTTOM

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

95ZV EX 23-12 23 Check & Adjustment Power Group

MEMO

95ZV EX 32-1 32 Function & Structure Torque Converter and Transmission Group

32 Function & Structure Torque Converter and Transmission Group Torque Converter ..................................................................32-2 Torque Converter Gear Pump ...............................................32-3 Clutch Pack ...........................................................................32-9 Power Flow Path in the Transmission .................................32-10 Hydraulic System Diagram..................................................32-15 Hydraulic Circuit Diagram....................................................32-16 Oil Flow ...............................................................................32-17 T/C and T/M Oil Circulation .................................................32-18 Modulator Valve Unit ...........................................................32-19 Modulation Mechanism .......................................................32-22 Clutch Solenoid Valve .........................................................32-25

95ZV EX 32-2 32 Function & Structure Torque Converter and Transmission Group Torque Converter

Torque Converter Torque multiplication

Output

Torque ratio (t)

4 Input

S P

95ZV32002

Torque converter structure 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.

0.5 Speed ratio (e)

1.0

95ZV32003

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

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

95ZV EX 32-3 32 Function & Structure Torque Converter and Transmission Group Torque Converter Gear Pump

Torque Converter Gear Pump (T/M S/N 0101~0523) 1

10 2

4 6 7

3 Hydraulic pump side

8 9

11,12 95ZV32015

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

Gear pump specifications Theoretical discharge

73.6 cc/rev (4.49 in3/rev)

Maximum operation pressure

3.4 MPa (35 kgf/cm2) (498 psi)

Maximum operation speed

2,600 min-1 (rpm)

Actual discharge

Approx. 40 L/min (10.5 gpm) Conditions: Pump speed 830 min-1 Oil temp. 80~100°C (176~212°F) Oil viscosity 10CST (SAE10W) Discharge pressure 3.4 MPa (35 kgf/cm2) (498 psi)

95ZV EX 32-4 32 Function & Structure Torque Converter and Transmission Group Torque Converter Gear Pump

(T/M S/N 0524~) A 6

10 2

001A

9 3

Outlet

5 11, 12 Section A-A

Inlet

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

95V2E32002

Gear pump specifications Theoretical discharge

73.6 cc/rev (4.49 in3/rev)

Maximum operation pressure

3.4 MPa (35 kgf/cm2) (498 psi)

Maximum operation speed

2,610 min-1 (rpm)

Actual discharge

Approx. 40 L/min (10.5 gpm) Conditions: Pump speed 830 min-1 Oil temp. 80~100°C (176~212°F) Oil viscosity 10CST (SAE10W) Discharge pressure 3.4 MPa (35 kgf/cm2) (498 psi)

95ZV EX 32-5 32 Function & Structure Torque Converter and Transmission Group Torque Converter Gear Pump

Clutch combination Clutch Speed range

Shift lever position 2

Position of shift lever

F1 F2 F3 F4 N

(Either 1st, 2nd or 3rd)

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

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

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

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

R2 R3

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

Function

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

QUAD switch operation

Planetary gear

This feature permits quick up and down shifting when in 2nd and Automatic. Ring gear

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

Planetary gear carrier Planetary gear

Sun gear 95V2E32021

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

95ZV EX 32-6 32 Function & Structure Torque Converter and Transmission Group Torque Converter Gear Pump

Gear train and number of teeth

T/C

82 22

L 82

82 23

E/G

R 79 27

E/G

63 65

61 89

2nd propeller shaft

3rd propeller shaft

95ZV32004

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

Clutch specifications Friction plate Name of clutch

Piston stroke (mm)

Low range clutch

3.5±0.5

Number of plate 6

Reverse clutch

3.5±0.5

High range clutch

2.5±0.5

1st speed clutch

4.5±0.5

2nd speed clutch

2.0±0.5

3rd speed clutch

2.5±0.5

Steel plate

Outer Inner dia. Thickness (mm) Number dia. (mm) New/Wear limit of plate (mm) ø360 ø236 ø360

ø279

4±0.13 / 3.5 (Sintered)

ø159

4±0.1 / 3.4 (Sintered)

4±0.13 / 3.8 (Paper)

ø279

5 6 3

Number of Outer Inner dia. Thickness (mm) return spring dia. (mm) New/Wear limit (mm) ø426 ø252 ø426

ø298 ø173 ø298

3.5±0.1 / 3.3 3.2±0.1 / 3.0 3.5±0.1 / 3.3

6 12 12 12 12 12

95ZV EX 32-7 32 Function & Structure Torque Converter and Transmission Group Torque Converter Gear Pump

Friction plate For low, reverse clutch mm (in)

3.0 (0.12) 0.6 (0.02)

Detail drawing of groove 95V2E32023

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

1.2 (0.05) 360 (14.2 )

2.6 (0.10)

279 +- 00.8 (11.0 +- 00.03 )

0.1 (0.004) above

Detail drawing of groove 95V2E32024

1. Plate 2. Facing (paper) For high, 1st speed clutch mm (in)

159 +- 00.5 (6.26 +- 00.02)

2.6 (0.10)

0.25 0.01 0.3 +- 0.05 (0.01 +- 0.002 )

Detail drawing of groove 95V2E32025

1. Plate 2. Facing (sintered)

95ZV EX 32-8 32 Function & Structure Torque Converter and Transmission Group Torque Converter Gear Pump

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

0 0 426 +- 1.5 (16.7 +- 0.06 )

1.0 298 +- 3.0 (11.7 +- 0.04 0.1 )

mm (in)

95V2E32026

For high, 1st speed clutch

0 252 +- 00.5 (9.92 +- 0.02 )

mm (in)

95V2E32029

95ZV EX 32-9 32 Function & Structure Torque Converter and Transmission Group Clutch Pack

Clutch Pack Inlets for reverse and low range clutch oil 10 12 11

Inlets for 2nd and 3rd speed clutch 17 15 oil

23 25

9 8 6

Inlet of 1st speed clutch oil Inlet of high range clutch oil

Inlet of lubricating and cooling oil

1 7 4 3

1. Clutch input shaft 2. High range clutch drum 3. Spider 4. High 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 range clutch piston 17. Low range planetary gear

20 34

13 14

18. Low range ring gear 19. Low range sun gear 20. Anchor pin 21. 3rd speed clutch piston 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 (Helical type) 32. Clutch output shaft 33. 2nd speed planetary gear carrier 34. Low/3rd speed planetary gear carrier

95ZV32005

95ZV EX 32-10 32 Function & Structure Torque Converter and Transmission Group Power Flow Path in the Transmission

Power Flow Path in the Transmission Forward 1st speed flow path

1st speed clutch

Inlet of low range clutch oil

17 18

Low range clutch

Input power

Inlet of 1st speed clutch oil

Output power

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.

95ZV32016

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 Sun gear (19)

Low range ring gear (18)

Low range planetary gear (17) 95ZV32006

95ZV32007

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

95ZV EX 32-11 32 Function & Structure Torque Converter and Transmission Group Power Flow Path in the Transmission

Forward 2nd speed flow path

2nd speed clutch

2nd speed clutch oil Low range clutch oil Low range clutch Input power

Output power 95ZV32017

Forward 3rd speed flow path 3rd speed clutch oil Low range clutch oil Low range 3rd speed clutch clutch Input power

Output power 95ZV32018

95ZV EX 32-12 32 Function & Structure Torque Converter and Transmission Group Power Flow Path in the Transmission

Forward 4th speed flow path 2nd speed clutch oil

High range clutch

2nd speed clutch Input power High range clutch oil

Output power 95ZV32019

95ZV EX 32-13 32 Function & Structure Torque Converter and Transmission Group Power Flow Path in the Transmission

Reverse 1st speed flow path Reverse clutch oil

Reverse clutch

1st speed clutch Input power 1st speed clutch oil

Output power 95ZV32020

Reverse 2nd speed flow path 2nd speed clutch oil

Reverse clutch oil

Reverse clutch

2nd speed clutch Input power

Output power 95ZV32021

95ZV EX 32-14 32 Function & Structure Torque Converter and Transmission Group Power Flow Path in the Transmission

Reverse 3rd speed flow path 3rd speed clutch oil

Reverse clutch oil Reverse clutch 3rd speed clutch Input power

Output power 95ZV32022

95ZV EX 32-15 32 Function & Structure Torque Converter and Transmission Group Hydraulic System Diagram

Hydraulic System Diagram Note Numbers below correspond to the next page.

Shift lever

Control box

12 10

11 6 17

21 20

4 16 8 13

23 24 27 25

97ZA32-27

95ZV EX 32-16 32 Function & Structure Torque Converter and Transmission Group Hydraulic Circuit Diagram

Hydraulic Circuit Diagram Neutral position

Modulator valve unit

12 9 GA

GB 8

30K 7 6

3K 4

24 15 19

1st 25

3 20

2nd 26

3rd

Note All orifice measurements ( ø) are in mm.

21 27

K95ZV32001

1. Transmission oil pan 2. Strainer 3. Torque converter gear pump 4. Line filter with bypass valve 5. Clutch pressure regulator valve 6. Modulator valve (1) 7. Relief valve 8. T/C inlet relief valve 9. Modulator valve (2) 10. Check valve (1)

11. Check valve (2) 12. Pressure difference sensor 13. Torque converter 14. T/C outlet relief valve 15. Oil cooler 16. High speed range clutch solenoid valve 17. Reverse clutch solenoid valve 18. Low speed range clutch solenoid valve

19. 1st speed clutch solenoid valve 20. 2nd speed clutch solenoid valve 21. 3rd speed clutch solenoid valve 22. High speed range clutch 23. Reverse clutch 24. Low speed range clutch 25. 1st speed clutch 26. 2nd speed clutch 27. 3rd speed clutch

95ZV EX 32-17 32 Function & Structure Torque Converter and Transmission Group Oil Flow

Oil Flow Oil flow in the torque converter line From torque converter charge pump to 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 converter's inlet pressure exceeds 0.9 MPa (9 kgf/cm2) (128 psi), it forces open the torque converter inlet relief valve (8), allowing the oil to escape to the oil pan.

From torque converter to cooling circuit Return oil from the torque converter flows through the outlet relief valve (14) (set pressure=0.3 MPa (3 kgf/ cm2) (42.7 psi)) in the torque converter housing and to the torque converter cooler (15).

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

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.

95ZV EX 32-18 32 Function & Structure Torque Converter and Transmission Group T/C and T/M Oil Circulation

T/C and T/M Oil Circulation

(S/N 0101~0230) (S/N 9001~9010)

Radiator

(S/N 0231~0238) (S/N 9011)

(S/N 0101~0230) (S/N 9001~9010)

(S/N 0239~) (S/N 9012~)

(S/N 0231~) (S/N 9011~) Torque converter oil cooler

Torque converter

Transmission oil filter Transmission

K95ZV32002

95ZV EX 32-19 32 Function & Structure Torque Converter and Transmission Group Modulator Valve Unit

Modulator Valve Unit Clutch solenoid valve assy

Modulator valve unit

1st speed clutch solenoid valve

K95ZVE32001

Unit configuration

9 6

K95ZVE32002

1. — 2. — 3. — 4. — 5. Clutch pressure regulator valve 6. Modulator valve (1) (Reducing valve) 7. Relief valve (2.9 MPa (30 kgf/cm2) (427 psi)) 8. — 9. Modulator valve (2) (Solenoid valve) 10. — 11. — 12. Pressure difference sensor (S/N ~0556) Note Numbers above also correspond to "Hydraulic Circuit Diagram" page 32-16.

95ZV EX 32-20 32 Function & Structure Torque Converter and Transmission Group Modulator Valve Unit

Red

Black

White

E-E

GP E ø 3.0 orifice

ø 0.9 orifice 6

9 9 GT

GB 7 F

C F-F

5 (+) Line red

View A

Line black (-)

1. — 2. — 3. — 4. — 5. Clutch pressure regulator valve 6. Modulator valve (1) 7. Relief valve (2.9 MPa (30 kgf/cm2) (427 psi)) 8. T/C inlet relief valve (0.9 MPa (9 kgf/cm2) (128 psi)) 9. Modulator valve (2) (Solenoid valve) 10. Check valve 1 (0.6 MPa (6 kgf/cm2) (85 psi)) 11. Check valve 2 (0.4 MPa (4 kgf/cm2) (57 psi)) 12. Pressure difference sensor (S/N ~0556) Note Numbers above also correspond to "Hydraulic Circuit Diagram" page 32-16.

ø 4.5 orifice

10 C-C

D-D 95ZV32008

95ZV EX 32-21 32 Function & Structure Torque Converter and Transmission Group Modulator Valve Unit

Interior schematic (example) To clutch solenoid valve

10 9 0.6 Mpa (85 psi)

0.4 Mpa (57 psi)

5 6

To torque converter 0.9 MPa 2 (9 kgf/cm ) (128 psi)

Drain From pump

1. — 2. — 3. — 4. — 5. Clutch pressure regulator valve 6. Modulator valve (1) (Reducing valve) 7. Relief valve (2.9 MPa (30 kgf/cm2) (427 psi)) 8. T/C inlet relief valve (0.9 MPa (9 kgf/cm2) (128 psi)) 9. Modulator valve (2) (Solenoid valve) 10. Check valve 1 (0.6 MPa (6 kgf/cm2) (85 psi)) 11. Check valve 2 (0.4 MPa (4 kgf/cm2) (57 psi)) 12. Pressure difference sensor (S/N ~0556) Note Numbers above also correspond to "Hydraulic Circuit Diagram" page 32-16.

2.9 MPa (30 kgf/cm2) (427 psi)

Drain

12 (S/N ~0556) 9 GA

To transmission clutch

10 GP

To torque converter

GB 8 9K

30K 7 6

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

From pump 95ZV32013

95ZV EX 32-22 32 Function & Structure Torque Converter and Transmission Group Modulation Mechanism

Modulation Mechanism Modulator valve function

Modulator valve 1

When changing forward/reverse 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.

Pressure difference sensor (S/N ~0556) To clutch solenoid valve

Modulator valve 2

For such effects, the modulation mechanism controls the clutch oil pressure rising time as follows:

6 kgf/cm2 4 kgf/cm2

An electrical signal from the shift control unit (SCU) controls the trimmer operation. For information on the SCU refer to "Electrical Group" section.

Clutch pressure regulator valve

Modulator valve 1

Port P

F f To torque converter

9 kgf/cm2

From pump

Drain

30 kgf/cm2

Drain

95ZV32009

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 left 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 0.9 MPa (9 kgf/cm2) (128 psi) to the drain port, reducing clutch oil pressure.

95ZV EX 32-23 32 Function & Structure Torque Converter and Transmission Group Modulation Mechanism

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. When the modulator valve 2 is energized, the spool moves to the left and the oil in the clutch circuit is drained through the ø 0.9 orifice. The oil from the pump forces open the 0.6 MPa (6 kgf/cm2) (85 psi) 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.

Pressure difference sensor (S/N ~0556) 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 (4 kgf/ cm2) (57 psi) and the ø 4.5 orifice. Oil stops flowing through the check valve and the ø 4.5 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 ø 4.5 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.

Clutch oil pressure control at the time of engine starting

Clutch oil pressure

Modulator valve 2

Starter SW Engine ON start Specified pressure 3 sec

Time 95ZV32010

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.)

95ZV EX 32-24 32 Function & Structure Torque Converter and Transmission Group Modulation Mechanism

Modulator valve operation

1. Initial oil charging (t1) into the clutch piston chamber

Modulation chart (Neutral1st forward)

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

ON Low range clutch OFF solenoid valve ON

1st speed clutch solenoid valve

Modulator valve 1

Oil filling completed

Current (mA)

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.

about 400 mA

about 170 mA 0

Modulator valve 2

The time taken for this initial charging, which depends on the capacity of the clutch piston chamber, is controlled by a microcomputer.

ON OFF

OFF

2. Low pressure holding (t2)

Main pressure Pressure MPa (kgf/cm2)

Low range clutch pressure Pressure MPa (kgf/cm2)

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.

0 t1

This time is also controlled by the microcomputer. When shifted

Shift completed

3. Pressure rise (t3) 95V2E32019

charging t1 Initial time

Changes with combination of clutches

0~0.12 sec

pressure t2 Low holding time

Changes with engine speed

Less than 0.5 sec

rise t3 Pressure time

Changes with combination of clutches

0.3~0.7 sec

with combination of 0.5~1.3 sec t4 Restoration time Changes clutches

P1 0.2~0.5 MPa (2~5 kgf/cm2) (28~71 psi) P2 2.3~2.5 MPa (23~26 kgf/cm2) (327~370 psi) 2

speed 2.5~2.8 MPa (26~29 kgf/cm ) (370~412 psi) P3 1st Except 1st speed 2.6~2.9 MPa (27~30 kgf/cm2) (384~427 psi)

- E/G high idle

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.

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

95ZV EX 32-25 32 Function & Structure Torque Converter and Transmission Group Clutch Solenoid Valve

Clutch Solenoid Valve Clutch solenoid valve assy

Modulator valve unit

1st speed clutch solenoid valve

K95ZVE32001

Note The 1st speed clutch solenoid valve is installed as a separate unit on the transmission housing.

Unit configuration

3rd

2nd

Solenoid valve K95ZVE32003

95ZV EX 32-26 32 Function & Structure Torque Converter and Transmission Group Clutch Solenoid Valve

3 4

Side view 95ZV32012

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)

95ZV EX 32-27 32 Function & Structure Torque Converter and Transmission Group Clutch Solenoid Valve

For high/reverse and speed clutches After power-off (Clutch disengaged status)

From modulator valve

3 4

To T/M oil pan

From clutch piston chamber

95ZV32023

When the coil (3) 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.

95ZV EX 32-28 32 Function & Structure Torque Converter and Transmission Group Clutch Solenoid Valve

After power-on (Clutch engaged status)

From modulator valve

To T/M oil pan

To clutch piston chamber

95ZV32024

When the coil (3) 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. Inserting a push rod into the hole at the end of the clutch solenoid valve will push down on the pin (4). This forces the main spool down and engages the clutch. This may be used for testing the movement of the main spool.

95ZV EX 33-1 33 Check & Adjustment Torque Converter and Transmission Group

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

95ZV EX 33-2 33 Check & Adjustment Torque Converter and Transmission Group Clutch Oil Pressure and Time Lag

Clutch Oil Pressure and Time Lag Measuring clutch oil pressure

Gauge port 1. Location:

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

3rd speed clutch

Valve unit

1st speed clutch

Solenoid valve

Main clutch 95ZV33001

Transmission oil pressure test port location

Measurement instrument - Pressure gauge - Tachometer - Stop watch

R clutch L clutch 2nd speed clutch 95ZV33002

2. Measuring port: Main, 1st clutch PF 3/8 Except main, 1st clutch PF 1/4 3. Oil pressure gauge: 5 MPa (50 kgf/cm2) (1,000 psi) with 2 ~ 3 m (6 ~ 10 ft.) hose Note Warm-up the engine before measuring the clutch oil pressure and time lag

95ZV EX 33-3 33 Check & Adjustment Torque Converter and Transmission Group Clutch Oil Pressure and Time Lag

Possible causes for low clutch oil pressure

Standard measurement value 1st speed

2.2 -2.5 (22 - 25) (313 - 356)

Except 1st

2.3 - 2.5 (23 - 26) (327 - 370)

1st speed

2.5 - 2.8 (26 - 29) (370 - 412)

Except 1st

2.6 - 2.9 (27 - 30) (384 - 427)

Neutral1st forward speed (engine speed: 1,500 min-1 (rpm))

0.3 ± 0.1

Low idle Clutch pressure MPa (kgf/cm2) (psi)

Engine speed High idle

Clutch time lag (sec)

Clutch oil pressure measurement procedure - Lower the boom to the lowest limit, and lower the bucket onto the ground. - Set the parking brake to the "ON" position. - Set the transmission shift lever to the neutral position. - Stop the engine. Attach the pressure gauge to the pressure measurement port. Place the gauge inside the operator's area, start the engine. - As the clutch oil pressure rises just after the engine is started, adjust the engine to the specified speed before the pressure measurement. - Measure and record the pressure in each speed range. - Change the transmission speed range while keeping the shift lever at the neutral position. Check that the pressure instantaneously lowers just after speed change, and then rises to the original pressure again.

Possible cause

Solution

Malfunctioning modulator valve (1) operation

Inspection & repair

Malfunctioning modulator valve (2) operation

Inspection & repair

Defective controller

Replacement

Oil leakage from clutch

Disassembly & repair

95ZV EX 33-4 33 Check & Adjustment Torque Converter and Transmission Group Clutch Oil Pressure and Time Lag

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

Time lag measurement procedure - Lower the boom to the lowest limit, and fully roll back the bucket until the bucket contacts to the stopper. - Set the parking brake switch to the "OFF" position. Do not apply the service brakes. - Set the transmission shift lever to the neutral 1st speed. - Keep the engine speed at 1,500 min-1 (rpm). - Move the shift lever to the forward position. At the same time, start the stop watch to measure the time required before the machine moves.

Possible causes for clutch time lag Possible cause

Solution

Defective pressure difference sensor (S/N ~0556)

Replacement

Malfunctioning modulator valve (1) operation

Inspection & repair

Malfunctioning modulator valve (2) operation

Inspection & repair

Defective controller

Replacement

Defective clutch

Disassembly & repair

95ZV EX 42-1 42 Function & Structure Hydraulic Group

42 Function & Structure Hydraulic Group Flushing Hydraulic Circuit......................................................42-2 Cautions on Hydraulic Parts Replacement............................42-3 Hydraulic Circuit Symbols .....................................................42-4 Hydraulic System Operation..................................................42-8 Layout of Hydraulic Units ....................................................42-10 Hydraulic Tank.....................................................................42-11 Hydraulic Pump ...................................................................42-17 Hydraulic Cylinder ...............................................................42-28 Loading System ..................................................................42-32 Reducing Valve (for Pilot Pressure) ....................................42-33 Pilot Valve (S/N 0101~0290, 9001~9080) ...........................42-34 Pilot valve (S/N 0291~0408, 9081~) ...................................42-39 Pilot valve (S/N 0409~0410) ...............................................42-44 Pilot valve (S/N 0411~)........................................................42-49 Multiple Control Valve (KML35A/2T003B)...........................42-54 Adapter (Orifice) ..................................................................42-66 Vibration Damper (OPT)......................................................42-67 Steering System ..................................................................42-78 Orbitrol® ...............................................................................42-79 Steering Valve (KVS32-A4.0) ..............................................42-86 Stop Valve ...........................................................................42-99 Reducing Valve (for Orbitrol®) ...........................................42-103 Steering Line Filter ............................................................42-104 Fan Motor System .............................................................42-106 Fan Motor Line (S/N 0101~0230)......................................42-108 Fan Motor Line (S/N 0231~)..............................................42-116 Fan Motor Line (S/N 9001~9010)......................................42-131 Fan Motor Line (S/N 9011~) ..............................................42-139 Emergency Steering (for Europe)......................................42-149

95ZV EX 42-2 42 Function & Structure Hydraulic Group Flushing Hydraulic Circuit

Flushing Hydraulic Circuit Purpose of flushing

Debris To tank

95ZV42001

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

95ZV EX 42-3 42 Function & Structure Hydraulic Group Cautions on Hydraulic Parts Replacement

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

95ZV EX 42-4 42 Function & Structure Hydraulic Group Hydraulic Circuit Symbols

Hydraulic Circuit Symbols Hydraulic lines

Pumps & motors (1)

Working hydraulic line

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

Pilot line Drain line

(2)

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

Lines joining

Flexible line

(2)

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

Lines passing

Line to tank (Above fluid level)

(2)

(1)

Line to tank (Below fluid level)

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

Hydraulic tank (Pressurized type)

Fixed restriction

(2)

Cylinders (1)

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

(2)

Single acting cylinder (without spring)

Single acting cylinder (with spring)

Double acting cylinder (single rod)

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

(1)

(2)

(1)

(2)

(1)

(2)

(1)

(2)

95ZV EX 42-5 42 Function & Structure Hydraulic Group Hydraulic Circuit Symbols

Operation methods

Pressure control valve

Spring

Single flow path valve, Normally closed

Adjustable spring

Single flow path valve, Normally open

Control methods Pressure relief valve

Lever

Push button Unloading valve Pedal or treadle

Mechanical control Sequence valve Plunger

Pressure reducing valve

Spring Solenoid control Single acting solenoid

Flow control valve

Double acting solenoid

Flow control valve, Adjustable noncompensated

Electric motor control Unidirectional

Pressure compensated flow control valve fixed

Bidirectional

M variable

Detent

Flow dividing valve

95ZV EX 42-6 42 Function & Structure Hydraulic Group Hydraulic Circuit Symbols

Directional control valve

Check valve

Two position Two ports

Check valve

Three position Four ports

Check valve Pilot operated

Four ports with restrictor

Shuttle valve

Two position Two ports Mechanical control

Spring offset Pressure control Two position Three ports Pressure control

Spring offset Solenoid control Restrictor Two ports

Three ports

Four ports

Servo valve

95ZV EX 42-7 42 Function & Structure Hydraulic Group Hydraulic Circuit Symbols

Miscellaneous hydraulic symbols (1) Hydraulic tank (1) Vented (2) Pressurized

(2)

Manual shut off valve

Pressure switch

Accumulator

Electric motor

Internal combustion

Power source

Filter or strainer

Heater

Cooler

Pressure gauge

Temperature gauge

Flow meter

95ZV EX 42-8 42 Function & Structure Hydraulic Group Hydraulic System Operation

Hydraulic System Operation Hydraulic system operation outline The hydraulic system consists of the following systems: - Loading system - Steering system - Fan motor system - Vibration damper system (OPT)

Loading system The loading system consists of the following components. All numbers base on page 92-4 or page 92-7. - Hydraulic pump (1) - Unloader valve (22) - Line filter (81) - Reducing valve (46) - Check valve (32) - Reducing valve (28) - Pilot valve (16) - Multiple control valve (3) - Boom cylinders (5) - Bucket cylinders (6) Oil from pump (1) flows to pilot valve (16) through unloader valve (22), line filter (81), reducing valve (46), check valve (32) and reducing valve (28). Oil to pilot valve (16) is reduced to 3.5 MPa (36 kgf/cm2) (512 psi) by reducing valve (28). When the pilot control lever is operated, the pilot valve line is opened, and the oil pressure is generated depending on the position of the pilot control lever. The pilot pressure entering the oil pack to multiple control valve (3) moves the spool against its return spring. The spool press-in distance (displacement) depends on the pilot valve pressure. Oil from the loader pump is then directed through multiple control valve (3) to boom cylinders (5) and bucket cylinder (6). Return oil from the cylinders flows through the multiple control valve (3) to the oil cooler, return filter (12) and into the hydraulic tank. Even if no hydraulic pump supplies oil to the loading and pilot control circuits due to trouble, or if the engine is shut off, the boom can be lowered to the ground by the pressure in the accumulator (33) in the brake circuit in case of an emergency.

95ZV EX 42-9 42 Function & Structure Hydraulic Group Hydraulic System Operation

Steering system

Fan motor system

The steering system consists of the following components.

The fan motor system consists of the following components.

- Hydraulic pump (2) - Steering valve (4) - Line filter (81) - Reducing valve (18) - Orbitrol® (14) - Stop valve (15) - Steering cylinders (8)

- Hydraulic pump (2) - Unloader valve (22) - Fan motor (71) - Relief valve (two-step relief) (73) (S/N 9001~9010) - Thermo sensing valve (76) (S/N 9011~)

Oil from pump (2) flows to Orbitrol® (14) through steering valve (4), line filter (81) and reducing valve (18). Oil to Orbitrol® (14) is reduced to 3.5 MPa (36 kgf/cm2) (512 psi) by reducing valve (18). A small amount of pilot oil supplied from the Orbitrol® (14) controls the steering valve (4) to realize steering operations. When the steering wheel is turned, oil at a flow rate proportional to the turning speed is sent from the Orbitrol® (14) and supplied to the oil pack of the steering valve (4). At this time, the pilot pressure is generated. The pilot pressure strokes the spool of the steering valve (4), and supplies hydraulic oil at large flow rate proportional to the flow rate of the supplied pilot oil to the cylinder line.

The cooling fan is driven by hydraulic motor (71). The pressure oil from unloader valve (22) flows into the port P of the fan motor assy and then turns fan motor (71). (S/N 9001~9010) The fan revolution is regulated by two-step relief valve (73) integrated into the line. When the water temperature is below 94ºC (200ºF), relief valve (73) is set to the low pressure, and the maximum fan speed is set to 955 min-1 (rpm). When the water temperature is over 94ºC (200ºF), it sets relief valve (73) to the high pressure, as a result, the maximum fan speed is set to 1,365 min-1 (rpm). (S/N 9011~) The fan revolution is regulated by thermo sensing valve (76). The setting pressure of thermo sensing valve (76) is changed in accordance with the engine cooling water temperature, and the regulated maximum number of revolutions varies depending on the cooling water temperature.

The excessive pilot oil flows through the steering valve (4) to the other side of the pilot port. Shortly before the full turn, the stop valve (15) activates, the pilot circuit is closed. While the steering wheel is not turned, almost all hydraulic oil from the steering pump (2) is sent to the loading line by the action of the flow control spool. Oil returns from the steering cylinders (8) flows through the steering valve (4) and oil cooler or cooler bypass valve (11). Finally it returns to the tank through the return filter (12).

Vibration damper system (OPT) Refer to "Vibration Damper (OPT)" page 42-67 for the information.

95ZV EX 42-10 42 Function & Structure Hydraulic Group Layout of Hydraulic Units

Layout of Hydraulic Units

7 1 9

8 4

11 2 5,6

10 11

95ZV42039

1. Multiple control valve 2. Pilot valve (for loading) 3. Orbitrol® 4. Steering valve 5. Hydraulic pump (for steering) 6. Hydraulic pump (for loading, for pilot & brake)

7. Fan motor 8. Relief valve (for fan) 9. Bucket cylinder 10. Boom cylinder 11. Steering cylinder

95ZV EX 42-11 42 Function & Structure Hydraulic Group Hydraulic Tank

Hydraulic Tank Hydraulic tank specifications Type

Semi-closed type

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

150 (40 US gal)

Filtration area (cm )

25,500

Filtration particle size (µm)

Return filter

28 (MPa) (kgf/cm2) (psi)

Relief valve opening pressure (filter bypass)

Suction strainer

Loading Pilot & brake Steering

0.1 ± 0.02 (1.0 ± 0.2) (14 ± 2.8)

Filtration area (cm )

2,550

Filtration particle size (µm)

105

Steering

Filtration area (cm )

1,640

Filtration particle size (µm)

105 2

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

1 (0.01) (0.14)

Discharge valve setting pressure (kPa) (kgf/cm ) (psi) Breather valve (oil filling port) (S/N 0101~0450) (S/N 9001~)

29 (0.3) (4.3)

Filtration area (cm )

235

Filtration particle size (µm)

Pushing load before turning cap required for venting pressure, removing or installing cap N (kgf) (lb)

186 ~ 216 (19 ~ 22) (42 ~ 48)

Suction valve setting pressure (kPa) (kgf/cm2) (psi) Breather valve (oil filling port) (S/N 0451~)

3.9 (0.04) (0.57)

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

29 (0.3) (4.3)

Filtration area (cm )

160

Filtration particle size (µm)

Hydraulic oil level check Before checking the hydraulic oil level, observe the following items: - Check that the machine is on level ground. - Check the hydraulic oil level before operation (when oil is not warm). - Lower the boom to the lowest limit, and set the bucket level on the ground. Check that the oil level is at the center of the oil level sight gauge.

Bucket on ground

Hydraulic tank

Oil amount 150 L (40 US gal)

Oil level sight gauge

150 L

(40 US gal)

Cold level

Note If the oil is at operating temperature 60 ~ 90°C (140 ~ 200°F) the oil level may be at or near the top of the oil level sight gauge.

90ZVE42004

95ZV EX 42-12 42 Function & Structure Hydraulic Group Hydraulic Tank

Hydraulic tank (S/N 0101~0450, 9001~) 10

Viewed from top

9 8

3 As seen from chassis out

Outside of machine

To chassis

1. Oil tank 2. Oil level sight gauge 3. Breather valve (tank cap) 4. Filter 5. Suction strainer (loading, brake) 6. Suction strainer (steering) 7. Return filter element

8. Filter bypass valve 9. Spring 10. Cover 11. Drain plug 12. Inspection port 13. Vent pipe (to axle housing) 95ZV42068

95ZV EX 42-13 42 Function & Structure Hydraulic Group Hydraulic Tank

Hydraulic tank breather valve (tank cap) (S/N 0101~0450, 9001~)

4 5

For Asia and Africa

a b

Viewed from section A For Europe

Viewed from section A

1. Cover 2. Filter element 3. Spring (for exhaust valve) 4. Valve assembly (a) Exhaust valve (b) Suction valve (c) Air bleeder valve 5. Spring (for suction valve) 6. Key (same as starter key) 7. Attaching bolts (3 pcs) socket head 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 to a certain point 29 kPa (0.3 kgf/cm2) (4.3 psi), 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.

K95V42001

Therefore 29 kPa (0.3 kgf/cm2) (4.3 psi) pressure is always applied to the inside of the hydraulic tank. The pressure applied to the inside of the hydraulic tank prevents the dust and dirt from being drawn into the tank and improves performance of the pump. The positive pressure pushes the oil to the pump reducing the possibility of pump cavitation. To release the internal pressure from the hydraulic tank, press downward on the cover (1). The air bleeder valve (c) will be lowered to release the internal pressure. The pressure is also applied to the axles.

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

95ZV EX 42-14 42 Function & Structure Hydraulic Group Hydraulic Tank

Air breather line

Rear axle

Front axle

A (S/N 0101~0135, 9001~9003)

(S/N 0136~0262, 9004~9064)

K95ZV42001

95ZV EX 42-15 42 Function & Structure Hydraulic Group Hydraulic Tank

Hydraulic tank (S/N 0451~) 10 (S/N 0477~)

Viewed from top

3 As seen from chassis out

Outside of machine

To chassis

A 12

11 14 1. Oil tank 2. Oil level sight gauge 3. Breather valve (tank cap) 4. — 5. Suction strainer (loading, brake) 6. Suction strainer (steering) 7. Return filter element

8. Filter bypass valve 9. Spring 10. Cover 11. Drain plug 12. Inspection port 13. Vent pipe (to axle housing) 14. Magnet plug (S/N 0477~) K95ZV42024

95ZV EX 42-16 42 Function & Structure Hydraulic Group Hydraulic Tank

Hydraulic tank breather valve (tank cap) (S/N 0451~) When the pressure inside the hydraulic tank drops below the outside air pressure, the outside air flows through filter element (2) and to valve assembly (4). Suction valve (b) is then opened to let the air flow into the tank.

PUSH

When the air pressure inside the hydraulic tank rises to a certain point 29 kPa (0.3 kgf/cm2) (4.3 psi), Exhaust valve (a) is lifted (opened) so that the air can flow out of the tank through filter element (2).

1 6

One cycle (down and up) of the boom applies pressure to the inside of the tank.

The positive pressure pushes the oil to the pump reducing the possibility of pump cavitation.

a b 5 K65D2J42001

1. Cap 2. Filter element 3. Spring (for exhaust valve) 4. Valve assembly (a) Exhaust valve (b) Suction valve (Air bleeder valve) 5. Spring (for suction valve) 6. Hex nut

To release the internal pressure from the hydraulic tank, press down cap (1). Air bleeder valve (b) will be lowered to release the internal pressure. The pressure is also applied to the axles.

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

95ZV EX 42-17 42 Function & Structure Hydraulic Group Hydraulic Pump

Hydraulic Pump (S/N 0101~0258) (S/N 9001~9065)

Hydraulic pump (for steering)

Hydraulic pump (for loading, pilot & brake)

Torque converter

Hydraulic tank

K95ZVE42001

95ZV EX 42-18 42 Function & Structure Hydraulic Group Hydraulic Pump

(S/N 0259~) (S/N 9066~)

Hydraulic pump (for steering)

Hydraulic pump (for loading, pilot & brake)

Torque converter

Hydraulic tank

K95ZVE42002

95ZV EX 42-19 42 Function & Structure Hydraulic Group Hydraulic Pump

Loading and pilot and brake pump 5

2 6

3 4 7

8 (S/N 0387~)

K95V2U42005

5. Oil seal 6. Bushing 7. Wear plate (floating type) 8. Damper (Sleeve) (S/N 0387~)

1. Drive gear (front) 2. Drive gear (rear) 3. Driven gear (front) 4. Driven gear (rear)

Pump specifications Applicable circuit Theoretical discharge Maximum operation pressure Maximum speed

cm3/rev 2

MPa (kgf/cm ) min-1

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

Front

Rear

Loading circuit

Pilot & Brake circuit

90.7

74.9

23.5±0.5 (240±5) (3,414±71)

18.6 (190) (2,702) 2,500

95ZV EX 42-20 42 Function & Structure Hydraulic Group Hydraulic Pump

Steering pump (S/N 0101~0258, 9001~9065) 6

5 97ZV42012

1. Drive gear 2. Driven gear 3. Oil seal

4. Oil seal 5. Bushing 6. Wear plate (fixed type)

Pump specifications Applicable circuit Theoretical discharge Maximum operation pressure Maximum speed

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

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

113 24.5±0.5 (250±5) (3553±73) 2,500

95ZV EX 42-21 42 Function & Structure Hydraulic Group Hydraulic Pump

Steering pump (S/N 0259~0398, 9066~)

95ZV42108

Pump specifications KAWASAKI PART NUMBER

HALDEX BARNES MODEL NUMBER

DISPLACEMENT in3/REV (mL/REV)

MAXIMUM SPEED min-1 (rpm)

MAXIMUM PRESS. P.S.I. (bar)

44083-61640

P1-F3-G3030W-4EJ18DJ18-12B61L-S40

4.13 (68)

2,500

4,000 (310)

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

95ZV EX 42-22 42 Function & Structure Hydraulic Group Hydraulic Pump

K95ZVE42003

95ZV EX 42-23 42 Function & Structure Hydraulic Group Hydraulic Pump

Steering pump (S/N 0399~0465)

95ZV42108

Pump specifications Applicable circuit Theoretical discharge Maximum operation pressure Maximum speed

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

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

58+58 27.5 (281) (4000) 3,000

95ZV EX 42-24 42 Function & Structure Hydraulic Group Hydraulic Pump

K95V42003

95ZV EX 42-25 42 Function & Structure Hydraulic Group Hydraulic Pump

Steering pump (S/N 0466~) 5

2 6

3 4

7 K95ZV42025

5. Oil seal 6. Bushing 7. Wear plate (floating type) 8. Damper (Sleeve)

1. Drive gear (front) 2. Drive gear (rear) 3. Driven gear (front) 4. Driven gear (rear)

Pump specifications Applicable circuit Theoretical discharge Maximum operation pressure Maximum speed

Steering circuit cm3/rev

56.4+56.4

MPa (kgf/cm2)

24.5 (250)

min-1

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

2,500

95ZV EX 42-26 42 Function & Structure Hydraulic Group Hydraulic Pump

Hydraulic pump principle

Inlet

Outlet

Inlet

Outlet

Inlet

Outlet

95ZV42040

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

95ZV EX 42-27 42 Function & Structure Hydraulic Group Hydraulic Pump Both sides of the gear consists of floating type pressure plates having balancing functions. The pressure plates maintain optimum clearance on both sides of the gear (pressure balance mechanism) so that the high volumetric efficiency is ensured.

Hydraulic pump wear plate

General structure of pressure plate Suction

Discharge

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

Discharge High pressure area Backup ring

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

Hydraulic pump bushing lubrication

O-ring

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

Suction

Oil groove for lubricating bearing

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

Suction

Starting up a new pump with oil supplied to it. - Allow new pump to idle (low rpm/no load) for 5 minutes. Confinement prevention groove

Discharge

115ZV42006

- Use the proper viscosity for the coldest possible start up temperature. Change viscosity if seasonal temperature changes are great (more than 20°C (68°F)).

95ZV EX 42-28 42 Function & Structure Hydraulic Group Hydraulic Cylinder

Hydraulic Cylinder Boom cylinder

20,23

21 16 15 14 12,13 1

6,7 10,11 9

5,17

18 3

4 97ZV42025

: Piston nut (16): 6,669 N-m (680 kgf-m) (4,920 lb-ft) : Bolt (18): 843 N-m (86 kgf-m) (622 lb-ft) 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. Back ring 14. O-ring 15. Wear ring 16. Piston nut 17. Stop ring 18. Flange bolt 19. — 20. Dust seal

21. Wear ring 22. — 23. Bushing

95ZV EX 42-29 42 Function & Structure Hydraulic Group Hydraulic Cylinder

Bucket cylinder (S/N 0101~0272, 9001~9065) 22 16 14 15 12 13

20, 23

21 1

8 7 11 10 6 9 17

25, 26

20, 23 4

A 29 (Gauge port PF1/4)

27, 28 (Gauge port PF1/4)

95ZV42022

: Piston nut (16): 4,217 N-m (430 kgf-m) (3,111 lb-ft) : Bolt (25): 883 N-m (90 kgf-m) (651 lb-ft)

(S/N 0273~, 9066~)

20 23

16 15 30 15 1

11 6 17 9 10 4 8 7 5 25

20 23

A 27,28 (Gauge port PF1/4)

27,28 95V2E42004

: Piston nut (16): 5,900 ± 300 N-m (602 ± 30.6 kgf-m) (4,353 ± 221 lb-ft) Bolt (25): 880 ± 90 N-m (90 ± 9.2 kgf-m) (649 ± 67 lb-ft) (S/N 0273~0450, 9066~) Bolt (25): 500 ± 65 N-m (51 ± 6.6 kgf-m) (370 ± 48 lb-ft) (S/N 0451~) 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. Back ring 14. O-ring 15. Wear ring 16. Piston nut 17. Stop ring 18. — 19. — 20. Dust seal

21. Wear ring 22. Stop ring 23. Bushing 24. — 25. Bolt 26. Washer 27. Plug 28. O-ring 29. Plug

95ZV EX 42-30 42 Function & Structure Hydraulic Group Hydraulic Cylinder

880 ± 90 N-m (90 ± 9 kgf-m)

500 ± 65 N-m (51 ± 6.6 kgf-m) K70V2J42023

Note The number of mounting bolt (25) has been increased on S/N 0451 and thereafter. Be advised the tightening torque has been also changed.

Steering cylinder

20,23

15 14 13 12 1

8 6,7 10,11 9 11 17 5

20,23

97ZV42027

: Rod cover (4): 1,765 N-m (180 kgf-m) (1,302 lb-ft) : Piston nut (16): 1,275 N-m (130 kgf-m) (941 lb-ft) 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. Back ring 14. O-ring 15. Wear ring 16. Piston nut 17. Stop ring 18. — 19. — 20. Dust seal

21. — 22. Stop ring 23. Bushing

95ZV EX 42-31 42 Function & Structure Hydraulic Group Hydraulic Cylinder

Hydraulic cylinder specifications mm (in) Inner dia. x rod dia. x stroke Boom cylinder

Pin hole (inner dia. x width)

Piston rod

ø100 x 226 (3.93 x 8.90)

Cylinder

ø100 x 228.5 (3.93 x 9.00)

Inner dia. x rod dia. x stroke Bucket cylinder

Pin hole (inner dia. x width)

ø160 x ø80 x 605 (6.30 x 3.15 x 23.82)

Piston rod

ø90 x 100 (3.54 x 3.93)

Cylinder

ø90 x 100 (3.54 x 3.93)

Inner dia. x rod dia. x stroke Steering cylinder

ø190 x ø100 x 953 (7.48 x 3.93 x 37.52)

ø90 x ø50 x 600 (3.54 x 1.96 x 23.62)

Piston rod

ø50 x 70 (1.97 x 2.75)

Cylinder

ø50 x 70 (1.97 x 2.75)

95ZV EX 42-32 42 Function & Structure Hydraulic Group Loading System

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

Control lever Pilot valve (S/N 0291~, 9081~)

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. Oil to the pilot valve is supplied from the brake line while being reduced to 3.5 MPa (36 kgf/cm2) (512 psi) by the reducing valve.

Valve (for safety lock) (S/N 0291~, 9081~) Control lever

Pilot valve (S/N 0101~0290, 9001~9080)

Oil packs

Multiple control valve

Oil packs

From steering valve Cooler

Reducing valve

P Return filter From brake line

K95ZV42003

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

95ZV EX 42-33 42 Function & Structure Hydraulic Group Reducing Valve (for Pilot Pressure)

Reducing Valve (for Pilot Pressure) (S/N 97C4-9066~)

Pressure adjustment stud

(S/N 97C49001~9065

Locknut Ball

Passage B

(T)

(P) (TA) (ACCR)

(PARKING)

(ACCF)

(PA) (Z1)

(Z2) (PPI)

Tank Valve assembly

Note: Valve is shown rotated 180º from normal.

Orifice 2

From front brake accumulator circuit

A A

Orifice 1 Passage Z

Plunger

Pilot oil circuit

This valve provides pilot oil pressure to operate the park brake, auto brake, fan speed control, and loader pilot valve functions. The oil fed from the brake accumulator circuit flows into the loading & fan motor pilot oil circuit by way of passage Z. The oil pressure in the pilot oil circuit is applied also on chamber C by way of orifice 1. When the oil pressure in the pilot oil circuit is at or above the set pressure, the oil in chamber C unseats the ball by way of orifice 2, and escapes to the tank by way of passage Y. As a result, the pressure in chamber C decreases, then the plunger moves up and closes passage Z so that the pressure on the pilot oil circuit side does not exceed the set pressure. When the oil pressure on the pilot oil circuit side becomes less than the set pressure, the ball moves down and the pressure at chamber C becomes equivalent to the pressure on the pilot oil circuit side (B). As a result, the plunger moves down by a spring, opens the passage Z, then introduces the accumulator pressure to the pilot oil circuit side so that the pressure is maintained at the specified value.

T Hydraulic circuit diagram

K90ZV42005

This pressurized oil is supplied to the multiple control valve oil pack through the pilot valve and moves the multiple control valve spool. Set pressure 3.5 MPa (36 kgf/cm2) (512 psi)

95ZV EX 42-34 42 Function & Structure Hydraulic Group Pilot Valve (S/N 0101~0290, 9001~9080)

Pilot Valve (S/N 0101~0290, 9001~9080) For bucket control

Neutral Roll back (Detent)

For bucket control

Dump

For boom control

8 2

T 3 To tank port

4 5

6 From pump port

To / from MCV oil packs

Bucket spool in MCV

Boom spool in MCV

80ZV42017

1. Lever 2. Disc 3. Push rod 4. Spring seat 5. Spring for secondary pressure 6. Return spring 7. Spool 8. Detent magnet solenoid

95ZV EX 42-35 42 Function & Structure Hydraulic Group Pilot Valve (S/N 0101~0290, 9001~9080) For boom control

Raise (Detent)

Neutral

Down Float (Detent)

To tank port

95ZV42012

Note Color coded and reverse coupled connectors help keep wires plugged correctly. The pilot valve applies oil pressure in proportion to the operating angle of the lever, there-by carrying out remote control of the spool in the multiple control valve.

95ZV EX 42-36 42 Function & Structure Hydraulic Group Pilot Valve (S/N 0101~0290, 9001~9080) Accordingly the 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 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.

Pilot valve operation (Modulated position)

The 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 spool being moved the desired amount. Oil flow from the loading pump to the cylinder is also proportional. Cylinder speed is easily controlled. T 5 P 7

Reducing valve

Multiple control valve Oil pack

From front brake accumulator 70ZV42051

When the lever (1) is in the neutral position, the spool (7) closes the pump port and the tank port is opened. Therefore the oil pressure is not applied to the multiple control valve oil pack. The spool 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 pump port is opened. As a result, the pressurized oil from the pump flows into the multiple control valve oil pack. The spool of the multiple control valve moves allowing oil from the loading pump to flow to the cylinder. When the oil pressure in the multiple control valve oil pack reaches over the desired pressure, the spool (7) moves up. As a result, the tank port is opened and the pump port is closed. - Spool diameter at tank side is greater than spool diameter at pump side.

95ZV EX 42-37 42 Function & Structure Hydraulic Group Pilot Valve (S/N 0101~0290, 9001~9080)

(Full pressure position)

To tank port

4 From pump port

5 From pump port

Port 3

Port 4

When lever is in neutral

Port 3

Port 4

When lever is shifted from neutral 95ZV42078

When the lever (1) is moved fully forward or back the multiple control valve spool should also be moved full stroke. This allows maximum oil flow to the cylinders for the fastest cylinder movement. In the boom down circuit the multiple control valve spool must be fully stroked to reach the "FLOAT" position. To be sure the multiple control valve spool is fully stroked a special spring (5) and spring seat (4) are used. This allows the spool (7) to be fully stroked and full pilot pressure will be directed into the oil pack fully stroking the multiple control valve spool.

95ZV EX 42-38 42 Function & Structure Hydraulic Group Pilot Valve (S/N 0101~0290, 9001~9080)

Pilot valve detent magnet solenoid Solenoid

Detent adjustment procedure

Steel ball for detent

Plate Lock nut Solenoid

Lock nut Disc

70ZV42052

To tank port

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.

70ZV42053

When the proximity switch for the bucket leveler 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.

1. Turn on key switch and position the boom or bucket so that the proximity switch will complete the circuit, energizing the coil of the detent solenoid. [Float is always on.]

When the lever is shifted, the steel ball is positioned at the detent notch and the lever is held at that position.

2. Loosen the lock nut to the solenoid coil.

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 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.

3. Turn the magnet counterclockwise so it will back the steel ball away from the "pocketed" disc. 4. Position the lever so that the steel ball will drop into the detent "pocket". 5. Begin to turn the magnet clockwise until the magnet exerts a detent 'influence', because ball begins to drop into the "pocket" of the disc. Mark the position of where the magnet is in rotation. 6. Continue to turn the magnet in until detent influence is no longer felt on the lever. Again, mark the position of where the magnet is in rotation. 7. Reverse the rotation of the detent to exactly the 1/2 way point between the two marks. 8. Tighten the lock nut in its' position.

95ZV EX 42-39 42 Function & Structure Hydraulic Group Pilot valve (S/N 0291~0408, 9081~)

Pilot valve (S/N 0291~0408, 9081~) Float/Down

Raise (Detent)

White (Female) (for port 3 solenoid) Blue (Female) (for port 2 solenoid)

White (Male) (for port 4 solenoid)

Roll back (Detent)

Dump

From Top 18.20

16.20

A For bucket control

B For boom control

A (Port 1, 2)

From Bottom

B (Port 3, 4)

K115V2U42003

95ZV EX 42-40 42 Function & Structure Hydraulic Group Pilot valve (S/N 0291~0408, 9081~)

Dump

Roll back (Detent)

Float (Detent) Down

Raise (Detent)

2 7

3 9

4 6

Identifying mark

8 10

2 5 Identifying mark

9 10

13 22

To tank port

14 15

From pump port

17 Port1 Port2 To/from MCV oil packs

Port3 Port4 To/from MCV oil packs

For bucket control

For boom control

(Section A-A)

(Section B-B)

1. Lever 2. Push rod 3. Push rod 4. Push rod 5. Detent solenoid coil (boom down / float) 6. Detent solenoid coil (boom raise) 7. Detent solenoid coil (bucket level) 8. Fixing disc 9. Fixing disc (Identifying mark) 10. Push rod 11. Spring 12. Plug 13. Spring seat

14. Spring 15. Spring 16. Spring 17. Spool 18. Detent bushing 19. Spring 20. Detent ring 21. Steel ball (4 pieces per spool) 22. Spring seat 23. Spring seat 24. Casing 25. Spring

115V2U42021

95ZV EX 42-41 42 Function & Structure Hydraulic Group Pilot valve (S/N 0291~0408, 9081~)

Pilot valve operation 1

The pilot valve applies oil pressure in proportion to the operating angle of the lever, there-by carrying out remote control of the spool in the multiple control valve.

21 19

(modulated position)

3 Predetent section

22 14

23 14

15 24

Lever is in the neutral position

85V2E42009

P Reducing valve Multiple control valve Oil pack

From front brake accumulator

85V2E42008

The pilot valve has holes of lengthwise direction in which the reducing valve is built. The reducing valve section are consist of spool (17), spring for secondary pressure (15)(16), return spring (14) and spring seat (22)(23). Being inserted in the plug (12), push rod (10) can be moved smoothly to change the bending quantity of secondary pressure spring (15)(16). Return spring (14) contacts casing (24) and spring seat (22)(23). This spring works on returning the push rod (10) to it’s original position without relation to secondary pressure, therefore it ensures returning the spool to neutral. Also it has the effect as reactive force spring to give the modulation feeling to operator. When the lever (1) is in the neutral position, the force of secondary pressure spring (15)(16) is not worked on spool (17) and spool is pushed up to push rod (10) by return spring (14). As the spool (17) close the pump port and the tank port is opened, the oil pressure is not applied to the multiple control valve oil pack. The spool of multiple control valve is held in neutral by its centering springs. There is no oil flow to the cylinder.

95ZV EX 42-42 42 Function & Structure Hydraulic Group Pilot valve (S/N 0291~0408, 9081~)

21 20

Predetent section

25 13 22

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

(Full pressure position) 17

When the lever (1) is moved fully forward or back the multiple control valve spool should also be moved full stroke.

Lever is shifted from the neutral 85V2E42010

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

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

95ZV EX 42-43 42 Function & Structure Hydraulic Group Pilot valve (S/N 0291~0408, 9081~)

Pre-detent and detent magnet solenoid 1 21 20

21 19

3 2 18

7 3

8 9

The figure that fixing disc (8) is absorbed by the detent solenoid coil (7).

10 T T

P Actuation of electromagnetic detent 85V2E42012

Actuation of pre-detent 85V2E42011

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

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

95ZV EX 42-44 42 Function & Structure Hydraulic Group Pilot valve (S/N 0409~0410)

Pilot valve (S/N 0409~0410) Float/Down

Raise (Detent)

White (Female) (for port 3 solenoid) Blue (Female) (for port 2 solenoid)

White (Male) (for port 4 solenoid)

Roll back (Detent)

Dump

From Top 18.20

16.20

A For bucket control

B For boom control

A (Port 1, 2)

From Bottom

B (Port 3, 4)

K115V2U42003

95ZV EX 42-45 42 Function & Structure Hydraulic Group Pilot valve (S/N 0409~0410)

Dump

Roll back (Detent)

Float (Detent) Down

Raise (Detent)

2 7

3 9

4 6

Identifying mark

8 10

2 5 Identifying mark

9 10

11 12 23 22

To tank port

14 15

From pump port

17 Port1

Port2

Port3

To/from MCV oil packs

For bucket control (Section A-A)

For boom control (Section B-B)

14. Spring 15. Spring 16. Spring 17. Spool 18. Detent bushing 19. Spring 20. Detent ring 21. Steel ball (4 pieces per spool) 22. Spring seat 23. Spring seat 24. Casing

Port4

K92V2E42001

95ZV EX 42-46 42 Function & Structure Hydraulic Group Pilot valve (S/N 0409~0410)

Pilot valve function 1

The pilot valve applies oil pressure in proportion to the operating angle of the lever, there-by carrying out remote control of the spool in the multiple control valve.

21 19

Pilot valve operation (modulated position) 3 Predetent section

22 14

23 14

15 24

Lever is in the neutral position K92V2E42003

P Reducing valve Multiple control valve Oil pack

From front brake accumulatorK92V2E42002

The pilot valve has holes of lengthwise direction in which the reducing valve is built. The reducing valve section are consist of spool (17), spring for secondary pressure (15)(16), return spring (14) and spring seat (22)(23). Being inserted in plug (12), push rod (10) can be moved smoothly to change the bending quantity of secondary pressure spring (15)(16). Return spring (14) contacts casing (24) and spring seat (22)(23). This spring works on returning push rod (10) to it’s original position without relation to secondary pressure, therefore it ensures returning the spool to neutral. Also it has the effect as reactive force spring to give the modulation feeling to operator. When lever (1) is in the neutral position, the force of secondary pressure spring (15)(16) is not worked on spool (17) and spool is pushed up to push rod (10) by return spring (14). As spool (17) close the pump port and the tank port is opened, the oil pressure is not applied to the multiple control valve oil pack. The spool of multiple control valve is held in neutral by its centering springs. There is no oil flow to the cylinder.

95ZV EX 42-47 42 Function & Structure Hydraulic Group Pilot valve (S/N 0409~0410)

21 20

Predetent section

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

Lever is shifted from the neutral K92V2E42004

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

95ZV EX 42-48 42 Function & Structure Hydraulic Group Pilot valve (S/N 0409~0410)

Pre-detent and detent magnet solenoid 1 21 20

21 19

3 2 18

7 3

8 9

The figure that fixing disc (8) is absorbed by the detent solenoid sub (7).

10 T T

P Actuation of electromagnetic detent K92V2E42006

Actuation of pre-detent K92V2E42005

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

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

95ZV EX 42-49 42 Function & Structure Hydraulic Group Pilot valve (S/N 0411~)

Pilot valve (S/N 0411~) Float/Down

Raise (Detent)

White (Female) (for port 3 solenoid)

Roll back (Detent)

Blue (Female) Dump

From Top

(for port 2 solenoid)

18.20

White (Male) (for port 4 solenoid)

16.20

For bucket control

For boom control

P T 1

(Port 1, 2)

(Port 3, 4)

A 1

From Bottom

90Z542003

95ZV EX 42-50 42 Function & Structure Hydraulic Group Pilot valve (S/N 0411~)

Dump

Roll back (Detent)

Float (Detent) Down

Raise (Detent)

2 7

3 9

4 6

Identifying mark

2 5 Identifying mark 9 10 11 12 23

14 15

16 From pump port

To tank port

15 24

Port1

Port2

Port3

To/from MCV oil packs

For bucket control (Section A-A)

For boom control (Section B-B)

13. — 14. Spring 15. Spring 16. Spring 17. Spool 18. Detent bushing 19. Spring 20. Detent ring 21. Steel ball (4 pieces per spool) 22. Spring seat 23. Spring seat 24. Casing

Port4

90Z542004

95ZV EX 42-51 42 Function & Structure Hydraulic Group Pilot valve (S/N 0411~)

Pilot valve function 1

The pilot valve applies oil pressure in proportion to the operating angle of the lever, there-by carrying out remote control of the spool in the multiple control valve.

21 19

Pilot valve operation (modulated position) 3 Predetent section

22 14

23 14

15 24

Lever is in the neutral position 90Z542006

P Reducing valve Multiple control valve Oil pack

From front brake accumulator

90Z542005

Return spring (14) contacts casing (24) and spring seat (22)(23). This spring works on returning push rod (10) to it’s original position without relation to secondary pressure, therefore it ensures returning the spool to neutral. Also it has the effect as reactive force spring to give the modulation feeling to operator. When lever (1) is in the neutral position, the force of secondary pressure spring (15)(16) is not worked on spool (17) and spool is pushed up to push rod (10) by return spring (14). As spool (17) close the pump port and the tank port is opened, the oil pressure is not applied to the multiple control valve oil pack. The spool of multiple control valve is held in neutral by its centering springs. There is no oil flow to the cylinder.

95ZV EX 42-52 42 Function & Structure Hydraulic Group Pilot valve (S/N 0411~)

21 20

Predetent section

The oil pressure to the multiple control valve is proportional to lever (1) angle, and is balanced with the lever angle. This results in the multiple control valve spool being moved the desired amount. Oil flow from the loading pump to the cylinder is also proportional. Cylinder speed is easily controlled. When lever (1) is moved fully forward or back the multiple control valve spool should also be moved full stroke. This allows maximum oil flow to the cylinders for the fastest cylinder movement.

Lever is shifted from the neutral 90Z542007

95ZV EX 42-53 42 Function & Structure Hydraulic Group Pilot valve (S/N 0411~)

Pre-detent and detent magnet solenoid 1 21 20

21 19

3 2 18

7 3

8 9

The figure that fixing disc (8) is absorbed by the detent solenoid sub (7).

T P

Actuation of electromagnetic detent 90Z542009

Actuation of pre-detent 90Z542008

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

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

95ZV EX 42-54 42 Function & Structure Hydraulic Group Multiple Control Valve (KML35A/2T003B)

Multiple Control Valve (KML35A/2T003B)

7 3 B2

b2 C

C B1

b1 B

B P

2 P

A 1

A-A

Bucket Spool

Boom Spool

6 B1

6 B2

A1 4

5 a1

B-B

C-C 95ZV42074

1. Main relief valve 2. Spool (Bucket) 3. Spool (Boom) 4. Overload relief valve (Bucket circuit) (with make-up valve) 5. Make-up valve (Boom circuit) 6. Load check valve 7. Casing 8. Spring cover 9. Cover 10. Gauge port

95ZV EX 42-55 42 Function & Structure Hydraulic Group Multiple Control Valve (KML35A/2T003B)

Boom

B2 A2

Multiple control valve specifications

Bucket

B1 A1

Model

KML35A/2T 003B

Main relief valve setting pressure

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

Overload relief valve setting pressure

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

b2 b1 Hydraulic line diagram

P 95ZV42023

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

OLRV installation point

MUV installation point

Bucket Boom Bucket Boom

Rod side

Installed

Bottom side

Installed

Rod side

Non-installed

Bottom side

Non-installed

Rod side

Installed

Bottom side

Installed

Rod side

Installed

Bottom side

Non-installed

95ZV EX 42-56 42 Function & Structure Hydraulic Group Multiple Control Valve (KML35A/2T003B)

Multiple control valve main relief valve

Main relief valve operation Relief poppet

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

Passage B

Plunger Orifice 1

Tank port

Pump port

Spring seat

Spring Seat Passage C

Adjusting screw

Filter

Body

Passage A

Passage D Tank port

Lock nut Cap nut

Plug

Pump port

Plunger 90ZV42018

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

95ZV EX 42-57 42 Function & Structure Hydraulic Group Multiple Control Valve (KML35A/2T003B) Note Clogging of the orifice in plunger will cause low pressure. Another possible cause of low pressure is contamination in, or damage to, the seat of relief poppet or plunger.

Adjusting set pressure Loosen the lock nut and adjust the pressure by the adjusting screw. Turn clockwise the adjusting screw to raise the set pressure, or turn counterclockwise the adjusting screw to lower the set pressure. After adjustment, be sure to tighten the lock nut. Set pressure 20.6 ± 0.5 MPa (210 ± 5 kgf/cm2) (2,986 ± 71 psi)

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

95ZV EX 42-58 42 Function & Structure Hydraulic Group Multiple Control Valve (KML35A/2T003B)

Multiple control valve overload relief valve (Installed on both the rod and bottom sides of the bucket circuit) Each overload relief valve (with make-up function) is installed in the circuit between the cylinder and the control valve spool. When the spool is in the NEUTRAL position, if external force on the cylinder becomes too strong and the oil pressure is greatly increased, the overload relief valve will return the oil to the tank to protect the cylinders and pipes from breakage.

Overload relief valve operation When the oil pressure is at the set point or below: Orifice1 Relief poppet

Passage A

Plunger seat

Plunger

Spring Seat

Passage B

Tank port

Cylinder port 90ZVE42013

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

Adjusting screw

Passage C

Passage D

Plunger

Lock nut Body

Tank port

Cylinder port 90ZVE42014

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

95ZV EX 42-59 42 Function & Structure Hydraulic Group Multiple Control Valve (KML35A/2T003B)

Make-up valve operation Plunger

Adjusting set pressure Plunger seat

Spring Adjusting screw

Tank Cylinder port port Passage E

Lock nut

Tank port

Cylinder port

90ZVE42015

90ZVE42026

When the overload relief valve on one side of the cylinder port is actuated, the plunger in the control valve is in neutral. The port opposite to the one in which high pressure was produced has a greatly reduced pressure. When the pressure is reduced below the tank pressure, the make-up valve is opened. When the pressure at the cylinder port becomes less than tank pressure, the plunger seat is moved to the right by the pressure area difference of the plunger seat between the right and left. The plunger seat opens the port and the oil flows to the cylinder port through passage E. It prevents a vacuum (negative pressure) in the cylinder.

Loosen the lock nut and adjust the pressure by the adjusting screw. Turn clockwise the adjusting screw to raise the set pressure, or turn counterclockwise the adjusting screw to lower the set pressure. After adjustment, be sure to tighten the lock nut. Set pressure 23.5 ± 0.5 MPa (240 ± 5 kgf/cm2) (3,413 ± 71 psi)

95ZV EX 42-60 42 Function & Structure Hydraulic Group Multiple Control Valve (KML35A/2T003B)

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

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

95ZV EX 42-61 42 Function & Structure Hydraulic Group Multiple Control Valve (KML35A/2T003B)

Multiple control valve bucket spool Bucket spool operation 1. “Bucket Roll Back” position

D A1

From pilot valve

Pa1

To pilot valve Pb1

Spool

C From pump

95ZV42024

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

- On the other hand, the oil on the rod side of the bucket cylinder returns from the B1 port to the tank.

95ZV EX 42-62 42 Function & Structure Hydraulic Group Multiple Control Valve (KML35A/2T003B) 2. “Bucket Dump” position

To pilot valve

Pa1

From pilot valve Pb1

Spool

C From pump

95ZV42025

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

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

95ZV EX 42-63 42 Function & Structure Hydraulic Group Multiple Control Valve (KML35A/2T003B)

Multiple control valve boom spool Boom spool operation 1. “Boom Raise” position

D B2

A2 From pilot valve

Pa2

To pilot valve Pb2

Spool

C From pump

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

95ZV42026

95ZV EX 42-64 42 Function & Structure Hydraulic Group Multiple Control Valve (KML35A/2T003B) 2. “Boom Down” position

D A2

To pilot valve

Pa2

From pilot valve Pb2

Spool

C From pump

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

95ZV42027

95ZV EX 42-65 42 Function & Structure Hydraulic Group Multiple Control Valve (KML35A/2T003B) 3. “Boom Float” position

A2 To pilot valve

Pa2

From pilot valve Pb2

Spool

From pump

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

95ZV42028

95ZV EX 42-66 42 Function & Structure Hydraulic Group Adapter (Orifice)

Adapter (Orifice)

ø1.3 mm

O-ring

Orifice

Adapter

Installation position

Port b2

Multiple control valve

80ZV42018

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

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

95ZV EX 42-67 42 Function & Structure Hydraulic Group Vibration Damper (OPT)

Vibration Damper (OPT) Vibration damper hydraulic circuit 4 (15)

(18)

(16)

(H) (X)

(Ac)

(14)

(Ac2)

(T)

(5)

(13)

(Ac1)

9.5 L Gas pressure

(Ac1)

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

From multiple control valve

(br) (R)

Multiple control valve P line

Multiple control valve T line

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

(P)

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

(11)

(T)

95V2E42011

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

95ZV EX 42-68 42 Function & Structure Hydraulic Group Vibration Damper (OPT)

Vibration damper operation Preparation mode (vibration damper switch is OFF) 4 (15)

(18)

(16)

(H) (X)

(Ac)

(14)

(Ac2)

(T)

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

(Ac1)

(5)

(13)

9.5 L Gas pressure

(Ac1)

From multiple control valve

(br) (R)

Multiple control valve P line

Multiple control valve T line

(P)

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

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

(11) 95V2E42011

95ZV EX 42-69 42 Function & Structure Hydraulic Group Vibration Damper (OPT)

Running mode (vibration damper switch is ON) 4 (15)

(18)

(16)

(H) (X)

(Ac)

(14)

(Ac2)

(T)

9.5 L Gas pressure

(Ac1)

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

(Ac1)

(5)

From multiple control valve

1 (13) Multiple control valve P line

Multiple control valve T line

(br) (P)

(R)

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

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

(11)

115V2E42029

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

95ZV EX 42-70 42 Function & Structure Hydraulic Group Vibration Damper (OPT)

Vibration damper valve assembly (Reducing valve circuit) Outline drawing

1 Tank

Pump

2 (T) (P)

(R)

Boom cylinder rod side

(Ac1) Accumulator

4 6 5

1. Block 2. Reducing valve 3. Solenoid 4. Valve 5. Check valve 6. Bleeder valve

(T) #2

#3,#4

(P) (R) #5 (Ac1) #6

(br) Hydraulic circuit 95V2E42012

95ZV EX 42-71 42 Function & Structure Hydraulic Group Vibration Damper (OPT)

Reducing valve

Check valve

Passage A

Accumulator

Passage B

Bleeder valve

Passage B Tank

Poppet

Tank Orifice 2

Sleeve

Ball

Reducing valve Orifice 1

Pump

95V2E42014

Oil from the reducing valve pushes the poppet up and flows to the accumulator circuit.

Passage A Plunger

Check valve 95V2E42013

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

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

95ZV EX 42-72 42 Function & Structure Hydraulic Group Vibration Damper (OPT)

Solenoid valve

Solenoid

Chamber A Spring Orifice

Boom cylinder rod side

Sleeve

Seat face Spool Tank

95V2E42015

When the solenoid valve is not energized, the spool is pulled up by the spring, and the chamber A is connected to the tank port through the orifice. The same pressure is applied to both upper and lower sides of the spool, and the spool is pulled up by the spring force. Therefore the surface of both the sleeve and the spool is surely fit. When the solenoid valve is energized, the spool is pushed down. The seat face between the spool and the sleeve opens, and the boom cylinder rod side port is connected to the tank port.

Solenoid specifications Voltage

DC 24 V

Current

0.69 A

Resistance

34.8 Ω

95ZV EX 42-73 42 Function & Structure Hydraulic Group Vibration Damper (OPT)

Vibration damper valve assembly (Accumulator circuit) Outline drawing 6

2 1

3 4 T

Tank

Boom cylinder bottom side

AC1

Reducing valve

AC2

AC Accumulator

1. Block 2. Selector valve 3. Solenoid 4. Valve 5. Shuttle valve 6. Plug

95V2E42016

#3,#4

#2 (H) #5

(X) (Ac1) (T)

(Ac2) (Ac) Hydraulic circuit

95V2E42017

95ZV EX 42-74 42 Function & Structure Hydraulic Group Vibration Damper (OPT)

Shuttle valve

Solenoid valve

Movable iron core Passage A

Solenoid valve Solenoid Passage B

Accumulator

Rod Passage C

Ball Boom cylinder bottom side

Spool

Passage B 95V2E42018

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

Tank Shuttle valve

Passage A A Selector

valve

Sleeve 95V2E42019

When the solenoid valve is not energized, the oil from the accumulator flows to the check valve, via the shuttle valve, through the passage A and the oil port A of the spool. When the solenoid valve is energized, the movable iron core moves downward and pushes down the rod and the spool. As a result, the oil port A and the passage A are closed, and both the oil port B and the passage B of the spool are connected. Then the oil is drained from the check valve to the tank. Solenoid specifications Voltage

DC 24 V

Current

0.52 A

Resistance

45.9 Ω

95ZV EX 42-75 42 Function & Structure Hydraulic Group Vibration Damper (OPT)

Check valve Passage B

Reducing valve (sol. valve)

Pressure receive face E Poppet

Passage A

Passage C Boom cylinder bottom side

Shuttle valve

Passage D

Pressure receive face F

Sleeve

Seat face Accumulator

95V2E42020

When the solenoid valve is not energized, the oil from the reducing valve flows into the chamber (A) through the passages A and B. Then the poppet is pushed down, and the circuit between the accumulator and the boom cylinder bottom side is closed. In this time, the boom cylinder bottom pressure applies to the pressure receive faces E and F. Also the accumulator pressure applies to the bottom side of the poppet. However the poppet is pushed down because the pressure receive area at the chamber (A) side is larger. When the solenoid valve is energized, the oil in the chamber A flows to the tank port through the solenoid valve. As a result, the oil pressure in the chamber (A) lowers, and the accumulator pressure pushes the poppet up. At the same time, the boom cylinder bottom pressure applies to the pressure receive faces E and F on the poppet through the passages C and D, and the poppet is pushed up. As a result, the circuit between the boom cylinder bottom side and the accumulator is connected, and the accumulator absorbs the oil pressure fluctuations in the boom cylinder bottom side.

95ZV EX 42-76 42 Function & Structure Hydraulic Group Vibration Damper (OPT)

Accumulator (for vibration damper)

9 8

6 5 6

14 8 9 3 11

10 12

K90ZV42014

1. Body 2. Hydraulic cap 3. Gas cap 4. Piston 5. O ring 6. Washer 7. Ring 8. Seal 9. Washer 10. Gas valve 11. Gas valve O ring 12. Gas valve guard 13. Bolt 14. Name plate

While the vibration damper operates, the accumulator absorbs fluctuation of the boom cylinder bottom pressure by air cushion function of the nitrogen gas charged in the cylinder. The cylinder contains N2 (Nitrogen) gas at 1.96 MPa (20 kgf/cm2) (285 psi).

Accumulator specification Maximum operation pressure MPa (kgf/cm2) (psi)

20.6 (210) (2,986)

Nitrogen gas pressure MPa (kgf/cm2) (psi)

1.96 (20) (285)

Capacity L (gal)

9.5 (2.5)

95ZV EX 42-77 42 Function & Structure Hydraulic Group Vibration Damper (OPT)

Vibration damper hydraulic line

(S/N 0291~, 9081~)

Multiple control valve

Accumulator

Front chassis

K95ZVE42004

95ZV EX 42-78 42 Function & Structure Hydraulic Group Steering System

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

From reducing valve

Orbitrol®

At this time, the pilot pressure is generated. The pilot pressure strokes the spool of the steering valve, and supplies hydraulic oil at large flow rate proportional to the flow rate of the supplied pilot oil to the cylinder line.

Steering cylinder

The excessive pilot oil flows through the steering valve to the other side of the pilot port.

Stop valve

Stop valve RH

While the steering wheel is not turned, almost all hydraulic oil from the steering pump is sent to the loading line by the action of the flow control spool. The pilot oil pressure from the steering pump is limited by the reducing valve, then supplied to the Orbitrol®.

Steering valve To loading line

To Orbitrol®

Oil returns from the steering cylinders flows through the steering valve and oil cooler or cooler bypass valve.

Cooler bypass valve

Reducing valve

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

Finally it returns to the tank through the return filter.

Oil cooler Return filter

95ZV EX 42-79 42 Function & Structure Hydraulic Group Orbitrol®

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

Orbitrol® specification Model

ND-K2-D (S/N 9001~9038) ND-K5-D (S/N 9039~)

Theoretical discharge (cm3/rev)

120

Operation pressure MPa (kgf/cm2)

3.5 (36)

95ZV EX 42-80 42 Function & Structure Hydraulic Group Orbitrol®

Orbitrol® structure

- Spool (1) and sleeve (2) as a set form a rotary-type directional change-over valve. The spool (1) in this valve is linked to the steering wheel by means of a spline.

Valve part

- 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. 6 7

T L Valve

Rotor part

1 2

5 Oil groove To tank

3 4

To steering valve

Rotor

To steering valve Oil hole

From reducing valve (pump) 70ZV42023

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

70ZV42022

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

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

95ZV EX 42-81 42 Function & Structure Hydraulic Group Orbitrol®

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

L Oil hole

6 7

Oil groove

1 2

70ZV42025

3 4

70ZV42024

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

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

- 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). - This Orbitrol® is the closed center and non-load reaction type. When in the neutral position, the oil groove of the spool does not match the oil hole of the sleeve, so the flow route of oil from the pump to the steering valve is totally closed.

95ZV EX 42-82 42 Function & Structure Hydraulic Group Orbitrol®

Turn (When the steering wheel is being turned)

8 6 1

6 7

2 Oil hole

Oil groove

5 1

To steering valve Pa port From steering valve Pb port

From reducing valve (pump)

3 4

70ZV42026

65ZV42036

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

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

- When in the neutral position, the valve part is totally closed and oil remains sealed inside the rotor, and the rotor cannot move. The sleeve (2) is directly linked to the rotor by means of a cross pin (7) and drive shaft (5); it is also fixed. - When the steering wheel begins to be turned, rotary force is applied to 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. - As a result, all four ports (pump, tank and oil pack on right and left side of steering valve) are opened, allowing the oil to flow and rotating the rotor.

95ZV EX 42-83 42 Function & Structure Hydraulic Group Orbitrol®

Orbitrol® feed-back mechanism operation

To Steering valve Pa port From Steering valve Pb port

70ZV42027

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

- If the turning of the steering wheel stops, the spool immediately stops rotating; but, as long as there exists an angle of displacement between the spool and the sleeve, oil continues flowing into the 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.

95ZV EX 42-84 42 Function & Structure Hydraulic Group Orbitrol®

Steering speed and flow rate control Low steering speed

Hydraulic pump oil amount and steering force - When there is plenty of oil flowing from the pump, the force required to turn the steering wheel need only overcome the sliding resistance of the sleeve or rotor, so the steering wheel turns very smoothly.

High steering speed

1 3 Small displacement angle

Large displacement angle

70ZV42028

1. Spool 2. Sleeve 3. Centering spring - For this steering mechanism, the flow rate must be regulated depending on the speed at which the steering wheel is turned. - For the steering valve (pilot), the flow rate is regulated by changing the displacement angle of 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 circuit. - As steering speed increases, the amount of delay (displacement angle) of the sleeve (2) increases, and the flow rate rises.

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

95ZV EX 42-85 42 Function & Structure Hydraulic Group Orbitrol®

Orbit rotor operation principle Drive shaft (0 rotation) Rotor center

Drive shaft (1/14 rotation)

Drive shaft (1/7 rotation)

Rotor (rotation) Stator (fixed)

Locus of rotor center

1 7

6 4

3 5

1 2

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

- Inside the rotor there is a stator with 7 internal gears that is fixed to the housing and a 6-tooth rotor that is engaged with the stator. - Half of the chamber formed by the stator and the rotor is connected to the high-pressure side and the other half to the low-pressure side. When high-pressure oil flows into the chamber, the rotor is forced to turn in the direction that will expand the area of the chamber (by means of pressure difference). - Out of this turning movement, rotation alone is taken out by the drive shaft to turn the sleeve by means of the cross pin. - With this rotation, and at the same time due to the relationship of the position between the sleeve port and the housing port, the position of oil flowing into the rotor part is gradually delayed in sequence. - The rotor makes a 1/6 turn per rotation of the rotor, pushing out oil equivalent to 7 chambers. When the rotor rotates once, oil equivalent to 42 chambers (7 chambers x 6 turns) is pushed out.

70ZV42029

- For the motor, it has 6 times larger torque or a 1/6 reduction effect.

95ZV EX 42-86 42 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0)

Steering Valve (KVS32-A4.0) (S/N 0101~0185, 9001~9003) ø 3.0 mm (0.059”)

7 (G)

3 MR A

5 T P. B.

(F) 2 3 MR

ø 3.0 mm (0.059”)

A-A

(LC)

4 AR

B-B

1. Steering spool 2. Flow control spool 3. Main relief valve 4. Overload relief valve (with make-up valve) 5. Check valve 6. Orifice [ø 0.5 mm] (with filter) 7. Gauge port K95ZV42007

95ZV EX 42-87 42 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0) (S/N 0186~, 9004~)

ø 3.0 mm (0.059”)

(G)

3 MR A

5 T P. B.

(F) 2 3 MR

ø 3.0 mm (0.059”)

A-A

(LC)

4 AR

B-B

1. Steering spool 2. Flow control spool 3. Main relief valve 4. Overload relief valve (with make-up valve) 5. Check valve 6. Orifice (with filter) [ø 0.5 mm] (S/N 0186~0207, 9004~9010) [ø 0.7 mm] (S/N 0208~, 9011~) 7. Gauge port

IMPORTANT Flow control plunger orifice must not be blocked. Pump damage may result. K95ZV42008

95ZV EX 42-88 42 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0) 1. Steering spool AB

The movement of the steering spool is controlled by the oil pressure supplied from the Orbitrol® to the main steering valve oil pack. At the center of the spool, there is a variable orifice with chamfers (throttle grooves). This orifice controls the oil flow rate. Also inside the steering spool, there are check valves which apply a positive back pressure to oil returning from the cylinders.

AR BR Pa

Pb RF

(G)

P. B.

Orifice

2. Flow control spool

Pc Pc

Hydraulic line K95ZVE42005

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

KVS32-A4.0

Main relief valve setting pressure

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

Overload relief valve setting pressure

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

95ZV EX 42-89 42 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0)

Steering valve operation Neutral position

To loading line

95ZV42042

- In the NEUTRAL position, steering spool (1) closes all the ports to stop flow of the pressurized oil from the steering pump. The pressure in the pump line, therefore, will rise.

- When the pump line pressure increases to 0.63 MPa (6.4 kgf/cm2) (91.4 psi), the flow control spool (2) is moved to the right due to the pressure difference between chambers A and B. Thus the flow control spool is opened, and all the oil from the steering pump is sent to the loading line.

95ZV EX 42-90 42 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0)

Left turn position

Loading circuit

Pump

Pilot pressure

Check valve

1 Tank Variable throttle

95ZV42043

- When steering spool (1) is pushed in to the left, the pressurized oil from the pump is sent to steering cylinders through the variable throttle section and the check valve. The pressurized oil moves the cylinder rods and the machine turns to the left.

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

95ZV EX 42-91 42 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0) - For high-speed turning, steering spool (1) is pushed all the way to the left, and the variable throttle is fully opened. Under such a condition, all the oil is used for steering to enable high-speed turning.

Steering plunger variable throttle

- At a low engine speed, the oil flow rate from the steering pump is low, therefore the pressure difference between the front and rear of the throttle section is small, and flow control spool (2) is closed.

- At a high engine speed, oil flow rate to the variable throttle is increased, therefore the pressure difference between the front and rear of the throttle section is increased to activate the flow control spool. As a result, the excess oil is sent to the loading line.

Variable throttle 95ZV42044

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

95ZV EX 42-92 42 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0)

Steering valve flow control plunger Loading circuit Pump

Spring

PA PB B

Variable throttle

Steering circuit

Loading circuit Pump

PA PB

Steering circuit

95ZV42045

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

95ZV EX 42-93 42 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0)

Steering valve main relief valve When the pressure is at the preset value or less

Loading circuit

Pump

Flow control spool Filter

Steering spool

Cylinder

Tank

Cylinder

95ZV42047

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

95ZV EX 42-94 42 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0)

When the pressure exceeds the preset value

Loading circuit

Pump

Flow control spool

Steering spool

Tank

95ZV42048

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

95ZV EX 42-95 42 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0)

Steering valve overload relief valve External force

Overload relief valve with make-up valve Operates as overload relief valve

Overload relief valve with make-up valve Operates as make-up valve

Tank

Overload relief valves with makeup valve are located in the circuit between the steering cylinder and the steering spool on the both sides of the steering cylinder. While the steering spool is located in the neutral position, the steering cylinder circuits are closed.

95ZV42049

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

95ZV EX 42-96 42 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0)

Overload relief valve operation C

Make-up valve operation K

G A Cylinder

Cylinder

E D

Tank

115ZV42052

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

Cylinder

E D

Tank

115ZV42053

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

Tank

115ZV42054

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

95ZV EX 42-97 42 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0)

Steering pilot circuit and its operation

From pump Orbitrol®

Reducing valve

To tank

Steering valve

Filter To tank

To cylinder

From cylinder

Stop valve

End cover

Flow amp notch Pilot line

To tank

Pilot orifice

K97V2J42006

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

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

95ZV EX 42-98 42 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0)

Return spring force

Return spring

Pilot oil

Hydraulic force

Pilot pressure

Flow amplifier notch and pilot orifice

End cover Pilot orifice Flow amplifier notch Pilot line

Flow amp. notch opening

K115V2J42005

Pilot orifice ®

Return spring force

Hydraulic force

Pilot pressure

- If no oil is sent from the Orbitrol , the spool is held in the neutral position by the return spring and the flow amplifier notch is closed. When pilot oil is sent from the Orbitrol® the oil flows through the pilot orifice, the pressure of the oil inside the end cover rises, pushing the spool and opening the flow amplifier notch. Then, the oil flows through the flow amplifier notch and the pilot orifice.

Flow amp. notch opening

Pilot orifice 80V2U42005

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

80V2U42006

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

95ZV EX 42-99 42 Function & Structure Hydraulic Group Stop Valve

Stop Valve (Full stroke)

17 mm (0.67 in)

From pilot valve (Orbitrol®)

A B

To steering valve

(S/N 0101~0290, 9001~9080)

(S/N 0291~0410, 9081~)

1. Housing 2. Spool 3. Check valve 4. Plug 5. Washer 6. Plug 7. Flange 8. Spring

9. Spring 10. Bolt 11. Spacer 12. Boot 13. U-packing 14. Dust seal 15. O-ring 16. O-ring

9 B

K90ZV42010

95ZV EX 42-100 42 Function & Structure Hydraulic Group Stop Valve (S/N 0411~)

(Full stroke)

14.5 0.5 mm (0.57 0.02 in) From Orbitrol®

A B

To steering valve

K80Z542005

1. Housing 2. Spool 3. Check valve 4. Plug 5. Washer 6. Plug 7. Flange 8. Spring

97ZV42042

9. Spring 10. Spacer 11. Boot 12. U-packing 13. Dust seal 14. O-ring

95ZV EX 42-101 42 Function & Structure Hydraulic Group Stop Valve

Stop valve function (S/N 0101~0290) (S/N 9001~9080) Stopper (bolt) Spool

Installed on front chassis

Bolt

Port B To steering valve

Port A From Orbitrol®

Check valve Installed on rear chassis 70ZV42049

(S/N 0291~) (S/N 9081~) Stopper (bolt) Spool

Installed on front chassis

Port B To steering valve

Port A From Orbitrol®

Check valve Installed on rear chassis 90V2U42003

A stop valve is provided to reduce the impact caused to the chassis steering stopper block when the machine is making a full turn while the hydraulic pressure of the steering cylinder is still working.

95ZV EX 42-102 42 Function & Structure Hydraulic Group Stop Valve

Stop valve operation (S/N 0101~0290, 9001~9080)

(S/N 0291~, 9081~)

97ZV42044

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

95V2E42049

95ZV EX 42-103 42 Function & Structure Hydraulic Group Reducing Valve (for Orbitrol®)

Reducing Valve (for Orbitrol®) (S/N 0107~, 9004~)

(S/N 0101~0106, 9001~9003)

Spring

Sleeve

Tank

Plunger Pump

Pump

Passage Z

(A)

Tank

Plunger

(T)

Sleeve

(T)

Passage Z B

(A)

Passage Y

B A

Passage Y (TS)

(B)

Orbitrol®

(B) Orbitrol®

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

T T

Hydraulic circuit diagram

95ZV42083

This oil is supplied from the Orbitrol® to the steering valve pilot port, and moves the spool. Set pressure 3.5 MPa (36 kgf/cm2) (512 psi)

95ZV EX 42-104 42 Function & Structure Hydraulic Group Steering Line Filter

Steering Line Filter

From pump (steering valve)

To reducing valve

FILTER

5 70ZV42040

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

1. Case 2. Nipple 3. Strainer 4. O-ring 5. O-ring

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

Front Reducing valve Line filter

Rear chassis

95ZV42037

95ZV EX 42-105 42 Function & Structure Hydraulic Group Steering Line Filter On steering pilot relief

(A)

Steering pilot relief

(A) Reducing valve Line filter

Steering valve

95ZV42075

On unloader valve

Unloader valve

Rear chassis

Line filter Oil tank

95ZV42076

95ZV EX 42-106 42 Function & Structure Hydraulic Group Fan Motor System

Fan Motor System Fan motor mount (S/N 0101~0466, 9011~)

2 3

1 A

T2 T1 Detail of A (S/N 0101~0230, 9001~9010)

2 2

T2 T1 Nut Detail of A (S/N 0231~, 9011~) K115ZV42018

1. Fan motor 2. Fan 3. Flange

: T1: 93.7 N-m (9.55 kgf-m) (69 lb-ft) T2: 142 N-m (14.5 kgf-m) (105 lb-ft) T3: 474 N-m (48.3 kgf-m) (350 lb-ft) T1, T2, T3: With lubrication oil (Engine oil or gear oil)

95ZV EX 42-107 42 Function & Structure Hydraulic Group Fan Motor System (S/N 0467~)

T1 1

(S/N 0557~)

2 Detail of A

2 1 T2

K95ZV42026

1. Fan motor 2. Fan 3. Flange 4. Flange (S/N 0557~)

: T1: 94 N-m (9.55 kgf-m) (69 lb-ft) T2: 230 N-m (23.5 kgf-m) (170 lb-ft) T3: 539 N-m (55.0 kgf-m) (398 lb-ft) T1, T2: With lubrication oil (Engine oil or gear oil)

95ZV EX 42-108 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 0101~0230)

Fan Motor Line (S/N 0101~0230) Cooling fan Solenoid valve (74)(75)

Fan motor (71) Number of revolutions of fan (min-1) (rpm)

80.0 cm3/rev

G1 T2 G1/4

High speed: Solenoid coil is de-energized.

1,500

A Fan motor relay

(G1/4)

Water temperature > 94 ºF...OFF

(G1/4)

From reducing valve (28) in valve block (26) Pressure is 3.5 MPa (36 kgf/cm2) (512 psi)

Valve assembly (72)

Low speed: Solenoid coil is energized.

1,050

F3 Water temperature < 94 ºF...ON

Idle Number of revolutions of engine

(G1/4)

G1 P1

(G1/4) High pressure set: 16.1 MPa (164.2 kgf/cm2) (2,335 psi) Low pressure set: 8.5 MPa (86.7 kgf/cm2) (1,233 psi) at 150 L/min

Full

Fan revolution status From unloader valve (22)

Relief valve (73)

Shown with solenoid coil de-energized and relief valve in the high pressure position.

Hydraulic line diagram K95V42004

The oil discharged from the pilot & brake pump enters the fan motor by way of the unloader valve, and drives the fan. As the number of revolutions of the engine increases, the number of revolutions of the fan also increases as shown in the upper right figure. However, the maximum fan speed is regulated by the relief valve (73) integrated into the line. In the case “Engine water temperature < (less than) 94 ºC (200 ºF)” The water temperature switch is ON, and the power is supplied to the solenoid valve (74)(75). As a result, the relief valve (73) is set to low pressure, and the maximum fan speed is set to 1,050 min-1 (rpm).

In the case “Engine water temperature > (greater than) 94 ºC (200 ºF)” The water temperature switch is OFF, and the power is not supplied to the solenoid valve (74)(75) as shown in the upper left figure. The pilot pressure from the reducing valve (28) enters the relief valve (73), and sets the relief valve (73) to high pressure. As a result, the maximum fan speed is set to 1,500 min-1 (rpm), preventing rise of the engine water temperature, the hydraulic oil temperature, etc. The fan motor revolution changes as follows. 1,050 min-1 (rpm) 1,500 min-1 (rpm) at 94±2 ºC (200±4 ºF) 1,500 min-1 (rpm) 1,050 min-1 (rpm) at 84±2 ºC (184±4 ºF)

95ZV EX 42-109 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 0101~0230)

71 Fan motor

72 Fan motor valve assembly

(S/N 0101~0121)

22 Unloader valve 26 Valve unit

26 Valve unit

K95ZVE42007

The numbers above correspond to those in the "Loading/Steering Hydraulic Line (S/N 0101~0230)" page 924.

95ZV EX 42-110 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 0101~0230)

Fan motor (GM30C) (S/N 0101~0230) 15

16 17

6 7

14 97ZV42049

1. Drive gear 2. Driven gear 3. Front cover 4. Center section 5. Rear cover 6. Oil seal (inner) 7. Oil seal (outer) 8. Retaining ring 9. Gland seal 10. O-ring 11. Wear plate (front) 12. Wear plate (rear) 13. O-ring 14. Seal retainer 15. Bolt 16. Nut 17. Washer 18. Plug (drain)

Fan motor specifications Displacement capacity

80.0 cm3/rev

Operating number of revolutions

1,500 min-1 (rpm)

Motor efficiency

95%

IMPORTANT This motor is designed to rotate only in one direction. Hoses must be connected correctly or damage to motor will result from reverse rotation.

95ZV EX 42-111 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 0101~0230)

Valve assembly (for fan motor)

Oil from unloader valve

To fan motor

PG P2

Oil from fan motor

Oil from reducing valve

Relief valve (Two step relief)*

80.0 cm3/rev

DR G1/4

1 B

(G1/4) (G1/4)

C P2

Solenoid valve coil

Valve

(G1/4)

(G1/4) G1 P1

High pressure set: 16.1 MPa (164.2 kgf/cm2) (2,335 psi) Low pressure set: 8.5 MPa (86.7 kgf/cm2) (1,233 psi) at 150 L/min

Hydraulic line diagram (std. spec.)

K95V42005

Relief valve high pressure set value: 16.1 MPa (164.2 kgf/cm2) (2,335 psi) Relief valve low pressure set value: 8.5 MPa (86.7 kgf/cm2) (1,233 psi)

Note Refer to the following section, Relief valve (two-step relief).

95ZV EX 42-112 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 0101~0230)

Relief valve (two-step relief) 3

12 14

Pump port

Pilot port

1 2

Tank port

8 9

1. Piston 2. Plunger 3. Backup ring 4. O-ring 5. O-ring 6. Spring 7. Spring 8. O-ring 9. Backup ring 10. Seat 11. Filter stopper 12. Filter

Note For pressure adjustment, set the pressure on the high pressure side first.

13. Poppet 14. Body 15. O-ring 16. O-ring 17. Spring 18. Plug 19. Piston 20. O-ring 21. Lock nut 22. Adjustment screw (high pressure side) 23. Lock nut 24. Adjustment screw (low pressure side)

95ZV42060

95ZV EX 42-113 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 0101~0230)

Relief valve (two-step relief) operation When the pressure is lower than the setting pressure

Pump port (to fan)

Pilot port

Tank port

10 95ZV42061

The chamber B is filled with the pressure oil which has entered by way of the hole (A) in the piston (1). As a result, plunger (2) is in secure contact with the seat (10).

When the pressure is greater than the setting pressure (low pressure)

13 17

Pump port (to fan)

Pilot port

Tank port

When the pump port pressure reaches the setting pressure of spring (17), the oil pressure opens poppet (13) and flows into the tank port from hole C by way of the clearance between the seat (10) and the body (14).

95ZV42062

95ZV EX 42-114 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 0101~0230)

13 17

Pump port (to fan)

Pilot port

Tank port

19 95ZV42063

Setting of high pressure When the piston (19) is pushed to the left of the E stroke by the pressure oil coming from the pilot port, the setting pressure of the spring (17) increases.

Make-up valve operation

Pump port

Pilot port

Tank port

10 95ZV42064

When the engine is stopped, the pump port pressure status is changed from positive to negative pressure (or a void) because the fan continues to turn by the inertia but oil is not sent to the fan motor. When the pump port pressure status changes to negative pressure (or a void), the tank port pressure applied on plane A of seat (10) moves seat (10) to the right, flowing oil from the tank port to the pump port so that generation of negative pressure is prevented.

95ZV EX 42-115 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 0101~0230)

Solenoid valve (for fan speed control)

Solenoid coil

Moveable iron core Rod

A Spool

Passage B

C Tank

Hydraulic circuit diagram

B Oil from the reducing valve

A A To the two-stepped relief valve

Passage A 95ZV42066

Solenoid valve (for fan speed control) operation Amp

The power is supplied to the solenoid until the engine water temperature reaches 94ºC (200ºF). Because oil port B in the spool is connected to the passage B, the oil in the two-stepped relief valve circuit is released to the tank port.

a 0

When the engine water temperature reaches 94ºC (200ºF) or more, voltage is not supplied to the solenoid and the status of the valve becomes as shown above. As a result, passage A is connected to oil port A in the spool, and the pressure oil fed from the reducing valve flows into the two-stepped relief valve and sets the two stepped relief valve to high pressure. Note The varistor (variable resistor) is used for the solenoid coil to protect the circuit.

Volt

Varistor 95ZV42079

Solenoid valve specifications Voltage

DC24 V

Current

0.52 A

Resistance

45.9 

95ZV EX 42-116 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 0231~)

Fan Motor Line (S/N 0231~) Fan motor (71)

Cooling fan 80.0 cm3/rev

Note Relief is “pressure compensated”.

Check valve (73)

To drain

P1 Ps G1/4

16.1 MPa (164 kgf/cm2) T2

Radiator

High pressure set: 16.5 MPa (168 kgf/cm2) (2,390 psi) Low pressure set: 6.2 MPa (63 kgf/cm2) (900 psi)

G1/4

To thermo-sensing valve Detail of relief valve (72)

From fan motor circuit

Thermo-sensing valve (74)

80ZV42008

From unloader valve Relief valve (72) Hydraulic line diagram

K95V42006

The cooling fan is driven by the hydraulic motor. The maximum number of revolutions of the cooling fan is regulated, as shown in the chart below, by the set temperature of the thermo-sensing valve (74) installed to the radiator upper tank.

Engine cooling water temperature

Max. number of cooling fan revolutions

80ºC (176ºF) or lower

955

93ºC (200ºF) or higher

1,500

High temperature [93ºC (200ºF)] or higher

(min-1)

Number of fan revolution

1,500 Stepless control range

955

(565)

Low temperature [80ºC (176ºF)] or lower

0 600

800

(1,245)

(1,764)

Engine revolution

*Values in ( ) are for reference.

Fan revolution (Controlled by thermo-sensing valve) K95V42007

95ZV EX 42-117 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 0231~) When the oil pressure reaches the set pressure [16.1 MPa (164 kgf/cm2) (2,335 psi)] or more, the relief valve (72) releases the pressure oil to the tank, as a result, the maximum fan revolution is regulated. On the other hand, the relief valve (72) and the thermosensing valve (74) are connected each other by way of the port Pp. Because the set pressure of the thermosensing valve (74) changes in accordance with the engine cooling water temperature, the regulated maximum number of revolutions varies depending on the cooling water temperature.

95ZV EX 42-118 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 0231~)

(S/N 0467~) (S/N 0467~)

Fan motor

(S/N 0264~)

Fan motor valve assembly (S/N 0264~)

Fan motor valve assembly

Unloader valve

Note The numbers above correspond to those in the "Loading/Steering Hydraulic Line (S/N 0231~)" page 92-5.

K95ZV42027

95ZV EX 42-119 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 0231~)

Fan motor (GM30C) (S/N 0231~0313) 15

16 17

6 7

14 97ZV42049

Fan motor specifications Displacement capacity

80.0 cm3/rev

Operating number of revolutions

1,500 min-1 (rpm)

Motor efficiency

95%

IMPORTANT This motor is designed to rotate only in one direction. Hoses must be connected correctly or damage to motor will result from reverse rotation.

95ZV EX 42-120 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 0231~)

Fan motor (GM30W) (S/N 0314~0398) 13 8 12 11 10 9 8 7

3 2 1 14

19 17 15

9 10 11 18 17 16 K115ZV42022

1. Nut 2. Washer 3. Stud bolt 4. Oil seal (outer) 5. Retaining ring 6. Oil seal (inner) 7. Front cover 8. O-ring 9. Bushing 10. Oil seal (E-ring) 11. Seal retainer 12. Wear plate 13. Center section

14. Steel ball 15. Driven gear 16. Drive gear 17. O-ring 18. Wear plate 19. Rear cover Note The same fan motor model “GM30C” is used on the machines S/N 0231~0313. Refer to "Fan motor (GM30C) (S/N 0101~0230)" page 42-110 for details.

95ZV EX 42-121 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 0231~)

Fan motor specifications Displacement capacity

80.0 cm3/rev

Operating number of revolutions

1,500 min-1 (rpm)

Motor efficiency

95%

IMPORTANT This motor is designed to rotate only in one direction. Hoses must be connected correctly or damage to motor will result from reverse rotation.

95ZV EX 42-122 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 0231~)

Fan motor (FM30) (S/N 0399~0466) 13 11

10 9 8

2 1

19 15

17 9 10 18

16 1. Nut 2. Washer 3. Stud bolt 4. Oil seal (outer) 5. Retaining ring 6. Oil seal (inner) 7. Front cover 8. O-ring 9. Bushing 10. Oil seal (E-ring)

K95V42008

11. Seal retainer 12. Wear plate 13. Center section 14. Steel ball 15. Driven gear 16. Drive gear 17. O-ring 18. Wear plate 19. Rear cover

95ZV EX 42-123 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 0231~)

Fan motor specifications Displacement capacity

80.0 cm3/rev

Operating number of revolutions

1,500 min-1 (rpm)

Motor efficiency

95%

IMPORTANT This motor is designed to rotate only in one direction. Hoses must be connected correctly or damage to motor will result from reverse rotation.

95ZV EX 42-124 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 0231~)

Fan motor (S/N 0467~)

Port P

Port Tc

Port T 115V2E42030

Note For normal rotation only.

Fan motor specifications Displacement capacity

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

Pressure

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

Speed

1,600 min-1

Flow

144 L/min (38 gal/min)

Control method

Continuous variable control with the proportional valve (not included in fan motor)

Rating

Speed control

95ZV EX 42-125 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 0231~)

Fan motor structure 1

A-A

14 P

TC 17

T 16

15 B-B

1. Output shaft 2. Case 3. Thrust plate 4. Piston assy 5. Cylinder block 6. Valve plate 7. Retainer guide 8. Retainer shoe 9. Main bearing

K95V2J42001

10. Sub bearing 11. Oil seal 12. End cover 13. Center spring 14. Make-up valve 15. Safety valve 16. Main spool 17. Spring

95ZV EX 42-126 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 0231~)

Fan motor function and the operation principle

This hydraulic motor is swash plate type axial piston motor. This converts the power of pressured oil sent from the hydraulic pump into rotary motion.

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

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

85V2E42043

This force pushes thrust plate (3) fixed at a certain angle  for output shaft (1), and it is divided into two component force F2 and F3. Among the component forces, radial component force F3 generates the torque T (T=F3 x ri) at each piston (4) located at a half of plate (6) separated by Y-Y line linking a top dead center to a bottom dead center.

F1 F2

Resultant force of this torque (T= (F3 x ri)) goes through a piston as turning force and turns cylinder block (5).

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

85V2E42044

4 5

Supply side

3 Discharge side

85V2E42045

95ZV EX 42-127 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 0231~)

Thermo sensing valve 1

3 2

P 11

4 8

7 65ZV42022

Relief pressure MPa (kgf/cm2) (psi)

Thermo sensing valve specifications Set temperature ºC (ºF)

Temperature ºC (ºF) K95ZV42016

1. Body 2. Wax element 3. O-ring 4. Spring seat 5. Poppet 6. Poppet guide 7. Orifice 8. Spring C 9. Spring B 10. Shim 11. Screen 12. Cap seat

Relief pressure MPa (kgf/cm2) (psi)

80 ± 2 (176 ± 3.6)

6.2 ± 0.69 (63 ± 7) (900 ± 100)

93 ± 2 (200 ± 3.6)

16.5 ± 0.2 (168 ± 2) (2,390 ± 100)

95ZV EX 42-128 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 0231~)

Thermo sensing valve operation

Tank P2

Tank

1. Poppet

2. Wax element

3. Piston

Relief valve

4. Spring

Relief valve

1. Poppet

2. Wax element

3. Piston 65ZV42025

Seat face 65ZV42024

- When the engine cooling water temperature is lower than 80±2ºC (176±3.6ºF) (low pressure status): The piston (3) of the wax element (2) is in the shortest position, and the load to the spring (4) is also minimum. The poppet (1) is pressed against the seat face by this spring load. When the oil quantity flowing through the seat is 0.15 L/min (0.04 gal/min), the pressure P (P1 - P2) is set to 6.2 ± 0.69 MPa (63 ± 7 kgf/cm2) (900 ± 100 psi).

- While the engine cooling water temperature is rising (pressure increase status): When the engine cooling water temperature exceeds 80±2ºC (176±3.6ºF), the wax element (2) senses the water temperature. As the engine cooling water temperature increases, the piston (3) is gradually pushed out. When the piston (3) is pushed out, the spring load applied on the poppet (1) increases, and the pressure P1 increases also. - When the engine cooling water temperature is 93±2ºC (200±3.6ºF) or higher (high pressure status): The stroke of the piston (3) is determined by the engine cooling water temperature. When the engine cooling water temperature increases over 93±2ºC (200±3.6ºF), the piston (3) is pushed out fully as shown in the figure, the spring load applied on the poppet (1) becomes maximum, and the pressure DP increases to the maximum value.

95ZV EX 42-129 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 0231~)

Fan motor relief valve assembly

1 To tank

T PP To thermo sensing valve

T1 From thermo sensing valve

T2 To fan motor

P1 PS

P 2 From pump (unloader valve)

1. Relief valve 2. Check valve (Make-up valve)

P1 Ps

T 1

K95ZV42017

P Ts Hydraulic circuit diagram 95ZV42090

: Tightening torque Relief valve (1): 60~65 N-m (6.12~6.63 kgf-m) (44~48 lb-ft)

95ZV EX 42-130 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 0231~)

Fan motor relief valve

Fan motor check valve (make-up valve) Body

Passage A

Seat

Ball

Passage A

Passage C

Pump

Passage B To thermo sensing valve

Orifice 2

Passage D

Fan motor

To tank Passage B

Plunger

Passage C

Passage E Orifice 1

Poppet Sleeve From pump (unloader valve)

65ZV42028

Tank

Sleeve 80ZVE42017

The oil from the pump goes through orifices 1 and 2 and passages A and B, then flows from the body perimeter to the thermo-sensing valve. When the engine cooling water temperature increases and reaches 93 ± 2ºC (200 ± 3.6ºF), the spring load of the thermo-sensing valve becomes maximum, and the pressure in the fan motor line increases. When this pressure reaches 15.1 MPa (154 kgf/cm2) (2,190 psi), the pressure oil from the orifice 2 pushes up the ball and releases into the tank by way of passages C and D. As a result, the oil pressure in chamber A decreases, the pressure oil from the pump pushes up the plunger and flows into the tank port by way of passage E. Accordingly, the maximum number of revolutions (1,500 min-1) of the fan motor is determined by this relief pressure. Set pressure (guideline) 16.1 MPa (164 kgf/cm2) (2,335 psi)

While the engine is running, the oil from the pump enters the chamber A by way of passages A and B, and presses both the spring and the poppet against the sleeve. As a result, the oil does not flow into the tank port. When the engine is stopped, the pressure in the pump port (chamber A) becomes negative pressure (or a void) because the oil is not fed to the fan motor though the fan continues to turn by the inertia. In order to prevent generation of negative pressure, the poppet is pushed up from the tank port side, and the oil at the tank port flows into the fan motor line by way of passage C. This status continues until revolution of the fan caused by the inertia is attenuated and stopped.

95ZV EX 42-131 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 9001~9010)

Fan Motor Line (S/N 9001~9010) Cooling fan Solenoid valve (74)(75)

Fan motor (71) Number of revolutions of fan (min-1) (rpm)

80.0 cm3/rev

G1 T2 G1/4

High speed: Solenoid coil is de-energized.

1,365

A Water temperature switch

Water temperature < 200 ºF...ON

(G1/4)

Water temperature > 200 ºF...OFF

(G1/4)

From reducing valve (28) in valve block (26) Pressure is 3.5 MPa (36 kgf/cm2) (512 psi)

Valve assembly (72)

Low speed: Solenoid coil is energized.

955

Idle Number of revolutions of engine

(G1/4)

G1 P1

(G1/4) High pressure set: 15.1 MPa (154 kgf/cm2) (2,190 psi) Low pressure set: 8.2 MPa (83.6 kgf/cm2) (1,189 psi)

Full

Fan revolution status From unloader valve (22)

Relief valve (73)

Shown with solenoid coil de-energized and relief valve in the high pressure position.

Hydraulic line diagram K95ZVE42006

In the case “Engine water temperature > (greater than) 94 ºC (200 ºF)” The water temperature switch is OFF, and the power is not supplied to the solenoid valve (74)(75) as shown in the upper left figure. The pilot pressure from the reducing valve (28) enters the relief valve (73), and sets the relief valve (73) to high pressure. As a result, the maximum fan speed is set to 1,365 min-1 (rpm), preventing rise of the engine water temperature, the hydraulic oil temperature, etc. The fan motor revolution changes as follows. 955 min-1 (rpm) 1,365 min-1 (rpm) at 94±2 ºC (200±4 ºF) 1,365 min-1 (rpm) 955 min-1 (rpm) at 84±2 ºC (184±4 ºF)

95ZV EX 42-132 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 9001~9010)

71 Fan motor

72 Fan motor valve assembly

(S/N 9001~9003)

22 Unloader valve 26 Valve unit

Note The numbers above correspond to those in the "Loading/Steering Hydraulic Circuit (S/N 9001~9010)" page 92-6.

26 Valve unit

K95ZVE42007

95ZV EX 42-133 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 9001~9010)

Fan motor (GM30C) (S/N 9001~9010) 15

16 17

6 7

14 97ZV42049

Fan motor specifications Displacement capacity

80.0 cm3/rev

Operating number of revolutions

1,500 min-1 (rpm)

Motor efficiency

95%

IMPORTANT This motor is designed to rotate only in one direction. Hoses must be connected correctly or damage to motor will result from reverse rotation.

95ZV EX 42-134 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 9001~9010)

Valve assembly (for fan motor)

Oil from unloader valve

To fan motor

PG P2

Oil from fan motor

Oil from reducing valve

Relief valve (Two step relief)*

80.0 cm3/rev

DR G1/4

1 B

(G1/4) (G1/4)

C P2

Solenoid valve coil

Valve

(G1/4)

(G1/4) G1 P1

Hydraulic line diagram

K95ZVE42011

Relief valve high pressure set value: 15.1 MPa (154 kgf/cm2) (2,190 psi) Relief valve low pressure set value: 8.2 MPa (83.6 kgf/cm2) (1,189 psi)

Note Refer to the following section, Relief valve (two-step relief).

95ZV EX 42-135 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 9001~9010)

Relief valve (two-step relief) 3

12 14

Pump port

Pilot port

1 2

Tank port

8 9

1. Piston 2. Plunger 3. Backup ring 4. O-ring 5. O-ring 6. Spring 7. Spring 8. O-ring 9. Backup ring 10. Seat 11. Filter stopper 12. Filter

Note For pressure adjustment, set the pressure on the high pressure side first.

13. Poppet 14. Body 15. O-ring 16. O-ring 17. Spring 18. Plug 19. Piston 20. O-ring 21. Lock nut 22. Adjustment screw (high pressure side) 23. Lock nut 24. Adjustment screw (low pressure side)

95ZV42060

95ZV EX 42-136 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 9001~9010)

Relief valve (two-step relief) operation When the pressure is lower than the setting pressure

Pump port (to fan)

Pilot port

Tank port

10 95ZV42061

The chamber B is filled with the pressure oil which has entered by way of the hole (A) in the piston (1). As a result, plunger (2) is in secure contact with the seat (10).

When the pressure is greater than the setting pressure (low pressure)

13 17

Pump port (to fan)

Pilot port

Tank port

95ZV42062

95ZV EX 42-137 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 9001~9010)

13 17

Pump port (to fan)

Pilot port

Tank port

19 95ZV42063

When the poppet (13) is open, the oil pressure in chamber B decreases and piston (1) moves to the right. The pressure difference between the pump port and chamber B caused by the ringlike portion of the piston (1) in part D (where the piston diameter is a little smaller than the inner diameter of the plunger (2)) pushes the plunger (2) to the right, causing the oil to flow from the pump port to the tank port. Setting of high pressure When the piston (19) is pushed to the left of the E stroke by the pressure oil coming from the pilot port, the setting pressure of the spring (17) increases.

Make-up valve operation

Pump port

Pilot port

Tank port

10 95ZV42064

When the pump port pressure status changes to negative pressure (or a void), the tank port pressure applied on plane A of seat (10) moves seat (10) to the right, flowing oil from the tank port to the pump port so that generation of negative pressure is prevented.

95ZV EX 42-138 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 9001~9010)

Solenoid valve (for fan speed control)

Solenoid coil

Moveable iron core Rod

A Spool

Passage B

C Tank

Hydraulic circuit diagram

B Oil from the reducing valve

A A To the two-stepped relief valve

Passage A 95ZV42066

Solenoid valve (for fan speed control) operation Amp

a 0

Volt

Varistor 95ZV42079

Solenoid valve specifications Voltage

DC24 V

Current

0.52 A

Resistance

45.9 

95ZV EX 42-139 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 9011~)

Fan Motor Line (S/N 9011~) Fan motor (71)

Cooling fan 80.0 cm3/rev

Note Relief is “pressure compensated”.

Check valve (73)

To drain

P1 Ps G1/4

15.1 MPa (154 kgf/cm2) T2

Radiator

High pressure set: 16.5 MPa (168 kgf/cm2) (2,390 psi) Low pressure set: 6.2 MPa (63 kgf/cm2) (900 psi)

G1/4

To thermo-sensing valve Detail of relief valve (72)

From fan motor circuit

Thermo-sensing valve (74)

80ZV42008

From unloader valve Relief valve (72) Hydraulic line diagram

K95ZVE42008

Engine cooling water temperature

Max. number of cooling fan revolutions

80ºC (176ºF) or lower

955

93ºC (200ºF) or higher

1,365

High temperature [93ºC (200ºF)] or higher

(min-1)

Number of fan revolution

1,365 Stepless control range

955

(565)

Low temperature [80ºC (176ºF)] or lower

0 600

800

(1,245)

(1,764)

Engine revolution

*Values in ( ) are for reference.

Fan revolution (Controlled by thermo-sensing valve) K95ZVE42009

95ZV EX 42-140 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 9011~) When the oil pressure reaches the set pressure [15.1 MPa (154 kgf/cm2) (2,190 psi)] or more, the relief valve (72) releases the pressure oil to the tank, as a result, the maximum fan revolution is regulated. On the other hand, the relief valve (72) and the thermosensing valve (74) are connected each other by way of the port Pp. Because the set pressure of the thermosensing valve (74) changes in accordance with the engine cooling water temperature, the regulated maximum number of revolutions varies depending on the cooling water temperature.

95ZV EX 42-141 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 9011~)

71 Fan motor

72 Fan motor valve assembly (S/N 9066~)

22 Unloader valve

Fan motor valve assembly

K95ZVE42010

Note The numbers above correspond to those in the "Loading/Steering Hydraulic Circuit (S/N 9011~)" page 92-7.

95ZV EX 42-142 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 9011~)

Fan motor (GM30C) (S/N 9011~9065) 15

16 17

6 7

14 97ZV42049

Fan motor specifications Displacement capacity

80.0 cm3/rev

Operating number of revolutions

1,500 min-1 (rpm)

Motor efficiency

95%

IMPORTANT This motor is designed to rotate only in one direction. Hoses must be connected correctly or damage to motor will result from reverse rotation.

95ZV EX 42-143 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 9011~)

Fan motor (GM30W) (S/N 9066~) 13 8 12 11 10 9 8 7

3 2 1 14

19 17 15

9 10 11 18 17 16 K115ZV42022

1. Nut 2. Washer 3. Stud bolt 4. Oil seal (outer) 5. Retaining ring 6. Oil seal (inner) 7. Front cover 8. O-ring 9. Bushing 10. Oil seal (E-ring) 11. Seal retainer 12. Wear plate 13. Center section

14. Steel ball 15. Driven gear 16. Drive gear 17. O-ring 18. Wear plate 19. Rear cover Note The same fan motor model “GM30C” is used on the machines S/N 9011~9065. Refer to "Fan motor (GM30C) (S/N 9001~9010)" page 42-133 for details.

95ZV EX 42-144 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 9011~)

Fan motor specifications Displacement capacity

80.0 cm3/rev

Operating number of revolutions

1,500 min-1 (rpm)

Motor efficiency

95%

IMPORTANT This motor is designed to rotate only in one direction. Hoses must be connected correctly or damage to motor will result from reverse rotation.

95ZV EX 42-145 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 9011~)

Thermo sensing valve 1

3 2

P 11

4 8

7 65ZV42022

Relief pressure MPa (kgf/cm2) (psi)

Thermo sensing valve specifications Set temperature ºC (ºF)

Temperature ºC (ºF) K95ZV42016

1. Body 2. Wax element 3. O-ring 4. Spring seat 5. Poppet 6. Poppet guide 7. Orifice 8. Spring C 9. Spring B 10. Shim 11. Screen 12. Cap seat

Relief pressure MPa (kgf/cm2) (psi)

80 ± 2 (176 ± 3.6)

6.2 ± 0.69 (63 ± 7) (900 ± 100)

93 ± 2 (200 ± 3.6)

16.5 ± 0.2 (168 ± 2) (2,390 ± 100)

95ZV EX 42-146 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 9011~)

Thermo sensing valve operation

Tank P2

Tank

1. Poppet

2. Wax element

3. Piston

Relief valve

4. Spring

Relief valve

1. Poppet

2. Wax element

3. Piston 65ZV42025

Seat face 65ZV42024

95ZV EX 42-147 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 9011~)

Fan motor relief valve assembly

1 To tank

T PP To thermo sensing valve

T1 From thermo sensing valve

T2 To fan motor

P1 PS

P 2 From pump (unloader valve)

1. Relief valve 2. Check valve (Make-up valve)

P1 Ps

T 1

K95ZV42017

P Ts Hydraulic circuit diagram 95ZV42090

: Tightening torque Relief valve (1): 60~65 N-m (6.12~6.63 kgf-m) (44~48 lb-ft)

95ZV EX 42-148 42 Function & Structure Hydraulic Group Fan Motor Line (S/N 9011~)

Fan motor relief valve

Fan motor check valve (make-up valve) Body

Passage A

Seat

Ball

Passage A

Passage C

Pump

Passage B To thermo sensing valve

Orifice 2

Passage D

Fan motor

To tank Passage B

Plunger

Passage C

Passage E Orifice 1

Poppet Sleeve From pump (unloader valve)

65ZV42028

Tank

Sleeve 80ZVE42017

The oil from the pump goes through orifices 1 and 2 and passages A and B, then flows from the body perimeter to the thermo-sensing valve. When the engine cooling water temperature increases and reaches 93 ± 2ºC (200 ± 3.6ºF), the spring load of the thermo-sensing valve becomes maximum, and the pressure in the fan motor line increases. When this pressure reaches 15.1 MPa (154 kgf/cm2) (2,190 psi), the pressure oil from the orifice 2 pushes up the ball and releases into the tank by way of passages C and D. As a result, the oil pressure in chamber A decreases, the pressure oil from the pump pushes up the plunger and flows into the tank port by way of passage E. Accordingly, the maximum number of revolutions (1,365 min-1) of the fan motor is determined by this relief pressure. Set pressure (guideline) 15.1 MPa (154 kgf/cm2) (2,190 psi)

95ZV EX 42-149 42 Function & Structure Hydraulic Group Emergency Steering (for Europe)

Emergency Steering (for Europe) Note Emergency steering is a standard equipment for the European market. It is available as an optional equipment for the other area.

Emergency steering line oil flow

The emergency steering works automatically when the steering hydraulic pressure goes down or the engine stops while the machine is operating.

In normal operation

When the steering hydraulic pressure goes down while the engine is running, the steering hydraulic warning lamp lights up.

See the diagram on the next page.

Oil flows goes out from gear pump (A) through hose (13) to block (4) via check valve (9). Then, the oil enters the steering valve via P port, and goes to the steering cylinder to steer the machine.

When the emergency steering system works

Emergency steering 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 lowers below 0.4 MPa (4 kgf/cm2) (57 psi). 3. Hydraulic pressure in the Orbitrol® hydraulic circuit rises above 0.4 MPa (4 kgf/cm2) (57 psi).

Oil flows goes out from gear pump (B) through hoses (19)(23) to the motor pumps, and goes to block (4) through hoses (21)(24) via check valves (8). Then, the oil enters the steering valve via P port, and goes to the steering cylinder to steer the machine.

95ZV EX 42-150 42 Function & Structure Hydraulic Group Emergency Steering (for Europe)

Emergency steering hydraulic diagram

Motor pump

19 13

21 35 16

14 24

Gear pump (A)

Gear pump (B)

4 Reducing valve for Orbitrol®

P port Steering valve From oil tank

95ZVE42007

1. — 2. — 3. — 4. Block 5. Oil pipe 6. Adapter 7. Elbow adapter 8. Check valve 9. Check valve

10. — 11. Adapter 12. Adapter 13. High pressure hose 14. Adapter 15. Elbow fitting 16. Adapter 17. Connector 18. —

For the electrical wiring diagram/ connection diagram, refer to “Electrical Group”.

19. Heat resisting hose 20. — 21. High pressure hose 22. — 23. Heat resisting hose 24. High pressure hose 25. Line filter 26. — 27. —

28. — 29. — 30. — 31. — 32. — 33. — 34. — 35. High pressure hose

95ZV EX 42-151 42 Function & Structure Hydraulic Group Emergency Steering (for Europe)

Machine speed signal

Relay

Machine speed

OFF

(km/h)

85V2E42051

Emergency steering motor and pump CW rotation

Magnetic switch

Relief valve

+24 V

Motor

+24 V

Pump

Customer's power connection

Customer's switch connection

Relief valve 11.7 MPa (119.3 kgf/cm2)

Customer's ground connection

Electric/Hydraulic schematic

95V2E42039

85V2E42052

Emergency steering motor and pump Model

ND-K2-D

Discharge (cm3/rev)

Relief valve setting pressure MPa (kgf/cm2) (psi)

11.7 (119.3) (1,696)

95ZV EX 42-152 42 Function & Structure Hydraulic Group

MEMO

95ZV EX 43-1 43 Check & Adjustment Hydraulic Group

43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve ....................................43-2 Hydraulic Cylinder ...............................................................43-12 Stop Valve ...........................................................................43-14 Fan Revolution (S/N 0101~)................................................43-15 Fan Revolution (S/N 9001~)................................................43-19

95ZV EX 43-2 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve

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

Measurement instruments Pressure gauge 30 MPa (300 kgf/cm2) (5,000 psi) (for loading line with 3 m (10 ft.) hose and steering line with 1.5 m (4 ft.) hose) 5 MPa (50 kgf/cm2) (1,000 psi) (for pilot line) with 2~3 m (6~10 ft.) hose Note For safety, route the gauge to an area where it may be safely read by the person doing the test.

Standard measurement value

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

CAUTION Be careful, you may get burned if the high pressure oil spouts out. To prevent such an accident, be sure to release the residual pressure from the pipe, and open the cap of the hydraulic oil tank before removing the plug from the pressure measurement port. Releasing residual pressure from tank and pipes Keep the bottom surface of the bucket horizontal, and stop the engine when the bucket is approximately 30 cm (1 ft.) above the ground. Tilt down the bucket until it comes in contact with the ground. Place the bucket control lever in the roll back position, and then lower the boom. Push down on, then open the cap of the hydraulic oil tank to release the residual pressure.

Loading line main relief pressure (at maximum speed)

20.6 ± 0.5 MPa (210 ± 5 kgf/cm2)

Loading line overload relief pressure (at idling speed)

23.5 ± 0.5 MPa (240 ± 5 kgf/cm2)

Pilot line

3.5 MPa (36 kgf/cm2)

Hydraulic oil temp: 50~80ºC (120~180ºF)

95ZV EX 43-3 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve

Gauge port

Multiple control valve Gauge port location

Port size

Main relief pressure (1), (2), (3)

(1) Rc (PT) 1/4

Overload relief pressure

(1), (2), (3)

(2), (3) G (PF) 1/4 with O-ring

(4)

(4) G (PF) 3/8 with O-ring

Pilot line pressure (Reducing valve)

Make-up valve Overload relief valve

Bucket cylinder (S/N 0101~0272, 9001~9065) Overload relief valve

Main relief valve

(3) 95ZV43002

(1)

Valve assembly (4)

(2)

(PPI)

95ZV43001

(Z2)

(Z)

(Z1)

(PA)

ACF

(ACCF)

(ACCR)

(PARKING) (TA)

(S/N 0273~, 9066~)

(T)

(P)

Reducing valve (for pilot) (S/N 0101~0265) (S/N 9001~9065)

(2) (1) K97V2J43003

(S/N 0266~) (S/N 9066~)

K95ZVE43001

95ZV EX 43-4 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve

Measuring loading circuit main relief pressure 1. Unload the bucket.

Adjusting main relief pressure

Cap Lock nut

2. Lower the boom to the lowest limit. 3. Attach the pressure gauge 30 MPa (300 kgf/cm2) (5,000 psi) to the quick connector port (3). 4. Set the parking brake switch to the "ON" position. 5. Move the bucket control lever to the roll back position. Hold the lever at that position. 6. Increase the engine speed to the maximum, and measure and record the pressure using the pressure gauge.

Adjusting screw

Main relief valve

95ZV43004

IMPORTANT At the completion of check and adjustment of main relief valve pressure, be sure to tighten the lock nut.

95ZV EX 43-5 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve

Measuring loading circuit overload relief pressure 1. Attach the pressure gauge to the port (3).

Adjusting overload relief pressure

Lock nut

2. Adjust the main relief valve pressure to 24.5 MPa (250 kgf/cm2) (3,555 psi) + 1/4 additional turn, so the pressure is above the overload relief pressure. Bucket cylinder bottom side 1. Lower the boom to the lowest limit. 2. Move the bucket control lever to the roll back position. 3. Keep the engine speed at low idle. 4. Hold the bucket control lever at the roll back position and record the pressure. Bucket cylinder rod side 1. Keep the boom horizontal. 2. Move the bucket control lever to the dump position, hold and then measure and record the pressure.

Adjusting screw Overload relief valve

95ZV43005

IMPORTANT At the completion of check and adjustment of overload relief valve pressure, be sure to reset the main relief valve to the original condition.

95ZV EX 43-6 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve

Measuring pilot circuit relief pressure

Adjusting pilot line pressure

WARNING Lock nut

Trapped pressure in brake circuit could cause serious injury when the plug is removed. Fully release all residual accumulator pressure before servicing. 1. Attach the pressure gauge to the port (4).

Adjusting screw

WARNING

Reducing valve

90ZVE43004

Loosen the lock nut and adjust the pressure by the adjusting screw. Turn clockwise the adjusting screw to raise the pilot line pressure.

IMPORTANT

Injection Hazard Depress brake pedal 80~100 times to completely discharge the brake accumulators prior to removing these plugs.

After the completion of the adjustment of the pilot line pressure, be sure to tighten the lock nut. K65ZV42022

2. Keep the engine speed at low idle (when the brake line pressure is normal) and then measure and record the pressure.

95ZV EX 43-7 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve

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

Standard measurement value

Steering line main relief pressure (at maximum speed)

20.6 ± 0.5 MPa (210 ± 5 kgf/cm2)

Steering line overload relief pressure (at idling speed)

24.5 +1.0 0 MPa (250 +100 kgf/cm2)

Pilot line

3.5 MPa (36 kgf/cm2)

Hydraulic oil temp: 50~80ºC (120~180ºF)

Steering valve Main relief valve

Releasing residual pressure from tank and pipes Keep the bottom surface of the bucket horizontal, and stop the engine when the bucket is approximately 30 cm (1 ft.) above the ground. Tilt down the bucket until it comes in contact with the ground. Place the bucket control lever in the roll back position, and then lower the boom. Push down on, then open the cap of the hydraulic oil tank to release the residual pressure.

Overload relief valve 95ZV43006

95ZV EX 43-8 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve

Gauge port Gauge port location

Port size

Main relief pressure (1), (2)

G (PF) 1/4 with O-ring

(3)

Rc (PT 1/8)

Overload relief pressure Reducing pressure

Steering cylinder

(2)

(1)

70ZV43007

Reducing valve

(A)

(3)

(B)

115ZV43006

95ZV EX 43-9 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve

Measuring steering circuit main relief pressure

Adjusting steering line main pressure Lock nut Adjusting screw

Steering cylinder

(2)

(1) 95ZV43007 70ZV43007

Main relief valve

1. Attach the pressure gauge to the gauge port ((1) or (2)).

Loosen the lock nut and adjust the pressure by the adjusting screw.

2. In case the pressure gauge is installed to (1), steer the machine to the left until the front and rear chassis contact each other. Continue to hold the steering wheel fully turned.

Turn clockwise the adjusting screw to raise the steering line main pressure.

WARNING If the machine begins to move with the articulation stopper applied, it may cause an accident resulting in injury or death. After the measurement, be sure to disconnect and store the articulation stopper. 3. Increase the engine speed to high idle, and measure and record the pressure.

95ZV EX 43-10 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve

Measuring steering circuit overload relief pressure

Adjusting overload relief pressure Lock nut

1. Attach the pressure gauge to the port ((1) for the left turn, (2) for the right turn).

Adjusting screw

2. Adjust the main relief valve pressure to 25.5 MPa (260 kgf/cm2) (3,697 psi) + 1/4 additional turn, so the pressure is above the overload relief pressure. 3. Steer the machine until the front and rear chassis contact each other. Continue to hold the steering wheel fully turned. 95ZV43008

(S/N 0101~0290, 9001~9080)

Stopper (bolt)

Port B To steering valve

Port A From Orbitrol®

Loosen the lock nut and adjust the pressure by the adjusting screw.

Spool

Turn clockwise the adjusting screw to raise the set pressure, or turn counterclockwise the adjusting screw to lower the set pressure.

WARNING Installed on front chassis

Bolt

Check valve Installed on rear chassis 95ZV42033

(S/N 0291~, 9081~)

Stopper (bolt)

Port B To steering valve

Port A From Orbitrol®

If the machine begins to move with the articulation stopper applied, it may cause an accident resulting in injury or death. After the measurement, be sure to disconnect and store the articulation stopper.

IMPORTANT

Spool

At the completion of check and adjustment of overload relief valve pressure, be sure to reset the main relief valve to the original condition.

Installed on front chassis

Check valve Installed on rear chassis 90V2U42003

Note Because the stop valve is installed into the steering line, oil pressure does not reach the set point when the steering is fully turned. When measuring oil pressure, be sure to apply the articulation stopper or screw the stopper (bolt) in until the front and rear chassis contact each other. 4. Keep the engine speed at low idle, and measure and record the pressure. Raise the engine speed to 1,000 min-1 if fail to do.

95ZV EX 43-11 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve

Measuring pilot circuit relief pressure (reducing pressure) (S/N 0107~, 9004~)

Adjusting screw Lock nut

Adjusting pilot line pressure Loosen the lock nut and adjust the pressure by the adjusting screw. Turn clockwise the adjusting screw to raise the pilot line pressure.

IMPORTANT After the completion of the adjustment of the pilot line pressure, be sure to tighten the lock nut.

(T)

(A)

(3) (TS)

(B)

115ZV43007

1. Attach the pressure gauge to the port (3). Gauge port plug width across flat 5 mm (0.2 in) 2. Keep the engine speed at low idle and record the pressure.

95ZV EX 43-12 43 Check & Adjustment Hydraulic Group Hydraulic Cylinder

Hydraulic Cylinder Cylinder natural drift WARNING Standing under the boom or bucket during service work is dangerous. An accident resulting in injury or death may be caused. To prevent such an accident, be sure to lock the boom and bucket control levers in the cab, securely support the boom, and remove the starter key. In addition, hang a "DO NOT OPERATE!" tag on the steering wheel.

Cylinder natural drift measurement procedure 1. Unload the bucket. 2. Keep the boom and bucket horizontal. 3. Set the parking brake switch to the "ON" position. 4. Lock the boom and bucket control levers using the safety lock. 5. Stop the engine. 6. Mark the cylinder rod at a point 100~150 mm (4~6 in) away from the cylinder head cover.

Measurement instrument

7. Measure the accurate distance from the cylinder head cover to the vinyl tape. This is distance "A" mm (in). Measure the distance again 5 minutes later. This is distance "B" mm (in).

- Scale 150 to 300 mm (1 ft.) - Stop watch - Black vinyl "electrician's" type Note Warm-up the hydraulic oil before measuring cylinder drift.

Standard measurement value Boom cylinder

3 mm/min (1/8 in/min) or less

Bucket cylinder

4 mm/min (5/32 in/min) or less

Cylinder drift (mm/min) A – B (mm) (in) = -------------(in/min) 5 (min)

95ZV EX 43-13 43 Check & Adjustment Hydraulic Group Hydraulic Cylinder Reference

Mark (Vinyl tape) Scale 95ZV43009

Drift rate depends on the viscosity of the hydraulic oil and its temperature. In other words, high temperature of the hydraulic oil reduces the viscosity. Reduction in oil viscosity increases oil leakage through the seals, and increases the drift rate. Cold thick oil reduces the drift rate.

IMPORTANT At the completion of measurement, if the vinyl tape used for measurement is not removed from the cylinder rod, the tape may be caught by the rod seal. The tape will cause oil leakage from the rod seal. To prevent oil leakage, be sure to remove the vinyl tape.

95ZV EX 43-14 43 Check & Adjustment Hydraulic Group Stop Valve

Stop Valve Stop valve adjustment procedure

Reference dimension Front chassis

Stop valve (rear chassis)

Stopper (bolt)

(L.H, R.H)

Front chassis

Rear chassis

Reference dimension 23~27.5 mm (0.9~1.1 in) Stopper (bolt) length

Reference dimension 28~48 mm (1.1~1.9 in) Clearance between machine body and stopper

115ZV43005

115ZV43004

Articulation angle ( º)

WARNING When the machine turns, the clearance in the articulation area closes. As a result, people may be caught, leading to a severe accident. To prevent such an accident, observe the following items strictly when adjusting the steering stopper. - Stop the engine before starting adjustment of the stopper bolt. - When confirming the operation after setup, keep proper distance from the articulation area of the machine. The stop valve works when the spool is pushed in 3 mm (0.118 in). Adjust the stopper bolt by using the following procedure. - Adjust the stopper (bolt) length so that the clearance between the machine body and the stopper becomes the reference dimension “28~48 mm (1.1~1.9 in)” shown in the table below.

Clearance between machine body and stopper (mm) (in)

28 38 48 (1.102) (1.496) (1.890)

Stopper (bolt) length (mm) (in)

23 25 27.5 (0.906) (0.984) (1.083)

*The target value should be the articulation angle “36º”. - After adjustment, turn the steering wheel slowly at a rate of 5 seconds or more per turn, and confirm the clearance between the machine body and the stopper. - When adjustment is completed, tighten the lock nut of the stopper (bolt). : 90 N-m (9.2 kgf-m) (67 lb-ft)

95ZV EX 43-15 43 Check & Adjustment Hydraulic Group Fan Revolution (S/N 0101~)

Fan Revolution (S/N 0101~) Fan maximum revolution measurement (S/N 0101~0230) WARNING Trapped hydraulic pressure in the hydraulic line could cause serious injury when the plug is removed. Observe the following items: - Park the machine on level ground, and apply the parking brake. In addition, block the tires with chocks to prevent wheels from moving. - Relieve the internal pressure from the hydraulic tank and the hydraulic line to prevent the oil from spouting out. - Remove the engine key, and hang a "DO NOT START ENGINE!" tag on steering wheel. Note Whenever the fan max. revolution is adjusted, always adjust the high revolution first, because when the high revolution is changed, the low revolution is also changed.

Measurement instrument Spanner: 22, 27, 32 mm Pressure gauge about 30 MPa (300 kgf/cm2) (5,000 psi) (gauge will work) [Gauge port: PG port (PF1/4)] Tachometer (Photo tachometer)

Standard measurement value Engine water temperature

Fan revolution

Set pressure

<94 ºC

1,050 min-1

8.5 MPa (86.7 kgf/cm2)

>94 ºC

-1

1,500 min

16.1 MPa (164.2 kgf/cm2)

95ZV EX 43-16 43 Check & Adjustment Hydraulic Group Fan Revolution (S/N 0101~)

Measuring and adjusting the maximum number of revolutions

PX P2

Note Do not raise the pressure more than 18.6 MPa (2,700 psi) during adjustment. Set revolution 1,500 min-1 (rpm) [Set pressure 16.1 MPa (164.2 kgf/cm2) (2,335 psi)]

23 24

Solenoid valve

1. Remove the solenoid valve connection wire. When the solenoid valve is OFF, the high revolution can be adjusted. 2. Loosen the lock nut (21), adjust the rpm's (pressure) by turning the adjusting screw (22). Turn the adjusting screw clockwise as viewed from the valve end to raise the rpm's (pressure).

21 22

High revolution (High pressure) adjustment

95ZV42065

3. After adjusting the fan rpm's, tighten the lock nut (21) while holding adjusting screw (22) so as not to turn it at the same time. : Lock nut: 45 N-m (4.6 kgf-m) (33 lb-ft)

Low revolution (Low pressure) adjustment 1. Confirm the radiator cooling water temperature is lower than 80 ºC (176 ºF), and then adjust the rpm's keeping the solenoid valve connection wire installed on the relief block. When the radiator cooling water temperature is low, the solenoid valve is ON. 2. Loosen the lock nut (23), adjust the rpm's (pressure) by turning the adjusting screw (24). Turn the adjustment screw clockwise as viewed from the valve end to raise the rpm's (pressure). Set revolution 1,050 min-1 (rpm) [Set pressure 8.5 MPa (86.7 kgf/cm2) (1,233 psi)] 3. After adjusting the fan rpm's, tighten the lock nut (23) while holding the adjusting screw (24) so as not to turn it at the same time. : Lock nut: 31 N-m (3.2 kgf-m) (23 lb-ft)

95ZV EX 43-17 43 Check & Adjustment Hydraulic Group Fan Revolution (S/N 0101~)

Fan maximum revolution measurement (S/N 0231~)

Measuring and adjusting the maximum number of revolutions

WARNING

Adapter

The residual oil pressure in the hydraulic line could spout high pressure oil and cause serious injury such as burn when a hose or plug is removed. Make sure to release the residual pressure from the line and the internal pressure from the tank before starting adjustment.

Relief valve

P1 P PP

Fan motor

Cooling fan 80.0 cm3/rev

Check valve

T1 Plug

P1 Ps G1/4

16.1 MPa (164 kgf/cm ) T2

Radiator

G1/4

Thermo-sensing valve High pressure set: 16.5 MPa (168 kgf/cm2) (2,390 psi) Low pressure set: 6.2 MPa (63 kgf/cm2) (900 psi)

From unloader valve Relief valve Hydraulic circuit diagram

K95V42006

1. Remove hose and adapter from the port PP, and plug port PP.

2. Remove the plug from the port PS, and attach a gauge. Gauge: About 20 MPa (200 kgf/cm2)(3,000 psi) Port size: PF 1/4 3. Measure the number of fan revolutions while the engine is at high idle.

Standard values Engine at high idle

95ZV42091

Port size: PF 1/4

Relief valve assembly

2,350±50 min-1 (rpm)

Number of fan revolution

High

-1 1,500 +75 - 50 min (rpm)

Low

-1 955 +75 - 50 min (rpm)

Relief set pressure (guideline)

High

16.1 MPa (164 kgf/cm2)

Low

6.2 MPa (63 kgf/cm2)

95ZV EX 43-18 43 Check & Adjustment Hydraulic Group Fan Revolution (S/N 0101~)

Adjusting screw

Lock nut Relief valve

65ZV43007

4. If the maximum number of revolutions is not correct, adjust it using the adjusting screw in the relief valve. Turn the adjusting screw clockwise to increase both the pressure and the number of fan revolution. Note The relief valve on the low pressure side cannot be adjusted because it accommodates a thermo-sensing valve. It can be only confirmed. After placing hose and adapter in the Port PP to normal, measure the pressure while the fan is moving at low speed. At this time, the engine cooling water temperature should be 80 ºC (176 ºF) or less (Engine at HI).

95ZV EX 43-19 43 Check & Adjustment Hydraulic Group Fan Revolution (S/N 9001~)

Fan Revolution (S/N 9001~) Fan maximum revolution measurement (S/N 9001~9010) WARNING Trapped hydraulic pressure in the hydraulic line could cause serious injury when the plug is removed. Observe the following items: - Park the machine on level ground, and apply the parking brake. In addition, block the tires with chocks to prevent wheels from moving. - Relieve the internal pressure from the hydraulic tank and the hydraulic line to prevent the oil from spouting out. - Remove the engine key, and hang a "DO NOT START ENGINE!" tag on steering wheel. Note Whenever the fan max. revolution is adjusted, always adjust the high revolution first, because when the high revolution is changed, the low revolution is also changed.

Measurement instrument Spanner: 22, 27, 32 mm (0.87, 1.06, 1.26 in) Pressure gauge about 30 MPa (300 kgf/cm2) (5,000 psi) Tachometer (Photo tachometer)

Standard measurement value Engine water temperature

Fan revolution

<94 ºC (200 ºF)

955 min-1

8.2 MPa (83.6 kgf/cm2) (1,189 psi)

>94 ºC (200 ºF)

1,365 min-1

15.1 MPa (154 kgf/cm2) (2,190 psi)

Set pressure

95ZV EX 43-20 43 Check & Adjustment Hydraulic Group Fan Revolution (S/N 9001~)

Measuring and adjusting the maximum number of revolutions

PX P2

Note Do not raise the pressure more than 18.6 MPa (2,702 psi) during adjustment. Set revolution 1,365 min-1 (rpm) [Set pressure 15.1 MPa (154 kgf/cm2) (2,190 psi)]

23 24

Solenoid valve

21 22

High revolution (High pressure) adjustment

95ZV42065

3. After adjusting the fan rpm's, tighten the lock nut (21) while holding adjusting screw (22) so as not to turn it at the same time. : Lock nut: 45 N-m (4.6 kgf-m) (33 lb-ft)

Low revolution (Low pressure) adjustment 1. Confirm the radiator cooling water temperature is lower than 80 ºC (176 ºF), and then adjust the rpm's keeping the solenoid valve connection wire installed on the relief block. When the radiator cooling water temperature is low, the solenoid valve is ON. 2. Loosen the lock nut (23), adjust the rpm's (pressure) by turning the adjusting screw (24). Turn the adjustment screw clockwise as viewed from the valve end to raise the rpm's (pressure). Set revolution 955 min-1 (rpm) [Set pressure 8.2 MPa (83.6 kgf/cm2) (1,189 psi)] 3. After adjusting the fan rpm's, tighten the lock nut (23) while holding the adjusting screw (24) so as not to turn it at the same time. : Lock nut: 31 N-m (3.2 kgf-m) (23 lb-ft)

95ZV EX 43-21 43 Check & Adjustment Hydraulic Group Fan Revolution (S/N 9001~)

Fan maximum revolution measurement (S/N 9011~)

Measuring and adjusting the maximum number of revolutions

WARNING

Adapter

The residual oil pressure in the hydraulic line could spout high pressure oil and cause serious injury such as burn when a hose or plug is removed Make sure to release the residual pressure from the line and the internal pressure from the tank before starting adjustment.

Relief valve

P1 P PP

Fan motor

Cooling fan 80.0 cm3/rev

Check valve

T1 Plug

P1 Ps G1/4

15.1 MPa (154 kgf/cm ) T2

Radiator

High pressure set: 16.5 MPa (168 kgf/cm2) (2,390 psi) Low pressure set: 6.2 MPa (63 kgf/cm2) (900 psi)

G1/4

Thermo-sensing valve

From unloader valve Relief valve Hydraulic line diagram

K95ZVE42008

Standard value Engine at high idle

2,250±50 min-1 (rpm)

Number of fan revolution

High

-1 1,365 +75 - 50 min (rpm)

Low

-1 955 +75 - 50 min (rpm)

Relief set pressure (guideline)

High

15.1 MPa (154 kgf/cm2) (2,190 psi)

Low

6.2 MPa (63 kgf/cm2) (896 psi)

Relief valve assembly

95ZV42091

1. Remove hose and adapter from the port PP, and plug port PP. Port size: PF 1/4 2. Remove the plug from the port PS, and attach a gauge. Gauge: About 20 MPa (200 kgf/cm2)(3,000 psi) Port size: PF 1/4 3. Measure the number of fan revolutions while the engine is at high idle.

95ZV EX 43-22 43 Check & Adjustment Hydraulic Group Fan Revolution (S/N 9001~)

Adjusting screw

Lock nut Relief valve

65ZV43007

4. If the maximum number of revolutions is not correct, adjust it using the adjusting screw in the relief valve. Turn the adjusting screw clockwise to increase both the pressure and fan speed. Note The relief valve on the low pressure side cannot be adjusted because it accommodates a thermo-sensing valve. It can be only confirmed. After placing hose and adapter in the Port PP to normal, measure the pressure while the fan is moving at low speed. At this time, the engine cooling water temperature should be 80 ºC (176 ºF) or less (Engine at HI).

95ZV EX 52-1 52 Function & Structure Brake Group

52 Function & Structure Brake Group Brake System Outline............................................................52-2 Brake Units Layout ................................................................52-3 Unloader Valve ......................................................................52-4 Valve Unit ..............................................................................52-7 Reducing Valve .....................................................................52-8 Brake Accumulator Line ........................................................52-9 Brake Valve .........................................................................52-13 Stop Lamp Pressure Switch ................................................52-22 Service Brake ......................................................................52-24 Parking Brake......................................................................52-32 Parking Brake (Rear)...........................................................52-33 Parking Brake (Front) (for Europe only) ..............................52-38 Auto Brake ..........................................................................52-43

95ZV EX 52-2 52 Function & Structure Brake Group Brake System Outline

Brake System Outline The brake system is the all-hydraulic type, and has two independent systems consisting of the front system and the rear system for enhancing safety. The service brake is the wet disc type. The parking brakes are the internal expansion drum type and the dry disc type.

Service brake Oil from the pump is regulated in a range from 6.9~11.8 MPa (70~120 kgf/cm2) (995~1,706 psi) by the unloader valve (22), and accumulated in the accumulator (33) provided for the front and rear wheels. When the brake valves (23)(24) are depressed, the pressure oil in the accumulator enters the disc brake piston chamber for the front and rear wheels, pushes the piston, and generates braking power.

Parking brake The internal expansion type drum brake for parking is applied by the spring chamber (55). The spring chamber (55) operates when the pressure oil inside the spring chamber returns to the tank while the power is not supplied to the solenoid valve (29) (that is, while the parking switch is ON). The dry type disc brake for parking is applied by pressure oil accumulated in the accumulator (33) while the power is not supplied to the solenoid valve (63) (that is, while the parking switch is ON).

Auto brake When the machine speed exceeds the specified value, power is supplied to the solenoid valve (27) by the signal sent from the T/M controller. As a result, the pressure oil depressurized by the reducing valve (28) acts on the brake valve (23), and applies the service brake.

Adjustment of axle internal pressure While the brake pedal is not pressed, the internal pressure of the hydraulic tank is always applied on the brake piston chamber, and there is a possibility that the brake may drag. To prevent the brake from dragging, the axle housing air chamber is connected to the hydraulic tank air chamber so that the pressure inside the axle housing becomes equivalent to the pressure inside the hydraulic tank.

95ZV EX 52-3 52 Function & Structure Brake Group Brake Units Layout

Brake Units Layout The brake system is the all-hydraulic type, and has two independent systems consisting of the front system and the rear system for enhancing safety.

The service brake is the wet disc type. The parking brakes are the internal expansion drum type and the dry disc type.

1 4

10 3 2

95ZV52023

1. Accumulator 2. Solenoid valve (for parking) 3. Solenoid valve (for auto-brake) 4. Brake valve 5. Parking brake (rear) 6. Parking brake (front)*

7. Spring chamber assembly (for rear parking brake) 8. Accumulator (for front parking brake)* 9. Solenoid valve (for front parking brake)* 10. Unloader valve *: For Europe only

95ZV EX 52-4 52 Function & Structure Brake Group Unloader Valve

Unloader Valve (S/N 0101~0328, 9001~9095)

To accumulator

B-B

To tank

8 9

To fan motor

Filter

17 Pilot port (accumulator feedback port)

16 A-A

15 12

From pump

Pump port

Fan motor port

Accumulator port

Fan motor port Pilot port (accumulator feedback port) Tank port

Tank port

1. Body 2. Spring 3. Spool 4. O-ring 5. Plug 6. Orifice 7. Orifice 8. O-ring

Rc 1/8

Accumulator port Hydraulic circuit diagram

P Pilot port (accumulator feedback port)

9. Plug 10. Plug (gauge port) 11. Governor plunger 12. Spring 13. O-ring 14. Plug 15. Pilot valve 16. Spring seat

Pump port Outline drawing

17. Spring 18. Spring 19. O-ring 20. Plug 21. Adjusting screw 22. Lock nut 23. Packing 24. Cap

K115ZV52001

95ZV EX 52-5 52 Function & Structure Brake Group Unloader Valve (S/N 0329~, 9096~)

To accumulator

B-B

To tank

To fan motor

22 8

10 1

26 18

Filter

4 15

Pilot port (accumulator feedback port)

A-A

From pump

Fan motor port

Pump port

Accumulator port

Fan motor port Pilot port (accumulator feedback port)

Tank port

Rc 1/8

Tank port

Accumulator port

P Pilot port (accumulator feedback port)

Hydraulic circuit diagram

1. Body 2. Spring 3. Spool 4. O-ring 5. Plug 6. Orifice 7. Orifice 8. O-ring 9. Plug 10. Plug (gauge port) 11. Governor plunger 12. Spring 13. O-ring

Pump port K115ZV52002

14. Plug 15. Pilot valve 16. Spring seat 17. Spring 18. Spring 19. O-ring 20. Plug 21. Adjusting screw 22. Lock nut 23. — 24. — 25. Seat 26. O-ring

95ZV EX 52-6 52 Function & Structure Brake Group Unloader Valve The unloader valve controls the flow rate and the pressure of the hydraulic oil sent from the pump to the accumulator. The body (1) is equipped with ports (pump, fan motor, accumulator, pilot and tank). The spool (3) which opens and closes the pump port to the fan motor port, the orifice (6) which regulates the flow rate to the accumulator port with high priority, and the pressure governor mechanism which controls the pressure on the accumulator port side are built in the unloader valve.

Unloader valve operation While the unloader valve is not operating, the spool (3) is pushed back by the spring (2) and the pump port to the fan motor port is closed. Oil flowing from the pump port is sent to the accumulator port through the orifice (6), and the pressure at the accumulator port increases accordingly. When an excess flow rate is generated, the spool (3) moves to the fan motor port side and the excess flow rate flows out to the port to the fan motor. The pressure at the accumulator port is transferred to the inside of the pressure governor through the orifice (7). When the pressure at the accumulator port increases and exceeds the load of the springs (17) (18) applied on the pilot valve (15), the pilot valve opens and increase of the pressure at the accumulator port stops (cut-out pressure). At this time, the pressure in the accumulator connected to the pilot port pushes the governor plunger (11), and continuously releases the pilot valve. When the pressure in the accumulator decreases and the spring attached to the pilot valve pushes back the governor plunger, the pilot valve is closed and the pressure at the accumulator port starts to increase again (cut-in pressure). Setting pressure

OFF 11.8 ± 0.5 MPa (120 ± 5 kgf/cm2) (1,706 ± 71 psi) ON

6.9 ± 1.0 MPa (70 ± 10 kgf/cm2) (995 ± 142 psi)

95ZV EX 52-7 52 Function & Structure Brake Group Valve Unit

Valve Unit 5

Loading line pilot valve

(PPI) (Z2)

Auto-brake (PA) solenoid valve

Note: Unloader valve (PI) "Feed back" signal is acquired from front brake accumulator.

Fan motor solenoid valve (Z)

(Z1) ACF

(ACCF)

(ACCR)

(PARKING)

spring chamber for parking brake

CXCDXAN

PPDBLDN

(S/N 0101~0265, 9001~9065)

(S/N 0266~, 9066~)

4 B

5 B

(P)

Pump port (from unloader valve)

CXCDXAN

3 4 P=Pump supply T=Tank circuit PI=Pump feedback to unloader (From ACCF circuit) ACCR=Accumulator circuit-rear ACCF=Accumulator circuit-front PPI=Pilot valve circuit

K95ZV52001

ACCR 5

P A

ACCF

(S/N 0231~) (S/N 9011~)

(S/N 0101~0230) (S/N 9001~9010)

ACCR

P A

Unloader valve "feed back" signal.

(TA)

Tank

(PI)

ACCF

ACF 2

T ACF

Z PPI Hydraulic circuit

ACF

P T A

P T

PA Z2 T

T ACF

Z1 95ZV52027

1. Solenoid valve for parking brake 2. Reducing valve [3.5 MPa (36 kgf/cm2) (512 psi)] (Serves as pressure for fan solenoid, loading pilot control, auto brake and park brake)

Z PPI Hydraulic circuit

PA Z2 T

Z1 K95ZVE52001

3. Check valve (front brake circuit) 4. Check valve (rear brake circuit) 5. Accumulator low pressure switch (2 used) [3.9 ± 0.5 MPa (40 ± 5 kgf/cm2) (569 ± 71 psi)]

95ZV EX 52-8 52 Function & Structure Brake Group Reducing Valve

Reducing Valve

Passage Z Ball

Tank port Orifice 2

Chamber C

Pump port (From unloader valve)

Orifice 1 (To accumulator)

Passage Y

Plunger (S/N 0107~, 9004~) (To tank)

B Accumulator line port (To main brake manifold block)

T A (From pump) Hydraulic circuit diagram

K95ZV52024

The oil fed from the pump flows into the reducing valve by way of port A, and passage Y. The oil pressure in the accumulator line is applied also on chamber C by way of orifice 1. When the oil pressure in the accumulator line reaches the set pressure or greater, the oil in chamber C pushes up the ball by way of orifice 2, and escapes to the tank by way of passage Z. As a result, the pressure in chamber C decreases, then the plunger moves up and closes passage Y so that the pressure on the accumulator line side does not exceed the set pressure.

When the oil pressure on the accumulator line side becomes less than the set pressure, the ball moves down and the pressure in chamber C becomes equivalent to the pressure on the accumulator side. As a result, the plunger moves down due to spring force, opens passage Y, then introduces the oil from the pump to the accumulator line side so that the pressure is maintained at the specified value. Set pressure 12.3 MPa (125 kgf/cm2) (1,783 psi)

95ZV EX 52-9 52 Function & Structure Brake Group Brake Accumulator Line

Brake Accumulator Line Accumulator

Reducing valve (for accumulator circuit)

Solenoid valve (for parking)

(S/N 0266~, 9066~)

Valve unit (Main brake manifold block)

(S/N 0107~, 9004~)

In-line filter

(S/N 0107~, 9004~)

Unloader valve (S/N 0101~0265) (S/N 9001~9065)

K95ZVE52002

95ZV EX 52-10 52 Function & Structure Brake Group Brake Accumulator Line

Accumulator

7 2

3 13 10

12 11 5 8 9 6

95ZV52058

1. Body 2. Hydraulic cap 3. Gas cap 4. Piston 5. V-O-ring 6. Backup ring 7. Wear ring 8. O-ring 9. Backup ring 10. Gas valve 11. Gas valve O-ring 12. Gas valve guard 13. Bolt

The accumulator holds a reserve of pressurized oil for the brake circuit prevent disability of the brakes caused by a problem with the pump, etc. Two accumulators are provided in the service brake line. Nitrogen gas at 2.94 MPa (30 kgf/cm2) (427 psi) is charged in the gas chamber. One accumulator of the same type is also provided in the dry type parking brake line, located in the front chassis. Accumulator specifications Maximum operating pressure MPa (kgf/cm2) (psi)

12.3 (125) (1,778)

Nitrogen gas charging pressure MPa (kgf/cm2) (psi)

2.94 ± 0.1 (30 ± 1) (427 ± 14)

Nitrogen gas capacity L (Gal.)

3.0 (0.793)

95ZV EX 52-11 52 Function & Structure Brake Group Brake Accumulator Line

In-line filter

FILTER

From unloader valve

To combination valve (via reducing valve)

5 70ZV42040

1. Case 2. Nipple 3. Strainer 4. O-ring 5. O-ring

This 95 micron filter protects the brake manifold and related valves from contamination. It must be back flushed to keep it clean. Replace it when there has been any system contamination or if the pilot and brake pump has failed. Pieces of debris can be lodged and may not blow out with compressed air, but may release later causing erratic valve troubles. The line filter is item No. 81 in the "Brake Circuit" page 92-8.

95ZV EX 52-12 52 Function & Structure Brake Group Brake Accumulator Line

Brake circuit check valve (S/N 9066~)

(S/N 9001~ 9065)

Poppet (T)

(P)

(TA)

Seat face

(PI)

A Pump supply through reducing valve

(ACCR)

(PARKING)

(ACCF)

(PA) (Z1)

(Z2)

(ACF)

(Z)

(PPI)

B (ACCF) Reducing valve

Valve assembly (180º rotated view)

Accumulator

Hydraulic circuit diagram The pressure oil fed from the pump pushes down the poppet, opens the seat face, and flows into the accumulator circuit. It also flows into the reducing valve. (ACCF side only) When the pressure oil is not fed from the pump (either the unloader valve is "cut-out" or the engine is shut off), the poppet is pushed up by the pressure in the accumulator circuit, and the seat face is closed to prevent back flow. This allows the accumulator circuit to store oil under pressure for emergency braking. There is one check valve for the front brake accumulator circuit and another for the rear.

P=Pump supply T=Tank circuit PI=Pump feedback to unloader (from ACCF circuit) ACCR=Accumulator circuit-rear ACCF=Accumulator circuit-front PPI=Pilot valve circuit K95ZV52017 PA=Auto brake circuit

95ZV EX 52-13 52 Function & Structure Brake Group Brake Valve

Brake Valve Brake main valve (left pedal) Tandem type Operates both with direct pedal application of pedal, and as a pilot operated servo valve to the right pedal.

(S/N 0101~0252, 9001~9048)

2 36

3 4

34 10

7 8

A-A

9 11

10 A

12 13 Tank port

Pilot port

15 17 20

16 18

Rear brake port

19 Accumulator port

26 27

23 24 Accumulator ports

Front brake port

25 Accumulator port

28 29 30

31 32

33 70ZV52023

1. Brake pedal 2. Roller 3. Bushing 4. Seat 5. Pedal stopper 6. Boot 7. Push rod 8. Oil seal 9. Flange 10. Bracket

11. Pilot piston 12. Retainer 13. Spring 14. Rod 15. Spring 16. Spring 17. O-ring 18. Primary cylinder 19. Spool 20. Spring

21. Plunger 22. Retainer 23. O-ring 24. Spool 25. Secondary cylinder 26. Snap ring 27. Spring 28. Plunger 29. Spring 30. O-ring

31. Retainer 32. Snap ring 33. End cap 34. Bushing 35. Pin 36. Pin 37. Collar 38. Bolt 39. Bolt

95ZV EX 52-14 52 Function & Structure Brake Group Brake Valve

(S/N 0253~, 9049~)

(S/N 0253~0254, 9049~9061)

2 3 35

6 10

(S/N 0255~, 9062~)

8 A-A

9 11 A

12 13 37

Pilot port

Tank port

16 18

Rear brake port

Accumulator port

21 23

26 27

39 Accumulator ports

Front brake port

25 Accumulator port 31

28 29 30

32 33

1. Brake pedal 2. Roller 3. Bushing 4. Seat 5. Pedal stopper 6. Boot 7. Push rod 8. Oil seal 9. Flange 10. Bracket

11. Pilot piston 12. Retainer 13. Spring 14. Rod 15. Spring 16. Spring 17. O-ring 18. Primary cylinder 19. Spool 20. Spring

21. Plunger 22. Retainer 23. O-ring 24. Spool 25. Secondary cylinder 26. Snap ring 27. Spring 28. Plunger 29. Spring 30. O-ring

K95ZVE52003

31. Retainer 32. Snap ring 33. End cap 34. Bushing 35. Pin 36. Pin 37. Collar 38. Bolt 39. Bolt

95ZV EX 52-15 52 Function & Structure Brake Group Brake Valve

Brake pilot valve (right pedal) This is a pilot valve that sends a pilot signal to the left pedal. (S/N 0101~0164, 9001~9003)

2 29 28

3 4 5

6 A

A-A

7 8 9 11

Tank port

30 15

32 Accumulator ports

16 17

19 Brake port (pilot port)

20 Accumulator port

21 24

22 25

23 26 K95ZV52006

1. Brake pedal 2. Roller 3. Bushing 4. Seat 5. Pedal stopper 6. Boot 7. Push rod 8. Oil seal 9. Flange 10. Bracket

11. Retainer 12. Spring 13. Rod 14. Spring 15. Spring 16. O-ring 17. Retainer 18. Cylinder 19. Spring 20. Spool

21. Plunger 22. Retainer 23. Snap ring 24. Spring 25. O-ring 26. End cap 27. Bushing 28. Pin 29. Pin 30. Collar

31. Bolt 32. Bolt

95ZV EX 52-16 52 Function & Structure Brake Group Brake Valve

(S/N 0165~, 9004~)

(S/N 0101~0254, 9004~9061)

2 29 28

3 4

(S/N 0255~, 9062~)

A A-A

7 8 9 11 10

Tank port

19 Brake port (pilot port)

16 17

32 Accumulator ports

20 Accumulator port

21 24

22 25

23 26 K95ZVE52004

1. Brake pedal 2. Roller 3. Bushing 4. Seat 5. Pedal stopper 6. Boot 7. Push rod 8. Oil seal 9. Flange 10. Bracket

11. Retainer 12. Spring 13. Rod 14. Spring 15. Spring 16. O-ring 17. Retainer 18. Cylinder 19. Spring 20. Spool

21. Plunger 22. Retainer 23. Snap ring 24. Spring 25. O-ring 26. End cap 27. Bushing 28. Pin 29. Pin 30. Collar

31. Bolt 32. Bolt

95ZV EX 52-17 52 Function & Structure Brake Group Brake Valve

Brake valve performance chart (S/N 0101~0164, 9001~9003) Main valve (Left pedal, tandem type)

Pilot valve (Right pedal)

255.7(26.09)

255.5(26.05)

N(kgf)

294(30)

196(20) 139.6(14.24) 98(10)

68.6(7.00) 59.5(6.07) 49.4(5.04)

( ) 15 16.4

10 12

Pedal pressing force (F)

294(30)

196(20) 137.7(14.05) 98(10) 50.0(5.10) 40.8(4.18) 36.2(3.69)

Pedal stroke

3.13 0.3 (31.9 3)

MPa (kgf/cm2)

2.0(20)

1.0(10)

( ) 0

10 12

15 16.4

Pedal stroke

MPa (kgf/cm2)

2.95(30.1)

Output oil pressure (pilot port output to feed left pedal)

Output oil pressure (Brake port)

Pedal stroke

2.9(30)

( ) 15 16.4

2.95 0.3 (30.1 3)

MPa (kgf/cm2)

0.92(9.42) 0.20(2)

10 12

2.9(30)

2.0(20) 1.10(11.18) 1.0(10) 0.20(2)

10 12

( ) 15 16.4

Pedal stroke

Output oil pressure (Brake port)

4.9(50) K95ZVJ52005

0 0.33 (3.4)

MPa (kgf/cm2) 3.13 (31.9)

4.9 (50)

Pilot oil pressure (Pilot port input) K95ZVJ52004

95ZV EX 52-18 52 Function & Structure Brake Group Brake Valve (S/N 0165~0252, 9004~9048)

(S/N 0253~, 9049~)

Main valve (Left pedal, tandem type)

233.9(23.87)

285(29.1)

N(kgf)

196(20) 122.5(12.5) 98(10)

38.2(3.90)

10 12 Pedal stroke

Output oil pressure (Brake port)

98(10)

78.4(8.0) 70.6(7.2)

1.13(11.6) 1.0(10)

( ) 2

10 12

15 16.4

0 0.33 (3.4)

3.23(33)

MPa (kgf/cm2) 3.41 (34.8)

10 12 Pedal stroke

( ) 15 16.4

3.39 0.3 (34.6 3)

2.0(20) 1.23(12.6) 1.0(10) 0.57(5.8) 0

10 12

( ) 15 16.4

Pedal stroke

4.9 (50)

Pilot oil pressure (Pilot port input)

Output oil pressure (Brake port)

2.9(30)

Pedal stroke

MPa (kgf/cm2) 4.9(50)

MPa (kgf/cm2)

2.0(20)

106(10.8)

3.23 0.3(33 3)

2.9(30)

196(20)

( ) 15 16.4

MPa (kgf/cm2)

0.20(2)

167(17.0)

Output oil pressure (Brake port)

55.4(5.65) 46.2(4.71)

294(30)

Pedal pressing force (F)

294(30)

3.23(33)

MPa (kgf/cm2) 4.9(50)

0 0.33 (3.4)

MPa (kgf/cm2) 3.41 (34.8)

4.9 (50)

Pilot oil pressure (Pilot port input) K95ZVJ52008

K95ZVJ52010

95ZV EX 52-19 52 Function & Structure Brake Group Brake Valve (S/N 0165~, 9004~) Pilot valve (Right pedal) 208.2(21.24) N(kgf)

Pedal pressing force (F)

294(30)

196(20) 105.2(10.73) 98(10) 52.7(5.38) 35.3(3.60) 32.0(3.27)

( ) 15 16.4

10 12 Pedal stroke

3.41 0.3 (34.8 3)

Output oil pressure (pilot port output to feed left pedal)

MPa (kgf/cm2) 2.9(30)

2.0(20) 1.31(13.4) 1.0(10) 0.37(3.8) 0

10 12

( ) 15 16.4

Pedal stroke

K95ZVJ52009

95ZV EX 52-20 52 Function & Structure Brake Group Brake Valve

Brake valve outline

Main valve (tandem type) operation

The brake valve integrated into the pedal converts the pump oil pressure into the pressure corresponding to the pedal pressing force, and transmits it to the brake.

While the valve is not operating

The main valve (in the left pedal) is the tandem type, and consists of two independent systems. The pilot valve (in the right pedal) is the single type. When the right side pedal is depressed, the oil pressure from this valve acts as the pilot pressure applied to the main valve.

Brake pedal

Each valve is the closed center type (in which the inport is closed while the pedal is released). High pressure is always applied on the in-port side to improve the response during operation. Push rod

Note The illustrations of a different valve model having the same inner structure are used below for easier understanding of valve operation.

Pilot chamber Tank

Pilot port Pilot piston

Spool 1

Passage 1 Reaction chamber Accumulator

B1 Rear brake Passage 2 Passage 3

Spool 2 Accumulator

B2 Front brake A2

Passage 4

Reaction chamber

70ZV52025

Oil sent from the pump is stored in the accumulator, and sent to the in-ports A1 and A2. The passages 2 and 4 (out-ports B1 and B2) are closed by spools (1)(2). Spools (1)(2) are pushed to the non-operation position by the springs. Oil in the brake piston chamber is sent into the inside of the valve from the out-ports B1 and B2, and returned to the tank from the tank port T. As a result, the pressure inside the brake piston chamber becomes equivalent to the pressure in the tank.

95ZV EX 52-21 52 Function & Structure Brake Group Brake Valve At this time, the brake line pressure acts on the reaction chamber inside the spools (1)(2) through the orifices (1)(2). As a result, the pressure in the reaction chamber works as a force to return the spools (1)(2) upward.

While the valve is operating

When the pressure in the reaction chamber becomes balanced with the spring load, it returns the spools (1)(2) to close the passages A1-B1 and A2-B2 to hold the pressure.

Brake pedal

By this operation, the brake pressure in proportion to the pedal pressing force is obtained, and the spring load by deflection are transmitted to the operator as pedal pressing force. Push rod

Pilot valve operation Pilot piston Pilot chamber Pilot port

Brake pedal

Spool 1 Orifice 1

Passage 1

Reaction chamber Accumulator

B1 A1

Rear brake Passage 2 Passage 3

Spool 2 Accumulator

Orifice 2

B2 A2

Front brake Passage 4

Reaction chamber

70ZV52026

When the brake pedal is pressed, the push rod and the pilot piston are pushed by the roller, then spools (1)(2) are pushed down by way of the spring pack. As a result, passages 1 and 3 and the tank port T are closed. When the spools (1)(2) are pushed down further, passages 2 and 4 are opened and pressure oil from the accumulator is sent to the brake piston chamber to apply the brake.

Spool 1 Main valve pilot port

Accumulator

70ZV52027

When the pilot valve (right brake valve) pedal is pressed, the spool is pushed down, and pressure oil from the accumulator enters the pilot port of the main valve (left brake valve), pushes the pilot piston, then pushes down the spools (1)(2) by way of the spring. After that, the pilot valve operates in the same way as the main valve (left brake valve).

95ZV EX 52-22 52 Function & Structure Brake Group Stop Lamp Pressure Switch

Stop Lamp Pressure Switch Pressure switch (for stop lamp) A pressure switch is installed between the left brake valve and the rear brake. Pressing the brake pedal turns on this pressure switch, and lights the stop lamp.

Pressure switch for declutch

Pressure switch for stop lamp

Left brake valve

K80ZV52013

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

95ZV52056

1. Case 2. Seal film 3. Packing 4. Disc 5. Inner cover 6. Guide pin 7. Spring

8. Contact 9. Contact 10. Terminal 11. Terminal 12. Base 13. Cover 14. Connector

95ZV EX 52-23 52 Function & Structure Brake Group Stop Lamp Pressure Switch

Pressure switch specifications (for stop lamp) Contact

Normally open

Voltage (VDC)

Current (A)

3.5 (MAX)

Resistance ()

6.9

Operating pressure MPa (kgf/cm2) (psi) Return pressure MPa (kgf/cm2) (psi)

(S/N 0101~0245, 9001~9023)

Operating pressure MPa (kgf/cm ) (psi) Return pressure MPa (kgf/cm2) (psi)

(S/N 0246~, 9024~)

Pressure switch (for declutch) Refer to “Electrical Group: "Transmission cut off (Declutch)" page 62-55”.

0.5 ± 0.1 (5.0 ± 1.0) (71.1 ± 14.2) 0.3 ± 0.05 (3.0 ± 0.5) (42.7 ± 7.1) 0.25 ± 0.02 (2.6 ± 0.2) (37.0 ± 2.9) 0.22 ± 0.02 (2.2 ± 0.2) (31.3 ± 2.9)

95ZV EX 52-24 52 Function & Structure Brake Group Service Brake

Service Brake The service brake is an enclosed wet type multi-plate hydraulic brake, and is incorporated in the axle housing.

Service brake operation

This type of service brake ensures good braking power even in muddy or sandy soil.

Oil from the pump is regulated in a range from 6.9~11.8 MPa (70~120 kgf/cm2) (995~1,706 psi) by the unloader valve, and accumulated in the accumulator provided for the front and rear wheels.

Even if the brake disc is worn, the integrated adjustment mechanism always adjusts for a constant pedal stroke (S/N 0101~0311, 9001~9095 only). Piston stroke adjuster

(S/N 0101~0311, 9001~9095)

Wheel hub 14 Brake oil inlet port

12 Axle housing 1

5 4

When the brake valves are depressed, the pressure oil in the accumulator enters the disc brake piston chamber for the front and rear wheels, pushes the piston, and generates braking power.

95ZV52033

9. O-ring (for brake piston) 1. Internal gear hub 10. O-ring (for gear hub) 2. Brake piston 3. Piston return spring 11. O-ring (for gear hub) 12. Air bleeder nipple 4. Steel plate 13. Socket bolt 5. Friction plate 14. Tolerance ring 6. Disc gear 15. Sleeve 7. Axle shaft 8. O-ring (for brake pis-16. Bushing ton)

While the brake pedal is not pressed, the internal pressure of the hydraulic oil tank is always applied on the brake piston chamber, and there is a possibility that the brake may drag. To prevent the brake from dragging, the axle housing air chamber is connected to the hydraulic oil tank air chamber so that the pressure inside the axle housing becomes equivalent to the pressure inside the hydraulic oil tank.

95ZV EX 52-25 52 Function & Structure Brake Group Service Brake

Service brake friction plate

400 (15.75)

1.2 (0.047)

(A)

(S/N ~9060) 0.65 mm (0.026) (S/N 9061~) 0.55 mm (0.022) Detailed drawing of groove K95ZVE52005

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.

Service brake steel plate A brake disc includes two steel plates, and the tooth pattern of two steel plates differ from each other.

Upper Spring pin

Internal gear

The steel plate shown in the upper figure should be installed on the piston side. As to the installation direction, this steel plate can be installed either side inward as there is no inward or outward direction. The steel plate shown in the lower figure has the section (A) where several teeth are intentionally absent. This steel plate should be installed on the brake backing plate side (outer side of the machine body). The section (A) of this plate is used for measurement of friction plate wear. If this steel plate is installed incorrectly, measurement of wear is impossible.

Upper Spring pin

Therefore, this steel plate should be installed correctly so that the teeth section (A) is located (or indexed) as shown in the lower figure.

There is no inside or outside on this plate either. It may be installed either way.

K95ZV52012

95ZV EX 52-26 52 Function & Structure Brake Group Service Brake

Service brake piston (S/N 0101~0311, 9001~9095)

Upper

A 3

4 2

6 2

A-A

K95ZV52014

(S/N 0312~, 9096~)

Upper

A 3

6 4

6 A

A-A K95ZV52015

95ZV EX 52-27 52 Function & Structure Brake Group Service Brake

1. Holes for piston return spring (12 equivalent divisions of circumference) 2. Holes for brake pedal stroke adjustment mechanism (4 equivalent divisions of circumference, M10 x 1.5) 3. Holes for pushing down piston (4 equivalent divisions of circumference) 4. Holes for removing piston (2 equivalent divisions of circumference, M10 x 1.5) 5. Holes to drain the oil trapped behind piston (4 places) 6. Cooling oil passage (3 places)

95ZV EX 52-28 52 Function & Structure Brake Group Service Brake

Service brake pedal stroke adjusting mechanism (S/N 0101~0311, 9001~9095)

Fig. 1

Piston Sleeve

Approx. 1.8mm (0.07 in)

Tolerance ring

WARNING Machine (S/N 0312, 9096) and up do not have autoadjusting mechanism at shipment. The auto-adjusting mechanism may be removed from the wheels if all of the auto-adjusters on all four wheels are removed. Do not remove the auto adjusters from only one wheel. Removing the auto-adjusters may extend the brake life in certain applications.

Socket bolt

Bushing 115ZV52028

When the brake disc is not worn and the hydraulic pressure is not applied on the brake piston, the piston is pulled back by the return spring.

Piston Brake stroke adjusting mechanism

At that time, there is clearance of approximately 1.8 mm (0.07 in) between the sleeve and the socket bolt.

Fig. 2

1.8 mm (0.07 in)

95ZV52036

This is the automatic adjuster function which always offers a constant pedal stroke even if the brake disc is worn. 115ZV52030

When the brake disc is worn and the brake piston, is shifted by approximately 1.8 mm (0.07 in) or more, the sleeve is gradually pulled out to the left by the socket bolt by the amount corresponding to the wear. At that time, there is clearance of approximately 1.8 mm (0.07 in) between the sleeve and the socket bolt.

95ZV EX 52-29 52 Function & Structure Brake Group Service Brake

Tolerance ring

Fig. 3

Wave

1.8 mm (0.07 in)

Tolerance ring 115ZV52031

When the brake pedal is released and the hydraulic pressure is not applied on the brake piston, the brake piston is pulled back by the return spring by approximately 1.8 mm (0.07 in), and stopped by the sleeve. In other words, the brake piston return amount is set to approximately 1.8 mm (0.07 in) so that a constant pedal stroke is always offered.

95ZV52020

The tolerance ring tightens easily the shaft (sleeve) and the boss (bushing) to transmit the torque and the thrust force. The tolerance ring is a press-in ring made of elastic wave sheet steel.

Motions of the sleeve are regulated by the tolerance ring (spring). The sleeve is not moved by the return spring force of the piston.

Tolerance ring installation procedure

Boss (bushing)

Tolerance ring

Shaft (sleeve)

K90ZV52010

- Attach the tolerance ring to the boss (bushing). - Press-fit the shaft (sleeve).

95ZV EX 52-30 52 Function & Structure Brake Group Service Brake

Brake circuit air bleeding procedure Before air-bleeding the service brake:

WARNING Unexpected movement of the machine may cause a severe accident. To prevent such an accident, take the following safety measures when performing air bleeding with the engine running. - Park the machine on level ground. - Apply the parking brake. - Block the tires with chocks to prevent the wheel from moving. - Determine the signals between the persons related to this work for engine starting to prevent an accident. - When moving up the boom, install a safety column under the boom. - Apply the articulate stopper.

1. Verify that the wheels are securely blocked, and the articulation lock is in the "locked" position.

Air bleeder nipple

IMPORTANT Before bleeding the service brakes, it is important to remove all air from the brake valve manifold block, and all related valves. These include the reducing valve and park brake valve. Failure to do this correctly will result in unsatisfactory brake modulation with use of the right brake pedal due to air being trapped in the top of the left brake pedal.

Left brake valve 95ZV52039

2. Connect a clear vinyl tube [About 1.5 m (5 ft.) long] to the left brake pedal air bleeder nipple, and open the bleeder valve. Valve assembly (Brake manifold block assembly)

Solenoid valve for auto-brake

Reducing valve assembly

Solenoid valve for parking

Hydraulic oil tank Step location

Hydraulic tank, as seen from top

95ZV52057

3. Charge the accumulator to full pressure, then shut off the engine, and complete the procedure. 4. Turn the park brake solenoid valve release knob counterclockwise then back to neutral five times with a five second wait period between each turn. Position the knob back to the normal position when finished.

95ZV EX 52-31 52 Function & Structure Brake Group Service Brake

Bleeding air from the brake valves

Button (diameter: approximately 4 mm)

1. Depress the right brake pedal five times at intervals of five seconds. 2. Check for air in the line. If air is observed, repeat step 1 until air is completely purged. 3. Close the left brake valve bleed fitting.

Solenoid valve pressure nut

Solenoid valve

(S/N 0107~, 9004~)

Auto brake solenoid valve (S/N 0101~0265, 9001~9065) K95ZV52019

: Air bleeder nipple 9 N-m (0.9 kgf-m) (6.5 lb-ft)

Button (diameter: approximately 4 mm)

7 mm (0.28 in)

Bleeding air from brake pipes and axle housing hubs Solenoid valve pressure nut

Solenoid valve

Auto brake solenoid valve (S/N 0266~, 9066~)

K95ZV52020

Air bleeder nipple

5. Press the auto-brake solenoid valve release button five times with a five second wait period between each turn. Position the knob back to the normal position when finished. Vinyl tube 70ZV52019

1. Connect a vinyl tube to the air bleeder nipple provided in the axle housing, and place an oil can for hydraulic oil recovery. (The air bleeder nipple is equivalent to the one provided in the left brake valve). 2. Loosen the air bleeder nipple a little. Press and hold the left brake pedal until oil containing no air comes from the air bleeder nipple. After that, tighten the air bleeder nipple. Perform this operation for each of the four wheels. : Air bleeder nipple 9 N-m (0.9 kgf-m) (6.5 lb-ft)

95ZV EX 52-32 52 Function & Structure Brake Group Parking Brake

Parking Brake There are two types of parking brake applicable to the 95ZV. 1. Rear parking brake - Drum style internal expansion design, mounted on the transmission output shaft 2. Front parking brake (for Europe only) - Dry disc type mounted on the front differential input shaft

Parking brake operation chart Drum brake (rear parking brake)

Dry type disc brake (front parking brake)

Parking switch

OFF

Solenoid valve

Power-off

Power-on

Power-off

Power-on

Oil cylinder

Oil released

Oil charged

—

Parking brake

Braking

Released

Braking

Released

95ZV EX 52-33 52 Function & Structure Brake Group Parking Brake (Rear)

Parking Brake (Rear) (Internal expansion type drum brake)

5 Parking brake spring chamber (actuator)

C-C

Parking brake lever

Drum rotational direction for traveling in reverse

Drum 95ZV52011

Rear parking brake operation

2 A

When the parking switch is turned on, the solenoid valve is powered off, oil in the spring chamber is released to the tank, and the oil cylinder rod pulls up lever (6) by spring force in the spring chamber.

Because lever (6) is connected to cam shaft (5), turning of the cam shaft causes shoes (2) on the both sides of the cam to expand.

As a result, the revolving brake drum is braked. 4

A-A

1. Support plate 2. Brake shoe 3. Brake lining

B-B

4. Adjusting screw 5. Cam shaft 6. Lever 95ZV52012

95ZV EX 52-34 52 Function & Structure Brake Group Parking Brake (Rear)

Parking brake solenoid valve (rear)

Spring chamber (brake actuator)

Solenoid (S/N 0101~0265, 9001~9065) Knob Solenoid (S/N 2066~, 9066~)

Reducing valve

T Seat face A

Seat face B

Manual release (counterclockwise rotation)

Spool

Tank

Hydraulic circuit diagram

K90ZV52012

Parking solenoid valve operation (rear) When the parking switch is set to OFF (that is, when the power is supplied to the solenoid), the spool is pushed to the left, the seat face A is open, and the seat face B is closed. As a result, the oil from the reducing valve enters the spring chamber, and the parking brake is released.

Amp

a 0

Volt

Note The varistor (variable resistor) is used for the solenoid coil to protect the circuit.

Varistor 95ZV42079

While the parking switch is ON (that is, while the power is not supplied to the solenoid), the seat face A is closed and the seat face B is open. As a result, the spring chamber port is connected to the tank, and the parking brake is applied.

Solenoid valve specifications Voltage

DC24 V

Current

0.69 A

Resistance

34.8 

95ZV EX 52-35 52 Function & Structure Brake Group Parking Brake (Rear)

Parking brake manual release procedure (rear)

Valve assembly

If the park brake cannot be released due to an electrical problem, such as a failed park brake solenoid valve coil or electrical circuit, perform the following operation.

WARNING Sudden accidental movement of the machine could result in serious injury or death. Before manually operating the parking brake solenoid: - Lower the boom and attachment to the ground. - Place chocks on both sides of the tires. - Be sure the machine is in neutral and engine is stopped.

Solenoid valve for parking Knob

Method 1

Turn it counterclockwise. (S/N 0101~0265, 9001~9065)

(S/N 0266~, 9066~) K95ZV52018

Valve assembly

Solenoid valve for parking Hydraulic oil tank

Turn the park brake solenoid valve knob counterclockwise. When you feel the detent position of the solenoid valve, this will turn the park brake valve "OFF", and supplies oil to the spring chamber, thereby releasing the park brake.

WARNING Installation position

95ZV52041

If the manual operation knob is not returned to the running position, the parking brake is disabled and may result in a severe accident. Be sure to return the manual operation knob to the OFF position after releasing the parking brake by hand. Test the operation of park brake by using the controls in the operators cab.

95ZV EX 52-36 52 Function & Structure Brake Group Parking Brake (Rear)

Method 2

Parking brake spring chamber (actuator)

Link

Lever

Pin ON

Link

OFF Rope or wire Prybar (used to nail puller-carpentry) 95ZV52014

To release the parking brake while the regular oil pressure source may not function due to an engine related trouble, etc., perform the following operation. - When there is another oil pressure source Supply oil pressure to the oil inlet of park brake spring chamber from another oil pressure source, then remove the pin when it releases. - When there is no other oil pressure source Secure a rope or wire to the link, pull downward on the rope or wire with a pry bar to control the spring force of the spring chamber, then remove the pin when it releases.

95ZV EX 52-37 52 Function & Structure Brake Group Parking Brake (Rear)

Parking brake spring chamber

1. Cylinder tube 2. Piston rod 3. Rod cover 4. Piston 5. U-nut 6. Spring 7. Gland metal 8. U-packing 9. Dust seal 10. O-ring 11. O-ring 12. Filter 13. Head cover 14. Tie bolts

95ZV52049

2,206 N (225 kgf) (505.4 lb) 1,981 N (202 kgf) (453.7 lb) 1,461 N (149 kgf) (334.7 lb)

18.6 25 136 (adhesion length) Stroke 161 60 118

221 (installation length) 339 (free length) Spring specifications

95ZV52019

The oil applies pressure to the internal spring to release the parking brake.

WARNING Careless disassembling work may cause serious injury or death. The spring applies high force to the rod cover, therefore carefully disassemble the spring chamber using a press.

95ZV EX 52-38 52 Function & Structure Brake Group Parking Brake (Front) (for Europe only)

Parking Brake (Front) (for Europe only) Front parking brake operation

(Dry type disc brake)

The brake disc is sandwiched by friction pads located on the both sides. The disc brake is applied by accumulator pressure oil.

Upper side Front differential

When the parking switch is turned on, the power of the solenoid valve is turned off and the pressure oil from the accumulator for parking brake pushes out piston (10). As a result, friction pads (5) press and brake the brake disc. The auto adjuster mechanism is integrated in the disc brake so that the distance between the brake disc and the friction pads is always kept constant and that heat generation and energy loss caused by dragging can be prevented. Dry type disc brake

Brake disc profile

95ZV52040

1 6

18 2

14 20 19

22 9

4 3 7

Brake oil

13 7

16 10

12 21

17 15

13 Brake disc

95ZV52013

1. Body 2. Bleeder valve 3. Bolt 4. Pin 5. Friction pad 6. Bolt 7. Washer 8. Cap, inlet 9. Packing 10. Piston 11. Boot 12. Packing

13. Nut 14. Spring 15. Washer 16. Retaining ring 17. Sleeve, adjuster 18. Guide, adjuster 19. Guide, adjuster 20. Packing 21. Ring, back-up 22. Ring, back-up

95ZV EX 52-39 52 Function & Structure Brake Group Parking Brake (Front) (for Europe only)

Parking brake solenoid valve (front)

To tank

C Passage Z Rod

Solenoid

Passage Y

Button for manual release

A To parking brake

A A

Sleeve

B C

Movable iron core Spool

Hydraulic circuit diagram

B From accumulator

95ZV52046

Parking solenoid valve operation (front) While the parking switch is ON (that is, while the power is not supplied to the solenoid), the oil from the accumulator flows into the parking brake by way of passage Y of the sleeve and the oil hole A of the spool. As a result, the parking brake is applied. When the parking switch is set to OFF (that is, when the power is supplied to the solenoid), the movable iron core is pulled to the left and pushes the rod, then the rod pushes the spool. When the spool is pushed to the left, the oil hole A is not connected to passage Y, and the oil hole B of the spool is connected to passage Z. As a result, the oil which has been acting on the parking brake escapes to the tank by way of passage Z, and the parking brake is released.

Solenoid valve specifications Voltage

DC24 V

Current

0.52 A

Resistance

45.9 

95ZV EX 52-40 52 Function & Structure Brake Group Parking Brake (Front) (for Europe only)

Front parking brake auto adjuster mechanism

Friction pad

Body

From opposite half of caliper

Piston

Spring

From opposite half of caliper

Retaining ring

A K95ZV52021

Washer

Brake disc

Adjuster guide Sleeve

When the friction pad is worn and the piston is pushed beyond the clearance A, the sleeve is pushed to the left by way of the washer by the amount corresponding to the wear amount.

From opposite half of caliper

95ZV52047

When the friction pad is not worn and the oil pressure is not applied on the piston, the piston is pulled back by the spring and the friction pad is free between the piston and the brake disc. At this time, there is the clearance A between the sleeve and the washer. 95ZV52063

When the brake pedal is released and the oil pressure is not applied on the piston, the piston is pulled back by the spring by as much as the clearance A and stopped by the sleeve. The sleeve is regulated by the sliding resistance between the sleeve and the adjuster guide, and does not move by the spring force. Therefore, the friction pad is always free, and heat generation and energy loss caused by drawing are not generated.

95ZV EX 52-41 52 Function & Structure Brake Group Parking Brake (Front) (for Europe only)

Parking brake line air bleeding procedure (front parking) WARNING Upper side

Air bleeder nipple

Front differential

Unexpected movement of the machine may cause a severe accident. To prevent such an accident, take the following safety measures when performing air bleeding with the engine running. - Park the machine on level ground. - Apply the parking brake. - Block the tires with chocks to prevent wheels from moving. - Determine the signals between the persons related to the work. - When raising up the boom, install a safety support under the boom. - Apply the articulate stopper.

Air bleeding procedure 1. Start the engine. Keep the engine at low idle during the air bleeding work.

Dry type disc brake Air bleeder nipple

2. Connect a vinyl tube to the air bleeder nipple provided on the upper side of the disc brake, and place an oil can for hydraulic oil recovery. Vinyl tube length: Approximately 1.2 to 1.3 m Nipple outer diameter: 7 mm 3. Set to ON the parking switch. Loosen the air bleeder nipple a little. Wait until oil containing no air comes from the air bleeder nipple. After that, tighten the air bleeder nipple. : Air bleeder nipple: 28.5 N-m (21 lb-ft)

95ZV52048

95ZV EX 52-42 52 Function & Structure Brake Group Parking Brake (Front) (for Europe only)

Parking brake manual release procedure (front) Front parking solenoid valve

Front chassis

Solenoid valve location 95ZV52043

Solenoid valve

5 mm (0.19 inch)

Lock nut

Bolt for manual release Bracket 95ZV52044

Loosen the lock nut for the manual release bolt. Turning the bolt in moves the spool of the solenoid valve and releases the parking brake.

WARNING If the manual operation knob is not returned to the normal operating position, the parking brake is disabled and a severe accident may be caused. Be sure to return the manual operation knob to the OFF (normal operating position) position after releasing the parking brake by hand.

95ZV EX 52-43 52 Function & Structure Brake Group Auto Brake

Auto Brake When the traveling direction is switched over between forward and reverse at a machine speed of 12 km/h (7.5 mph) or more, the auto brake is applied to protect the transmission clutches. When the machine speed is too high, the auto brake is applied also to prevent problems caused by excess speed in the engine and the transmission (over speeding).

Auto brake circuit 61

Auto brake operation set value 1. When the traveling direction is switched over between forward and reverse at a machine speed of 12 km/h (7.5 mph) or more while the shift lever is set to position A. 2. When the machine speed is too high in each speed range. Actual speed will vary with tire size. Speed range

Set value

1st

Approximately 15 km/h (9.4 mph)

2nd

Approximately 22 km/h (13.7 mph)

Shown in the "released" position

3rd

To rear service brake (S/N 0101~0164, 9001~9010)

4th/A

31 A C B

23 Pi

1.2 1.0 B

From unloader valve (Pump)

T/M controller signal

From reducing valve (Pump)

K95ZVE52006

When the auto brake signal enters from the T/M controller to the solenoid valve for auto brake (27) the solenoid valve (27) is energized and magnetized. The pilot oil from the reducing valve enters the pilot port of the left brake valve (23) through the shuttle valve (31), and actuates the pilot piston and the spool of the brake valve. When the spool is moved over, the high-pressure oil coming from the pump through the unloader valve and the reducing valve enters the front and rear brake piston chambers to apply the service brake.

Approximately 36 km/h (22.5 mph)

95ZV EX 52-44 52 Function & Structure Brake Group Auto Brake

Solenoid valve (for autobrake circuit) Not activated Brake valve (shuttle valve)

Reducing valve

Spool

(S/N ~0265, ~9065)

Seat face A

Tank

Seat face B

(S/N 0266~, 9066~)

Solenoid

P T Hydraulic circuit diagram

When the auto brake actuation signal is not given by the transmission controller (that is, when the power is not supplied to the solenoid), the seat face A is closed and the seat face B is open. As a result, the brake valve port is connected to the tank, and the auto brake is not applied. When the auto brake actuation signal is given by the transmission controller (that is, when the power is supplied to the solenoid), the spool is pushed to the left, the seat face A is open, and the seat face B is closed. As a result, the oil from the reducing valve enters the brake valve, and the brake is applied.

K115ZV52016

Solenoid specifications Voltage

DC24 V

Current

0.69 A

Resistance

34.8 

Amp

a 0

Volt

Varistor 95ZV42079

Note The varistor (variable resistor) is used for the solenoid coil to protect the circuit.

95ZV EX 52-45 52 Function & Structure Brake Group Auto Brake

Shuttle valve 1

To brake valve port Pi

To auto brake valve

To brake valve port Ap

Hydraulic line diagram

4 95ZV52054

1. Block 2. Plug 3. Ball 4. O-ring The shuttle valve is a kind of direction control valve having two inlet ports (A) (B) and one common outlet port (C). The outlet port is automatically connected to an inlet port having higher pressure.

95ZV EX 52-46 52 Function & Structure Brake Group

MEMO

95ZV EX 53-1 53 Check & Adjustment Brake Group

53 Check & Adjustment Brake Group Brake Circuit Oil Pressure .....................................................53-2 Service Brake ........................................................................53-8 Parking Brake......................................................................53-12

95ZV EX 53-2 53 Check & Adjustment Brake Group Brake Circuit Oil Pressure

Brake Circuit Oil Pressure Unloader valve setting pressure WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items: - Park the machine on level ground. - Apply the parking brake. - Block the tires with chocks to prevent the tires from moving. - Determine the signals between the service men.

(PPI)

(Z2)

(Z)

(Z1)

(PA)

(PARKING)

(ACCF)

ACF

(ACCR)

(TA)

(T)

(P)

WARNING (S/N 0101 ~0265, 9001 ~9065)

ACF port

(S/N 0266~, 9066~)

Injection Hazard Depress brake pedal 80~100 times to completely discharge the brake accumulators prior to removing these test plugs.

Valve assembly K95ZV53001

65ZV03009

Brake line main pressure is regulated by the unloader valve.

Measurement instrument Hydraulic pressure gauge 20 MPa (200 kgf/cm2) (3,000 psi)

Gauge port ACF port on valve assembly Rc (PT) 1/8

Standard measurement value Cut-out

11.8 ± 0.5 MPa (120 ± 5 kgf/cm2) (1,706 ± 71 psi)

Cut-in

6.9 ± 1.0 MPa (70 ± 10 kgf/cm2) (995 ± 142 psi)

95ZV EX 53-3 53 Check & Adjustment Brake Group Brake Circuit Oil Pressure

Measuring unloader valve setting pressure

Adjusting unloader valve setting pressure

1. Lower the boom to the lowest limit, and tilt the bucket down to the ground. Then set the parking brake switch to the "ON" position.

(S/N 0101~0328, 9001~9095)

24 21

22 Fan motor port

2. Stop the engine. Repeatedly depress and release the brake pedal till you feel light brake to discharge accumulator pressure. 3. Remove one of the ACF port plug on the valve assembly and attach the pressure gauge to the port. Tightening torque : ACF port plug: 11.3 N-m (1.15 kgf-m) (8.3 lb-ft)

Pump port Unloader valve

4. Start the engine, and keep the speed at low idle. Measure and record the pressure when the pointer of the pressure gauge stops rising (cut-out pressure). 5. Keep the engine at low idle, and repeatedly depress and release the brake pedal to reduce the accumulator pressure. Measure and record the pressure when the pointer of the pressure gauge stops and then starts rising again (cut-in pressure).

70ZV53001

(S/N 0329~, 9096~)

Fan motor port

Pump port Unloader valve

K115ZV53002

1. Remove cap nut (24) when mounted. Loosen lock nut (22). 2. Adjust the pressure by adjusting screw (21). Turn the screw clockwise to raise the pressure. Note In a case that the "ON" or "OFF" pressure does not match the standard setting pressure, set the "ON" (cutin) pressure to the standard setting pressure. Tightening torque : Lock nut (22): 16.7 N-m (1.7 kgf-m) (12.3 lb-ft) : Cap nut (24): 78.5 N-m (8.0 kgf-m) (57.86 lb-ft)

95ZV EX 53-4 53 Check & Adjustment Brake Group Brake Circuit Oil Pressure

Accumulator circuit pressure

Standard measurement value

Accumulator line pressure is regulated by the unloader valve. However, the reducing valve also may affect brake manifold pressure or accumulator pressure, as it is installed between the unloader valve and brake manifold. Measure pressure at the ACF ports to determine the manifold pressure when there is a brake pressure problem.

12.3 MPa (125 kgf/cm2) (1,780 psi)

Measurement procedure

WARNING

Measuring reducing valve setting pressure

(PPI)

(Z2)

(Z)

Injection Hazard Depress brake pedal 80~100 times to completely discharge the brake accumulators prior to removing these test plugs.

(Z1)

(PA)

(PARKING)

(ACCF)

ACF

(ACCR)

(TA)

65ZV03009 (T)

(P)

Measurement procedure (S/N 0101 ~0265, 9001 ~9065)

1. Lower the boom to the lowest limit, and tilt the bucket down to the ground. Then, set the parking brake switch to the "ON" position.

ACF port

2. Stop the engine. Repeatedly depress and release the brake pedal till you feel light brake to discharge accumulator pressure.

(S/N 0266~, 9066~) Valve assembly K95ZV53001

Measurement instrument Hydraulic pressure gauge 20 MPa (200 kgf/cm2) (3,000 psi)

Gauge port ACF port on valve assembly: Rc (PT) 1/8 Tightening torque : ACF port plug: 11.3 N-m (1.15 kgf-m) (8.3 lb-ft)

3. Remove one of the ACF port plug on the valve assembly and attach the pressure gauge to the port. 4. Start the engine, and keep the speed at low idle. Measure and record the pressure. Note In case the pressure is lower than the unloader cut-in pressure, adjust the reducing valve setting pressure to see if this may affect the pressure setting. It may have a stuck plunger or another malfunction.

95ZV EX 53-5 53 Check & Adjustment Brake Group Brake Circuit Oil Pressure

Adjusting reducing valve setting pressure Pressure test port (S/N 0107~, 9004~)

Lock nut

Adjusting screw

Reducing valve

1. Install an additional pressure gauge to the unloader valve. (Refer to page 53-3.) 2. Start the engine, and keep the speed at low idle. 3. Raise the setting pressure of the unloader valve to 12.3 MPa (125 kgf/cm2) (1,780 psi). 4. Loosen the locknut of the reducing valve and adjust the pressure by the adjusting screw. Turn clockwise the screw to raise the pressure. Note After raising the pressure to check function of valve, be sure to reset the unloader valve pressure to the original setting pressure.

K115ZV53007

Tightening torque : Lock nut: 7.8 N-m (0.8 kgf/cm2) (5.8 lb-ft)

95ZV EX 53-6 53 Check & Adjustment Brake Group Brake Circuit Oil Pressure

Brake valve oil pressure

Gauge port

(S/N 0255~, 9062~)

Remove air bleeder nipple on the axle housing, and then install the pressure gauge to the bleeder position. Size of air bleeder port Rc (PT) 3/8 (In case of the bleeder valve M10 X 1.0)

Force Pedal angle 16.4º (S/N 0101~0252, 9001~9048) 0m m

Air bleeder nipple fitting (S/N 0188~, 9004~) Air bleeder nipple fitting (S/N ~0187, ~9003)

(S/N 0253~0254, 9049~9061)

K95ZV53003

K95ZVE53001

Air bleeder nipple : 59 N-m (6.0 kgf-m) (43 lb-ft) : Three Bond 1327 or equivalent

Measurement instrument

Measuring brake valve oil pressure Hydraulic pressure gauge 10 MPa (100 kgf/cm2) (1,500 psi)

Check to be sure the brake valve is fully released. Press down the brake pedal to check that the oil pressure rises in proportion to the pedal angle. Release the brake pedal to check that the oil pressure drops to zero in proportion to the pedal angle. In addition, visually check for brake oil leakage.

95ZV EX 53-7 53 Check & Adjustment Brake Group Brake Circuit Oil Pressure

Brake valve performance Refer to the curves shown in the above figures.

Main Valve (Left pedal)

When the measured value does not match the performance curve, check the following points. 3.23 0.3(33 3) 3.39 0.3(34.6 3)

Solution Repair or replacement

1.0(10)

0.20(2)

N (S/

~ 004 2, 9 5 2 5~0 016

(S/N

1.23(12.6)

8) 904

0.92 (9.42)

2.95 0.3 (30.1 3)

1.13 (11.6)

() 15 16.4

Pedal stroke K95ZVE53004

Pilot Valve (Right pedal)

MPa (kgf/cm2)

3.41 0.3(34.8 3)

2.9(30)

2.0(20)

1.31 (13.4)

1.0(10)

, 90 65~

N (S/

0.37(3.8) 0.20(2) 0

N (S/

, 90 164 1 ~0 0 1 0

3.13 0.3 (31.9 3)

) 04 ~

3) 900 01~

Check and repair

IMPORTANT

N0 101 ~

2.0(20)

025 3

~, 9

2.9(30)

049 016 ~) 4, 9 001 ~90 03)

Brake line oil pressure low (Pump, reducing valve malfunction)

0.57(5.8)

Output oil pressure (brake port)

Possible cause Malfunctioning brake valve

(S/

Output oil pressure (brake port)

MPa (kgf/cm2)

1.10 (11.18)

() 15 16.4

Pedal stroke K95ZVE53005

After measuring oil pressure, be sure to tighten the air bleeder valve. Also be sure to bleed air.

95ZV EX 53-8 53 Check & Adjustment Brake Group Service Brake

Service Brake Service brake performance check

Method 2

Method 1

If no test course available as described "Method 1", carry out the following method.

WARNING Separate the test course by using rope etc. and keep persons away from the test course. In addition, post persons in several positions near the course to warn others and avoid an accident while checking the service brake performance.

Condition

IMPORTANT The following method is easy and simple, however it is not an accurate way, because the braking force and rim-pull may vary on each machine. Confirm engine & transmission performance via using a stall test. See page 03-3. Reconfirm the brake performance by the method 1 as soon as possible.

1. Test course Level, straight, dry and the paved ground. 2. Run the machine and depress the brake pedal at 35 km/h (22 mph). Measure and record the braking distance.

Standard measurement value Braking distance 20 m (22 1/4 yd) or shorter

Possible causes of extremely long braking distance Possible cause Low brake line pressure

Solution Check and repair

Friction plate wear

Check and repair

Brake valve malfunction

Check and repair

WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Before starting brake performance check, be sure to observe the following items: - Place the machine on level ground. - Check that there is enough clearance for brake performance check around the machine. - During performance check, prohibit any person to walking near the machine. 1. Lower the boom to the lowest limit, and roll back the bucket fully until the bucket contacts to the stopper. 2. Set the parking brake switch to the "OFF" position. 3. Set the T/M (transmission) cut-off switch to OFF, and then depress the brake pedal all the way to the floor. 4. Set the shift lever to 2nd reverse speed.

Note The brake performance check condition and standard measurement value are based on the law and the regulation in Japan. When checking the service brake performance, follow the law and/or local regulation in your country, state, or province.

5. Gradually increase the engine speed. The machine should not move at the maximum engine speed.

Possible cause of machine moving during brake performance check Possible cause Low brake line pressure

Solution Check and repair

Friction plate wear

Check and repair

Brake valve malfunction

Check and repair

95ZV EX 53-9 53 Check & Adjustment Brake Group Service Brake

Service brake friction plate wear measurement A

Air bleeder nipple

Slide calipers

Retainer

Steel plate Friction plate

95ZV53004

WARNING Oil inlet port

Internal gear

Top 5º

Spring pin

Inner steel plate

Outer steel plate 95ZV53005

Unexpected movement of machine could cause serious injury or death. To prevent such an accident, observe the following items before checking the brake friction plate wear: - Park the machine on level ground. - Apply the parking brake. - Stop the engine. - Determine the signals between the persons related to this work for engine starting to prevent an accident. - Prohibit any person from walking into the dangerous area.

IMPORTANT After inserting calipers, do not rotate the wheels. If the wheels are rotated, the calipers may be caught and broken by the reduction gear. In this case, the reduction gear must be disassembled.

95ZV EX 53-10 53 Check & Adjustment Brake Group Service Brake

Measurement procedure Turn the planetary gear so that the oil supply plug is positioned at the place about ±5º from the top. Check that the teeth of steel plate are as shown in the figure in the previous page (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. Wear limit for dimension A: 25.1 mm (0.988 in) (S/N 0101~0254, 9001~9060) 24.7 mm (0.972 in) (S/N 0255~, 9061~) Dimension A when the plate is new: 29.0 mm (1.142 in) (S/N 0101~0254, 9001~9060) 28.6 mm (1.126 in) (S/N 0255~, 9061~) Note To aid quick measurement on the front axle-raise the front of the machine so the front tires clear the ground by about 25 mm (1 in). This allows easy rotation of the wheel to align the gear teeth.

95ZV EX 53-11 53 Check & Adjustment Brake Group Service Brake

Cautions when installing brake discs (S/N 0101~0311, 9001~9095 only) A

When only the friction plates or the steel plates are to be replaced, if the brake piston and brake stroke adjusting mechanism are installed as they are, the brake may drag and the brake discs may seize.

Wheel hub

Push back the brake piston and brake stroke adjusting mechanism by using the following procedure. 1. Loosen the axle housing air bleeder nipple.

Upper side

Brake piston K95ZV52038

3. After pushing back the piston, confirm dimension “A” from the piston end face to the wheel hub end face. Brake piston

IMPORTANT Wheel bearings must be adjusted correctly to get an accurate measurement for dimension “A”. Dimension should be equal at the top and the bottom. A: 162.45 ~ 163.85 mm (6.4 ~ 6.45 in) (S/ N 0101~0311, 9001~9095) A: 161.90 ~ 163.30 mm (6.37 ~ 6.43 in) (S/ N 0312~, 9096~)

For pushing down brake piston

Note: Piston stroke B 1.15~3.65 mm (0.045~0.144 in) (S/N 0101~0311, 9001~9095) 1.20~1.90 mm (0.047~0.075 in) (S/N 0312~, 9096~) A

4. After confirming that the piston is fully retracted (Dimension A is correct) remove all four bolts. K95ZV52037

2. Insert bolts into four holes for pushing back the brake piston, then tighten the four bolts evenly. The piston should return evenly. Bolt size for pushing brake piston back (4 required) M10 x 1.5 - 45~50 mm (1.77~1.97 in) long (fully threaded)

5. After finishing the installation work, bleed air completely from the brake line.

95ZV EX 53-12 53 Check & Adjustment Brake Group Parking Brake

Parking Brake Parking brake performance check

Method 2 If no test course available as described "Method 1", carry out the following method.

Method 1

IMPORTANT

The following method is easy and simple, however it is not an accurate way, because the braking force and rim-pull may vary on each machine. Confirm engine & transmission performance via stall test. See page 03-3. Reconfirm the brake performance by the method 1 as soon as possible.

Condition 1. Test course 1/5 slope (Approx. 11º 19') 2. Bucket empty 3. Parking switch ON

1. Set the parking brake switch to the "ON" position.

Standard measurement value

2. Disconnect the cable connector of parking brake solenoid valve.

No movement on 1/5 slope.

3. Set the parking brake switch to the "OFF" position.

Possible cause of machine moving during brake performance check Possible cause

Solution

Clearance between brake drum and shoe too large

Clearance adjustment

Improperly adjusted oil cylinder link

Check and adjustment

Broken oil cylinder spring

Check and repair

Parking brake solenoid valve malfunction

Check and repair

Note The brake performance check condition and standard measurement values are based on the law and the regulation in Japan. When checking the service brake performance, follow the law and/or local regulation in your country, state, or province.

4. Place the shift lever to the 3rd reverse position. 5. Gradually increase the engine speed. The machine should not move at the maximum speed.

IMPORTANT If the machine begins to move with the parking brake applied, the brake shoes are burnt or misadjusted. At the completion of parking brake test, be sure to connect the connector of electrical line to the solenoid valve again.

95ZV EX 53-13 53 Check & Adjustment Brake Group Parking Brake

Possible cause of machine moving during brake performance check Possible cause

Solution

Clearance between brake drum and shoe too large

Clearance adjustment

Improperly adjusted oil cylinder link

Check and adjustment

Broken oil cylinder spring

Check and repair

Parking brake solenoid valve malfunction

Check and repair

95ZV EX 53-14 53 Check & Adjustment Brake Group Parking Brake

Parking brake clearance adjustment

Adjustment procedure

Drum rotational direction for backward traveling Brake lining

Brake shoes Support plate

2nd propeller shaft

B A

Inspection hole

Approx. 8º

For replacement of shoe assembly, refer to Section 54. A-A

Brake shoe expansion direction

Rivet

B-B

Position of adjusting screw

Adjusting screw

Brake shoe

95ZV52015

WARNING Unexpected movement of the machine may 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. If the machine moved during parking brake performance check, the clearance between the brake drum and the lining is too large.

Brake lining

Lining thickness A: 6.15 mm (0.24 in) 80ZV53003

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 8º counterclockwise from the vertical position as shown in the figure. After that, use a screw driver or brake tool to turn the adjusting screw to adjust the clearance. Turn the adjusting screw clockwise (upward) to expand the brake shoes until the linings come in contact with the brake drum. After that, turn the adjusting screw 8 notches counterclockwise (down). The clearance will be adjusted to 0.23 mm (0.009 in). Adjustment range 0.10 ~ 0.25 mm (0.004 ~ 0.010 in) 3. After the adjustment, check the performance of the parking brake by referring to "Parking brake performance check".

95ZV EX 53-15 53 Check & Adjustment Brake Group Parking Brake

Brake lining abrasion check

Shoe

Rivet

Abrasion limit

Lining

Wear limit B: 0.8 mm (0.03 in) 80ZV53004

12 rivets are inserted to fix the lining to the brake shoe. If the distance from the lining to the rivet head "B" is 0.8 mm (0.03 in) or less at one of the 12 rivet areas, replace the shoe assembly.

95ZV EX 53-16 53 Check & Adjustment Brake Group

MEMO

95ZV EX 62-1 62 Function & Structure Electrical Group

62 Function & Structure Electrical Group How to Use Electrical Wiring Diagram....................................................... 62-2 Electrical Cable Color Codes..................................................................... 62-8 Electrical Circuit Symbols .......................................................................... 62-9 Sensor Mount .......................................................................................... 62-10 Fuse......................................................................................................... 62-11 Engine Start Circuit.................................................................................. 62-15 Power Generating/Charging Circuit......................................................... 62-24 ECM (Engine Controller) ......................................................................... 62-25 Transmission Control Circuit and Monitor Circuit (S/N 0101~0358, 9001~) ............................................................................................................ 62-43 Transmission Control Circuit and Monitor Circuit (S/N 0359~)................ 62-66 Monitoring System (S/N 0101~0358, 9001~) .......................................... 62-71 Instrument Panel and Switch................................................................... 62-76 Electrical Detent Circuit ........................................................................... 62-85 Diode ....................................................................................................... 62-88 Diagnostic System (S/N 0101~0358, 9001~) .......................................... 62-92 MODM (S/N 97C4-0359~) ..................................................................... 62-102

95ZV EX 62-2 62 Function & Structure Electrical Group How to Use Electrical Wiring Diagram

How to Use Electrical Wiring Diagram Example 10

10 9

20 19 18 17 16

15 14 13 12 11 21

40 39

32 31

WIDTH LAMP RELAY

VIBRATION NEUTRAL DAMPER RELAY RELAY

BACK LAMP RELAY

HORN RELAY

RB B611

LgSb YV H133 E214

RL SbP H610 E220

RL LB H128 E219

GW GL H127 B501

R R D114 D114

Br Lg D112 D103

G L D102 D002

R Lg D111 D103

G G D107 D107

A520 C201 H129

LgW E218

LgW L A405 D001 1

CONTROLLER FAULT RELAY

(BLACK)

(BLUE)

(1) (2)

6 D507 A306 F306 OR RO RW

A905 RLg

A503 YB

1 D112 E802 E803 Br GL GO

C206 A302 F303 E312 PB RBr RY WO

E523 G302 SbY BrB

C205 F504 F704 F804 RB RL GW PL

E109 G402 A105 E522 W BrW WP BrL

E501 C801 A005 B304 WL RG RGy LgG 40

E520 E108 F004 LgL W LgSb 36

E804 WY

E601 BrR

(3)

The address method is used for electrical wiring diagrams. For this method, a symbol is attached to each connector and connector terminal in order to easily locate the other terminal where the other end of the cable is connected. Example 1 Symbol under (or above) connector, such as F6: Shows the address of the connector. Example 2 Symbol at the multi-terminal connector, such as 1 and 10: Shows the terminal number and the numbering direction.

95ZV62001

Example 3 Checking the other connector terminal where F704 RL (item (3)) is connected: 1. F704 Shows that the terminal is connected to the 4th terminal of the F7 connector. Check the description in the 4th terminal of the F7 connector (F704), it shows that the F704 terminal is connected to H128. This means that the 4th terminal of the F7 connector is connected to the 28th terminal of the H1 connector. 2. RL Shows the color of the wire "RL" represents that the insulation color is red, and "L" represents a blue stripe is on the red insulation.

95ZV EX 62-3 62 Function & Structure Electrical Group Utilisation des schémas des câblages électriques (FRANÇAIS)

Utilisation des schémas des câblages électriques (FRANÇAIS) Exemple 10

10 9

20 19 18 17 16

15 14 13 12 11 21

40 39

32 31

Relais de la lampe d’ écartement

Relais du contrôle de marche

Relais neutre

Relais de la lampe arrière

Relais du klaxon

RB B611

LgSb YV H133 E214

RL SbP H610 E220

RL LB H128 E219

GW GL H127 B501

R R D114 D114

Br Lg D112 D103

G L D102 D002

R Lg D111 D103

G G D107 D107

A520 C201 H129

LgW E218

LgW L A405 D001 1

Relais de défaillance du contrôleur

(Noir)

(Blue)

(1) (2)

6 D507 A306 F306 OR RO RW

A905 RLg

A503 YB

1 D112 E802 E803 Br GL GO

C206 A302 F303 E312 PB RBr RY WO

E523 G302 SbY BrB

C205 F504 F704 F804 RB RL GW PL

E109 G402 A105 E522 W BrW WP BrL

E501 C801 A005 B304 WL RG RGy LgG 40

E520 E108 F004 LgL W LgSb 36

E804 WY

E601 BrR 31

(3)

Les schémas des câblages électriques sont basés sur la méthode de l’adressage. Suivant cette méthode, un symbole correspond à chaque connecteur et à chaque borne du connecteur de manière à localiser facilement la borne de connection de l’autre extrémité du câble. Exemple 1 Symbole au-dessous (ou au-dessus) du connecteur, comme F6: Il indique l’adresse du connecteur. Exemple 2 Symbole sur le connecteur multibornes, comme 1 et 10: Il indique le numéro de la borne et le sens de la numérotation.

95ZV62001

Exemple 3 Contrôle de la borne du connecteur à laquelle F704 RL (point (3)) est connectée: 1. F704 Indique que la borne est connectée à la 4ème borne du connecteur F7. Contrôlez la description de la 4ème borne du connecteur F7 (F704), elle indique que la borne F704 est connectée à H128. Ceci signifie que la 4ème borne du connecteur F7 est connectée à la 28ème borne du connecteur H1. 2. RL Indique la couleur du fil. “RL” signifie que la couleur de l’isolation est rouge, et “L” que la raie bleu est sur l’isolation rouge.

95ZV EX 62-4 62 Function & Structure Electrical Group Verwendung des elektrischen Schaltplans (DEUTSCH)

Verwendung des elektrischen Schaltplans (DEUTSCH) Beispiel 10

10 9

20 19 18 17 16

15 14 13 12 11 21

40 39

32 31

Breitenleuchtenrelais

Fahrtsteuerrelais

Neutrales Relais

Rückleuchtenrelais

Hupenrelais

RB B611

LgSb YV H133 E214

RL SbP H610 E220

RL LB H128 E219

GW GL H127 B501

R R D114 D114

Br Lg D112 D103

G L D102 D002

R Lg D111 D103

G G D107 D107

A520 C201 H129

Reglerfehlerrelais

LgW L A405 D001 1

LgW E218

(Schwarz)

(Blau)

(1) (2)

6 D507 A306 F306 OR RO RW

A905 RLg

A503 YB

1 D112 E802 E803 Br GL GO

C206 A302 F303 E312 PB RBr RY WO

E523 G302 SbY BrB

C205 F504 F704 F804 RB RL GW PL

E109 G402 A105 E522 W BrW WP BrL

E501 C801 A005 B304 WL RG RGy LgG 40

E520 E108 F004 LgL W LgSb 36

E804 WY

E601 BrR 31

(3)

Für den elektrischen Schaltplan wird die Adressenmethode verwendet. Damit wird jeder Steckvorrichtung und jeder Anschlußklemme ein Symbol zugeordnet, damit die Klemme, an die das andere Ende des Kabels angeschlossen werden muß, leicht gefunden werden kann. Beispiel 1 Symbol unterhalb (oder oberhalb) der Steckvorrichtung, wie z. B. F6: Zeigt die Adresse der Steckvorrichtung an. Beispiel 2 Symbol an der Mehrklemmen- Anschlußstelle, wie z. B. 1 und 10: Zeigt die Klemmennummer und die Zählrichtung an.

95ZV62001

Beispiel 3 Überprüfung der anderen Steckvorrichtungsklemme, wo F704 RL (Artikel (3)) angeschlossen ist: 1. F704 Zeigt, daß die Klemme an die vierte Klemme der F7-Steckvorrichtung angeschlossen ist. Überprüfen Sie die Beschreibung in der vierten Klemme des F7-Steckvorrichtung (F704). Zie gibt an, daß die Steckvorrichtung F704 an H128 angeschlossen ist. Dies bedeutet, daß die vierte Klemme der F7-Steckvorrichtung an die 28. Klemme der H1-Steckvorrichtung angeschlossen ist. 2. RL Zeigt die Farbe des Kabels an. „ RL ” bedeutet, daß der lsolierdraht rot ist, und „ L ” bedeutet, daß sich auf dem roten lsoliermaterial ein blauer Streifen befindet.

95ZV EX 62-5 62 Function & Structure Electrical Group Modalità di utilizzo dello schema dei collegamenti elettrici (ITALIANO)

Modalità di utilizzo dello schema dei collegamenti elettrici (ITALIANO) Esempio 10

10 9

20 19 18 17 16

15 14 13 12 11 21

40 39

32 31

Relè di larghezza della lampada

Relè di controllo della guida

Relè neutro

Relè della lampada posteriore

Relè del clacson

RB B611

LgSb YV H133 E214

RL SbP H610 E220

RL LB H128 E219

GW GL H127 B501

R R D114 D114

Br Lg D112 D103

G L D102 D002

R Lg D111 D103

G G D107 D107

A520 C201 H129

LgW E218

LgW L A405 D001 1

Relè del controller d’ errore

(Nero)

(Blu)

(1) (2)

6 D507 A306 F306 OR RO RW

A905 RLg

A503 YB

1 D112 E802 E803 Br GL GO

C206 A302 F303 E312 PB RBr RY WO

E523 G302 SbY BrB

C205 F504 F704 F804 RB RL GW PL

E109 G402 A105 E522 W BrW WP BrL

E501 C801 A005 B304 WL RG RGy LgG 40

E520 E108 F004 LgL W LgSb 36

E804 WY

E601 BrR 31

(3)

Per gli schemi elettrici si utilizza il metodo degli indirizzi, in base al quale a ciascun connettore e a ogni suo contatto viene associato un simbolo che permette di identificare agevolmente il contatto cui è collegata l’altra estremità del cavo. Esempio 1 simbolo al di sopra o al di sotto del connettore, ad esempio F6: Mostra l’indirizzo del connettore. Esempio 2 simbolo presso un connettore a più contatti, ad esempio 1 e 10: Mostra il numero del contatto e il senso di numerazione.

95ZV62001

Esempio 3 verifica del contatto dell’altro connettore cui è collegato F704 RL (elemento (3)): 1. F704 Indica che il terminale è collegato al contatto n. 4 del connettore F7. Verificare la descrizione del contatto n.4 del connettore F7 (F704): essa mostra che il contatto F704 è collegato a H128. Ciò indica che il contatto n.4 del connettore F7 è collegato al contatto n. 28 del connettore H1. 2. RL Indica il colore del cavo: “RL” significa che il colore dell’isolante è rosso, e “L” rappresenta che una linea blu è presente sull’isolazione rossa.

95ZV EX 62-6 62 Function & Structure Electrical Group Cómo utilizar un Diagrama de Alambrado Eléctrico (ESPAÑOL)

Cómo utilizar un Diagrama de Alambrado Eléctrico (ESPAÑOL) Ejemplo 10

10 9

20 19 18 17 16

15 14 13 12 11 21

40 39

32 31

Relé de la lámpara ancha

Relé de control de recorrido

Relé neutro

Relé de la lámpara trasera

Relé de la bocina

RB B611

LgSb YV H133 E214

RL SbP H610 E220

RL LB H128 E219

GW GL H127 B501

R R D114 D114

Br Lg D112 D103

G L D102 D002

R Lg D111 D103

G G D107 D107

A520 C201 H129

LgW E218

LgW L A405 D001 1

Relé de fallos del controlador

(Negro)

(Azul)

(1) (2)

6 D507 A306 F306 OR RO RW

A905 RLg

A503 YB

1 D112 E802 E803 Br GL GO

C206 A302 F303 E312 PB RBr RY WO

E523 G302 SbY BrB

C205 F504 F704 F804 RB RL GW PL

E109 G402 A105 E522 W BrW WP BrL

E501 C801 A005 B304 WL RG RGy LgG 40

E520 E108 F004 LgL W LgSb 36

E804 WY

E601 BrR 31

(3)

El método de dirección se utiliza para diagrama de alambrado eléctrico. Para este método, se pega un símbolo a cada conector y terminal de conector a fin de localizar fácilmente el otro terminal al cual se conecta el otro extremo del cable. Ejemplo 1 Símbolo debajo (o encima) de conector, tal como F6: Muestra la dirección del conector. Ejemplo 2 Símbolo en el conector del multiterminal, tal como 1 y 10: Muestra el número de terminal y la dirección de numerado.

95ZV62001

Ejemplo 3 Comprobando el otro terminal de conector donde se conecta F704 RL (ítem (3)): 1. F704 Muestra que el terminal está conectado al terminal 4o del conector F7. Compruebe la descripción en el terminal 4o del conector F7 (F704). Esto muestra que el terminal F704 está conectado a H128 y significa que el terminal 4o del conector F7 está conectado al terminal 28o del conector H1. 2. RL Muestra el color del alambre “RL” y representa que el color aislante es rojo, y “L” representa que una raya azul está en el aislamiento rojo.

95ZV EX 62-7 62 Function & Structure Electrical Group Como Utilizar o Diagrama de Ligações Eléctricas (PORTUGUÊS)

Como Utilizar o Diagrama de Ligações Eléctricas (PORTUGUÊS) Exemplo 10

10 9

20 19 18 17 16

15 14 13 12 11 21

40 39

32 31

Relé de luz de largura

Relé de controlo de viagem

Relé do ponto morto

Relé da luz traseira

Relé da buzina

RB B611

LgSb YV H133 E214

RL SbP H610 E220

RL LB H128 E219

GW GL H127 B501

R R D114 D114

Br Lg D112 D103

G L D102 D002

R Lg D111 D103

G G D107 D107

A520 C201 H129

LgW E218

LgW L A405 D001 1

Relé de controlo de falha

(Preto)

(Azul)

(1) (2)

6 D507 A306 F306 OR RO RW

A905 RLg

A503 YB

1 D112 E802 E803 Br GL GO

C206 A302 F303 E312 PB RBr RY WO

E523 G302 SbY BrB

C205 F504 F704 F804 RB RL GW PL

E109 G402 A105 E522 W BrW WP BrL

E501 C801 A005 B304 WL RG RGy LgG 40

E520 E108 F004 LgL W LgSb 36

E804 WY

E601 BrR 31

(3)

O método de endereçamento é utilizado para os diagramas de ligações eléctricas. Para este método, cada conector e terminal de conector tem um símbolo acoplado para facilitar a localização do outro terminal onde a outra extremidade do cabo deve ser ligada. Exemplo 1 Símbolo por baixo (ou por cima) do conector, como F6: Indica o endereço do conector. Exemplo 2 Símbolo no conector de multiterminais, como 1 e 10: Indica o número do terminal e a direcção da numeração.

95ZV62001

Exemplo 3 Verificar o outro terminal de conectores, no qual F704 RL (item (3)) é ligado: 1. F704 Ilustra que o terminal é ligado ao 4o terminal do conector F7. Verifique a descrição no 4o terminal do conector F7 (F704), indica que o terminal F704 está ligado ao H128. Isto significa que o 4o terminal do conector F7 está ligado ao 28o terminal do conector H1. 2. RL Indica a cor do fio. “RL” representa que a cor do isolamento é vermelha e “L” representa uma faixa azul está no isolamento vermelho.

95ZV EX 62-8 62 Function & Structure Electrical Group Electrical Cable Color Codes

Electrical Cable Color Codes Color of stripe Color of insulation

Y G (yellow) (green)

(sky blue)

Br (brown)

L (blue)

W (white)

R (red)

YSb

YBr

SbW

SbR

B O Lg (black) (orange) (light green)

Y (yellow)

G (green)

Sb (sky blue)

SbY

SbG

Br (brown)

BrY

BrG

BrL

BrW

BrR

BrB

L (blue)

LBr

W (white)

R (red)

B (black)

O (orange)

OSb

Lg (light green)

LgY

LgG

LgSb

P (pink) Gy (grey)

GyY

P (pink)

SbO

SbLg

SbP

LLg

RLg

BLg

LgL

LgW

LgR

LgB

GyG

GyL

GyW

RBr

LgBr

V (violet)

GyB

V (violet)

YGy

WV RGy

PB GyR

Gy (grey)

P GyO

Gy V

Insulation color Stripe color

70ZV62001

95ZV EX 62-9 62 Function & Structure Electrical Group Electrical Circuit Symbols

Electrical Circuit Symbols Name

Symbol

Name

Direct current

Motor

Alternating current

Equipment

Conductor (General)

Fuses

Branching connection

Lamp

Conductors (Connected)

Rectifiers

Conductors (Not connected)

Mechanical coupling

Terminal

Relay contact ("a" contact)

Ground

Relay contact ("b" contact)

Resistance or Resistor

Switch

Variable resistance or Variable resistor

Pressure switch or Temperature switch

Inductance or Electromagnetic coil

Negative -positive-negative (NPN) transistor

Battery or Direct voltage source

Positive -negative-positive (PNP) transistor

Symbol

95ZV EX 62-10 62 Function & Structure Electrical Group Sensor Mount

Sensor Mount 2

9 6

11 11 3

8 7

1. Engine water level alarm sensor 2. T/M oil temperature switch 3. T/C oil temperature sensor 4. Engine water temperature sensor 5. Engine water temperature switch 6. Temperature switch for cold starter 7. Engine speed sensor 8. T/C oil temperature switch 9. Air cleaner clogging switch 10. Machine speed sensor 11. Fuel level sensor

10 K95ZV62001

95ZV EX 62-11 62 Function & Structure Electrical Group Fuse

Fuse The following fuses are provided to protect electrical circuits.

(S/N 0361~)

2 1

Fusible link 70 A x 2, 30 A x 1 Fuse box 15 fuses x 2 (for chassis and cab) 6 fuses x 1 (for engine controller)

CAUTION Possible burn hazard. Before replacing a fuse, be sure to turn off the starter switch.

S95ZV3104

IMPORTANT Replace a fuse with the same capacity. If a fuse blows immediately after replacement, the electric system is defective. Locate the defective part, and then repair it.

Fuse box location (S/N 0101~0290, 9001~9080)

S97ZVOM0087

1. For chassis 2. For cab 3. For ECM 1

(For installation positions, refer to "Electrical Equipment Layout" too.)

S97ZVOM0086

(S/N 0291~0360, 9081~)

2 1

S97ZV8210

95ZV EX 62-12 62 Function & Structure Electrical Group Fuse

Fuse box

3. For engine controller (ECM)

1. For chassis

Fuse No.

Fuse capacity (A)

20A

Lighting head light

15A

Rear work light

10A

Boom kickout Bucket leveler

15A

Back lamp Stop lamp Turn signal

10A

Parking brake Controller

15A

Front work light

10A

Spare

15A

Spare

15A

Spare

15A

4-way flasher Horn Room lamp Radio backup

10A Spare

Protective circuit

20A

Spare

15A

10A

Spare

15A

Cold starter

Buzzer Monitor

Neutral relay

Battery relay ECM

Spare

2. For cab Fuse No.

Fuse capacity (A)

Protective circuit

Spare

Rear wiper

10A

Front wiper

10A

Cigar lighter

15A

Spare

Radio

10A

Spare

10A

Spare

20A

Spare

Air conditioner

10A

Air conditioner

20A

Air conditioner

20A

Spare

Spare 20A Spare 15A Spare 10A Spare 5A

Fuse capacity (A)

Protective circuit

10A

ECM

7.5A

Spare

7.5A

Spare

7.5A

Spare

10A

ECM

10A

Spare

95ZV EX 62-13 62 Function & Structure Electrical Group Fuse

Fusible link

12V

[W]

30A

BATTERY

ECM

[W] WR

WR F15 5A

[WV] BATTERY RELAY

F14 5A

R1 BR B AC R2 C

12V

70A

STARTER

Fusible link

(1)

[R]

K95ZV62013

MAGNETIC S/W

BW VOLTAGE [WG] RELAY

Fusible link

Cover

(Lg) (WG)

F13

Fuse element

CHARGE LAMP

(2)

F12 15A

ALTERNATOR

COLD START S/W

R EI

70A

MONITOR CONTROLLER

THERMO S/W

ETHER INJECTOR

[BrR] WP

Box for fusible link

Fusible link

F13 5A

70ZV62010

The fusible link is located in the box as shown in the above figures. If excessive current flows through the starter switch or the electric line downstream of the starter switch due to shortcircuit, the fuse element will be blown to protect the circuit. The condition of the fuse element can be seen through the transparent cover. Determine the cause before replacing the fusible link. For replacement of a fusible link, remove 2 bolts and pull it up.

ACC’ (BR)

(Lg) T/M CONTROLLER

Fusible link location (S/N 0101~) 95ZVE62030

95ZV EX 62-14 62 Function & Structure Electrical Group Fuse Problems caused by blown fusible link Fuse damaged

30A [W]

W W5

12V

[W5] ECM

During engine stop

30A

- All the electrical circuit will not function. - Engine can not be started

70A (1)

- Horn [and optional flasher] will operate. - All the others will not operate and the machine can not be operated. - Engine will not stop automatically but can be stopped by turning the starter switch to “OFF”.

- The same conditions as “During engine operation” but engine can be started.

70A (2)

- The machine can be operated but the batteries can not be charged and the batteries will be discharged soon.

- The same conditions as “During engine operation”.

BATTERY RELAY

F14 5A

G1.25

During engine operation - Engine will stop automatically. - All the power for all electrical circuit will be OFF.

12V

BATTERY

1.25

WR F15 WR 5A [WV]

R1 BR B AC R2 C

G1.25 70A

STARTER

(1)

BC [R5] MAGNETIC S/W

BW5 VOLTAGE [WG] RELAY

RL1.25 NR F13

(Lg) (WG)

MONITOR CONTROLLER

CHARGE LAMP

(2)

ALTERNATOR

70A

R I E 20

COLD START S/W

R F12 15A

WB M1 M2

1.25

WR F13 5A B

THERMO ETHER S/W KIT

[BrR]

WP M

EMERGENCY STEERING PUMP

(Lg)

ACC’

T/M CONTROLLER

Fusible link location (S/N 9001~)

K95ZVE62001

Problem (symptom)

95ZV EX 62-15 62 Function & Structure Electrical Group Engine Start Circuit

Engine Start Circuit Engine start circuit diagram (S/N 0101~0358, 9001~) Starter switch Terminal

C AC

OFF ON

Fusible link

Start

Battery (24 V)

T/M controller

Shift lever F/R position

F15

Shift lever

Battery relay

ECM Diode unit Starter motor From alternator

F14 +24V

Magnetic S/W

LED (Indication: N)

Neutral relay

* When shift lever is in F/R position: OFF When shift lever is in N position: ON

Neutral starter To prevent the machine from unexpected movement at engine start up, the machine is so designed that the engine can start only while the shift lever is in the neutral (N) position.

+24V Neutral (F5) current alternator

Voltage relay

95ZV62151

As a result, the magnetic switch turns ON, the starting current flows in the starter motor, and the engine starts. At this time, the LED (indication: N) of the output circuit is lit.

Shift lever forward/reverse (F/R) position While the shift lever is located in the F or R position, the power is not supplied to the neutral relay coil, and the main contact is OFF. As a result, the starting current from the starter switch terminal C does not flow in the magnetic switch, and the engine does not start. At this time, the LED (indication: N) of the output circuit is off.

95ZV EX 62-16 62 Function & Structure Electrical Group Engine Start Circuit

Engine start circuit diagram (S/N 0359~) (S/N 0359~0560)

Starter switch

B BR ACC R1 R2 C Preheat

Off On Start

MCU

23A

Fusible link

12V

Battery

B11

Diode unit

F15 5A

D12 D05

Starter motor

Battery relay

D03 D10

(1) 70A

D04

B12

F N R

30A

F14

D11

Shift lever F/R position

E24

12V B18

+24 V

B C

Magnetic switch 3

Neutral relay

* When shift lever is in F/R position: OFF When shift lever is in N position: ON

Voltage relay

F13

+24 V (F5)

MCU E24

Charge lamp (2) 70A

R E

Alternator 95ZVE62058

95ZV EX 62-17 62 Function & Structure Electrical Group Engine Start Circuit (S/N 0561~) Starter switch

Preheat

Off On Start

MCU

Fusible link

Battery

Diode unit

Starter motor assy

Battery relay

Starter motor

Magnetic switch

Voltage relay

Neutral relay Charge lamp

Voltage relay

MCU E24

* When shift lever is in F/R position: OFF When shift lever is in N position: ON

Alternator

95ZV EX 62-18 62 Function & Structure Electrical Group Engine Start Circuit

Neutral starter To prevent the machine from unexpected movement at engine start up, the machine is so designed that the engine can start only while the shift lever is in the neutral (N) position.

Shift lever neutral (N) position When the starter switch is turned to the ON position while the shift lever is located in the N position, the coil actuation circuit of the neutral relay is connected to the ground of the MCU unit and the contact of the neutral relay is switched over to ON. (S/N 0359~0560) When the starter switch is turned to the START position, the start command current flows from the starter switch terminal C to the neutral relay, the magnetic switch and the voltage relay. As a result, the magnetic switch turns ON, the starting current flows in the starter motor, and the engine starts. (S/N 0561~) When the starter switch is turned to the START position, the start command current flows from the starter switch terminal C to the neutral relay, the voltage relay and the magnetic switch. As a result, the magnetic switch turns ON, the starting current flows in the starter motor, and the engine starts.

95ZV EX 62-19 62 Function & Structure Electrical Group Engine Start Circuit

Starter switch OFF 30º ON (Run) 35º Start B

AC C

BR R2

Connection table

To magnetic switch

WRx2 WBx2

BR B ACC R2 C

ACC

To battery relay

From battery

W3 W5 OFF ON Start

WR WR

W W

K90ZV62002

Starter switch

OFF Enables insertion and removal of the starter key. All the electrical circuits (except the horn and optional hazard flasher) will be turned off. ON Supplies power to the charge, lamp, and monitor circuits. Start Starts the engine.

S65ZV5088

95ZV EX 62-20 62 Function & Structure Electrical Group Engine Start Circuit

Battery relay

Alternator I terminal wire 12V

12V

30A [W]

Moving contact

F14

Main contacts

F15

R1 BR B AC R2 C

ECM (2) (3) [WV]

Battery relay

Terminals for coil energizing current (4 mm)

Battery

(1)

(2)(3)

Diode unit

Suppression diode

BR B

Coil for energizing

Terminals for main current (8 mm) 95ZV62017

When the starter switch is turned to ON or the Start position, the battery relay is turned on. When the starter switch is set to the OFF position, the alternator stops generating power, and the battery relay is automatically turned off so that the electrical circuits will not function. If the battery relay was not used, a large amount of current would be directly sent through the starter switch when it is turned on. However, use of the battery relay reduces the amount of current because this relay needs only a small amount of current to energize it.

Battery relay operation Starter switch ACC

From charge circuit To main circuit

Battery relay

(E)

Battery

(B)

Suppression diode

65ZV62028

Battery relay Rated voltage

DC 24 V

Minimum operating voltage

20 V or less

Release voltage

9 V or less

When current flows from the starter switch terminal ACC, 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.

Charge circuit Monitor circuit

Neutral relay

From alternator I terminal K95ZVE62002

Engine motion-active circuit: When the starter switch is turned OFF, the battery relay is automatically turned OFF since the command current from the starter switch terminal ACC stops flowing and the coil is demagnetized. Then the charging circuit from the alternator is shut down. However, the alternator is still generating power and the load dump surge may be generated. This may damage the related circuits and equipment. In order to prevent this trouble, this circuit (1) is provided to hold the battery relay in the "ON" position.

95ZV EX 62-21 62 Function & Structure Electrical Group Engine Start Circuit 1. Diode (2) This diode is provided to prevent the roundabout current from the alternator to the controller.

Diode unit

WV WR WP

WV: To battery relay WR: To starter switch terminal ACC (VIA F15), ECM WP: To alternator

2. Diode (3) This diode is provided to prevent the roundabout current from the starter switch ACC to the alternator I terminal.

Diode storage section 70ZV62017

The diode unit is incorporated in the milky white connector near the battery relay. It is provided for the following purpose.

SbP

Neutral relay

Internal connection dia.

Body black

K95ZV62014

Position of shift lever

Between 1 and 3

Between 2 and 4

Starting

F or R

Not energized

OFF

Impossible

Energized

Possible

The structures of the neutral relay, back-up relay, horn relay, width lamp relay and the head lamp relay, the oil pressure relay and the water temperature relay are identical each other. Note The illustration shows the de-energized condition. When the shift lever is in the N position while the starter switch is kept at the Start position, the neutral relay is magnetized and electric current flows from the battery to the neutral relay / magnetic switch / voltage relay through the starter switch terminal C.

Rating

DV 24 V

Operating voltage

16 V or less

Reset voltage

2.4 V or more

Coil resistance

320 

95ZV EX 62-22 62 Function & Structure Electrical Group Engine Start Circuit

Magnet switch (S/N 0101~0560, 9001~)

Rating 24V x 200A

M’

C’

M C

C’ M’

70ZV62019

Note The illustrations show the de-energized condition.

When the neutral relay is magnetized, electric current flows from the battery to the neutral relay and the magnetic switch through the starter switch terminal C. It magnetizes the magnetic switch. On the other hand since the battery relay is already ON at this time, electric current flows from the battery to the starter motor terminal C through the battery relay and the magnetic switch, engaging the starter motor to start engine.

95ZV EX 62-23 62 Function & Structure Electrical Group Engine Start Circuit

Voltage relay

Once the engine is started, the alternator starts generating electric power.

(S/N 0101~0335, 9001~)

When electric current is supplied from the alternator R terminal to the voltage relay, the voltage relay is magnetized and is turned OFF. 1

2 3

4 70ZV62020

Note The illustrations show the de-energized condition. Voltage relay Contact point closed

Contact point open

(S/N 0336~) Blue

K70V2J62005

Voltage relay Contact point closed

Contact point open

Consequently the magnetic switch turns OFF and no electric current flows to the starter motor terminal C, disengaging the starter motor.

95ZV EX 62-24 62 Function & Structure Electrical Group Power Generating/Charging Circuit

Power Generating/Charging Circuit Alternator Engine

Mechanical energy supply

Alternator

Rotor coil excitation current

Electrical energy conversion

In the electricity generated in the alternator, the voltage fluctuates depending on the number of revolutions of the engine and the load size if no measures are taken.

Generated power

Voltage adjustment

<Load>

For rotor coil initial excitation

Battery

Battery charge

Starter switch

Load circuit operation

For battery relay operation

Adjusted voltage

IC regulator For rotor coil initial excitation

The alternator driven by the engine rectifies, with 6 diodes, full waves in three phases of the AC output generated in the stator coil by the three-phase start connection (Y connection) into DC output, then supplies it as the electric power to the battery and the machine load.

70ZV62021

The power generating/charging device and the charging circuit consisting of an alternator, regulator, battery, etc. generate and supply the power required to all electrical units of the machine.

To prevent fluctuation, a regulator is integrated so that the voltage supplied to the battery and the load circuit is always constant.

95ZV EX 62-25 62 Function & Structure Electrical Group ECM (Engine Controller)

ECM (Engine Controller) Function of ECM - Stops the engine. - Operates the engine. - Monitors the engine, and diagnoses it for faults.

Connection diagram

B [W] 46 37 36 26 27

(Y)

B C

(YB)

(YG)

DATA LINK CONNECTOR

(YL)

(YO)

A [W] F31

[GY]

10A

7 8

17 [W] F35 [GR] 10A

18 28

48 47 49

THROTTLE PEDAL

BrW

THROTTLE OPENING SENSOR

YV BLg

Power supply to ECM is from ACC term. of key s/w WR

F15

13 F13

STOP

(Lg)

(BrR)

WARNING (BrB) PROTECTION(BrW)

INC/DEC SW

(Lg)

GyB

(S/N 0361~, 9019~)

INC (m)

PG PW

DEC 41 9

E/G MODE SELECTION

BrG

F13

IDLE

DIAGNOSTIC SW

TO TACHOMETER CONVERTER

GyW

4 YO

IDLE SW OFF IDLE

GyY

(S/N 9004~)

BL BL E GyO BrL GyR

(S/N 0101~0230, 9011~9018)

(S/N ~0230, ~9010)

FR EP

6 19 5

30 39 40 50

ECM

E/G ECM connection diagram

K95ZVE62008

95ZV EX 62-26 62 Function & Structure Electrical Group ECM (Engine Controller)

Monitor lamp test

Key switch

Engine protection lamp

Engine warning lamp

Engine stop lamp

ON OFF

Approx. 2 sec

ON Orange

OFF ON

Lights when abnormality occurs.

OFF

Yellow

ON Red

OFF

95ZV62025

STOP

Engine protection lamp Engine warning lamp Engine stop lamp 95ZV62117

When the starter switch is set to ON, three engine monitor lamps (engine protection, engine warning and engine stop) are lit for approximately 2 seconds. After that, if there is an abnormality in a circuit, a corresponding monitor lamp lights.

95ZV EX 62-27 62 Function & Structure Electrical Group ECM (Engine Controller)

Failure diagnosis There are two optional equipment for the engine failure diagnostic. One is mounted in the instrument panel of the machine. The other is the assembled parts of cable and switches to be temporarily connected to the provided connector.

Engine diagnostic switch (option) Diag. switch (Part Number: 35010-60130)

G R L W

Inc./Dec. switch (Part Number: 35010-60180)

R G Y

Cable assembly (Part Number: 33191-49150) 70ZV62069

Diagnostic switch

Increment/decrement switch K85ZV62007

When premounted in the instrument panel:

2 95ZV62115

1. Diagnostic switch (option) 2. Increment / decrement switch (option)

95ZV EX 62-28 62 Function & Structure Electrical Group ECM (Engine Controller) When temporarily connected to the provided connector:

Refer to the following "Engine diagnostic switch (option)" page 62-29 for details.

SHIFT S/W

DIAG. INC./DEC. SWITCH

PILOT VALVE

BY E119

H123 BrW

YL E116

H113 BrB Br D112

Br D112

1 1

FLOAT

The increment/decrement switch is used to check the history of the engine failure.

BrG BL H614 H613

POSITIO -NER

KICK OUT

PG PW H633 H623

The engine diagnostic switch is used to check the engine failure when any one of the engine warning lamp is turned on.

BrB

1 (BLUE)

BrW

G5 K95ZVE62003

Diag Inc/Dec switch connector (S/N 0149~, 9004~)

Fuse box (Cab) Fuse box (Main)

Front Diag Inc/Dec switch connector (S/N ~0148, ~9003) K115ZVE62005

The Diag. Inc/Dec switch assembly is available to be temporarily connected to the Diag. Inc/Dec switch connector at the cab control box.

The increment/decrement switch is also used to adjust the engine idle revolution. Refer to "Increment decrement switch (option)" page 62-31 for details.

95ZV EX 62-29 62 Function & Structure Electrical Group ECM (Engine Controller) After checking the fault, terminate the fault diagnosis with the following procedure.

Engine diagnostic switch (option) When any one of the engine warning lamp is turned on, use this switch to check the engine failure as follows.

1. Set the engine diagnostic switch to OFF. 2. Set the starter switch to OFF.

When no fault has occurred: OFF

The three engine monitor lamps remain lit. START

When any fault has occurred: The three engine monitor lamps light, become extinguished once, then the red (engine stop) and yellow (engine warning) lamps flash to indicate a recorded three-digit fault code. 95ZV62028

1. Set the starter switch to OFF.

The chart below shows how the flashing pattern should be converted into a three-digit fault code. At first, the yellow lamp lights and becomes OFF. Next, the red lamp flashes to indicate a fault code recorded in a 3-digit number. After a fault code is indicated once, the yellow lamp lights again and becomes OFF again.

Refer to the chart on the next page for example. The same fault code is continuously indicated until the next fault code is indicated by pressing the inc/dec switch (option).

Diagnostic switch 95ZV62027

2. Set the engine diagnostic switch to ON. 3. Set the starter switch to ON.

ON OFF Orange 1 sec

1 sec

ON OFF Yellow ON OFF Red

0.5 sec Second digit

First digit 1 sec

Third digit 1 sec

Fault code

Indicated repeatedly 95ZV62029

95ZV EX 62-30 62 Function & Structure Electrical Group ECM (Engine Controller)

Failure diagnostic chart

Key switch

Diagnostic switch

ON OFF ON OFF

[When there is not fault code] Engine protection lamp

Engine warning lamp

Engine stop lamp

ON OFF ON OFF ON OFF

[When there is fault code] Engine protection lamp

ON OFF 1 sec

Engine warning lamp

Engine stop lamp

1 sec

ON OFF ON OFF

100's digit

1 sec

10's digit

1 sec

1's digit

Fault code [Example: Failure code 131] High voltage detected at throttle position signal circuit. Engine protection lamp

ON OFF 1 sec

Engine warning lamp

Engine stop lamp

1 sec

ON OFF ON OFF

Following page explains more. 95ZV62026

95ZV EX 62-31 62 Function & Structure Electrical Group ECM (Engine Controller) This switch is used to

Increment decrement switch (option)

1. Check the history of the engine failures 2. Adjust the engine idle revolution

Check the engine failure history Set the starter switch to ON and set the engine diagnostic switch to ON. When a fault code is indicated, pressing this switch on the + side indicates the next fault code, and pressing on the - side indicates the previous fault code.

Increment/decrement switch

After indicating all currently present fault codes, pressing this switch to the + side to indicate the third or fourth fault code, and pressing this switch to the - side to indicate the first fault code.

When premounted in the instrument panel:

Refer to the section of the diagnostic switch for converting the flashing pattern to 3-digit fault code. Refer to the "Quantum fault code information" page 6232 for details.

Adjust the number of revolutions of the engine in the idle status 1

2 95ZV62115

In this status, press this switch either the + or - side to change the number of revolutions of the engine within the range between 650 min-1 (rpm) and 900 min-1 (rpm).

1. Diagnostic switch (option) 2. Increment / decrement switch (option) When temporarily connected to the provided connector: Diag Inc/Dec switch connector (S/N 0149~, 9004~)

Set the starter switch to ON, set the engine diagnostic switch to OFF, and run the machine in the idle status.

Fuse box (Cab) Fuse box (Main)

Pressing the switch + side increments the revolution number by “25 min-1 (rpm)” up to 900 min-1 (rpm). Pressing the switch - side decrements the revolution number by “25 min-1 (rpm)” down to 650 min-1 (rpm). The engine idle revolution number is not changed over 900 min-1 (rpm) or below 650 min-1 (rpm) even if pressing the switch.

Front Diag Inc/Dec switch connector (S/N ~0148, ~9003) K115ZVE62005

95ZV EX 62-32 62 Function & Structure Electrical Group ECM (Engine Controller)

Quantum fault code information These codes show the fault codes for the engine failure checked by the diagnostic switch (option).

EG111 Red

Engine Control Module (ECM) - critical internal failure.

EG115 Red

Engine Speed / Camshaft Position Sensor Circuit - lost both of two signals from the magnetic pickup sensor.

EG121 Yellow

Engine Speed / Position Sensor Circuit - lost one of two signals from the magnetic pickup sensor.

EG122 Yellow

Intake Manifold Pressure Sensor #1 Circuit - shorted high.

EG123 Yellow

Intake Manifold Pressure Sensor #1 Circuit - shorted low.

EG124 Yellow

Intake Manifold Pressure - above normal operation.

EG131 Red

Accelerator Pedal Position Sensor Circuit - shorted high.

EG132 Red

Accelerator Pedal Position Sensor Circuit - shorted low.

EG133 Red

Remote Accelerator Pedal Position Sensor Circuit - shorted high.

EG134 Red

Remote Accelerator Pedal Position Sensor Circuit - shorted low.

EG135 Yellow

Engine Oil Pressure Sensor Circuit - shorted high.

EG141 Yellow

Engine Oil Pressure Sensor Circuit - shorted low.

EG143 Yellow

Engine Oil Pressure Low - warning.

EG144 Yellow

Engine Coolant Temperature Sensor Circuit - voltage above normal or shorted high.

EG145 Yellow

Engine Coolant Temperature Sensor Circuit - voltage below normal or shorted low.

EG146 Yellow

Engine Coolant Temperature High - warning.

EG147 Red

Accelerator Pedal Position Sensor Circuit - low frequency.

EG148 Red

Accelerator Pedal Position Sensor Circuit - high frequency.

EG151 Red

Engine Coolant Temperature High - critical.

EG153 Yellow

Intake Manifold Air Temperature Sensor Circuit - voltage above normal or shorted high.

EG154 Yellow

Intake Manifold Air Temperature Sensor Circuit - voltage below normal or shorted low.

EG155 Red

Intake Manifold Air Temperature Sensor High - critical.

QST30 (135ZV)

QSK19 (115ZV)

QSX15 (95ZV)

QSM11 (90ZV)

DESCRIPTION

QSL9 (85ZV)

FAULT CODE/ LAMP

QSB5.9 (70ZV)

Please note that not all are used in the 95ZV machine application. Refer to Cummins Engine troubleshooting fault codes list for more information.

EG187 Yellow

Sensor Supply Voltage #2 Circuit - shorted low.

EG195 Yellow

Coolant Level Sensor Circuit - shorted high.

EG196 Yellow

Coolant Level Sensor Circuit - shorted low.

EG197 Yellow

Coolant Level Low - warning.

EG212 Yellow

Engine Oil Temperature Sensor Circuit - shorted high.

EG213 Yellow

Engine Oil Temperature Sensor Circuit - shorted low.

EG221 Yellow

Ambient Air Pressure Sensor Circuit - shorted high.

EG222 Yellow

Ambient Air Pressure Sensor Circuit - shorted low.

EG223 Yellow

Engine Oil Burn Valve Solenoid Circuit - shorted low.

EG227 Yellow

Sensor Supply Voltage #2 Circuit - shorted high.

EG234 Red

Engine Speed High - critical.

EG235 Red

Engine Coolant Level Low - critical.

EG238 Yellow

Sensor Supply Voltage #3 Circuit - shorted low.

EG241 Yellow

Vehicle Speed Sensor Circuit - data incorrect.

EG242 Yellow

Vehicle Speed Sensor Circuit - invalid signal detected.

EG245 Yellow

Fan Control Circuit - shorted low.

EG253 Red

Engine Oil Level - below normal operating range.

EG254 Red

Fuel Shutoff Solenoid Supply Circuit - less than +6 VDC detected.

EG255 Yellow

Fuel Shutoff Solenoid Supply Circuit - externally supplied voltage detected.

EG256 Yellow

Ambient Air Temperature Sensor Circuit - shorted low.

EG259 Red

Fuel Shutoff Valve - stuck open.

EG261 Yellow

Fuel Temperature High - warning.

EG263 Yellow

Fuel Temperature Sensor Circuit - shorted high.

EG265 Yellow

Fuel Temperature Sensor Circuit - shorted low.

EG268 Yellow

Fuel Pressure Sensor Circuit - data incorrect.

EG271 Yellow

Fuel Control Actuator Circuit - shorted low.

EG272 Yellow

Fuel Control Actuator Circuit - shorted high.

QST30 (135ZV)

QSK19 (115ZV)

QSX15 (95ZV)

QSM11 (90ZV)

DESCRIPTION

QSL9 (85ZV)

FAULT CODE/ LAMP

QSB5.9 (70ZV)

95ZV EX 62-33 62 Function & Structure Electrical Group ECM (Engine Controller)

EG284 Yellow

Engine Speed / Position Sensor #1 (Crankshaft) Supply Voltage Circuit - shorted low.

EG285 Yellow

SAE J1939 Data Link Multiplexing PGN Timeout Error.

EG286 Yellow

SAE J1939 Data Link Multiplexing Configuration Error.

EG287 Red

SAE J1939 Multiplexing Accelerator Pedal Sensor System Error.

EG288 Red

SAE J1939 Multiplexing Remote Accelerator Pedal Sensor System Error.

EG293 Yellow

Auxiliary Temperature Sensor Input #1 Circuit - shorted high.

EG294 Yellow

Auxiliary Temperature Sensor Input #1 Circuit - shorted low.

EG295 Yellow

Ambient Air Pressure Sensor Circuit - data incorrect.

EG296 Red

Auxiliary Pressure Sensor Input #2 Engine Protection - critical.

EG297 Yellow

Auxiliary Pressure Sensor Input #2 Circuit - shorted high.

EG298 Yellow

Auxiliary Pressure Sensor Input #2 Circuit - shorted low.

EG311 Yellow

Injector Solenoid Valve Cylinder #1 Circuit - grounded circuit.

EG312 Yellow

Injector Solenoid Valve Cylinder #5 Circuit - grounded circuit.

EG313 Yellow

Injector Solenoid Valve Cylinder #3 Circuit - grounded circuit.

EG314 Yellow

Injector Solenoid Valve Cylinder #6 Circuit - grounded circuit.

EG315 Yellow

Injector Solenoid Valve Cylinder #2 Circuit - grounded circuit.

EG319 Yellow

Real Time Clock - power Interrupt.

EG321 Yellow

Injector Solenoid Valve Cylinder #4 Circuit - grounded circuit.

EG322 Yellow

Injector Solenoid Valve Cylinder #1 Circuit - open circuit.

EG323 Yellow

Injector Solenoid Valve Cylinder #5 Circuit - open circuit.

EG324 Yellow

Injector Solenoid Valve Cylinder #3 Circuit - open circuit.

EG325 Yellow

Injector Solenoid Valve Cylinder #6 Circuit - open circuit.

EG331 Yellow

Injector Solenoid Valve Cylinder #2 Circuit - open circuit.

EG332 Yellow

Injector Solenoid Valve Cylinder #4 Circuit - open circuit.

EG334 Yellow

Coolant Temperature Sensor Circuit - data erratic, intermittent, or incorrect.

EG341 Yellow

Engine Control Module - data lost.

EG343 Yellow

Engine Control Module - warning internal hardware failure.

QST30 (135ZV)

QSK19 (115ZV)

QSX15 (95ZV)

QSM11 (90ZV)

DESCRIPTION

QSL9 (85ZV)

FAULT CODE/ LAMP

QSB5.9 (70ZV)

95ZV EX 62-34 62 Function & Structure Electrical Group ECM (Engine Controller)

EG351 Yellow

Injector Power Supply.

EG352 Yellow

Sensor Supply Voltage #1 Circuit - shorted low.

EG378 Yellow

Fueling Actuator #1 Circuit - open circuit.

EG379 Yellow

Fueling Actuator #1 Circuit - grounded circuit.

EG386 Yellow

Sensor Supply Voltage #1 Circuit - shorted high.

EG387 Yellow

Accelerator Pedal Position Sensor Supply Voltage Circuit - shorted high.

EG394 Yellow

Timing Actuator #1 Circuit - open circuit.

EG395 Yellow

Timing Actuator #1 Circuit - grounded circuit.

EG396 Yellow

Fueling Actuator #2 Circuit - open circuit.

EG397 Yellow

Fueling Actuator #2 Circuit - grounded circuit.

EG398 Yellow

Timing Actuator #2 Circuit - open circuit.

EG399 Yellow

Timing Actuator #2 Circuit - grounded circuit.

EG415 Red

Engine Oil Pressure Low - critical.

EG418 Yellow

Water in Fuel Indicator High - maintenance.

EG419 Yellow

Intake Manifold Boost Pressure Imbalance.

EG422 Yellow

Engine Coolant Level Sensor Circuit - data incorrect.

EG426 Yellow

SAE J1939 Datalink - cannot transmit.

EG428 Yellow

Water in Fuel Sensor Circuit - shorted high.

EG429 Yellow

Water in Fuel Sensor Circuit - shorted low.

EG431 Yellow

Accelerator Pedal Idle Validation Circuit - data incorrect.

EG432 Red

Accelerator Pedal Idle Validation Circuit - out of calibration.

EG433 Yellow

Intake Manifold Pressure Sensor Circuit - data incorrect.

EG434 Yellow

Unswitched Battery Supply Circuit.

EG435 Yellow

Engine Oil Pressure Switch Circuit - data incorrect.

EG441 Yellow

Battery #1 Voltage Low - warning.

EG442 Yellow

Battery #1 Voltage High - warning.

EG443 Yellow

Accelerator Pedal Position Sensor Supply Voltage Circuit - shorted low.

QST30 (135ZV)

QSK19 (115ZV)

QSX15 (95ZV)

QSM11 (90ZV)

DESCRIPTION

QSL9 (85ZV)

FAULT CODE/ LAMP

QSB5.9 (70ZV)

95ZV EX 62-35 62 Function & Structure Electrical Group ECM (Engine Controller)

EG449 Yellow

Fuel Pump Delivery Pressure High - warning.

EG451 Yellow

Injector Metering Rail #1 Pressure Sensor Circuit - shorted high.

EG452 Yellow

Injector Metering Rail #1 Pressure Sensor Circuit - shorted low.

EG466 Yellow

Turbocharger #1 Wastegate Control Circuit - shorted low.

EG482 Yellow

Fuel Pressure Low - warning.

EG483 Yellow

Injector Metering Rail #2 Pressure Sensor Circuit - shorted high.

EG484 Yellow

Injector Metering Rail #2 Pressure Sensor Circuit - shorted low.

EG485 Yellow

Injector Metering Rail #2 Pressure High - warning.

EG486 Yellow

Injector Metering Rail #2 Pressure Low - warning.

EG487 Yellow

Start Assist Device - canister Empty (Ether Injection).

EG488 Yellow

Intake Manifold Temperature High - warning.

EG496 Yellow

Engine Speed / Position Sensor #2 (Camshaft) Supply Voltage.

EG497 Yellow

Multiple Unit Synchronization Switch Circuit - data incorrect.

EG498 Yellow

Engine Oil Level Sensor Circuit - voltage above normal or shorted high.

EG499 Yellow

Engine Oil Level Sensor Circuit - voltage below normal or shorted low.

EG527 Yellow

Auxiliary Input / Output #2 Circuit - shorted high.

EG528 Yellow

OEM Alternate torque validation switch - data incorrect.

EG529 Yellow

Auxiliary Input / Output #3 Circuit - shorted high.

EG546 Yellow

Fuel Delivery Pressure Sensor Circuit - shorted high.

EG547 Yellow

Fuel Delivery Pressure Sensor Circuit - shorted low.

EG551 Yellow

Accelerate Pedal Idle Validation Circuit - shorted low.

EG553 Yellow

Injector Metering Rail #1 Pressure High - warning level.

EG554 Yellow

Fuel Pressure Sensor Error.

EG559 Yellow

Injector Metering Rail #1 Pressure Low - data valid but below normal operational range - moderately severe level.

EG584 Yellow

Starter Relay Circuit - shorted high.

EG585 Yellow

Starter Relay Circuit - shorted low.

EG595 Yellow

Turbocharger #1 Speed High - warning level.

QST30 (135ZV)

QSK19 (115ZV)

QSX15 (95ZV)

QSM11 (90ZV)

DESCRIPTION

QSL9 (85ZV)

FAULT CODE/ LAMP

QSB5.9 (70ZV)

95ZV EX 62-36 62 Function & Structure Electrical Group ECM (Engine Controller)

EG596 Yellow

Electrical Charging System Voltage High - warning level.

EG597 Yellow

Electrical Charging System Voltage Low - warning level.

EG598 Red

Electrical Charging System Voltage Low - critical level.

EG599 Red

OEM Commanded Dual Output Shutdown.

EG611 None

Engine Hot Shutdown.

EG649 Yellow

Change Lubricating Oil and Filter.

EG687 Yellow

Turbocharger Speed Sensor - below normal operating range.

EG689 Yellow

Crankshaft Engine Speed Signal Error.

EG691 Yellow

Turbocharger #1 Compressor Inlet Air Temperature Sensor Circuit - voltage above normal or shorted high.

EG692 Yellow

Turbocharger #1 Compressor Inlet Air Temperature Sensor Circuit - voltage below normal or shorted low.

EG731 Yellow

Mechanical Timing Misalignment.

EG757 Yellow

Electronic Control Module Data Lost.

EG758 Yellow

Injector Metering Rail #2 Pressure Malfunction.

EG778 Yellow

Engine Speed Sensor (Camshaft) - data erratic, intermittent, or incorrect.

EG779 Yellow

Auxiliary Equipment Sensor Input #3 (OEM Switch).

EG951 None

Cylinder Power Imbalance Detected.

EG1117 None

Power Lost with Ignition ON - data erratic, intermittent, or incorrect.

EG1119 Yellow

Engine Coolant Temperature - data valid but above normal operating range.

EG1139 Yellow

Injector Cylinder #1 - mechanical system not responding properly or out of adjustment.

EG1141 Yellow

Injector Cylinder #2 - mechanical system not responding properly or out of adjustment.

EG1142 Yellow

Injector Cylinder #3 - mechanical system not responding properly or out of adjustment.

EG1143 Yellow

Injector Cylinder #4 - mechanical system not responding properly or out of adjustment.

EG1144 Yellow

Injector Cylinder #5 - mechanical system not responding properly or out of adjustment.

EG1145 Yellow

Injector Cylinder #6 - mechanical system not responding properly or out of adjustment.

EG1358 Yellow

Accelerator Pedal Position Sensor 1 Circuit - voltage above normal or shorted high.

EG1359 Yellow

Accelerator Pedal Position Sensor 1 Circuit - voltage below normal or shorted low.

EG1361 Yellow

Remote Accelerator Pedal Position Sensor 1 Circuit - voltage below normal or shorted low.

QST30 (135ZV)

QSK19 (115ZV)

QSX15 (95ZV)

QSM11 (90ZV)

DESCRIPTION

QSL9 (85ZV)

FAULT CODE/ LAMP

QSB5.9 (70ZV)

95ZV EX 62-37 62 Function & Structure Electrical Group ECM (Engine Controller)

EG1514 Yellow

Accelerator Pedal Position Sensor 1 Circuit Frequency - abnormal frequency.

EG1595 Yellow

Remote Accelerator Pedal Position Sensor 1 Circuit - voltage above normal or shorted high.

EG1911 Yellow

Injector Metering Rail 1 Pressure - above normal operating range.

EG2185 Yellow

Sensor Supply Voltage #4 Circuit - shorted high.

EG2186 Yellow

Sensor Supply Voltage #4 Circuit - shorted low.

EG2215 Yellow

Fuel Pump Delivery Pressure - data valid but below normal operational range - moderately severe level.

EG2216 Yellow

Fuel Pump Delivery Pressure - data valid but above normal operational range - moderately severe level.

EG2217 Yellow

ECM Program Memory (RAM) Corruption - condition exists.

EG2265 Yellow

Fuel Priming Pump Control Signal Circuit - shorted high.

EG2266 Yellow

Fuel Priming Pump Control Signal Circuit - shorted low.

EG2311 Yellow

Fueling Actuator #1 Circuit Error - condition exists.

EG2321 None

Engine Speed Sensor #1 - data erratic, intermittent, or incorrect.

EG2322 None

Engine Speed Sensor #2 - data erratic, intermittent, or incorrect.

EG2345 Yellow

Turbocharger speed invalid rate of change detected - abnormal rate of change.

EG2346 Yellow

Exhaust Gas Temperature - data above normal.

EG2347 Yellow

Turbocharger Compressor Outlet Temperature - data above normal.

EG2555 Yellow

Intake Air Heater #1 Circuit - voltage above normal or shorted high.

EG2556 Yellow

Intake Air Heater #1 Circuit - voltage below normal or shorted low.

EG2963 None

Engine Coolant Temperature High - warning.

EG2964 None

Intake Manifold Temperature High - warning.

EG2973 Yellow

Intake Manifold Pressure Sensor Circuit - data erratic, intermittent, or incorrect.

QST30 (135ZV)

QSK19 (115ZV)

QSX15 (95ZV)

QSM11 (90ZV)

DESCRIPTION

QSL9 (85ZV)

FAULT CODE/ LAMP

QSB5.9 (70ZV)

95ZV EX 62-38 62 Function & Structure Electrical Group ECM (Engine Controller)

95ZV EX 62-39 62 Function & Structure Electrical Group ECM (Engine Controller)

Accelerator pedal (S/N 0101~0230, 9001~9010)

Pedal R

48 47 49

THROTTLE PEDAL

BrW YV BLg

THROTTLE OPENING SENSOR G B

GyY

IDLE SW O OFF IDLE

C M

3 13

Potentiometer

Y GyW

V IDLE

Circuit diagram

Connector

(0) 6 (V) 5 (Y) 4

1 (G) 2 (B) 3 (R)

A View A

95ZV62118

Note To calibrate a new pedal to the ECM, do the following within about a 5-second time frame. - Turn "ON" the starter switch. - Stroke the pedal fully up and down 3 times. - Turn "OFF" the starter switch. Potentiometer voltage (V) Input

0.4~0.7

3.5~4.05

Pedal Test. Typical pedal potentiometer resistance at 65ºF. Wire colors are at the pedal harness with accelerator pedal unplugged. Wire colors

 at pedal up position

 at pedal down position

R-G

2,290

685

R-B

2,340

Y-O

Open

1.8

Y-V

4.5

Open

95ZV EX 62-40 62 Function & Structure Electrical Group ECM (Engine Controller) When the accelerator pedal is pressed, the voltage corresponding to the pressing angle is input as a signal from the potentiometer to the ECM (engine controller) to control the engine revolution.

Installation angle

Throttle pedal sends electrical signal to the engine ECM*. When the throttle pedal or the ECM* is replaced or when the battery cable is disconnected the throttle pedal must be calibrated, or "initialized", with the ECM*. Failure to initialize the throttle pedal will result in a fault code warning light, and a possible power deration. When a new throttle pedal or ECM* is installed or when the battery cable is re-connected or a fault code (listed below) is indicated follow these steps within a time frame of about 5 or 6 seconds to initialize the throttle pedal with the ECM*.

Pedal angle

1. Shut off the engine

Max. 21º Pedal stop

Accelerator pedal installation

Full range

2. Turn the key to "ON"

3. Fully depress and release the throttle pedal three times.

Pedal Angle

4. Turn the key to "OFF".

5V Potentiometer Voltages when plugged in, key "ON"

The throttle pedal and ECM* have now been initialized or calibrated. The engine may be restarted and retested for proper performance.

Between terminal 47 (YV-G) and 49 (BLg-B) Refer to circuit diagram for details.

3.9 V

4 3 2

Using the Quantum fault code information section the following fault codes may indicate a non-initialized throttle pedal:

1 0.66 V 0

If the problem continues disconnect the wiring harness connector at the throttle pedal and inspect both sides. The pins and sockets should be clean, dry and straight. If there is a problem correct it, reconnect the connector, follow the steps above and retest.

0 Pedal Angle

95ZV62119

- Fault Code 132 - Fault Code 134 (This may show, but is not relevant to our application.) - Fault Codes 287, 288 (These may show, but are not relevant to our application.) - Fault Code 431 - Fault Code 432 - Fault Code 443 If the problem is not corrected contact your Cummins Engine distributor for assistance. *Engine Control Module; Computer that controls engine functions, and monitors engine faults.

95ZV EX 62-41 62 Function & Structure Electrical Group ECM (Engine Controller)

Accelerator pedal (S/N 0231~, 9011~) [ Wire color and signal ] A-Black-APS signal B-White-APS ground C-Red-APS supply (5 V) D-Green-Throttle active E-Blue-Idle active F-Orange-IVS supply (5 V)

THROTTLE PEDAL 48 47 49

E C M

BrW

THROTTLE OPENING SENSOR

BLg

Note APS: Acceleration Position Signal IVS: Idle Validation Switch

Pedal

Potentiometer

GyY

GyW

IDLE SW OFF IDLE

IDLE

Circuit diagram

(G) 6 (L) 5 (O) 4

1 (B) 2 (W) 3 (R)

Connector

View A 1-Black-APS signal 2-White-APS ground 3-Red-APS supply (5 V) 4-Orange-IVS supply (5 V) 5-Blue-Idle active 6-Green-Throttle active

K90ZV62006

Note To calibrate a new pedal to the ECM, do the following within about a 5- or 6-second time frame. - Turn "ON" the starter switch. - Stroke the pedal fully up and down 3 times. - Turn "OFF" the starter switch. Potentiometer voltage (V) Input

1.3~1.4

4.9~5.0

Pedal Test Typical pedal potentiometer resistance at 65ºF. Wire colors are at the pedal harness with accelerator pedal unplugged. Wire colors

 at pedal up position

 at pedal down position

R-G

2,205

570

W-B

356

1,985

R-W

2,530

G-O

Open

1.1

L-O

0.9

Open

95ZV EX 62-42 62 Function & Structure Electrical Group ECM (Engine Controller) When the accelerator pedal is pressed, the voltage corresponding to the pressing angle is input as a signal from the potentiometer to the ECM (engine controller) to control the engine revolution.

Installation angle 35 Pedal stop

Accelerator pedal installation Throttle pedal sends electrical signal to the engine ECM*. When the throttle pedal or the ECM* is replaced or when the battery cable is disconnected the throttle pedal must be calibrated, or "initialized", with the ECM*. Failure to initialize the throttle pedal will result in a fault code warning light, and a possible power deration. When a new throttle pedal or ECM* is installed or when the battery cable is re-connected or a fault code (listed below) is indicated follow these steps within a time frame of about 5 or 6 seconds to initialize the throttle pedal with the ECM*.

Pedal angle

1. Shut off the engine

Max. 17º

Full range

2. Turn the key to "ON"

3. Fully depress and release the throttle pedal three times. Pedal Angle

4. Turn the key to "OFF".

5V Potentiometer Voltages when plugged in, key "ON"

The throttle pedal and ECM* have now been initialized or calibrated. The engine may be restarted and retested for proper performance.

Between terminal 47 (YV-B) and 49 (BLg-W) Refer to circuit diagram for details.

4 3 2

Using the Quantum fault code information section the following fault codes may indicate a non-initialized throttle pedal:

1 0.66 V 0

0 Pedal Angle

K90ZV62007

95ZV EX 62-43 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit (S/N 0101~0358, 9001~)

Transmission Control Circuit and Monitor Circuit (S/N 0101~0358, 9001~) Controller

LED'S for inputs or outputs

E1 9

E2 5

20 19 18 17 16 15 14 13 12 11 10

E3 4

18 17 16 15 14 13 12 11 10 9 12 11 10 9

6 115ZV62061

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. Note 1. The couplers are shown for controller side. 2. Connector symbols correspond to symbols in the wiring diagram.

95ZV EX 62-44 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit (S/N 0101~0358, 9001~)

LED inspection windows Connector E1 (Input) IN (Input signal) Symbol

Signal

OUT (Output signal) Symbol

Signal

No.

Symbol

Signal

No.

Symbol

Inching switch (+)

Shift lever 3 (+)

Signal

Shift lever position F

Controller failure

Failure history reset

Shift lever 2 (+)

Shift lever position R

Back relay ON

Vibration damper (OPT)

Parking switch (+)

Shift lever position 1

Modulator valve 2 ON

Shift lever 1 (+)

Shift switch (+)

Shift lever position 2

Low clutch solenoid valve ON

Shift lever R (+)

Shift lever F (+)

Shift lever position 3

High clutch solenoid valve ON

Engine speed sensor (+)

Failure history call

For switch input (-)

Shift lever position A

Reverse clutch sol. valve ON

COM

Engine speed machine speed (-)

Auto shift cancellation

Buzzer

Machine speed sensor (+)

SSG

Press diff. sensor signal

Shift switch ON

Neutral relay ON

GND

Power for press. diff. sensor

Parking switch OFF (Running position)

BRK

Auto brake sol. valve ON

Shift lever A (+)

+24V

Inching switch ON

1st clutch sol. valve ON

Emergency steering

2nd clutch sol. valve ON

Sl1

Spare

3rd clutch sol. valve ON

Connector E2 (Output)

Connector E3 (Output) No.

Symbol

4 (right) lamp

3rd clutch sol. valve

3 (right) lamp

2nd clutch sol. valve

2 (right) lamp

1st clutch sol. valve

1 (right) lamp

PC+

Modulator valve 1 (+)

4 (left) lamp

Buzzer

3 (left) lamp

Reverse clutch sol. valve

2 (left) lamp (-)

High clutch sol. valve

ESO

Emergency steering (output)

Low clutch sol. valve

ESI

Emergency steering (input)

Modulator valve 2

SI1

Spare

BRK

Auto brake solenoid valve

PC-

Modulator valve 1 (-)

Solenoid valve (-)

No.

Symbol

Signal

11 12

SO1

Vibration damper relay (OPT)

Auto lamp

Auto brake lamp

Neutral lamp

Controller failure relay

Back-up relay

Neutral relay

Signal

95ZV EX 62-45 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit (S/N 0101~0358, 9001~)

Controller connection diagram CIRCUIT PROTECTOR

ACC’ L

10A

7A CP

(L)

F13 (L)

MODULATOR VALVE 2

(BY) 1

(Gy)

(GyG)

LG LO

(GyL)

(LgL)

SPEED

(SbO)

E/G REVOLUTION

(L)

CONTROLLER FAILURE RELAY

(L)

NR X

(SbP)

PRESS.DIFF. SENSOR

(YR) (YB)

YGy LB

(YBr) (YG)

(GR)

(LY)

INSTRUMENT PANEL MONITOR

(YL)

(LP)

AUTO

(YL)

(LG)

E/G OIL PRESS.

GyG

E/G WATER TEMP.

(S/N 231~, 9011~) (S/N ~230, E/G WATER TEMP. ~9010) T/M OIL TEMP.

LgL SbO

AIR CLEANER [SbR]

T/M OIL FILTER

RADIATOR WATER LEVEL

ALTERNATOR TERMINAL R FUEL LEVEL SENSOR

1/2

1/4

YBr

1/4

1/8

EMPTY

SbR

(O)

QUAD SHIFT S/W

3/4

EMERGENCY STEERING

(S/N 9081~)

F13

(LO)

(LW)

(BY)

(GY)

AB F3

FAILURE HISTORY RECALL

FAILURE HISTORY RESET

SbR

(Y)

(R)

(S/N 9081~)

BRAKE OIL PRESS. (MAIN)

GyL

LgBr

LgW

(LB)

PARKING S/W [SbY]

GyG

LgBr

YW RR

SbY

BUZZER

LgB

NEUTRAL RELAY

(GO)

(Sb)

LgR

SPPC (MV1)

BACK-UP RELAY

23A

(GyB)

(SbY)

Y LB

MODULATOR VALVE 1

R N F (BY)

DC (MV2)

LBr

SHIFT LEVER

LBr

CENTRAL ALARM

T/M CONTROLLER

T/M CLUTCH SOLENOID VALVE

(L)

ACC’

PARKING SOLENOID

(Lg)

MONITOR CONTROLLER

STEERING PRESS. S/W

ES YGy

M1 M2

FRONT PARKING SOLENOID ON

(L)

REAR PARKING SOLENOID

OFF ON

(SbW)

(Lg)

F13

LgG

OFF

(GO)

PARKING S/W MONITOR CONTROLLER

AUTO BRAKE SOLENOID

(BY) (LgR)

LLg

F13

(Lg)

(LgY)

T/M CUT OFF T/M CONTROLLER FAILURE

CENTRAL ALARM

T/M CUT OFF S/W

(LgW)

(GyB)

(For Europe specification)

INCHING S/W (DECLUTCH)

MONITOR CONTROLLER

CONTROLLER FALURE RELAY CONTACTS

K95V62001

95ZV EX 62-46 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit (S/N 0101~0358, 9001~)

Controller function Forward/reverse (F/R) shifting and speed change From T/C pump

LED (Indication: F) Shift lever

Shift switch

LED (Indication: F)

H R

(For input detection)

LED (Indication: S)

Surge suppression diode (incorporated in solenoid valve)

Modulation mechanism

To solenoid valve bank

Clutch piston 2

Speed sensor Engine speed sensor

LED (Indication: 2)

7 segment LED (Indication: Character) 7 segment LED (Indication: Character)

Drain Common ground

Clutch control solenoid valve energized de-energized

clutch engage clutch disengage

Auto indicator lamp Setting shift lever to A: Switch on

95ZV62037

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.

Input detection 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. Because the shift lever contact is not connected to the R (reverse) input circuit, 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 speed change, the transmission controller judges the set speed position of the shift lever in the same way as described above.

Operation error preventive function (Simultaneous input of two or more commands) If both the forward and reverse commands are input at the same time due to a problem, the forward and reverse clutches will not function. In addition, if two or more speed commands are input at the same time, all speed output command comes to OFF. As a result, no speed clutches will function. Since two conflicting input LED's will be on at the same time, troubleshooting is easier.

95ZV EX 62-47 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit (S/N 0101~0358, 9001~)

Shift lever

KNIGHT BEAM CO,LTD BM51-111 JAPAN >PAMXD6-G50<

Forward F

Neutral N

Reverse R

1st speed 2nd speed

3rd speed Auto

Grounding for speed change side (B) 1st speed (GW)

2nd speed (GL)

Auto (G)

3rd speed (GY)

F (GR)

Unused

R (GB)

Grounding for F/R side (BY)

70ZV62025

1. Bracket assembly 2. Grip 3. Connector

Operator controlled shifting from 2  1  2 in either “2” or “A” is done by momentarily depressing the QUAD switch on the boom 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.

Shift lever neutral (N) position The shift lever has no neutral (N) contact. Therefore, if neither the forward nor the reverse (F and R) signal is input, the controller will judge that the shift lever is at the neutral (N) position.

95ZV EX 62-48 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit (S/N 0101~0358, 9001~)

Automatic shift

Operation of solenoid valve

Clutch solenoid valve (Common to L·H·R·1·2·3)

10 N-m (1 kgf-m)

Shift up Shift down

Speed

4 Negative side

Positive side

3 2

39.2 N-m (4 kgf-m) 13.5 11.5 Reverse

10 12

Speed km/h

17 20 Forward (Approx. speed)

Automatic shift map (standard set value) K95ZVE62004

Machine speed LED

E/G rev. LED

Solenoid valve (with built-in diode) Rated voltage

DC 24 V

Coil resistance value

Approx. 24 

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 transmission is set to neutral.

T/M controller

Machine speed

Displayed font E/G rev.

95ZV62035

When the shift lever is set to A, the AUTO indicator lamp in the cab will light and one of the 2nd through 4th speed solenoid valves will be automatically energized according to the machine speed. In addition, the speed indicator lamp will light. The input signal for automatic shift is controlled by the pulse generated by the speed sensor. While the speed sensor is transmitting the pulse, the “SS” LED indicator flashes according to the pulse.

95ZV EX 62-49 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit (S/N 0101~0358, 9001~) 7 segment LED indication Indication

Machine speed (km/h) 32

E/G rev. (rpm)

160

320

480

640

800

960

1,120

1,280

1,440

1,600

1,760

1,920

2,080

2,240

2,400

95ZV EX 62-50 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit (S/N 0101~0358, 9001~)

Machine speed sensor

Clearance adjustment 0.17~1.3 mm (0.007~0.052 in) K95ZV62004

Internal resistance *

2.3±0.2 k (25 ºC) (77 ºF)

* Internal resistance changes greatly with temperature. At lower temperature resistance is lower. At operating temperature the resistance increases. If resistance is 0  or   the speed sensor is defective.

Sensor location Engine speed sensor

The detector is adjacent to the transmission output gear. The pulse voltage is transmitted to the transmission controller. Note To prevent electronic “noise” from other sources that may corrupt signal, “twist” the wire from sensor all the way to the T/M controller.

IMPORTANT Make sure to check the adjusted clearance when replacing the sensor. Shims are available to adjust clearance as needed.

Machine speed sensor 95ZV62042

95ZV EX 62-51 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit (S/N 0101~0358, 9001~)

Switching from automatic to manual

QUAD (downshift) switch operation QUAD (downshift) switch

CNA

T/M controller Dip switch

115ZV62045

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. DIP switch This switch is provided on the board for setting properties of the T/M controller. This switch is not used frequently. This switch is usually used for settings which rarely change after being set.

80ZVE62017

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 move the shift lever to neutral or to the opposite direction, the speed will be changed to the 2nd again. Note that when the speed is shifted, the “S” LED indicator of the controller will momentarily light (blink). QUAD switch

When the T/M controller cover is removed, this switch can be seen in the position shown to right. YL

70ZV62031

Allowable value

Max. voltage

DC 24 V

Current

10 mA

The QUAD switch is of the momentary type. It is spring loaded to the “OFF” position.

95ZV EX 62-52 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit (S/N 0101~0358, 9001~)

Modulation at clutch switching Input side

Shift lever

4 3 2

Clutch selection input signal

Output side

T/M controller

Press. diff. sensor

+ 24 V

Output current control

ON during modulation

+ 24 V

Modulator valve (1) No output LED is provided

Modulator valve (2) Output LED (Indication: DC)

E/G speed sensor Machine speed sensor 95ZV62043

Press. diff. sensor

Modulator valve (2)

Modulator valve (1) Press. diff. sensor

To T/M clutch To T/C

Modulator valve (1) From pump 115ZV62064

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 unit hydraulic circuit

115ZV62065

95ZV EX 62-53 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit (S/N 0101~0358, 9001~) - Initial charging (t1)

Modulator valve (1) [MV1] 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.

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. - 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.

Operation of modulator valve (1), (2) and clutch pressure change. Clutch selection

- Completion of the charging ON Low clutch sol. OFF valve 1st clutch sol. valve

ON Completion of charging

Modulator valve (1) Current flow (mA)

Approx. 400 mA

Approx. 170 mA

0 Modulator valve (2)

The pressure differential 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. - Pressure rise (t3)

OFF

The clutch oil pressure rises gradually in proportion to the current rise. Main pressure

Pressure MPa(psi)

0 Low clutch pressure Pressure MPa(psi)

95ZV62044

Note - If the MV1 coil is damaged or disconnected, the clutch oil pressure rises only 0.2 to 0.5 MPa (28 to 71 psi) and the pressure value is not enough to engage the clutch. - Transmission controller provides 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.

95ZV EX 62-54 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit (S/N 0101~0358, 9001~) Modulator valve (2) [MV2] This valve assists MV1 in controlling (lowering) the clutch oil pressure. Unlike MV1, it performs an ON and OFF operation. Controlling the clutch oil pressure Modulator valve (2) is energized simultaneously when the current in MV1 changes from high to low current flow. It is de-energized some time after the current in MV1 returns to a higher level and the clutch oil pressure reaches the specified value. Note Modulator valve (2) If MV2 is damaged or disconnected, the machine will have severe shift shock during clutch engagement. In this case, the lowest clutch pressure will be only about 0.7 to 1.0 MPa (100 to 142 psi) during charging. The highest clutch oil pressure reaches the specified value.

95ZV EX 62-55 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit (S/N 0101~0358, 9001~)

Transmission cut off (Declutch) Clutch cut-off switch (located on operator's LH console)

Transmission controller

Forward/reverse clutch solenoid valves

F13

Transmission cut-off

(Indication: I)

BY BY

Pressure switch for inching

95ZV62046

While the transmission cut off switch on the instrument panel is ON, pressing the brake pedal actuates the pressure switch (inching switch), turns off the power of the solenoid valves of the forward/reverse clutches (L, H, R) by way of the T/M controller, and sets the transmission to the neutral status. At this time, the monitor lamp and the controller LED (indication: I) light.

Pressure switch for declutch Pressure switch for stop lamp

When the clutch cut off switch on the instrument panel is set to OFF, the transmission cut off function is disabled and the brake pedal is dedicated to braking. At this time, the monitor lamp on the instrument panel is no longer illuminated.

Left brake valve

K80ZV52013

95ZV EX 62-56 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit (S/N 0101~0358, 9001~)

Pressure switch for inching (declutch) (S/N ~0230, ~9010)

Pressure switch specifications Contact

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

Normally open

Voltage (VDC)

Current (A)

16 17 A

2.3 (MAX.)

Resistance ()

10.4

Operating pressure MPa (kgf/cm2) (psi)

1.1±0.15 (11±1.5) (159±21) 2

Return pressure MPa (kgf/cm ) (psi)

0.9±0.1 (9.1±1.0) (130±14)

View A

14 95ZV62047

1. Case 2. Seal film 3. Packing 4. Disc 5. Inner cover 6. Guide pin 7. Spring 8. Contact 9. Contact

10. Terminal 11. Terminal 12. Base 13. Cover (connector) 14. Guide 15. Stopper 16. Connector terminal 17. Housing seal

(S/N 0231~, 9011~)

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

95ZV52056

1. Case 2. Seal film 3. Packing 4. Disc 5. Inner cover 6. Guide pin 7. Spring

8. Contact 9. Contact 10. Terminal 11. Terminal 12. Base 13. Cover 14. Connector

Pressure switch specifications Contact Voltage (VDC) Current (A) Resistance ()

Normally open 24 3.5 (MAX) 6.9

Operating pressure MPa (kgf/cm2) (psi)

0.5 ± 0.1 (5.0 ± 1.0) (71.1 ± 14.2)

Return pressure MPa (kgf/cm2) (psi)

0.3 ± 0.05 (3.0 ± 0.5) (42.7 ± 7.1)

95ZV EX 62-57 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit (S/N 0101~0358, 9001~)

Back-up alarm +24V F4 15A

+24V

LED

IN Circuit protector +Vcc

+24V

(Indication: R)

Shift lever

4 (A)

3 2

Back-up lights

Back-up relay 3

Back-up buzzer

F13 5A

LED (Indication: RR)

+24V

70ZVE62015

When the shift lever is set to the reverse (R) position, the coil of the back-up (or reverse) relay will be energized, and the main contact will be closed. The back-up lamp, therefore, will light, and the buzzer will sound.

Body black

Back-up relay

Chassis side coupler

Elec. circuit

K95ZV62015

Note This relay is identical to the relays for neutral, horn, head light, E/G water temperature, E/G oil pressure and machine width lamp relay. They may be interchanged for testing purposes.

Shift lever position

Between 1 and 3

Between 2 and4

Lamp and buzzer

Electric power supply

F or N

No electric power supply

OFF

Rating

DC 24 V

Operation voltage

16 V or less

Reset voltage

2.4 V or more

Coil resistance

320 

95ZV EX 62-58 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit (S/N 0101~0358, 9001~)

Parking brake

5A P Parking S/W ON

F13 Monitor lamp

+24 V P Accumulator Parking brake

Running Oil cylinder

Parking OFF ON

+Vcc

OFF

C.P. F5

LED indication: P Monitor controller

L H

10 A

Solenoid valve for parking brake

+24 V

95ZV62121

The parking brake solenoid valve activates the parking brake. Parking switch ON:

Parking switch OFF:

- Drum brake

The power of the solenoid valve is turned off, oil is not sent to the oil cylinder of the parking brake, and the drum brake is applied by the force of the spring built in the cylinder. - Disc brake (For Europe only) The power of the solenoid valve is turned off, and the disc brake is applied by the accumulator pressure. At this time, the input LED "P" turns OFF. When the transmission shift lever is set to the F or R position, buzzer sounds and the clutch is not engaged (emergency start alarm).

The power of the solenoid valve is turned on, oil is sent to the oil cylinder. The pressurized oil will depress the spring in the cylinder to release the drum brake. - Disc brake (For Europe only) The power of the solenoid valve is turned on, the pressurized oil will be discharged from parking disc brake and returned to the oil tank to release the brake. At this time, the input LED "P" lights.

95ZV EX 62-59 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit (S/N 0101~0358, 9001~) Parking brake operation Parking switch

Monitor lamp

Buzzer

Parking brake solenoid valve

LED indicator of controller

Parking *

“Parking” position (pulled up)

Sounds when shift lever is set to F or R

No electric power supply

Input “P” LED indicator: Off

Running

“Running” position (pushed in)

Off

No buzzer

Electric power supply

Input “P” LED indicator: On

*When the parking switch is set to "parking", the forward or reverse clutch is disengaged and set to neutral.

Parking brake solenoid valve

Spring chamber (brake actuator)

Solenoid (S/N 0101~0265, 9001~9065) Knob Solenoid (S/N 0266~, 9066~)

Reducing valve

T Seat face A

Seat face B

Manual release (counterclockwise rotation)

Spool

Tank

Hydraulic circuit diagram

Auto brake solenoid valve

Solenoid valve specifications Valve assembly

Parking brake solenoid valve Hydraulic oil tank Valve location

95ZV62050

Voltage

DC24 V

Current

0.69 A

Resistance

34.8 

K90ZV52012

95ZV EX 62-60 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit (S/N 0101~0358, 9001~) Front parking brake (For Europe only)

To tank

C Passage Z Rod Passage Y

Solenoid

Button for manual release

A To parking brake

A A

Sleeve

B C

Movable iron core Spool

Hydraulic circuit diagram

B From accumulator

95ZV52046

Front parking solenoid valve

Front chassis

Solenoid valve location 95ZV52043

Solenoid specifications Voltage

DC24 V

Current

0.52 A

Resistance

45.9 

95ZV EX 62-61 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit (S/N 0101~0358, 9001~)

Auto brake

Input side

Output side

Shift lever position selector signal

T/M controller

Shift lever

+24V

Solenoid valve for auto brake

LED (Indication: BRK)

Auto brake monitor lamp, buzzer

Machine speed

+24V

Machine speed sensor

Solenoid valve for forward/reverse clutch

H R

Installation position of solenoid valve for auto brake. Refer to the description on the solenoid valve for parking brake.

95ZV62053

Shown in the "released" position

To rear service brake (S/N 0101~0164, 9001~9010)

31 A C B

23 Pi

1.2 1.0 B

From unloader valve (Pump)

T/M controller signal

From reducing valve (Pump)

When the traveling direction is switched over between forward and reverse at a machine speed of 12 km/h (7.5 mph) or more, the auto brake is applied to protect the transmission clutches. When the machine speed is too high, the auto brake is applied also to prevent troubles caused by excess speed in the engine and the transmission. When the auto brake signal enters from the T/M controller to the solenoid valve for auto brake (27) and the solenoid valve (27) is energized and magnetized, the pilot oil from the reducing valve enters the pilot port of the left brake valve (23) through the shuttle valve (31), and actuates the pilot piston and the spool of the brake valve. When the spool is switched over, the high-pressure oil coming from the pump through the unloader valve and the reducing valve enters the front and rear brake piston chambers to apply the service brake. At this time, the BRK LED and the monitor lamp on the instrument panel light, and buzzer sounds. While the auto brake is applied, the forward/reverse clutches of the transmission are disengaged and kept in the neutral status until the actual machine speed decreases and reaches the set value.

K95ZVE52006

95ZV EX 62-62 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit (S/N 0101~0358, 9001~) When the traveling direction is switched over between forward and reverse at a machine speed of 12 km/h (7.5 mph) or more

When machine speed is excessive

Operation chart (Example: Shifting from forward to reverse)

Machine speed

Machine speed Shifting between 3 km/h forward and reverse (1.9 mph)

Machine speed 2 km/h (1.25 mph)

Operation chart (Example: Machine speed excessive in forward direction)

F solenoid valve

Speed clutch solenoid valve Brake solenoid valve OFF Monitor lamp

ON OFF T/M in neutral

ON OFF

Machine speed

F solenoid valve

T/M in neutral

Service brake operating

115ZV62067

OFF

R solenoid valve Brake solenoid valve OFF Monitor lamp

When the machine speed reaches or exceeds the set value, the service brake is applied as in the above case. When the machine speed drops below the specified value, the service brake is released.

ON OFF

During service brake application, the transmission is placed in neutral.

Service brake operating

115ZV62066

When the traveling direction is switched over between forward and reverse while the shift lever is in the position A, the power of the solenoid valve for auto brake turns on and the service brake is applied until the machine speed is reduced to 3 km/h (1.9 mph). At the same time, the power of all solenoid valves for forward/ reverse clutches is turned off, and the transmission is set to the neutral position. When the machine speed reaches 3 km/h, the power of the solenoid valve for auto brake turns off and the clutch for the opposite direction is engaged. (However, the brake remains applied until the machine speed becomes approximately 2 km/h (1.25 mph) because oil discharge is delayed.) While the shift lever is not in the position A, the auto brake function is disabled even if the traveling direction is switched over between forward and reverse.

Speed range

Set value

1st

About 15 km/hr

9.4 mph

2nd

About 22 km/hr

13.8 mph

About 36 km/hr

22.5 mph

3rd 4th

95ZV EX 62-63 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit (S/N 0101~0358, 9001~) Auto brake solenoid valve Brake valve (shuttle valve)

Reducing valve

Spool

(S/N ~0265, ~9065)

Seat face A

Tank

Seat face B

(S/N 0266~, 9066~)

Solenoid

P T Hydraulic circuit diagram

K115ZV52016

Auto brake solenoid valve Valve assembly

Parking brake solenoid valve Hydraulic oil tank Valve location

Solenoid specifications Rated voltage

DC24 V

Rated current

0.69 A

Resistance

34.8 

95ZV62050

95ZV EX 62-64 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit (S/N 0101~0358, 9001~)

Transmission controller failure warning

Controller fault relay

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

If a warning is given as a result of self-diagnosis of the transmission controller

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.

Elec. circuit (normally closed)

If the monitor lamp lights up under the cause 1 above, it is an indication that the transmission controller's program has malfunctioned and the transmission controller assembly must be replaced. If the monitor lamp lights up under the cause 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".

Chassis side coupler

K95ZV62016

Rating

Replacement of the transmission controller

LgW

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 LED on the output circuit side of the controller will not be lit. Some input LED may still be operating (ON).

Body blue

DC 24 V

Operation voltage

16 V or less

Reset voltage

2.4 V or more

Coil resistance

320 

95ZV EX 62-65 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit (S/N 0101~0358, 9001~)

Emergency steering function (for Europe spec only) When the steering hydraulic pressure goes down while the engine is running, the pressure switch is turned on. Then the input signal is sent to the transmission controller.

Ground

As a result, the emergency steering relay turns on, and the emergency steering motor and pump is driven. Then it is ready to steer the machine. Pressure switch (B contact) preset value Steering hydraulic pressure ON: at 0.4 MPa (4 kgf/cm2) (58 psi) or lower

Pressure switch

To monitor controller

To operation stand

Fuse box

Emergency steering pump T/M controller Input

Ground

Relay Output (lamp, relay)

Output (Solenoid valve)

Operation stand Monitor controller Monitor controller

Floor harness Operation stand Above the floor board Below the floor board Pressure switch K95ZV62012

Battery Pump assy (R. H) Motor relay Pump assy (L. H)

Motor relay

Battery relay

Battery

K95ZVE62005

95ZV EX 62-66 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit (S/N 0359~)

Transmission Control Circuit and Monitor Circuit (S/N 0359~) Machine control unit (MCU)

To S1

To S2

To S3

To S4

To S5

85V2E62041

95ZV EX 62-67 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit (S/N 0359~)

Connector

MCU

To S1

To S2

To S3

To S4

To S5

C 1.2S_SE C 2.DSUB2 C 3.DSUB4 C 4.BSLC 5.TT C 6.AC C 7.ET C 8.BL C 9.BD C10.DSUB1 C11.DSUB3 C12.DR C13.BSL+ C14.TF C15.WL

C16.EP C17.F C18.ASUB1 C19.ASUB2 C20.1/2 C21.1/8 C22.2S C23.EG_H C24.IP_SW C25.FR C26.KO_P C27.ES_SE C28.3/4 C29.1/4 C30.DC

MCU A 1.2S_SO A 2.2_SO A 3.ES_R A 4.DD_SO A 5.3_SO A 6.HM A 7.LU_SO A 8.4_SO A 9.OTH_OUT A10.R_L A11.F_L A12.ST_L A13.WL_L A14.CW_L A15.ET_L

A16.TT_L A17.D_SO A18.1_SO A19.EP_L A20.AB_L A21.A_L A22.1/2_L A23.E_L A24.FR_L A25.SC_SW A26.TF_L A27.AC_L A28.BP_L A29.N_L A30.SC_L

A31.1/4_L A32.SS_L A33.3/4_L A34.EG_SW1 B 1.H_SO B 2.PWM_SO B 3.IP_SO B 4.R_SO B 5.MO_SO B 6.FR_SO B 7.SSL_SO B 8.BSL_SO B 9.BZ B10.BSL_R B11.KO_R

A10

A11

A12

A13

A14

A15

A16

A17

A18

A19

A20

A21

A22

A23

A24

A25

A26

A27

A28

A29

A30

A31

To S1

A32

A33

A34

B12.X_R B13.F_SO B14.B_SO B15.EG_SW2 B16.RIN1 B17.OUT_MD2 B18.N_R B19.BR_L B20.CAN_R1 B21.CAN_R2 B22.DOUT1 B23.OUT_FEW B24.MT B25.ET_SE B26.TXD1

B10

B11

B12

B13

B14

B15

B16

B17

B18

B19

B20

B21

B22

B23

B24

To S2

B25

B26

E 1.SSR_SO E 2.FC_SO E 3.KEY E 4.KEY E 5.GND E 6.GND E 7.GND E 8.GND E 9.+5V E10.TGEG E11.KEY E12.KEY E13.CANH1 E14.EGR2 E15.EGR1

E16.SPD E17.BATT E18.CANL1 E19.SS_P E20.CANLO E21.TM_M E22.B_SE2 E23.WT_SE E24.ALT E25.RXD1 E26.TGSP E27.INCH_SE E28.SC_P E29.CANHO E30.B_SE1

E31.TT_SE E32.OT_SE E33.OUT_RSE E34.ET_M

E10

E11

E12

E13

E14

E15

E16

E17

E18

E19

E20

E21

E22

E23

E24

E25

E26

E27

E28

E29

E30

E31

E32

E33

To S3 Connector details

E34

C31.BSL C32.EG_M C33.DD_S C34.AFR D 1.PRK D 2.AM_SW D 3.SL_2 D 4.SL_R D 5.SL_3 D 6.S_UP D 7.S_DOWN D 8.EG_SW D 9.M_SW D10.SL_1 D11.SL_F

C10

C11

C12

C13

C14

C15

C16

C17

C18

C19

C20

C21

C22

C23

C24

C25

C26

C27

C28

C29

C30

C31

To S4

C32

C33

C34

D12.SL_A D13.SS_N D14.KD D15.INCH_S D16.OD_SW D17.SH D18.SS_SW D19.SS_F D20.TMP D21.INCH D22.KO_S D23.SC D24.AR D25.SM_SW D26.SS_R

D10

D11

D12

D13

D14

D15

D16

D17

D18

D19

D20

D21

D22

D23

D24

D25

D26

To S5

85V2U62009

95ZV EX 62-68 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit (S/N 0359~)

Machine control unit (MCU) connection diagram (S/N 0359~0476) ACC’

E F5 10A

(L)

L, (L) G

F10

PARKING S/W

L E17 LR

ACC’

F N R

23A

LO LG LY

PARKING SOL. LgG

OFF ON OFF

(SbW)

(Lg)

(YL)

SHIFT S/W F13

LLg

(L )

(GyW )

RIDE CONTROL S/W AUTO / MANUAL SELECTION

A BrB M

T/M MODE SELECTION

BrY

LLg

DECLUTCH (LgY)

(Lg)

F13

D04

D12 D03

1ST SPEED SOLENOID VALVE 2ND SPEED SOLENOID VALVE

A05 LO

3RD SPEED SOLENOID VALVE

A17 LP

D SOLENOID VALVE

D14

B14

D01

A04

D21 B05

RIDE CONTROL SOLENOID VALVE

YV LgR

LgR

MODULATION VALVE

C33

B18 (SbP )

C04

C12

AUTO BRAKE SOLENOID VALVE

(L)

LgW

NEUTRAL RELAY CONTROLLER FAILURE RELAY

(L) F13

C11

(Lg)

B11 (LB )

BACK LAMP RELAY

C13 BrW BrR

[SbY]

BRAKE OIL PRESS.

SbY

BRAKE OIL PRESS. DIFF. S/W

C22 C23

E/G OIL LEVEL S/W

C02

C03 Gy GyG

E/G COOLANT TEMP. S/W

GyL

T/M OIL TEMP. S/W [SbR]

T/M OIL FILTER S/W

SbO LgL

AIR CLEANER CLOGGING S/W

RADIATOR WATER LEVEL S/W

STEERING OIL PRESS. S/W

FUEL LEVEL F

FUEL LEVEL 3/4

FUEL LEVEL 1/2

YBr

FUEL LEVEL 1/4

FUEL LEVEL 1/8 YW

T/M PRESS. DIFF. SENSOR

ECM (11)

MACHINE SPEED SENSOR

Y WL

ALTERNATOR

C07 C05 C14 C06 C15 C08 C17

(GL)

CENTRAL WARNING LAMP

A28 (LgY)

A19 (Gy) A15 (GyG) A16 (GyL)

BRAKE OIL PRESS. WARNING LAMP E/G OIL PRESS. WARNING LAMP E/G COOLANT TEMP. WARNING LAMP T/M OIL TEMP. WARNING LAMP

A26 (SbO)

T/M OIL FILTER WARNING LAMP

A27 (LgB)

AIR CLEANER WARNING LAMP

A13 (Sb)

RADIATOR WATER LEVEL WARNING LAMP STEERING OIL PRESS. WARNING LAMP

C20

A24 (LY)

1ST SPEED INDICATION LAMP

C29

A25 (LG)

2ND SPEED INDICATION LAMP

A30 (LO)

3RD SPEED INDICATION LAMP

C19

A34 (LW)

4TH SPEED INDICATION LAMP

E15

A11 (YR)

E16

A33 (YB)

E08

A22 (YL)

FUEL LEVEL 1/2

E24

A31 (YBr)

FUEL LEVEL 1/4

A23 (YG)

FUEL LEVEL E

B09 (LgBr)

BUZZER

C28

C21

FUEL LEVEL F FUEL LEVEL 3/4

E29

(GW)

CAN_L

AUTO BRAKE LAMP

A14 (GyB)

A12 (O)

F13 (Lg)

AUTO SHIFT INDICATOR LAMP NEUTRAL INDICATOR LAMP

A20 (GY)

C16

E09 YGy

A21 (LgR) A29 (GR)

C09

E/G OIL PRESS. S/W

CAN_H

R SOLENOID VALVE

A18 LY

C10

FR23 SELECTION F34 SELECTION

MODM

H SOLENOID VALVE

D10

D02

E20

E TXD

RS-232C

RXD GND

B04 LBr

D05

Note Refer to Section 92 for the detailed electrical connection diagram for the controller (MCU) including modification information.

F SOLENOID VALVE

B01 LW

B12

MODEL SELECTION 1 MODEL SELECTION 2 MODEL SELECTION 3 MODEL SELECTION 4

(LgR)

DECLUTCH S/W

A02 LG

B13 D11

SHIFT LEVER

LBr

GR GL (BY)

B22 B16 E7

B24

MCU

(WL)

TACHOMETER

95ZVE62090

95ZV EX 62-69 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit (S/N 0359~)

Machine control unit (MCU) connection diagram (S/N 0477~) ! $

% '

* % '

! $

)

% '

! " ! " " ! ! % ( ' " !

! " 1 &

/" 0

& % # '

" 0 ! 0 ! ! "

/ " ! % & ' " ! !" ! "

% & '

% '

% & '

/ 0

% '

!" !

, ( -

(

! "! ! 0 " " 1 0

% 0 3'

0+ #

% '

! " 1 ! " !

! % #'

0 " 1 ! " ! 0 ! 1 ! " ! 0 " 1 ! " ! 0 " " ! " ! !" ! ! " ! ! "! ! ! " ! " " 1 ! " ! " " ! " ! " " ! " !

! % # ' ! % # ' ! % ( ' ! % & ' ! % (' ! % ' ! ) % ' ! % ' ! % '

! % '

)

! % '

% ' % '

% '

! ! !

! + % & '

! ./ ! .

! /" " " ! ! ! " " ! ! ! ! " !

! /"

" " ! " ! ) / " " ! " !

% '

! %

0) 0 0)

! ! !

% &'

! ) % # '

% &'

% '

! % ' ! %

! " ! ! ! !" !

% '

! " !

! ) % '

! ! " ! " " !

+ % ( '

Note Refer to Section 92 for the detailed electrical connection diagram for the controller (MCU) including modification information.

0) 0 0) 0+ 0 1 " 1

" !

! % & '

( ) &

" 0

0 " 1 0 0 " " 0

" !

% & '

0 ! 1 0

" !

& & !

" ) "

" !

! +

)

0 " 1 0

/ " !

)

(

" !

)

0 " " " " " )

, ( -

! )

! " 1

! " 1 " 1 0 0 " 0

)

! " 0

) % '

! /

! "

95ZV EX 62-70 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit (S/N 0359~)

Machine control unit (MCU) failure warning Should the MCU stop working due to the following cause, a dash mounted monitor lamp lights up to give warning. MCU failure monitor lamp

If a warning is given as a result of self-diagnosis of the MCU

If the monitor lamp lights up under the cause above, it is an indication that the MCUÅfs program has malfunctioned and the MCU assembly must be replaced. When installing a new MCU on the machine, all specifications must be registered into the MCU through the MODM.

Elec. circuit

LgW

MCU replacement

LgW

The MCU has a self-diagnosis function incorporated in it, and if the computer program becomes abnormal due to abuse or defect, a dangerous condition may occur, the monitor lamp lights up and all the outputs from the MCU are turned OFF.

Body blue

Chassis side coupler

K95ZV62016

MCU fault relay (Normally closed) Rating

DC 24 V

Operation voltage

16 V or less

Reset voltage

2.4 V or more

Coil resistance

320 

95ZV EX 62-71 62 Function & Structure Electrical Group Monitoring System (S/N 0101~0358, 9001~)

Monitoring System (S/N 0101~0358, 9001~) Monitor controller

Connector (E5) (Input) Sym bol

Signal

No.

Sym bol

Alternator voltage

Fan 2-step relief solenoid valve

Steering oil press. sw. (opt)

Central alarm sw.

1/8

Fuel level (1/8)

1/8

Fuel level lamp (1/8)

1/2

Fuel level (1/2)

1/2

Fuel level lamp (1/2)

—

Fuel level lamp (F)

Connector

Connector pin layout E5

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

11 10 9 8 7 6 5 4 3 2 1

26 25 24 23 22 21 20 19 18 17 16 15 14

22 21 20 19 18 17 16 15 14 13 12

T/M oil filter sw.

E/G water temp. sw.

E/G oil press. sw.

*The couplers shown are for controller side.

Connector (E6) (Output)

No.

—

Signal

— T/M oil filter alarm lamp

Water temp. alarm lamp

E/G oil press. alarm lamp

Brake oil press. alarm lamp

95ZV62058

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.

Parking sw.

Memory call

—

DC24V

—

DC24V

Buzzer

—

EMP

Fuel level lamp (E)

—

1/4

Fuel level lamp (1/4)

3/4

Fuel level lamp (3/4)

EMP

Fuel level (E)

1/4

Fuel level (1/4)

Emergency steering lamp (option)

3/4

Fuel level (3/4)

E/G water level alarm lamp

E/G water level sw.

Air cleaner alarm lamp

Air cleaner sensor

T/M oil temp. alarm lamp

T/M oil temp. sw.

—

Fan 2-step relief solenoid valve

—

Brake oil press. (Main) sw.

Memory reset

—

GND

—

GND

95ZV EX 62-72 62 Function & Structure Electrical Group Monitoring System (S/N 0101~0358, 9001~)

Monitor controller connection diagram

ACC’ (BR)

E F5

10A F13

(L)

PARKING SOLENOID

CP (Lg)

(L)

ACC’

CENTRAL WARNING LAMP

(GyB)

(GO)

PARKING S/W

SbY

(Gy)

INSTRUMENT PANEL MONITOR LAMP

(GyG) (GyL)

BRAKE OIL PRESS. (MAIN)

MONITOR CONTROLLER

(SbY)

[SbY]

GyG

E/G OIL PRESS.

GyG GyL

(LgL)

LgL

(SbO)

SbO

(Sb)

TO T/M CONTROLLER

(S/N 0231~, 9011~)

E/G WATER TEMP.

(S/N ~0230, ~9010)

T/M OIL TEMP. AIR CLEANER [SbR]

T/M OIL FILTER RADIATOR WATER LEVEL

BUZZER LgBr

E/G WATER TEMP.

ALTERNATOR TERMINAL R FUEL LEVEL SENSOR

(YR)

F (YB) 3/4 (YL)

FUEL LEVEL INDICATOR LAMPS

3/4

1/2

1/2 (YBr)

1/4

YBr

1/4 (YG)

1/8

E (O)

EMPTY

SbR F13 D R

(S/N 9081~) FAILURE HISTORY RECALL (DIAGNOSTIC) FAILURE HISTORY RESET

SbR (Y)

TO T/M CONTROLLER

(R)

(For Europe market only)

K95V62002

95ZV EX 62-73 62 Function & Structure Electrical Group Monitoring System (S/N 0101~0358, 9001~)

Monitor controller function If a problem of a unit is detected while the engine is running, a monitor lamp lights to inform the operator. For some problems, the buzzer sounds also, and the central alarm lamp flashes also.

When the starter switch is set to ON, all of the monitor lamps are lit for 3 seconds and buzzer sounds to check whether the monitor lamps are normal (not burn out).

Items to be monitored and operation condition No.

Item to be monitored

Monitor lamp Lighting color

Controller (red)

Brake oil pressure (red)

Engine oil pressure (red)

Torque converter oil (transmission) temperature

Engine water level

Auto brake operation

While engine running 0.1 MPa (1.0 kgf/cm2) (16 psi) or less

—

(red)

Filter resistance: 635 ± 58 mmAq or more (25 inches H2O)

—

(red)

Pressure difference at 50 ± 2 ºC (122 ± 4 ºF) or more 0.3 MPa (3.15 kgf/cm2)(45 ± 4 psi) or more

(red)

When operates steering under the steering pressure less than 0.4 MPa (4 kgf/cm2) (57 psi)

Steering oil pressure (option)

Remarks

Unloader valve accumulator port oil pressure 3.9 ± 0.5 MPa (40 ± 5 kgf/cm2) (569 ± 71 psi)

120 ± 5 ºC or more (248 ± 9 ºF or more)

(red)

Lamp test

Defective controller (CPU) Control Processor Unit

—

Clogged air cleaner

Clogged transmission oil filter

Buzzer

101 ± 2 ºC or more (214 ± 4 ºF or more)

Engine water temperature (red)

Operation condition

Symbol

When E/G water level drops (before start up only)

—

When auto-brake works (red)

Centralized alarm

For items 1-8

—

Flashing type

(red) 12

Engine protection lamp

— (orange)

Engine warning lamp (yellow)

Engine stop lamp

Any fault in engine detected by ECM (Engine controller)

— (2 sec.) —

(red)

95ZV EX 62-74 62 Function & Structure Electrical Group Monitoring System (S/N 0101~0358, 9001~)

Operation monitor lamps Monitor lamp No.

Monitor item

Lighting color

Lighting condition

Remarks

Symbol

Parking

Red

When parking brake switch is set to ON

Transmission cut off

Green

When transmission cut off switch is set to ON

Working light

Green

When working light (rear) switch is set to ON

Turn signal indicator (left)

Green

When turn signal lever (left) is actuated

Turn signal indicator (right)

Green

When turn signal lever (right) is actuated

High beam

Blue

When head lamp is set to high beam

Auto shift

Green

When transmission shift lever is set to automatic position

Neutral

Green

When transmission shift lever is set to neutral position

Transmission status

Yellow

When transmission shift lever is set to corresponding gear (1~4)

Vibration damper

Green

When vibration damper switch is set to ON

For declutch

(OPT)

Caution on storage of individual instrument panel

IMPORTANT

Gauge pointer

Pointer axis Axis hole

When storing the instrument panel individually, make sure that the panel face (transparent face) faces upward. If the panel face faces below the vertical direction, the damper oil may leak from meter pointer axis holes.

Main body frame

Meter

Damper oil

Magnet 70ZV62039

95ZV EX 62-75 62 Function & Structure Electrical Group Monitoring System (S/N 0101~0358, 9001~)

Monitor sensor & switch

T/M oil filter clogging switch

Air cleaner clogging switch

(S/N 0101~0230, 9001~9010)

Indicator

Air cleaner

Torque converter

K95ZV62005

K115ZV62012

Set value

(S/N 0231~0238, 9011)

Resistance: 635±58 mmAq or more

Continuity established across terminals

Engine water temperature alarm sensor Set value

101±2ºC (214±4ºF) or more

Torque converter

Continuity established across terminals C and NO K95ZV62006

Transmission oil temperature alarm switch (S/N 0239~, 9012~) Set value

120±5ºC (248±9ºF) or more

Continuity established across terminal and body

Transmission oil temperature switch Set value

50±2ºC (122±4ºF) or more

Continuity established across both terminals Torque converter

Engine water level alarm sensor Set value

Full radiator water level K95ZV62007

No continuity established across terminal and body

Refer to "Sensor Mount" page 62-10 for the location of these switches and sensors.

Set value

0.3 MPa (3.15 kgf/cm2) (45±4 psi) or more

Continuity established across terminal and body

95ZV EX 62-76 62 Function & Structure Electrical Group Instrument Panel and Switch

Instrument Panel and Switch Instrument panel (S/N 0101~0476, 9001~)

22 6 21 7 2

12 13

33 0 0 0 0 0 0 1/10h

AUTO

14 42

3 0

30 x100r/min

2 1

STOP

16 17 18 19

25 9

K95ZVE62007

1. Tachometer 2. Engine coolant temperature gauge 3. Torque converter oil temperature gauge 4. Fuel gauge 5. Central warning lamp 6. Parking brake indicator lamp 7. Auto brake indicator lamp 8. Transmission cut-off (declutch) selection indicator lamp 9. Working light indicator lamp (rear) 10. — 11. Controller warning lamp 12. Brake oil circuit warning lamp 13. Engine oil pressure warning lamp 14. Engine coolant temperature warning lamp 15. Torque converter oil temperature warning lamp 16. Air cleaner clogging warning lamp 17. Charge warning lamp 18. Transmission oil filter clogging monitor lamp 19. Engine coolant level warning monitor lamp 20. Turn signal indicator lamp (left) 21. Turn signal indicator lamp (right)

22. High beam indicator lamp 23. Auto shift indicator lamp 24. Neutral indicator lamp 25. Transmission status monitor 26. Hour meter 27. — 28. Engine stop lamp 29. Engine warning lamp 30. Engine protection lamp 31. Ride control selector indicator lamp (option) 32. Steering circuit error warning lamp (option) 33. Working light switch (front) 34. Working light switch (rear) 35. — 36. — 37. Emergency flasher indicator lamp switch 38. Transmission cut-off (declutch) selector switch 39. Ride control switch (option) 40. Cold starter switch 41. — 42. Economy switch

95ZV EX 62-77 62 Function & Structure Electrical Group Instrument Panel and Switch (S/N 0477~)

23 20 22 6 5 7 8 9 21 2

3 14 15 16 17 18 19

28 29 30

4 K95ZV62018

95ZV EX 62-78 62 Function & Structure Electrical Group Instrument Panel and Switch

Instrument panel rear surface (S/N 0101~0476, 9001~)

CN4 L11

L1 L2

CN1

58 57

Engine water temperature sensor

Transmission oil temperature sensor

Tachometer

L19

E L10

L18

L10

56 L10

L21

L17 V

16P

L16

S V

12P L10

L15

CN3

L20

L14

L10

Hour meter

L10

L13

L12

CN2

L22

L23

L24

L25

L26

L27

20P 19

Layout of connector pins (Instrument panel side) CN1(8P)

1 2 3 4 5 6 7 8

Pin No.

9 10 11 12 13 14 15 16 17 18 19 20 22 23 24 25 26 27 28

29 30 31 32 33 34 35 36 37 38 39 40

CN2(20P)

Signal

CN3(12P/16P)

Pin No.

Signal

Lamp No.

Pin No.

—

Engine water level alarm

Charge lamp

Air cleaner clogging alarm

T/M oil temperature alarm

Fuel level lamp (3/4)

Engine water temperature alarm

Fuel level lamp (1/2)

Engine oil pressure alarm

Fuel level lamp (1/4)

—

Brake oil pressure alarm

Fuel level lamp (E)

—

Controller failure alarm

GND (–)

—

+24 V power supply

—

Emergency steering

L22

—

A9 CN4(2P)

41 42 43 44 46 47 48 49 50 53 54 55 56

Lamp No.

Fuel level lamp (F)

58 57

Signal

85V2E62052

Lamp No.

AUTO lamp

L20

—

Auto brake

L16

—

Converter (+)

—

Converter (–)

—

— —

T/M cut-off (Declutch) lamp —

— L17 L19

Work lamp

L18

—

Central alarm lamp

L14

—

GND (–)

—

Vibration damper (option)

L23

—

Engine warning lamp

L25

—

Engine protection lamp

L24

Engine stop lamp

L26

Neutral

—

High-beam lamp

L12

L21

Turn signal (left) lamp

L13

Turn signal (right) lamp

L11

L27

+24 V power supply

—

Engine water temperature gauge

—

1st speed indication

—

T/M oil temperature gauge

—

2nd speed indication

—

Hour meter (–)

—

3rd speed indication

—

Hour meter (+)

—

Instrument panel illumination

L10

4th speed indication

—

T/M oil filter clogging alarm

Parking brake lamp

L15

95ZV EX 62-79 62 Function & Structure Electrical Group Instrument Panel and Switch (S/N 0477~)

1 19

CN2

E S

Pin No.

E S

CN1 12

CN1(24P)

CN2(36P)

12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13

18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19

CN1-Signal Secondary steering (option)

Lamp No.

Pin No.

CN2-Signal

Lamp No.

Pin No.

—

CN2-Signal Fuel level 3/4

Lamp No. 4

—

Engine water level warning lamp 19

Charge lamp

—

Ride control (option)

80Z562010

Declutch lamp

— T/C (T/M) oil temperature gauge

—

— 3 —

4th speed indication

3rd speed indication

AUTO brake

Air cleaner clogging alarm

2nd speed indication

Central alarm lamp

T/C (T/M) oil temperature alarm

1st speed indication

Neutral indication

Engine water temperature alarm

GND (–)

—

Turn signal (left) lamp

Engine oil pressure alarm

Backup battery

—

AUTO lamp

+24 V power supply

—

T/M oil filter clogging alarm

—

Tacho meter

Instrument panel illumination

—

Parking brake lamp

High-beam lamp

—

Brake circuit warning lamp

— 12

—

Work lamp

E/G stop lamp

—

Turn signal (right) lamp

E/G warning lamp

—

Fuel level F

E/G protection lamp

—

Controller failure alarm

—

Hour meter

Fuel level E

Fuel level 1/2

Fuel level 1/4

Engine water temperature gauge

—

95ZV EX 62-80 62 Function & Structure Electrical Group Instrument Panel and Switch Sensors detect the temperature respectively, and convert them into electric signals. The signals are transmitted to the corresponding gauges that indicate the transmitted values.

Gauge circuit (S/N 0101~0476, 9001~)

Controller

Grounding

Power supply 24V

S E

Note If a gauge is removed from the panel, the resistance between the terminals will differ from the standard value shown in the table.

15V

Viewed from rear surface of instrument panel K90ZV62016

Gauge

Engine water temperature 97ºC(206ºF)

T/C, T/M oil temperature 110ºC(230ºF)

100ºC(212ºF)

35ºC(95ºF)

103ºC(217ºF)

100ºC(212ºF)

120ºC(248ºF)

50ºC(122ºF)

125ºC(257ºF)

Indication

White

Red

White

Resistance between S and E ()

120~125

75~80

Resistance between S and V ()

120~125

85~90

Resistance between E and V ()

170~190

130~150

Engine water temperature

T/C, T/M oil temperature

(S/N 0477~) Gauge

67C° (152.6°F) 50C° (122°F)

56C° 102C° (132.8°F) (215.6°F)

125C° (257°F)

Indication

White Red

White

Red

Resistance between S and E ()

80~95

Resistance between S and V ()

26~30

Resistance between E and V ()

106~126

95ZV EX 62-81 62 Function & Structure Electrical Group Instrument Panel and Switch

Temperature sensor (For engine coolant temperature and torque converter oil temperature) (S/N 0101~0476, 9001~)

Flat terminal

Thermistor

95ZV62066

Temperature of detection part (ºC)

60 [140ºF]

80 [176ºF]

100 [212ºF]

120 [248ºF]

Resistance () between terminal and body

56.3

29.5

16.5

(S/N 0477~0488) For torque converter oil temperature

K95ZV62020

Temperature of detection part (ºC)

50 [122ºF]

60 [140ºF]

70 [158ºF]

80 [176ºF]

90 [194ºF]

100 [212ºF]

110 [230ºF]

120 [248ºF]

130 [266ºF]

Resistance () between terminal and body

4.40

3.19

2.34

1.75

1.33

1.02

0.79

0.62

0.49

(S/N 0477~) For engine coolant temperature (S/N 0489~0554) For torque converter oil temperature Temperature of detection part (ºC)

50 [122ºF]

70 [158ºF]

105 [221ºF]

115 [239ºF]

Resistance () between terminal and body

99.5

44.2±5

15.5±0.5

12.4

(S/N 0555~) For torque converter oil temperature

70Z42E62003

Temperature of detection part (ºC)

56 [132.8ºF]

70 [158ºF]

90 [194ºF]

125 [257ºF]

Resistance () between terminal and body

68.2±6.8

41.6

22.7

8.4±0.7

95ZV EX 62-82 62 Function & Structure Electrical Group Instrument Panel and Switch

E C M

Converter

Tachometer circuit

24 V 0

Tachometer

0.3 V

Number of rotations of engine x 12 pulses

95ZV62125

The cummins ECM transmits the engine speed signal (square wave) to the converter. And the converter transmits the square wave signal to the tachometer.

Tachometer Its pointer moves in proportion to the input frequency. Input frequency (Hz)

Instructed number of rotations (min-1)

66.67

500 ± 50

200

1,500 ± 45

333.33

2,500 ± 125

95ZV EX 62-83 62 Function & Structure Electrical Group Instrument Panel and Switch (S/N 0101~0262, 9001~9064)

Fuel gauge circuit The level sensor provided inside the fuel tank is equipped with five float switches.

1/2 3/4

When the oil level becomes low, the contact of the corresponding float switches turns on. The float switch signals are transmitted to the monitor controller, electrically processed, then only one lamp corresponding to the gauge level lights on the instrument panel as in the table below.

1/4

E 1/8

View A

SW1 (3/4) (white)

(brown) SW3 (1/4)

SW5 (E) (green)

Float switch switching and indicator lamp lighting status Indicator lamp O: Lit : Flashing – : Extinguished

Float switch O: ON X: OFF E

1/8 1/4 1/2 3/4

1/4 1/2 3/4

SW2 (1/2) (blue)

–

View B

From 3/4 to 1/2 X

–

From 1/2 to 1/4 X

–

From 1/4 to 1/8 X

–

From 1/8 to E

–

E or less



–

Actual fuel level

3/4 or more

Any other pattern

Example of failure: When the wire of the "1/4" float switch is broken, the indicator lamps for "1/8" and "E" do not light even if the fuel amount becomes 1/2 or less. Indicator lamps

+24 V (YR) (YB) (YL) (YBr) (YG)

SW4 (yellow) (1/8)

SW2 (1/2)

SW3 (1/4) Float switch

SW4 (1/8)

Fuel level sensors

Monitor controller

3/4 1/2 1/4 1/8 E

OFF

SW1 (3/4)

Liquid surface

SW5 (E)

YL YBr K115ZV62016

YG GND

Fuel level sensor circuit

K115ZV62017

95ZV EX 62-84 62 Function & Structure Electrical Group Instrument Panel and Switch (S/N 0263~, 9065~)

Float switch

(3/4)

ON (1/2)

(1/4) ON (1/8) ON (E) ON Fuel level sensor (Brown)

(Black) 3/4

E (Yellow)

(White) 1/2

1/8 (Green)

(Red) 1/4 View A

K95ZV62009

95ZV EX 62-85 62 Function & Structure Electrical Group Electrical Detent Circuit

Electrical Detent Circuit After dumping, if the bucket control lever is set to the “bucket roll back” position, the bucket control lever is held in the “bucket roll back” position until the bucket is tilted to the preset angle. This is because the detent magnet in the pilot valve is energized so that the holding plate connected to the spool is held by magnetic force.

Bucket leveler Detent solenoid Pilot valve (S/N 0291~, 9081~)

Detent solenoid Pilot valve (S/N 0101~0290, 9001~9080)

When the bucket is positioned at the set angle, the rod retracts from the proximity switch. The proximity switch, therefore, turns off, and the coil of the detent solenoid is de-energized and demagnetized. As a result, the bucket control lever is automatically returned to the neutral position by the spring, and the bucket reaches the preset digging angle. The bucket digging angle can be arbitrarily adjusted by loosening bolts and moving a plate equipped with the proximity switch.

Multiple control valve

Bucket cylinder

Bucket digging angle

Dimension A

-7º

6 mm (0.24 in)

0º

57 mm (2.24 in)

+7º

154 mm (6.06 in)

When installing the proximity switch A Bolt

Rod (detecting element)

5–2 5 2

2.5

5 2

Clearance between proximity switch and rod

- Clearance between the proximity switch and the rod (detecting element): 5 ± 2 mm (0.197 ± 0.079 in) - Attach the proximity switch so that the indicator lamp (LED) is located on the lower side.

2.5

Plate

Indicator lamp Cover Proximity switch

Clearance between cover and rod K95ZV62010

: Proximity switch: 19.6 N-m (2 kgf-m) (13 lb-ft)

95ZV EX 62-86 62 Function & Structure Electrical Group Electrical Detent Circuit

Boom kick-out (option)

Boom

Float Plate position when operating the machine with the boom elevation angle at 0º

Bolt

Plate

When the boom control lever is set to the “boom float” position, it is held in that position. The boom control lever can be released manually.

43.6

Cover

Proximity switch 45

* ****

Operation indicator lamp (LED)

1 (Br)

Proximity switch View Z

Lowest boom position

Sensing element

3 (L)

Proximity switch Br (1)

Cover

Switch main circuit

B (2) L

(3) Plate

2 (B)

Detent coil inside pilot valve

95ZV62072

95ZV62128

While the boom is being raised, the boom control lever is held in the “boom raise” position. When the boom reaches the preset height, the boom control lever is automatically returned to the neutral position. The detent function and its release method are the same as those of the bucket positioner. The boom elevation angle can be arbitrarily adjusted in the range from 43.6º to 0º by loosening bolts and sliding a plate. Installation of proximity switch - Clearance between the proximity switch and the plate (**) = 7 ± 1 mm (15/64~5/16 in) - Clearance between the cover and the plate (*) = 5 mm (13/64 in) - Attach the indicator lamp (LED) so that the it can be checked from the bottom of the machine. : 19.6 N-m (14 lb-ft)

95ZV EX 62-87 62 Function & Structure Electrical Group Electrical Detent Circuit

Detent solenoid Three detent solenoids are installed in the pilot valve. One detent solenoid, for the bucket leveler, is installed in the pilot valve bucket side. Two detent solenoids, for the boom kick-out and float, are installed in the pilot valve boom side. (S/N 0101~0290, 9001~9080) Solenoid

(S/N 0291~, 9081~)

Steel ball for detent

Plate

Push rod

Lock nut

Detent solenoid 95ZV42014

Disc

Fixing disc

Voltage

DC 24 V

Coil resistance

238±10  K90ZV62013

Voltage

DC 24 V

Coil resistance

62±3 

95ZV EX 62-88 62 Function & Structure Electrical Group Diode

Diode Open circuit, failed in open position.

Symbols

+24V Switch

[Anode]

Solenoid

[Cathode]

Surge voltage

(forward direction)

Current flow

(backward direction)

70ZV62051

Diode

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

Normal Current flow

+24V

Switch Solenoid

Diode

Current flows while the diode is normal (The solenoid is energized.)

70ZV62052

Short-circuit, failed in closed position.

The + side is called "anode", and the - side is called "cathode". The current can flow only in the direction from the anode to the cathode. When a diode is connected in the current flow direction, it is called forward direction. When a diode is connected in the current non-flow direction, it is called backward direction. Some electrical parts, as solenoid valves, buzzers, relays, all equipped with electromagnetic coils may generate a surge voltage caused by counter electromotive force when the power is turned off. This surge voltage may cause malfunction of equipment. Diodes are provided to prevent such a malfunction.

+24V

Switch Solenoid

Diode

Current flows through the diode with smaller resistance. The solenoid is not energized. 95ZV62074

However, if a diode is damaged and short-circuited (or fails closed) in its inside, electronic parts may be harmed. Therefore, if a malfunction occurs in electrical equipment, electrical connection diagrams should be referred to first, to determine and repair the cause. If a diode is provided in the electrical equipment, the diode should be checked for damage.

95ZV EX 62-89 62 Function & Structure Electrical Group Diode

Diode check method

Caution for diode check method Continuity check mode When checking the continuity by continuity check mode of volt-ohm-ammeter, only in case that the resistance is about 300  or smaller, the continuity is detected.

Coil

If the continuity check mode of volt-ohm-ammeter is used to check the continuity of diode with 500~600 , no continuity is detected both ways.

+ Analog type tester

Use a volt-ohm-ammeter with diode mode for checking diode continuity. 95ZV62129

Diode check mode 12V

12V

30A

F15 5A

F14

R1 BR B AC R2 C

Neutral relay

(2) (3)

Battery

(1)

Diode unit Suppression diode Charge circuit Monitor circuit Battery relay

(2)(3)

From alternator I terminal 70ZVE62009

Normal Abnormal

Forward check

Continuity is detected in the status shown in the figure. Continuity is not detected when tester terminals are connected in opposite way. Continuity is not detected in either way Disconnection Continuity is detected in either way

Short-circuit

Note When the circuit tester is the digital (number indication) type, exchange the positions of the terminals of the tester during the check. Some solenoid coils contain diodes inside the solenoid coil pack. Backward check 85V2E62036

Forward check

Backward check

Continuity (voltage value)

Over level

Judgement Normal

Over level

Open circuit

0 volt

Short-circuit

95ZV EX 62-90 62 Function & Structure Electrical Group Diode

Resistance check mode Analog type tester

R1>0

R2=

Forward check

Backward check Digital type tester

R1>0

R2=

Forward check

Backward check

Judgement

R  (0<R<)



Normal



Open circuit

0

Short-circuit

95ZV EX 62-91 62 Function & Structure Electrical Group Diode

Surge voltage and surge suppression diodes

Fig. 3

Surge suppression diode

Fig. 1

Coil

Voltage Current Voltage [V] Current [A]

Current direction

Battery

Electromagnetic field forms when switch closes.

Switch or transistor K70V2J62006

Time [sec]

When the surge voltage was generated, it causes to increase wear on the switch points.

Load 115ZVE62032

Some electrical parts such as solenoid valves are equipped with a coil. When a coil is energized, an electromagnetic field is formed. See fig. 1. Fig. 2

Battery

Coil

When the switch opens, the field collapses across the coil windings. Voltage

Voltage [V] Current [A]

Current

Load

During the coil is being activated by the transistor, when the excruciating high voltage is loaded on the transistor, the transistor may be broken. In order to absorb this surge voltage, connect the diode parallel to the coil in the reverse direction against the power supply. When the switch is off, the same amount of electric current, that was flown till now, flows through the diode. This electric current is attenuated gradually and finally it reaches zero. That means no surge voltage is generated in the circuit. This diode is called as flywheel diode.

ON OFF Time [sec]

Surge voltage 115ZVE62033

When the solenoid coil is de-energized, the field collapses across the coil. The collapse of this electromagnetic field across the solenoid coil generates an unregulated voltage surge. See fig. 2. This can damage transistors, contacts, and other electronic parts. (See connection diagram.)

95ZV EX 62-92 62 Function & Structure Electrical Group Diagnostic System (S/N 0101~0358, 9001~)

Diagnostic System (S/N 0101~0358, 9001~) Diagnostic system flow Diagnostic system flow Starter SW ON

Date indication (3 seconds)

(Engine OFF)

Failure code indication window

EPROM program date: [Year] [Month] [Day] One second each Example: 01.06.16 (or June 16, 2001)

ON (Momentary ON)

Diagnosis SW

OFF Current condition

Abnormal

Normal M/C speed indication E/G speed

T/M control warning lamp ON

Failure code for current failure flashes on and off

Failure history indication Failure code flashes on every 2 seconds

Reset SW

3 seconds ON: Release switch to the “off” position when the screen goes blank. (Timing is critical.)

Failure history memorized is deleted completely. (Buzzer sounds 0.5 second)

If more than one failure code is in memory the newest failure code will be displayed first. After 2 seconds the next failure code will be displayed. If no failure codes are memorized “FF” is displayed for 2 seconds.

If the switch is being pushed, the failure code is ON continuously during the switch remains pushed. 95ZV62075

95ZV EX 62-93 62 Function & Structure Electrical Group Diagnostic System (S/N 0101~0358, 9001~)

Failure code (T/M controller) The failure code is displayed on the failure code indication window on the T/M controller. Code

Failure

Detection condition

Shift lever F and R contact ON at the same time

In case the failure continues for more than “3 seconds”

Shift lever all 1 • 2 • 3 • 4 contacts ON at the same time

The same as the above

Shift lever 1 • 2 • 3 contacts ON at the same time

The same as the above

Shift lever 1 • 2 • 4 contacts ON at the same time

The same as the above

Shift lever 1 • 3 • 4 contacts ON at the same time

The same as the above

Shift lever 2 • 3 • 4 contacts ON at the same time

The same as the above

Shift lever 1 • 2 contacts ON at the same time

The same as the above

Shift lever 1 • 3 contacts ON at the same time

The same as the above

Shift lever 1 • 4 contacts ON at the same time

The same as the above

Shift lever 2 • 3 contacts ON at the same time

The same as the above

Shift lever 2 • 4 contacts ON at the same time

The same as the above

Shift lever 3 • 4 contacts ON at the same time

The same as the above

Shift lever all 1 • 2 • 3 • 4 contacts OFF

In case all 1 • 2 • 3 • 4 signal OFF continues for more than “3 seconds”

QUAD switch malfunction

In case the switch is ON for more than “10 seconds”

Inching (Declutch) switch malfunction

In case the switch is ON for more than “3 minutes”

1st solenoid coil or wiring circuit is open or disconnected

In case the failure continues for more than “1 second”

2nd solenoid coil or wiring circuit is open or disconnected

The same as the above

3rd solenoid coil or wiring circuit is open or disconnected

The same as the above

H solenoid coil or wiring circuit is open or disconnected

The same as the above

L solenoid coil or wiring circuit is open or disconnected

The same as the above

R solenoid coil or wiring circuit is open or disconnected

The same as the above

Modulator valve (2) solenoid coil or wiring circuit is open or disconnected

The same as the above

Auto-brake solenoid coil or wiring circuit is open or disconnected

The same as the above

Modulator valve (1) solenoid coil or wiring circuit is open or disconnected

In case the current value less than “5 mA” continues for more than “10 seconds”

Pressure difference sensor malfunction (1) - The problem may be an electrical malfunction of the sen- E/G revolution is more than “1,500 min-1 (rpm)” and the shift lever is sor or wiring. changed more than “10 times”, however the sensor voltage never - The problem may be a mechanical malfunction (sticking) reaches more than “2 V” of the switch.

Pressure difference sensor malfunction (2) - The problem is probably a mechanical malfunction (sticking) of the switch.

In case the signal voltage is more than “3 V” and it continues for more than “10 seconds”

E/G speed sensor malfunction

In case the E/G revolution detection value is more than “3,000 min-1 (rpm)”

Machine speed sensor malfunction

In case all the machine speed detection value is more than “50 km/h (31 mph)”

EPROM write frequency limitation

In case the write frequency is more than “80 thousands”

No failure record memorized

95ZV EX 62-94 62 Function & Structure Electrical Group Diagnostic System (S/N 0101~0358, 9001~)

Diagnostic (T/M controller) failure code detection condition 1. Failure code indication for current failure: If more than one failure code is stored in memory the newest one is displayed first. To review older failure codes switch ON the diagnostic switch. 2. Shift lever failure detection codes (codes 11~23): Codes 11~22 indicate a short circuit in either the shift lever or the wiring. Code 23 indicates an open circuit in the shift lever or a broken wire. The machine may operate normally in all but one speed. 3. QUAD switch malfunction code (code 25): Normally the switch is not pushed for more than 10 seconds. If the switch stays ON (contacts closed) for more than 10 seconds the controller considers it to be a short circuit in the switch or its wiring. 4. Inching (declutch) switch malfunction code (code 26): When using the inching (also called declutch or clutch-cutout) switch it is normal for it to be ON (contacts closed) while the brake pedal is depressed. However, if the switch remains ON for more than 3 minutes the controller considers that there is a short in the switch or its wiring. Should the operator keep the pedal depressed more than 3 minutes the malfunction code will be stored in the controller but the machine will continue to operate normally. 5. Solenoid open circuit codes (codes 51~58): If the transmission solenoid coil is internally open, has high resistance (more than 35 ), or a broken wire between the controller and the solenoid coil. The machine will not move in the gear that has the open circuit (malfunction codes 51~56). The symptom may be the same as 2 above. Read the malfunction code to determine which malfunction has actually occurred. If the modulator valve 2 (MV2) is disconnected (malfunction code 57) harsh shifting will occur. If the auto-brake solenoid coil is defective or disconnected the auto-brake feature will not work.

6. Modulator Valve (MV1) open circuit codes (code 59): The normal current value is about 450 milliamperes (mA) through MV1 coil. When the current value through the MV1 coil is less than 5 mA for more than 10 seconds the controller senses an open circuit in the coil or its wiring. In this case the transmission pressure will be very low and may not move. 7. Pressure differential sensor malfunction #1 (code 60): When this code is indicated the sensor itself is defective. However, the internal spool may be stuck rather than an electrical defect. 8. Pressure differential sensor malfunction #2 (code 61): This code indicates the signal from the sensor is not correct. While the sensor may be electrically or mechanically (stuck spool) defective there is the possibility that internal leakage in the clutch pack seal (s). Replacement to the sensor will not correct the problem if the seal is defective. 9. Engine speed sensor malfunction (code 71): This code occurs when the signal from the engine speed sensor is extremely high (over 3,000 min-1 (rpm)). While this could occur from an engine over speed situation it can also occur from electronic "noise" from other sources. Be sure the wiring from the sensor to the controller is twisted through the harness. Twisting the wire prevents it from acting like an antenna and picking up the electronic noise generated from other sources. Note If the speed sensor is defective or disconnected no LED characters will be displayed when the engine is running (refer to the controller display).

95ZV EX 62-95 62 Function & Structure Electrical Group Diagnostic System (S/N 0101~0358, 9001~) 10. Machine speed sensor malfunction (code 72): This code occurs when the signal from the engine speed sensor is extremely high (over 50 km/H). While this could occur from an engine over speed situation it can also occur from electronic "noise" from other sources. Be sure the wiring from the sensor to the controller is twisted through the harness. Twisting the wire prevents it from acting like an antenna and picking up the electronic noise generated from other sources. Note If the speed sensor is defective or disconnected no LED characters will be displayed when the engine is running (refer to the controller display). 11. EPROM write frequency limitation (code E1): The EPROM is designed to have enough capacity to outlast the life of the machine and should never be displayed. 12. No malfunction code recorded (code FF): If the diagnostic switch is installed and pressed and there are no malfunction codes stored in memory the display will be show "FF". If the machine will not move and "FF" is displayed check the input LED's to be sure there are no open circuit from the lever. Open circuits (except code 23 which is for speed circuits [1,2,3,A] only) from the shift lever will not be stored in memory.

Fault diagnostic result storage condition 1. Faults are stored in the time series (from the oldest one to the latest one). 2. Thirty two faults can be stored. 3. If the code was recorded past and it was not deleted, the same code is not recorded newly. Therefore when the cause of the fault was removed, delete the code once recorded.

95ZV EX 62-96 62 Function & Structure Electrical Group Diagnostic System (S/N 0101~0358, 9001~)

Monitor controller Diagnostic system flow Starter SW ON

Current condition

(Engine OFF)

Abnormal

Normal

Diagnostic SW

Warning lamp ON

2 seconds ON: Release switch to the "off" position when the screen goes blank. (Timing is critical.)

Failure history indication Warning lamp flashes on and off every 3 seconds.

Reset SW

3 seconds ON: Release switch to the "off" position when the screen goes blank. (Timing is critical.)

If the failure code memorized is more than one the newer failure code flashes on and off first in order. In case no failure code memorized, all warning lamps come on for 1.5 seconds.

Failure history memorized is deleted completely (Buzzer sounds 0.5 seconds) 70ZV62056

95ZV EX 62-97 62 Function & Structure Electrical Group Diagnostic System (S/N 0101~0358, 9001~)

Alarm monitor actuation and data storage Alarm monitor control Central alarm lamp

Fuel level

Brake oil pressure Engine oil pressure Engine water temperature T/M oil temperature Air cleaner

T/M oil filter Engine water level

Emergency steering

1. Lamp test When the power is turned on, monitor lamps (central alarm, brake oil pressure warning, engine oil pressure warning, T/M oil temperature warning, engine water temperature warning, air cleaner clogging, T/M oil filter clogging, engine water level warning and emergency steering (option)) are lit for 3 seconds and buzzer sounds for 3 seconds. 2. Check before operation (engine water level). After the lamp test is finished, if there is something abnormal in the engine water level while the engine is stopped (that is, while no signal is input from the alternator), the engine water level warning monitor lamp lights and the alarm item (engine water level) is stored in memory. When the engine starts (that is, when a signal is input from the alternator), the engine water level warning monitor lamp turns OFF. 3. Abnormal T/M oil temperature, engine water temperature, air cleaner or T/M oil filter. If there is something abnormal in the T/M oil temperature, engine water temperature, air cleaner or T/M oil filter, the central alarm lamp flashes and a corresponding warning monitor lamp lights. In addition, the corresponding alarm item is stored in memory.

95ZV62077

4. Abnormal engine oil pressure. After the lamp test is finished, if there is something abnormal in the engine oil pressure while the engine is running (that is, while a signal is input from the alternator), the central alarm lamp flashes and the engine oil pressure warning monitor lamp lights. In addition, buzzer sounds, and the alarm item (engine oil pressure) is stored in memory. 5. Abnormal brake oil pressure. After the lamp test is finished, if there is something abnormal in the brake oil pressure (main pressure), the central alarm lamp flashes and buzzer sounds. In addition, the alarm item (brake oil accumulator pressure) is stored in memory.

95ZV EX 62-98 62 Function & Structure Electrical Group Diagnostic System (S/N 0101~0358, 9001~) 6. Emergency steering alarm

Fault diagnostic result storage condition

After the lamp test is finished, if there is something abnormal in the steering oil pressure, the emergency steering monitor lamp lights. After the lamp test is finished, if there is something abnormal in the steering oil pressure while the engine is running (that is, while a signal is input from the alternator), the central alarm lamp flashes and the emergency steering monitor lamp lights. In addition, buzzer sounds, and the alarm item (steering oil pressure) is stored in memory. Fuel level indication 1. Lamp test When the power is turned on, all of the fuel level indicators are lit for 3 seconds. 2. Fuel level indication If the displacement status continues for 4 seconds or more, the fuel level lamps change as shown in the table below. After the lamp test is finished, if there is something abnormal in the input (that is, if the “Except the above” status shown in the table below remains for 4 seconds or more), the input signal status at that time is stored in the memory. Input

Output

1/4

1/2

3/4

1/4

1/2

3/4

–

○

–

● –

● – –

○

–

○

●

● –

○

○ ○ ○ Except the above

○

◎ –

–

Fuel level sensor switch ○ : Input signal (Yes) × : Input signal (No)

–

LED indication ● : ON – : OFF ◎ : ON and OFF (flash)

95ZV62078

1. Faults are stored in the time series (from the oldest one to the latest one). 2. Sixty three faults can be stored. 3. If the result of the sensor check performed at first after the power is turned on is equivalent to the latest stored fault, it is not stored. 4. When an error of the same combination occurs intermittently (that is, when the cause of the fault is not removed) - Alarm monitor control An error of the same combination is stored up to three times, and ignored after that. - Fuel indication An error of the same combination is not stored. 5. When the memory is full, the stored data is deleted from the oldest one.

95ZV EX 62-99 62 Function & Structure Electrical Group Diagnostic System (S/N 0101~0358, 9001~)

Diagnostic failure history indication and deletion Failure history indication When the starter switch is set to ON (without starting the engine) and the diagnostic switch is pressed and held for 2 seconds or more, all monitor lamps and fuel level lamps are lit for 1.5 seconds. And each of stored alarm monitor items is indicated (a corresponding monitor lamp lights) in the reverse order of the time series (that is, from the latest one to the oldest one) 3 times respectively in the 1-second cycle. (Between two items, all lamps are extinguished for 1.5 seconds.) After that, the fuel level lamps light, become extinguished or flash to indicate the input status at that time. After all stored alarms are indicated, the history indication is finished and the machine returns to the normal mode. Diagnostic switch - Starter switch ON (E/G OFF) 2 sec ON Diag. SW Newest failure

OFF 1.5 sec ON

1 sec

OFF Warning lamp 1 ON

1.5 sec

OFF Warning lamp 2

ON Fuel level lamp

1.5 sec

OFF

ON Oldest failure

Buzzer

OFF Finish 95ZV62079

95ZV EX 62-100 62 Function & Structure Electrical Group Diagnostic System (S/N 0101~0358, 9001~)

Failure history deletion When the starter switch is set to ON (without starting the engine) and the reset switch is pushed for more than 3 seconds, all failure history memorized is deleted completely. At that time the buzzer sounds 0.5 second. Reset switch - Starter switch ON (E/G OFF)

3 sec

Reset SW 0.5 sec

Buzzer Failure history memorized is deleted completely. 95ZV62131

Note 1. If the memory call switch is pressed and held for 2 seconds or more while the stored fault data is indicated, the fault data is indicated from the first fault. 2. If the revolution signal is input or the starter switch is set to OFF while the stored fault data is indicated, fault data indication stops.

CAUTION When the engine is stopped (starter switch ON) and the reset switch is being pushed for more than 3 seconds, both the failure history for the transmission controller and the monitor controller are deleted at the same time.

95ZV EX 62-101 62 Function & Structure Electrical Group Diagnostic System (S/N 0101~0358, 9001~)

Diagnostic switch

Reset switch OFF

ON OFF

(A) ON

B Y

R B

To T/M controller (machine body harness)

95ZV62081

When performing the diagnostic procedure, connect the diagnostic switch coupler to the controller as shown above. Necessary parts 1. Diagnostic switch assembly (A) Part Number 35020-20510 - Diagnostic sw - Reset sw - Harness assembly

95ZV EX 62-102 62 Function & Structure Electrical Group MODM (S/N 97C4-0359~)

MODM (S/N 97C4-0359~) (Machine Operation Diagnostic Module)

[ ]button

Display window

Monitor Changeover [

]button

[ (step back)] [ (step forward)] button button

Replacement monitor

Fault log monitor

Information monitor

Input/Output monitor

Specification setting monitor

Parameter setting monitor

90ZV-262001

MODM function The MODM has the following functions:

Change over the monitor using the following procedure: When the starter switch is ON, the machine information screen displays information relative to the machine function.

- Information monitor Displays machine speed and engine speed and voltage. - Replacement monitor Not used. - Fault log monitor Allows check of previous errors, and displays active errors. - Input/Output monitor - Parameter setting monitor Allows check and change of the calendar setting only. - Specification setting monitor Allows check of the program number only.

Changing display from one function to next Press both the [ (step back)] button and [ (step forward)] button at the same time to change over the monitor mode in sequence "Information monitor  Replacement monitor  Fault log monitor  Input/Output monitor  Parameter setting monitor  Specification setting monitor Information monitor". However the monitor mode can not be changed in reverse such as "Information monitor  Specification setting monitor  Parameter setting monitor ....." The display will not be changed to the next monitor when you hold the buttons.

$ * + ,*

! " # $ % &' ( $ & % $ ) %

- *

. $

- *

95ZV EX 62-103 62 Function & Structure Electrical Group MODM (S/N 97C4-0359~)

Odometer / Trip Meter

Cycle

Hydraulic Oil Temperature

Transmission Oil Temperature

Engine Coolant Temperature

Machine Speed / Engine Speed

Outside Temperature (Information Menu Initial Screen)

Hour Meter

Information Monitor

(Not used)

Unit Conversion

(Not used)

Hour Meter

Voltage

Outside Temperature

Hydraulic System Oil Pressure

Cycle

Odometer

(Not used)

Language Selection

Active Error

(

Press any button: )

Replace Monitor

Specification Setting Monitor

Press any button

Active Error

2 sec Change No Change

3 sec

95ZV EX 62-104 62 Function & Structure Electrical Group MODM (S/N 97C4-0359~)

95ZVE62076

Machine Fault Log 1

Maximum Machine Fault Log

Machine Fault Log 3

Machine Fault Log 2

Machine Fault Log 1 (Initial Screen for Machine Fault Log)

Machine Fault Log Maximum

Machine Fault Log

Fault Log Monitor

Clear Fault Log

Clear Fault Log 2 seconds or more: Return after clear Return without clear

2 sec

Clear Fault Log

2 seconds or more: Return after clear Return without clear

2 sec

2 seconds or more: Return after clear Return without clear

2 sec

2 seconds or more: Return after clear Return without clear

2 sec

(Not used)

Engine Fault Log

Replace Monitor

Active Fault

(

Press any button )

Input/Output Monitor

Press any button

Active Fault

95ZV EX 62-105 62 Function & Structure Electrical Group MODM (S/N 97C4-0359~)

95ZVE62077

95ZV EX 62-106 62 Function & Structure Electrical Group MODM (S/N 97C4-0359~)

Failure code (Input side) Code

Failure

Detection condition (In case of)

CN121

Shift lever F & R switch malfunction

Shift lever F & R contact ON at the same time Failure continues for more than 3 seconds

CN122

Shift lever 1•2•3•A switch malfunction (1)

Shift lever any of more than two 1•2•3•A contact ON at the same time Failure continues for more than 3 seconds

CN123

Shift lever 1•2•3•A switch malfunction (2)

All 1•2•3•A signal OFF continues for more than 3 seconds

CN145

Kick-down switch malfunction

Switch is ON for more than 10 seconds

CN152

T/M Press. diff sensor malfunction

T/M Press. diff sensor voltage is larger than 3V for more than 10 seconds

CN161

Machine speed sensor malfunction (1)

Input circuit is disconnected for more than 3 seconds

CN162

Machine speed sensor malfunction (2)

Input value is over 70 km/h (44 mile/h) for more than 3 seconds

CN163

E/G speed sensor 1 (ECM output) malfunction (1)

No E/G speed sensor input for more than 3 seconds when E/G speed sensor selection is OFF (Input circuit is disconnected)

CN164

E/G speed sensor 1 (ECM output) malfunction (2)

Input value is more than 3,000 min-1 for more than 3 seconds when E/G speed sensor selection is OFF

CN165

E/G speed sensor 2 (Sensor output) malfunction (1)

No E/G speed sensor input for more than 3 seconds when E/G speed sensor selection is ON (Input circuit is disconnected)

CN167

E/G speed sensor 2 (Sensor output) malfunction (2)

Input value is more than 3,000 min-1 for more than 3 seconds when E/G speed sensor selection is ON

CN213

Inching sensor malfunction (1)

Switch is ON for more than 180 seconds

CN254

Low secondary steering oil pressure

Steering oil pressure switch is ON for more than 1 second during engine running

CN381

Fuel level sensor malfunction

Input signal corresponds to "any other pattern" in fuel level indication table

CN412

Abnormal brake oil pressure (1)

Brake oil pressure sensor 1 detects pressure below 4,081 kPa (41.6 kgf/ cm2) (592 psi) for more than 1 second during engine running

CN414

Abnormal brake oil pressure difference

Brake oil pressure difference switch is in abnormal condition for more than 1 second

CN420

Abnormal engine oil amount

Engine oil amount switch is OFF for more than 2 seconds when no engine running

CN421

Abnormal engine oil pressure

Engine oil pressure switch is OFF for more than 2 seconds during engine running

CN431

Abnormal engine coolant temperature (1)

Engine coolant temperature switch is ON for more than 2 seconds

CN451

Abnormal T/M oil temperature (1)

T/M oil temperature switch is ON for more than 2 seconds

CN471

Clogged T/M oil filter

30 minutes after starter switch is ON, T/M oil filter switch is ON for more than 2 seconds when T/M oil temperature sensor detects oil temperature more than 60 deg. C (140 deg. F)

CN481

Clogged air cleaner element

Air cleaner switch is ON for more than 2 seconds

CN491

Abnormal cooling water level in radiator

Radiator cooling water level switch is OFF for more than 2 seconds when the engine is off.

CN912

Abnormal MCU voltage (1)

Voltage is larger than 30±1 V

CN913

Abnormal MCU voltage (2)

Voltage is lower than 22±0.5 V for more than 10 seconds during engine running

95ZV EX 62-107 62 Function & Structure Electrical Group MODM (S/N 97C4-0359~)

Fuel level display table Input

Output

1/8

1/4

1/2

3/4

—

Other than above : No input signal given x : Input signal given

1/4

1/2

3/4

—

: Lamp on

—

: Lamp flashing

— : Lamp off

Note This table applies to the 95/115/135ZV-2 units.

Failure code (Output side) Code

Failure

Detection condition

CN512

F solenoid valve malfunction

F solenoid valve is short-circuited or disconnected

CN514

R solenoid valve malfunction

R solenoid valve is short-circuited or disconnected

CN516

1st solenoid valve malfunction

1st solenoid valve is short-circuited or disconnected

CN518

2nd solenoid valve malfunction

2nd solenoid valve is short-circuited or disconnected

CN521

3rd solenoid valve malfunction

3rd solenoid valve is short-circuited or disconnected

CN526

D solenoid valve malfunction

D solenoid valve is short-circuited or disconnected

CN528

H solenoid valve malfunction

H solenoid valve is short-circuited or disconnected

CN534

Auto brake solenoid valve malfunction

Auto brake solenoid valve is short-circuited or disconnected

CN537

Speed change control solenoid valve malfunction (2)

Speed change control solenoid valve is disconnected

DO Port 6

DI Port 7

Input Sensor Screen

DO Port 3

DI Port 3

Input Signal Screen

DI Port 1

DO Port 2

2 sec

DI Port 2

2 sec

Analogue Input

2 sec

DO Port 1

DI Port 7

2 sec

Input Signal

2 sec

DI Port 1 (Initial Screen for I/O Monitor)

Other Output

2 sec

Input/Output Monitor

Output Signal Screen

DO Port 1

DO Port 6

Output Signal 2 sec

2 sec

Input Signal

2 sec

Cooling Fan Current Output

Other Output

Active Error

(

Press any button )

Parameter Setting Monitor

Fault Log Monitor

Press any button

Active Error

95ZV EX 62-108 62 Function & Structure Electrical Group MODM (S/N 97C4-0359~)

95ZVE62081

D solenoid valve

1st speed indicator lamp

OUTPUT 2

OUTPUT 3

3rd speed indicator lamp

Fuel level 3/4

OUTPUT 5

OUTPUT 6

Fuel level 1/2

Auto shift indicator lamp

Brake oil pressure warning lamp

2nd speed solenoid valve

1st speed solenoid valve

OUTPUT 1

OUTPUT 4

Ride control solenoid valve

Fuel level 1/4

Neutral indicator lamp

3rd speed solenoid valve

Fuel level 1/4

Fuel level 1/2

Fuel level 3/4

Engine oil pressure switch

Model selection 3

Declutch switch

Shift lever 1

INPUT 7

Steering oil pressure switch

Kick-down

Shift lever R

Brake differential pressure switch

Machine speed selection 2

Shift lever F

INPUT 6

INPUT 5

INPUT 4

INPUT 3

INPUT 2

INPUT 1

A/M selection (automatic/manual)

Engine speed sensor selection (ECM output/sensor output)

Fuel level E

E/G oil level warning lamp

Back lamp relay

2nd speed indicator lamp

MCU failure relay

Axle oil temperature warning lamp

Reverse fan solenoid valve

H solenoid valve

Air cleaner clogging switch

Steering oil pressure warning lamp

Neutral relay

4th speed indicator lamp

Transmission oil temperature warning lamp

R solenoid valve

Axle oil temperature switch

Auto brake indicator Radiator water level Central warning lamp lamp warning lamp

Engine coolant temperature warning lamp

F solenoid valve

Fuel level F

Transmission oil temperature switch

Engine oil pressure warning lamp

4th speed solenoid valve

Fuel level 1/8

Engine coolant temperature switch

Model selection 2

Brake oil pressure switch

Alternator neutral point voltage

Stick steering (K-Lever) arm rest switch

Shift-up

Shift lever A

Machine speed selection 1 Model selection 1

Parking switch

Shift lever 3

Ride control switch

Shift lever 2

Buzzer

Fuel level F

Emergency steering motor relay

Air cleaner warning lamp

Brake solenoid valve

Abnormal brake switch

E/G oil level switch

Model selection 4

Shift-down

95ZV EX 62-109 62 Function & Structure Electrical Group MODM (S/N 97C4-0359~)

MODM: Input/output monitor - Input/output signal correspondence table

(Not used)

- TRACTION CONTROL F1 - TRACTION CONTROL DSsc - TRACTION CONTROL Isc - TRACTION CONTROL ti - TRACTION CONTROL SCv - TRACTION CONTROL SCeg - TRACTION CONTROL SCi - TRACTION CONTROL SCt - T/M CUT OFF IS - 2 STAGE DSon - POWER CONTROL TWni

Power Control (Vni) Setting 2

- SPEED METER DIV2 - TACHOGRAPH DIV1 - TACHOGRAPH DIV2 - EMG STEERING ON - EMG STEERING OFF - K-LEVER V1 - K-LEVER V2 - K-LEVER Vmax - K-LEVER i1 - K-LEVER i2 - K-LEVER imax

Speed Meter Divide Setting 1

Ride Control Setting 2

Ride Control Setting 1

Deceleration Prevention Setting 2

Deceleration Prevention Setting 1 (Initial Screen for Parameter Setting)

Calendar

Parameter Setting Monitor

(Not used)

Deceleration Prevention Setting 1

lower left

lower right

upper left)

Subtraciting 1 to the value where the cursor is.

Adding 1 to the value where the cursor is

The cursor skips (digits/column) which can not be changed.

(upper right

The cursor moves rightward.

Parameter Setting 2 sec Change No Change

2 sec

(Not used)

(lights for 0.5 second and lights off for 0.5 second).

The cursor flashes in a 1-second cycle.

Parameter Setting

Calendar

Lift Kick Out

Lower Kick Out

Power Control (Vni) Setting 2

Specification Selection Monitor

Input/Output Monitor

95ZV EX 62-110 62 Function & Structure Electrical Group MODM (S/N 97C4-0359~)

95ZVE62083

01 02

95 ZV

115 ZV

MODM Display

yymmdd

Program Date

: Space yy : Year (last 2 digits) mm : Month dd : Date

Model

Program No. (Initial Screen for Specification)

Specification Setting Monitor

yymmdd

Program Date

Information Monitor

Parameter Setting Monitor

95ZV EX 62-111 62 Function & Structure Electrical Group MODM (S/N 97C4-0359~)

95ZVE62084

95ZV EX 62-112 62 Function & Structure Electrical Group

MEMO

95ZV EX 63-1 63 Check & Adjustment Electrical Group

63 Check & Adjustment Electrical Group Cautions Regarding Electric Circuit Check ...........................63-2 Electrical Transmission Control System Troubleshooting Flowchart (S/N 0101~0358, 9001~) ......................................63-5 Transmission Controller Abnormal Operation Judgment (S/N 0101~0358, 9001~).......................................................63-6 Electrical Circuit Check (S/N 0101~0358, 9001~)...............63-10 Shift Lever ...........................................................................63-30

95ZV EX 63-2 63 Check & Adjustment Electrical Group Cautions Regarding Electric Circuit Check

Cautions Regarding Electric Circuit Check Disconnecting or reinstalling connector

Inserting waterproof round connector

Removing square connector

80ZV63006

80ZV63003

80ZV63007

Removing waterproof round connector

80ZV63004

1. Before disconnecting or reinstalling the connector, be sure to turn the power off (turn the starter switch to OFF). 2. To disconnect a connector, firmly grab the connector, and press and hold the stopper claw. While holding down the claw, pull out the connector in the straight direction. Do not pull the electric cable or wires. They may be damaged. Do not twist the connector or the female terminal cover may be damaged to cause poor contact.

Inserting square connector

3. When reconnecting, insert it until the stopper claw clicks. If the connector is not completely connected, it may cause poor contact. 80ZV63005

95ZV EX 63-3 63 Check & Adjustment Electrical Group Cautions Regarding Electric Circuit Check Note In corrosive environments (such as salt air, phosphate plants, or fertilizers) the square type connectors will require special coatings to prevent or minimize electrical problems. Use only an approved sealant like Dow Corning 738 or Loctite "Ultra Blue". Other silicone sealants may contain acetic acid which may corrode the wiring. (Hint: If the silicon has a vinegar type odor it has acetic acid and should not be used.) Use only a very small amount of di-electric grease if needed.

95ZV EX 63-4 63 Check & Adjustment Electrical Group Cautions Regarding Electric Circuit Check

How to attach the probes of the circuit tester

How to attach the probes of the circuit tester to the square connector.

80ZV63008

How to attach the probes of the circuit tester to the waterproof round connector. 80ZV63009

When checking the conductivity or the voltage, follow the procedure below: 1. Square connector Insert the probes for the tester to the wire side of the connector. Do not insert the probes into the open side of the connector. The damaged connector may cause poor contact. 2. Waterproof round connector For the waterproof round connector, do not attach the probes of the tester to the wire side because the wire side is waterproofed. Attach the probes to the open connector side. Do not force the probes into the female side. The damaged connector may cause poor contact.

95ZV EX 63-5 63 Check & Adjustment Electrical Group Electrical Transmission Control System Troubleshooting Flowchart (S/N 0101~0358, 9001~)

Electrical Transmission Control System Troubleshooting Flowchart (S/N 0101~0358, 9001~) For a problem regarding transmission control, check the electric control system first, and then check the mechanical system.

To check the electric control system, determine the cause of the problem while referring to the flowchart below, and then solve the problem.

Standard troubleshooting flowchart Cause of problem Is the "controller failure" monitor lamp on?

- The transmission controller failure. If the circuit protector in the controller is off, the power supply or output circuit is short-circuited. Check for damaged solenoid coils or their wiring.

Abnormal

- The input circuit or one of the input units is defective.

off

Check the other monitor lamps.*

Normal

Check the on/off statuses of the transmission controller LED indicators.*

* Check that the monitor lamps are properly turned on and off according to operation of the respective unit, such as shift lever and parking switch.

Abnormal

Normal

* Refer to the table "Transmission controller LED indicator". Also check for logged fault codes.

Check operation of the output circuit and output units.*

Problem detected (disconnection, etc.)

No problem

* Measure the resistance of the output circuit and output units (solenoid valve, etc.) while operating the input units.

Check mechanical operation of the output units.*

No problem

Problem detected

- The input circuit or one of the input units is defective. - The transmission controller is defective. (The defective controller judgment standard is described on the next page.)

- The output circuit or one of the output units is defective.

- An output unit is defective.

* Disassemble the output units (solenoid valve, etc.), and check them for sticking. Check the drive line and the transmission for mechanical problems. 70ZVE63009

95ZV EX 63-6 63 Check & Adjustment Electrical Group Transmission Controller Abnormal Operation Judgment (S/N 0101~0358, 9001~)

Transmission Controller Abnormal Operation Judgment (S/N 0101~0358, 9001~) Transmission controller check To judge whether the transmission controller operates properly, follow the procedure below:

IMPORTANT When performing test 3, be careful not to arc across to other terminals. Damage to controller can result. Use plug in connector pig-tail wires to do this with.

When the output units (solenoid valve, etc.) do not operate properly: Remove connector E2, E3 from the output side. Operate the shift lever, parking switch, etc., and check the on/off statuses of the transmission controller LED indicator. ON/OFF status of LED

Input side

No LED

Normal LED

Output side

No LED

Normal LED

No LED

Judgment for controller

When the "controller failure" monitor lamp lights: Under the condition, check the position of the circuit protector switch (on or off). (After turning the starter switch to the OFF position, turn on the circuit protector switch.) Circuit protector

OFF

Judgment for controller

Normal

Abnormal

Cause

Power supply or output circuit short-circuited

Defective transmission controller (IC self-diagnosis)

Solution

Check the power supply and output circuits

Replace the transmission controller assembly

Normal

Abnormal

Cause

Defective input unit or circuit

Defective output unit

Defective transmission controller

Solution

Check the input units and the circuit

Check the output units and the circuit

Replace the transmission controller assembly

95ZV EX 63-7 63 Check & Adjustment Electrical Group Transmission Controller Abnormal Operation Judgment (S/N 0101~0358, 9001~)

If the input units or circuit are not defective

Directly inputting input signal Shortcircuit (connect) the terminals of connector E1 using the probes of the tester or a jumper wire. Input signal

9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11 10

Comparable shift lever position

LED's for inputs or outputs

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

Note The couplers shown are for controller side.

95ZV62083

There is a strong possibility that the transmission controller is defective. To check the transmission controller, directly input the input signal, and then check the on/off statuses of the transmission controller LED indicator. If a LED indicator is not on, judge that the transmission controller is defective. Replace it. Set-up Remove all the controller connectors, and then supply power to connector E1 (terminal 20: +24V/Terminal 9 or 17: Grounding).

Terminals to be connected

Inlet LED

15-17

5-17

4-17

12-17

11-17

10-17

Parking

13-17

Inching (Declutch)

1-17

95ZV EX 63-8 63 Check & Adjustment Electrical Group Transmission Controller Abnormal Operation Judgment (S/N 0101~0358, 9001~)

Transmission controller LED indicator The transmission controller LED indicator should be on as shown below if the transmission controller is operating normally and inputs are correct. In running status

Shift lever position • F

Shift lever position • R

Shift lever position • 1

Shift lever position • 2

Shift lever position • 3

Shift lever position • A

Automatic shift cancel

Shift switch ON

Parking switch OFF (running status)

Inching switch ON

F • A

R • 1

R • 2

R • 3

R • A

F • 4

QUAD switch switching

F • 3

During autobraking

F • 2

Inching

F • 1

Backward

Speed change

Forward Shift lever position

Input side LED window

Normal running (“A” shows automatic shift position)

Machine condition

LED on - - Related LED on (depending on machine speed)

Automatic shift cancel

Only the LED's related to the transmission circuit are shown.

R F1 F1 F •   • 3 F2 R2 2

F • 2

F2 F2 R2 R2     F1 R1

Remarks

 

LED ON: In running status

Machine speed

Indicates in character according to the engine revolution.

Engine revolution

Indicates in character according to the machine speed.

T/M controller (when working properly: ON)

RR Back-up relay ON Output side LED window

DC Modulator valve 2 ON L

LED ON: During clutch change only

Low clutch sol. valve ON

High clutch sol. valve ON

Reverse clutch sol. valve ON

BZ Buzzer N

Neutral relay ON

BRK

Auto brake sol. valve ON

1st clutch sol. valve ON

2nd clutch sol. valve ON

3rd clutch sol. valve ON



 

95ZV EX 63-9 63 Check & Adjustment Electrical Group Transmission Controller Abnormal Operation Judgment (S/N 0101~0358, 9001~)

Input side LED window

Shift lever position • F

Shift lever position • R

Shift lever position • 1

Shift lever position • 2

Shift lever position • 3

Shift lever position • A

Automatic shift cancel

Shift switch ON

Parking switch OFF (running status)

Inching switch ON

Circuit protector on when controller failure alarm is on

Usual parking Neutral

LED on - - Related LED on (depending on machine speed)

Circuit protector OFF

Machine condition Shift lever position

In parking status (During engine operation)

Machine speed Engine revolution X

T/M controller (when working properly: ON)

RR Back-up relay ON Output side LED window

DC Modulator valve 2 ON L

Low clutch sol. valve ON

High clutch sol. valve ON

Reverse clutch sol. valve ON

BZ Buzzer N

Neutral relay ON

BRK

Auto brake sol. valve ON

1st clutch sol. valve ON

2nd clutch sol. valve ON

3rd clutch sol. valve ON

Related Character: ON

95ZV EX 63-10 63 Check & Adjustment Electrical Group Electrical Circuit Check (S/N 0101~0358, 9001~)

Electrical Circuit Check (S/N 0101~0358, 9001~) Shift lever input electrical circuit check

Disconnection check: Shift lever position

Terminals to be checked

Between terminals F and F/R common grounding (BY)

Between terminals R and F/R common grounding (BY)

Between terminals 1 and speed change common grounding (B)

Between terminals 2 and speed change common grounding (B)

Between terminals 3 and speed change common grounding (B)

Between terminals A and speed change common grounding (B)

Check result

Judgment

Conductive (Resistance 0 )

Normal

If the line is not conductive, judge that the switch or wire is damaged or defective. Shortcircuit check: Shift lever position

Connector B4 Grounding for speed change side (B) 1st speed (GW)

2nd speed (GL)

Auto (G)

3rd speed (GY)

F (GR)

Unused

R (GB)

Grounding for F/R side (BY)

70ZV63002

Check that the LED indicator corresponding to the shift lever position is on. LED

Judgment

Corresponding LED indicator is on

Normal

Corresponding LED indicator is off Wrong LED indicator is on

Abnormal

Terminals to be checked

Between terminals R and F/R common grounding (BY)

Between terminals F and F/R common grounding (BY)

Between terminals 1 and speed change terminal other than 1

Between terminals 2 and speed change terminal other than 2

Between terminals 3 and speed change terminal other than 3

Between terminals A and speed change terminal other than A

Check result

Judgment

Non conductive (Resistance  )

Normal

If a section is conductive, judge that the switch is sticking.

Disconnection Shortcircuit

If the judgment is abnormal, follow the check procedure below: <Step 1> Shift lever conductivity test Set the starter switch to the OFF position, and then disconnect connector B4 so that the shift lever assembly is disconnected. Perform conductivity test using a tester (circuit tester).

In this case two or more signals would be sent at the same time (e.g. forward and reverse; 1st and 3rd) <Solution> If disconnection or shortcircuit is detected, replace the shift lever assembly. The shift lever has no serviceable parts and must be replaced. If the conductivity check reveals that the shift lever is not defective, go to step 2.

95ZV EX 63-11 63 Check & Adjustment Electrical Group Electrical Circuit Check (S/N 0101~0358, 9001~) <Step 2> Checking conductivity of shift lever input circuit cable

Shift lever circuit

Shift lever position

Terminals to be checked

LR-BY (E117 to E119)

LBr-BY (E105 to E119)

LY-BY (E104 to E119)

LG-BY (E114 to E119)

LO-BY (E113 to E119)

LW-BY (E112 to E119)

Check result

Judgment

Conductive

Normal

If a line is not conductive, judge that the cable is defective. Also check that only the above terminals are conductive. Otherwise there could be a short circuit in the wiring.

Transmission controller

<Solution> Repair or replace the defective cable.

LED’s for inputs or outputs

LR LBr BY E117 E105 E119 LW BY E112 E119 LY LG LO E104 E114 E113

T/M CONTROLLER

INPUT GND SP COM

SSG

LR GO LG LO LW L YW YGy BY Y YL B401 B405 D001 H710 H709 E403 B403 G201 B303 B408 B407 B406 C701 G202 B Y Y/W W LBr LY R LLg H626 H134 H124 B402 B409 E402 A202 H636 11

K95ZVE63001

Connect connector B4 to the shift lever, and disconnect connector E1 from the transmission controller. Check the conductivity of the cable connector terminals.

Transmission cut-off monitor lamp

DECLUTCH T/M CUT S/W 2 5

Inching (declutch) switch (S/N 0101~0230, 9001~9010) 2

1 3 4 6

LgY A703

OFF

T/M controller INPUT (see “abbreviation chart” page 62-44)

SSG

Remarks

—

Normal

—

Disconnect

—

Inching impossible

Defective Machine stays in SW or short- the inching circuit (declutch) mode Normal

Inching function cancel

Abnormal

Defective wiring

On — Off

<Solution> Repair or replace the defective cable.

B401 L YW YGy BY Y LR YL GO LG LO LW B405 D001 H710 H709 E403 B403 G201 B303 B408 B407 B406 C701 G202 B Y Y/W W LBr LY R LLg H626 H134 H124 B402 B409 E402 A202 H636 11

Judgment

Released

Check the conductivity between the cable terminals of each switches and the controller.

LgR BY A201 E119

Pressed down

<Step 1> Checking inching switch

Inching (declutch) switch (S/N 0231~, 9011~)

Brake pedal

LLg LgR E101 C702 4

LgR BY A201 E119

GND SP COM

Input LED "I"

Abnormal

Inching (declutch) input electrical circuit check

Transmission cut-off switch

95ZV EX 63-12 63 Check & Adjustment Electrical Group Electrical Circuit Check (S/N 0101~0358, 9001~)

Inching switch specification 1

K95ZVE63002

Turn the transmission cut-off (Declutch) switch on the instrument panel "ON". Note that the transmission cutoff monitor lamp will light if the lamp circuit is not defective. Press down the left brake pedal, and check the on/ off status of the transmission controller "I" LED indicator.

WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Be sure to observe the following items before starting work. - Position the machine on level ground, and lower the bucket onto the ground. - Block the tires with chocks to prevent them from moving

(S/N 0101~0230, 9001~9010) Operating pressure MPa (kgf/cm2) (psi)

1.1 ± 0.15 (11.2 ± 1.5) (159 ± 21)

Return pressure MPa (kgf/cm2) (psi)

0.9 ± 0.1 (9.2 ± 1.0) (131 ± 14)

Resistance ()

10.4

(S/N 0231~, 9011~) Operating pressure MPa (kgf/cm2) (psi)

0.5 ± 0.1 (5.0 ± 1.0) (71.1 ± 14.2)

Return pressure MPa (kgf/cm2) (psi)

0.3 ± 0.05 (3.0 ± 0.5) (42.7 ± 7.1)

Resistance ()

6.9

95ZV EX 63-13 63 Check & Adjustment Electrical Group Electrical Circuit Check (S/N 0101~0358, 9001~) <Step 2> Checking assembly

transmission

cut-off

switch

OFF Transmission cut-off switch

7 8

4 1

5 2

6 3

LgY A703

Cable side connector

LLg LgR E101 C702 4

95ZV62087

Disconnect the A2 connector of the transmission cut-off switch assembly from the instrument panel. Perform conductivity test using a tester. Conductivity test

Between terminals 5 and 6 (Transmission controller input) Between terminals 2 and 3 (Lamp circuit)

Switch position ON

OFF

0







 0  (other than 

Judgment Normal Abnormal

Terminals to be checked

Disconnect Shortcircuit

95ZV EX 63-14 63 Check & Adjustment Electrical Group Electrical Circuit Check (S/N 0101~0358, 9001~)

QUAD switch input electrical circuit check

If the "S" indicator does not light: Checking QUAD switch: Disconnect the switch G2 connector. Check that the terminal line between 1 and 2 is conductive when the switch is depressed. <Solution>

E119

E116

If the switch is defective (non-conductive), replace it. If the switch is not defective, judge that the cable or connector between the control box and switch is defective. Repair or replace the defective unit.

T/M controller INPUT (see “abbreviation chart” page 62-44) GND SP COM

SSG

B401 LR GO LG LO LW L YW YGy BY Y YL B405 D001 H710 H709 E403 B403 G201 B303 B408 B407 B406 C701 G202 R LLg B Y Y/W W LBr LY E402 A202 H626 H134 H124 B402 B409 H636 11

K95ZVE63003

[While traveling at the 2nd speed, turn on the QUAD switch, and the speed will be shifted to the 1st speed. (For both manual and automatic modes)] Turn the switch ON again and the transmission should be shifted back to the 2nd speed. The QUAD switch does not shift the speed [Checking transmission controller input LED indicator] Check that the transmission controller “S” LED indicator lights instantaneously when the QUAD switch is turned ON. LED

Judgment

Normal

OFF

Abnormal

Disconnect

Remarks Shift change impossible

95ZV EX 63-15 63 Check & Adjustment Electrical Group Electrical Circuit Check (S/N 0101~0358, 9001~)

Machine speed sensor input electrical circuit check

<Step 1> Checking sensor Installation adjustment: Adjust the clearance between the sensor and gear to 0.17~1.3 mm (0.007~0.052 in). Checking sensor for disconnection: Disconnect the sensor connector, and then measure the resistance between the terminals.

Clearance adjustment 0.17~1.3 mm (0.007~0.052 in)

Resistance Shims are available to set clearance as needed. 33190–20970 is 0.04" thick. 33190–21660 is 0.02" thick.

2 Y Y H626 H636

SP COM

SSG

Normal

 (Disconnection) 0  (Short)

Abnormal

*Note The speed sensor resistance varies greatly with temperature. A hot sensor will have higher resistance, cold will reduce the resistance.

If the sensor is defective, replace it. If the sensor is not defective, the cable or connector between the sensor and the transmission controller is defective.

LR GO LG LO LW L YW YGy BY Y YL B401 D001 H710 H709 E403 B403 G201 B303 B408 B407 B406 B405 C701 B Y Y/W W LBr LY LLg R G202 H626 H134 H124 B402 B409 E402 A202 H636 11

Approx. 2.3 k ± 10% (25 ºC) (77 ºF)*

T/M controller INPUT (see “abbreviation chart” page 62-44) GND

Judgment

Repair or replace the defective unit.

K95ZVE63004

- Problem The automatic shift function is not working. The automatic shift function needs a speed signal. [Transmission controller input LED indicator] Checking conditions

Note The machine speed sensor is the same type as the engine speed sensor. Therefore, to check the machine speed sensor, replace the machine speed sensor with the engine speed sensor for easy troubleshooting. Sensor location Engine speed sensor

1. Select an open site away from people, other equipment and buildings. 2. Watch the segment LED indicator while the machine is moving at 1~5 km/h. LED [SS]

Judgment

Flashes according to the speed

Normal

Does not light (flash)

Abnormal

Note To prevent electronic "noise" from external sources that may corrupt the signal, "twist" the wire from the sensor all the way to the T/M controller.

Machine speed sensor Installation position

95ZV62042

95ZV EX 63-16 63 Check & Adjustment Electrical Group Electrical Circuit Check (S/N 0101~0358, 9001~)

Clutch solenoid valve output electrical circuit check

- Check valve for sticking

- Problem A clutch will not engage.

Unexpected movement of the machine may cause an accident resulting in injury or death. Be sure to observe the following items before starting work. - Position the machine on level ground, and lower the bucket onto the ground. - Block the tires with chocks to prevent them from moving.

Set the shift lever to the problem position. If the corresponding transmission controller input/output LED indicator is properly turned on and off, judge that the coil of the corresponding solenoid valve is disconnected, or the valve is sticking, or the cable of the output circuit is disconnected or poorly connected. - Problem The circuit protector is turned off. The cable (power supply side) between the transmission controller and the solenoid valve is short-circuited or the solenoid valve coil is internally defective. - Problem The machine can run at only one shift lever position. The machine runs at a certain shift lever position, though it does not run or runs too slow at any other position. In this case, judge that the cable (negative) of the solenoid valve is short-circuited, or the valve is sticking.

Note The solenoid valve for L, H, R, 1, 2 and 3 are the same. Therefore, to check the 1st speed solenoid, for example, replace the 1st speed solenoid with one of these solenoids. Be sure engine is off before checking. Push the manual operation knob to the ON position by hand, and then check that the spool operates smoothly. If it does not operate smoothly, judge that the valve is sticking. <Solution> If the coil is disconnected or the valve is sticking, replace the defective unit as an assembly. Manual operation knob

<Step 1> Checking solenoid valve

10 N-m (1 kgf-m)(7.2 lb-ft)

- Measuring coil resistance Disconnect the connector from the solenoid valve, and then measure the coil resistance using a tester. Note that a diode is incorporated in the coil. Coil resistance

WARNING

Negative side

Positive side

Judgment

Approx. 24 

Normal

Disconnect short 0

Abnormal

To check the coil and the diode: Use an analog (needle type) Volt-Ohm Meter (VOM) with an Rx1  setting. Adjust the meter's zero setting. Measure the resistance through the coil in both directions by reversing the test probes. The meter reading will be different for each measurement if the diode is good. If the diode is defective the meter will read the same in both directions. If the diode is defective replace the solenoid valve assembly. A defective diode can cause a controller failure over time.

59 N-m (6 kgf-m)(43 lb-ft)

95ZV62132

95ZV EX 63-17 63 Check & Adjustment Electrical Group Electrical Circuit Check (S/N 0101~0358, 9001~) <Step 2> Checking output circuit and cable T/M controller OUTPUT (sol) (see “abbreviation chart” page 62-44) BZ

PC+

PC-

BRK

LB LgB WO LP LR LW LBr H711 H707 H117 H712 H706 H705 H704 LgBr LgR G802 H708

LY LG LO H703 H702 H701

E3 H7

(S/N 0101~0230, 9001~9010) (S/N 0231~, 9011~)

H706 H705 H704 H703 H702 H701 LW LBr LG LO LR LY H712 H711 H710 H709 H708 H707 LP LB YW YGy LgR LgB

Disconnect the connector from the problem solenoid valve, and then set the starter switch to the ON position (engine OFF; shift lever set to problem speed; parking brake OFF). Measure the voltage of the connector terminal on the cable side using a tester. Example Measure the voltage between terminals LY and LB to check the connector of the 1st speed solenoid valve. Note Power is supplied to a solenoid valve only when the shift lever is set to the corresponding position. (When the output LED is on) To check the 4th speed connector, be sure to cancel the automatic shift function.

J102 ~702 J902 LP J701

IMPORTANT

YW YGy LgR LgB J903 J901 J801 J802

LR LW LBr LY LG LO J101 J201 J301 J401 J501 J601 6

When measuring voltage, do not shortcircuit two terminals of a connector. This is because the electronic parts inside the controller may be damaged.

T/M SOLENOID VALVE L L

LR LB J006 J011

+ 1

LW LB J005 J011

Modulator valve (1)

Checking negative cable Terminals to be checked

Voltage

Judgment

Between terminals LB and body grounding

Approx. 1 V

Normal

Approx. 24 V

Abnormal

<Solution> J7

If the voltage is abnormal, the cable may be broken. In this case, check the connector, find a defective part, then repair or replace it.

J8 2

YW J010

Abnormal

PRESS. DIFF. SENSOR

Approx. 0 V

LgR LgB J008 J007

SPPC

LP LB J012 J011

Normal

Modulator valve (2)

Judgment

LO LB J001 J011

Voltage Approx. 24 V

LG LB J002 J011

Terminals to be checked Between terminals LY and body grounding (For 1st speed solenoid)

LY LB J003 J011

J2 2

LBr LB J004 J011

Checking positive cable

YGy LB J009 J011

W 1

Colors of output circuit cables

L H R 1 2 3

(+) ( ) LR LW LBr LB LY LG LO K95ZV63003

95ZV EX 63-18 63 Check & Adjustment Electrical Group Electrical Circuit Check (S/N 0101~0358, 9001~)

Modulator valve output electrical circuit check

- Clutch oil pressure and symptoms in case of modulator valve (1) or (2) sticking or shorted at full stroke position. Stuck under ON condition

Normal modulation at clutch selection ON OFF

Modulator valve (2) 400 mA H

H L

Modulator valve (1) Po

Approx. 3.0 MPa (Approx. 30 kgf/cm2)

170 mA

Approx. 2.3~2.5 MPa (Approx. 23~26 kgf/cm2)

Clutch oil pressure PL

Approx.0.2~0.5 MPa (Approx. 2~5 kgf/cm2) Time PL = Pressure low PO = Pressure operating

115ZV62048

Inspection and remedy of output circuits of modulator valve (1) and (2) - Symptoms and clutch oil pressure in the case of a broken wire in output circuit wiring of modulator valve (1) or (2): Broken wire or stuck under OFF condition

Clutch oil pressure MPa (kgf/cm2)

Remarks (symptoms)

During (PL) charging

After (PO) selection

Modulator valve (1)

0.2~0.5 (2~5)

Approx. 1.0 (10)

Sluggish and apt to slip

Modulator valve (2)

Approx. 1.0 (10)

At 1st speed, approx. 2.5 (25) At other position, approx. 2.9 (30)

Harsh engagement

Clutch oil pressure MPa (kgf/cm2) During (PL) charging

After (PO) selection

Modulator valve (1)

At 1st speed, approx. 2.0 (20) At other position, approx. 2.8 (29)

At 1st speed, approx. 2.5 (25) At other position, approx. 2.9 (30)

Modulator valve (2)

0.2~0.5 (2~5)

2.3~2.5 (23~26)

Remarks (symptoms) Harsh engagement Slightly sluggish

Electrical problem or faulty clutch? If all the clutches have similar symptoms in regard to time lag, jolt, clutch oil pressure, the electrical circuit, and modulator valves (1) and (2) should be suspected.

95ZV EX 63-19 63 Check & Adjustment Electrical Group Electrical Circuit Check (S/N 0101~0358, 9001~)

Check output circuit wiring

<Step 1> Check modulator valve (1) or (2)

T/M controller OUTPUT (sol) (see “abbreviation chart” page 62-44) BZ

PC+

PC-

BRK

Decision

LB LgB WO LP LR LW LBr H711 H707 H117 H712 H706 H705 H704 LG LO LY H703 H702 H701

LgBr LgR G802 H708 7

E3 H7

(S/N 0101~0230, 9001~9010) (S/N 0231~, 9011~)

J102 ~702 J902

Modulator valve (2)

Modulator valve (1)

J7 2

LgR LgB J008 J007

SPPC 1

J8 2

K95ZV63004

Disconnect the connector of modulator valve (1) or (2) and measure voltage between both terminals of the wiring connector. Decision Normal Abnormal (Broken wire)



- Check for sticking If necessary, disassemble the valve and inspect. <Solution>

LP LB J012 J011

About 24 Ohms

Abnormal (Broken wire)

MV2 resistance check: To check the coil and the diode:

YW YGy LgR LgB J903 J901 J801 J802

LY LG LO LR LW LBr J101 J201 J301 J401 J501 J601 6

Normal

If a broken wire or sticking valve is found, replace the entire modulator valve assembly.

H712 H711 H710 H709 H708 H707 LP LB YW YGy LgR LgB

Resistance of modulator valve (1) or (2)*

H706 H705 H704 H703 H702 H701 LR LW LBr LY LG LO

LP J701

Using a tester volt-ohm meter, measure resistance between both terminals of the connector.

Voltage 14 V ~ 18 V (MV1) Approx. 24 V (MV2) 0 V if broken wire

- Voltage for modulator valve (2) can be measured only during clutch selection. <Solution> If a wire is broken, check at the next connector to locate the faulty spot, and repair or replace the wiring or connector. To find the faulty spot use a VOM (Volt-Ohm Meter) and measure the resistance through each wire until a high resistance is found.

Use an analog (needle type) Volt-Ohm Meter (VOM) with an Rx1  setting. Adjust the meter's zero setting. Measure the resistance through the coil in both directions by reversing the test probes. The meter reading will be different for each measurement if the diode is good. If the diode is defective the meter will read the same in both directions. If the diode is defective replace the solenoid valve assembly. A defective diode can cause controller failure over time.

95ZV EX 63-20 63 Check & Adjustment Electrical Group Electrical Circuit Check (S/N 0101~0358, 9001~)

Neutral relay electrical circuit check

<Step 1> Checking cable of output circuit 1. Disconnect connector F6 from the neutral relay, and then set the starter switch to the ON position. Set the shift lever to the neutral (N) position, and then measure the voltage of the connector terminal on the cable side.

NEUTRAL RELAY

2. Checking positive cable +

RL SbP H610 E220

G L D102 D002 2

(BLACK)

Terminals to be checked

Voltage

Judgment

Between terminals L and body grounding

Approx. 24 V

Normal

Approx. 0 V

Abnormal

3. Checking negative cable G - From fuse F14 (starter switch terminal C) RL - To magnetic switch terminal SbP - to T/M controller E220

Terminals to be checked

Voltage

Judgment

Between terminals SbP and body grounding

Approx. 24 V

Normal

Approx. 1 V

Abnormal

L - To T/M circuit protector for T/M controller 95ZV63002

- Problem Engine does not start with the shift lever in neutral position. Though the transmission controller "N" LED indicator is on, the engine will not start, judge that the neutral relay contact is not closed. - Problem The engine will start at the shift lever forward or reverse position. If the engine starts though the transmission controller "N" LED indicator is off, judge that the neutral relay contact is sticking, or the transmission controller is defective.

<Solution> If the voltage is abnormal, judge that the cable is disconnected or short-circuited. Repair or replace the cable. <Step 2> Checking neutral relay individually The neutral relay is the same type as the back-up lamp relay, horn relay, etc. Therefore, to check the neutral relay, replace it with one of these relays, then detect which one between the neutral relay and the wiring is the cause of the fault. <Solution> If the relay is defective, replace it.

95ZV EX 63-21 63 Check & Adjustment Electrical Group Electrical Circuit Check (S/N 0101~0358, 9001~)

Parking brake electrical circuit check

Unexpected movement of the machine may cause an accident resulting in injury or death. To prevent such an accident, observe the following items before checking the parking brake circuit: - Park the machine on level ground. - Block the tires with chocks to prevent wheels from moving.

PARKING S/W L

G Y B

L D003

LgG H137

GO SbW E115 A607 E510 3

B 1

L0 1

LgG H137

(24V) 2

REAR PARKING SOLENOID

WARNING

(0~1V)

[Step 1] Parking brake switch OFF (35

)

[Step 2] Coil resistance

95ZV62096

- Problem The parking brake cannot be applied or cannot be released. The parking switch is interlocked to the parking lamp of the instrument panel. It turns on and off the parking lamp. If the lamp turns on when the switch is pulled up and goes off when it is pushed in the switch is working properly. If the lamp does not work the switch, lamp or wiring is defective. If the lamp works with the switch, check the parking brake solenoid or its wiring.

95ZV EX 63-22 63 Check & Adjustment Electrical Group Electrical Circuit Check (S/N 0101~0358, 9001~) <Step 2> Checking solenoid valve

<Step 1> Checking cable of output circuit Disconnect the connector from the solenoid valve, and then measure the voltage of the connector terminal on the cable side using a tester. Note that the starter switch should be "ON", engine "OFF" and parking switch should be at the OFF position. Checking positive cable Terminals to be checked

Voltage

Judgment

Between terminals LgG and body grounding

Approx. 24 V

Normal

Approx. 0 V

Abnormal

Valve assembly

Parking brake solenoid valve Hydraulic oil tank Valve location

Checking negative cable

95ZV52041

- Measuring coil resistance Terminals to be checked

Voltage

Judgment

Between terminals L and body grounding

Approx. 0 V

Normal

Other than 0 V

Abnormal

Disconnect the connector from the solenoid valves, and then measure the resistance of the coil using an analog meter.

<Solution> Coil resistance

If a cable is disconnected or a wire broken, measure the voltage of the next connector in the same way. Find the defective cable, and then repair or replace the cable.

Judgment

Approx. 35 

Normal

Disconnect or short-circuited 0

Abnormal

Note The diode is incorporated in the coil. - Checking sticking of solenoid valve Run engine and charge the brake accumulator, move the manual operation knob on the solenoid valve, then check whether the parking brake can be turned on and off. If the parking brake cannot be turned on and off, the solenoid valve is stuck. <Solution> If wire breakage or a sticking valve is detected in the coil, replace the valve assembly.

95ZV EX 63-23 63 Check & Adjustment Electrical Group Electrical Circuit Check (S/N 0101~0358, 9001~)

Solenoid valve on the front side

<Step 2> Checking solenoid valve

(For Europe only) <Step 1> Checking cable of output circuit

G Y B

Front parking solenoid valve

L D003

LgG H137

GO SbW E115 A607 E510 3

Front chassis

H1 K1 R8

(24 V)

(0~1 V)

1 B

LgG K105

Solenoid valve location

[Step 1] Parking brake switch OFF

(46

)

- Measuring coil resistance Disconnect the connector from the solenoid valves, (for front and rear parking brake) and then measure the resistance of the coil using a tester. Coil resistance

[Step 2] Coil resistance 95ZV62098

FRONT PARKING SOLENOID

Disconnect the connector from the solenoid valve, and then measure the voltage of the connector terminal on the cable side using a tester. Note that the key should be "ON", engine "OFF" and parking switch should be at the OFF position. Checking positive cable Terminals to be checked

Voltage

Between terminals LgG and body grounding

Approx. 24 V

Judgment Normal

Approx. 0 V

Abnormal

95ZV52043

Judgment

Approx. 35 

Normal

Disconnect or short-circuited 0

Abnormal

Note The diode is incorporated in the coil. - Checking sticking of solenoid valve Accumulate the brake oil in the brake accumulator, push in the manual operation knob on the solenoid valve, then check whether the brake can be turned on and off. If the brake cannot be turned on and off, the solenoid valve is stuck. <Solution> If wire breakage or a sticking valve is detected in the coil, replace the valve assembly.

Checking negative cable Terminals to be checked

Voltage

Judgment

Between terminals B and body grounding

Normal

Other than 0 V

Abnormal

<Solution> If a cable is disconnected or a wire broken, measure the voltage of the next connector in the same way. Find the defective cable, and then repair or replace the cable.

95ZV EX 63-24 63 Check & Adjustment Electrical Group Electrical Circuit Check (S/N 0101~0358, 9001~)

Auto brake electrical circuit check Shown in the "released" position

To rear service brake (S/N 0101~0164, 9001~9010)

To front service brake

- If auto-braking does not occur Possible causes include a broken wire in the auto braking solenoid valve output circuit, a broken coil in the solenoid valve, or a sticking valve.

31 A C

WARNING

23 Pi

Unexpected movement of the machine may cause an accident resulting in injury or death. To prevent such an accident, observe the following items before checking the auto brake circuit. - Park the machine on level ground. - Block the tires with chocks to prevent wheels from moving. <Step 1> Checking solenoid valve

1.2 1.0

- Measuring coil resistance

Disconnect the connector from the solenoid valve, and then measure the resistance of the coil using a tester.

From unloader valve (Pump)

T/M controller signal

Coil resistance

From reducing valve (Pump)

K95ZVE52006

PC+

H1 G2

PC-

BRK

WO H117

LB LgB WO LP LR LW LBr H711 H707 H117 H712 H706 H705 H704 LgBr LgR G802 H708

LY LG LO H703 H702 H701

Normal

Disconnect or short-circuited 0

Abnormal

- Checking sticking of solenoid valve

T/M controller OUTPUT (sol) (see “abbreviation chart” page 62-44) BZ

Judgment

Approx. 35 

Run engine and charge the brake accumulator, push in the manual operation button (diameter: approximately 4 mm) on the solenoid valve, then check whether the brake can be turned on and off. If the brake cannot be turned on and off, the solenoid valve is stuck.

<Solution> W

If wire breakage or a sticking valve is detected in the coil, replace the valve assembly.

AUTO BRAKE SOLENOID 95ZV62100

95ZV EX 63-25 63 Check & Adjustment Electrical Group Electrical Circuit Check (S/N 0101~0358, 9001~) <Step 2> Checking wiring in output circuit Check continuity of the wiring from the controller to the solenoid valve. If continuity is not detected, the wiring is broken. In this case, check continuity between each connector, detect a defective part, then repair or replace the wiring. If any defective part is not detected in the steps 1 and 2 above and something is still wrong with the auto brake, the controller may be defective. In this case, replace the controller assembly. Before replacement of the controller assembly, confirm that the input circuit is normal. (Refer to the description on the inspection of the speed sensor input circuit.)

95ZV EX 63-26 63 Check & Adjustment Electrical Group Electrical Circuit Check (S/N 0101~0358, 9001~)

Gauge circuit electrical circuit check

Torque converter oil temperature and engine water temperature

INSTRUMENT PANEL (see “abbreviation chart” page 92-25) +

(+)

EG2 EG1 EG3

WTM TTM

1/2

1/4

RB SbO C211 E607

3/4

EMP GND

YR YB YL YBr YG E605 E616 E604 E615 E614

Lg O O BrB BrW BrR D103 B901 B902 H629 H619 H639

YB YSb H105 H638 1

E/G WATER TEMP. SENSOR

YSb

H638

YB H105

T/C OIL TEMP. SENSOR K95ZVE63005

The sensors detect the torque converter oil temperature and engine water temperature and then convert them into electric signals. The electric signals are then fed to the respective gauges and indicated on the gauges. If a gauge indicates wrong values, either the sensor, gauge or wiring will be defective. Determine the defective unit by using the following procedure. <Step 1> Checking sensor signal Disconnect the connector A5 from the instrument panel, or disconnect the connector from the corresponding sensor. Measure the resistance between the sensor signal terminal and the ground terminal. If the measurement value is acceptable compared with the standard value shown below, the sensor is not defective. If the measurement value is abnormal, check the wire in addition to the sensor because the cable may be defective (corroded, broken, or high resistance).

Temperature of detection area (ºC)

60 (140 ºF)

80 (176 ºF)

100 (212 ºF)

120 (248 ºF)

Resistance between terminal and body ()

56.3

29.5

16.5

95ZV EX 63-27 63 Check & Adjustment Electrical Group Electrical Circuit Check (S/N 0101~0358, 9001~) Resistance between gauge terminals()

<Step 2> Checking gauge

Controller

Grounding

V V 15V15V

E E

E/G water temperature

T/C, T/M oil temperature

Between S and E

120~125

75~80

Between S and V

120~125

85~90

Between E and V

170~190

130~150

Remove the instrument panel, and then disconnect the connector from the panel. Measure the resistance between the screw terminals on the rear surface of the panel. Judge whether the resistance value is acceptable.

Power supply 24V

S S

Gauge

Viewed from rear surface of instrument panel

Note If a gauge is removed from the panel, the resistance between the terminals will differ from the standard value shown in the table. Please see table at bottom of page.

K90ZV62016 70ZV62042

Instrument panel (back side view)

CN4 1 5

L12 L14 L15

V E Engine water temperature sensor L10

L10

L19 9

L8 E L9

Transmission oil temperature sensor

Tachometer

L18

E L10

L17

56 L10

L16

16P

L21

L3 L4

12P L10

L10

CN3

L20

58 57 Hour meter

L10

L13

L11

L1 L2

CN1

CN2

L22

L23

L24

L25

L26

L27

20P 19

115ZV63002

Resistance between gauge terminals () Between S and E

160

Between S and V

150

Between E and V

310

S E

Note When the ground of the gauge is defective such as contact failure and derailment, the pointer scales out. Before replacing the gauge, check the ground circuit.

Viewed from rear surface of gauge 70ZV63014

95ZV EX 63-28 63 Check & Adjustment Electrical Group Electrical Circuit Check (S/N 0101~0358, 9001~)

Fuel level gauge electrical circuit check Indicator lamps

(YR)

1/2 YR

3/4

(YB)

View A YBr

(Brown)

SW1 (3/4) (White)

GND

Fuel level circuit

SW3 (1/4)

K115ZV62017

Indicator lamp O: Lit : Flashing – : Extinguished

Float switch O: ON X: OFF E

1/8 1/4 1/2 3/4

1/4 1/2 3/4

From 3/4 to 1/2 X

From 1/2 to 1/4 X

From 1/4 to 1/8 X From 1/8 to E

E or less

Actual fuel level

–

Any other pattern

SW5 (E) (Green)

Float switch switching and indicator lamp lighting status

3/4 or more

1/4

E 1/8

1/8

(YG)

1/4

(YBr)

3/4

1/2

(YL)

(S/N 0101~0262, 9001~9064)

Fuel level sensors

Monitor controller

+24 V

<Step 1> Checking level sensor

–



–

SW4 (Yellow) (1/8)

SW2 (1/2) (Blue)

SW1 (3/4)

View B

SW2 (1/2)

SW3 (1/4)

Example of failure: When the wire of the "1/4" float switch is broken, the indicator lamps for "1/8" and "E" do not light even if the fuel amount becomes 1/2 or less.

Float switch

SW4 (1/8)

Only a fuel level lamp corresponding to the actual oil level lights.

OFF

Liquid surface

SW5 (E)

If no fuel level lamp lights, it should be judged which one between the fuel level sensor and the fuel level lamps is defective. The level sensor has five float switches. When a float moves down, a corresponding switch contact is closed. When the fuel tank becomes empty, the contact of all float switches is closed and the lamp “E” flashes on the fuel level gauge.

INSTRUMENT PANEL (see “abbreviation chart” page 92-25) +

(+)

RB SbO C211 E607

When the fuel tank becomes full, the contact of all float switches is open and the lamp “F” lights on the fuel level gauge.

EG2 EG1 EG3 F

3/4

SS WTM TTM 1/2

1/4

EMP GND

YR YB YL YBr YG E605 E616 E604 E615 E614

Lg O O BrB BrW BrR D103 B901 B902 H629 H619 H639

YB YSb H105 H638 1

K95ZVE63006

95ZV EX 63-29 63 Check & Adjustment Electrical Group Electrical Circuit Check (S/N 0101~0358, 9001~) (S/N 0263~, 9065~)

Disconnect the connector N1 of the level sensor, and perform conductivity test between the terminals and body using tester (circuit tester). A

Float position At the top end

At the bottom end

Float switch

(3/4)

ON (1/2)

(1/4) ON (1/8) ON (E) ON Fuel level sensor (Brown)

(Black) 3/4

E (Yellow)

(White) 1/2

1/8 (Green)

(Red) 1/4 View A

K95ZV62009

Check result

Judgment

Conductive

Abnormal

Non-conductive

Normal

Conductive

Normal

Non-conductive

Abnormal

95ZV EX 63-30 63 Check & Adjustment Electrical Group Shift Lever

Shift Lever Operation force measurement

97ZV63004

To be measured in the 30 mm (1 1/8 in) position from the tip of the lever.

Changeover between forward and reverse Specification value 6 ± 1.5 N (0.6 ± 0.15 kgf) (1.3 ± 0.3 lbf)

Transmission gear changeover Specification value 0.3 ± 0.05 N-m (3 ± 0.5 kgf-cm) (7 ± 1.0 lbf)

95ZV EX 72-1 72 Function & Structure Operator Station Group

72 Function & Structure Operator Station Group Cabin .....................................................................................72-2 Operator Seat........................................................................72-9 Steering and Transmission Shift Lever................................72-10 Air Conditioner ....................................................................72-13

95ZV EX 72-2 72 Function & Structure Operator Station Group Cabin

Cabin B A

A 3

7 5 6

A-A 4

B-B

The cabin equipped with the ROPS (Roll Over Protective Structure) is provided as standard. 1. Door (left side) 2. Front wiper 3. Window washer jet nozzle 4. Outside air suction port (air conditioner) 5. Antenna 6. Sun visor 7. Rear view mirror

85V2E72001

95ZV EX 72-3 72 Function & Structure Operator Station Group Cabin

Glass

70V2E72001

1. Front glass 2. Front side glass 3. Rear glass

95ZV EX 72-4 72 Function & Structure Operator Station Group Cabin

1. Part number 32011-21690

Clear glass (Outside)

2. Part number 32011-21700

Clear glass (Outside)

Laminate: 0.76 mm

T=3.0

Laminate: 0.76 mm

T=3.0

Green glass (Inside)

T=3.0

A-A

(mm) 327.5 (mm) R3

953

299.5

52.5

R53

1149

1195

699

646.5

70V2E72002

Note This glass must comply with ECE REG43.

70V2E72003

Note This glass must comply with ECE REG43.

95ZV EX 72-5 72 Function & Structure Operator Station Group Cabin

3. Part number 32011-21500

(mm) 1262.5

848

0 R3

T=6.0

1325.5

70V2E72004

Note This glass must comply with ECE REG43.

95ZV EX 72-6 72 Function & Structure Operator Station Group Cabin

Wiper mount Front wiper

714 (Along surface)

Wipin g ang le 56º

ng surf ace)

R750(A lo

1 4

97ZV72004

1. Wiper motor 2. Wiper arm 3. Wiper blade

4. Intermittent wiper relay 5. Washer jet nozzle

Rear wiper

106

450

97ZV72005

1. Wiper motor 2. Wiper arm

3. Wiper blade 4. Washer jet nozzle

95ZV EX 72-7 72 Function & Structure Operator Station Group Cabin

Wiper motor Front Cabin

(Automatic stop position) 12 159200 589 24V

100

e) ol rh ø5 the a re

115

80 70

±0 5.6 R8

(3º 10')

Wipin

g angl e 56º

tati ng

dire cti

(-1) AVS0.85 W

(-2) AVS0.85 L

(+) AVS0.85 R

(S) AVS0.85 Y

(+) AVS0.85 R

( L1~L3=3.7µH C1~C3=0.2µF )

MOTOR Circuit breaker L3

Washer motor

C2 R

C1 L

24 V OFF LOW HIGH

SWITCH

Circuit diagram

97ZV72100

Wiper motor (front) specifications 1. Wiper motor assembly 2. Link assembly 3. Washer 4. Nut 5. Cap 6. Nut 7. Crank arm

Nominal torque

23.5 N-m (2.4 kgf-m)

Rated voltage Rotating speed Load: 1.0 N-m (0.1 kgf-m) Rotating speed Load: 4.0 N-m (0.4 kgf-m)

DC 24 V Low

46±4 min-1

High

68±7 min-1

Low

≧ 32 min-1

High

≧ 42 min-1

No-load starting voltage (Minimum)

≦ 16 V

Automatic stopping voltage (Maximum)

≧ 32 V

No-load current

≦2A

Locked rotor current

≦ 15 A

95ZV EX 72-8 72 Function & Structure Operator Station Group Cabin Rear

Wiping angle: 106º±3º

Automatic stop position

L(+) LB (+1)

Y(S)

Cabin

AVS0.85 LB (+1) AVS0.85 L (+)

AVS0.85 WB ( )

MOTOR (Circuit breaker)

AVS0.85 Y (S)

M 2 LB

Cabin

L +

Pantograph arm

Tightening torque: 6.4~9.3 N-m (0.6~0.9 kgf-m)

OFF ON

24V

SWITCH Circuit diagram (motor stop position)

K97V2J72001

1. Wiper motor 2. Washer 3. Packing 4. Nut 5. Cap 6. Nut

Wiper motor (rear) specifications Nominal torque

12 N-m (1.2 kgf-m)

Rated voltage Rotating speed Load: 0.6 N-m (0.6 kgf-m) Rotating speed No load

DC 24 V Speed

38±5 min-1

Current

2 A or less

Speed

40±5 min-1

Current

1 A or less

Starting voltage

16 V or less

Locked rotor current

7 A or less

95ZV EX 72-9 72 Function & Structure Operator Station Group Operator Seat

Operator Seat Armrests Rotate control knob (3) to select desired angle. Pivot up and parallel with backrest when not in use. Combined height and weight adjuster 3

1. Sit on the seat. 2. Turn handle (4) to adjust seat height. Clockwise to raise seat. Anti-Clockwise to lower seat.

2 1

3. Check ride indicator (5) shows green. If red, readjust seat height. Within the green band of the ride indicator there is 75 mm of height adjustment for any driver.

95ZV OM EU SEAT

Note The seat is designed so that it is unnecessary to make any adjustment for the driver weight. Up-stop height adjustment control (for Europe)

85V2E72003

1. Reclining adjustment lever 2. Back-and-forth adjustment lever 3. Arm rest height adjuster 4. Height and Weight adjuster 5. Ride indicator 6. Handwheel Seat adjustment Adjust the seat for comfort and so that the pedals may be pushed fully down when the operator's back is fully back. Reclining Move adjustment lever (1) forward and hold, select backrest angle, release adjustment lever. Forward/Backward Lift lever (2) up and hold, slide seat to desired position, release lever.

To adjust the up-stop height, rotate the handwheel (6) clockwise to raise the seat unseated, rotate it counterclockwise to lower the seat unseated.

95ZV EX 72-10 72 Function & Structure Operator Station Group Steering and Transmission Shift Lever

Steering and Transmission Shift Lever Tilt quantity 56

4 5 4 6

Operator stand

1. Steering wheel 2. Transmission shift lever 3. Turn signal indicator and head lamp high/low selector lever 4. Handle tilt adjustment lever 5. Gas spring 6. Column shaft assembly 7. Lower column shaft 8. Orbitrol® The tilt case (1) ~ (6) can select the optimal position in the following range:

95ZVE72009

Handle tilt 56 mm in each direction from the center Handle slide 70 mm upward and downward Note - Install the gas spring (5) with its rod side facing downward as shown in the figure above. - Install the lower column shaft (7), together with the Orbitrol®, from the underside of the operator stand.

95ZV EX 72-11 72 Function & Structure Operator Station Group Steering and Transmission Shift Lever

Tilt case 8

1 1

4 2

Lock release position

6 7

Slide quantity 70

2 5 4 Operator stand

9 270 (355 when slid)

Operator stand Lock position

K65ZV72001

1. Column shaft assembly 2. Bracket 3. Bracket 4. Handle tilt adjustment lever (tapered mounting hole) 5. Bolt (left-hand double-start thread) 6. Nut (left-hand double-start thread, tapered in lever mounting area) 7. Nut (left-hand double-start thread) 8. Nut 9. Bushing 10. Nut 11. Bolt (flanged bolt is not applicable)

: (6): 21.5 N-m (2.2 kgf-m) : (7): 49 N-m (5.0 kgf-m) : (8): 54 N-m (5.5 kgf-m) : (10) (inside): 31.9 N-m (3.3 kgf-m) : (10) (outside): 89.1 N-m (9.1 kgf-m) Note - Apply grease at the slider of bracket (3) (shaded part). - When mounting tilt lock lever, install nut (6) to bolt (5) first, fix lever (4) with nut (7) while holding nut (6). Adjust lever (4) to tilt at an angle of 5º against column shaft (1). The control force at the end of lever (4) is 130~150 N (13~15 kgf).

95ZV EX 72-12 72 Function & Structure Operator Station Group Steering and Transmission Shift Lever

Column shaft Grease charged

Adhesive applied

1 8

11 5

6 Waterproof seal

13 11 11

B-B

A-A 97ZV72018

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

Shift lever Refer to "Electrical Group 62".

95ZV EX 72-13 72 Function & Structure Operator Station Group Air Conditioner

Air Conditioner Air conditioner components

4 1-1

3 1-2

1 7 9

6 13

97ZV72020

1. Air conditioner assembly 1-1 Cooling unit assembly 1-2 Blower assembly 2. Air distributor assembly 3. Air filter 4. Control panel 5. Condenser assembly 6. Compressor assembly 7. Receiver dryer 8. Receiver holder 9. Joint 10. Drain hose 11. Relay 12. Thermistor (inside air sensor) 13. Thermistor (outside air sensor) 14. Solar sensor (insolation sensor)

Air conditioner specifications (system performance) Cooler performance Cooling capacity

4.65 kw ± 10%

Air quantity

550 m3/h ± 10%

Rated voltage

DC 24 V

Power consumption

345 W ± 10%

Heater performance Heat radiation quantity

5.2 kw ± 10%

Air quantity

380 m3/h ± 10%

Rated voltage

DC 24 V

Power consumption

170 W ± 10%

(Difference in temperature: 65ºC, water flow rate: 6 L/min)

95ZV EX 72-14 72 Function & Structure Operator Station Group Air Conditioner

Air conditioner structure Cooling unit 37

14 57

38 13 25

50 49

9 24

23 6

5 15 4

3 16 12

97ZV72021

95ZV EX 72-15 72 Function & Structure Operator Station Group Air Conditioner

1. Cooling unit case (rear) 2. Cooling unit case (front) 3. — 4. Evaporator 5. Heater core 6. Expansion valve 7. — 8. Tube 9. Thermistor 10. — 11. Door (upper) 12. Door (lower) 13. Door (foot) 14. Damper (vent) 15. Pressure switch (triple) 16. Liquid tube 17. Suction tube 18. — 19. —

20. — 21. — 22. — 23. Power IC assembly 24. Servo motor (A/M, air mixing) 25. Servo motor (mode) 26. — 27. — 28. — 29. — 30. — 31. — 32. — 33. — 34. — 35. — 36. — 37. Lever (face, door) 38. Lever (foot, door)

39. — 40. — 41. — 42. — 43. — 44. — 45. — 46. — 47. — 48. — 49. Lever (face, front) 50. Control lever (face, front) 51. Door (S/A) (face, front) 52. — 53. — 54. — 55. — 56. — 57. Thermo sensor (water temperature)

95ZV EX 72-16 72 Function & Structure Operator Station Group Air Conditioner

Heater and accessories

Air distributor (hood & defroster selection box) 13 3

7 2

2 5 1 1

97ZV72024

11 17

97ZV72023

1. Blower case 2. Blower case 3. Air damper case 4. Air damper case 5. Blower & blower motor 6. Servo motor 7. Door 8. — 9. — 10. Bracket 11. Pipe (for cooling motor) 12. — 13. — 14. — 15. — 16. — 17. Relay

1. Air damper case 2. Air damper case 3. — 4. — 5. — 6. Control lever 7. Door 8. — 9. Control lever 10. — 11. — 12. — 13. Servo motor (AY, inside/outside air)

95ZV EX 72-17 72 Function & Structure Operator Station Group Air Conditioner

Air compressor (with magnetic clutch)

2-1 2

2-2

2-3

2-6 5~7

1 97ZV72025

3. — 4. — 5. Plate washer 6. Plate washer 7. Plate washer

1. Compressor 2. Magnetic clutch assembly 2-1 Magnetic stator 2-2 Magnetic clutch rotor 2-3 Clutch hub 2-6 Plate washer

Condenser unit 3

1 2 4 7

10 4

1. Condenser core 2. Blower assembly 3. Condenser bracket 4. Condenser bracket 5. — 6. —

97ZV72026

7. Cover 8. — 9. — 10. Wire harness 11. — 12. Resistor

95ZV EX 72-18 72 Function & Structure Operator Station Group Air Conditioner

Control unit

Control amplifier

Control panel

97ZV72027

Control panel

OFF switch

Inside/outside air selector switches

Blower switches

Temperature setting switches

Liquid crystal display (LCD) unit

Vent mode selector switch

AUTO switch

Air conditioner ON/OFF switch

97ZV72028

95ZV EX 72-19 72 Function & Structure Operator Station Group Air Conditioner

Cooling mechanism

Refrigerant

Principle of cooling

An object which circulates inside the cooling circuit and transmits heat is called "refrigerant". The refrigerant changes repeatedly its state, from "liquid --> gas --> liquid --> gas ...", and carries heat from the low temperature side (inside the cabin) to the high temperature side (outside the cabin) while changing its status.

Indoor

Evaporator

Expansion valve Expansion Evaporation Condensation

Deprives heat of the adjacent area.

Condenser Releases heat to the outside.

There are many types of refrigerants. This air conditioner adopts refrigerant R134a which does not contain chlorine and does not destroy the ozone layer.

Compression Refrigerant

IMPORTANT

Compressor Basic cooling cycle

97ZV72029

When alcohol is applied on your skin, you feel cool. When the garden is watered in summer, you feel cool also. It is because alcohol or water deprives heat (which is called "latent heat") of its adjacent area when evaporated. These phenomena clearly show the principle of cooling. Cooling offers coldness and coolness by utilizing such natural phenomena. Generally, a cooler seals the liquid, which evaporates easily and is called "refrigerant", inside its circuit, and makes the refrigerant vaporized and liquefied repeatedly while circulating it. The figure on the right shows the basic cooling cycle.

Make sure to use the specified refrigerant (Freon R134a). If any other refrigerant is used, the following problems may occur: - The air does not become cool enough. - The equipment may be damaged. And never mix Freon R134a with any other refrigerant. Chemical formula

CH2FCF3

Molecular weight

102.03

Boiling point

-26.19ºC

Critical temperature

101.14ºC

Critical pressure

4.1 MPa (41.45 kgf/cm2)

Critical density

511 kg/m3

Density of saturated liquid (at 25ºC)

1,206 kg/m3

Specific volume of saturated vapor (at 25ºC)

0.0310 m3/kg

Latent heat of evaporation (at 0ºC)

197.54 KJ/kg (47.19 kcal/kg)

Combustibility

Incombustible

Ozone decomposition modulus

95ZV EX 72-20 72 Function & Structure Operator Station Group Air Conditioner Generally, the fluid (which is the generic name for gas and liquid) has the following properties.

Refrigerant characteristics

1. When the temperature of gas at a certain pressure decreases, the gas starts to condense and change into liquid at a certain temperature. For each substance (liquid), this temperature is fixed if the pressure is determined. This temperature determined by the pressure is called the "saturated temperature".

Refrigerant temperature (ºC)

100

40 35 20 15 0

20 30 0

3.6 5 8 10 353 490 785 981

15 1,471

20 1,961

25 2,452

30 2,942

35 3,432

Gauge pressure (kgf/cm2G) Relationship between saturated pressure and saturated temperature of R134a

40 (kgf/cm ) 3,923 (kPa) 2

97ZV72030

2. On the contrary to (1), when the temperature is determined, the pressure at which liquefaction starts is fixed. This pressure is called "saturated pressure". The figure on the left shows the relationship between the saturated temperature and the saturated pressure of refrigerant R134a. At the temperature and the pressure below (= on the lower right side of) the curve, the refrigerant is liquid. At the temperature and the pressure above (= on the upper left side of) the curve, the refrigerant is gas. Suppose that the air conditioner is used in mid summer. When evaporated, the refrigerant absorbs the heat of evaporation from the air inside the cabin. Accordingly, in order to cool down the air inside the cabin to approximately 25ºC, the refrigerant should change (be evaporated) from liquid into gas at a temperature lower than 25ºC. From the figure, it can be seen that the refrigerant R134a can sufficiently cool down the air inside the cabin at a pressure above the atmospheric pressure. (If used refrigerant requires a pressure below the atmospheric pressure to cool down the air to the necessary temperature, air enters into the circuit and the ability of the cooler is deteriorated.) In the process in which the vaporized refrigerant is returned to liquid, the refrigerant is cooled down by the outside air of 35ºC or more so that it condenses. Accordingly, as is seen from the figure, the refrigerant can be liquefied at the pressure of 785 kPa (8.0 kgf/ cm2G) or more.

95ZV EX 72-21 72 Function & Structure Operator Station Group Air Conditioner The figure on the left shows the cooling circuit of the air conditioner.

Cooling circuit

Inside cabin

Pressure bulb

Expansion valve

Evaporator Blower

Inside engine room

Compressor

Cooling fan

Receiver dryer Condenser Structure of cooling circuit 95ZVE72017

In this circuit diagram, the area which cools down the air inside the cabin is the evaporator. The cooling circuit utilizes the fact that the refrigerant absorbs heat (latent heat of evaporation) from the adjacent area when evaporated, and cools down the air inside the cabin. The area where the refrigerant is evaporated is the evaporator. The "cooling" effect can be obtained only when the air to be cooled down is continuously fed to the area around the evaporator by the blower fan and the liquid refrigerant (wet evaporation refrigerant with low degree of dryness) is supplied into the evaporator. For example, in order to cool down the air to 15ºC, the refrigerant can absorb the latent heat of evaporation from the air only when it is evaporated at a temperature lower than 15ºC. It can be seen from the figure in the previous page that the pressure of the refrigerant inside the evaporator should be 353 kPa (3.6 kgf/cm2G) or less to realize it. And in order to keep sufficient cooling effect, the supplied refrigerant quantity should be adjusted so that the refrigerant supplied to the evaporator is completely evaporated inside the evaporator into dry vapor or gas. Accordingly, the cooling circuit should be constructed to reduce the pressure inside the evaporator and supply proper quantity of refrigerant into the evaporator so that the evaporator can cool down the air sufficiently. The supplied refrigerant quantity can be adjusted by the expansion valve. The pressure inside the evaporator is kept at a low value by the closing action of the expansion valve and the suction action of the compressor. The compressor works as a pump which circulates the refrigerant. The refrigerant in the dry vapor status returns into liquid by the compression action of the compressor and heat change (heat radiation) of the condenser.

95ZV EX 72-22 72 Function & Structure Operator Station Group Air Conditioner

Electrical circuit Control schematic drawing

Outside air sensor

Input signals

Set temperature, room temperature, water temperature, air temperature after evaporator

Insolation sensor Outside air sensor

e = Inside air temperature - Set temperature

Insolation sensor

Set temperature correction

Frost sensor

Water temperature sensor

BLC Temperature control servo HOT Blower motor Temperature control servo

Blow-off servo

Warm-up control

Blower voltage

Water temperature (ºC)

Blower voltage/temperature control/blow-off servo motor position determination

Inside air sensor

COOL FACE B/I FOOR Y value

Blow-off servo Compressor ON-OFF ON 3

Frost sensor temperature (ºC)

95ZVE72018

95ZV EX 72-23 72 Function & Structure Operator Station Group Air Conditioner

Air conditioner functions of components Control panel Name and function of each part on control panel (1) OFF switch

Indicator lamps

(2) Blower switches

(6) Inside/outside air selector switches

(3) Temperature setting switches

(7) Liquid crystal display (LCD) unit

- (1) OFF switch This switch stops the operation of the blower and the air conditioner. When the OFF switch (1) is pressed, the set temperature and the air blow quantity displayed on the LCD unit (7) as well as the indicator lamps above the AUTO switch (5) and the air conditioner ON/OFF switch (8) are extinguished, and the operation is stopped.

(4) Vent mode selector switch

Indicator lamps

(5) AUTO switch

(8) Air conditioner ON/OFF switch

97ZV72036

- (2) Blower switches These switches change over the air flow quantity in six steps. The air flow quantity is displayed on the LCD unit. When the switch is pressed, the air flow quantity increases. When the switch is pressed, the air flow quantity decreases. In the automatic mode, the air flow quantity is automatically changed over. Display on the LCD unit and the air blow quantity Display on LCD unit

Air blow quantity Air quantity "weak" Air quantity "medium 1" Air quantity "medium 2" Air quantity "medium 3" Air quantity "medium 4" Air quantity "strong"

95ZV EX 72-24 72 Function & Structure Operator Station Group Air Conditioner - (3) Temperature setting switches These switches set the temperature inside the cabin in the range from 18.0 to 32.0ºC. When the switch is pressed, the set temperature increases. When the switch is pressed, the set temperature decreases. Usually, set the set temperature to 25.0ºC. Display on the LCD unit and the function Display on LCD unit 18.0 18.5~31.5 32.0

Set temperature Maximum cooling Temperature inside cabin is controlled so that set temperature is realized. Maximum heating

- (4) Vent mode selector switch This switch changes over the vent mode. When the vent mode selector switch (4) is pressed, the vent mode displayed on the LCD unit (7) is changed over, and air is blown from the displayed vent positions. In the automatic mode, the vent mode is automatically changed over. Display on LCD unit

Vent mode

Vent positions (A)

(B)

Face (blow-off to upper portion of body mainly during cooling)

○

Face & foot

○

Foot (blow-off to feet mainly during heating)

(C)

(D)

Remarks

○

Foot & defroster

○

Defroster

○

This mode is not selected in automatic mode.

○

This mode is not selected in automatic mode.

- (5) AUTO switch This switch automatically changes over the air flow quantity, the vent mode and the inside/outside air in accordance with the set temperature. When the AUTO switch (5) is pressed, the indicator lamp above it lights. Usually, press this switch, set the temperature by using the temperature setting switches (3), and use the air conditioner in the automatic mode.

When the automatic mode is changed over to the manual mode, the indicator lamp above the AUTO switch (5) is extinguished. In the manual mode, the air flow quantity, the vent mode and the inside/outside air can be changed over by manipulating each switch.

95ZV EX 72-25 72 Function & Structure Operator Station Group Air Conditioner - (6) Inside/outside air selector switches These switches change over inside air circulation and outside air introduction. When an either switch is pressed, the indicator lamp above it lights to indicate the selected air flow status. In the automatic mode, outside air introduction and inside air circulation are automatically changed over. Inside air circulation

Outside air introduction

The outside air is shut down, and the air inside the cabin is circulated. Press this switch to rapidly cool or heat the air inside the cabin or when the outside air is dirty. The outside air is introduced into the cabin. Press this switch to introduce clean air into the cabin or defog the windows.

- (7) Liquid crystal display (LCD) unit This LCD unit indicates the set temperature, the air flow quantity and the vent mode during operation. When the OFF switch (1) is pressed, the set temperature and the air flow quantity are extinguished and the operation is stopped. - (8) Air conditioner ON/OFF switch This switch turns on and off the air conditioner (cooling or dehumidification/heating). When this switch (8) is pressed, the air conditioner is turned on and the indicator lamp above the switch lights. When this switch is pressed again, the air conditioner is turned off and the indicator lamp is extinguished. However, the air conditioner is turned on only while the blower is operating (that is, while the air blow quantity is displayed on the LCD unit.)

95ZV EX 72-26 72 Function & Structure Operator Station Group Air Conditioner 2. Stopping the automatic operation

Operating method Normal use 1. Automatic operation

Set temperature

(1) OFF switch

(3) Temperature setting switches

(5) AUTO switch

97ZV72041

Air flow quantity

(8) Air conditioner ON/OFF switch 97ZV72040

(a) Set the AUTO switch (5) to ON. Confirm that the set temperature and the air flow quantity are displayed on the LCD unit, and that the indicator lamps above the AUTO switch (5) and the air conditioner ON/ OFF switch (8) are lit. (b) Adjust the temperature setting switches (3), and set arbitrary temperature. The air conditioner automatically changes over the air flow quantity, the vent mode and the inside/outside air to realize the set temperature. Note When the vent mode is set to or in the automatic operation, if the engine water temperature is low, the air flow quantity is restricted to prevent blow-off of cold air.

Press the OFF switch (1). Then, the set temperature and the air flow quantity displayed on the LCD unit are extinguished, the indicator lamps above the AUTO switch (5) and the air conditioner ON/OFF switch (8) are extinguished, and the operation is stopped.

95ZV EX 72-27 72 Function & Structure Operator Station Group Air Conditioner 4. Stopping the manual operation

3. Manual operation

(2) Blower switches

(3) Temperature setting switches

(6) Inside/outside air selector switch

(4) Vent mode selector switch

(1) OFF switch

(8) Air conditioner ON/OFF switch 97ZV72042

97ZV72041

(a) Press the blower switches (2), and adjust the air flow quantity. Confirm that the set temperature and the air flow quantity are displayed on the LCD unit.

(b) Set to ON the air conditioner ON/OFF switch (8). Confirm that the indicator lamp above the switch lights. (c) Adjust the temperature setting switches (3), and set arbitrary temperature. (d) Press the vent mode selector switch (4), and select arbitrary vent mode. (e) Press an either inside/outside air selector switch (6) to select inside air circulation or outside air introduction.

95ZV EX 72-28 72 Function & Structure Operator Station Group Air Conditioner 2. Defroster operation

Other uses 1. Head cooling, feet heating (bi-level) operation

(2) Blower switches

(4) Vent mode selector switch

(4) Vent mode selector switch (2) Blower switches

(5) AUTO switch

(6) Inside/outside air selector switch (6) Inside/outside air selector switch

(3) Temperature setting switches 97ZV72044

(a) Press the blower switches (2), and adjust the air flow quantity. Confirm that the set temperature and the air flow quantity are displayed on the LCD unit. (b) Press the vent mode selector switch (4), and display the vent mode on the LCD unit.

(3) Temperature setting switches 97ZV72045

(d) Press the temperature setting switches (3), and display the set temperature "32.0" (maximum heating status) on the LCD unit.

(d) Arbitrarily set the blower switches (2), the temperature setting switches (3) and the inside/outside air selector switches (6).

Adjust the louver at each vent position so that air flow reaches the windows.

Then, the air conditioner realizes the bi-level operation in which cold air is blown to the head and hot air is blown to the feet.

When defogging the windows or dehumidifying the air inside the cabin in rainy season, set the air conditioner ON/OFF switch (8) to ON.

95ZV EX 72-29 72 Function & Structure Operator Station Group Air Conditioner 3. Failure code deletion

Other functions Self-diagnosis function Each sensor and equipment used in the air conditioner can be diagnosed for failure.

(1) OFF switch

After completing the inspection and/or the repair, delete the failure codes memorized in the computer. If fail to do it, the failure codes memorized in the computer continue to display on the LCD whenever diagnosing. To delete the failure codes, press and hold both air intake control switches (6) for 3 seconds or more. <Display on the LCD unit and the failure mode> Display

(6) Inside/outside air selector switches

(3) Temperature setting switches Press and hold both the " " and " " switches together 97ZV72035 (for 3 seconds or more).

1. Press the OFF switch to stop the operation. (The set temperature and the air flow quantity displayed on the LCD are extinguished.) 2. When the both temperature setting switches " " and " " (3) are pressed and held together for 3 seconds or more, the failure mode is displayed on the LCD unit. (a) If two or more failure are detected, the displayed contents can be changed over in turn by pressing either temperature setting switch (3) " " or " ". (b) Press the OFF switch (1) again to finish the self diagnosis function and return to the normal display.

Failure mode

E-

No failure

E11

Wire breakage in inside air sensor

E12

Short-circuit in inside air sensor

E13

Wire breakage in outside air sensor

E14

Short-circuit in outside air sensor

E15

Wire breakage in water temperature sensor

E16

Short-circuit in water temperature sensor

E18

Short-circuit in insolation sensor

E21

Wire breakage in vent sensor

E22

Short-circuit in vent sensor

E43

Abnormality in vent damper

E44

Abnormality in air mixing damper

E45

Abnormality in inside/outside air

E51

Abnormality in refrigerant pressure

Celsius-Fahrenheit selector function for the set temperature display While the blower is operating, press and hold the both temperature setting switches (3) " " and " " together for 5 seconds or more to change over the unit of the displayed value between Celsius and Fahrenheit. However, the unit itself is not displayed. Only the set value is displayed. Value displayed on LCD unit Celsius (ºC)

18.0~32.0

Fahrenheit (ºF)

63~91

95ZV EX 72-30 72 Function & Structure Operator Station Group Air Conditioner

Air conditioner unit

Air mixing damper

[In the case of maximum cooling] Air mixing damper A (completely opened) Heater radiator Evaporator

Cold air Co

air

Air mixing damper B (completely closed) [In the case of maximum heating] Air mixing damper A (completely closed)

Ho ta ir

Blower motor Inside/outside air selection damper Air mixing damper A

ld a

Inside air

Outside air

Fan

Blower motor Heater radiator

Evaporator Air mixing damper B

80ZVE72001

The air conditioner unit has the cooling, heating and air blowing functions to perform conditioning of the air inside the cabin, and consists of an evaporator which cools down the air, a heater radiator which warms the air and a blower motor which blows the air. The temperature in the vent position is adjusted when the opening/closing position of the air mixing damper is so controlled that the cooled air while passing through the evaporator and the warmed air while passing through the heater radiator are mixed. The air mixing damper is controlled by the servo motor for air mixing assembled in the unit.

Air mixing damper B (completely opened)

80ZVE72002

During maximum cooling, the air mixing damper B is completely closed, and the air mixing damper A is completely opened. As a result, the air cooled by the evaporator does not go through the heater radiator but is blown off. During maximum heating, the air mixing damper A is completely closed, and the air mixing damper B is completely opened. As a result, all the air which has gone through the evaporator goes through the heater radiator, then the warmed air is blown off.

95ZV EX 72-31 72 Function & Structure Operator Station Group Air Conditioner

Evaporator

The evaporator is an important heat exchanger which evaporates liquid refrigerant set to low temperature and low pressure by an expansion valve, utilizes its latent heat, and absorbs heat from air (target) inside the cabin. Accordingly, heat should be smoothly transmitted between the target and the refrigerant in the evaporator.

(4)

For this purpose, fins are provided on the air side of the evaporator to extend the heat transmission area on the air side so that heat can be smoothly transmitted between the refrigerant and the air.

Evaporator

(7)

(5)

(2)

By cooling, the moisture contained in the air condenses, changes into water drops, and adheres to the outside of the evaporator. If these water drops are frozen, the cooling effect deteriorates. To prevent this, attention should be paid also to proper drainage of condensed water.

(8) (1)

(6)

The refrigerant quantity supplied to the evaporator is adjusted by the expansion valve described next. In order to ensure that the refrigerant quantity is accurately adjusted, pressure drop of the refrigerant inside the evaporator should be minimal.

(3)

Refrigerant flow inside evaporator ( From expansion valve(1) to (8) Compressor

)

Accordingly, reduction of pressure drop is an element to enhance the performance of the evaporator. 97ZV72048

Troubleshooting the evaporator Item Gas leak

Symptom

Cause

Both high pressure and low pressure are low, and air bubbles can be seen through sight glass.

- Joint portion of supply area - Cracks in evaporator main body

Action - Tightening - Repair/replacement

Blockage in circuit

Both high pressure and low pressure are low.

- Blockage inside

- Cleaning/replacement

Blockage in fins

Air quantity is small. (Filters may be clogged.)

- Blockage in fins

- Cleaning

Freezing

Air quantity is small, and low pressure is low.

- Blockage in filter (Evaporator is not preforming inadequately.)

- Cleaning/replacement

95ZV EX 72-32 72 Function & Structure Operator Station Group Air Conditioner

Expansion valve (box type)

(Evaporator)

Expansion valve operation

Diaphragm

Evaporator

Spring Temperature sensing rod Diaphragm

Temperature sensing rod Needle valve (To compressor) (From receiver)

Needle valve From receiver (High pressure)

Structural drawing of box type expansion valve

To compressor (Low pressure)

97ZV72049

97ZV72050

The expansion valve offers the following two functions.

The temperature sensing rod detects the temperature of the refrigerant which has gone through the evaporator, and transfers the detected temperature to the refrigerant gas chamber located in the upper portion of the diaphragm chamber.

1. By injecting the liquid refrigerant at high temperature and high pressure which has gone through the receiver from a small hole, the expansion valve expands dramatically the liquid refrigerant into mist refrigerant at low temperature and low pressure. 2. Promptly in accordance with the vaporized status of the refrigerant inside the evaporator, the expansion valve adjusts the refrigerant quantity. In order to ensure that the evaporator offers its full performance, the liquid refrigerant should be kept in a state in which it deprives heat of the adjacent area and its evaporation is always completed at the exit of the evaporator. To realize this, the expansion valve automatically adjusts the refrigerant quantity in accordance with fluctuation of the temperature inside the cabin (cooling load) and fluctuation of the rotation speed of the compressor. The expansion valve consists of a needle valve, a diaphragm and a temperature sensing rod. The temperature sensing rod detects the temperature of the refrigerant which has gone through the evaporator, and transfers the detected temperature to the refrigerant gas chamber located in the upper portion of the diaphragm chamber.

The gas pressure changes in accordance with the detected temperature, the temperature sensing rod directly connected to the diaphragm is moved, then the needle valve opening is adjusted. - When the temperature at the exit of the evaporator is low (that is, when the cooling load is small) The gas pressure inside the diaphragm chamber becomes low, the volume decreases, the temperature sensing rod moves to the right, and the needle valve is closed. - When the temperature at the exit of the evaporator is high (that is, when the cooling load is large) The gas pressure inside the diaphragm chamber becomes high, the volume increases, the temperature sensing rod moves to the left, the needle valve is opened, and more quantity of refrigerant is supplied to the evaporator.

95ZV EX 72-33 72 Function & Structure Operator Station Group Air Conditioner Troubleshooting the expansion valve Item

Symptom

Cause

Action

Blocked expansion Both high pressure and low pressure are low, valve or defective and air bubbles cannot be seen through sight adjustment (too closed) glass.

- Expansion valve

- Cleaning/adjustment or replacement

Defective adjustment (too open)

Low pressure is too high, and compressor head is cold.

- Expansion valve

- Adjustment or replacement

Freezing caused by moisture

Cooling is disabled during operation. Frosting is not detected in evaporator. Both high pressure and low pressure are low, and air bubbles cannot be seen through sight glass.

- Expansion valve

- Replace receiver tank, evacuate air, then charge gas again.

95ZV EX 72-34 72 Function & Structure Operator Station Group Air Conditioner

Heater radiator

Fin

Heater core

97ZV72051

The heater radiator utilizes the engine cooling water as the heat source. When going through the heater radiator, the air receives heat from the heater radiator fins and is warmed. The hot water inside the heater radiator is forcedly circulated by the engine water pump. Troubleshooting the heater radiator Item Water leak

Symptom Water leaks from heater core.

Cause

Action

- Joint portion of supply area - Cracks in heater core main body

- Repair/replacement

Blockage in circuit

Air inside cabin does not become warm.

- Blockage inside heater radiator

- Replacement

Blockage in fins

Air quantity is small.

- Blockage in fins

- Cleaning

95ZV EX 72-35 72 Function & Structure Operator Station Group Air Conditioner

5 4

3 2 1

Servo motor

1 2

5 6

97ZV72052

When a switch on the control panel is pressed, the power is applied from the control panel on the terminal (6) or (7) of the servomotor. (The rotating direction is determined by the terminal on which the power is applied.) A variable resistor is provided inside the servo motor. As the motor rotates, the resistance of this resistor changes accordingly. When the 5 V voltage is supplied from the control panel to this variable resistor, the control panel detects the variable resistor position based on the electric potential difference. When the variable resistor reaches the position specified by each switch, the power supplied to the motor is stopped. Note If the power is directly applied on terminals of the motor, the output shaft of the motor may be damaged or wire breakage may occur in the motor coil. Do not directly drive terminals of the motor. Troubleshooting the servo motor Item Motor is locked (disabled). Contact is contacting poorly.

Symptom

Cause

Action

- Servo motor does not rotate.

- Motor - Control unit

- Repair/replacement

- Indicator lamps of temperature setting switches do not light in accordance with preset pattern. - Servo motor does not stop in accordance with preset pattern.

- Fixed plate - Moving contact - Control unit

- Repair/replacement

95ZV EX 72-36 72 Function & Structure Operator Station Group Air Conditioner

Blower motor assembly

Blower motor assembly specifications

Fan

Blower motor

Voltage

DC 24 V

Number of rotations of motor

3,100 min-1

Power consumption

225 W ± 10%

Fan outer diameter

ø150

Cause

Action

Air Air 97ZV72053

The blower motor assembly consists of a DC motor and a fan, and blows air. Troubleshooting the blower motor Item Blower motor operation is defective.

Symptom Air is not blown at all.

- Blower motor - Control unit

- Repair/replacement

BLC (blower linear control)

85V2U72004

97ZV72054

This resistor changes over the air quantity of the blower motor. Troubleshooting the blower linear control Item

Symptom

Cause

Action

Wire in BLC is broken.

Air quantity does not change.

- BLC - Control unit

- Replacement

Blower motor operation is defective.

Air is not blown at all.

- Blower motor - Control unit

- Repair/replacement

95ZV EX 72-37 72 Function & Structure Operator Station Group Air Conditioner

De-icing sensor (Thermistor (or thermal resistor))

Evaporator

Appearance of thermistor 8,000

Resistance ()

7,000

Thermistor

6,000 5,000

Heater radiator

97ZV72056

4,000 3,000 2,000 1,000 0

Temperature (ºC) Characteristics curve between temperature 97ZV72055 and resistance of thermistor

The thermistor, a kind of semi-conductor, offers the characteristics as shown in the curve on the above. When the temperature becomes high, its resistance becomes small. When the temperature becomes low, its resistance becomes large.

The thermistor mounted on the blowoff port side of the evaporator detects the temperature of the air cooled by the evaporator, and transmits it as a signal to the control amplifier. If the air at the vent is 3ºC or less, the control amplifier turns off the compressor clutch relay. If the air at the blowoff port becomes 4ºC or more, the control amplifier turns on the compressor clutch relay again to restart cooling. Because the air temperature at the vent is detected and the compressor clutch relay is turned on and off accordingly, freezing of the evaporator is prevented.

Troubleshooting the thermistor Item

Symptom

Cable in thermistor is broken.

Compressor clutch does not work.

Thermistor is short-circuited.

Air not blowing.

Cause - Thermistor

Action - Replacement

95ZV EX 72-38 72 Function & Structure Operator Station Group Air Conditioner

Water temperature sensor

Foot/defroster selection box

Air conditioner unit

Foot Def 97ZV72057

97ZV72059

This sensor detects the temperature of the engine cooling water flowing into the heater core, and feeds it back to the control panel.

This selection box changes over the vent positions between the foot side and the defroster side.

This sensor is installed on the rear side of the heater core, and can be taken out when being pulled out. Temperature

Resistance value

-30ºC

91.4 k

25ºC

5 k

100ºC

0.321 

Inside air sensor

97ZV72058

This sensor detects the air temperature inside the cabin, and feeds it back to the control panel. This sensor is installed in the inside are suction port, and can be taken out when the clamp is removed. Temperature

Resistance value

0ºC

16.45 k

25ºC

5 k

When the vent mode selector switch (MODE) on the control panel is pressed, the servo motor in this selection box changes over the vent selection damper to the foot side or the defroster side by way of a link and lever.

95ZV EX 72-39 72 Function & Structure Operator Station Group Air Conditioner

Compressor and magnetic clutch

Compressor specifications

Compressor Piston

Discharge valve

Suction valve Diagonal plate

Suction valve

Suction/compression action Model

9 11 97ZV72060

1. Compressor 2. Magnetic clutch 3. Rotor 4. Stator 5. Hub 6. Pulley

7. Coil 8. Bearing 9. Shaft 10. Dust proof cover 11. Pressure relief valve

The compressor is driven by the V belt from the engine by way of the magnetic clutch. The compressor sucks and compresses the gaseous refrigerant at low temperature and low pressure which deprived heat of the air inside the cabin in the evaporator and was vaporized to make the gaseous refrigerant be at high temperature and high pressure, then feeds it to the circuit on the high pressure side again. Five pairs of pistons (with ten cylinders) reciprocate in the same direction with the shaft in accordance with rotations of the shaft. Accordingly, when one piston of a pair is in the compression stroke, the other one is in the suction stroke. The compressor is lubricated by the compressor oil contained in the gaseous refrigerant and the oil splashed by the diagonal plate. Accordingly, if the refrigerant quantity decreases, the compressor is seized by oil shortage. To prevent seizure, a pressure switch is provided in the circuit so that the power supplied to the magnetic clutch is shut down and the compressor is protected when the refrigerant quantity decreases.

97ZV72061

10S150

Cylinder diameter

ø32

Stroke

20.8 mm

Number of cylinders

Cylinder capacity

167.3 cm3

Maximum allowable number of rotations

6,000 min-1

Lubricating oil

ND-OIL8

Lubricating oil quantity

180 cm3

95ZV EX 72-40 72 Function & Structure Operator Station Group Air Conditioner

Magnetic clutch

Magnet clutch specifications

Suction force Stator

Switch Iron piece (rotor)

Power supply Magnetic force N

Principle of magnetic clutch

97ZV72062

The magnetic clutch controls mechanical connection between the engine and the compressor. When the engine is rotating and the air conditioner ON/OFF switch is ON, if the temperature inside the cabin reaches or exceeds the temperature set by the temperature setting switches, the magnetic clutch stops or drives the compressor.

Suction face

Pulley Stator coil

Hub

Rotor

Stator Ball bearing

Magnet clutch 97ZV72063

The hub of the magnetic clutch is fitted onto the shaft of the compressor. While the compressor is not driven, the hub is separated from the rotor and only the pulley is rotating. When the air conditioner switch is set to ON, the current flows in the stator coil, the stator works as a magnet and engages the hub, then the compressor rotates together with the pulley. When the current applied on the stator coil is set to OFF, the hub is not immediately separated but rotates together with the pulley because the pulley has residual magnetism. Accordingly, clearance is provided between the hub and pulley so that they are not in close contact with each other during disengagement. This clearance is called air gap.

Model

L50T

Voltage

DC 24 V

Power consumption

40 W

Drive belt

V-ribbed belt (six ribs)

Air gap

0.5±0.15 mm

95ZV EX 72-41 72 Function & Structure Operator Station Group Air Conditioner Troubleshooting the compressor and magnetic clutch Item

Symptom

Suction or exhaust valve is damaged.

- Compressor temperature is abnormally high. - High pressure is abnormally low, and low pressure is abnormally high. - Air bubbles cannot be seen through sight glass.

Cause

Action

- Suction or exhaust valve

- Repair/replacement

Clutch draw voltage is low.

- Stator coil

- Replacement

Power is not supplied to stator coil.

- Wiring on main body - Control amplifier - Pressure switch

- Repair - Replacement - Replacement

- Magnetic clutch

- Replacement

Compressor main body is defective (seized, etc.).

- Shaft, piston

- Repair/replacement

Clutch bearing is damaged.

- Clutch bearing

- Replacement

- Magnetic clutch

- Replacement

- V belt

- Adjustment/replacement

- Inside

- Repair/replacement

- V belt

- Adjustment/replacement

- Abnormal sounds are made while clutch is turned on.

Gap between hub and rotor is large.

Contact or slippage caused by too small gap between hub and rotor.

- Compressor does not rotate. (Air does not become cool enough.)

- Abnormal sounds are made while clutch is turned off.

V belt is slack. Compressor main body is defective. V belt is slack.

- Abnormal sounds are made while clutch is turned on.

95ZV EX 72-42 72 Function & Structure Operator Station Group Air Conditioner

Condenser unit

Condenser fan motor

Cover

Condenser

The condenser fan motor used to cool down the condenser is mounted on the condenser together with a fan shroud. Condenser specifications

Blower assembly Fan motor

Resister 97ZV72064

Each condenser unit consists of a condenser, a condenser fan motor and a resistor. Two condenser units are arranged in series with the piping. The condenser units cool down the gaseous refrigerant at high temperature and high pressure sent from the compressor, and change it into liquid refrigerant.

Condenser The condenser consisting of tubes and fins cools down the gaseous refrigerant at high temperature and high pressure (70ºC, 1,618 kPa (16.5 kgf/cm2)) sent from the compressor, and change it into liquid refrigerant during passing tubes.

Voltage

DC 24 V

Power consumption

80 W x 10%

Air quantity

1,750±10 m3/Hr

Number of rotations of motor

2,200 min-1

95ZV EX 72-43 72 Function & Structure Operator Station Group Air Conditioner

Resistor The resistor controls rotation of the condenser fan motor in two steps in accordance with a command given by the fan control pressure switch (medium pressure switch). Resistor specifications 4.0 

Resistance

Troubleshooting the condenser unit Item

Symptom

Heat radiation quantity is insufficient due to blockage. Both high pressure and low pressure are abnormally high, and air does not become cool Rotation of condenser fan enough. motor is defective.

Cause

Action

- Blockage or crushed fins

- Cleaning or replacement

- Fan motor

- Repair or replacement

Blockage in circuit

High pressure is abnormally high, low pressure is abnormally low, and air does not become cool enough. Air bubbles can be seen through sight glass.

- Inside

- Cleaning or replacement

Gas leak

Both high pressure and low pressure are abnormally low, and air bubbles can be seen through sight glass.

- Leaks at joints - Cracks in main body

- Tightening - Repair or replacement

95ZV EX 72-44 72 Function & Structure Operator Station Group Air Conditioner

Receiver dryer

Desiccant

Refrigerant inlet Refrigerant outlet

Desiccant

If moisture is present inside the cooling circuit, the compressor valve and oil may deteriorate, metal constituting the circuit may corrode, or moisture may be frozen inside the expansion valve and the circuit may be clogged. To prevent such failure, synthetic zeolite is accommodated inside the air conditioner as the desiccant suitable to the circuit so that it absorbs moisture entering the circuit during installation or refrigerant charging. When the expansion valve is often frozen by moisture (icing), the desiccating agent does not have enough absorption ability. In such a case, replace the receiver dryer.

Strainer

Desiccant specifications

Receiver tube

Receiver tank

97ZV72065

The receiver dryer consists of a receiver tank, desiccant, strainers, and a receiver tube.

Receiver tank In the air conditioner, the number of rotations of the compressor changes and the proper refrigerant quantity in the cooling circuit fluctuates in accordance with fluctuation of the number of revolution of the engine. The receiver tank receives such fluctuation. When the cooling circuit does not require much refrigerant, the receiver stores temporarily excess refrigerant. When the cooling circuit requires much refrigerant, the receiver tank supplies refrigerant from its receiver tube to the circuit. In addition, the receiver tank stores excessive refrigerant in order to take balance of charging of the refrigerant and respond to any minute leaks of the refrigerant caused by permeation through rubber hoses.

Capacity

550 cm3

Desiccating agent

Synthetic zeolite

Desiccating agent capacity

290 g

IMPORTANT If parts of the cooling circuit are removed and left for a long time for repair or another reason, the desiccant absorbs moisture contained in the air and loses its absorption performance, and the receiver dryer should be replaced. To prevent this, after parts are removed, all openings should be plugged.

95ZV EX 72-45 72 Function & Structure Operator Station Group Air Conditioner

Strainers If dusts enter the circuit, the expansion valve may be clogged, the compressor may be damaged, and the cooling function may be deteriorated. The strainers are provided to prevent dusts flowing with the refrigerant from flowing forward. The strainers cannot be cleaned. When they are considerably clogged (In this case, the high pressure becomes high and the low pressure becomes low.), the entire receiver dryer should be replaced. Troubleshooting the receiver tank Item

Symptom

Cause

Action

Icing

- At first, air in cab will cool down, but after a short time no longer will cool properly.

- Desiccating agent in receiver

- Replacement of receiver dryer

Blockage in strainers

- High pressure is excessively high, low pressure is excessively low, and air does not become cool enough.

- Blockage in strainers

- Replacement of receiver dryer

95ZV EX 72-46 72 Function & Structure Operator Station Group Air Conditioner

Sight glass

Pressure switches

Sight glass

Terminal

Receiver joint

Contact area

Receiver dryer

97ZV72066

97ZV72067

This sight glass is installed on the receiver joint located on the top of the receiver dryer. Only through this sight glass, the refrigerant quantity inside the circuit can be visually checked.

The pressure switch detects the pressure on the high pressure side of the cooling circuit, and stops the compressor when detecting any abnormality so that damage of the equipment in the cooling circuit can be prevented. There are three types of pressure switches, high pressure type, medium pressure type and low pressure type, which function as shown in the table below.

Switch

Function

Switching pressure kPa (kgf/cm2)

Switch operation confirmation method

Causes of abnormal pressure

Pressure switch coupler

A High pressure switch

When pressure between compressor and expansion valve becomes abnormally high, this switch shuts down power supplied to compressor magnetic clutch to protect circuit.

2,550 (26)

3,136 (32)

Heat radiation of condenser is insufficient due to clogging in condenser or defective rotation of condenser fan.

OFF

Check conductivity between A and B.

Medium pressure switch

When detecting fluctuation of pressure between compressor and expansion valve, this switch gives a signal to control amplifier about whether to rotate condenser fan motor at low speed or high speed. While this switch is ON, fan motor rotates at high speed. While this switch is OFF, fan motor rotates at low speed.

Low pressure switch

When pressure between compressor and expansion valve becomes abnormally low due to refrigerant leak, this switch shuts down power supplied to compressor magnetic clutch to prevent seizure of compressor caused by insufficient compressor oil which decreased together with refrigerant.

1,519 (15.5)

Check conductivity between C and D in pressure switch coupler shown above.

OFF 1,225 (12.5)

226 (2.3)

ON OFF

196 (2.0)

Check conductivity between A and B Refrigerant leak from a part in pressure switch coupler shown of circuit. above.

95ZV EX 72-47 72 Function & Structure Operator Station Group Air Conditioner Troubleshooting the pressure switch Item

Symptom

Insufficient cooling

Gas leak

Cause

Action

- Condenser fan motor does not change its speed (to high speed).

- Medium pressure switch

- Replacement

- Even when abnormal high pressure (3,136 kPa (32 kgf/cm2)) occurs, compressor does not turn off. - Even when gas (refrigerant) has run short, compressor does not turn off.

- High or low pressure switch*

- Replacement

*If abnormal high pressure occurs while the high pressure switch is nonconforming, the equipment in the cooling circuit may be damaged. The pressure relief valve releases the refrigerant to the atmosphere in order to prevent damages of the equipment.

Pressure relief valve

Flow rate (L/min) 113

Gas discharge route while valve is operating 97ZV72071 0

Pressure 28.1 2,756

35.0 3,430

42.4 4,158

(kgf/cm2 ) (kPa)

This valve mounted on the high pressure side of the compressor service valve releases the refrigerant to the atmosphere when abnormal high pressure occurs.

IMPORTANT Characteristics drawing of relief valve operation 97ZV72069

Pressure relief valve 97ZV72070

When the refrigerant quantity inside the cooling circuit is correct, the pressure switch always remains ON even if the compressor is stopped because the refrigerant pressure is approximately 588 kPa (6.0 kgf/cm2) as far as the outside air temperature is around 25ºC. When the outside air temperature becomes 0ºC or less, the pressure switch for low pressure detection turns off even if the refrigerant quantity is proper because the refrigerant pressure becomes 196 kPa (2.0 kgf/cm2) or less. As a result, the compressor does not work. It means that the pressure switch for low pressure detection functions also as a thermostat which detects the outside air temperature.

95ZV EX 72-48 72 Function & Structure Operator Station Group Air Conditioner

Relay A

Relay B

(Condenser fan, condenser fan high, compressor clutch)

(Evaporator fan motor, low/high)

97ZV72072

Relay A specifications

97ZV72099

Relay B specifications

Rated voltage

DC 24 V

Rated voltage

Rated current

16 A

Rated current

DC 24 V 11 A

Rated coil current

0.1 A

Rated coil current

0.075 A

Troubleshooting the relay Item

Coil wire is broken. Contact is melted down.

Symptom

Cause

- Blower motor does not rotate at all. - Blower motor remains rotating.

- Blower motor main relay

- Blower motor does not rotate at high speed. - Blower motor remains rotating at high speed.

- Blower motor Hi relay

- Blower motor does not rotate at medium speed Me2. - Blower motor speed does not change from Me2 to Me1.

- Blower motor Me2 relay

- Blower motor does not rotate at medium speed Me1. - Blower motor speed does not change from Me1 to low speed.

- Blower motor Me1 relay

- Both condenser fans do not rotate. - Both condenser fans remain rotating.

- Condenser fan relay

- When condenser fan is at high pressure, it does not rotate at high speed. - When condenser fan is at low pressure, it remains rotating at high speed.

- Condenser fan relay 1

- Compressor magnetic clutch does not turn on. - Compressor magnetic clutch remains ON.

- Compressor clutch relay

Action

- Replacement

95ZV EX 72-49 72 Function & Structure Operator Station Group Air Conditioner

Refrigerant hose

Outer layer Reinforcing layer

Mouth ring Inner layer Intermediate layer 97ZV72073

White line and “R134a“ indication

97ZV72074

As shown in the figure on the above, the refrigerant hose consists of the outer layer, the reinforcing layer, the intermediate layer and the inner layer, and the mouth ring is crimped. Region

Material

Outer layer

Ethylene propylene rubber

Reinforcing layer

Polyester

Intermediate layer

Chlorinated butyl rubber

Inner layer

Nylon

The mouth ring of this hose is changed and the symbol "R134a" is indicated on this hose as shown in the figure on the right.

IMPORTANT Never use any other hose or any other refrigerant. Otherwise, refrigerant may leak.

95ZV EX 72-50 72 Function & Structure Operator Station Group Air Conditioner

Charge of refrigerant WARNING WARNING Serious accidents may occur in the refrigerant charging work. Observe the following contents. - Only trained or experienced specialists having sufficient knowledge on the contents of the work should be allowed to perform the refrigerant charging work. - If the refrigerant comes into contact with your eyes, you may lose your eyesight. Make sure to wear protective goggles. - The refrigerant in the liquid status is at low temperature (approximately -30ºC). If it splashes on your skin, you may suffer from frostbite. Pay close attention when handling it. - If the refrigerant (Refrigerant R134a) touches a hot object (approximately +400ºC or more), it decomposes and generates harmful substances. Never release the refrigerant in a room where ventilation is bad and there is a hot object or a fire (such as in the presence of a stove). - In order to protect the environment, do not release the gaseous refrigerant to the atmosphere.

Serious accidents may occur during storage and transportation of a service can. Observe the following contents. - A service can accommodates high pressure gas in the saturated liquid status. If the temperature rises, the pressure may increase drastically and the can may burst. Keep the temperature of the service can at 40ºC or less. Make sure to keep the can away from hot objects or fire. - During storage, make sure to avoid direct sunlight, and store the can in a dark and cool place. - Inside the closed cabin (including trunk), the air temperature may rise considerably due to solar heat, etc., and may become dangerously temperature even in winter if the closed cabin is exposed to direct sunlight. Never put the can inside the cab. - If the service can suffer from flaws, dents and deformations, its strength deteriorates. Never hit or drop it. And never throw or drop a package of cans while loading or unloading it. - Keep the can away from the reach of children.

IMPORTANT CAUTION Serious accidents may occur during the refrigerant charging work. Observe the following contents. - When warming a service can to charge the refrigerant, make sure to open the low pressure valves of the service can and the gauge manifold, then warm it with hot water of 40ºC or less (temperature at which you feel warm when putting your hand into it). Never warm the can with boiling water or overheat it with open fire. If the can is treated in such a way, it may burst. - When charging the refrigerant after having started the engine, never open the high pressure (Hi) valve. If it is opened, the high pressure gas may flow in the reverse direction, and the service can and the hose may burst.

- It is prohibited by law to reuse service cans. Never reuse them. - Pay close attention so that air and dusts do not enter into the cooling circuit. - Never charge the refrigerant excessively. - The air conditioner is so designed as to be used with Refrigerant R134a. Never charge any other refrigerant such as Freon R12. - If the compressor oil (ND-OIL 8) adheres to the painting face or the resin area, the painting may peel off or the resin may be damaged. If so, wipe it off soon. - Tighten the piping at the specified torque.

95ZV EX 72-51 72 Function & Structure Operator Station Group Air Conditioner

Work procedure

Gas charging process

The refrigerant charging process is mainly divided into "air evacuation process" and "gas charging process" as shown in the chart below.

The "gas charging process" charges the refrigerant to the circuit in the vacuum status. The gas charging process not only affects the cooling ability of the air conditioner but also affects the life time of parts constructing the circuit. If the refrigerant is charged too much, the pressure inside the circuit may become extremely high and the cooling ability may deteriorate. If the refrigerant quantity is too small, the lubricating oil for the compressor may not circulate smoothly and the sliding area of the compressor may seize.

Air evacuation process The "air evacuation process" eliminates the moisture present inside the cooling circuit. If the moisture remains inside the circuit, it may cause varied problems even if its quantity is extremely small: The moisture may be frozen inside the expansion valve during operation, and may block the circuit or generate oxidation. To prevent such problems, the air inside the cooling circuit should be evacuated, and the moisture inside the circuit should be boiled and evaporated so that the moisture is eliminated before the refrigerant is charged into the circuit.

Because the gas charging process involves high pressure gas, it is extremely dangerous if it is performed with the wrong procedure. Observe the work procedure shown below and the cautions, and charge the refrigerant correctly.

Work chart Start air evacuation.

-750 mmHg or less

20~30 min Air evacuation process

Stop air evacuation.

Check and repair connection area.

Leave for 5 min. Check air tightness.

When gage indicates an abnormal value

When gage indicates a normal value Charge refrigerant.

Charge gaseous refrigerant until gauge pressure reaches 98 kPa (1 kgf/cm2).

Check for gas leak. Gas charging process Charge refrigerant.

Check for gas leak.

Performance test 95ZVE72042

95ZV EX 72-52 72 Function & Structure Operator Station Group Air Conditioner

Refrigerant charging tools

Charging hose and quick joints

Vacuum pump Vacuum pump adapter

Gauge manifold

Vacuum pump

Low pressure charging hose (blue)

High pressure charging hose (red)

97ZV72076

Quick joint (Lo)

A vacuum pump should be used to eliminate the moisture inside the circuit. Center charging hose (green) Quick joint (Hi)

97ZV72077

These three hose of three colors are used to evacuate the air and charge the gas. (The colors may be different depending on the manufacturer.) Red hose Connects the high pressure valve of the gauge manifold and the high pressure charging valve (with "H" mark on its cap) of compressor outlet hose. Blue hose Connects the low pressure valve of the gauge manifold and the low pressure charging valve (with "L" mark on its cap) of the compressor inlet hose. Green hose Connects the center valve of the gauge manifold and the vacuum pump (or the service can valve).

95ZV EX 72-53 72 Function & Structure Operator Station Group Air Conditioner

Gauge manifold Low pressure gauge

Service can valve High pressure gauge

Gauge manifold

Low pressure valve Low pressure charging hose Center valve mounting nipple Center charging hose mounting nipple

High pressure valve

Center charging hose

Service can valve

Service can T joint

High pressure charging hose mounting nipple 97ZV72078

97ZV72079

It is used to evacuate the air and charge the gas, and equipped with a high pressure gauge, a low pressure gage, many valves and hose mounting nipples as shown in the figure on the above.

This valve is attached to a service can when gas is charged, and used to open the service can, supply the gas and stop supply of the gas. In order to open the service can or stop supply of the gas, tighten the handle clockwise completely. In order to supply the gas, loosen the handle counterclockwise completely.

95ZV EX 72-54 72 Function & Structure Operator Station Group Air Conditioner

Cautions on handling of quick joint and charging valve

2. Disconnecting the quick joint

When discharging the refrigerant, use a quick joint. Sleeve

1. Connecting the quick joint

"Click" sound (OK)

(A)

Sleeve

"Click" sound (OK)

(B)

(A) 97ZV72081

Charging valve Quick joint 97ZV72080

Slide the sleeve upward, push the quick joint against the charging valve, press and hold securely part (A) until a click is heard, then slide the sleeve downward.

Screwdriver, etc. Valve pin

IMPORTANT - Push the quick joint against the charging valve vertically. - If refrigerant remains inside the charging hose, the quick joint may not be easily connected. Release the refrigerant from the hose.

Spring

Charging valve 97ZV72082

While pressing and holding the part (A) of the quick joint, slide the sleeve upward to disconnect the quick joint.

IMPORTANT If you push the valve pin with a considerable force [294 kPa (3 kgf/cm2)] with a screwdriver, etc., the spring may come off and the refrigerant may leak. Never do this.

95ZV EX 72-55 72 Function & Structure Operator Station Group Air Conditioner

Refrigerant charging procedure

1. Connecting the gauge manifold

Air evacuation work

WARNING If hoses are connected incorrectly, serious accidents may occur. Observe the following contents. - Never confuse connection of hose to the high pressure side and the low pressure side of the gauge manifold.

Valve setting Lo Hi Closed Closed High pressure valve

Low pressure valve

(red) (blue)

IMPORTANT

(green)

A depression pin is provided on the L-shape end of the hose. Attach a quick joint to this end.

(Hi) (Lo) Charging valve on high pressure side (located on receiver dryer) Vacuum pump (stopped) Compressor (stopped) 95ZVE72045

(a) Close both the high pressure (Hi) valve and the low pressure (Lo) valve of the gauge manifold. (b) Connect the charging hose. Red hose To be connected between the high pressure (Hi) valve of the gauge manifold and the high pressure charging valve. Blue hose To be connected between the low pressure (Lo) valve of the gauge manifold and the low pressure charging valve of the compressor. Green hose To be connected between the center valve of the gauge manifold and the vacuum pump.

IMPORTANT Connect quick joints to both the high pressure and low pressure sides before starting air evacuation. The check valve of the quick joint cannot hold the vacuum status. If one side of the quick joint is not connected, the vacuum status cannot be realized.

95ZV EX 72-56 72 Function & Structure Operator Station Group Air Conditioner 3. Checking for leaks

2. Evacuating the system

Valve setting Valve setting

Lo Hi Closed Closed

Valve setting

After air evacuation Lo Hi Lo Hi for 30 minutes OpenedOpened Closed Closed

Leave for 5 minutes or more

Low pressure gauge

Pointer of low pressure gauge moves toward "0".

High pressure valve

Low pressure valve Moves toward "0".

(red) (blue)

Tighten connection areas of piping. 97ZV72085

(green)

(Hi) (Lo) Charging valve on high pressure side Vacuum pump (operating) Compressor (stopped)

(stopped)

Leave the circuit for 5 minutes or more while each valve of the gauge manifold is closed. Then, make sure that the pointer of each gauge does not move. If the pointer of the gauge moves toward "0", a leak has occurred somewhere in the circuit. Tighten the connection areas of the piping, evacuate the system again, then make sure that there is no leaks.

IMPORTANT 95ZVE72046

(a) Open both the high pressure (Hi) valve and the low pressure (Lo) valve of the gauge manifold. (b) Turn on the switch of the vacuum pump, and evacuate until the degree of vacuum becomes -750 mmHg or less (for approximately 20 to 30 minutes). (c) After finishing evacuation, close both the high pressure valve and the low pressure valve of the gauge manifold. Then, turn off the switch of the vacuum pump.

IMPORTANT If you stop the vacuum pump before closing each valve of the gauge manifold, the circuit in the vacuum status is released to the atmosphere. First close each valve.

Make sure to tighten the connection areas of the piping at a specified tightening torque. For the tightening torque, refer to the volume "Maintenance Standard".

95ZV EX 72-57 72 Function & Structure Operator Station Group Air Conditioner

Refrigerant charging process

WARNING Valve setting

When charging the refrigerant from the high pressure side, the refrigerant may flow in the reverse direction and the can and the hose may be burst if you start the engine and operate the compressor. Never start the engine.

Lo Hi Closed Closed

Press the valve pin.

Open the service can valve.

IMPORTANT

Air purge Blue Red Charging hose R134a (green)

Valve setting Lo Hi Closed Opened

After 1~1.5 service cans are charged

Service can 97ZV72086

If you charge the refrigerant while making the service can stand upside down, the refrigerant is sucked in the liquid status by the compressor and the compressor may be damaged. Never do this. 1. Charging the refrigerant from the high pressure side

Valve setting Lo Hi Closed Closed

High pressure valve

(a) After evacuation, disconnect the charging hose (green) of the gauge manifold from the vacuum pump, and connect it to the service can. (b) Air purge

Low pressure valve

(Hi)

Open the service can valve (while closing the high and low pressure valves of the gauge manifold), and press the valve core shaft of the service port on the low pressure side of the gauge manifold with a screwdriver, etc. so that the air inside the charging hose is discharged by the refrigerant pressure.

Charging valve on high pressure side

(c) Open the high pressure valve of the gauge manifold, and charge the gaseous refrigerant until the gauge pressure reaches 98 kPa (1 kgf/cm2). (One to one and half service cans are required.)

(red)

(blue)

(Lo)

Compressor (stopped)

(green)

Service can valve (opened charge R134a closed)

(d) After charging, close the high pressure valve of the gauge manifold and the service can valve. 2. Check for gas leak

95ZVE72052

Check for gas leak in the circuit using a leak tester, etc. If leak is detected, tighten the connection areas.

IMPORTANT Make sure to tighten the connection areas of the piping at a specified tightening torque. For the tightening torque, refer to the volume "Maintenance Standard".

95ZV EX 72-58 72 Function & Structure Operator Station Group Air Conditioner 3. Charging the refrigerant from the low pressure side Valve setting Lo Hi Opened Closed

Charge the refrigerant until air bubbles seen through the sight glass disappear.

Valve setting

(c) Start the engine, and increase the number of rotations to approximately 1,500 min-1. (d) On the control panel, press the HI blower switch to set the air quantity to the maximum value, and set the vent port temperature switches to the coldest status.

Lo Hi Closed Closed

High pressure valve

Low pressure valve

(e) Open the low pressure valve of the gauge manifold and the service can valve to charge the refrigerant. When air bubbles seen through the sight glass of the receiver dryer disappear, charge the refrigerant further more by 150~250 g.

(red)

IMPORTANT (blue)

(green)

(Lo)

(Hi)

Charging valve on high pressure side

Compressor (On-load)

Service can valve (opened charge R134a closed) 95ZVE72052

Sight glass

Receiver joint

When replacing the service can during the refrigerant charging work, make sure to purge the air from the line. (f)

After charging, close the low pressure valve of the gage manifold and the service can valve. Then, stop the engine. Refrigerant quantity to be charged (guideline) 900±50 g

Refrigerant quantity

Proper

Gas bubbles are few. (When the number of rotations of the engine is gradually increased from the idle status to 1,500 min-1, air bubbles disappear.)

Too much

Gas bubbles are not seen in the flow at all. (In this case, both the high pressure and the low pressure are high, and the cooling ability is deteriorated.)

Insufficient

Gas bubbles are seen in the flow. (Gas bubbles go through continuously.)

Receiver dryer

97ZV72066

(a) Make sure that the high and low pressure valves of the gauge manifold and the service can valve are closed. (b) If the inside of the cabin becomes cold during the charging process, the compressor magnetic clutch turns off and system charging is disabled. When charging, open the doors and the windows of the cabin completely.

Sight glass situation

95ZV EX 72-59 72 Function & Structure Operator Station Group Air Conditioner 4. Guideline for judgement of the refrigerant charge quantity

5. Disconnecting the gauge manifold

Judge the refrigerant charge quantity under the following condition. Sleeve Item

Criteria

Doors

Completely open

Temperature control switches

Maximum cooling

Blower speed

Inside/outside air selection

Inside air

Number of rotations of engine

1,500 min-1

Air conditioner switch

Pressure on high pressure side

1,862 kPa (19 kgf/cm2) or less

IMPORTANT - If the outside air temperature is high (40ºC or more) or if the pressure on the high pressure side is 1,862 kPa (19 kgf/cm2) or more when the judgement condition above is set, perform the following so that the pressure becomes 1,862 kPa (19 kgf/ cm2) or less, then check the refrigerant quantity. - Close the doors completely, and set the blower fan to the low speed (by pressing the Lo switch). - Use a shaded area or a place indoors away from sunlight. - If you turn on the air conditioner while the refrigerant quantity is extremely small, lubricant in the compressor may be insufficient and a failure such as seizure of the compressor may occur. Never do this. - If the refrigerant quantity is over charged, cooling may be insufficient or the pressure inside the circuit may become abnormally high (which is dangerous). Never do this.

"Click" sound (OK)

(A)

(B)

97ZV72081

After inspecting the refrigerant charge, disconnect the charging hose from the high and low pressure charging valves using the following procedure. (a) While pressing and holding the part (A) of the quick joint, slide the sleeve upward and disconnect the quick joint. (b) Attach a cap to each of the high and low pressure charging valves.

95ZV EX 72-60 72 Function & Structure Operator Station Group Air Conditioner

Troubleshooting using the gauge manifold

Condition

Normal status

After warming up the engine, check the pressure under the following condition.

<Low pressure side> 215~275 kPa (2.2~2.8 kgf/cm2)

- Doors Completely open

<High pressure side> 1,470~1,765 kPa (15~18 kgf/cm2)

- Inside/outside air selection Inside air - Number of rotations of engine 1,500 min-1 - Temperature at suction port of air conditioner 30~35ºC (86~95ºF) - Blower speed High - Temperature control switches Maximum cooling

97ZV72091

Pressure values indicated by gauges in the normal status A/C suction port temperature 20~25ºC 25~30ºC 30~35ºC 35~40ºC

Pressure

Pressure value by gauge

High pressure side

1,000~1,215 kPa

(10.2~12.4 kgf/cm2)

Low pressure side

127~167 kPa

(1.3~1.7 kgf/cm2)

High pressure side

1,215~1,470 kPa

(12.4~15.0 kgf/cm2)

Low pressure side

167~215 kPa

(1.7~2.2 kgf/cm2)

High pressure side

1,470~1,784 kPa

(15.0~18.2 kgf/cm2)

Low pressure side

215~275 kPa

(2.2~2.8 kgf/cm2)

High pressure side

1,784~2,146 kPa

(18.2~21.9 kgf/cm2)

Low pressure side

275~353 kPa

(2.8~3.6 kgf/cm2)

95ZV EX 72-61 72 Function & Structure Operator Station Group Air Conditioner

When the refrigerant charge quantity is insufficient <Low pressure side> 49~98 kPa (0.5~1.0 kgf/cm2)

<High pressure side> 686~981 kPa (7~10 kgf/cm2)

When the refrigerant does not circulate (due to clogging in the cooling circuit) <Low pressure side> Negative value

<High pressure side> 490~588 kPa (5~6 kgf/cm2)

97ZV72092

Symptom

Cause

- Pressure is low on both low and high pressure sides.

- Refrigerant quantity is insufficient.

- Gas bubbles go through sight glass continuously.

- Gas is leaking.

- Temperature of blown air is not cold.

Inspection/action point - Find and repair leaks. - Repair leak. Add refrigerant. - If pressure indicated by gage is around "0", detect and repair leaks, vacuum system and recharge.

97ZV72093

Symptom

Cause

Inspection/action point

- If cooling circuit is completely blocked, needle on low pressure side indicates a vacuum immediately.

Clogging in cooling circuit

- Inspect receiver dryer, expansion valve, etc. (Temperature is different between IN and OUT of failing part.)

- If cooling circuit is partially blocked, needle on low pressure side slowly indicates a vacuum.

- After finishing work, evacuate system and recharge.

95ZV EX 72-62 72 Function & Structure Operator Station Group Air Conditioner

When the moisture has entered into the cooling circuit. <Low pressure side> Abnormal status Vacuum

<High pressure side> 686~981 kPa (7~10 kgf/cm2)

Normal status 215~275 kPa (2.2~2.8 kgf/cm2)

1,470~1,765 kPa (15~18 kgf/cm2)

When the compression in compressor is defective. <Low pressure side> 392~588 kPa (4~6 kgf/cm2)

<High pressure side> 686~981 kPa (7~10 kgf/cm2)

97ZV72095

97ZV72094

Symptom

Cause

Inspection/action point

- Air conditioner operates normally for a while after startup, but pressure on low pressure side indicates a vacuum value later.

Expansion valve is frozen due to entry of moisture.

- Inspect expansion valve, replace if needed. - Replace receiver dryer. - After finishing work, evacuate system completely and recharge.

Symptom

Cause

Inspection/action point

- Pressure on low pressure side is unusually high, and pressure on high pressure side is unusually low.

Compressor is defective.

- Review 2nd symptom.

- Shortly after air conditioner turns off, pressure becomes equal between high pressure side and low pressure side.

- If pressure in compressor is low, compressor will not build much heat due to lack of pressure. - Replace compressor. - After finishing work, evacuate system and recharge.

95ZV EX 72-63 72 Function & Structure Operator Station Group Air Conditioner

When there is too much refrigerant or cooling in the condenser is insufficient <Low pressure side> 245~343 kPa (2.5~3.5 kgf/cm2)

When air has entered into the cooling circuit

<Low pressure side> 245~294 kPa (2.5~3.0 kgf/cm2)

<High pressure side> 1,961~2,452 kPa (20~25 kgf/cm2)

97ZV72097

97ZV72096

Symptom

Cause

Inspection/action point

Symptom

Cause

Inspection/action point

- Pressure is high on both low pressure side and high pressure side.

- Refrigerant quantity is too much.

- Check and correct refrigerant charge pressure.

- Pressure is high on both low pressure side and high pressure side.

Air has entered system.

- Refrigerant is bad.

- Plugged or bent condenser fins.

- Inspect and repair condenser fins.

- Even when engine rpm’s (min-1) are reduced, gas bubbles cannot be seen at all in sight glass. - Air in cab does not become cool enough.

- Bad fan motor or fan blade. - Heat transfer does not occur in evaporator has plugged fins

- Repair or replace fan or fan motor - Inspect and repair evaporator fins.

- Low pressure piping is not cold.

- Evacuate system completely.

- Gas bubbles go through sight glass.

- Replace refrigerant.

95ZV EX 72-64 72 Function & Structure Operator Station Group Air Conditioner

When the expansion valve is opened too much <Low pressure side> 294~392 kPa (3.0~4.0 kgf/cm2)

<High pressure side> 1,961~2,452 kPa (20~25 kgf/cm2)

97ZV72098

Symptom

Cause

Inspection/action point

- Pressure is high on both low pressure side and high pressure side.

Expansion valve is defective.

- Temperature sensing rod may be sticking. - Inspect expansion valve. Check temp in and out of valve to determine if it is operating correctly.

- Condensation forms on low pressure side pipes.

Thermal expansion valve

To and from evaporator

Diaphragm

Spring

Temperature sensing rod Needle valve Compressor return From receiver dryer

97ZV72049

95ZV EX 72-65 72 Function & Structure Operator Station Group Air Conditioner

Air conditioner troubleshooting

Display

Fault diagnosis procedure

Hearing check

Error code check ∗

Phenomenon check

Basic check In accordance with fault phenomenon

1) Control mechanism 2) V-belt 3) Sight glass 4) Piping connection

Refrigerant cycle check - Pressure check - Gas leak check

 Error code table

Electrical system check

Repair/check

End

80V2E01012

Failure mode

E-

No failure

E11

Wire breakage in inside air sensor

E12

Short-circuit in inside air sensor

E13

Wire breakage in outside air sensor

E14

Short-circuit in outside air sensor

E15

Wire breakage in water temperature sensor

E16

Short-circuit in water temperature sensor

E18

Short-circuit in insolation sensor

E21

Wire breakage in vent sensor

E22

Short-circuit in vent sensor

E43

Abnormality in vent damper

E44

Abnormality in air mixing damper

E45

Abnormality in inside/outside air

E51

Abnormality in refrigerant pressure

95ZV EX 72-66 72 Function & Structure Operator Station Group Air Conditioner Basic check 1. Check of control mechanism Operate the switch arranged on the control panel, to check that it is operable smoothly and securely. 2. Check of V-belt Check that the V-belt is tensioned properly, and that it is not damaged. 3. Check of refrigerant level through sight glass When the air bubble is observed a lot through sight glass, the refrigerant is probably insufficient. In such a case, therefore, perform the checking with using a gauge manifold.

Sight glass

Receiver joint

Receiver drier

95ZVE01003

4. Check of piping connection At the piping connection where the oil stain is seen, there is probably a refrigerant leakage. In such a case, remove the stain, and then check for gas leakage.

Cooling failure

Normal air flow rate

With diagnostic display: E51 (refrigerant high/ lower pressure error)

With diagnostic display: E44 (A/M servo motor error)

Without diagnostic display

Air flow rate failure

See D-2 .

See D-1 .

See C-3 .

Check the wiring. Replace the servo motor with a new one. Remove the foreign matter.

Replace the V-belt with a new one. Replace the compressor with a new one. Repair the magnet switch, or replace it with a new one. Check the wiring.

See C-1 .

Servomotor failure Blocked foreign matter

Wiring failure, disconnection, disengaged connector

Magnet clutch failure Clutch engagement failure due to electrical system failure

Broken or slipped belt Compressor failure (locking)

Insufficient refrigerant.

See C-4 . See C-5 .

See C-3 .

High pressure both at high-pressure side and low-pressure side Low pressure both at high-pressure side and low-pressure side

See C-2 .

Too low pressure at high-pressure side(Pressure is not increased to approx. 981kPa[10kgf/cm2] or over) Too low pressure at low-pressure side(Pressure is decreased to approx. 49kPa[0.5kgf/cm2] or less

Close the window and door. Adjust the inside/outside air changeover damper. Re-set the link.

∗ Examine the cause before taking the corrective measure,and then replace the fuse with that of the same capacity. See B-1 . Replace the blower main relay with a new one. Replace the blower motor with a new one. Correct the interference. Replace the panel with a new one. Earth the body securely. Check the wiring. Replace the motor with a new one.

Examine the cause of over-voltage before taking the corrective measure.

Check the battery charging system. Correct the contact failure. Replace the blower motor with a new one. Replace the BLC with a new one.

Too high pressure at low-pressure side(approx. 294kPa[3kgf/cm2] or over)

Disengaged A/M link

Mixing of outside air

Operation of BLC protective function due to locked motor

Blower switch failure Body earth failure Wiring failure, disconnected connector

Blown fuse Blower main relay failure Blower motor failure Interference of blower with case

Operation of BLC over-voltage protective function

Decreased supply voltage Battery terminal contact failure Blower motor rotation failure BLC failure

See A-1 .

Operation of low-pressure cut function

Pressure error

Normal pressure

Rotation failure for all modes

Blower is rotated only when the fan switch is selected to High-speed position.

Slow rotation

Adhesion of dust to surface of evaporator

Deformed or damaged blower Frosting in evaporator

Existence of obstacle at vicinity of suction port

Clean the filter. Clean the filter. Remove the obstacle. Replace the blower with a new one. Stop the air compressor, to melt the ice. Examine the cause before taking the corrective measure. Clean the surface of evaporator.

Operation of high-pressure cut function

Compressor rotation failure

Compressor normal rotation

Blower motor rotation failure

Blower motor rotation

Normal rotation

Clogged inner air filter Clogged outer air filter

95ZV EX 72-67 72 Function & Structure Operator Station Group Air Conditioner

80V2E01013

C-2

C-1

B-1

A-1

Voltage not applied to magnet clutch

Voltage applied to magnet clutch Check for characteristic.

Thermister(frosting sensor) characteristic failure

Clogging of dust or mud, etc. in fin.

Excessively opened expansion valve

Replace the valve with a new one. Correction Contact failure in pressure needle valve

Replace the compressor with a new one.

Valve failure

Foreign matter caught by suction valve

Broken suction valve

Discharge the refrigerant to proper level.

Over-filled refrigerant Broken head gasket

Fully discharge the refrigerant, and execute the evacuation, and fill the refrigerant again to proper level.

Mixing of air during refrigerating cycle

Compressor failure

Discharge the refrigerant to proper level.

Over-filled refrigerant

Insufficiently cooled condenser

Clean(Washing with water) the fin.

Check the wiring.

Unusually high outside air temperature

Perform the checking, referring to the wiring diagram.

Evaporator

Sort-circuit wiring

Replace the blower motor with a new one.

Replace the magnet clutch with a new one. Thermister (frosting sensor)

12 ± 5 mm (0.5 ± 0.2 in)

Adjust the gap (12 ± 5 mm) (0.5 ± 0.2 in).

Replace the thermister(frosting sensor) with a new one.

Correction

Replace the clutch relay with a new one.

Erroneous wiring

Locked blower motor

Magnet clutch failure

Adjustment failure of gap between the thermister(frosting sensor) and evaporator

Check the short-circuit.

Check the clutch circuit.

Thermister(frosting sensor) wiring failure

Magnet clutch circuit failure

95ZV EX 72-68 72 Function & Structure Operator Station Group Air Conditioner

85V2U72008

C-5

C-4

C-3

Over-filled refrigerant

Clogging of dust or mud, etc. in fin.

Discharge the refrigerant to proper level.

Clean(washing with water) the fin.

Execute the evacuation fully after replacing the valve and receiver with a new one respectively.

Temporary clogging(mixing of moisture content) due to frozen valve

Insufficiently cooled condenser

Replace the valve with a new one.

Relieved gas from pressure needle valve

to A-1

Replace the valve with a new one.

Replacement

Clogged valve(mixing of foreign matter)

Clogging due to foreign matter in the course of piping

Clogged receiver & drier

Perform the leak test and repair the location of failure before filling the refrigerant.

Gas leakage

Execute the evacuation fully after replacing the valve and receiver with a new one respectively.

Clogging(mixing of moisture content) due to frozen valve

Fill the refrigerant to proper level.

Replace the valve with a new one.

Relieved gas from pressure needle valve

Limited amount of refrigerant filled

Replace the valve with a new one.

Clogged valve(mixing of foreign matter)

Suction/discharge valve failure

Locked piston

Replace the compressor with a new one.

Perform the leak test and repair the location of failure before filling the refrigerant.

Gas leakage

Swash plate shoe seizure

Fill the refrigerant to proper level.

Limited amount of refrigerant filled

Frosted evaporator

Expansion valve failure

Clogging during refrigerating cycle

Limited refrigerant

Unusually low outside air temperature

Expansion valve failure

Compressor failure

Limited refrigerant

Unusually low outside air temperature

95ZV EX 72-69 72 Function & Structure Operator Station Group Air Conditioner

80V2E01015

D-2

D-1

C-4

Replacement

High/low-pressure switch failure

Excessively low pressure [981 kPa(10kgf/cm )or lower]

Replacement

Thermo-sensor failure

C-1

Replacement

Compressor clutch relay failure

Excessively high pressure [2452 kPa(25kgf/cm2)or over]

Replace the control panel with a new one.

Blower switch failure

High-pressure error

Replace the control panel with a new one.

Re-charging

Battery voltage drop

Air conditioner switch failure

Replacement

Rare-short in coil

Disassembling/repair

Remove the oil.

Stained clutch surface due to oil

Foreign matter caught between rotor and stator

Replace the key with a new one.

Slippage due to broken key or key insertion failure

Repair or replacement

Excessive air gap between rotor and stator

Slipped clutch

Replacement

Disconnected stator coil

95ZV EX 72-70 72 Function & Structure Operator Station Group Air Conditioner

80V2E01016

Leakage of water in operator's cab

Heating failure

Normal wind force

Insufficient wind force

Fill the coolant to proper level. Replace the heater core with a new one.

Limited engine cooling water Broken heater core

Replacement

Cleaning

Check the wiring.

Servo motor failure

Remove the foreign matter.

Foreign matter caught

Wiring failure, disconnection, disconnected connector

Re-set the link.

Disengaged temperature controller link

IN side and OUT side reversed.

The temperature controller LED is not operated properly.

Clogged drain hole

Repair or replacement

Clogged or bent piping Excessively low outside air temperature

Discharge the air.

The air is mixed in hot-water circuit.

Note: Do not fail to check that the pump pressure is normal, and that the heater hose is not connected with

The temperature controller LED is operated properly.

Normal water temperature

Low water temperature

Same as "Cooling failure"

95ZV EX 72-71 72 Function & Structure Operator Station Group Air Conditioner

85V2U72009

(without inside air sensor error)

Without diagnostic display

(short-circuit inside air sensor)

setting temperature

With diagnostic display: E12

higher or lower than

(disconnected inside air sensor)

With diagnostic display: E11

(inside air/outside air servo motor abnormal)

With diagnostic display: E45

(inside air/outside air servo motor normal)

Without diagnostic display

(blow-off servo motor abnormal)

With diagnostic display: E43

Room temperature

changeover failure

Outside air/inside air

failure

Blow-off changeover

(blow-off servo motor normal)

Without diagnostic display

Cooling failure, heating failure

Short-circuit inside air sensor

Perform the checking in accordance with the paragraph "Cooling failure/heating failure".

Replacement

Check the wiring.

Replacement

Disconnected inside air sensor Short-circuit harness

Re-check the wiring.

Remove the foreign matter.

Foreign matter caught

Disconnected harness, disengaged connector

Replacement

Re-check the wiring

Wiring failure, disconnection, disconnected connector Servo motor failure

Re-set the link.

Remove the foreign matter.

Foreign matter caught

Disengaged link

Replacement

Check the wiring.

Wiring failure, disconnection, disconnected connector Servo motor failure

Re-set the link.

Disengaged link

95ZV EX 72-72 72 Function & Structure Operator Station Group Air Conditioner

80V2E01018

95ZV EX 73-1 73 Check & Adjustment Operator Station Group

73 Check & Adjustment Operator Station Group Air Conditioner ......................................................................73-2

95ZV EX 73-2 73 Check & Adjustment Operator Station Group Air Conditioner

Air Conditioner Adjustment of lubricating oil quantity when components of air conditioner are replaced

WARNING In order to protect the environment, do not release excess refrigerant when removing components of the air conditioner.

IMPORTANT

Fig. 1

97ZV73002

- When replacing components of the air conditioner, if the lubricating oil quantity is too small, the compressor may seize. And if the lubricating oil quantity is too much, the cooling ability may deteriorate. Be sure to correctly adjust lubricating oil quantity. - When connecting a joint, apply compressor oil (ND-OIL 8) on the O ring before tightening (Fig. 1). - If the compressor oil (ND-OIL 18) sticks to the paint, the paint may peel off or be damaged. If it gets on a painted surface, wipe it off soon. - Tighten the piping, etc. at the recommended torque. Tightening torque table Connection area

Nut type (Fig. 2) Fig. 2

Tightening torque N-m (kgf-cm)

ø8 pipe

14.7 (150)

1/2 pipe

24.5 (250)

5/8 pipe

34.3 (350)

M6 bolt in receiver (4T)

6.9 (70)

Any M6 bolt other than above (6T)

11.8 (120)

97ZV73003

Block joint (Fig. 3)

Fig. 3

Pipe size or bolt size

97ZV73004

95ZV EX 73-3 73 Check & Adjustment Operator Station Group Air Conditioner

When the compressor is replaced

New compressor

Old compressor to be replaced

Compressor mounting bolt 29 N-m (3.0 kgf-m) Hose block joint on high pressure side 12 N-m (1.2 kgf-m) Hose block joint on low pressure side 12 N-m (1.2 kgf-m) Example

Oil quantity remaining inside circuit

Suppose that the oil quantity (A) removed from the compressor to be replaced is 100 cm3.

(B)

Oil quantity remaining inside circuit (B) = 180 cm3 - (100 + 20) = 60 cm3

97ZV73005

1. Remove the oil from the removed compressor, and measure the oil quantity. (Approximately 20 cm3 of oil cannot be removed, and remains inside the compressor.).......... A cm3 2. The compressor can accommodate 180 cm3 of oil. Obtain the remaining oil quantity using the following equation. Oil quantity remaining inside circuit = 180 - (Oil quantity A discharged from removed compressor + 20 cm3) 3. Discharge the oil by as much as the quantity remaining inside the circuit from a new compressor, then attach the new compressor. Compressor lubricating oil ND-OIL 8

IMPORTANT 3

- Oil (180 cm ) required for the cooling circuit is sealed inside a new compressor. When replacing the compressor, excessive oil should be discharged from a new compressor. - The compressor oil can easily contain moisture. Seal the compressor immediately after adjusting the oil quantity. - Never use the oil for the R12.

Remove 60 cm3 from the new compressor.

95ZV EX 73-4 73 Check & Adjustment Operator Station Group Air Conditioner

When the evaporator is replaced

When the condenser is replaced Lubricating oil quantity lost by replacement Approximately 40 cm3

When replacing the condenser, add 40 cm3 of compressor oil (ND-OIL 8) to a new condenser. : (1): 25 N-m (2.5 kgf-m) : (2): 15 N-m (1.5 kgf-m)

Evaporator

When the receiver dryer is replaced Lubricating oil quantity lost by replacement Approximately 20 cm3

Expansion valve

The oil quantity lost by replacement is within the allowable range, and supplement is not required at the first time. At the second time and later, however, add 20 cm3 of compressor oil (ND-OIL 8) to a new receiver dryer. : (1): 7 N-m (0.7 kgf-m) : (2): 15 N-m (1.5 kgf-m)

97ZV73006

Lubricating oil quantity lost by replacement Approximately 40 cm3 When replacing the evaporator, add 40 cm3 of compressor oil (ND-OIL 8) to a new evaporator. : (1): 12 N-m (1.2 kgf-m)

95ZV EX 73-5 73 Check & Adjustment Operator Station Group Air Conditioner

Adjustment of air gap (between hub and rotor) in compressor magnetic clutch

1. Remove the front cover of the magnetic clutch. 2. Measure the size A between the rotor end face and the hub end face while the magnetic clutch is OFF. 3. Apply the battery voltage directly on the connector of the magnetic clutch, and measure the size of B in the same way as step 2 above.

Position while magnetic clutch is OFF

A (OFF status) Position while magnetic clutch is ON

Criteria of air gap (A - B) 0.5±0.15 mm

Reference plane Air gap 0.5±0.15 mm

If the obtained value does not agree with the criteria, loosen the head bolt, remove the hub, and adjust the air gap by utilizing the thickness of the washer plate between the hub and the shaft.

B (ON status)

Hub Head bolt Washer plate

Rotor

95ZVE73002

WARNING If you adjust the air gap while the engine is rotating, serious accidents such as injury to your hands may occur. Set the starter switch to OFF, stop rotation of the engine, pull out the starter key, then start adjustment.

95ZV EX 73-6 73 Check & Adjustment Operator Station Group Air Conditioner

Parts to be replaced periodically

Receiver dryer

Air filters

Replacement Once/3 years

Air filter for outside air Cleaning Once/2 weeks However, if the operating environment is severe (with much sand, dust, etc.) and the air filter is easily clogged, clean it more frequently. In cleaning, blow the compressed air of 196~294 kPa (2~3 kgf/cm2) mainly from the inside of the filter. Replacement Once/year When the air quantity is so small as to hinder air conditioning even after cleaning, or when the air filter has been cleaned 20 times, replace it.

Air filters for inside air Cleaning Once/1 month However, if the air filters are easily clogged, clean them more frequently. In cleaning, blow the compressed air of 196~294 kPa (2~3 kgf/cm2) mainly from the inside of the filters. Replacement Once/3 years When the air quantity is so small as to hinder air conditioning even after cleaning, or when the air filters have been cleaned 6 times, replace them.

WARNING When replacing the receiver dryer, do not release the refrigerant into the atmosphere.

INDEX A Accelerator pedal ................................................ 62-39, 62-41 Accelerator pedal installation .............................. 62-40, 62-42 Accumulator ....................................................................52-10 Accumulator (for vibration damper) ................................42-76 Accumulator circuit pressure ............................................53-4 Adapter (Orifice) .............................................................42-66 Adjusting reducing valve setting pressure ........................53-5 Adjusting set pressure ........................................ 42-57, 42-59 Adjusting shim ..................................................................13-5 Adjusting tooth contact ...................................................23-10 Adjusting unloader valve setting pressure ........................53-3 Adjustment ........................................................................13-3 Adjustment of air gap (between hub and rotor) in compressor magnetic clutch .........................................73-5 Adjustment of axle internal pressure ................................52-2 Adjustment of lubricating oil quantity when components of air conditioner are replaced ......................................73-2 Air compressor (with magnetic clutch) ............................72-17 Air Conditioner ...................................................... 72-13, 73-2 Air conditioner components ............................................72-13 Air conditioner functions of components .........................72-23 Air conditioner specifications (system performance) ......72-13 Air conditioner structure ..................................................72-14 Air conditioner troubleshooting .......................................72-65 Air conditioner unit ..........................................................72-30 Air distributor (hood & defroster selection box) ...............72-16 Air filters ............................................................................73-6 Alarm monitor actuation and data storage ......................62-97 Alternator ........................................................................62-24 Alternator I terminal wire .................................................62-20 Auto Brake ......................................................................52-43 Auto brake ............................................................ 52-2, 62-61 Auto brake circuit ............................................................52-43 Auto brake operation set value .......................................52-43 Automatic shift ................................................................62-48 Axle ...................................................................................23-5 Axle Assembly ........................................................ 22-9, 92-2 Axle nut tightening procedure ...........................................23-5 Axle Support ...................................................................22-10

B Back-up alarm .................................................................62-57 Battery relay ....................................................................62-20 Battery relay operation ....................................................62-20 Bearing installation ...........................................................23-9 Bleeding air from brake pipes and hubs .........................52-31 Bleeding air from the brake valves .................................52-31 Bolt tightening torque ......................................................00-13 Boom cylinder .................................................................42-28 Boom kick-out (option) ....................................................62-86 Boom spool operation .....................................................42-63 Brake Accumulator Line ....................................................52-9 Brake Circuit (S/N 0101~, 9001~) .....................................92-8 Brake circuit air bleeding procedure ...............................52-30 Brake Circuit Check Valve ..............................................52-12

Brake Circuit Oil Pressure ................................................ 53-2 Brake lining abrasion check ........................................... 53-15 Brake main valve (left pedal) .......................................... 52-13 Brake pilot valve (right pedal) ......................................... 52-15 Brake System Outline ....................................................... 52-2 Brake Units Layout ........................................................... 52-3 Brake Valve .................................................................... 52-13 Brake valve oil pressure ................................................... 53-6 Brake valve outline ......................................................... 52-20 Brake valve performance ................................................. 53-7 Brake valve performance chart ...................................... 52-17 Bucket cylinder ............................................................... 42-29 Bucket hinge pin section .................................................. 13-4 Bucket leveler ................................................................. 62-85 Bucket spool operation ................................................... 42-61

C Cabin ................................................................................ 72-2 Caution for diode check method ..................................... 62-89 Cautions ......................................................................... 00-20 Cautions on Hydraulic Parts Replacement ....................... 42-3 Cautions on Safety ........................................................... 03-2 Cautions Regarding Electric Circuit Check ...................... 63-2 Cautions regarding parts removal .................................. 00-18 Cautions regarding reassembly ...................................... 00-18 Cautions regarding welding repair service ..................... 00-20 Cautions when installing brake discs (S/N 0101~0311, 9001~9095 only) ............................ 53-11 Center Pin ............................................................... 12-8, 13-5 Changeover between forward and reverse .................... 63-30 Changing display from one function to next ................. 62-102 Charge of refrigerant ...................................................... 72-50 Check output circuit wiring ............................................. 63-19 Check valve ................................................42-6, 42-71, 42-75 Clutch combination ........................................................... 32-5 Clutch Oil Pressure and Time Lag ................................... 33-2 Clutch oil pressure control at the time of engine starting .................................................................................... 32-23 Clutch oil pressure measurement procedure ................... 33-3 Clutch Pack ...................................................................... 32-9 Clutch Solenoid Valve .................................................... 32-25 Clutch solenoid valve output electrical circuit check ...... 63-16 Clutch specifications ......................................................... 32-6 Column shaft .................................................................. 72-12 Como Utilizar o Diagrama de Ligações Eléctricas (PORTUGUÊS) ............................................................ 62-7 Cómo utilizar un Diagrama de Alambrado Eléctrico (ESPAÑOL) .................................................................. 62-6 Compressor and magnetic clutch ................................... 72-39 Condenser unit .................................................... 72-17, 72-42 Connection diagram ....................................................... 62-25 Connector ....................................................................... 62-67 Contact between pinion and side gear ........................... 22-22 Continuity check mode ................................................... 62-89 Control panel .................................................................. 72-23 Control schematic drawing ............................................. 72-22

Control unit ..................................................................... 72-18 Controller ........................................................................ 62-43 Controller connection diagram ....................................... 62-45 Controller function .......................................................... 62-46 Coolant ........................................................................... 00-10 Coolant specification ...................................................... 00-10 Cooling circuit ................................................................. 72-21 Cooling mechanism ........................................................ 72-19 Cooling unit .................................................................... 72-14 Cylinder natural drift ....................................................... 43-12 Cylinders .......................................................................... 42-4

D Detent adjustment procedure ......................................... 42-38 Detent solenoid .............................................................. 62-87 Diagnostic (T/M controller) failure code detection condition .................................................................... 62-94 Diagnostic failure history indication and deletion ........... 62-99 Diagnostic switch ......................................................... 62-101 Diagnostic System (S/N 0101~0358, 9001~) ................. 62-92 Diagnostic system flow ........................................ 62-92, 62-96 Difference in gear shapes .............................................. 22-22 Differential Gear ............................................................. 22-18 Differential gear adjustment procedure ............................ 23-7 Diode .............................................................................. 62-88 Diode check method ...................................................... 62-89 Diode check mode ......................................................... 62-89 Diode unit ....................................................................... 62-21 Directional control valve ................................................... 42-6 Disconnecting or reinstalling connector ........................... 63-2 Dust seal .......................................................................... 12-9

E ECM (Engine Controller) ................................................ 62-25 Electrical Cable Color Codes ........................................... 62-8 Electrical circuit .............................................................. 72-22 Electrical Circuit Check (S/N 0101~0358, 9001~) .......... 63-10 Electrical Circuit Diagram (Cabin Air Conditioner) ......... 92-36 Electrical Circuit Symbols ................................................. 62-9 Electrical Connection Diagram (1/2) (S/N 0477~0560) .................................................................................... 92-31 Electrical Connection Diagram (1/2) (S/N 0561~) .......... 92-33 Electrical Connection Diagram (2/2) (S/N 0477~0560) .................................................................................... 92-32 Electrical Connection Diagram (2/2) (S/N 0561~) .......... 92-34 Electrical Connection Diagram (S/N 0101~0358) .......... 92-29 Electrical Connection Diagram (S/N 0359~0476) .......... 92-30 Electrical Connection Diagram (S/N 5001~5140) .......... 92-35 Electrical Connection Diagram (S/N 9001~) .................. 92-35 Electrical Detent Circuit .................................................. 62-85 Electrical Equipment Layout ........................................... 92-39 Electrical Transmission Control System Troubleshooting Flowchart (S/N 0101~0358, 9001~) ............................. 63-5 Electrical Wiring Diagram (1/2) (S/N 0101~0358) ............ 92-9 Electrical Wiring Diagram (1/2) (S/N 9001~9080) .......... 92-20 Electrical Wiring Diagram (1/2) (S/N 9081~) .................. 92-22 Electrical Wiring Diagram (1/3) (S/N 0359~0476) .......... 92-11 Electrical Wiring Diagram (1/3) (S/N 0477~0560) .......... 92-14 Electrical Wiring Diagram (1/3) (S/N 0561~) .................. 92-17

Electrical Wiring Diagram (2/2) (S/N 0101~0358) .......... 92-10 Electrical Wiring Diagram (2/2) (S/N 9001~9010) .......... 92-21 Electrical Wiring Diagram (2/2) (S/N 9081~) .................. 92-23 Electrical Wiring Diagram (2/3) (S/N 0359~0476) .......... 92-12 Electrical Wiring Diagram (2/3) (S/N 0477~0560) .......... 92-15 Electrical Wiring Diagram (2/3) (S/N 0561~) .................. 92-18 Electrical Wiring Diagram (3/3) (S/N 0359~0476) .......... 92-13 Electrical Wiring Diagram (3/3) (S/N 0477~0560) .......... 92-16 Electrical Wiring Diagram (3/3) (S/N 0561~) .................. 92-19 Electrical Wiring Diagram (CAB) ....................................92-27 Electrical Wiring Diagram (Cabin Air Conditioner) .......... 92-37 Electrical wiring diagram abbreviation chart (S/N 0101~0358, 9001~) ............................................ 92-24 Electrical wiring diagram abbreviation chart (S/N 0359~0476) ........................................................92-25 Electrical wiring diagram abbreviation chart (S/N 0477~) ................................................................92-26 Emergency steering (for Europe) ................................. 42-149 Emergency steering function (for Europe spec only) ......62-65 Emergency steering hydraulic diagram ........................ 42-150 Emergency steering line oil flow ................................... 42-149 Emergency steering operation condition ...................... 42-149 Engine ..............................................................................23-2 Engine / Transmission ...................................................... 22-3 Engine / transmission mount ............................................22-3 Engine diagnostic switch (option) ........................62-27, 62-29 Engine Start Circuit (S/N 0101~0360, 9001~) ................ 62-15 Engine start circuit diagram (S/N 0101~0358, 9001~) ....................................................................................62-15 Engine start circuit diagram (S/N 0359~) ........................ 62-16 Equipment Operation Table (Cabin Air Conditioner) ......92-38

F Failure code (T/M controller) ..........................................62-93 Failure diagnosis ............................................................ 62-27 Failure diagnostic chart ..................................................62-30 Failure history deletion ................................................. 62-100 Failure history indication ................................................. 62-99 Fan maximum revolution measurement .........................43-19 Fan maximum revolution measurement (S/N 0101~0230) ........................................................43-15 Fan maximum revolution measurement (S/N 0231~) ....................................................................................43-17 Fan maximum revolution measurement (S/N 9011~) ....................................................................................43-21 Fan motor (FM30) (S/N 0399~0466) ............................ 42-122 Fan motor (GM30C) (S/N 0101~0230) ......................... 42-110 Fan motor (GM30C) (S/N 0231~0313) ......................... 42-119 Fan motor (GM30C) (S/N 9001~9010) ......................... 42-133 Fan motor (GM30C) (S/N 9011~9065) ......................... 42-142 Fan motor (GM30W) (S/N 0314~0398) ........................ 42-120 Fan motor (GM30W) (S/N 9066~) ................................ 42-143 Fan motor (S/N 0467~) ................................................. 42-124 Fan motor check valve (make-up valve) ..........42-130, 42-148 Fan motor function and the operation principle ............ 42-126 Fan Motor Line (S/N 0101~0230) ................................. 42-108 Fan Motor Line (S/N 0231~) ......................................... 42-116 Fan Motor Line (S/N 9001~9010) ................................. 42-131 Fan Motor Line (S/N 9011~) ......................................... 42-139 Fan motor relief valve ......................................42-130, 42-148

Fan Motor Relief Valve Assembly .................................42-147 Fan motor relief valve assembly ...................................42-129 Fan motor specifications ...............................................42-142 Fan Motor System ........................................................42-106 Fan motor system .............................................................42-9 Fan Revolution (S/N 0101~) ...........................................43-15 Fan Revolution (S/N 9001~) ...........................................43-19 Fault diagnosis procedure ..............................................72-65 Fault diagnostic result storage condition ........................62-95 Flanged hexagon bolt .....................................................00-16 Float ................................................................................62-86 Floor board .......................................................................12-7 Floor board mount ............................................................12-7 Flow amplifier notch and pilot orifice ...............................42-98 Flow control valve .............................................................42-5 Flushing Hydraulic Circuit .................................................42-2 For high/reverse and speed clutches ..............................32-27 Forward 1st speed flow path ...........................................32-10 Forward 2nd speed flow path .........................................32-11 Forward 3rd speed flow path ..........................................32-11 Forward 4th speed flow path ..........................................32-12 Forward/reverse (F/R) shifting and speed change .........62-46 Friction plate .....................................................................32-7 Front Chassis ....................................................................12-2 Front differential - Transmission .......................................22-7 Front parking brake auto adjuster mechanism ...............52-40 Front parking brake operation .........................................52-38 Front wiper ........................................................................72-6 Fuel gauge circuit ...........................................................62-83 Fuel level gauge electrical circuit check .........................63-28 Fuel tank (S/N 0101~0262, 9001~9064) ..........................12-5 Fuel tank (S/N 0263~, 9065~) ..........................................12-6 Function of ECM .............................................................62-25 Function of T.P.D ............................................................22-22 Fuse ................................................................................62-11 Fuse box .........................................................................62-12 Fuse box location ............................................................62-11 Fusible link ......................................................................62-13

G Gauge circuit ...................................................................62-80 Gauge circuit electrical circuit check ...............................63-26 Gear pump specifications ....................................... 32-3, 32-4 Gear train and number of teeth .........................................32-6 Glass .................................................................................72-3 Grease nipple installation direction ...................................13-5

H Heater and accessories ..................................................72-16 Hexagon bolt ...................................................................00-13 Hose band tightening torque ...........................................00-17 How to assemble ..............................................................13-4 How to attach the probes of the circuit tester ...................63-4 How to Use Electrical Wiring Diagram ..............................62-2 How to Use Manual ..........................................................00-2 How to wind a seal tape ..................................................00-19 Hydraulic Circuit Diagram ...............................................32-16 Hydraulic Circuit Symbols .................................................42-4 Hydraulic Cylinder ............................................... 42-28, 43-12

Hydraulic cylinder specifications .................................... 42-31 Hydraulic lines .................................................................. 42-4 Hydraulic oil level check ................................................. 42-11 Hydraulic Pump .............................................................. 42-17 Hydraulic pump bushing lubrication ............................... 42-27 Hydraulic pump oil amount and steering force ............... 42-84 Hydraulic pump principle ................................................ 42-26 Hydraulic pump wear plate ............................................. 42-27 Hydraulic System Diagram ............................................. 32-15 Hydraulic System Operation ............................................. 42-8 Hydraulic system operation outline .................................. 42-8 Hydraulic Tank ............................................................... 42-11 Hydraulic tank (S/N 0101~0450, 9001~) ........................ 42-12 Hydraulic Tank (S/N 0451~) ........................................... 42-15 Hydraulic tank breather valve (tank cap) (S/N 0101~0450, 9001~) ........................................... 42-13 Hydraulic tank breather valve (tank cap)(S/N 0451~) .... 42-16 Hydraulic tank specifications .......................................... 42-11

I If the input units or circuit are not defective ...................... 63-7 Inching (declutch) input electrical circuit check .............. 63-12 Increment decrement switch (option) ............................. 62-31 In-line filter ...................................................................... 52-11 Inspection and Maintenance Table .................................. 00-5 Installing bearing outer ring .............................................. 13-6 Instrument panel ............................................................. 62-76 Instrument Panel and Switch .......................................... 62-76 Instrument panel rear surface ........................................ 62-78 Interior schematic (example) .......................................... 32-21 Items to be monitored and operation condition .............. 62-73

L Layout of main components ............................................. 00-4 LED inspection windows ................................................ 62-44 Left turn position ............................................................. 42-90 Liner ................................................................................. 13-2 Linkage Pin ....................................................................... 13-2 Liquid gasket and screw lock agent ............................... 00-18 Loading and pilot and brake pump ...................... 42-18, 42-19 Loading circuit relief valve setting pressures .................... 43-2 Loading linkage ................................................................ 12-2 Loading linkage pin .......................................................... 12-4 Loading System .............................................................. 42-32 Loading system ................................................................ 42-8 Loading/Steering Circuit Relief Valve ............................... 43-2 Loading/Steering Hydraulic Circuit (S/N 9001~9010) ...... 92-6 Loading/Steering Hydraulic Circuit (S/N 9011~) .............. 92-7 Loading/Steering Hydraulic Line (S/N 0101~0230) .......... 92-4 Loading/Steering Hydraulic Line (S/N 0231~) .................. 92-5 Lower center pin ............................................................... 12-8 Lubrication chart ............................................................. 00-11

M Machine control unit (MCU) ............................................ 62-66 Machine control unit (MCU) connection diagram (S/N 0359~0476) ....................................................... 62-68 Machine control unit (MCU) connection diagram (S/N 0477~) ............................................................... 62-69

Machine control unit (MCU) failure warning ................... 62-70 Machine speed sensor ................................................... 62-50 Machine speed sensor input electrical circuit check ...... 63-15 Magnet switch ................................................................ 62-22 Main relief valve operation ............................................. 42-56 Main valve (tandem type) operation ............................... 52-20 Make-up valve operation ....................................42-59, 42-60, 42-96, 42-114, 42-137 Measuring brake valve oil pressure ................................. 53-6 Measuring clutch oil pressure .......................................... 33-2 Measuring clutch time lag ................................................ 33-4 Measuring engine oil pressure ......................................... 23-2 Measuring engine speed .................................................. 23-2 Measuring loading circuit main relief pressure ................. 43-4 Measuring loading circuit overload relief pressure ........... 43-5 Measuring pilot circuit relief pressure ............................... 43-6 Measuring pilot circuit relief pressure (reducing pressure) (S/N 0107~, 9004~) ................................................... 43-11 Measuring reducing valve setting pressure ...................... 53-4 Measuring steering circuit main relief pressure ................ 43-9 Measuring steering circuit overload relief pressure ........ 43-10 Measuring unloader valve setting pressure ..................... 53-3 Miscellaneous hydraulic symbols ..................................... 42-7 Modalità di utilizzo dello schema dei collegamenti elettrici (ITALIANO) ...................................................... 62-5 MODM (S/N 97C4-0359~) ........................................... 62-102 MODM function ............................................................ 62-102 MODM: Input/Output Monitor - Input/Output Signal Correspondence Table ............................................ 62-109 Modulation at clutch switching ....................................... 62-52 Modulator valve 1 ........................................................... 32-22 Modulator valve 2 ........................................................... 32-23 Modulator valve function ................................................ 32-22 Modulator valve operation .............................................. 32-24 Modulator valve output electrical circuit check ............... 63-18 Modulator Valve Unit ...................................................... 32-19 Monitor Changeover ..................................................... 62-102 Monitor controller ................................................ 62-71, 62-96 Monitor controller connection diagram ........................... 62-72 Monitor controller function .............................................. 62-73 Monitor lamp test ............................................................ 62-26 Monitoring System (S/N 0101~0358, 9001~) ................. 62-71 Multiple Control Valve (KML35A/2T202) ........................ 42-54 Multiple control valve boom spool .................................. 42-63 Multiple control valve bucket spool ................................ 42-61 Multiple control valve main relief valve ........................... 42-56 Multiple control valve make-up valve ............................. 42-60 Multiple control valve overload relief valve ..................... 42-58 Multiple control valve specifications ............................... 42-55

N Neutral ............................................................................ 42-81 Neutral position .............................................................. 42-89 Neutral relay ................................................................... 62-21 Neutral relay electrical circuit check ............................... 63-20 Neutral starter ..................................................... 62-15, 62-18

O Oil Flow .......................................................................... 32-17

Oil flow in the torque converter line ................................ 32-17 Oil flow to the clutch ....................................................... 32-17 Oil seal installation ............................................................ 23-9 Operation force measurement ........................................ 63-30 Operation methods ........................................................... 42-5 Operation monitor lamps ................................................62-74 Operation of T.P.D .......................................................... 22-23 Operator Seat ...................................................................72-9 Orbit rotor operation principle ......................................... 42-85 Orbitrol® .......................................................................... 42-79 Orbitrol® feed-back mechanism operation ......................42-83 Orbitrol® operation .......................................................... 42-81 Orbitrol® specification .....................................................42-79 Orbitrol® structure ...........................................................42-80 Outline ..............................................................................00-4 Overload relief valve operation ............................42-58, 42-96

P Parking Brake ......................................................52-32, 53-12 Parking brake ...................................................................52-2 Parking brake (front, dry type disc brake) (for Europe only) ........................................................52-38 Parking brake (rear, internal expansion type drum brake) ................................................................52-33 Parking brake clearance adjustment .............................. 53-14 Parking brake electrical circuit check ............................. 63-21 Parking brake line air bleeding procedure (front parking) ............................................................. 52-41 Parking brake manual release procedure (front) ............ 52-42 Parking brake manual release procedure (rear) ............. 52-35 Parking brake operation chart ........................................ 52-32 Parking brake performance check ..................................53-12 Parking brake solenoid valve ...............................52-34, 62-59 Parking brake solenoid valve (front) ...............................52-39 Parking brake spring chamber ........................................ 52-37 Parking solenoid valve operation (front) .........................52-39 Parking solenoid valve operation (rear) .......................... 52-34 Part number 32011-21500 ................................................ 72-5 Part number 32011-21690 ................................................ 72-4 Part number 32011-21700 ................................................ 72-4 Parts to be replaced periodically ......................................73-6 Pilot Valve (S/N 0101~0290, 9001~9080) ......................42-34 Pilot valve (S/N 0291~0408, 9081~) ...............................42-39 Pilot valve (S/N 0409~0410) ........................................... 42-44 Pilot valve (S/N 0411~) ...................................................42-49 Pilot valve detent magnet solenoid ................................. 42-38 Pilot valve function ...............................................42-46, 42-51 Pilot valve operation ................................ 42-36, 42-41, 52-21 Pilot valve operation (modulated position) ...........42-46, 42-51 Planetary gear ..................................................................32-5 Planetary gear oil drain and refill ......................................23-6 Possible causes for clutch time lag .................................. 33-4 Possible causes for low clutch oil pressure ......................33-3 Power flow path ................................................................32-2 Power Flow Path in the Transmission ............................32-10 Power Generating/Charging Circuit ................................ 62-24 Power Line ........................................................................22-2 Pre-detent and detent magnet solenoid ............................................................. 42-43, 42-48, 42-53 Preload adjustment ........................................................... 23-8

Pressure control valve ......................................................42-5 Pressure relief valve .......................................................72-47 Pressure sensor (S/N ~0556) .........................................32-23 Pressure switch (for declutch) ........................................52-23 Pressure switch (for stop lamp) ......................................52-22 Pressure switch for inching (declutch) ............................62-56 Pressure switches ...........................................................72-46 Principle of cooling ..........................................................72-19 Propeller Shaft ........................................................ 22-6, 23-3 Propeller shaft phase ........................................................23-3 Propeller shaft tightening torque .......................................23-4 Proximity switch ..............................................................62-86 Pump specifications ........... 42-19, 42-20, 42-21, 42-23, 42-25 Pumps & motors ...............................................................42-4 Purpose of flushing ...........................................................42-2

Q QUAD (downshift) switch operation ................................62-51 QUAD switch input electrical circuit check ......................63-14 QUAD switch operation ....................................................32-5 Quantum fault code information ......................................62-32

R Radiator ............................................................................22-4 Radiator mount .................................................................22-5 Rear Chassis ....................................................................12-5 Rear parking brake operation .........................................52-33 Rear wiper ........................................................................72-6 Receiver dryer ...................................................... 72-44, 73-6 Recommended lubricants .................................................00-8 Recommended mixture of antifreeze ..............................00-10 Reducing Valve .................................................................52-8 Reducing valve ...............................................................42-71 Reducing Valve (for Accumulator Circuit) .........................52-8 Reducing Valve (for Orbitrol®) ......................................42-103 Reducing Valve (for Pilot Pressure) ................................42-33 Refrigerant ......................................................................72-19 Refrigerant characteristics ..............................................72-20 Refrigerant charging procedure ......................................72-55 Refrigerant charging tools ...............................................72-52 Refrigerant hose .............................................................72-49 Relay A ...........................................................................72-48 Relay B ...........................................................................72-48 Relief valve (two-step relief) ........................... 42-112, 42-135 Relief valve (two-step relief) operation ........... 42-113, 42-136 Resistance check mode ..................................................62-90 Reverse 1st speed flow path ..........................................32-13 Reverse 2nd speed flow path .........................................32-13 Reverse 3rd speed flow path ..........................................32-14 Rotor part ........................................................................42-80

S Safety precautions ............................................................00-2 Screw lock agent application procedure .........................00-19 Second propeller shaft alignment .....................................23-3 Second propeller shaft assembly ......................................22-7 Sensor Mount .................................................................62-10 Service Brake ....................................................... 52-24, 53-8 Service brake ....................................................................52-2

Service brake friction plate ............................................. 52-25 Service brake friction plate wear measurement ............... 53-9 Service brake operation ................................................. 52-24 Service brake pedal stroke adjusting mechanism (S/N 0101~0311, 9001~9095) ................................... 52-28 Service brake performance check .................................... 53-8 Service brake piston ....................................................... 52-26 Service brake steel plate ................................................ 52-25 Shift Lever ...................................................................... 63-30 Shift lever ....................................................................... 72-12 Shift lever forward/reverse (F/R) position ............ 62-15, 62-18 Shift lever input electrical circuit check ........................... 63-10 Shift lever neutral (N) position ............................. 62-15, 62-18 Shift lever position ............................................................ 32-5 Shuttle Valve .................................................................. 52-45 Shuttle valve ................................................................... 42-74 Sight glass ...................................................................... 72-46 Solenoid valve ..................................................... 42-72, 42-74 Solenoid valve (for autobrake circuit) ............................. 52-44 Solenoid valve (for fan speed control) ............. 42-115, 42-138 Solenoid valve (for fan speed control) operation ..................................................................... 42-115, 42-138 Solenoid valve on the front side ..................................... 63-23 Standard Measurement Values for Performance Check ...................................................................................... 03-3 Standard troubleshooting flowchart .................................. 63-5 Starter switch .................................................................. 62-19 Steel plate ........................................................................ 32-8 Steering and Transmission Shift Lever .......................... 72-10 Steering circuit relief valve setting pressures ................... 43-7 Steering cylinder ............................................................. 42-30 Steering Line Filter ....................................................... 42-104 Steering pilot circuit and its operation ............................ 42-97 Steering plunger variable throttle ................................... 42-91 Steering pump (S/N 0101~0258, 9001~9065) ............... 42-20 Steering pump (S/N 0259~0398, 9066~) ....................... 42-21 Steering pump (S/N 0399~0465) ................................... 42-23 Steering pump (S/N 0466~) ........................................... 42-25 Steering speed and flow rate control .............................. 42-84 Steering System ............................................................. 42-78 Steering system ................................................................ 42-9 Steering Valve (KVS32-A4.0) ......................................... 42-86 Steering valve flow control plunger ................................ 42-92 Steering valve main relief valve ...................................... 42-93 Steering valve operation ................................................. 42-89 Steering valve overload relief valve ................................ 42-95 Stop Lamp Pressure Switch ........................................... 52-22 Stop Valve ........................................................... 42-99, 43-14 Stop valve adjustment procedure ................................... 43-14 Stop valve function ....................................................... 42-101 Stop valve operation ..................................................... 42-102 Surge voltage and surge suppression diodes ................ 62-91 Switching from automatic to manual .............................. 62-51 Symbols ............................................................................ 00-3

T T/C and T/M Oil Circulation ............................................ 32-18 Tachometer .................................................................... 62-82 Tachometer circuit .......................................................... 62-82 Temperature sensor ....................................................... 62-81

Thermo sensing valve ..................................... 42-127, 42-145 Thermo sensing valve operation ..................... 42-128, 42-146 Third propeller shaft assembly ......................................... 22-8 Tilt case .......................................................................... 72-11 Time lag measurement procedure ................................... 33-4 Tolerance ring ................................................................ 52-29 Torque Converter ............................................................. 32-2 Torque Converter and Transmission ................................ 92-3 Torque Converter Gear Pump .......................................... 32-3 Torque Converter structure .............................................. 32-2 Torque multiplication ........................................................ 32-2 Transmission - Rear differential ....................................... 22-8 Transmission Control Circuit and Monitor Circuit (S/N 0101~0358, 9001~) ........................................... 62-43 Transmission Control Circuit and Monitor Circuit (S/N 0359~) ............................................................... 62-66 Transmission Controller Abnormal Operation Judgment (S/N 0101~0358, 9001~) ............................ 63-6 Transmission controller check .......................................... 63-6 Transmission controller failure warning .......................... 62-64 Transmission controller LED indicator ............................. 63-8 Transmission cut off (Declutch) ...................................... 62-55 Transmission gear changeover ...................................... 63-30 Troubleshooting using the gauge manifold .................... 72-60 Turn ................................................................................ 42-82

U Unloader Valve ................................................................. 52-4 Unloader valve operation ................................................. 52-6 Unloader valve setting pressure ....................................... 53-2 Upper center pin ............................................................... 12-8 Utilisation des schémas des câblages électriques (FRANÇAIS) ................................................................ 62-3

V Valve assembly (for fan motor) ....................... 42-111, 42-134 Valve part ....................................................................... 42-80 Valve Unit ......................................................................... 52-7 Verwendung des elektrischen Schaltplans (DEUTSCH) ...................................................................................... 62-4 Vibration Damper (OPT) ................................................ 42-67 Vibration damper function .............................................. 42-67 Vibration damper hydraulic circuit .................................. 42-67 Vibration damper hydraulic line ...................................... 42-77 Vibration damper operation ............................................ 42-68 Vibration damper system (OPT) ....................................... 42-9 Vibration damper valve assembly (Accumulator circuit) .................................................................................... 42-73 Vibration damper valve assembly (Reducing valve circuit) .................................................................................... 42-70 Viscous mount .................................................................. 12-7 Voltage relay .................................................................. 62-23

W Weight of main components ........................................... 00-12 When the "controller failure" monitor lamp lights: ............ 63-6 When the compressor is replaced .................................... 73-3 When the condenser is replaced ...................................... 73-4 When the evaporator is replaced ..................................... 73-4

When the output units (solenoid valve, etc.) do not operate properly: ..........................................................63-6 When the pressure exceeds the preset value ................ 42-94 When the pressure is at the preset value or less ...........42-93 Wiper motor ...................................................................... 72-7 Wiper mount .....................................................................72-6 Work procedure ..............................................................72-51

MEMO

Maintenance Log Date

Machine hours

Service performed

Date

Machine hours

Service performed

Date

Machine hours

Service performed

Date

Machine hours

Service performed

Notes

95ZV EX 92-1 92 Cross-Section Drawing & Diagrams

92 Cross-Section Drawing & Diagrams Axle Assembly ......................................................................................................................... 92-2 Torque Converter and Transmission........................................................................................ 92-3 Loading/Steering Hydraulic Line (S/N 0101~0230) ................................................................. 92-4 Loading/Steering Hydraulic Line (S/N 0231~) ......................................................................... 92-5 Loading/Steering Hydraulic Circuit (S/N 9001~9010) .............................................................. 92-6 Loading/Steering Hydraulic Circuit (S/N 9011~) ...................................................................... 92-7 Brake Circuit ............................................................................................................................ 92-8 Electrical Wiring Diagram (1/2) (S/N 0101~0358) ................................................................... 92-9 Electrical Wiring Diagram (2/2) (S/N 0101~0358) ................................................................. 92-10 Electrical Wiring Diagram (1/3) (S/N 0359~0476) ................................................................. 92-11 Electrical Wiring Diagram (2/3) (S/N 0359~0476) ................................................................. 92-12 Electrical Wiring Diagram (3/3) (S/N 0359~0476) ................................................................. 92-13 Electrical Wiring Diagram (1/3) (S/N 0477~0560) ................................................................. 92-14 Electrical Wiring Diagram (2/3) (S/N 0477~0560) ................................................................. 92-15 Electrical Wiring Diagram (3/3) (S/N 0477~0560) ................................................................. 92-16 Electrical Wiring Diagram (1/3) (S/N 0561~) ......................................................................... 92-17 Electrical Wiring Diagram (2/3) (S/N 0561~) ......................................................................... 92-18 Electrical Wiring Diagram (3/3) (S/N 0561~) ......................................................................... 92-19 Electrical Wiring Diagram (1/2) (S/N 9001~9080) ................................................................. 92-20 Electrical Wiring Diagram (2/2) (S/N 9001~9080) ................................................................. 92-21 Electrical Wiring Diagram (1/2) (S/N 9081~) ......................................................................... 92-22 Electrical Wiring Diagram (2/2) (S/N 9081~) ......................................................................... 92-23 Electrical wiring diagram abbreviation chart (S/N 0101~0358, 9001~).................................. 92-24 Electrical wiring diagram abbreviation chart (S/N 0359~0476).............................................. 92-25 Electrical wiring diagram abbreviation chart (S/N 0477~)...................................................... 92-26 Electrical Wiring Diagram (CAB)............................................................................................ 92-27 Electrical Connection Diagram (S/N 0101~0358) .................................................................. 92-29 Electrical Connection Diagram (S/N 0359~0476) .................................................................. 92-30 Electrical Connection Diagram (1/2) (S/N 0477~0560) ......................................................... 92-31 Electrical Connection Diagram (2/2) (S/N 0477~0560) ......................................................... 92-32 Electrical Connection Diagram (1/2) (S/N 0561~) ................................................................. 92-33 Electrical Connection Diagram (2/2) (S/N 0561~) ................................................................. 92-34 Electrical Connection Diagram (S/N 9001~) .......................................................................... 92-35 Electrical Circuit Diagram (Cabin Air Conditioner)................................................................. 92-36 Electrical Wiring Diagram (Cabin Air Conditioner)................................................................. 92-37 Equipment Operation Table (Cabin Air Conditioner).............................................................. 92-38 Electrical Equipment Layout .................................................................................................. 92-39

95ZV EX 92-2 92 Cross-Section Drawing & Diagrams Axle Assembly

Axle Assembly The only difference between the front and rear axle is the differential housing (1) and axle housing (2). Other parts are the same as the rear axle assembly.

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 11. Internal gear 12. Internal gear hub 13. Snap ring 14. Planetary pin 15. Spring pin 16. Wear ring 17. Wear ring 18. Piston 19. Separation disc 20. Friction disc 21. Brake backing plate 22. Plate 23. Axle nut 24. Taper roller bearing (inner) 25. Taper roller bearing (outer) 26. Needle cage 27. Axle lock plate 28. Separation disc 29. Snap ring 30. Floating seal

Brake adj. mechanism (S/N 97C4-9001~9095)

A-Detail

31. D-ring 32. D-ring 33. O-ring 34. O-ring 35. Magnet plug 36. O-ring 37. Socket bolt 38. Spring 39. U-nut 40. Bolt 41. O-ring 42. Spacer 43. Ring 44. O-ring 45. Plug 46. Spring 47. Sleeve 48. Bushing 49. Socket bolt 50. Bolt 51. Bolt 52. Bolt 53. Socket bolt 54. Flange bolt 55. 56. 57. Plug 58. 59. 60. Magnet plug

95ZV EX 92-3 92 Cross-Section Drawing & Diagrams Torque Converter and Transmission

Torque Converter and Transmission (Model: Kawasaki PT315C01) 26

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

19 20

(T/M S/N 0495~)

21 23 12 14

16 17

24 18

95ZV32025

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 (Helical) 21. Output gear (Helical type) 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 valve 29. Pilot boss

95ZV EX 92-4 92 Cross-Section Drawing & Diagrams Loading/Steering Hydraulic Line (S/N 0101~0230)

Loading/Steering Hydraulic Line (S/N 0101~0230) 5

DOWN UP

14 T

6 ¿1.3

DUMP RAISE

23.5 0.5 MPa (240 5 kgf/cm2) at 100 L/min L

TS Rc1/4 TS G1/4

23.5 0.5 MPa (240 5 kgf/cm2) at 100 L/min

120 cm3 / rev

P TS (G1/4) DR

(b1) B2

A2 (a1)

(b2) B1

A1 (a2)

8 G1/4 TS

Cooling fan

(74,75)

Pb Pa

12.3 MPa (125.4 kgf/cm2) at 0 L/min

TS Rc1/8 B

17 (18)

Priority control flow rate: 10 L/min

High pressure set: 16.1 MPa (164.2 kgf/cm2) Low pressure set: 8.5 MPa (86.7 kgf/cm2) at 150 L/min

95 m

3.5 MPa T (36 kgf/cm2) at 0 L/min

113.0 cm3 / rev

91.0 74.0 cm3 / rev cm3 / rev

0.3 0.06 MPa (3 0.6 kgf/cm2)

ACCF

95 m ACF

22 Cut out: 11.8 0.5 MPa (120 kgf/cm2) Cut in: 6.9 1.0 MPa (70 kgf/cm2)

(S/N 0107~)

(28) B

3.5 MPa (36 kgf/cm2) at 0 L/min

Z2 (G1/4)

29.4 kPa (0.3 kgf/cm2)

PPI

Port size Rc...... PT G........PF (with O-ring) (G).......PF (without O-ring)

0.1 0.02 MPa (1 0.2 kgf/cm2)

TS G1/4

1.0 kPa (0.01 kgf/cm2)

10 m TS G1/4

(73) 21

Capacity 3.0 L Gas charge pressure 2.94 0.1 MPa (30 1 kgf/cm2)

ON when pressure drops. 3.9 0.5 MPa (40 5 kgf/cm2)

B P.B.

(49)

(32)

20.6 0.5 MPa (210 5 kgf/cm2) at 250 L/min

ACCR

45(46)

80.0 cm3 / rev

To parking brake

(250 5 kgf/cm2) at 15 L/min

24.5 0.5 MPa (250 5 kgf/cm2) at 15 L/min

From auto brake solenoid valve

B 24.5 0.5 MPa

To auto brake solenoid valve

To axle housing (vent between "trapped air" chambers)

TS G1/4

To brake valve (front axle circuit)

To tank (from brake valve)

To brake valve (rear axle circuit)

20.6 0.5 MPa (210 kgf/cm2) at 450 L/min

1. Hydraulic pump (loading + pilot & brake) 2. Hydraulic pump (steering) 3. Multiple control valve (loading circuit) 4. Steering valve 5. Boom cylinders 6. Bucket cylinders 8. Steering cylinders 11. Check valve (oil cooler bypass) 12. Return filter element 13. Relief valve (return filter bypass) 14. Orbitrol® 15. Stop valve 16. Pilot valve (for loading) 17. Valve assembly (18) Reducing valve (Orbitrol® circuit) 19. Adapter (orifice, slow spool return) 21. Breather valve (oil filling port) 22. Unloader valve 26. Valve assembly (main brake manifold block) (28) Reducing valve (pilot, parking brake, auto-brake) (29) Solenoid valve for parking (R) (32) Check valve (49) Pressure switch (for brake oil pressure) 33. Accumulator 45. Valve assembly (46) Reducing valve (for accumulator circuit) 71. Fan motor 72. Valve assembly (for fan motor) (73) Relief valve (two-step relief) (74) Solenoid valve (75) Solenoid valve 81. Line filter 82. Suction strainer 83. Suction strainer

Hydraulic oil cooler (incorporated in radiator)

Hydraulic oil tank

K95V92001

95ZV EX 92-5 92 Cross-Section Drawing & Diagrams Loading/Steering Hydraulic Line (S/N 0231~)

Loading/Steering Hydraulic Line (S/N 0231~) 7586 9

79 :0;

!"#$% #%&'

0 $ #

0 + #

!"#$% #%&'

$% # ./>

0 + # 7

+ # 0

(

3&'! " '

0 $ #

(

0#6 D

(

!"#$% #%&'

$% # ./> $% # ./>

4 )./,, ./ ,/ 1&!- )./,, ./ ,/

$% # ./>

( $% # ./> $% # ./>

!"#$%

!"#$% #%&'

(

)

2& .

!"#$% #%&'

(

$% #./>

.& .& * $ ' . 3 "3 4 . / #%&'

?% =

!"#$% &' ( !"#$%

!"#$% #%&'

!"#$%

. ,&@/ $ + +

1*2. 3&$ &3 $ 3/. &'$ .) . /2 &' . 2& .

!"#$%

< + #

0 + #

) $& * + , $- .!/ )./,, ./ !"#$%

56 4-/' )./,, ./ 2. ), !"#$%

?% 0 + #

' ". % . / > 3>/

!"#$% #%&'

) . &'! . /

=. % . / , 3/' &2 > 3>/ B3/ - ,&'! >/' / 4//' C . ))/2 &.C $- % /.,

0 + #

. / > 3>/ ". ' B3/ $&.$ &

!"#$% #%&'

. / > 3>/ ./ . B3/ $&.$ &

. / , 3/' &2 > 3>/

1. Hydraulic pump (loading + pilot & brake) 2. Hydraulic pump (steering) 3. Multiple control valve (loading circuit) 4. Steering valve 5. Boom cylinders 6. Bucket cylinders 8. Steering cylinders 11. Check valve (oil cooler bypass) 12. Return filter element 13. Relief valve (return filter bypass) 14. Orbitrol® 15. Stop valve 16. Pilot valve (for loading) 17. Valve assembly (18) Reducing valve (Orbitrol® circuit) 19. Adapter (orifice, slow spool return) 21. Breather valve (oil filling port) 22. Unloader valve 26. Valve assembly (main brake manifold block) (28) Reducing valve (pilot, parking brake, auto-brake) (29) Solenoid valve for parking (R) (32) Check valve (49) Pressure switch (for brake oil pressure) 33. Accumulator 45. Valve assembly (46) Reducing valve (for accumulator circuit) 71. Fan motor 72. Relief valve 73. Check valve 76. Thermo sensing valve 81. Line filter 82. Suction strainer 83. Suction strainer

= 4& - 5A.&'! = 4& - 5A.&'!

1*2. 3&$ &3 '

95ZV EX 92-6 92 Cross-Section Drawing & Diagrams Loading/Steering Hydraulic Circuit (S/N 9001~9010)

Loading/Steering Hydraulic Circuit (S/N 9001~9010) 5

DOWN UP

3 T

B2 A2

DUMP RAISE

120 cm3 / rev

17 (18)

TS Rc1/4 TS G1/4

3.5 MPa (36 kgf/cm2) T

To brake valve (rear axle circuit)

T DR

(b1) B2

A2 (a1)

(b2) B1

A1 (a2)

G1/4 TS

T A

16 Cooling fan T

(74,75)

45(46)

12.3 MPa (125.4 kgf/cm2) at 0 L/min

20.1 L/min at 9.4 MPa

P T1

(28)

High pressure set: 15.1 MPa (154 kgf/cm2) Low pressure set: 8.2 MPa (83.6 kgf/cm2) at 100 L/min

93 11.7 MPa

10 cm3 / rev

113.0 cm3 / rev

90.7 74.9 cm3 / rev cm3 / rev

B Z2 T

ACF Rc1/8

PPI

Z1 (G1/4) TA (G3/8)

TS G1/4

(73)

1.0 kPa (0.01 kgf/cm2)

21 TS G1/4

(29)

3.5 MPa (36 kgf/cm2) at 0 L/min

20.1 L/min at 9.4 MPa

ACF Rc1/8

10 cm3 / rev

Priority control flow rate: 10 L/min

11.7 MPa

ACCF

P.B.

ACCR

(49)

(32)

80 cm3 / rev

Pb Pa

29.4 kPa (0.3 kgf/cm2)

Hydraulic oil cooler (incorporated in radiator)

Hydraulic oil tank

09701-02590 K95V92003

To axle housing (vent between "trapped air" chambers)

From auto brake solenoid valve

To tank (from brake valve)

17 (18)

To auto brake solenoid valve

3.5 MPa (36 kgf/cm2) at 0 L/min B

TS G1/4

To parking brake

(S/N 9004~)

To brake valve (front axle circuit)

(S/N ~9003)

95ZV EX 92-7 92 Cross-Section Drawing & Diagrams Loading/Steering Hydraulic Circuit (S/N 9011~)

Loading/Steering Hydraulic Circuit (S/N 9011~) 3 T

DOWN UP

19 b2

DUMP RAISE

120 cm3 / rev

TS Rc1/4 TS G1/4

TS (b1) B2

A2 (a1)

(b2) B1

A1 (a2)

G1/4 TS

TS G1/4

T A

16 71

Cooling fan

T A

P1 Ps

12.3 MPa (125.4 kgf/cm2) at 0 L/min

ACCR

(49)

(32) B

Radiator

15.1 MPa

P.B.

45(46)

80.0 cm3/rev

Pb Pa

ACCF

T A

T2 PC

Priority control flow rate: 10 L/min

P Low pressure set:

6.2 MPa High pressure set: 16.5 MPa

20.1 L/min at 9.4 MPa

(28) 3.5 MPa (36 kgf/cm2) at 0 L/min

10 cm3 / rev

91 20.1 L/min at 9.4 MPa

10 cm3 / rev

113.0 cm3 / rev

90.7 74.9 cm3 / rev cm3 / rev

21 TS G1/4

B Z2

11 ACF Rc1/8

PPI

Z1 (G1/4) TA (G3/8)

TS G1/4

1.0 kPa (0.01 kgf/cm2)

(S/N 9066~) M

T PA

11.7 MPa

(29)

11.7 MPa

ACF Rc1/8

29.4 kPa (0.3 kgf/cm2)

58.0 58.0 cm3/rev cm3/rev

TS G1/4

Hydraulic oil cooler (incorporated in radiator)

Hydraulic oil tank

09701-03340 K95V92004

To axle housing (vent between "trapped air" chambers)

From auto brake solenoid valve

To tank (from brake valve)

17 (18)

To parking brake

3.5 MPa (36 kgf/cm2) at 0 L/min B

To brake valve (front axle circuit)

To brake valve (rear axle circuit)

To auto brake solenoid valve

1. Hydraulic pump (loading + pilot & brake) 2. Hydraulic pump (steering) 3. Multiple control valve (loading circuit) 4. Steering valve 5. Boom cylinders 6. Bucket cylinders 8. Steering cylinders 11. Check valve (oil cooler bypass) 12. Return filter element 13. Relief valve (return filter bypass) 14. Orbitrol® 15. Stop valve 16. Pilot valve (for loading) 17. Valve assembly (18) Reducing valve (Orbitrol® circuit) 19. Adapter (orifice, slow spool return) 21. Breather valve (oil filling port) 22. Unloader valve 26. Valve assembly (main brake manifold block) (28) Reducing valve (pilot, parking brake, auto-brake) (29) Solenoid valve for parking (R) (32) Check valve (49) Pressure switch (for brake oil pressure) 33. Accumulator 45. Valve assembly (46) Reducing valve (for accumulator circuit) 71. Fan motor 72. Relief valve 73. Check valve 76. Thermo sensing valve 81. Line filter 82. Suction strainer 83. Suction strainer 91. Pump unit (Emergency steering) 92. Check valve 93. Check valve 94. Pressure switch

95ZV EX 92-8 92 Cross-Section Drawing & Diagrams Brake Circuit

Brake Circuit Front axle

1. Hydraulic pump (loading + pilot & brake) 11. Check valve (oil cooler bypass) 12. Return filter element 13. Relief valve (return filter bypass) 21. Breather valve (oil filling port) 22. Unloader valve 23. Brake valve 24. Brake valve (pilot) 26. Valve assembly (main brake manifold block) (28) Reducing valve (for auto-brake) (29) Solenoid valve for parking (R) (32) Check valve 27. Solenoid valve for auto brake 31. Shuttle valve 33. Accumulator 37. Adapter (orifice) 45. Valve assembly (46) Reducing valve (for accumulator circuit) 49. Pressure switch (for brake oil pressure) 51. Pressure switch (for inching) 52. Pressure switch (for stop lamp) 55. Spring chamber (for parking) 61. Bleed screw 62. Check valve 63. Solenoid valve for parking (F) 64. Filter 81. Line filter 83. Suction strainer 85. Orifice (S/N ~0164, ~9010)

9010

9023

9011~

9024~

Rear axle

51 61 For europe specification

R1/8

85 (S/N ~0164,

Vent return to hydraulic tank

~9010)

31 A

C B

23 A

From multiple control valve

To pilot valve

Disc brake (front chassis parking brake)

45(46)

(32) 12.3 MPa (125.4 kgf/cm2)

ACCR

B P A

ACCF

From fan motor relief valve

Parking brake

Priority control flow rate: 10 L/min

(~S/N 9010)

From pilot valve

From fan motor

From stop valve

From steering valve

To multiple control valve

(29)

ACF Rc1/8

(28)

To fan motor P

T PA

90.7 74.0 cm3 / rev cm3 / rev

ACF Rc1/8

PPI

TS G1/4

1.0 kPa (0.01 kgf/cm2)

29.4 kPa (0.3 kgf/cm2)

Hydraulic oil cooler (incorporated in radiator)

Vent from axle housing

Hydraulic oil tank

09701-02590 K95V92005

95ZV EX 92-9 92 Cross-Section Drawing & Diagrams Electrical Wiring Diagram (1/2) (S/N 0101~0358)

Electrical Wiring Diagram (1/2) (S/N 0101~0358) &

' #

# % % #

! + A"

) ) + + + ) &

( (

' * &

' &

# #

* #

' % % % &

! &"

* $

! + A"

)

# $

% #

& &

% ' & # & & & # & $ & &

! + $A"

) ! " ) ! "

$ $ $ &

! "

' % $ $ * $ $ $ $ #

% # ' $ $ $ $ #

$ # $ $ $ $ $ % & $ $ $ $

, , ' %

! + A"

)

& #

, , $

% !

+ A #" ! + $A"

7 )

& )

! "

+ A #" + $A" % & ! , # !

# & $

+ A #" + $A"

& &

! "

& &

! "

)

! + A #"

& & & &$ & &

& # & #

' &

! "

)

, ' *

% ' % $

* , , * # $

# %

! + $A"

(

& +&

! "

' $

) ! 00 **%0>78273: 648%2"

!?35" &

(

' &

)

) &

' &

# #

& $

& +

& & & &$ & &

+ A " - ! + A"

% &

! ,

# '

& % # %

# % , , & , %

! "

& ! "

, #

& #

' % # ' &

& #

% * *

% &

+ A"

& & ) )

% &

&# &#

! + A" ! + A " ! + A" ! + A "

! + $A"

)

% $ # & &#

& & & &$ & &

, , * #

# # # #

' & &

, ' * # #

& &

' % ' & $ #

! "

$ # % ,

& % * %

# # # $ $ ! + A" &

# $ # $

+ $A"

& & '

)

# $ $ , '

% !

/ 010% 23 240 05062%7685 97%7:' ;78'%8< ! 8*".

& . +

, !

! + A"

! ) @ "

! + $A" $

! + A #@ A" ! + $A "

) .

)

(

)

! 00 **%0>78273: 648%2"

, * ' ' % & # # # # # # $ $ # # # # # # # # # # + % ' ' % ' $ $ # $ # # # #

! + A "

% ! + A #" ! $ # %

# $ $ #

& &

' &

) & )

# $

, & #

, & $

# $

' & $ , & #

) + )

% #

)

! + A "

' #

* #

, , * ' $ * ' , $

! + A "

( !("

! + A"

(

! 00 **%0>78273: 648%2"

# $

)

! + A "

' ' #

) ! 00 **%0>78273: 648%2"

) & +

# $

& ! "

! + A"

)

' &

$ % , ' '

% !

+ A #"

, !

+ $A "

95ZV EX 92-10 92 Cross-Section Drawing & Diagrams Electrical Wiring Diagram (2/2) (S/N 0101~0358)

Electrical Wiring Diagram (2/2) (S/N 0101~0358)

$ $!

$ '

& /

- ! &/ -!

!& '

! &

(

! ! & &

! & & '

- .

& & ! !&

! &

& & ! & & !

& & ! !& ! !& ' !

! &

# # '

&& & / ))/

"! * " % * *

"! " %

! "

# $! "

- . ' - '.

& !& !&

' % '

$ ! '

& $ !

# # * ' *

' - '.

& * *

! & ! &

" + ,

! &

- .

& / ))/

& "

-! &

& !

' '

& %!

" &

" $ & &

' - .

* *

" " $ & &

" * *

% - .

- '.

% - '.

- . ' - '. '

' - .

$ * *

- &/

& " "

" !

$ '

! * *

) )

- &/ -!

)

- .

- ! &/ !

- . ' ) - '.

) 0

& )

- . 1 .

* *

$ - .

- /

- +

(" ("

- ! &/

)

- &/ -!

- )

* . * & "! " % # # * * *' *' * ! $ " * * * * * *

! $ " "! " % # # '

)

- & + )

- $

! "

" "

! -' "

" $ "

% - .

" " " " ! & "

! '

& "! " % # # * * * * * ' * ! $ " * * * * * *

& &

& /

" " "

# "

) &

! &

)

& &

" $

' '

! $! ' & &

* . * & "! " % # # * * * *' *' ! $ " * * * * * *

! " #

- '.

- .

$! %! &! " % '

( "

- .

' % - '.

' $

! "

! &

%" & " $ &'

$ " !

! $ " ( ( " & $

(" $ "

& $ " ! ' ! # '

(

- '.

! $! !& % '

- .

(

' '

! % # & ! '

& &

" (

$! $ ! # $ ! " $ ' '

! "

! &

' $ - .

' $ ! " $ $! $ ! #

) &

" + ,

95ZV EX 92-11 92 Cross-Section Drawing & Diagrams Electrical Wiring Diagram (1/3) (S/N 0359~0476)

Electrical Wiring Diagram (1/3) (S/N 0359~0476) T/M CUT S/W

INSTRUMENT PANEL

LgY A703

8 WB WP D105 H122

LLg LgR S521 C702 4

(+)

8 RO RO BP B611 A715 G003 H109 BP RBr RBr B610 A714 G003 H119

8 GyG Gy LgY LgW S115 S119 S128 F904 G602 Sb WG LgB GyL S113 F104 S127 S116

EG2 EG1 EG3

WTM TTM

3/4

1/2

1/4

EMP GND

YR YB YL YBr YG S111 S133 S122 S131 S123

O O BrB BrW BrR Lg D103 B901 B902 H629 H619 H639

YB YSb H105 H638

GND

GyB G601

B B

TC H

LgR GY WL S121 S120 S224

GR S129

STARTER S/W

LgY A207

R1 R2

LgG H137

LG LO LY S510 S503 S505 3

RB G WBr RLg O A511 D107 D504 A908 D510

L B201

3 4

8 RG RLg D113 C202 H106 RG RGy D113 A701

8 Lg D103

R RGy D109 A701 1

8 R RGy D109 H138

R D501 B

RB RY F502 F402

OW OG PL OR OL PB H120 H130 D509 D508 D507 D506

MODM

W D406

YO H606

Lg D103

GW S320

GR BY S307 S222

L S329

GL S216 1

2 4

FR23 F 34 CHANGE POINT SELECTION 2

LgR H711

BrR S423

OIL PRESS. SENSOR

Hi-BEAM RELAY

HEAD LAMP RELAY

NEUTRAL RELAY

WIDTH LAMP RELAY

BACK LAMP RELAY

W S408

YV S104

GyW S433

EMERGENCY STEERING

VOLTAGE RELAY

DYNAMIC DAMPER

BrY S404

BrW BrB S422 S502 1

T/M MODE SELECTION 2

LgR S205 1

1 3

RS232C

W H201

G D402 4

YB 2 H618 Y YG H608 H628

YL H616

O O A509 A508

W3 W 5

WR WR D401 D403

FUSE

STARTER SWITCH

HL BW

L C101 1

L C102

R D502

GyB H603

WBx2

ACC

CAB

L B202

P RBr RO RW G903 A303 A306 F306

LW BY S512 S307

LR LBr BY S511 S504 S307 6

WRx2

B RGy A901 A001

DATA LINK CONNECTOR

F802

L D007

L 4

HORN S/W

RY RBr RO F303 A302 A307

COMBINATION S/W

GO SbW S501 A612

ENGINE MODE CHANGE S/W

REAR WORKING LAMP

Lg D103

1 6

12 Lg LY LG LO LW SbW D103 S124 S125 S130 S134 B302

SHIFT LEVER

PARKING S/W

20 7

RB SbO C205 S126

GND

FRONT WORKING LAMP

HAZARD (OPT)

Lg D103

COLD STARTER S/W

2 O S112

CONTROLLER FAULT RELAY

HORN RELAY

1 12

CAB (AIRCON) 1

LgY BrB RB E811 E812 F503

BG BrW OL WG E907 E912 E913 E914

WR GO Sb E809 E808 E807

BL BR PL LgR WP E908 C902 E915 E813 E810 E911

6 4

(BLUE)

(BLACK)

6 RW B612

RY RY F302 B615

RY RY R A713 F403 D108 H118

R R D108 D108

RW H108

Gy GyR S416 H621 1

WG WL A403 H140 H640

GW LO RL Y BrY BY D601 C901 E804 E803 E802 E801

6 P VW YB PB V WY E814 E816 E817 E818 E819 E820

AIRCON UNIT

(BLACK)

LgW S212

LgW L A408 D006 1

(BLACK)

G G D107 D107 1

(BLACK)

GW GL H127 B501

Lg R D111 D103 1

RL LB H128 S211

L G D102 D005

(BLACK)

RL SbP H610 S218

(BLACK)

RB RB C303 B614 H129 R R D108 D108 1

20 V WY LgY BrB LgR P RL VW YB PB C301 C302 C407 C501 D601 C502 C503 C504 C505 C506

(BLUE)

WP WR GO Sb C406 C306 C305 C304

KICK OUT

STOP LAMP S/W

2 Y

OY D114

1 R RG D111 H139

PG PW H633 H623

BrG BL H614 H613

Br D110

1 Br

BrB

TURN SIGNAL

Br D110

BL BG C410 C401

Y RW RB R H102 H101 D702 D704 1

BrW

G D107

2 BP G A301 D107 A308 B

Lg D103

(BLUE)

P R B609 D111

LgBr S209 1

HAZARD 2

AIR TEMP. SENSOR

BR Y C409 C511

B 9

FLOAT

Br D110 1

18 RL RG BR BrW OL WG PL YR C409 C402 C403 C404 C408 H111 D601 D703

POSITIO -NER

DIAG INC/DEC SW

AIR-SUS.

BUZZER

PILOT VALVE MAGNETS

O Y V

YV BLg BrW H615 H605 H625

QUAD SHIFT S/W

R G B

H123 BrW

H113 BrB

LgR BY A201 S307

GyY GyW BL H634 H624 H613

S307

S514

INCHING SWITCH

BrY BY GW LO C510 C509 C508 C507

THROTTLE PEDAL 6

H1 H2

6 10

D509 A307 F304 OR RO RW

A908 RLg

A503 YB

C207 A302 F303 S214 PB RBr RY WR

E916 YR

B801 W

G402 A108 S407 BrW WP GyG

S406 LgL 35

D110 E904 E903 Br Y RW S402 G302 SbY BrB

C208 F503 F703 F803 PL RB GW RL F101 S324 C801 A008 B306 WL RG RGy LgG 40

R R

1 D201 D301 D302 D801 D901 D902

R R

F603 RL

1 D201 D301 D302 D801 D901 D902

R R

D201 D301 D302 D801 D901 D902

D101 A506 E003 S405 E005 WR BrW YB GyL YL

C602 S315 B002 S417 S421 W GyB YR YG BLg G101 C601 G104 C604 S428 YB YV BrG BL

A507 E002 S415 S316 Sb Y BrB Y

C603 C605 G102 S420 F201 BrW GyW PW YL GyR

E004 YG

E006 YO

F104 A505 A502 S414 S308 Y WG BrR YSb SbO 36

S213 S201 S204 S118 S102 S105 LR LW LBr LY LG LO 7

D404 C606 G103 S429 R GyY PG YBr 35

S117 LP

S309 S419 E302 YW YGy LgR

95ZV2-09709-09291 EXP 1/3 K95V92008

95ZV EX 92-12 92 Cross-Section Drawing & Diagrams Electrical Wiring Diagram (2/3) (S/N 0359~0476)

Electrical Wiring Diagram (2/3) (S/N 0359~0476)

A10

A11

A12

A13

A14

A15

A16

A17

B10

B11

B12

B13

E10

E11

E12

E13

E14

E15

E16

E17

C10

C11

C12

C13

C14

C15

C16

C17

D10

D11

D12

D13

A18

A19

A20

A21

A22

A23

A24

A25

B14

B15

B16

B17

B18

B19

E18

E19

E20

E21

E22

E23

E24

E25

C18

C19

C20

C21

C22

C23

C24

C25

D14

D15

D16

D17

D18

D19

A26

A27

A28

A29

A30

A31

SbO LgB LgY GR LO YBr A512 A402 A407 A601 A610 A518

A32

A33

A34

B20

B21

LW YB A516 A611 WR H117

YR Sb GyB GyG GyL LP 0 A515 E702 A404 G601 A405 A401 H707

GL E201

B25

B26

E26

E27

E28

E29

E30

E31

E32

E33

C26

E34

C27

SbP F602

C28

C29

C30

GW E120

C33

D20

C34

D22

SbY H114

D23

D24

D25

D26

YL G201

Gy SbO Sb YR H637 H627 F204 H602

YW Y H636 H709

D21

LLg A202

YG BrW BrR YGy YL H710 H622 H601 E404 E403

WL H140

L L D003 D004

C32

GyW E601

W Y G H604 H626 D107

LBr LgR H704 E301

C31

YB YBr H612 H632

GL E101

LB LgW LR F702 F902 H706

LW H705

B24

WL A706

LgBr G802

YV LO E602 H701

B23

GR E202

LY Gy GY LgR YL LY YG LG H703 A406 A707 A708 A517 A519 A608 A609

LG H702

B22

W BrY GyL LgL GyG E501 H617 H135 H121 E701

LR LY LW B403 B409 B406 B

GO BrB LG LBr LO B303 E401 B402 B408 B401

B405 E203 B407 G202 C701

FUSE BOX

FUSE BOX R5

RL RG LR LW YR YW

G301 G401 G501 H103

F301 8 F401 F404 F501 F504 C204 F801 7 F804 G701 G002 S317

O WR

O WR RL RG LR LW YR YW

14 R A002 A007

C802 F704 G902

Br WB A107

L RG OY D001 A902 F001 D002 A907 WR Lg G F604 H620

B007 E107 F701 G801

L D112

L S303 3

L S304 4

W B802 E001 WR G WR B707 B701 B706

R H301 H302 H401 H402 H501 H502

D0 1

R H635

1 A510 A606 A607 A801

L D112

L F601

L F901 6

L B304 7

1 C512 E815 E917

RG RB E918 E902 RL

R E901 1 4

OG OW OL OR O C212 C211 C210 C209 C201 H110 WBr R R C203 B101 B102 1

H301 H302 H401 H402 H501 1 H502

H301 H302 H401 H402 H501 H502

A 95ZV2-09709-09291 EXP 2/3

95ZVE62086

95ZV EX 92-13 92 Cross-Section Drawing & Diagrams Electrical Wiring Diagram (3/3) (S/N 0359~0476)

YR H602

2 Y Y H626 H636

YB YG H612 H601 YL YBr H622 H632

1/4 R

1/8 G

1/2 W

EMP Y

3/4 B

COM Br

L7 2

T/C OIL TEMP. SENSOR -

PARKING SOLENOID

N6 M2 1

AIR CLEANER

2 B

SbY M102

BRAKE OIL PRESS. (MAIN)

FUSIBLE LINK P9

ALTERNATOR

WP N803

N802

WV P303

RL P406

RL RB H129 H128 B

3 3

4 RL RB R401 R501

RGy H138

RGy R201 R301 2 2

REAR WORKING LAMP

RGy R102

B 1

REAR WORKING LAMP

RGy R102 B

BATTERY

RL R103

BACK UP ALARM

R501 1

P601 RL P602 WG 2

4 4

W P102 P103 H201

P301 P302 WR WP WR WP H620 N803 WG H640

3 3

R104

R502

RB B

LICENSE LAMP

REAR COMBINATION LAMP (R. H)

REAR COMBINATION LAMP (L. H)

RL WL H610 N801 6

3 3

WG P405

DIODE UNIT

H928 H918 GR

3 10

P404 P403 WR WP

4 11

BrR WL M802 M701 2

P701 WV

H907 H908 H917 1

12 23

1 N601 P401 BrR WL

MAGNETIC S/W

N8 2

WP M702

W W P901 P901

YR H111 1

ECM

GY GO GL GB GR

YGy LB H710 H708

BATTERY RELAY

BrR

GyG H121

H122

N801 H140

W W H124 H134 2

COMPRESSOR

I 2

E/G WATER TEMP. S/W (COLD STARTER)

FUSIBLE LINK

R H301 H302 H401 H402 H501 H502 H635

M603 B

YB H105

M602 M601 R Y G

M6 E/G WATER TEMP. SENSOR

YW H709

70A

W3 M503 M502 M501 B R Y 1

P403 WP

30A

FUSE BOX(ECM)

E/G REV. SENSOR

PRESS. DIFF. SENSOR

WATER LEVEL SENSOR

STARTER

E/G WATER TEMP. SW

24 J6

LgR LgB H711 H712

SPPC

AIR HORN (OPT)

BrB K101

Br K111

Br R803

BrB R802

ETHER INJECTION VALVE

70A

BrB L301

GW K109

70A

Br L303

1 B

BOOM KICKOUT (OPT)

LP LB H707 H708

GyR H621

BrG H614

BLg BrW YV Y H605 H625 H615 H628

LO LB H701 H708

WR YB YG H620 H618 H608

BrW K112

BUCKET POSITIONER

LG LB H702 H708

D Br K111

YO H604

Sb H627

SbY SbY H114 M201

BrR N802

PW H623

AUTO BRAKE SOLENOID

PG GyW H633 H624

GR YO YL P205 H606 H616

GyY GyB H634 H603

GR GY BrB P205 P201 H629

LY LB H703 H708

BrW H619

LBr LB H704 H708

GY GY BrR BL BL H613 H613 P201 P201 H639

2 B

T/M OIL FILTER

T/C OIL TEMP. S/W

B L502

T/M OIL TEMP. S/W

J1 2

LW LB H705 H708

RW Y L503 L504

CONDENSER

LR LB H706 H708

SPEED SENSOR (AUTO-SHIFT)

FUEL LEVEL SENSOR

T/M SOLENOID VALVE

1 B

R W

RW RY K103 K104

(BLUE)

FRONT HEAD LAMP(OUTSIDE)

LgG H137

K001

K107

RLg

WASHER MOTOR

L6 1

(OPT) WORKING LAMP (INSIDE)

L0 1

K802

LgL L506

K108

WO H117

L701 LgL

H129 H139 RB RG

4 F

L603 B

K801

L601 L602 RW Y

K702

PL H130

PB H120

K105

6 1

RBr

OR H110

K108

H129 H139 RB RG

1 4

YO H927

COMBINATION LAMP (OPT)

YG H936

H109 H128 RO RL

K701

L9 1

RW Y H101 H102

HORN (H)

GW K109

RL P406

YW YGy LgR LgB J903 J901 J801 J802

K602

LW LBr LY LG LO LR J101 J201 J301 J401 J501 J601

GW K109

LP J701

H119 H128 RBr RL

YR M001

Br Y RW K111 L504 L503

B K106

K601

YB YV BrG BL H947 H944 H909 N102 H910 BLg YO GyB YR YG H949 H911 H902 N101 N105

LgL H135

WR BrW YB GyL YL P404 H905 H937 N501 H926

H638

(OPT)

HORN (L)

R P801

YSb

BrW GyW PW YL GyR H948 H913 H924 N103 H027

R P801

H617

K108

BrB Sb Y Y H916 H946 N701 N201

R P801

GyL

J102 ~702 J902

R P801

N301

K602 K702 L402

(OPT)

SbY BrB M101 K101 YB M401

R GyY PG YBr P801 H903 H914 N104

SbR

K108

K402 K403

RY PB RBr WO L802 K105 K104 L901 R703 OR RO RW RLg L801 K110 K103 K107 R603

R P801

SbO H637

K401

W P901

36 WG BrR YSb SbO Y P405 H906 N502 N401 N202

R P801

N402

K110

R103 R602 R702

W BrW WP GyG M301 K112 M801 M502

K108

L301 BrB

COMBINATION LAMP (OPT)

35 W LgL L506 M302

WL RG RGy LgG M701 R605 R102 L001 R705 RL GW PL RB L803 K109

K108 R104 R604 R704

SbR

RW RY RBr B H108 H118 H119 L502

40 40

BrB H113

K301

K107

BrW Br RO GW RB RLg 7 H123 H103 H109 H127 H129 H106

RLg

7 B K001 K301 RLg

WORKING LAMP (INSIDE)

L303 L202 L203 K402 BrW Br RO

K401 K403 K501 K801 K901

RW RY K103 K104

2 R

L103 L102 K203 K202 K802 RW RY RBr

FRONT HEAD LAMP(OUTSIDE)

Electrical Wiring Diagram (3/3) (S/N 0359~0476)

BATTERY P4

95ZV2-09709-09291 EXP 3/3

95ZVE62087

95ZV EX 92-14 92 Cross-Section Drawing & Diagrams Electrical Wiring Diagram (1/3) (S/N 0477~0560)

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95ZV EX 92-15 92 Cross-Section Drawing & Diagrams Electrical Wiring Diagram (2/3) (S/N 0477~0560)

Electrical Wiring Diagram (2/3) (S/N 0477~0560)

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Electrical Wiring Diagram (3/3) (S/N 0477~0560)

95ZV EX 92-17 92 Cross-Section Drawing & Diagrams Electrical Wiring Diagram (1/3) (S/N 0561~)

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95ZV EX 92-18 92 Cross-Section Drawing & Diagrams Electrical Wiring Diagram (2/3) (S/N 0561~)

Electrical Wiring Diagram (2/3) (S/N 0561~)

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95ZV EX 92-20 92 Cross-Section Drawing & Diagrams Electrical Wiring Diagram (1/2) (S/N 9001~9080)

Electrical Wiring Diagram (1/2) (S/N 9001~9080)

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95ZV EX 92-21 92 Cross-Section Drawing & Diagrams Electrical Wiring Diagram (2/2) (S/N 9001~9080)

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Electrical Wiring Diagram (2/2) (S/N 9001~9080)

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95ZV EX 92-22 92 Cross-Section Drawing & Diagrams Electrical Wiring Diagram (1/2) (S/N 9081~)

Electrical Wiring Diagram (1/2) (S/N 9081~) 5

2 5

(+)

LgY A703

WB WP D105 H122

PARKING S/W

L C102

R D502

L C101

Lg LY LG LO LW SbW D103 E204 E203 E202 E201 B302

GyB G601

Lg D103

LP GY WL WB E215 E216 E702 E714

YB YSb H105 H638 1

GR E217

STARTER S/W

COMBINATION S/W

LgY A206

LW BY E112 E119 LG LO LY E104 E114 E113

P RBr RO RW G904 A303 A307 F304

RB RY F503 F403

B4 CAB RB G WBr RLg O A520 D107 D504 A905 D506

L B201

OW OG OR OL PB PL H120 H130 D507 D508 D509 D510

O A508

W3W5

STARTER SWITCH

R RGy D113 H138

YV BLg BrW H615 H605 H625

INCHING SWITCH

EMERGENCY STEERING RELAY

O WR

R A002 A006

BR Y C404 C505

RW H108

Gy GyR E508 H621 1

2 L

YGy YG H125 E210 H616 Br L D112 C001

(BLACK)

RW B613

RY RY F302 B610

RY RY R A712 F404 D114 H118

R R D114 D114

GND

COM EG

(BLACK)

6 D507 A306 F306 OR RO RW

A905 RLg

C206 A302 F303 E312 RY WO PB RBr

A503 YB

SSG

3/4

1/4

EMP

E520 E109 LgL W 35

B E524 E511 E102 E118 R Y

1/2

1/8

3/4

1/4

EMP

SbY Gy GyG SbO A406 A407 A408 A519

YR YL A516 A514

GyB G601

1 11

O WR RL RG LR LW YR YW

W B802 E001 G WR WR B706 B701 B707

L RG D004 A902 D006 A906 Lg G WR F602 H620

WB A106

E711 1 E722 F701 G801 H631

A510 A606 A612 A801 B006

H301 H302 H401 3 H402 H501 H502

OR O OG OW OL C201 C202 C203 C204 C207 H110 WBr R R B101 B102 C209

R H635

1 C506 E816 E911

RG RB E910 E902

H301 H302 H401 H402 H501 H502 1

R E901 1 2

H301 H302 H401 H402 H501 H502

SI2

SbP LB LgW GR GY LP F603 F703 F903 A601 A707 A708

PC+

PC-

SbR H606

LB LgB WO LP LR LW LBr H711 H707 H117 H712 H706 H705 H704

LW LY LG LO A611 A610 A609 A608

YG F003

CONVERTOR

OUTPUT (sol)

BRK

LgBr LgR G802 H708

+ +

LY LG LO H703 H702 H701

1 7

P PG

Lg D103

RXD TXD

RTG SMG TGG GND WB A705

B WL A706

YO H604

VW YB LgY BrB LgR PB V WY P RL C306 C305 C402 C512 D601 C511 C510 C509 C508 C507

WG PL RL RG BR BrW OL YR C404 C409 C408 C407 C403 H111 D601 D704

BrY BY GW LO C504 C503 C502 C501

BL BG C405 C410

Y RW RB R H102 H101 D703 D702

E8 NEUTRAL RELAY

BACK LAMP RELAY

HORN RELAY

CONTROLLER FAULT RELAY

RL SbP H610 E220

RL LB H128 E219

GW GL H127 B501

G L D102 D002

Lg R D111 D103

G G D107 D107

(BLACK)

(BLUE)

TURN SIGNAL R

Br D112

Br D112 1

FLOAT

Br D112 1

POSITIO -NER

R R

BrB

(BLUE)

BrW

1 D201 D301 D302 D801 D901 D902

R R

6 E211 F604 E005 E004 E006 E502 YL YG YO SbR RL

1 D201 D301 D302 D801 D901 D902

D201 D301 D302 D801 D901 D902

D101 A506 E003 E521 F004 WR BrW YB GyL YGy

C605 E705 B002 E518 E516 YO GyB YR YG BLg G101 C604 G102 C603 E504 BL YB YV BrG

A507 E002 E519 E110 BrB Y Sb Y

C606 C602 G103 E517 F201 BrW GyW PW YL GyR

A403 A505 A502 E506 E109 WG BrR YSb SbO Y 40 36

GyB A716 E602

P R B616 D111

LgBr E307 E613 Lg D103

BP G A301 D107 A305 B

G D107

H7 1

1 E310 E309 E308 E303 E302 E301 LR LW LBr LY LG LO E311 E314 E121 E120 E306 E313 LP LB YW YGy LgR LgB

95ZV-09709-07502 EU 1/2 95ZVE62055

D406 C601 G104 E503 D103 Lg R GyY PG YBr 35

6 10

HAZARD

BrG BL H614 H613

LgW L A405 D001

BUZZER

PILOT VALVE MAGNETS

PG PW H633 H623

LgW E218

QUAD SHIFT S/W

DIAG INC/DEC SW

O GyL LgL Sb YB YBr YG LgBr A401 A402 A404 A509 A515 A513 A512 G802

YB YBr SbR WL H612 H632 H606 H140

WP WR GO Sb C401 C303 C302 C301

WIDTH LAMP RELAY

B801 W

Gy GyG SbO F202 H121 H637

AIRCON UNIT

E912 YR

GyL LgL Sb YG YR YL H617 H135 H627 H602 H622 H601 B

1 10

D112 E904 E903 Br Y RW

F004 E108 G402 A105 E507 W BrW WP GyG YGy

E501 C801 A005 B304 WL RG RGy LgG

E523 G302 SbY BrB

C205 F504 F704 F804 PL GW RL RB

H1 10

OUTPUT (LAMP, RELAY) R

B401 L YW YGy BY Y YL LR GO LG LO LW B405 D001 H710 H709 E403 B403 G201 B303 B408 B407 B406 C701 G202 R LLg B Y Y/W W LBr LY B402 B409 E402 A202 H626 H134 H124 H636

RB RB C304 B611 H129 R R D114 D114 1

1 R RG D111 H139

SbY R E402 H114

1/8

KICK OUT

STOP LAMP SW

1/2

DIAG. S/W CONNECTION HEAD LAMP RELAY

C802 F702 G903 LR

Hi-BEAM RELAY

OIL PRESS. SENSOR

O Y V

INPUT

THROTTLE PEDAL Y

R G B

L GO Y L D003 D002 E403 B303

T/M CONTROLLER

3 GyY GyW BL H634 H624 H613

GyB H603

FUSE BOX

7 C210 F801 F802 G701 G003

W D404

Lg D103

R RGy D113 A701

F301 F401 F402 F501 F502

L L L B306 E512 E122 E513 F601 F901

RL Y BrY BY GW LO D601 C901 E804 E803 E802 E801

LgR BY A201 E119

L F001

L D110

YO H607

P VW YB PB V WY E817 E815 E814 E813 E812 E811

BL BR PL LgR WP E908 C902 E913 E818 E810 E917

W D404

YB 2 H618 Y YG H628 H608

YL H609

CAB (AIRCON)

BG BrW OL WG E907 E916 E915 E914

L D110

W H201

RL RG LR LW YR YW

DATA LINK CONNECTOR

WR GO Sb E809 E808 E807

LgY BrB RB E820 E819 F504

G D402

L B202

WR WR D401 D403

LR LBr BY E117 E105 E119

H123 BrW

LgG H137

H113 BrB

L D003

FUSE BOX

F002 G301 G401 G501 H103 TB

WRx2 WBx2

BR ACC

RG RLg D109 C208 H106 RG RGy D109 A701

OUTPUT

INPUT

B RGy A901 A001

RY RBr RO F303 A302 A306

CIRCUIT PROTECTOR

TC H

BG 1

MONITOR CONTROLLER

1 3 4 6

AIR TEMP. SENSOR

GND

F803

HORN S/W

GO SbW E115 A607 E510 3

YB YL YBr YG YR E605 E616 E604 E615 E614

Lg O O BrB BrW BrR D103 E617 B902 H629 H619 H639

EMP GND

3 B

RB SbO C211 E607

R D501

G Y B

1/4

WTM TTM

1/2

SHIFT LEVER

3/4

E119

EG2 EG1 EG3

ENGINE MODE CHANGE S/W

1 3 4 6

E116

GyG Gy SbY LgW E608 E609 E610 F902 G602 WG LgL GyL Sb E618 H640 E619 E620

RO RO BP B614 A710 G004 H109 BP RBr RBr B615 A711 G004 H119

LLg LgR E101 C702

REAR WORKING LAMP

1 3 4 6

INSTRUMENT PANEL

GND

1 3 4 6

Lg D103

FRONT WORKING LAMP

HAZARD

1 3 4 6

A405 LgW

T/M CUT S/W

COLD STARTER S/W

95ZV EX 92-23 92 Cross-Section Drawing & Diagrams Electrical Wiring Diagram (2/2) (S/N 9081~)

Electrical Wiring Diagram (2/2) (S/N 9081~) 1

K301

K601 K602

RW Y H101 H102

1 RB RBr

K102

1/4 R

1/8 G

1/2 W

EMP Y

3/4 B

BrW K112

Br L

BrB K106

PARKING SOLENOID

T/M OIL FILTER

GR GY BrB P205 P201 H629

PG GyW H633 H624

GR YO YL P205 H607 H609

PW H623

WR YB YG H620 H618 H608

LY LB H703 H711

1 GyY GyB H634 H603

BrW H619

J3 B

BL BL GY GY BrR H613 H613 P201 P201 H639

FUEL LEVEL SENSOR

BLg BrW YV Y H605 H625 H615 H628

YO H604

GyR H621

BL H613

BrG H614

N6 B

YGy H616

Sb H627

EMERGENCY STEERING MOTOR PUMP

BRAKE OIL PRESS. (MAIN)

27 15

13 4

6 1

3 10

17 7

28 29

26 14

30 31

J8 ECM

YW H710

YGy LB H709 H711

N8 2

R B

PRESS. DIFF. SENSOR

WATER LEVEL SENSOR

LgR LgB H708 H707

SPPC

ETHER INJECTION VALVE

LP LB H712 H711

+ 1

GW K109

LO LB H701 H711

50 2

BrR N802

2 SbY M102

LG LB H702 H711

+ 1

AIR HORN (OPT)

LBr LB H704 H711

T/C OIL TEMP. SENSOR

T/C OIL TEMP. S/W

T/M OIL TEMP. S/W

COM Br

SbY SbY H114 M201

LW LB H705 H711

Br K111

2 10

LR LB H706 H711

SPEED SENSOR (AUTO-SHIFT)

YGy H125

Br K111

T/M SOLENOID VALVE

AIR CLEANER

CONDENSER

BOOM KICKOUT (OPT)

YW YGy LgR LgB J903 J901 J801 J802

Y Y H626 H636

YL YBr H622 H632

BUCKET POSITIONER

LR LW LBr LY LG LO J101 J201 J301 J401 J501 J601

LP J701

YB YG H612 H601

RW RY K104 K103

(BLUE)

AUTO BRAKE SOLENOID

YR H602

FRONT HEAD LAMP(OUTSIDE)

LgG H137

B L502

K001

K107

LgL L506

(OPT) RLg

RW Y L503 L504

K108

1 RB

WORKING LAMP (INSIDE)

WO H117

WASHER MOTOR

4 F

L701 LgL

K801 K802

K108

PL H130 B

L603 B B

OR H110 PB H120

4 L601 L602 RW Y

COMBINATION LAMP

1 1

GW K109

K702

H638

LgL H135

B K101

K701

H909 H910 H941

BLg YG YO GyB YR H949 H911 H902 N101 N105

YSb

HORN(H)

J102 ~702 J902

YB N102

YV BrG H947 H944

H617

B GW K109

R P801

BrW GyW PW YL GyR H948 H913 H924 N103 H027

GyL

K108

(OPT)

HORN(L)

R P801

N301

(OPT) RB

R P801

R GyY PG YBr Lg P801 H903 H914 N104 R804

WR BrW YB GyL YGy H938 H905 H937 N501 N001 P403 RL YL YG YO SbR P401 H926 H936 H927 R803

SbR

K403

R P801

H637

K108

Br Y RW K111 L504 L503

R P801

N402

K602 K702 L402

YB M401

W P901

R P801

SbR

K110

RLg K107

Y BrB Sb Y H916 H946 N701 N201

YR M001

SbO

SbY BrB M101 K106

36 Y WG BrR YSb SbO P402 H906 N502 N401 N202

K108

W BrW WP GyG YGy N901 M301 K112 M801 M501

RY PB RBr WO L802 K102 K103 L902 R703 OR RO RW L801 K110 K104 R603

35 LgL W L506 M302

COMBINATION LAMP

K401 K402

R104 R602 R702

36 WL RG RGy LgG M701 R605 R103 K105 R705 L002 PL RB RL GW L803 K109

K107

40 K108 R102 R606 R706

BrB LgG RW RY RBr B H113 H137 H108 H118 H119 L502

3 RLg

BrW Br RO GW RB RLg H123 H103 H109 H127 H129 H106

WORKING LAMP (INSIDE)

RW RY K104 K103

K401 K403 K501 K801 K901

2 R

L103 L102 L302 R902 K203 K202 K802 BrB LgG RW RY RBr B L303 K001 L202 L203 K402 K301 BrW Br RO GW RB RLg

FRONT HEAD LAMP(OUTSIDE)

P403 P404 WR WP 1

3 3

P301 P302 WR WP WR WP H620 N803 WG H640

DIODE UNIT

W 2

SbR H606 Lg H631

R501

R102

RB B

LICENSE LAMP

B 3

R401 R402 BACK UP ALARM R502

REAR WORKING LAMP

R103

RGy

R104 RL

BATTERY

P601 P504 RL WL P602 P501 WG B 2

W P102 P103 H201

WL RL H610 N801 6

2 YR

H907 H908 H917 1

H928 H918 GR

P701 WV

N802

YR H111

BrR

N801 H140 WL 2

WL P406

REAR WORKING LAMP

R103

WG P402

WP N803

WG P402

RGy B

W W P901 P901

RL P401

H129 H139 RB RG

COMPRESSOR

GO GL GB

BrR WL M802 M701

2/4

REAR COMBINATION LAMP (R.H)

H122

GyG H121 1

E/G WATER TEMP. S/W (COLD STARTER)

M602 M603 R Y M601 B

YB H105

ALTERNATOR

M3 3

M6 E/G WATER TEMP. SENSOR

WV P303

RGy R201 R301

M503 M501 M502 B R Y 1

RGy H138

H129 H139 RB RG

W3 W W H124 H134

1 R H301 H302 H401 H402 H501 H502 H635

FUSE BOX(ECM)

70A

RL RB R401 R501

P5 VOLTAGE RELAY

WP M702

H109 H128 RO RL

70A

STEERING PRESS. SW

MAGNETIC S/W

2 RL RB H129 H128

P7 BATTERY RELAY

2 3

70A

E/G WATER TEMP. SW

P404 WP

FUSIBLE LINK

30A

STARTER

N601 P406 BrR WL

H119 H128 RBr RL

E/G REV. SENSOR

LgG K105

B W

FRONT PARKING SOLENOID

P9 FUSIBLE LINK

REAR COMBINATION LAMP (L.H)

BATTERY

95ZV-09709-08170 EU 2/2 +

95ZVE62056

95ZV EX 92-24 92 Cross-Section Drawing & Diagrams Electrical wiring diagram abbreviation chart (S/N 0101~0358, 9001~)

Electrical wiring diagram abbreviation chart (S/N 0101~0358, 9001~) INSTRUMENT PANEL

INSTRUMENT PANEL

MONITOR CONTROLLER

T/M CONTROLLER

Engine water level alarm

AUTO lamp

E/G water level sw.

Power for press. diff. sensor

Modulator valve 2

Charge lamp

Auto brake

3/4

Fuel level (3/4)

SSG

Press. diff. sensor signal

Low clutch sol. valve

Air cleaner clogging alarm

Converter (+)

1/4

Fuel level (1/4)

For switch input (–)

High clutch sol. valve

T/M oil temperature alarm

Converter (–)

EMP

Fuel level (E)

Failure history call

R clutch sol. valve

T/M cut-off (Declutch) lamp

Engine water temperature alarm

Engine oil pressure alarm

—

Shift lever F (+)

Brake oil press. alarm lamp

Shift switch (+)

CONVERTOR

Brake oil pressure alarm

E/G oil press. alarm lamp

Parking switch (+)

+ 24 V

Controller failure alarm

Work lamp

Water temp. alarm lamp

Shift lever 2 (+)

–

GND (–)

+24 V power supply

Central alarm lamp

T/M oil filter alarm lamp

Shift lever 3 (+)

–

GND (–)

GND

GND (–)

Shift lever A (+)

Sine wave signal (±) input

Fuel level lamp (F)

Emergency steering (output) Rectangular wave signal (+) input

Emergency steering (OPT for other than Europe)

Vibration damper (option)

EG2

Engine warning lamp

EG1

Engine protection lamp

EG3

Engine stop lamp

—

WTM

Engine water temperature gauge

TTM

T/M oil temperature gauge

(+)

Instrument panel illumination

T/M oil filter clogging alarm

—

— B

— — —

1/2

Fuel level lamp (1/2)

2 (left) lamp (–)

1/8

Fuel level lamp (1/8)

3 (left) lamp

Turn signal (left) lamp

Central alarm sw.

4 (left) lamp

RXD

For communication (RXD)

Turn signal (right) lamp

Fan 2-step relief sol. valve

TXD

For communication (TXD)

High-beam lamp

L R

— GND

Hour meter (–)

Hour meter (+)

— BL

MONITOR CONTROLLER

—

For speedometer (±) output

1 (right) lamp

For tachometer output (+)

T/M oil temp. alarm lamp

2 (right) lamp

+ 24 V

Air cleaner alarm lamp

3 (right) lamp

–

GND (–)

E/G water level alarm lamp

4 (right) lamp

–

GND (–)

Neutral relay

For sine wave signal input (GND)

Back-up relay PG

For rectangular signal input (GND)

—

DC 24 V

Emergency steering lamp (OPT for other than Europe)

—

DC 24 V

3/4

Fuel level lamp (3/4)

Fuel level lamp (F)

Memory call

1/4

Fuel level lamp (1/4)

Controller failure relay

3/4

Fuel level lamp (3/4)

Parking switch

EMP

Fuel level lamp (E)

Neutral lamp

1/2

Fuel level lamp (1/2)

Buzzer

Auto brake lamp

RTG

For communication (GND)

1/4

Fuel level lamp (1/4)

Auto lamp

SMG

GND (For speedometer)

EMP

Fuel level lamp (E)

E/G water temp. sw.

Vibration damper (option)

TGG

GND (For tachometer)

GND

GND (–)

T/M oil filter sw.

GND

Frame GND

— E/G oil press. sw.

—

T/M CONTROLLER

+ 24 V power supply

GND

S/2

Spare

—

1/2

Fuel level (1/2)

Machine speed sensor (+)

S/1

Emergency steering (input)

—

1/8

Fuel level (1/8)

COM

Engine rev. machine speed (–)

Buzzer

—

Steering oil press. sw. (OPT for other than Europe)

Engine rev. sensor (+)

PC+

Modulator valve 1 (+)

—

Alternator voltage

Neutral

–

GND

+ 24 V power supply

–

GND

Shift lever R (+)

1st clutch sol. valve

1st speed indication

Memory reset

Shift lever 1 (+)

2nd clutch sol. valve

2nd speed indication

Brake oil press. (Main) sw.

Vibration damper (option)

3rd clutch sol. valve

3rd speed indication

Fan 2-step relief sol. valve

Failure history reset

Solenoid valve (–)

4th speed indication

T/M oil temp. sw.

Inching switch (+)

PC–

Modulator valve 1 (–)

Parking brake lamp

Air cleaner sensor

+ 24 V

BRK

Auto brake solenoid valve

95ZV EX 92-25 92 Cross-Section Drawing & Diagrams Electrical wiring diagram abbreviation chart (S/N 0359~0476)

Electrical wiring diagram abbreviation chart (S/N 0359~0476) INSTRUMENT PANEL

INSTRUMENT PANEL

MCU

Radiator water level warning lamp

AUTO lamp

A21

Auto shift indicator lamp

—

E/G coolant temperature switch

D13

Charge lamp

Auto brake lamp

A22

Fuel level lamp (1/2)

—

Emergency steering oil press. switch

D14

Air cleaner clogging alarm

Converter (+)

A23

Fuel level lamp (E)

Power supply + 24 V

—

D15

—

T/M oil temperature alarm

Converter (–)

A24

1st speed indication lamp

Power supply + 24 V

C10

—

D16

—

Declutch lamp

Engine water temperature alarm

Engine oil pressure alarm

—

A25

2nd speed indication lamp

—

C11

—

D17

—

A26

T/M oil filter warning lamp

—

C12

—

D18

—

Brake oil pressure alarm

A27

Air cleaner warning lamp

Power supply GND

C13

D19

—

MCU error (failure alarm)

Work lamp

A28

Brake pressure warning lamp

Power supply GND

C14

T/M oil filter switch

D20

—

+24 V power supply

Central alarm lamp

A29

Neutral indicator lamp

+ 5 V output

C15

Radiator water level switch

D21

GND

GND (–)

A30

3rd speed indication lamp

E10

—

C16

E/G oil pressure switch

D22

—

A31

Fuel level lamp (1/4)

E11

—

C17

Fuel level F switch

D23

—

Emergency steering

Vibration damper (option)

EG2

Engine warning lamp

EG1

Engine protection lamp

EG3

Engine stop lamp

—

WTM

Engine water temperature gauge (sensor)

TTM

T/M oil temperature gauge (sensor)

(+)

Instrument panel illumination

T/M oil filter clogging alarm

—

— Downshift button

— —

A32

—

E12

—

C18

D24

—

High-beam lamp

A33

Fuel level lamp (3/4)

E13

—

C19

T/M pressure diff. sensor

D25

—

Turn signal (left) lamp

A34

4th speed indication lamp

E14

—

C20

Fuel level 1/2 switch

D26

—

Turn signal (right) lamp

H solenoid valve

E15

C21

Fuel level E switch

— GND

Hour meter (–)

Hour meter (+)

MCU

—

— 2nd speed solenoid valve

Fuel level lamp (F)

3/4

Fuel level lamp (3/4)

Ride control solenoid valve

— 3rd speed solenoid valve

ECM

—

E16

Machine speed sensor

C22

FR 23 change point selection

—

E17

Power supply

C23

F 34 change point selection

R solenoid valve

E18

—

C24

—

Modulation valve

E19

—

C25

—

C26

—

E20

MODM

—

E21

—

C27

—

E22

—

C28

Fuel level 3/4 switch

—

E24

Buzzer

B10

E23

— Alternator

C29

Fuel level 1/4 switch

C30

—

1/2

Fuel level lamp (1/2)

B11

Back lamp relay

E25

—

C31

—

1/4

Fuel level lamp (1/4)

—

B12

MCU fault relay

E26

—

C32

—

EMP

Fuel level lamp (E)

—

B13

L solenoid valve

E27

—

C33

GND

GND (–)

—

B14

Auto brake solenoid valve

E28

—

C34

+ 24 V power supply

—

B15

—

E29

Parking switch

—

A10

—

B16

Communication RXD

E30

—

Auto/Manual selection

—

A11

Fuel level lamp (F)

B17

—

E31

—

Shift lever 2

—

A12

Steering oil pressure warning lamp

B18

E32

—

Shift lever R

—

A13

Radiator water level warning lamp

B19

—

E33

—

Shift lever 3

Declutch switch

Neutral relay

MODM

Ride control switch —

Neutral

A14

Central warning lamp

B20

—

E34

—

–

GND (–)

A15

E/G coolant temperature warning lamp

B21

—

1st speed indication

A16

T/M oil temperature warning lamp

B22

Communication TXD

2nd speed indication

A17

D solenoid valve

B23

—

3rd speed indication

A18

1st speed solenoid valve

B24

4th speed indication

A19

E/G oil pressure warning lamp

B25

—

Parking brake lamp

A20

Auto brake lamp

B26

—

Tachometer

Brake oil pressure switch

—

T/M mode selection

D10

Shift lever 1

T/M oil temperature switch

D11

Shift lever F

Air cleaner clogging switch

D12

Shift lever A

95ZV EX 92-26 92 Cross-Section Drawing & Diagrams Electrical wiring diagram abbreviation chart (S/N 0477~)

Electrical wiring diagram abbreviation chart (S/N 0477~) INSTRUMENT PANEL (A5) +

INSTRUMENT PANEL (A6)

+24V power supply

BATT

GND

GND(-)

1st speed indication

2nd speed indication

EG4

3rd speed indication

EG1

4th speed indication —

MCU

—

A17

D solenoid valve

B23

—

A18

1st speed solenoid valve

B24

A19

E/G oil pressure warning lamp

B25

—

A20

Auto brake lamp

B26

—

Ride control

—

MCU

Tachometer

MCU

—

T/M mode selection

D10

Shift lever 1

—

T/M oil temperature switch

D11

Shift lever F

Air cleaner clogging switch

D12

Shift lever A

A21

Auto shift indicator lamp

—

E/G coolant temperature switch

D13

Engine protection lamp

A22

Fuel level lamp (1/2)

—

Emergency steering oil press. switch

D14

EG2

Engine warning lamp

A23

Fuel level lamp (E)

Power supply + 24 V

—

D15

—

EG3

Engine stop lamp

A24

1st speed indication lamp

Power supply + 24 V

C10

—

D16

—

A25

2nd speed indication lamp

—

C11

—

D17

—

A26

T/M oil filter warning lamp

A27

Air cleaner warning lamp

— —

SUB2

—

Brake circuit warning lamp —

— Power supply GND

— Downshift button

C12

—

D18

—

C13

—

D19

—

Secondary steering

A28

Brake pressure warning lamp

Power supply GND

C14

T/M oil filter switch

D20

WTM

Engine water temperature gauge

Engine oil pressure alarm

A29

Neutral indicator lamp

+ 5 V output

C15

Radiator water level switch

D21

1/4

Fuel level 1/4

Engine water temperature alarm

A30

3rd speed indication lamp

E10

—

C16

E/G oil pressure switch

D22

—

1/2

Fuel level 1/2

T/C (T/M) oil temperature alarm

A31

Fuel level lamp (1/4)

E11

—

C17

Fuel level F switch

D23

—

EMP

Fuel level E

Air cleaner clogging alarm

A32

—

E12

—

C18

D24

—

Hour meter

Charge lamp

A33

Fuel level lamp (3/4)

E13

—

C19

T/M pressure diff. sensor

D25

—

D26

—

EWL

—

SUB1

—

TTM

T/C (T/M) oil temperature gauge

3/4

Fuel level 3/4

CANH

—

CANL

—

Parking brake lamp

Tacho meter

INSTRUMENT PANEL (A6)

Engine water level warning lamp — —

MCU A1 A2

— 2nd speed solenoid valve

Controller failure alarm

Fuel level F

Ride control solenoid valve

— 3rd speed solenoid valve

—

A34

4th speed indication lamp

E14

C20

Fuel level 1/2 switch

H solenoid valve

E15

ECM

C21

Fuel level E switch

—

E16

Machine speed sensor

C22

FR 23 change point selection

—

E17

Power supply

C23

F 34 change point selection

B2 B3 B4

R solenoid valve

Modulation valve

E18

—

E19

—

C25

—

C26

—

E20

—

E21

—

C27

—

E22

—

C28

Fuel level 3/4 switch

—

E24

Buzzer

B10

MODM

C24

E23

— Alternator

C29

Fuel level 1/4 switch

C30

—

Turn signal (Right) lamp

B11

Back lamp relay

E25

—

C31

—

Work lamp

—

B12

MCU fault relay

E26

—

C32

—

High-beam lamp

—

B13

L solenoid valve

E27

—

C33

(+)

Instrument panel illumination

—

B14

Auto brake solenoid valve

—

C34

T/M oil filter clogging alarm

—

B15

—

E29

AUTO lamp

A10

—

B16

Communication RXD

E30

Turn signal (Left) lamp

A11

Fuel level lamp (F)

B17

—

E31

MODM

—

Parking switch

—

Auto/Manual selection

—

Shift lever 2

Neutral indication

A12

Steering oil pressure warning lamp

B18

E32

—

Shift lever R

Central alarm lamp

A13

Radiator water level warning lamp

B19

—

E33

—

Shift lever 3

Auto brake

A14

Central warning lamp

B20

—

E34

—

Declutch lamp

A15

E/G coolant temperature warning lamp

B21

—

A16

T/M oil temperature warning lamp

B22

Communication TXD

—

Neutral relay

E28

Ride control switch

Brake oil pressure switch

— Declutch switch

95ZV EX 92-27 92 Cross-Section Drawing & Diagrams Electrical Wiring Diagram (CAB)

Electrical Wiring Diagram (CAB) Gy B201

P B301

Br B102

BrB B101

Rotating light

10 Speaker (left)

10 Speaker (right)

Speaker

GW A706

Working light (left) 1

Working light (right) B5

RLg B408

2 Room lamp

WB A714 1

RY B302

DOOR SW

G B410

Wiper 3 switch (F)

Wiper 4 switch (R)

White

Black

(OPT)

B 1

9 Radio

8 Cigarette lighter

GB A713

(OPT)

WR A707

LY A904

PB B406

(Blue)

OL PL B403 B405

W YW L A803 A802 A905 3 A4

1 A5

(Blue)

L+

R-

L-

GY A601 +

WB GB G RB B701 B601 B410 B411

GR GY B801 B802 3

R+

Rear wiper motor M

B407

GR OL A602 B403

WR GW WV B702 B602 B409

Front wiper motor

Intermittent wiper relay

Y OR A906 B404

Y YW LY A806 A501 A506

L W A503 A502

OR PB B404 B406

No. 1 2 3 4 5 6 7 8 9 10

A9 B1 1 A105 BrB A104 Br

(For speaker)

Gy B2 A101

B3 1 C101 P B503 A203 RY

(For rotating light) (OPT)

Equipment name Head lamp Lamp Front wiper switch Rear wiper switch Front wiper motor Relay assembly Rear wiper motor Cigarette lighter Radio Speaker V CAB 09709-04700

B4 6

: Refer to the electrical wiring diagram (95ZV).

A902 A903 B803 A504 A604 A805 A605 PB PL OR OL B501 A712 A711 A303 A705 A201 A402 RB G WV RLg O

K95ZVE92007

95ZV EX 92-28 92 Cross-Section Drawing & Diagrams Electrical Wiring Diagram (CAB) Cab

Rotary warning lamp (spare) Working lamp (rear) Working lamp (front)

(B5)

(B7)

(A3)

Cab (R. H. Inside)

(CAB S/N 0101~0345) Rotary warning lamp (spare)

Speaker

Room lamp

Speaker (spare) (B6)

(B8)

Cab serial number plate location (CAB S/N 0346~)

(A2)

Car radio (A7)

Relay wiper intermittent Note Serial number (S/N) on this page shows the serial numbers for the cab and not for the machine.

Wiper motor (front) (A9)

(A8) Cigar lighter (A4) (CAB S/N 0101~0194) Wiper S/W (rear)(A6) (option) Wiper S/W (front)(A5)

Speaker (CAB S/N 0144~)

To floor board

(B1)

Cigar lighter & wiper S/W K95V92009

95ZV EX 92-29 92 Cross-Section Drawing & Diagrams Electrical Connection Diagram (S/N 0101~0358)

Electrical Connection Diagram (S/N 0101~0358)

( )

# ( )

% !

* # #

% % # ( " )

' '

#! *

" '

% #

! # *

! # % # *

# %

#% ! , % *

0 ! !

% !

( )

% # . ! % # . ! % # . ! # . !

" "

# . !

% #

# . !

( )

( ) ( )

#% % *

" "

# !

! "

+ +

( )

* # *

& &

! !

* # #

# 5 6 5 "

# +5 '

#! *

# #

* # #

# * # * # #

#!%

& +

% .

% # #

* #

# * # # % ! 0 % # % & & #$ !. # # % # * # # % " ! " ! # # # ## &

% ! # #

% ! *

% # . ! % # . ! % # . ! # . ! # . ! # . !

&+ & &

#% # .

0 ! !

% !

! #

# ! #

# 5

% * %

% %

# +5

0 ! !

0# # ! ##

% ! ' %

! , #% # .

# 5

# ! #

% * % %

# 5 6 5

% %

! #

% !

# # #%

# *

% % * %

% #

% % !

% #

% % * % %

! #

0 & !

# %

! # # #

#% #123 #

# ! %

% * % ! !

!. %

#$ (#$ )

# ! !

' !. !. # +5

% * % ! !

! !

! ##.

# 5 6 5

# +5

! ##. ! ##. *

* # #

! ##.* # #

! #

#$ (#$ )

#$ "

#$! ,

#!!

# ( )

! # *

( )

! % #

# #

! ## %

* #

95ZV EX 92-30 92 Cross-Section Drawing & Diagrams Electrical Connection Diagram (S/N 0359~0476)

Electrical Connection Diagram (S/N 0359~0476) PARKING

ACC’ F5

B BR ACC R1 R2 C

10A

F10

[W5]

1.25

LBr

12V F N R

BATTERY

WR F15

[WV] 1

BATTERY RELAY

F14

12V

ECM

G1.25

23A

STARTER

70A

LY B C [R5]

MAGNETIC S/W BW5 RL1.25

[WG]

VOLTAGE RELAY

PARKING SOL. LgG

OFF ON OFF

F13

(Lg)

(SbW)

F13

LLg

(L )

T/M CONTROLLER

R E

15A

DECLUTCH CUT OFF

DECLUTCH S/W

(LgY)

(Lg)

F13

(LgW)

X E

T/M CONTROL WARNING

F13

(Lg)

INSTRUMENT PANEL / BUZZER

FR23 SELECTION F34 SELECTION

BrR

[SbY]

BRAKE OIL PRESS.

SbY

20A

10A

Gy GyG GyL [SbR]

Sb W YR

FUEL LEVEL F

15A

20A

10A

15A

10A

15A

10A

7.5A

ALTERNATOR

SPARE

ECM

MODM

CAN_H

7.5A 7.5A 10A

15A

20A

1ST SPEED SOLENOID VALVE

A04

C05 C14 C06 C15 C08 C17 C28

LgR

1A (L)

F13 B11 (LB)

(Lg)

RS-232C

RXD GND

GR GL (BY)

A29 (GR)

AUTO SHIFT INDICATOR LAMP NEUTRAL INDICATOR LAMP

A20 (GY)

AUTO BRAKE LAMP

A14 (GyB)

CENTRAL WARNING LAMP

A28 (LgY)

F17

BOOM KICK-OUT

A19 (Gy) A15 (GyG) A16 (GyL) A26 (SbO) A27 (LgB) A13 (Sb) A12 (O)

HIGH BEAM PL

RIGHT HEADLIGHT (H)

10A

RIGHT HEADLIGHT (L)

(RGy)

3RD SPEED INDICATION LAMP

A34 (LW)

4TH SPEED INDICATION LAMP

E15

A11 (YR)

E16

A33 (YB)

(RGy)

REAR WORKING LIGHT S/W F4

E08

FUEL LEVEL 1/2

E24

A31 (YBr)

FUEL LEVEL 1/4

ACC’

B L E

F10

[W]

REAR WORKING LIGHT

B E L

RBr

10A

FLASHER UNIT (HAZARD)

RBr

(GL)

17 [W] F35 [GR] 10A

F13

B16 B24

(WL)

TACHOMETER

18 28

F15

RIGHT REAR TURN SIG. (OPT) LEFT TURN SIG. PL LEFT FRONT TURN SIG. (OPT) LEFT REAR TURN SIG. (OPT)

(BrR) (BrB)

(YL)

DATA LINK CONNECTOR

(Y0)

THROTTLE PEDAL

(BrW)

W/[YO]

YV BLg

GyW

IDLE

BrG

INC/DEC SW INC (m)

DEC

F13

GyB E

OFF IDLE

GyY

DIAGNOSTIC S/W

E/G MODE SELECTION

IDLE SW

BrW

THROTTLE OPENING SENSOR

MAINTENANCE

(Lg) E

(YG)

WARNING

CONTROLLER

HORN

(YB)

GW G

STOP

(Lg)

HORN S/W

7 8

RIGHT TURN SIG. PL

(RBr)

CAB B

A [W] F31 [GY]

RIGHT FRONT TURN SIG. (OPT)

(Y) B

LEFT BRAKE LAMP

COMBINATION S/W RO

ROOM LAMP E

ACC’

RIGHT BRAKE LAMP

FLASHER UNIT (WINKER)

TB TR G

BACK-UP LAMP

(RO)

ACC’

RADIO

(RB)

B22

CIGARETTE LIGHTER

(WBr)

NIGHT ILLUMINATION

BUZZER

STOP S/W

FUEL LEVEL E

B09 (LgBr)

CAB WORKING LIGHT

F20

F22

15A

FUEL LEVEL 3/4

CAB WORKING LIGHT

10A

TO WORKING LIGHT PL RGy

FUEL LEVEL F

A22 (YL)

AIR-SUS. COMPRESSOR

FRONT WORKING LIGHT

15A

AIR CLEANER WARNING LAMP

C19

RLg

TO FRONT WORKING LIGHT

TO CAB WORKING LIGHT

BACK-UP ALARM (OPT)

2ND SPEED INDICATION LAMP

1.25

T/M OIL FILTER WARNING LAMP

A30 (LO)

FL WIPER

FRONT WORKING LIGHT

BACK-UP LAMP

A25 (LG)

FR WIPER

WORKING LIGHT PL

RLg

T/M OIL TEMP. WARNING LAMP

C29

WIPER S/W

LEFT HEADLIGHT (L)

FRONT WORKING LIGHT S/W

RADIATOR WATER LEVEL WARNING LAMP STEERING OIL PRESS. WARNING LAMP

WASH

1.25

15A

E/G OIL PRESS. WARNING LAMP E/G COOLANT TEMP. WARNING LAMP

R WIPER

LEFT HEADLIGHT (H)

TO REAR WORKING LIGHT S/W

BRAKE OIL PRESS. WARNING LAMP

1ST SPEED INDICATION LAMP

BrB

FLOAT

LH RY UL

F6 A21 (LgR)

M S1 S2

(RY)

BACK LAMP RELAY

WASHER MOTOR

CONTROLLER FAILURE RELAY

(L)

WIPER MOTOR

BUCKET POSITIONER

COMBINATION S/W

RY LgW

E TXD

NEUTRAL RELAY

C20

E20

INSTRUMENT PANEL LIGHTING

WIPER

F16

E29

(GW)

BrW

HL B18 (SbP)

A23 (YG) (GL)

2 MITTENT 6

5A E

4 RELAY

F18

10A

MODULATION VALVE

5 3 1 INTER-

(WL)

TAIL LAMP

RIDE CONTROL SOLENOID VALVE

WASHER MOTOR

CONTROLLER

AUTO BRAKE SOLENOID VALVE

LgR

TACHOMETER

(-)

LICENSE LAMP (OPT)

D SOLENOID VALVE

A24 (LY)

C21

(+)

3RD SPEED SOLENOID VALVE

C16 C07

MACHINE WIDTH LAMP (OPT)

F WIPER

WASH B Sint S1

MACHINE WIDTH LAMP (OPT) RB

M WIPER S/W S2 S3

T/M OIL TEMP. GAUGE HOUR METER

(YSb)

FOR OPT LAMP

C22

C02

FOR OPT LAMP

(RB) B14

WIPER MOTOR OR

10A

E/G WATER TEMP. GAUGE

(YB)

ACC’ F19

2ND SPEED SOLENOID VALVE

A17 LP

C04

C23

E (Lg)

TAIL LAMP

A05 LO

C33 D02

ACC’ F13

10 2

8 27

GyR

6 19

33 32

(Lg)

CAN_L

SPARE

A18 LY

B05

F13

SPARE

15A

10A

Y Y

10A

MACHINE SPEED SENSOR

10A

15A

H SOLENOID VALVE R SOLENOID VALVE

D21

E09 YGy

ECM (11)

T/M PRESS. DIFF. SENSOR

SPARE

FUEL LEVEL 1/8

SPARE

10A SPARE

YBr

FUEL LEVEL 1/4

SPARE

FUEL LEVEL 1/2

SPARE

SbO LgL

FUEL LEVEL 3/4

15A

D01

C03

STEERING OIL PRESS. S/W

D14

COMBINATION S/W

B04 LBr

D10

E/G OIL LEVEL S/W

RADIATOR WATER LEVEL S/W

D03

C09

AIR CLEANER CLOGGING S/W

B01 LW

D05

BRAKE OIL PRESS. DIFF. S/W

T/M OIL FILTER S/W

20A

C13 BrW

E/G COOLANT TEMP. S/W

CAB

D12

C12

T/M OIL TEMP. S/W

MACHINE

F SOLENOID VALVE

C11

E/G OIL PRESS. S/W ACC’

C10

1.25

D04

B12

MODEL SELECTION 1 MODEL SELECTION 2 MODEL SELECTION 3 MODEL SELECTION 4

(LgR)

THERMO ETHER COLD START S/W S/W [BrR] KIT

BrY

T/M MODE SELECTION

LLg I 20

R F12

A BrB M

AUTO / MANUAL SELECTION

ALTERNATOR 20

(GyW )

RIDE CONTROL S/W

(WG )

CHARGE LAMP

70A

(YL)

SHIFT S/W

(Lg)

B13 D11

A02 LG

G1.25

1.25

E17

[W]

R1 BR B AC R2 C

ACC’

SHIFT LEVER

30A

B W

ACC’

W W5

F10

PREHEAT OFF ON START

(L) S/W

LfiL, (L)

15A

STARTER S/W

MCU

30 39 40 50

ECM

95ZVE62088

95ZV EX 92-31 92 Cross-Section Drawing & Diagrams Electrical Connection Diagram (1/2) (S/N 0477~0560)

Electrical Connection Diagram (1/2) (S/N 0477~0560)

+ ,

! 4 + ,

6! * .

( )

! 0

0 4

( . 1)

( )

0 ( . ) ! ( . ) ! ! !

4 ! ! ! ! ! '

! ' !

+ 1 ,

( 4 <) 42

/ /

* 4

+ 1 ,

6 ! ! !

! 4

! ! * 4

4' 4 4' 42 4 * ! *

30 3

( .)

( ) ( )

;

2 2

. .

2 ( 1 )

( ) ( )

( ) ( . )

( . )

( .)

( )

6 ! * !

( / ) ( 1 ) ( . ) ( 1) ( ) ' ( ) ( ) ( )

( )

! !

' 0 !

! !

( )

! 0 0 ! 0 (0) 0 ! 0 (0) ! 0 0 ! 0 ( ) 0 ! 0 ( )

( /)

6! ! 0 4

6! ! 0 6! ! 0 6! ! 0

( /)

6! ! 0 6! ! 0

6! ! 0 4 '

6; 6; 6; ( )

! 0 6 6

0 ! ( ! 6 ) ! 4

( )

! 0 ! * ( ) ! 0 ! * ( )

( )

0 ! (0 )

! * ( ) ! * ( )

' ( ) 0 !

( )

! 4

( )

4 ! * ! 4 * ! 4 ! * ! 4 ! ! ! ! ! ! ! ! ! * ! ! ! ! ! ! !

( / )

( .)

( ')

( )

! ! 2

(

)

! !

4 * 4 ! *

( 1)

( /)

0! ! 0 ( ) 0! ! 0 ( )

( )

2 ( . )

( )

! !

' ( / )

! ( ) ! !

0! ! ! ! !

( )

' ( )

( )

1 ' .

! 4

( )

4 ! * 4

6 ! * ! * 4 4 ! 4

4 ! * 4 4 ! ! 4

! 4

0 !

6 ! *

. ( / )

! 4 4 !

( . )

( )

0! 4

( )

( .)

0 0 4 4 + , 6!

6! 6 ! ! ( 1 ) !

( )

+ ,

6! 4

( ) ( ') ( ) ( ) 4 4 6! ! 0 ! ( 2) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ') 5 ( ) ( ) ( ')

0! ! ! ! ! ! 6 ! ! 0 ! ! 6! ! ! ! ! 6 ! * ! 4 ! * ! 4 * ! 4 ! * ! 4 ! ! ! ! ! ! ! ! ! ! * !

( . ) ( / ) ( ) ( ) ( . ) ( 1 ) ( . ) ( . ) ( /) ( / ) ( / ) ( 1 ) ( . ) ( 1) ( ) ( )

(

4 !

)

( )

4 !

( )

( ) ( )

( )

'#7

0 4

( ) -

( )

! !

+ ,

( )

: ( )

+ ,

0! 0

! ! ! 6!

( )

! 0 ! !

"#$%& $&

2; 4 6

95ZV EX 92-32 92 Cross-Section Drawing & Diagrams Electrical Connection Diagram (2/2) (S/N 0477~0560)

Electrical Connection Diagram (2/2) (S/N 0477~0560)

$ %

. 1 + ,+, /

( 1, 10 .+

$ %

, 0 . * (

$ %

(

+ ++ /,/ /

,& ,&

( +

(

&, / +, '

, '

/, + , .(,/ +, /

+ (, + +

+ + ( * / +

,/ +, / /

1,/ , +

, ++ , +

(

( (

(

'( ! ( +

(

( (

, + ! /+ +, / ! ( +

(

)

+ ! /+ +, / ! ( +

(

,/ ,& ' .+ ,& , +, / ! ( +

(

( +

& +, / ! ( +

(

+ (

/, + , .(,/ +, /

,/ ,& , / + ,

, '

, ( +

(

.+ ,& , /

+ /+ 1,/ , +

,/ '& ,/

,/+ 0 (,++ /+ ,

'$ %

' ( & +, /

+ ,/ + .( /+ / /,/ ,/ + .( /+ / ( ,/+ / / ,/ + .( /+ /

( +

+ ++ &

(

& + ,/1 // + &

, ( +

, / ./,+

(

( &

(

/& / ( +

(

2 3

4! 0 5 ' 1 4!

95ZV EX 92-33 92 Cross-Section Drawing & Diagrams Electrical Connection Diagram (1/2) (S/N 0561~)

Electrical Connection Diagram (1/2) (S/N 0561~) ,#-

#; ,#

0 1

% 0 1

%$ $

#" #

# $

% & "#. #2

%# % "

!$ , -

##2

,#2 5-

$# $4

$# $4 $ " ,#2 - & ! % # ,#2 - & ! % # !$ %&# % &

%$$/

, 3 % !

! !" # $ &" !" # # $ &" !" # # $ &" !" # # $ &" !" # # $ &"

0 5 1

% "&# .

3# 0 5 1

% % %

% %

& "&# .

## #

# # #

$! , !%$4&

!" !

. %

% #

"# "& %#

$ $ $ $ $ $ $ $

, 5 -

,#2-

,#2 -

, -

, 3#-

, 5"-

& &$% &" #%!

% ,#"-

& &$% &" #%!

, -

% , #-

# , -

, #-

# "

& 4 % #%! #

% #%!

, "-

$"! & % &" " #

#% 4 & , & -

%$ %#% ! ," -

& 4 " & . ," -

#% 4 & ,4% % -

& 4 % & . ," -

, -

# " & . ," # % & . ," -

## # ## #

$% , " ! % $ -

$4% #%! $% $& $ &

, #-

$" "## ,% $" "## ,% $" "## ,% $" "## ,% ! $ " % & & $4

% ! . % $" "## ! "&# ! . % $" "## % " 4& & &$% " #%! $ %#& %#% ! #%! %# & &$% " #%! % " % & &$% " #%! $# $4 & &$% " #%! % & & &$% " #%! $" "## %&# % & #%! % "&# . % & #%! "&# . % & #%! % ! . % & #%! ! "&# ! . % & #%! ! "&# &# % & #%! %& $# % $#" & % & #%! % &% " % # # % & #%! & "&# . % & #%!

,#2 , 3 , , ,#2 , 5 -

$" "## %&# #% $" "## ,% $" "## ,% $" "## ,% $" "## ,% $" "## ,% $" "## ,% $" "## ,% -

,#2 -

$" "## ,% -

,"-

$! , $! , $! , $" "## ,% $" "## ,% $" "## ,% $" "## ,% $" "## ,% $" "## ,% $" "## 7 ,% $" "## ,% $" "## ,% -

, -

% &

,#2 , 3, 3 , 3#, 5",#2 , 5-

, -

!%& % $

, -

## #

, -

# # #

, #-

# # #

, -

## #

, -

## #

,# -

,#"-

,# -

" & ! % # #%!

4" #%

, -

%$4"!

%$ #%!

% " & #& 4 % " & #& 4

, 3-

, -

" " & #& 4 " $% " & #& 4 3

4 % #& 4 ,#-

" " & #& 4

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95ZV EX 92-34 92 Cross-Section Drawing & Diagrams Electrical Connection Diagram (2/2) (S/N 0561~)

Electrical Connection Diagram (2/2) (S/N 0561~)

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95ZV EX 92-35 92 Cross-Section Drawing & Diagrams Electrical Connection Diagram (S/N 9001~)

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95ZV EX 92-36 92 Cross-Section Drawing & Diagrams Electrical Circuit Diagram (Cabin Air Conditioner)

Electrical Circuit Diagram (Cabin Air Conditioner) SW K 1 1

10A

13 FU B

FU A

20A

5A LIGHT SW SIGNAL

M RF

M V3

9 2RY 9 1.25RY

9 2RY

M CD

25 15 26 22

28 15 29 22

225W M V 3A

80W

1.25G

2 +B 6

2G 2G

3 1

1.25RY

M FRE

RL BM

REC

SP CD

RL CD

RL EC

DEF

GND

RL BM

FOOT

RL EC

RL CD

FU EC

FU CD

GND

39 5

M V 3B

25 35

SV 3

M RFA

S RF

M RFB

9 BLC B 3

RL CH BAT

BLC 01

BLC F

AC M

11 8

28 G

4 R CD

7 RL CH

22 B P

0.5B

15 14

TH AM

EC C

TH W

TH I

21 TH F

27 15

4 23

21 30

31 M AMB

33 M V 1B

S AM

M AMA

36 36

35 M V 1A

S V1

37 M V 2A

38 M V 2B

S V2

S SD

40W

GND

SHUT

37 15 38 22 Vz

34 22 35 15

GND

FACE

31 22 32 15

FOOT

FACE

GND

Mhot

Mcool

22 01

0.5B

SP HL

01 0.5B

0.5B

M AM

ACM

Air conditioner control amplifier

M AM

Air mixing servo motor

RL CH

Condenser HI relay

BAT

Battery

Blower motor

RL EC

Compressor clutch relay

BLC

BLC (blower linear controller)

M CD

Condenser motor

S SD

Solar insolation sensor

Diode 1

M RF

Inside/outside air servo motor

SPCD

Condenser speed change pressure switch

Diode 2

M V1

Vent servo motor

SPHL

Refrigerant high/low pressure switch

ECC

Compressor clutch

M V2

Front vent servo motor

SWK

Key switch

FU A

Air conditioner fuse

M V3

Defroster selection servo motor

TH AM

Outside air thermistor

FU B

Blower motor fuse

R CD

Condenser motor speed change resistor TH F

FU CD

Condenser motor fuse

RL BM

Blower main relay

TH I

Inside air thermistor

FU EC

Compressor clutch fuse

RL CD

Condenser relay

TH W

Water temperature thermistor

M V1

M V2

Dotted lines indicate the wiring on the machine side.

Frost prevention thermistor

95ZVE72019

95ZV EX 92-37 92 Cross-Section Drawing & Diagrams Electrical Wiring Diagram (Cabin Air Conditioner)

Electrical Wiring Diagram (Cabin Air Conditioner) Control panel

Illumination power supply

24V(BR')

Fuse box 26

22 32

21 31

20 30

19 29

18 28

3 11

2 10

RB A401

1 F26

RL B408

RG B409

RB B417

R B418

Outside air sensor (THAM)

Condenser relay (MB)

Compressor clutch relay (RLEC)

Condenser HI relay (RLCH)

RB BrY B417 B307

RG BrY B409 B307

Y B B415 B410

RW RL B416 B408

YR RL B407 B408

5A LgY VW YB A403 A604 A605

BR B A501 A509

BrR Y BY P GW WP WG OL A102 A611 A609 A606 A608 A506 A502 A503 BL A510

BrB Sb GO PB V WY WR LO BrY A402 A404 A405 A603 A602 A601 A406 A607 A610 10

BG RL RB LgR PL BrW A612 A401 A507 A101 A504 A505 A508

F27 5A F28

10A

F29

Insolation sensor (SS)

BR Y A509 A611

20A

B LgW B410 D104 1

(Black)

A4 1

Sb GO WR B304 B303 B302

LgY BrB RB A220 A210 A305

RB BrB LgY A801 B312 B311 1

P VW YB PB V WY A313 A218 A219 A207 A206 A205

WY V PB YB VW P B320 B319 B318 B317 B316 B314 1

Y R RB RW A704 A703 B101 B102

LO GW BY BrY Y RL B310 B309 B308 B307 A901 B315

Sb GO WR WP A404 A405 A406 A506

GW LO BrY BY B503 C601 C501 C903 B603 LgY BrB LgR V WY P RL VW YB PB C107 C106 D103 D201 C901 C203 C202 C407 C406 B807

BG BL B A505 A510 B103

BR RG RL PL WG OL BrW B YR A702 A701 B202 A508 A502 A503 A504 A509 A501 9

WP WR GO Sb C201 B806 B907 B906

WY V PB YB VW RL P LgR BrB LgY A601 A602 A603 A604 A605 A612 A606 A507 A402 A403

Floor harness

RL Y BrY BY GW LO A306 A315 A202 A314 A312 A203

1 LO GW BY BrY A607 A608 A609 A610

WP LgR PL BR BL B301 B313 B406 A902 B411 B402 B WG OL BrW BG B401 B405 B404 B403 B412

BG BrW OL WG B A301 A302 A309 A310 A212 5

10 3

BL BR PL LgR WP A308 A211 A303 A304 A311

B D101 1

BL BG C702 C405

Y RW RB R B704 B502 B504 C904

B801 B901 C103 C205

B702 B703 C701

BrW OL WG B805 B905 C105

C403 C502 C602 D202

YR B602

RG B604

Def selection servo motor (MV3) 9

B501 B601 D102

B803 B903 C101 C204 C401

Air mixing servo motor (MAM)

Vent selection servo motor (MV1)

Front vent selection servo motor (MV2)

Inside/outside air selection servo motor (MRF) 7

WP VW YB C203 C202 C201

Connector between floor and rear

PL C204

BR C205

C3 3

Rear harness

C307 C306 C305 VW YB WP

Electric blower condenser

1 1 3

B B410

WY WR BrW B320 B302 B403

PL B406

RW B416

BR B402

GO Sb OL B303 B304 B404 1

PL B406

BR B402

LgY BrB WG B311 B312 B405

BR B402

PB V BG B318 B319 B412

VW YB WP B316 B317 B301

BR PL B402 B406

PL B406

C303 C301 BR PL

Y B415

BR B402

PL B406

High/low pressure SW SP HL

Inside air sensor (THI)

Compressor clutch (ECC)

Blower main relay (RLBM)

BLC

Water temperature sensor (THW)

Blow-off thermistor (THF)

Blower motor (MB)

SP CD 4

1 4

B2 YR B407

WR GO Sb A204 A208 A209

3 2

G RY BL B C801 C802 B411 B410

BrR PL A316 A303

C7 BR GW B402 B309

BR BY B402 B308 1

RL B408 B B401

2 G C704 D302

LgW B701

RY RL D301 B315

RY C703 1

LgR B313

R LO B418 B310

G C801

BR B402

RY C902

P B314 1

95ZVE72020

95ZV EX 92-38 92 Cross-Section Drawing & Diagrams Equipment Operation Table (Cabin Air Conditioner)

Manual (Fully automatic mode is released.)

Fully automatic

Control

Equipment Operation Table (Cabin Air Conditioner) Operation condition Outside air Set temperatemperature ture on control panel

Display on control panel

Cycle status

Key switch

AUTO LED

A/C LED

Outside Inside air air LED LED

Relay LCD

Vent

Set temperature

Blower

Servo motor

Blower Compres- Conmain sor denser

Condenser high

> 30

High load (under burning sun in spring or summer)



18.5 ~ 31.5

Normal



Set value

30 ~0



High load

Automatic control



Normal



Frost cut



High pressure cut



Low pressure cut



High pressure error



Normal



Before engine is warmed Water temperature < 25ºC



Before/after engine is warmed Water temperature > 55ºC



35 ~0

18.5 ~ 31.5

Automatic control

Set value



Mode just before OFF is displayed.

Nothing is displayed.



Evaporator frost prevention control

Condenser clogging, etc.

Gas leak, etc.

High/low pressure cut, etc.

Outside air < 0  Fixed to "foot" and compressor disabled

Prevention of cold air blow at low temperature

Set value: 32  High air blow

FACE

Set value



FACE /FOOT



or X



FOOT



or X



FOOT /DEF



or X



DEF



or X



Automatic control



or X



or X



or X



Outside air

Inside air

or X X

(Hi or Lo) X

or X

Automatic control



OFF

(Hi or Lo) (Hi or Lo) (Hi or Lo) (Hi or Lo) (Hi or Lo) (Hi or Lo) (Hi or Lo) (Hi or Lo)

A/C manual 

Set value: 18  High air blow



Inside/ outside air manual

(Hi or Lo)

High pressure < 1,226 kPa (12.5 kgf/cm2)

Mode manual

Remarks

(Lo)

Hi ～ Lo X

Condenser motor

Outside air > 30  Fixed to "face" (Hi or Lo) Set value: 18  High air blow

High air blow

OFF

Compressor (clutch)

High pressure > 1,520 kPa (15.5 kgf/cm2)

OFF

BLC

(Hi)

X X

Blower motor

or X

Automatic control

HI ~ Lo

Blower manual

Blow-off

or X

High air blow

OFF

Air mixing

Major functional parts Inside/ outside air

95ZV EX 92-39 92 Cross-Section Drawing & Diagrams Electrical Equipment Layout

Electrical Equipment Layout Front chassis (S/N 0101~)

Bucket positioner (L2)

Horn Head lamp

Head lamp

Ground

(Ground)

To rear chassis

LH Side

To rear chassis

Top View

To rear chassis

RH Side 95ZV-03030-17444 EX K95V92010

95ZV EX 92-40 92 Cross-Section Drawing & Diagrams Electrical Equipment Layout Front chassis (S/N 9001~)

Bucket positioner (L2)

(S/N ~9004) Horn

Boom kick out (L3)

Front parking brake solenoid valve (R9) Head lamp

Head lamp

Ground

Parking brake solenoid valve (R9)

Ground Turn signal

Turn signal

(S/N 9065~)

(Ground)

To rear chassis

LH Side

To rear chassis

Top View

To rear chassis

RH Side 95ZV-03030-17792 K95ZVE92011

95ZV EX 92-41 92 Cross-Section Drawing & Diagrams Electrical Equipment Layout Front chassis (S/N 0101~)

(S/N 9001~) Combination lamp (option) (K4)

Head lamp

Working lamp Combination lamp (option) (K4)

Not used To rear chassis

Option

To rear chassis

(K2) Option (K1)

(K3)

(K1)

(K2) (K3)

(L2) Working lamp

(L2)

Bucket positioner

Working lamp

Head lamp

Option

Bucket positioner

Head lamp

Option

(K0) (K0) (L1)

Option

(L1) (R8) Vibration damper solenoid (OPT)(R9)

Vibration damper solenoid (OPT)(R0)

Parking solenoid (L3)

(L3)

Air horn (option) (L4) Horn (K6~K7)

Kickout sensor

Kickout sensor Air horn (option) (L4) Horn (K6~K7)

K95V92011

95ZV EX 92-42 92 Cross-Section Drawing & Diagrams Electrical Equipment Layout Rear chassis (S/N 0101~0268, 9001~9065)

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95ZV EX 92-43 92 Cross-Section Drawing & Diagrams Electrical Equipment Layout Rear chassis (S/N 0269~0560, 9066~)

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95ZV EX 92-44 92 Cross-Section Drawing & Diagrams Electrical Equipment Layout Rear chassis (S/N 0561~) 0 " " 3 43

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95ZV EX 92-45 92 Cross-Section Drawing & Diagrams Electrical Equipment Layout Rear chassis (S/N 0101~, 9001~)

8 A 0 : $ )

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95ZV EX 92-46 92 Cross-Section Drawing & Diagrams Electrical Equipment Layout Rear chassis (S/N 0101~, 9001~)

. /

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95ZV EX 92-47 92 Cross-Section Drawing & Diagrams Electrical Equipment Layout Rear chassis (S/N 0101~, 9001~)

)$1 0 5 )$1 0 4

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95ZV EX 92-48 92 Cross-Section Drawing & Diagrams Electrical Equipment Layout Floor board (S/N 0101~, 9001~)

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